Honda Civic Service Manual 96-98

Information General
1-2 .'.'..'.....'..'..'.." and Chassis PaintGodes " NumberLocations'..'.'.1-2O ldentification LabelLocations'..'..'1-21 Warning/Caution Emissions Under-hood ......1'25 Label.......... Control Lift and Support Points 1-21 Stands.'..".'..'..'.'.'.".' Lift and Safety 1'28 ....,.................. Jack Floor '.'....'1-29 Towing
and PaintCodes Chassis

U.S.1996Model l2-door Hatchback)
2AG
00001
2HG: HONDA CANADA OF
D16Y7: 1600SOHC16-valves Sequential Multiport Fuel-injected Engine
A4RA:4-speed Automatic Transmission S40 : s-speed ManualTransmission
H: AllistonPlant, Ontario, Canada Destin.iions
GY-16P NH-503P NH.583M R-97
Midori GreenPearl Granada BlackPearl New VogueSilverMetallic RomaRed
Vehicle ldentification Number and FederalMotor Vehicle Safety Standard Certification
Paint Code
COLOR GY.l6P
t-z
.\a
U.S. 1996Model {4-doorSedanl
J H ME J 6 2 * T S 0 0 0 0 0 1 5
D16Y7: 1600SOHC16-valves Sequential Engine Multipon Fuel-injected VTEC16-valves Sequential D16Y8; 1600SOHC MultiportFuel-injected Engine D16Y8 1300001JAPAN:D16Y7. U.S.A : D16Yt,D16Y8- 1500001-
Lino, Body 8nd EngineTyp EJ6: CIVIC4-door/Dl6Y7 EJ8: CIVIC4-door/D'16Y8 Body Typo and TransmissionType Manual 5: Sedan/s-speed
Automatic Transmission A4RA:4-speed ManualTransmission S40 : s-speed ManualTransmission S4C : s-soeed
A4RA {U.S.A.) : 5000001(JAPAN): 1000001S40. SaC

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 9: LX with ABS and A,/C ChckDigit Model Year T: 1996 L: EastLibertv. Ohio Plant,U.S.A. Japan Plant.Mie Prefecture, S: Suzuka H: AllistonPlant, Ontario, Canada
B-73M G-82P NH-538 NH-503P NH-583M R-95P
BlueMetallic Cyclone CypressGreenPearl FrostWhite BlackPearl Granada New VogueSilverMetallic lslandCoralPearl
PaintCode
Vehicle ldentification Number and FederalMotor Vehicle Safety Standard Cortification
COLOR B.73M
1-i
Chassis and PaintCodes

U.S. 1996Model (2-doorCoupe)
l H G E J 61 2 * T L 0 0 0 0 0 1
Lino, Body and EnginaTypc EJ6; ClvlCz-door/D16Y7 EJ7: ClVlC2-door/D16Y5 EJ8: ClVlC2-door/D16Y8 Body Type and Tranrmission Type
D16Y5: 1600SOHC WEC-E16-valves Sequential Multiport Fuel-injected Engine Dl6Y7: 1600SOHC16-valves Sequential Multiport Fuel-injected Engine D16Y8: 1600SOHC VTEC16-valves Sequential Multiport Fuel-injected Engine JAPAN:D16Y5 1300001U.S.A.: D16Y7. D16Y8 15OOO01-
3; OX with ABS, HX with ABS 4: DX with Ay'C, with Ay'C, HX EX 5: DX with ABS and Ay'C, with ABS HX and A"/C with ABS EX ChockDigit Modol Year T: 1996 L: EastLiberty, Ohio Plant,U.S.A.
A4RA : 4-speod Automatic Transmission S40,S4C:s-speed ManualTransmission M4VA ; Continuouslv Variable Transmission(CVT)
A4RA:5000001-
s40, s4c
M4VA: 1000001-

G-82P NH.5O3P NH-538 NH-583M B-81 R.95P CypressGreenPesrl Granada BlackPearl FroslWhite New VogueSilverMetallic MilanoRed lslandCoralPearl
PaintCode
COLOR G-82P
1 -4
1996 Modell2-door Hatchbackl CANADA 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 NH-503P NH.583M R-97 Midori GreenPearl Granada BlackPearl New VogueSilverMetallic Roma Red
Vehicle ldentification Number and CanadianMotor Vehicle Safety Standard Certification
PaintCode
COLOR GY.16P
1-5

CANADA 1996Model (4-doorSedan)
lHG EJ653*TL 800001
Lino, Body and EnginoTyp6 EJ6: ClVlC4-door/D16Y7 Body Typo and TransmissionTypo 5; Sedan/s-soeed Manual
4; LX with ABS 5: LX with ABS and A,/C 6: EX 7: EXwith ABS CheckDigit Model Year T: 1996 L: EsstLiberty, Ohio Plant,U.S.A.
A4RA;4-speed Automatic Transmission ManualTransmission S40 : 5-soeed A4RA:5000001S40 :1000001-
Vehicleldentification Number MotorVehicle andCanadian Safety Standard Gertif ication
B-73M G-82P NH-503P NH-538 NH-583M
Cyclone BlueMetallic Cypress GreenPearl Granada BlackPearl Frost White New VogueSilverMetallic
PaintCode
COLOR 8.73M
.'rr
F'.i!
1-6
CANADA 1996Model (2-doorCoupel
1HG J6 2*TL 000001 E 1
Lins, Body and EngineTypa EJ6: ClVlC2-door/D16\'/ EJ8: ClVlC2-doo./D16Y8 Body Typ6 and Transmi3sionType
1600 SOHC16-valves Sequential Multiport Fuel-injected Engine 1600SOHCWEC 16-valves Sequential Multipon Fuel-injected Engine
Transmission Number
A4RA- 5000001
Transmissionl A4RA I 4-soeed Automatic Transmission s40, s4c:s-soeedManualTransmission
3: Si with ABS 5: DX with ABS ChockDigit Model Yeat T: 1996 L: EastLiberty, Ohio Plant,U.S.A.
SerialNumbor A4RA :
s40, s4c:
Vehicle ldentif icationNumber MotorVehicle andCanadian SafetyStandardCertification
G-82P NH-503P NH-538 NH-583M R-81 R-95P
CypressGreen Pearl Granada BlackPearl Frost White New VogueSilverMetallic MilanoRed lsland Coral Pearl
PaintCode
COLOR NH-538
1-7

U.S. 1997Model (2-door Hatchback)
a
D16Y7i 1600SOHC16-valves Sequential Multipon Fuel-injected Engine
2 H GE J 6 2 * V H 1 0 0 0 0 1 3
Type ol Vohicl
Lino, Body and EnginoTypr EJ6: ClVlC3-door/D16Y7 Body Typo rnd Tranrmission Typc
3: CX with Ay'C 4: DX 5: DX with Ay'C 6: DX with ABS 7: DX with Ay'C and ABS Chcck Digit Model Yoar V; 1997 H; AllistonPlant, Ontario, Canada
A4RA:4-sDeed Automatic Transmission B4RA:4-speed Automatic Transmission S40 : s-speed ManualTransmission A4RA: 600000'lB4RA:6000001S40 : 1000001-
q
NH.503P NH.583M Pg-l 4P R-97 Granada BlackPearl New VogueSilverMetallic DarkAmethyst Pearl RomaRed
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 MultiportFuel-injected D16Y8:1600SOHCWEC 16-valvesSequential Engine MultiportFuel-injected JAPAN:D16Y7, D16Y8 2300001- 2500001U.S.A.: D16Yt,Dl6Y8
Lino, Body snd EngineTypo EJ6: ClVlC4-door/D16Y/ EJ8: ClVlC4-door/D16Y8 Body Typo and TrsnsmissionType Manual 5: Sedan/s-sDeed
A4RA: 4-soesdAutomatic Transmission B4RA: 4-spe6dAutomatic Transmission Transmission Automatic M4RA:4-speed S40 :s-speedManualTransmission
(U.S.A.)6000001: A4RA B4RA {U.S.A.) 6000001: 2000001M4RA UAPAN): S40(JAPAN) : 10000013: 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 ChockDigit Modol Ycsr V: 1997 L: EastLibertv, Ohio Plant,U.S.A. Japan Plant,Mie Prefecture. S: Suzuka Canada H: AllistonPlant.Ontario,
B.73M G-82P NH-538 NH-503P NH-583M R.96P
Cyclone BlueMetallic CypressGreenPesrl Frost White Granada BlackPearl New VogueSilverMetallic lnzaRed
Vehicle ldentification Number and FederalMotol Vehicle Safety Standard Certification
Paint Code
COLOR 8.73M
1-9

Vehicle ldentification Number
'tHG E J 61 4 * V L 0 0 0 0 0 1 Manutaqturer,Make and Type ol Vehicle lHG: HONDAOFAMERICA M F G ,I N C . , HONDAPassenger vehicle Line, Body and Engine Type EJ6; ClVlC2-door/D16Y7 EJ7: ClVlC2-door/D16Y5 EJ8: ClvlC2'door/D16Ya Body Typ and TransmissionType 1: Coupe/s-speed M an u a I 2; Coupe/4-speed Automatic, CVT Vehicle Grade 2: DX, HX 3: DX with ABS,HX with ABS 4: DX with A,./C, with A,./C. HX EX 5: DX with ABS and A,iC, with ABS HX and A'lC,EX with ABS Chsck Digit ModelYear V: 1997 FactoryCode L: EastLiberty, Ohio Plant,U.S.A. Serial Number
EngineNumber
D16Y5 2300001
EngineType D16Y5: 1600SOHC WEC-E16-valves Sequential Multiport Fuel-injected Engine D16Y7: 1600SOHC16-valves Sequential Multiport Fuel-injected Engine D16Y8: 1600SOHC VTEC16-valves Sequential Multipon Fuel-injected Engine Serial Numbr JAPAN:Dl6Y5 - 2300001U.S.A.: D16Y7, D16Y8 2500001-
Transmission Number
A4RA- 6000001 TransmissionType A4RA: 4-speed Automatic Transmission B4RA: 4-speed Automatic Transmission S40 :s-speedManualTransmission M4VA:Continuously Variable Transmission {CVT) Serial Number
A4RA 6000001: B4RA 6000001: S40 :1000001M4VA: 2000001-
G-82P NH.5O3P NH-538 NH.583M R-81
Cypress GreenPearl Granada BlackPearl Frost White New VogueSilverMetallic N4ilano Red
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 Multiport Sequential Fuel-injected Engine
Line, Body lnd EnginTypo EJ6; ClVlC3-door/D16Y7 Body Type and TransmissionType
A4RA:4-speed Automatic Transmission Automatic Transmission B4RA:4-sDeed S40 : s-sDeed MsnualTransmission
Canada H: AllistonPlant,Ontario,
Vehicle ldentification Number Motor Vehicle and Ganadian Safety Standard Certification
NH-503P NH.583M PB-74P R-97
G.anadaBlackPearl New VogueSilverMetallic DarkAmethyst Pearl RomaRed
Paint Code
COLOR NH-503P
1-11
and PaintGodes Chassis

1 H GE J 6 5 3 + V L 8 0 0 0 0 1
D16\.t: 1600SOHC16-valves Sequential Multiport Fueliniected Engine
Lino, Body and EngineTyps EJ6: ClVlC4-door/Dl6Y7 Body Type and TEnlmLrion Type 5: Sedan/s-soeed Manual
4: LX With ABS 5: LX with ABS and ly'C 7: EX with ABS 8: EX with ABS and !y'C
A4RA:4-speed Automatic Transmission 84RA:4-speed Automatic Transmission S40 : s-sDeed ManualTransmission
L: EastLibertv, Ohio Plant,U.S.A.
Vehicleldentification Number andCanadian MotorVehicle SafetyStandard Certif ication
B-73M G.82P NH-503P NH-538 NH-583M
Cyclone Metallic Blue Cypress Green Pearl Granada Black Pearl Frost White NewVogue Silver Metallic
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
Lino. Eody and Engins Type EJ6: CIVIC 2-doorlD16W EJ8: ClVlC2-door/D16Yg Body Type lnd Tran3missionType
D16Y7: 1600SOHC16-vslves Multiport Sequential Engine Fuel-injected WEC 16-valves D16Y8: 1600SOHC Multipon Sequential Engine Fuel-injected
3: Si with ABS 5: DX with ABS 6: OX with ABS and Ay'C 7: Si with ABS and Ay'C
44RA: 4-speedAutomatic Transmission Transmission B4RA:4-speed Automatic S40 :s-speedManualTransmission
A4RA: 6000001B4RA: 6000001S40 :1000001-
L: East Liberty, Ohio Plant. U.S.A.
Vehicle ldentif ication Numbel Motor Vehicle and Canadian Safety Standard Certification
G-82P NH-503P NH-538 NH-583M R-81
Cypress GreenPearl BlackPoarl Granada FrostWhite New VogueSilverMetallic MilanoRed
Paint Code
COLOR NH-538
1-13

U.S. 1998Model (2-doorHatchbackl
2HGEJ632 *WH 1 00001
D16Y7: 1600SOHC16-valves Sequential Multiport Fuel-injected Engine Line, Body and EngineType EJ6: ClvlC3-door/D16Y7 Body Type and TransmissionTyp
B4RA;4-speed Automatic Transmission S40 : s-speed ManualTransmission 3: CX with Ay'C 4: DX 5: DX with Ay'C 6: DX with ABS 7: DX with Ay'C and ABS CheckDigit Modl Year W: 1998 H: AllistonPlant.Ontario. Canada B4RA:7000001S40 : 1000001-
NH.592P NH-583M PB-74P R-97
Flamenco BlackPearl New VogueSilverMetallic DarkAmethystPearl RomaRed
Vehicle ldentification Number and FederalMotor Vehicle 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/:'1600 SOHC16-valves Sequential MultiportFuel-injected Engine VTEC16-vslves Squential D16Y8; 1600SOHC MultiportFuel-injected Engine D16Y8 3300001JAPAN:D16Y7. U.S.A : D16Y7, Dl6Y8 - 3500001-
Line, Body and EngineType EJ6: CIVIC4-door/D16Y7 EJ8: ClVlC4-door/D16Y8 Body Type and TransmissionType Manual 5: Sedan/5-speed
84RA: 4-soeed Automatic Transmission Automatic Transmission M4RA:4-sDeed ManuslTransmission S40 : s-soeed
(U.S.A.) 7000001: B4RA (JAPAN): M4RA 3000001' S40(JAPAN) : 10000013: DX with A"/C 4: DX WithABS,EX 5: DX with ABS and Ay'C 7: LX with A,/C 8: LX with ABS 9: LX with ABS and Ay'C
8.73M NH-578 NH-592P NH.583M R.96P
BlueMetallic Cyclone CypressGreen Pearl TaffetaWhite Flamenco BlackPearl New VogueSilverMetallic lnzaRedPearl
L: EastLiberty, Ohio Plant,U.S.A. Plant,Mie Prefecture, Japan S: Suzuka H: AllistonPlant, Ontario, Canada 000001: JAPAN,U.S.A. 500001: CANADA
Paint Code
COLOR 8.73M
VehicleldentificationNumbel and FederalMotor Vehicle Safety Standard Certification
1-15
Ghassis and PaintCodes

EngineNumber
1 H GE J 6 1 2 + W L 0 0 0 0 0 1
D16Y5 3300001
Engins Typ D16Y5: 1600SOHCVTEC-E t6-vatves Sequential Multipon Fuel-injected Engine D16Yr:1600SoHC 16-valves Sequential Multiport Fuel-injected Engine D16Y8: 1600SOHC WEC l6-vatves Sequential Multipon Fuel-injectd Engine Serial Numbor
Lin., Body and EnginaTypo EJ6: ClVlC2-door/Dt 6y7 EJ7: ClVlC2-door/D16y5 EJ8: ClVlC2-door/Dt6y8 Body Type and Transmbsion Type
1:Coupe/s-speed Manual 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, with ABS HX and Ay'C. with ABS EX ChackDigit Model Year W: 1998 L: EastLiberty, Ohio Plant,U.S.A.
JAPAN: D16Y5 3300001U.S.A. D16Y7, : 016Y8 350OOO1-
B4RA: 4-speed Automatic Transmissron S40 :s-speedManualTransmission M4VA:Continuously Variable (CVT) Transmission
Vehicleldentification Number and Fedoral Motor Vehicle SafetyStsndardCertifi cation
B4RA;7000001S40 :1000001M4VA: 4000001-
NH-592P NH-578 NH.583M R-81
CypressGreenPearl Flamenco BlackPearl TaffetaWhite New VogueSilverMetsllic MilanoRed
PaintCode
COLOR G-82P
1-16
CANADA 1998Model l2-door Hatchbackl

VehicleldentificationNumber
2HGEJ632 *WH 000001
Manufacturr.M!ke and Typ ot V6hicle 2HG: HONDAOF CANADA MFG.,INC. 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 Vchiclo G18d. 2: CX 3: CX-G Chock Digit Modol Yoar W;1998 FactoryCodo H: AllistonPlant, Ontario, Canada Sarial Number
B4RA: 4-speed Automatic Transmission S40 :s-speedManualTransmission B4RA: 7000001S40 :1000001-
Vehicleldentifi cation Numbsr and Canadian Motor Vchicle Srfoty StandardCertification

Paint Code
Flamenco BlackPeafl New VogueSilverMetallic DarkAmethyst Pearl RomaRed
COLOR NH.592P
1-17

Vehicleldentification Number
2HG EJ6 53 +W H 900001
Manutacturei. Make and Type of Vehicle

, \-
2HG: HONDAOF CANADA M F G .I N C , , HONDAPassenger vehicle JHM: HONDAMOTOR CO.. LTD. HONDAPassenger vehicle Line. Body and Engine Type EJ6: ClVlC4-door/Dl6Y7 Body Type and TransmissionType 5: Sedan/s-speed Manual 6: Sedan/4-speed Automatic
D16Y7: 1600SOHC16-valves Sequential Multiport Fuelinjected Engine
3750001-: U.S.A. 3700001-: JAPAN
Transmission Number
B4RA 7000001
TransmissionType B4RA: 4-speed Automatic Transmissron M4RA:4-speed Automatic Transmission S40 : s-speed ManualTransmission Ssrial Number
Vehicle Grade 0: EX 3: LX
4: LX with ABS 5: LX with ABS and A,/C 7: EX with ABS 8: EX with ABS and Ay'C ChockDigit Model Yoar W: 1998 FactoryCode H: AllistonPlant,Ontario, Canada S: Suzuka Plant,Mie Prefecture, Jaoan SerialNumb6r 800001-: JAPAN 900001-: CANADA
(U.S.A.) 7000001B4RA : (JAPAN):3000001M4RA S40(JAPAN) : 1000001-
B.73M G.82P NH.592P NH-s78 NH.583M
Cyclone BlueMetallic CypressGreenPearl Flamenco BlackPearl TaffetaWhite New VogueSilverMetallic
VehicleldentificationNumber and CanadianMotor Vehicle Safety Standard Certification
Paint Code
COLOR B-73M
1-18 t
GouPe) 1998Model (2-door CANADA a

1 H GE J 6 1 2 * W L 8 0 0 0 0 1
Line, Body and EnginType EJ6: ClVlC2-door/D16Y/ EJ8: ClvlC2-door/D'16Y8 Body Type and TlansmissionTyPe
D16Y7: 1600SOHC16-valves MultiPort Sequential Fuel-injected Engine WEC 16-valves D16Y8: 1600SOHC Multiport Sequential Engine Fuel-injected D16Y7: 3750001D16Y8:3780001-
Vehicle Grade 2: DX, Si 3: Si with ABS 5: DX with ABS 6: DX with ABS and AVC 7: Siwith ABS and A,/C CheckDigit Modsl Yoar W: 1998 Ohio Plant.U.S.A. L: EastLibertv,
Automatic Transmission B4RA: 4-speed M l S 4 0 : s - s p e e d a n u aT r a n s m i s s i o n
700000184RA: S40 :1000001-
VehicleldentificationNumber and CanadianMotor Vehlcle Safety Standard Gertification
G-82P NH-592P NH-578 NH.583M R-81
GreenPearl Cypress BlackPearl Flamenco TaffetaWhite New VogueSilverMetallic M i l a n oR e d
PaintCode
COLOR
NH-578
1-19
ldentification NumberLocations
V6hicl6 ldontification NumborlVlN)
\_
Transmission Numb6r
Numbl
*:., Y-
1-20
LabelLocations Warning/Caution
A A: CABLEREELCAUTION INSTRUC. MANUAL FOR DETAILED REFER SERVICE TO
C: DRIVER MOoULEDANGER DANGER EXPLOSIVE/FLAMMABLE CONTACTWITH ACID, WATER OR HEAVY METALSSUCH MAY PRODUCE HARMFUL LEADORMERCURY AS COPPER, AND IRRITATINGGASES OR EXPLOSIVECOMPOUNDS. MUST NOT EXCEED2OO"F TEMPERATURES STORAGE AND DISPOS. HANDLING, STORAGE {l(x}"CI, FORPROPER MANUAI- SRS SUPREFEi TO SERVICE AL PROCEDURES PLEMENT. POTSON SOOIUMAZIDEAND POTASSIUM CONTAINSPOISONOUS NITBATE. FIRST AID: ARE SWALLOWED, INDUCEVOMMNG, FOR IF CONTENTS EYECOI{TACT.FLUSIJEYESw|TH WATERFOR15 MINUIES. IF GASES(FROMACIO OR WATERCONTACI) ARE INHAI.ED, MEDICAL SEEKFRESH AIR. IN EVERYCASE,GET PROMPT ATTENNON. KEEP OUT OF REACH CHILDREN. OF
noNs.
MODUTIWARNING a: DRIVER
WARNING AND, IF ACCIDEN. THE AIRBAG INFLATORIS EXPLOSIVE HURTOR KILLYOU. TALLYDEPLOYED, CAN SERIOUSLY TESTEOUIPMENT PROB' OR . DO NOT USE ELECTRICAL ING DEVICES, DEPLOYMENT. THEYCAN CAUSEACCIDENTAL o NO SEnVICEABLE PARTSlNSlOE.DO NOT OISASSEM' 8tE. . PLACE WHENREMOVED. AIBBAGUPRIGHT CAREFULLY. . FOIIOW SERVICE MANUAL INSTRUC'TIONS
{cont'd)
1-21
Warning/Caution LabelLocations
(cont'dl
o.E
E
l----_l
=-+:
D: DRIVER INFORMATION: CANADA MODEIyouR SEAT 4!8q{Gt ALwAYsWEAR BELT
U.S. mod.l 198modell WASNING DEATHOR SERIOUS INJURYCAN (rcCUR. . CHILDREN AND UNDERCAN BE KII-LEDBY THE 12 AIRBAG. . THEBACKSEATlS THESAFEST PLACE FOBCHILDREN. . N E V E RP U T A R E A R . F A C I N G H I L DS E A T I N T I I E C FRONT. . SIT AS FARBACKAS POSSIBLE FROMTHEAIRBAG. . ALWAYS USE SEAT BELTSAND CHILDRESTRAINIS. . THESRS MUST BE INSPECTED TEN YEARSAFTER1TIS INSTALLED. . THE OATEOF INSTALLANON SHOWNON THE DRIV. IS ER'SDOORJAMB.
THISCAR IS EOUIPPED WITH A DRIVER AIRBAGAND A FRONTSEATPASSENGER AIFBAGTAS A SUPPLEMENTAL RESTRAINT SYSTEMISRSI. IT IS DESIGNED SUPPLEMENT TO THESEATBELT.
' Exc6mCANADACX E: SRSINFORMATION: U.S. modol {96,9? mod.l)
cAunoN
TO AVOID SERIOUS INJURY: . FORMAXIMUM SAFEW PROTECNON ALL TYPESOF IN CMSHES. YOU MUST ALWAYS WEAR YOUB SAFETY BELT. . DO NOT INSTALLREARWARD-FACING CHILDSEATSIN ANY FRONT PASSENGER SEATPOSITION. . DO NOT SIT OR LEAN UNNECESSARILY CLOSE THE TO ANBAG. . DO NOI PLACEANY OBJECTS OVEn THE AIRBAGOR BETWEEN THEAIRBAGANO YOURSELF. . SEETHE OWNER'SMANUAL FORFURTHER INFORMA. TION AND EXPLANATIONS. . THE SRS MUST BE INSPECTED TEN YEARSAFTEN|l |s INSTALLED. . TTIEDATE OF INSTALLATION SIIOWN OF THE DRIV. IS ER'SDOORJAMB,
1-22
F: ASSISTANT INFORMATIONT MOOEL{96,97 modell US AIRBAGSEEOTHER SIDE. U.S. model 198modell AIRBAGWARNING FLIPVISEROVER G: STEERING COLUMNNOTICE NOTICE TO PREVENT SRS DAMAGE, REMOVESTEERING WHEEL BEFOREREMOVING STEERINGSHAFT CONNECTING BOLT. H: MONITOR CAUTION NONCE . NO SERVICEABLE PAFTSINSIDE. . REFER SERVICE TO MANUAL FOR DETAILED INSTRUC.
J: SRSWARNINGIHOODI SUPPLEMENTAIRESTRAINT SYSTEMISRSI THIS VEHICLE EOUIPPED IS WITH DNIVER AND FBONT SEATPASSENGER AIRBAGS*. ALL SRS ELECTRICAL WIRINGAND CONNECTORS ARE COLORED YELLOW. TAMPERING WITH, OISCONNECTING USING ELECTRI. OR CAL TEST EOUIPMENT ON THE SRS WIRING CAN MAKE THE SYSTEMINOPERATIVE CAUSEACCIDENTAL OR FIR. ING OF THEINFLATOR. WARNING THE AIRBAG INFLATORIS EXPLOSIVE ANO. IF ACCIDENTALLY OEPI-OYED. CAN SERIOUSLY HURT YOU. FOLLOW SERVICE MANUAL INSTRUCTIONS CAREFULLY.
' Exc.et CANADA CX f: PASSENGER AIRBAG CAUnON U.S.rnodol mod.l) 198

WARNING CHILDREN CAN BE KILLEDOR INJURED 8Y PASSENGER AIRBAG. THE BACKSEAT IS THE SAFESTPLACEFORCHILDREN 12 AND UNDER, MAKE SUREALL CHILDRN USE SEATBELTS OR CHILO SEATS.
TtoNs.
I: FRONT SEATPASSENGER MODULEDANGER DANGER EXPLOSIVE/FLAMMABLE CONTACTWITH ACID, WATER OR HEAVY METALSSUCH AS COPPER, LEAD OR MERCURYMAY PRODUCE HARM. F U L A N D I F R I T A T I N G A S E SO R E X P L O S I V E O M G C POUNDS.STOBAGE TEMPERATURES MUST NOT EXCEED 2OO"F FOR PROPER HANDLING. IlOO"CI. STORAGE AND DISPOSAL PROCEDURES REFER SERVICE TO MANUAL, SRSSUPPLEMENT. POTSON CONTAINSPOISONOUS SODIUM AZIDEANO POTASSIUM NITRATE. FIRSTAID IF CONTENTS ARE SWALLOWED, INDUCEVOMITING.FOR EYE CONTACT,FLUSH EYES WITH WATER FOR 15 MIN. UTES,IF GASES IFROMACID OR WATER CONTACTI ARE INHALED, SEEKFRESH AIR IN EVERYCASE.GET PROMPT MEDICAL ATTEiITION. KEEP OUT OF REACI{ CHILDREN. OF WARNING THE AIBBAG INFLATORIS EXPLOSIVE AND, IF ACCIDEN. TALLYOEPLOYED, CAN SERIOUSLY HURTOR KILLYOU. o DO NOT USE El-ECTRICAL TESTEOUIPMENIOR PRO& ING DEVICES. THEYCAN CAUSEACCIDENTAL DEPLOYMENT. . NO SERVICEABLE PARTSINSIDE.OO NOT DISASSEM. BLE, . PLACE AIRBAGUPRIGHT WHENREMOVEO. . FOLLOWSERVICE MANUAL INSTRUCNONS CAREFULLY.
(cont'd)
1-23
Warning/CautionLabel Locations
(cont'd)
I
1-24
Under-hood Emissions ControlLabel(19!16, 1997modell

Emission Groupldentification
Example:
tsF COOUNI, USE 'o'EO SOLUTION
Engineand Evaporative Families

Engine Family:
Model Ysar T: 1996 V; 1997 Manufacturer H N :H o n d a Di3placomont V H N1 . 6 V J G K G K
VACUUMHOSE ROUTING DIAGRAM
Clsss
V: Light Duty Vehicle/Passenger Car Fuol Systsm and Numbsr of Valvo3 J: Electronic Sequential Multipon Injection (threeor more valvesper cylinder) Fuol Typ G: Gasoline Standard F; 49 or 50 States Tier 1 K: 49 or 50 StatesTier 1 1: California Tier 1 2: California TLEV 3: California LEV 4: California ULEV Catalyst E, F, G, H: Three Way Catalyst
VEHICLE EMISSION INFORMATION CONTROL

FAM|LY ls90.F}q? ENGlrlE vHNl6vJcrcr D.SB-ACEME{T O0 CIVIC EvApoMtrvt FAMrry vHNroTTByMAc p:9
Hrr.n u stcv'ct MA\uArro' aDofl ror{A, ro\. ff-Tl TUN! CO\DNOIIS: AT LP ENGIN! NOFMAI OPFMTING TTM'EqA-U8!. I I|rf ' ALtACCESSoRTESTUq{Eo FAN oFf,CooUNG oFf, TiANSMISSIONNEUIML IN N0 ollrEFaDJUSTT,TENTS NE!DEo. oBD CERTtftED IOLESPEED TMNSMISSION 12" I3TDC l
CATALYST rwcHo2s{2)sFl 'N.oRMA
OBD K - T: OBD Equipped Evaporative Family:

V H N 1 0 7 7B Y M A C
T!
e+l rr _9.,.'
THIS VTHICLE CONFORMSU.S. ANO IO EPA SIAIE OFCALIFO8NIA REGULAIIO1TS APPLICAELE TO1997 MOOEL NEI1 YEAN MOTON VEHICIES. CEBT]FICANON IN.USE 112 nE-N2 NtR1 NEA 1FUTL
ililulIl
ModetYsar
H0N0A MOTO8 tTD. C0.,
50ST {50 States}: THISVEHICLE CONFORMS U.S.EPAAND STATE TO OF C A L I F O R N I R E G U L A T I O NA P P L I C A B LT O 1 9 9 7 A S E MODEL YEARNEWMOTOR VEHICLES. 49ST (49 States/Fodoral): THISVEHICLE CONFORMS U.S.EPAREGULATIONS TO APPLICABLE 1997MODEL TO YEARNEW MOTOR VEHI-
T: 1996 | V:1997 ] Manutaqturer HN: Honda Storage System 1:Canister Canirtor Wolking Caprcity lgrEmsl CanisterContigurstion A: Plastic Housing(Closed Bottom) B: Plastic Housing{OpenEottom) Ful System Y: FuelInjection
Fuel Tank
TT
CAL (Californis): THISVEHICLE CONFORMS U.S.EPAAND STATE TO OF C A L I F O R N I R E G U L A T I O NA P P L I C A B LT O 1 9 9 7 A S E M O D E LY E A R N E W P A S S E N G E C A R SP R O V I D E D R THATTHISVEHICLE ONLYINTRODUCED IS INTOCOM. MERCE FORSALEIN THESTATE CALIFORNIA. OF
M: Metal Standard A: Current Evap E: Enhanced Evap Wild Card
(cont'd)
1-25
modell Emissions ControlLabel(1998 Under-hood

(cont'd) Emission Groupldentification
Example:
Model Y6ar
Families Engineand Evaporative

EngineFamily:
W: 1998 Manutacturer H N X :H o n d a
W HNX V 01.6JL2
Type
V: LightDutyVehicle/Passenger Car Displacment SequenceCharaqters
VEHICTE INFORIVIATION EMISSION CONTROL

OF RECULATIONSAPPLICABLE STAT CALTORNLA TO 1933 MOOELYEAR NEWTLFVPASSENGEfr INTBOOUCEOINTO COMMERCE SALE N TNE FOR
Evaporative Family:
ModlYear W: 1998 Manufacturar HNX:Honda Type E: EVAP CaniaterWork Capacitylgrams) SquoncaChrract6ls
W H N X E0065 AAD
two1r02s1?tEcR/sFt/0B0 E0 | cEBTtF
VAIVLASH
CATALYST
NONDAMOTORCO LTD
50ST{50 States): THISVEHICLE TO CONFORMS U.S.EPAAND STATE OF S C A L I F O R N I R E G U L A T I O NA P P T I C A B LT O I 9 9 8 A E MODEL YEARNEWMOTOR VEHICLES. 49ST(49 States/Fedral): THISVEHICLE CONFORMS U.S.EPAREGULATIONS TO APPLICABLE 1998MODEL TO YEARNEWMOTOR VEHI.
LLEJ.
CAL (Calilornial: THISVEHICLE CONFORMS U.S.EPAAND STATEOF TO S E C A L I F O R N I R E G U L A T I O NA P P L I C A B LT O 1 9 9 8 A M O D E LY E A R N E W P A S S E N G E C A R SP R O V I D E D R THATTHISVEHICLE ONLYINTRODUCED IS INTOCOMMERCE FORSALEIN THESTATE CALIFORNIA, OF
1-26
Lift and SupportPoints

Lift and SafetyStands
When heavy rear componnts such as suspension, ful 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/whel assembly weighsapproximately lbs {14 kg). placingthe front wheelsin the luggageareacan 30 assistwith the weight distribution. . Usethe samesupportpointsto supportthe vehicleon safetystands. 1. Place lift blocksas shown. the s) 2 . R a i s e t h e o i s t a f e w i n c h e ( c e n t i m e t e ra n 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 . h s 3. Raise hoisttolull height,and inspectlift pointstorsolidsupport. the
REARSUPPORT POINT
(cont'd)
1-27
Lift and SupportPoints

(cont'dl FloorJack
l.
Set the parkingbrakeand blockthe wheelsthat are not beinglifted. When liftingthe rearof the vehicle,put the gearshift 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 level.then lower the vehicle will be approximately onto them.
Alway3 u3a safoty stand3 whcn working on 01 undol anv vchiclo that b 3upportod by only a iack. Nover attompt to uso a bumper iack for lifting or supporting tho vohicl.
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
towIt the vehicleneedsto be towed,call a professional Nevertow the vehiclebehindanothervehiing service. 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 Equipmnt- The tow truck uses metal cables with hookson the ends.Thesehooksgo aroundpartsof and the cableslift that end of the frame oJ suspension, suspension and the vehicleoff the ground.The vehicle's damagedit this methodof towing body can be seriously is attemDted. it lf the vehiclecannotbe transported flat-bed, should by 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 CVT and . Release parkingbrake. the . Shiftthe transmission neutral(CVT E position). to to Transmission Automatic . Release parkingbrake. the . Startthe engine. . Shiftto lpl position, then E position. . Turn off the engine. CAUTION: . lmproper towing propantion will damsgo the transmi3sion, Follow tho above procodur x6ctly. It you cannot 3hift the lransmission 01 start th engine (automltic trsnsmissionl.your vhicl9 mu3t be trang portod on a ffot-bd. It is best to tow tho vshicls no farthol th.n 5{t mibs (80 km), lnd kosp tho sped 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.
Front:
TIE OOWN HOOKS
Roar:
TOWING
1-29
Specifications
Standardsand ServiceLimits .............. 3-2 D e s i g n p e c i f i c a t i o n.s . . . . . . . . . . . . . . . . . . .3 - . 5. . . S . .. 1 . Body Specifications .......... 3-18
and ServiceLimits Standards

- Section 6 Cylinder Head/Valve Train - arlilil,r(rrr o
MEASUREMENT Compression 250 rpm and wide open throttle kPa (kgf/cm',psi)
STANOARD {NEW}
SERVICE UMIT
'1,270 184) Nominal {13.0, 930 (9.5,135) Minimum Maximumvariation 200 Q.0,2al
Cylinder h6ad
Camshaft
Warpage Height Endplay oil Camshaft-to-holder clearance Total runout D16Y7 Cam lobeheight D16Y5 D16Y8
o*
- gs.or ta.arr r.66gt
0.05 {0.002)
(Cold) Valveclearance Valvestem O.D. clearance Stem-to-guide widrh height Stem installed Vslvespring Freelength
Valveguide
l.D. Installed height
0.05- 0.15(0.002 0.006) 0.050- 0.089(0.002 0.004) 0.03(0. 0 1 ) m a x . 0 lN 35.29911.3897) EX 37.24111.4678) Primary 38.127 1 1 . 5 1 2 9 ) IN 4l Scondary 3 2 . 1 9 3 i1.267 38,78411.5269) IN Primary 36.77411.4479) Mid 38.21111.50681 Socondary 37.06511.4592) 38.00811.4964) IN 0.18- 0.22{0.007 0.009} EX 0.23- 0.27(0.009 0.0111 IN 5.48- 5.19(0.2157 0.2161) EX 5.45- 5.46(0.2146 0.2150) IN 0.02- 0.05(0.001 0.002) EX 0.05- 0.08 (0.002 0.003) IN 0.85- 1.15(0.033 0.045) EX 1.25 1.55(0.049 0.061) IN 53.17- 53.6112.093 2.112) (2.093 2.112) EX 53.17 53.64 57.9(2.28) Dl6Yt D16Y5 IN 56,512.221 EX 57.9(2.28) D,I6Y8 IN 58.0(2.28) EX 58.7(2.31) IN 5.51- 5.53(0.217 0.218) EX 5.51- 5.53(0.217 0.218) IN 17.45- 18.35(0.703 0.722) (0.734 0.754) 18.65 19.15 IN EX
0.5{0.02) (0.0061 0.15 0.04(0.0021
iEi.rtnut
5.12 10.21341 0.08{0.003) 0.11(0.004) 1.6(0.063) 2.0{0.079} 53.49Q.1221 (2.122) 53.89
L
5.s5(0.219) 5.55{0.219}
Rocker arm
Arm-to-shaftclearance
(0.00070.0020) 0.0r7- 0.050 - 0.0021 0.018 0.054 10.0007 )
0.08(0.003) 0.08(0.003)
3-2
EngineBlock- Seaion 7
MEASUREMET'lT
Cylinder block Warpageof decksurface Eore diameter Bore taPer Rboring limit SkirtO.D. at 5 mm (0.2in) from bottom of skirt in Cloa16nce cylindor Groovewidth {tor ring) Top Second oil Ring-to-grooveclearance Top Second Ringend gap Top Second oil
Unitot length: mm (in)
STA]TDARD INEWI (0.003) max. 0.07 (2.953 2.954) 75.00 75.02

74.940- 74.990t2.9520 2.95241 0.010 't.0201.220 2.805 0.040 {0.0004 0.0016) 1.030(0.0402 0.0406) (0.0480 0.0484) 1.230 (0.1104 0.1110) 2.820
SERVICE UMIT
0.10(0.001) 75.07(2.956) 0.05(0.002) 0.5(0.02)
Piston
(2.9516) 74.970 0.05 {0.002) 1.05 {0.041) (0.049) 1.2s (0.112) 2.85 (0.005) 0.13 (0.005) 0.13
0.60 (0.024) 0.70 (0.028) 0.80(0.03r)
Pislonring
0.035 0.060 {0.00140.0024) 0.030 0.055 {0.0012 0,0022)

0.15- 0.30(0.006 0.012) 0.30- 0.45(0.012 0.018) 0.20- 0.70 (0.008 0.028) - 19.000(0.7478 0.7480) 18.994 (0.0004 0.0009) 0.010 0.022 0.014- 0.040(0.0006 0.0016) 18.96- 18.98 {0.746 0.747} 48.0(1.89) 0.15- 0.30(0.006 0.012) (2.16,142.1654) 54.976 55.000 -1.17171 44.976 45.000/.1.1701 (0.0001) m6x. 0.0025 (0.0001)max. 0.0025 0.10- 0.35(0.004 0.014) 0.03{0.001) max. 0.018- 0.03610.0007 0.00'14) (0.0009 0.0017) 0.024 0.042 0.020- 0.038(0.0008 0.0015)
pin Piston Connecting roo
o.D.
Pin-to-piston clearance Pin-to-rodinterlerence Small end bore diameter Largeend borediameter Nominal End play installedon crankshaft Mainjournaldiameter Rodiournaldiameter Taper Out-ot'round Endplay Totalrunout Main bearing-to-journal clearance oil No. 1 and 5journals N o . 2 . 3a n d4 j o u r n a l s Rod bearing-to-journ8l clarance oil
ororo.o'tur ooos to.ooort
Crankshatt
0.005 {0.0002) 0.45 {0.018) 0.04(0.002)

0.05 (0.002) 0.05 (0.002) 0.05 (0.002)
Bearings
EngineLubrication
Engine oil
Soction 8
MEASUREMENT (NEW) STANDARD
D16Y7 Dl6Y5, D16Y8
SERVICE LIM]T
Capacity f (uS qt, lmp ql)
4.3(4.5. 3.8)tor engineoverhaul 3.6(3.8, 3.2)foroil change. including filter 3.3 (3.5,2.9)for oilchange. withoutfilter 3.7 (3.9,3.3)for engine overhaul 3.3 (3.5, 2.9)for oil change, including filter 3.0 (3.2, 2.6)Ioroil change, withoutfilter
Oil pump
Reliofvalve
lnner-to-outerrotor radial clearance Pumphousing-to'outer rotorradialclearance Pump housing-torotor axial clearance Pressure settingwith oil temperature176'F (80'C) kPa (kg7cm,,psi) at idle at 3,000rpm
(0.0010.006) 0.02 0.14 (0.0040.007) 0.10 0.18 0.03 0.08(0.001 0.003)

7 0( 0 . 7 . ' 1 0 ) m i n . 340(3.5,50) min.
0.20 {0.008) 0.20{0.008) (0.006) 0.'15
3-3
Standardsand ServiceLimits
Cooling- Section 10
MEASUREMENT
Radiator Enginecoolantcapacity , (US qt, lmp qt) heater, cooling including engin6, line and reservoir Rosorvoircapacity: 0.41 (0.42 qt,0.35lmpqt, US Mll Nf
STAiIDARO INEWI
4.2 (4.4,3.7)tor overhaul 3.1 (3.3,2.7)tor coolsnt change D16Y/ 4.1 (4.3,3.6)tor overhaul change 3.0(3.2, 2.6)torcoolant D16Y8 4.3 (4.5,3.8)for oveIhaul 3.2 (3.3,2.8)for coolantchange 4.3(4.5, 3.8)foroverhaul 3.2 (3.3,2.8)tor coolantchango 13.5 17.8} 93 - 123{0.95 1.25, 169- 176(76 - 80) 194(90) 8 . 0( 0 . 3 1 1 m i n . '196 203 (91 - 95) "ON" temperatur Subtract5 - 15 (3 - 8) from actual
CVT
Radiatorcap Thermostat Opening pressure kPa (kgf/cm'.psi) Start to opening 'F ('C) Fullyopen 'F ('C) valve lift al tully open Thermoswitch"ON" temperature Thermoswitch"OFF" t6mperature
fan Cooling
.F (.C) "F (.C)
11 FuelandEmission Section
MEASUREMENT
Fuel pr6ssu16 regulator
STANDARD {i{EWI
260- 310 (2.7- 3.2,38 - 46) 1 5( 1 1 . 9 , 9 . 9 ) M/T (neutral)
Fuoltank Engine
Pressure with fuel pressureregulatorvacuum hose disconnected kPa {kg7cm',psi) CaDacity / (USqal,lmp gal) ldle speed rpm
M or CVr (E or E position)
u.s.A.
016Y5 D16\.' D16Y8
ldleCO %
Canada
u.s.A.
700I 50 700r 50 700f 50
Canada
670r 50 670I 50 670I 50

0.1 mx.
750r 50 750i 50
750+ 50 750r 50
L .
Clutch- Section12
MEASUREMENT
Clutchpedal Pedalheight Stroko Pedalplay Disengaggment height Clutchsurfac6runout Rivet head depth Thickness Warpage Diaphragm springfingersalignment
STA'{DAND INEW) (6 1/2) 165 to floo. 130 140(5 1,4- 5 1/2) 12- 21l1t2- 13t161 to floor 83 t3 r/4) to carpet 44(1 3/4)min.Reterence
max. 0.05{0.002}
SERVICE UMIT
0.15 (0.005)
clutchdisc
plat Pressure
1.3 1.9{0.05 0.07) 8.5- 9.1{0.33 0.36) (0.001) max. 0.03 0.6{0.02} max.
0.2(0.01) 5.510.221 0.15(0.(X)61 1.0(0.04)
ti."
3-4
ManualTransmission Section 13
MEASUREMET'lT
Transmission oil Mainshaft Capacity f (US qt, lmp qt) Endplay . Diameterof ball bearingcontactarsa A (Transmission housing sids) Diameterof 4th, sth gear contactarea B Diameterof 3rd gear contactar6aC Diameterof ball bearingcontac't area D sidel lClutchhousing Runout t.D. Endplay Thickness Mainshaft5th gear 3rd 4th 3rd 4th
Unit of length: mm (inl
STANDAND INEWI
1.9(2.0, 1.7)for overhaul 1.8(1.9, 1.6)fo. oilchangs
SERVICE T Ui
(0.0040.007) 0.r1-0.18 (0.86560.8661) 21.987 22.000
Adjust 21.930(0.8634)
(1.0622 1.0627) 26.930(1.0602) 26.980 26.993 33.984 3..000fi.3380 1.33861 33.930t1.3358) (1.0205) 25.917 25.990 11.0221 1.02321 25.920 max. 0.02 {0.001) 39.009 39.025 {1.5358 '1.5364) 0.06 0.21{0.002 0.008) 0.06 0.19{0.002 0.007) 30.22 30.27 11.1901.1921 (1.186 1.188) 30.'t2 30.17 - 37.025t1.4510 1.15711 37.009 0.06 0.19 {0.002 0.007) 24.42 28.17 .119 1.1211 t1
(1.1811 1.1817) 30.000 30.015 35.98,1-36.000(1.4167 1.4173) 24.980- 24.993(0.9835 0.9840) max. 0.02(0.001)
Mainshaft and 3rd 4th gears
t.0. Endplay Thickness

Diameterof needleb6aringcontactarea A Diameterof 1st gear contactarea B Diameterol ball bearingcontact areaC Runout
0.05(0.002) (1.538) 39.07 0.33 {0.013} (0.012) 0.31 (1.187) 30.15 (1.183) 30.05 (1.459) 37.07 (0.012) 0.31 (1.1161 28.35
Countershaft
Countershaftlst gar Countershaft 2nd gear Spacer collar (Countershaft 2nd gar) Spacercollar (Mainshaft4th and sth goar)
l.D. Endplay(When tightened lhe specifld by torque) Thickness t.D. Endplay(When tightened the spocitid by torque) Thickness
LD.
29.950 {1.1791) (1.4146) 35.930 24.930(0.98151 0.05{0.002) 41.00941.025 t1.61451.6152) 41.07 {1.617) 0.03 0.10{0.001 0.004} 0.22{0.009} (1.197 1.198) (1.195) 30.41 30.44 30.36
o.D.
Length
t.D. o.D.
Length
4th
5rh ath 5rh
(1.7326 1.7333) 44.009 44.025 0.04 0.12 {0.0020.@5) (1.256 1.258' 31.91 3'1.96 -33.0r0 fi.2992 1.2996) 33.000 -39.000{1.5350 1.535,r) 38.989 (1.261 1.262) 32.03 32.06 (1.06311.0635) 27.00227.012 (1.3381 1.3386) 33.989 34.000 (1.25941.2598) 31.98932.000 22.83 22.86 t0.899 0.9(X)) 23.53 23.56 {0.926 0.928)
15.016 15.043 t0.59'120.5922) 0.032- 0.077{0.0013 0.0030)
(1.735) 44.07 0.24(0.009) (1.254) 31.85 33.04 fi.3011 (1.533) 3{'.93 (1.260t 32.01
27.05{1.065) (1.336) 33.93 (1.257) 31.93 22.81(0.898) 23.51(0.926) 15.08{0.594) 0.r4 (0.006)
idlergear Reverse Synchroring Shitt fork
t.o.
gear shaft clearance Gear-to-revsrs6 Ring-to-gear clearance{Ring pushedagainstgear) Forktinger thickness lstnnd 3rd/4th Fork-to-synchro sleeveclea16nce Fork pawl groove width Fork-to-revrse idler gear clarance L-groovewidth Fork-to-5th/reverse shift oic6oin cl6a16nce Inner diameterof shift arm C contactpoint Shift arm A-to-shiftarm C clearance Inner diameterof shift arm B shaft contact point Shift arm B-to-shaft clearance Shift arm B-to-shittpiece clearance Diam6terot shift Diececontact Doint Backlash
(0.029 0.046) 0.73 1.'r8

O.2521 6.2 - 6.1 1O.2117.4 - 7.6 (0.291 0.299) 0.35- 0.65(0.014-0.026)
0.4(0.016)
to roonr
1.8(0.07) 0.5(0.02)
Reverse shift fork
(0.50 0.5'l) 12.7 13.0 0.5- 1.1(0.020 0.043) (0.2810.289) 7.15 7.35 0.05 0.35(0.002 0.014)
(0.514 0.517) 13.05 '13.'t3 0.05- 0.23 (0.002 0.009)
Shiftarm A Shift arm B
0.35 {0.014}
0.16(0.006) 0.62(0.02441 't2.78 (0.5031)
Finaldrivengear Differentielcarrier
Pinion shaft boro diamter Carrier-to-pinion shaft clearance Driveshaftbore diameter CarrieFto-driveshaft clearance pinion Backlash Differential gear Piniongear bore diameter Piniongear-to-pinionshaft cl6aranca Set ring.to-bearingorrterrace
13.97314.000 {0.550r0.5512} 0.013 0.070 {0.0005 0.0028) 0.2- 0.5(0.008 0.020) (0.50812.9 13.0 0.512) 0.07 0.130 {0.0028 0.0051) (0.70910.7@81 18.01018.028 0.023 0.057 t0.0009 0.0022) (1.02461.0254) 26.02526.04s (0.0018 0.0034) 0.045 0.086 0.05 0.15{0.002 0.006} - 0.7113) 18.042' I8.066 {0.7103 (0.0021 0.0037) 0.055 0.095 0 - 0.1(0- 0.004)
(0.007r) 0.180
o.ogu to.ooot
0.11 {0.006) (0.006) 0.15
Adjust with shim
3-5
Standards and ServiceLimits

Automatic Transmission-- c t l ; t t t t t 14 Section t . l
MEASUREMENT
Transmission fluid Hydraulic pressure (kgtcm', psi) Capacity f {US qt, lmp q0 rpm in E or E position Line pressureat 2,OOo lst clutch pressureat 2,000rpm in Pll position .2nd clutch pressureat 2,000rpm in E position
STANDARO {NEWI
5.2)toroverheul 5.9(6.2, 2.4}lorfluidchange 2.7{2,9, 830- 880 (8.5- 9.0,120- 130) '124) 800- 850 (8.2- 8.7, 120with linearsolenoid connector disconnected ( 0- 150 0- 1.5,0-21) with linear solsnoidconnectedto batteryvoltage 810- 860 (8.3- 8.8.1' 18 125) with linear solenoidconnector disconnected 0-150(0-1.5,0-21) with linear solenoidconnecledto batteryvoltage
SERVTC UM]T
110) 780 (8.0, 760 (7.7, 110) with linsar solenoid connctordisconnected 1 5 0{ 1 . 5 2 1 ) , with linar solenoid connectedto baftory voltage 760 (7.8, 1) 11 with linearsolenoid connectordisconnocted 1 5 0( 1 . 5 , 2 1 ) with linear solnoid to connectecl battery voltage 2,550- 2,450
pressure 2,000 rpm in lQl posi' at 3.d and4thclutch tion
with vehicle levelground) on Stallspeedrpm (Chck Clutchinitialclearance Clutch Clutch return spring free longth {A4RA,B4RATransmission) (M4RA Transmission) Clutch disc thickness Clutch plate thickness Clutchend plate thickness (A4RA, B4RA Transmission)
2,700
lst, 2nd 3rd, 4th lst 2nd,3rd,4th lst 2nd,3rd,4th 0.6s - 0.85 (0.026 0.033) 0.40- 0.60(0.016 0.024)
Clutchend platethickness Transmission) {M4RA
32.0(1.26) 30.5{1.20) 31.1 11.22) 30.5(1.20) 1.88 2.00(0.074 0.079) 1.55 1.65(0.061 0.065) lst 2 n d , 3 r d , 4 t h 1.95 2.0510.077 0.081) Mark 1 2.05- 2.10(0.081 0.083) Mark2 2.15- 2.20(0.085 0.087) Mark 3 2.25- 2.30{0.089 0.091) 2.35,2.40(0.093 0.094) Mark 4 Mark 5 2.{5 - 2.50 (0.096 0.098} 2.55- 2.60(0.100 0.102) Mark6 Mark7 2.65- 2.70(0.104 0.106) Mark8 2.75- 2.80(0.r08- 0.110) 2.85- 2.90(0.112 0.114) Mark9 Mark1 2.3 - 2.4 (0.091- 0.094) 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) 2.7- 2.8 (0.106 0,110) Mark5 Mark6 2.8- 2.9(0.110 0.114) Mark 7 2.9- 3.0 (0.114 0.118) 8 Mark8 3 . 0- 3 . 1( 0 . 1 1- 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)
3 0 , 01 . 1 8 ) { 2a.st1.12) ( 2 9 . 11 . 1 s ) 28.5 fi.12) wornout Untilgrooves Discoloration

Discoloration
I I
Discoloration Discoloration
Discoloration
\-
3- 6
AutomaticTransmission Section 14
MEASUREMEifl Transmission Diameterof needlebearingcontsct arsa on mainshaftstator shaft bearing 2nd gear On mainshaft On mainshaft4th gear collar 1st On mainshaft gearcollar On countershaft(left side) On countershaft3rd gear collar On countershaft4th gear On countershaftr6versegear collar On countrshaftlst gear collar On reverseidler gear shaft lnside diameterof noodlebearingcontactarea On mainshaft gear 1st 2nd gear On mainshaft On mainshaft4th gear on countershatt1st gear On countershaft3rd 96ar On countershaft4th gear On countorshaftreversegear On reverseidler gear On stator shaft (ATFpump sid) On stator shaft (statorside) Reverse idler gear shaft holder l.D. Endplay Mainshatt gear 1st Mainshaft 2nd gear Mainshaft4th gear Countelshaft1st gear Countershaft gear 3rd Countershaft4th gear Reverse idler gear Countershaftreversegear Selectorhub O.D. Mainshaft4th gear collar lngth Mainshatt4th gear collar flange thickness Mainshatt gearcollarlength 1st distancecollar length Countershaft STANDAND NEWI 22.980- 22.993(0.9047 0.9052) (1.4163 r.4169) 3s.97s 3s.991 -31.991(1.2589 1.2595) 31.975 30.975- 30.99'l(1.2195- 1.2201l(1.4175 1.4180) 36.004 36.017 (1.4165 1.4172) 35.980 35.996 (1.1016 1.1021) 27.980 27.993 -31.991(1.2589 1.2595) 31.975 31.975 31.99' (1.2589-1.2595) ] (0.5508 0.5512) 13.990 14.000 (1.3780 1.3786) 35.000 35.016 (1.6142 1.6148) 41.000 41.0't6 (1.4961 r.4967) 38.000 38.016 (1.4961 1.4967) 38.000 38.016 (1.6142 1.61481 41.000 41.016 33.000 33.0r6(1.2992 r.2998) (1.4961 1.43671 38.000 38.016 18.007 18.020(0.7089 0.7094) -29.01311.14111.14221 29.000 27.O00 27.021(1.0630 1.0638) (0.5676 0.5683) 14.416 14.434 0.08- 0.19{0.003- 0.007) 0.05- 0.13(0.002 0.005) (0.003 0.0071 0.075 0.185 0.'1- 0.5 (0.004 0.020) 0.05- 0.17(0.002 0.007) 0.10- 0.18(0.004 0.007) 0.05- 0.18(0.002 0.007) 0.10- 0.25(0.004 0.010) (2.042 2.0) 5r.87- 51.90 45.00 45.03 fl.771- 1.773) (0.1746 0.178' l) 4.435 4.525 27.00 27.15 {1.063 1.069} 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.'t 1.538 1.539) 0 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) (0.833 0.835) 21.15 21.20 20.65 20.70 {0.813 0.825) 14.5 14.6(0.571 0.575) 2.4- 2.6{0.094 0.102) 14.5 14.6(0.571 0.575) 2.4- 2.6{0.094 0.102)
unit of lngth: mm (in)
LIM]T SERVICE
Wearor damage
Wearor damage Wearor damage
War damage or
wuu, o, du-"n" Wear damage or
Countershaft gear collar length 3rd
'96, '97 models '98 model
Countershaft reverssgear collar length Countershaltreversegear collar flange thickness Countershaft1st gear collar length Countershaft1st gear collar flange thickness
Wear or damage Wear or damage
(cont'd)
3-7

Automatic Transmission {cont'd}
Taansmission
Section 14
STANDARD INEWI
3.974.024.07 4.12 4.17 4.224.274.32 4.371.124.00(0.r56- 0.157) 4.05(0.158 0.159) 4.10(0.160 0.161) 4.15(0.162 0.163) 4.20(0.164 0. t651 4.25(0.166 0.' t67) 4.30 (0.168 0.1691 4.35{0.170 0.171} -0.1131 4.1010.172 1.15 10.171-0.1751 SERVICE UMIT Wearor damage
MEASUREi'ENT
Mainshaft2nd gar thrust washgrthicknegs
1 I
Wear or damage
Thrust wash6r thickngss Mainehsfl ball boaring loft side Mainshaft 1st gear Counte6haft3rd garsplinedwasher '96,'97 models '98 model One-wayclutch contactarea Countershaftlst gea. l.D. Parkinggear O.D. Mainshaftleed pipe A, O.D.(at 15 mm (0.59in) trom end) Mainshaft foed pipe B. O.D.(at 30 mm {1.2in)trom end} Countershaft feed pipe O.D.{at 15 mm (0.59in}trom ndl Mainshattsealingring thickness ( 2 9m m ( 1 . 1 n ) a n d3 5 m m ( 1 . 4 n ) ) i i Mainshaft bushing l.D. Mainshaft bushingl.D. Couni6rhaft bu6hing l.D. Mainshaftsealingring goovo widlh Sealingring contactargo LD. Reverse shift fork finger thickhoss Parkingbrakopawl Parkingggar Shift fork shaft bore l.D. Shift tork shaft valvo bore i.D. ATF pump gear side clearance ATF pump gear-to-bodyclearance ATF pump driven gesr l.D. ATF pump driven gar shaft O.D. Pinion shaft contactaroa l.D. Carier-to-pinioncle616nc6 Driveshaftcontscl 8re LD. Carrier-to-driveshatt cloaranco
(0.1162.95 3.05 0.120) (0.0962. - 2.50 0.098) (0.1750.177) 4.15 4.50 (0.1950.197) 4.95 5.00 83.339 83.365 {3.2810 3.282r) (2.6254 2.6259) 66.685 66.698 8.97 8.98t0.353 0.354) 5.97 5.98(0.2350 0.2354) (0.31380.3142) 7.97 7.98 1.87 r.97{0.0740.078) (0.23590.2374) 6.018 6.030 9.000 9.015 {0.3543 0.3549) 8.000 8.015 {0.31500.3156t (0.0797 0.04171 2.025 2.075 35.000 35.025 t1.3780 1.3782) 5.90 6.00(0.232 0.236)
14.000 14.010 {0.5512 0.5516) 37.000 37.039(1.4567 1.4582)
;""i":,":",
Wear or damage Wsr or damag 8.95 (0.3s2) 5.95 (0.234) 7.95(0.313) 1.80{0.071) 6.045(0.2380) 9.03 (0.356) 8.03(0.316) 2.08 (0.082) (1.3799) 35.050
Rogulstor valve body Shifting deviceand parking br6kecontrol Servo body
s.40 {0.213} or otherdefect lWear

37.045 {1.4585}
ATFpump
Drive Drivan
0.03 0.05{0.00t 0.002) 0.07 (0.003) 0.r050 0.1325 {0.00410.0052} (0,00'140.0025) 0.0350 0.0625 14.01614.034 {0.55180.5525} Wearor damage (0.55040.5508) Wearor damage r3.980 13.990
18,010 18.028 {0.7091 0.7098) 0.023- 0.057(0.0009 0.0022) 26.02s 26.045 {1.0246 1.0254) 0.045- 0.086{0.00r8- 0.0034} 0.1(0.004) 0.12{0.005)
I Differsntla catnot
Diffsrential piniongear
Eacklash l.D. gear-to-pinion Pinion shrftclearance
Set ring-to-bsaringout6r race clearance
0.05 0.15t0.002 0.006) (0.71030.7113) 18.04218.066 (0.0022 0.0037) 0.055 0.095 o"r to.ooot 0 - 0.15 - 0.006} Adjusr {0
Automatic Transmission - Seqtion ltt

(NEWI STANDARD MEASUREMENT
Springs Regulatorvalve spring A Regulator valvespringB Stator reactionspring Modulator valvespring Torqueconvonercheckvalvespring Coolerreliefvalvespring Relielvalve spring 2nd orifico control valve spring 1-2shift valve spring 2-3shiftvalvespring 3-4 shift valve spring 1st accumulatorspring 4th accumulatorspring B 4th accumulator springA 2nd accumulalor springA springA 3rd accumulator springI 2nd accumulator 3rd accumulatorspring B 2nd accumulator springC Lock-upshilt valve spring Lock-uptiming v6lv6 spring Lock-upcont.ol valve spring 3-4 orifico controlvalve spring Servo control valve 6pring CPCvalve spring CPBvalve spring
Unit ot length: mm {in)
1.8(0.071) ( 1.8 0.071) 4.5(0.177) 1.4(0.055) 1.0(0.039) 1.0(0.039) 1.1{0.043) 0.7(0.028) 0.9{0.035) 0.9(0.03s) 0.9(0.035) 2.1(0.083) 2.3(0.09r) 2.6(0.102) 2.4(0.094) 2.8(0.110) 1.6(0.063) 2.2(0.087) 2.210.0811 0.9{0.035) 0.9(0.035) 0.7(0.028) 0.7(0.028) (0.039) 1.0 0.6(0.024) 0.9(0.035) 0.9(0.0351
14.7(0.584) 9.6(0.381) 35.4(1.407) 9.4(0.374) 8.4(0.334) 8.4{0.334) 8.6{0.342) 6.6(0.262) 7.6{0.302) 7.6{0.302) 7.6(0.302) 16.0{0.636} r0.2 {0.402} r7.0 (0.676) 29.0(1.152) 17.s(0.695) 9.0(0.3s8) 3 r . 01 1 . 2 2 0 ) 14.5{0.576} 7.610.3021 8.1 (0.3' 19) 6.6 (0.262) 6.6 (0.262) 8.1 (0.322) 5.6(0.223) 8.1 (0.322) 6.1t0.2421
87.8(3.4s7) 44.0(1.732) 30.3(1.193) 35.0(1.378) 33.8(1.331) 33.8 1.331) { 37.1 1.461) { 34.8{1.370) ('1.626) 4'1.3 57.0 t2.2441 57.0 12.2441 89.1 {3.508) 51.6{2.031) a1.0 13.4251 39.0(1.535) 89.3(3.5161 20.7{0.815) 35.1(1.382) 68.0(2.677) 73.7 12.9021 80.7(3.r77) 38.0(1.4961 37.5( 1.4751 52.1{2.051) 12.2{0.480) 47.211.858) 36.4(1.433)
16.5 11.0 1.9 10.9 8,2 13.4 22.0 26.8 26.8 13.8 14.2 2.9 15.6 6.1 2.4 13.9 32.0 45.8 14.1 21.6 20.4 5.5 18.3 19.5
cw
Sostion14
MEASUBEMENT STANDABD INEWI
6.4 (6.8,5.6)for overhaul 3.9{4.1, 3.4)for fluid change 1.4- 1.75114.3 17.A.203 2531 1.4 - 1.75 114.3 17.8, 203- 2331 SERVICE LIMIT Capacity f (US qt. lmp. qr) Forwardclutch prssureat 1,500rpm in Lqlposition
Transmiasion fluid
Hydraulic pressure MPa (kg7cm,, psi)
pressur 1,500 in El position rpm Reverse brake at
Drive pulley pre$ure at 1,500rpm in E position Drivgn pulley pressureat 1,500rpm in Lll position Lubricationpressureat 3.000rpm in E position with vehicle on levsl ground) Stall sp6d rpm {Ch6ck E position E, E, B positions Clutch Clutch initisl clearance Clutch return spring lree length Clutchdisc thicknss Clutch plate thicknss Forwardclutch Start clutch Reversebrake Forwardclutch Start clutch Reversebrake Forwardclutch Stan clutch Rovers brake Forwardclutch Start clutch Roverse brake
1 0 . 2- 0 . 71 2 .-0 . 1 , 2 8 1 0 1 1
1.5- 2.3(15.3 23.5. 218- 334) (2,30) Above0.2 2,500 3,000 0.6- 0.8(0.024 0.031) 0.5- 0.7{0.020 0.028) 0.45- 0.75(0.018 0.030) ( 30.5 1.201) 40.9{1.6' t0) 29.4 t1.1571 1.88 2.00{0.074 0.079) 1.88 2,00(0.074 0.079) 1.94 2.06{0.076 0.081} 1.95 2.05(0.077 0.081) -0.093} 2.25- 2.35{0.089 1.90 2.00(0.075 0.079) 2.350- 2,650 2,800 3,100
28.5 t1.122) 38.9(1.531) 27.4 11.O79J Until groovesworn out worn out Untilgrooves Oiscoloration Discoloration Discoloration
(cont'd)
3-9
Standardsand ServiceLimits
CvT {cont'dl - Section 14
MEASUREMENT Clutch Forwardclutch end piate thickness Mark 1 or 15 vlark or'16 2 Mark3 or 17 Mark4 or 18 Mark5 or 19 Mark6 or 20 M a r k 7o r 2 l Mark8 or 22 N4ark or 23 9 Mark 10or 24 Mark11or 25 Msrk '12or 26 Mark13or 27
STANDARD IiIEW}
3.4- 3.5(0.134 0.138) 3.5- 3.6(0.138 0.142) 3.6- 3.7(0.r42- 0.r46) 3.7- 3.8 (0.146 0.150) 3.8- 3.9(0.150 0.1s4) 3.9- 4.0{0.154 0.157) 7 4 . 0 - 4 . t ( 0 . 1 5- 0 . 1 6 1 ) 4.1- 4.2(0.161 0.165) 4.2- 4.3{0.165 0.169} 4.3- 4.4(0.169 0.1731 4.4- 4.5(0.173 0.' 177) 4.5- 4.6(0.177 0.r81) 4.6- 4.7(0.r81- 0.185) 3.55- 3.65 (0.140 0.'|44) 3.75- 3.85(0.1 - 0.152) 3.95- 4.05(0.r56- 0.1591 4.15- 4.2s(0.r63- 0.t67) 4.35- 4.45{0.171 0.175) 4.55- 4.65(0.r79- 0.1831 4.75- 4.85(0.187 0.1911 4.95- 5.05{0.19s 0.199) - 9.99 (0.3929 0.3933) 9.98 9.98- 9.99 {0.3929 0.3933} 10.000 10.015(0.3937 0.3943) 10.000 10.015 t0.3937 0.3943) 0.015 0.035 {0.0006 0.0014} 0.035 0.0505 {0.0014-0.0020) (0.0014-0.0020) 0.035 0.0505 19.987 20.000(0.7869 0.7874) 19.987 20.000(0.7869 0.7874) 43.981 43.991 {1.7315 1.7319) 24.007 24.020(0.945 0.946) 24.007 24.020(0.945 0.946) 0.050- 0.r 10 (0.0020 0.004:)) 0.000- 0.130(0.000- 0.005) 0.370 0.650 {0.015-0.026} 0.00- 0.1s(0.00 0,006)
SERVICELMTT
Disco loration
\--
Discooralron
Reverse endplate brake thickness
Disco otalton
U::I I vlark 3
vlark4 Vlark5 vlark6 t4ark7 vlark8
ATF pump
ATF pump drive gear shaft O.D. ATF pump drivengearshaftO.D. ATF pump body bushing LD.
Driv gar shaft Drivengearshaft
ATFpump gearsideclearance ATF pump gear-to-bodyclearance Drive gear Orivengear Transmission Diameterof needlebearingcontactare lnout shaft - flvwheel side Input shaft - forward clutch side Drive Dullevshaft - start clutch side Drive pulley shaft - flywheel side Drive oullev shaft - forward clutch side Thrust clearance Carrier and ring gear Driven pulley shaft and start clutch hub Input shaft and ATF pump drivon sprocket Secondarygoar shaft and flywheel ball bearing
loration Disco Woar or damaged Wsar or dmagd Wear or damaged W6ar or damagad 0.050(0.0021
Wear or damaged Wear or damaged Wear or damaged Wearor damagod Wearor damagod
L
3-10
cw
conld)
Saction 1 4
MEASUREMENT
mm (in) Unit of length:
STANDARO INEWI
1.02 1.05(0.040 0.041) 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) (0.0415 0.0427) 1.05s 1.085 (0.0443 0.0454) 1.125 1.155 (0.0470 0.0482) 1.195 1.225 (0.0498 0.0510) 1.265 1.295 1.335 1.365(0.0s26 0.0537) (0.0553 0.0565) 1.405 1.435 (0.0580 0.0593) 1.475 1.505 1.545 1.575(0.0608 0.0620) (0.0636 0.0648) 1.615 1.645 (0.0663 0.0675) 1.685 1.715 1.755 1.785 {0.0691 0.0703) - 2.90(0.113 0.114) 2.87 2.97- 3.00(0.117 0.118) 3.07- 3.10(0.121 0.122) 3.17- 3.20(0.125 0.126)
SERVICE UMTT
or oamageo
_.an3mission
Thrustshim.25x 31 mm thickness
Cottelslhickness
or damaged Wearor damaged Wear or damaged Wearor damagsd
ATF pump drive sprocketthrust shim, 22 x 28 mfi thickness
Secondarygear shaft thrust shim, 25 x 35 mm thickngss
(0.0440.04st 1.12 1.15 (0.0540.055) 1.37 1.40 1.62 1.65 {0.0640.065) (0.0740.075) r.87 1.90 (0.0830.085) 2.'t2 2.15 (0.093 0.094) 2.37 2.40 2.80 2.85 {0.1100.112) ( 2 . 9 0 2 . 9 50 . 1 1-40 . 1 1 6 ) (0.1180.120) 3.00 3.05 ( 3 . 1 0 3 . 1 50 . 1 2-20 . 1 2 4 ) (0.1260.128) 3.20 3.25 (0.r30 0.1321 3.30 3.35 - 0.136t 3.40 3.45 10.134 - 0.140) 3.50 3.5s 10.138 (0.1420.1441 3.60 3.65 - 0.148) 3.70 3.75 10.146 (0.1500.1521 3.80 3.85
6.97- 6.98(0.274-0.275) (0.4516 0.4520) 11.47 11.48 (0.2756 0.2762) 7.000 7,015 (0.4528 0.4535) 11.500 11.518 6.97- 6.98(0.274 0.275) (0.4516 0.4520) 11.47 11.48 8.97- 8.98 (0.353 0.354) 7.000 7.015 {0.2756 0.2762) (0.4528 0.45351 11.500 ' t1.518 9.000 9.015 {0.3s4 0.355) 2.50- 2.65{0.098 0.104) 88.900 88.935(3.500- 3.5011 2.00- 2.10{0.079 0.083) 24.007- 24.020(0.945- 0.946)
+ I
I
Wearor damaged or damaged
or oafiaqeo
Input shaft l6ed pip O.D. Drivs pulloy leed pipe Forwardclutch feed pipe Inputshaftbushingl.D. Drivepullyfoed pipebushing Forwardclutch feed pip bushing Drivenshaft teed pipe O.D. Start clutch f66d pipe (right side cover side) Drivenpulleyteed pip Start clutch feed pipe (flywhelhousing side) DrivenpullsyshaftbushingLO. Start clutch feed pip6 (right side cover sidel Drive pulley feed pipe Stan clutch feed pipe (fl)'wheelhousing sido) ring groovewidth drivengearsealing Secondary Stan clutch e-ndplate l.D. Inputshaftsealing ring groovewidth ring Drivepulleyshaftl.D.at sealing Shifting device and parking brakecontrol Parkingbrakocone Parkingbrakepawl gear Parking
6.95(0.274) (0.45' I) 11.45 7.030 10.2171 (0.454) 11.533 6.9510.27{} 1 1 . 4 50 . 4 5 1 ) { 8.95{0.352} 7.030(0.277) (0.454) 1'1.533 9.03 (0.3561 (0.105) 2.655 Wear or damaged (0.083) 2.105 Wear or damagsd W6ar or other defect Wear or other dafct Wear or other defect
(cont'd)
3-11

CW {cont'd} - Sectaon14
MEASUREMEiTT
Diffe rontiaI carier Pinionshaft contactarea l.D. CarrieFto-pinion cl6arance Drive shaft contactarea l.D. Carrier-to-driveshaft clearance
STANDARD {NEW}
(0.7091 0.7098) 18.010 18.028 0.023- 0.057(0.0009 0.0022) (1.0246 1.0254) 26.025 26.045 0.045- 0.086(0.0018 0.0034)
SERVICE LIMTT 0.1(0.004)
Differentialpinion gear
Backlash t.D. gear-to-pinion clearance Pinion shaft MEASUREMENT
Set ring'to-bearingouter raceclearance Springs PH 169ulator valve spring PH control valvo spring PL 169ulator valve spring PH-PL controlvalvespring Clutchrducing valvespring Lubrication valvespring Shift valve spring Shift control valve spring Start clutch control valve spring Pitot regulatorvalve spring Start clutch valve accumulatorspring Rgverse control valv6 spring Shift inhibitor valve spring
(0.005) 0.12 - 0.15 (0.0020.006) 0.0s (0.71030.71r3) r8.042 18.066 (0.00220.0037) 0.05s 0.095 nru to.oout ( 0-0.15 0-0.006) Adjust Wir. Dia. o.D. FJ.. Longth No. of Coilt 1.2t0.0471 9.0(0.354) 25.7{1.051} 10.0 (0.528) 1.7(0.067) 13.4 39.4(1.5511 4.7 0.9{0.035) 7.2 t0.283') 14.6(0.5751 (0.391) 1.0(0.039) 10.0 31.4{1.236) 8.6 1.9(0.075) 16.8 41.4 i'1.7481 {0.661} 8.0 (0.528) 1.6 13.4 t0.063) 51.6{2.031} 11.6 1.4{0.055} 8.2(0.323) 34.1(1.343) 13.0 1.0{0.039) 7.4{0.29r) 19.3{0.760} 0.4(0.016) 4.1 0.161) 12.1(0.476) { 6.8 0.6(0.024) 5.710.2211 9.5(0.374) 5.0 1.2 8.3(0.327) {0.047) 29.8('t.173) 12.3 (0.047) 1.2 9.4(0.370) 31.4(1.236) 11.0 (0.s20) 1.3{0.051) 13.2 48.3{1.902) 10.6
Steering- Section 17
MEASUREMENT Steeringwheel Play at steeringwheel circumference Starting load at steeringwheel circumference N {kgt. lbf) lvlanualsteering Powersteering Engine running Angle of rackguide screw loosened M/S trom lockedposition Preloadat pinion gear shaft N.m (kgf.cm,lbtin) M/S Pump pressurewith valve closed 40'C (105'F) {oiltemp./speed: min.,4dle. Do not run for morethan5 seconds). kPa{kgflcmr,psi) power steeringtluid Recommended Fluid capacity f (US qt, lmp qt) Reservoir Powersteering belt* Deflectionwith 98 N ('10kgf, 22 lbt) betweenpulleys
(NEwl STANDARD 0-10{0-0,4)

15(1.5, 3.3) 29 {3.0,6.5) 2015" 20 Max 0.5- 1.7{5 - 17,4.3- 14.8) 0 . 6 - 1 . 2( 6 - 1 2 , 5 . 2 - 1 0 . 4 2 ) 0 6,400- 7,400(65- 75, 920- 1.070)
G6arbox
Pump
Powerstee ng fluid
HONDA PowerSteering Fluid-V S or 0.85(0.90,0.75) disassembly at 0.4{0.42, 0.35) 10.5- 14.0{0.4'l- 0.55)with usod belt 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 816A2Engine Typeonly 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. Readjust deflectionor tonsionto used belt values. the
3-12
Suspension Sestion18
MEASUREMENT
Camber alagnment Caster Totaltoe Frontwheelturningangle Inwardwheel Outward wheel Aluminumwheel Rim runout Steelwheel Wheel bearing Endplay Front Rear Front Front Rear
Unit ot lgngth: mm (in)
STANDARD EWI I
0.00' l '1" 1.40' r 1. In 1.0t 2.0(1/16 1/16) t In 2.0:i3 {1/1611/15) 39"50' 33'10'(Reference)
SERV|CE UitlT
Axial Radial Axial Radial Front Rear
000000-
0.7{0- 0.03) 0.7(0- 0.03) (0 1.0 - 0.04) (0 1.0 - 0.04) 0.05(0- 0.002) 0.05(0- 0.0021
2.0(0.08) 1.5{0.05} 2.0(0.08t 1.5(0.06)
Brakes Section 19
MEASUREMENT
Parking brake lever Foot brake pedal Master cylinder Disc brake Play in strokeat 196 N (20 kgf. 44 lbfl lover force
STANDANO INEWI
To be lockedwhen pulled 6 - 9 notchos (6.16) 156.5 161(6 5/16) 1-5(1/16-3/16)
SERV|CEUi,llT
(withfloormatrefioved) hoight Pedal play Free

clarance Piston-to-pushrod Discthickness Oiscrunout Discparallelism Padthickness
M/T A,/T, CW
0 - 0.4(0- 0.02)
Front Front Rear Frontand rear Front 20.9- 21.8(0.82 0.86)
9.5- r0.5r1 8.5- 9.5*'
19.0 {0.75} 0.1s,(0.004) 0.10(0.004) (0.00061 0.015 1.6 {0.06) (0.06) 1.6
201(7.911 2.0 (0.08)
Rearbrake t.D. Lining thickness drum *1. 5410Stamped the caliper on body. *2. 2056Stamped the caliper body. on
2000 .a7l 4.0(0.16)
22 Air Conditioning Section

Conditioning MEASUREMENT (P/N38897- P13- AoIAH or 3889 Lubricanttype: SP-'10 Condenser Lubricantcapacity m? lll oz,lmp oz) Evaporator Line or hose Feceivr Lubricanttype: SP-10 Lubricantcapacity mf (ll oz, lmp 02) Fieldcoil resistance 68"F{20'C} o at plate clearance Pulley-to-pressure Deffection with 98 N (1Okgf,22lbtl betweenpulleys Belt tension N (kgf, lbf) Measuredwith belt tension gauge STANDARD {l{EW) - P13- A01l{Forretrigerant (R-134a}) HFC-134a 20 l2/3 0.71 45 112f3, 1.61 10 (1/3, 0.4) 1 0( 1 / , 0 . 4 )
Compressor
(4 130 1s0 r/3- 4.6, - 5.3) 5.0 3.05-3.35 r 0.5r 0.15(0.020 0.006 )
7.5 - 9.5 {0.30- 0.37)with used belt 5.0- 6.5 {0.20- 0.26)wilh new bolt with usod belt 340 - 490 (35 - 50, 77 - '110) 690 - 830 (70 - 85, 150- 190)with new blt
Compressor belt*
*: When using a new belt. adjust deflectionor tensionto new values.Run the engintor 5 minutesthen turn it off. Roadjust deflectionor tension to used belt values.
3-13

Electrical- Section 23
MEASUREMENT
lgnitioncoil Ratedvoltage V Primary windingresistance 68'F(20'C) 0 at 12
STANDARD INEWI
lgnition wire Sparkplug lgnitiontiming Alternatorbelt*
HITACH 0,45- 0.55 I TEC 0.63- 0.77 Scondarywinding resistance 68'F (20"C) kO at HITACHI 22.4- 33.6 12.4- 19.2 Resistance 68"F(20"C) k0 at 1-3-4-2 Firingorder Tvpe Seesection23 _i Gap 1,0- 1,1(0.043 oo.) Ar idle 12+2 " BTDC (Red) with usodbelt Oetlection with 98 N 11okgl,22lbf'l 8.0- 10.5{0.31 0.41) 6.0 8.5 (0.26 0.33)withnew belt betlveenpulleys 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
Alternator (MITSUBISHI} Output 13.5v at hot A (rotor) at 68'F 120"C) k0 Coil resistance Slip ring O.D. Brushlength Brushspringtonsion g (oz) Type Commutator mica depth Commutator runout Commutator O,D. Brush l.ngth Brushspringtension(new) N (ksl, lbf) 3.4- 3.8 22.7 t'.agl 1qnro76l 300- 450(10.6 15.9) Gear reduclion 0.4- 0.5 (0.016 0.020) 0 - 0.02 (0 - 0.0008) ( 2 2 8 . 0 2 8 . 1 1 . 1 0- 1 . 1 0 6 ) 15.8 16.2(0.62 0.64) 15.7 17.7 (1.60 1.80, - 4.0) 3.5
SERVICE UM]T
| 22.210.87) | - 0{0.20) t 5- ' 0.15(0.006) 0.05(0.002) 27.5(1.083) 11.0(0.43)
Startermotor (MITSUBA 1.0kw 1.2kW)
*: 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.
3-14
DesignSpecifications
a
I
Unit ot lengthi mm {in)
lTEM
DIMENSIONS OverallLength 2 door Coupe/+door Sedan 2-door Hatchback {1996,1997) (1998) OverallWidth OverallHeight 2-door Coupe/2-door Hatchback tl-door Sedan Wheelbase FronvRear Track GroundClearance Seating Capacity GrossVehicleWeight Rsting {GVWR) DX, HX M/I 2-door Coupe HX A,/T EX HX CVT(1996) HX CVT(1997) 1997) 2-doorHatchback CX.DX (1996, DX with ABS (1998)sMT 4AT 4-door Sedan OX, LX M/T, LX Ay'T LX A,/T with ABS, EX GrossVehicleWeight Rating{GVWR) DX (1996) 2-door Coupe DX (1997) si(1996) si(1997) cX-G (1996) 2-doorHatchback cX (1996), cx (1997), CX-G(1997) cx (1998), {1998) DX LX, EX M/T 4-door Sedan EX A/T
METBIC
4,445mm mm 4,170 4,180 mm 1,705 mm mm 1.375 1,390 mm 2,620 mm 1,47511 mm ,175 '150 mm
ENGUSH '175.0 in in 164.2 164.6 in 67.1in in 54.'1 54.7in 103.1 in in 58.1/58.1 5.9in
NOIES
(USA) WEIGHT
3,290lbs rbs 3,330 tbs 3,440 3,220 tbs 3,330lbs 3,285 tbs tbs 3,290 3,300 lbs 3,330lbs 3,460lbs
1,500 kg 1,510 kg 1,560kg 1.570 kg 1,495 kg kg 1,505 kg 1,510 1,510 kg 't,540kg wat6r-cooled,+stroke SOHC*',SOHC gasolineengine VTEC'3, SOHCWEC-E*1 transverse Inline 4-cylinder, 2.95x 3.54in 75.0x 90.0mm 1 '1,590 (m/) 97.0cu-in cm3 1 9.4 9.6 4 Beltdriven, SOHC valveper cvlindr Forcedand wet sump, trochoid pump 33.4f {35.3 qt,29.4lmpqt)/minute US 1251(132US qt, 110lmp qt)/minut gasolinewilh 86 Pump UNLEADED Octane Numbsror higher *,: Dl6Y7 *3:Dl6Y8 *+:D'|6Y5
(CANADA) WEIGHT
ENGINE Cylinder Arrangement Bore and Stroke Displacement D16Y7, Dl6Y5 Compression Ratio 016Y8 ValveTrain LubricationSystem at Oil Pump Displacement 6,800engine rpm Water Pump Displacement at 6,000engine rpm FuelRequired STARIER Type/Make NormalOutput NominalVoltage HourRatino Directionof notation
gA Gearreduction/MITSU 1.0kw, 1.2 kw 12V 30seconds from gearend Clockwise vigwed as (cont'd)
3-15
DesignSpecifications
(cont'dl
|TEM
(cont'd) STARTER Weight MITSUBA 1.2kW 1.0,
METRIC Mlf CW
ENGLISH
NOTES
CLUTCH
Clutch Type Clutch Facing Area
TRANSMISSION
TransmissionType
CW
PrimaryReduction TRANSMISSION Manualtransmission GearRatio 1st 2nd Jro 4th 5th Beverse Gearratio GartYPe
3.4kg 7.5 tbf Single plate dry, diaphraomspring Torque converter Multi plateswet sanp, hydraulic 25 sq-in 160crn' | Synchronized 5-speedforward, 1 reverse 4-speedautomatic,1 reverse Non-stage speedforward, 1 reverse Direct 1 : 1 Engine typ D16Y5 3.250 1.742 1.172 0.909 0.102 3.153 3.722
D16r'
3.250 1.182 1.172 0.909 0.102 3.153
D16Y8
FinalReduction Automatictransmission GoarRalio
3.7 11.034*' 22''

Single helicalgear
3.250 1.909 1.250 0.909 0.702 3.153 4.250
*1: 2'doorHatch oacx *2: 2-doorCoup6, and 4-door Sedan
Engine type lst 2nd 3rd 4th Reverse Gear ratio Geartype D,I6Y' 2.600 'L468 0.926 0.638 1.954 1.35"1 D16Y8 2.722 0.975 0.638 1.954 4.357
Final Reductaon
Singlehelicalgear 2.466- 0.449 2.466 4.357 3,530Kcal/h
cw
Low - O.D. Revelse SecondaryReductionGear Ratio FinalRgduction GearRatio Gear Ratio AIR CONDITIONING Cooling Capacity Compressor Type/Make No. of Cylinder Cspacity Max.Speed LubricantCapacity Type
14,000 BTU/h
Scroll/SANDEN u5,/ mt/tev I i.zz cu-rn/rev 10,000rpm '130 mf 4 1/3ll oz. | 4 . 6 l m po z | fin Corrugated Corrugatedfin Ian Sirocco 200w112v 4-speedvariable 460 m3/h 16.200 cu-Vh | Dry. single plate,poly-V-belldrive 40 W max./12V at 68'F (20'C) (R-134a) HFC-134a 6sohs 22.9 -laoz
sP-10
Condenser
Evaporator
Blower
Type
Type Motor Input SpeedControl Max. Capacity Type PowerConsumption Type Ouantity
TgmpratureControl CompressorClutch Refrigerant
L
3-16
Unit of length mm lin)
ITEM STEEBING SYSTEM Type OverallRatio Turns,Lock-to-Lock Wheel Dia. Steering

SUSPENSION WHEEL ALIGNMENT Type S h o c kA b s o r b e r Camber Caster TotalToe Front and Rear F r o n ta n d R e a r Front Rear Front Front Bear P/S M/S
METRIC
ENGLISH
NOTES
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 , S a c ka n d p i n i o n P/S:17.7,lt4/Sr20.3 P / S : 3 . 6 , / S :4 . 1 M 380rnm 15in i I n d e p e n d e nd o u b l ew i s h b o n e ,c o i l s p r i n s t 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 , 0.00' 1'40' I n 1 . 0m m I n 2 . 0m m l / 1 6i n I n 1 / 1 6i n
BRAKE SYSTEM Rear
Power-assistedsel{-adiusting ventilated disc Powe.assisted self-adjusting solid disc 3 7 . 5c m , \ 2 5 . 8s q - i nx 2 4 4 . 1 c m ,x 2 6 . 9 4s q - i nx 2
Unit:mm (in) 5,110 Stamped on ths 2 0 5 6S t a m p e do n t h e caliper body O r u m l . D . : 2 0 0( 7 . 9 ) D r u m l . D . : 1 8 0( 7 . ' ! )
Rear Parking Brake Type
6 7 . 2c m , x 2 10.4sq-inx2 7 . 8 s q - i nx 2 5 0 . 2c m , x 2 l,lechanicalactuating,rear Nvo wheel brakes P 1 7 5 D 0 R 1 8 2 S :D X 3 P 1 8 5 / 6 5 R ' 1 4 S :E X , H X ( U S A ) ,S i ( C a n a d a ) 85 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 ) 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) T 1 0 5 / 8 0 D 1C a r sw i t h o u t A B S E x c e p t 3 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 1 D X ( U S A ) ,4 ' d o o r S e d a nL X l U S A ) , 4 ) 2 - d o o rC o u p eD X ( C a n a d aC a r s 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 a r s with ABS 2-doot coupe 2.5 l.2.6,2.21 4'door Sedan 4.5 {4.8, 4.0} 2 - d o o rh a t c h b a c k . 5 ( 2 . 6 ,2.2) 2 4 . 5 ( 4 . 8 ,4.0) 12 V - 38AH/5HR 1 2 V - 1 . 0k W , 1 . 2k W 12V-154 7 . 5 A , 1 0A , 1 5A , 2 0 A 7.5 A, 10 A, 15 A, 20 A,30 A, 40 A, 80 A 7 . 54 , 2 0 A , 4 0 A 12V-60AsW
TIRE
Size Front and Rear 2-door Coupe 2-door Hatchback 4 - d o o rS e d a n S p a r eT i r e
t
WASHER RESERVOIR ELECTRICAL | Capacity (uS qt, lmp qt)
USAmodel model Canada DX Except OX
Battry Staner
I n U n d e r d a s h F u s e / R e l aB o x y In Under-hood Fuse/RelayBox In Under-hood ABS Fuse/RelayBox HighAow Headlights F r o n tT u r n S i g n a l / P a r k i nL i g h t s g R e E r u r n S i g n a lL i g h t s T Brek/Taillights I n n e rT a i l l i g h t s * ' H i g h M o u n t B r a k L i g h t Back up Lights License Plate Lights C e i l i n gL i g h t T r u n kL i g h t s G a u g eL i g h t s Indicator Lights l l l u m i n a t i o n n d P i l o tL i g h t s a Heater Control Panel Lights
12V 21tsW 't2v - 21W 12V-21/5W 12V5W 12V_ 18W*" 21Wrl.+3 12V-21W 12V 5W moonroof) 12V- 8 W (With 12V-5 W (Witholtmoonroof) 12v-1.4W,3W 1 2 V - 1 . 1 2 W ,. 4 1 W 1 2 V - 0 . 8 4 W ,. 4 1 W 12V-1.4W
P/S:Powersteering, M/S:Manualsteering *l: 2-doorCoupe *2: 2-doorHatchback *3: 4-doorSedan *4: USA (HAM), (HCM) produced Canada *5:JAPANoroduced
3-17
Body Specifications
L
2-door Coup:
U n i tm m ( i n ) :
L
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
............4-2 Lubrication Points for Maintenance Schedule 1996Model ........4-4 Normal Conditions 4-6 ......... Conditions Severe for Maintenance Schedule 1997Model 4-8 ........ NormalConditions 4-10 ......... Conditions Severe for Maintenance Schedule 1998Model ........4-12 NormalConditions .........4-14 Conditions Severe
Points Lubrication
For th6 details of lubrication points and types of lubricants to b applied, rsfsr to the lllustrated Index and various work procdurss(such as Asssmbly/Reassembly, Replacement, Overhaul,Installation,etc.)contained in each section. No. 'I LUBRICANON POINIS Engine LUBRICANT API ServiceGrade:Use SJ 'Energy Conserving" grade oil. The oil containerm8y alsodisplsythe APICenification mark shown below. Makesure it says "For Gasoline Engines," SAEViscosity: Se6chart below.
\-
Transmission
Manual
Automatic
CW
3 1
c
6 7 I o 10 11 12 13 l'[ 15 16 17
BrEka Ling clutch Lin Powr stering gesrbox Shift leverpivots{manual transmission) Release tork (manual transmission) Steering boots Tailgate hinges and latches(2-door Hatchbackl ball joints Steering Shift lever (sutomatictransmission) P6dallinkage Braks mast6r cylind6r pushrod Trunk hingesand lstch(,|-door Sedanand 2-door Couoe) Door hinges upper and lower Door opening dstents Hood hings and hood latch Fuelfillor lid Clutch m8st6r cylinder pushrod Throttlecablond and thronl6linksge Rear brakg shoe linkages Steering wheel (backside) Caliper piston seal,dust seal, caliperpin, piston Throttle cable end (dsshboardlower Danel) Pow6r st66ring system (for cars with P/Sl Air conditioning comprsssor
Genuine HondaMTF*1 GenuineHondaPremiumFormula Automatic Transmission Fluid(ATF)*, GenuineHondaCVTFluid'3 Hond8DOT3BrakeFluid*. Genuine Genuine HondaDOT3BrskeFluid'a
grease 08733 8070E P/N Stesring

Gressewith molvbdenum disulfide Super High Temp Urea Grease{P/N08798- 9002)
grease Multi-purpose
Honda White Lithim Grease
18 19 20 21 22 23 21 25 26
grease Multi-purpose
grease Silicons Genuine HondaPowerSteering Fluid-V S'5 or Comoressor oil: SANDEN: SP-10 38At - P13-A01AH or3@9- P13-A01 P/N (ForR6frigsrant: (R-f HFC-1348 34a))
Recornmendod Engine Oil
API SEFVICELABCL
API CERTIFICAIIOII SEAL
NOTE: Th following information as marked *1, *2, 13, *4 and 15 on above chart details for 1997model. Il: Alwsys use GenuineHonda MaoualTransmission Fluid (MTF).Using motor oil can causestiffer shifting becauseit dogs not contain the propor additivs, *2: Always use GenuineHondaPremiumFormulaAutomaticTransmission Fluid(ATF). Usinga non-Honda ATF 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 transmission fluid can causeincrass war 8nd poor steoringin cold weathsr.
ffi
,--;--i------
Engine viscosity oil for ambrent tempetureranges
4-2
@ (4{oo. s.d.n)
NOTE:Lubricate hinges,latches all and locksoncea year. In corrosive more frequentlubrication necessary. areas. is We recommend HondaWhite LithiumGrease.
4-3
I
MaintenanceSchedulefor 1996Model
NormalConditions
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Engine
......".'.'.... 5-1 Removal/lnstallation Engine 6-1 Train ........'..'.'.".. Head/Valve Cylinder .....'.'..'7-1 Block.......... Engine ........... 8-1 Lubrication Engine 9-1 System ........ lntakeManifold/Exhaust 10-1 ......... Gooling
Engine RemovaUlnstallation
Removal fnstalfation .......5-2 ...5-12
EngineRemovaUlnstallation
Removal @ .
.
4. Remove the battery and battery base. I x 1.25mm 21 N.m l2.1kgl.m, 17 lbf-ftl
Mako surs iacks and 3atety stands ar6 placed properly and hoist brackets aro attached to ihe corroct positions on th engine. will not roll olf rtands and fall Mako surc the brehiclo whilo you are working und.r it.
CAUTION: . Uso tandar covors to ayoid damaging painted surface. . 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 hoss or interf?ro with othor parts, 1, Secure hood as oDenas possible. the
2.. Disconnect batterynegative the terminalfirst, then terminal. the positive 3. Disconnectthe battery cables from the under-hood fuse/relaybox and battery positive terminal.
from the ECM/PCM. Disconnect connectors the

CABLES BATTERY
connsctor. Disconnect main wire harness the HARNESS MAINWIRE CONNECTOR
TERMINAL
ECM/PCM
5-2
\}
7. Remove intakeair duct and air cleanerhousing. the D16Y7 enqine: a. Remove resonator the and intakeair duct.
6x1.0mm
D16Y5, Dl5Y8 engines: 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 cleanerhousIn g .

INTAKE AIR OUCT
6x1.0mm 9.8N.m {1.0kgt.m,7.2lbt.ft)
INTAKE AIR DUCT
RESONATOR IAT SENSOR CONNECTOR
o.
(lAT)senDisconnect intakeair temperature the sor connector, remove air cleaner then the housing.
6x1.0mm 9.8 N.m 11.0 kgf.m, t.2lbtft)
8.
Disconnect the engine wire harnessconnector the leftside of the enginecompartment.
AIR CLEANER
(cont'd)
5-3
EngineRemoval/lnstallation
Removal (cont'dl
(seesection11), 9. Relieve fuel pressure uo not smot(ewhde working on th tuol !@ system. Kogp open flams or spark away from tho work arga.Drainfuel only into an approvedcoDtainer. 10. Removethe evaporativeemission (EVAp)control canister hoseand fuel feed hose D16Y7engin: 11. Remove the brakeboostervacuumhose,fuel return hoseand vacuumhose. D16Y7 engine:
VACUUM HOSE
Dl6Y5, D16Y8engines: FUEL FEED HOSE
Dl6Y5. D16Y8engines: BANJO EOLT 33N.m(3.4 kg{.m, 2s tbf.ftl
5-4
I
12. Remove the throttlecableby loosening the locknut, then slip the cable end out of the accelerator link age. NOTE: a Takecare not to bend the cablewhen removing it. Always replaceany kinkedcable with a new one. . Adjustthe throttlecablewhen installing (seesect i o n 11 ) . D16Y7 engine: 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 pull out the ECM/PCM connectors.
6x1.0mm
LOCKNUT
1 4 . Remove mounting the boltand lockbolt,then remove
(P/S) pumpbeltand pump. the powersteering NOTE:Do not disconnect P/Shoses. the NUT
MOUNTINGBOLT 8 x 1.25mm 24 N.m (2.4kgf.m, 17 lbf.ftl
Dl6Y5, D16Y8engines:
LOCKNUT
[ocK aoLT 8 x 1.25 mm 24N.m(2.4 kgf.m, lbt.ftl 17
(cont'd)
5-5
(cont'dl Removal
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 bolt, then remove the air conditioning(A/C)compressorbelt.
IOLER PULLEY CENTER NUT 10 x 1.25mm 4,r N'm 14.5 ksf.m.33 lbl.ftl
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 (M/T). assembly NOTE: . Do not disconnect pipe/hose the assembly. . Do not operatethe clutch pedal once the slave cylinderhasbeenremoved. . Takecarenot to bendthe line.
6x f.0mm ,t N.m (t.1 kg ,m,
8x1.25fifi 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. Remove shiftcable(CVT). the

WASHER LOCKNUT 29 N.m {3.0 kgt m, 22 lbtft)
HOSECLAMP
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 ) 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 clamp.
23. Drain the engine coolant (see page 10-6),Loosen the drainplug in the radiator. fluid. Reinstall drainplug the 24. Drainthe transmission usinga new washer(seesection13.14). the 25. Drainthe engineoil. Reinstall drain bolt using a new washer(seepage8-5). rod 26. Remove shift rod and extension (M,/T). the SHIFT ROO
20. Remove the radiator cap.
mm 8 x 1.25 kgf.m,16lbf,ft) 22 N.m(2-2 compressor. 27. Remove A,/C the hoses. the NOTE:Do not disconnect A,/C
use care when removing the radiator E@@ cap to avoid scalding by hot coolant or steam. 2 1 . Raise hoistto full height. the and the 22. Remove front tires/wheels splashshield.
8 x 1.25mm 2,r N.m {2.{ kgf.m, 17 lbf.ft} 6x1.0mm 9.8 N.m (1.0kd m, 7.2 rbl.ft)
A/C COMPRESSOR
SHIELD
(cont'd)
5-7
Engine Removal/lnstallation
(cont'd) Removal
28. Remove shiftcable(A,/T). the NOTE: . Takecare not to bend the cablewhen removing it. Always replaceany kinkedcable with a new one, . Adjust the shift cable when installing(see section14). 29. Remove exhaustpipe A. D16Y5, D16Y7 engines: 8 x 1.25 mm
22 N.m (2.2 kgt m, 16 lbl.ftl Replace.
mm I x 1.25 22 N.m12.2 kgd.m. 16lbtft)
SELF-LOCKING 8 x 1.25mm 16 N.m 11.6 kgt.m, 12 tbf'ft| Replace. PIPE A
SELF.LOCKING NUT 10 x 1.25m.n 33 N.m (3.4kgtm, 25 tbt.ftt Replace.
{
Dl6Y8 engine: 6x1.0mm 14 N.m {1.4kgf.m. 10 lbf.ft) 8 x'1.25 m m 22 N.m 12,2 kgf.m, 16lbtftl
GASKET
Feplace.
NUT SELF.LOCKING 8 x'1.25 mm 16 N.m (1.6kg'i.m,'12lbf'ftI Replace.
EXHAUST PIPE A
NUT SELF,LOCKING 10 x 1.25mm 5{ N.m {5.5kgt.m,,10lbf.tt} Replace.
5-8
30. Remove damperlorks (seesection'18). the

Jt,
Lowerthe hoist. 34. R e m o v e 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 t heaterhoses.
D i s c o n n e ctth e s u s p e n s i o no w e r a r m b a l l j o i n t s l (seesection18). Remove driveshafts. the CAUTION: o Do not pull on the driveshaft, the CV ioini may com apart. . Use care when prying out the assembly. Pull il straight to avoid damaging the difterential oil seal or intermediats shaft dust seal. w 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 es u r f a c e s i t h d cleanengineoil. Tie plasticbagsover the driveshaft enos.
HOSE RADIATOR
35. R e m o v e h e A T F c o o l e rh o s e s , h e n p l u g t h e ATF t t
coolerhosesand Dipes(Ay'T).
HOSES
(cont'd)
5-9
Engine Remov aUlnstaf lation

(cont'd) Removal
36. Attachthe chainhoistto the engine,
HOISTING BRACKET
lnstall on the cylinder head
witha8xl.25mmbolr.
5-10
37. Remove left and riqhtfront mount and bracket. the
the 39. Remove 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 transmission mount. TRANSMISSIOt{ MOUNT

TRANSMISSION MOUNT BRACKET
FROI{T
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 osnc o m p l e t e l y i 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 disconnectedf 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
BracketBolts Torque Specifications:
10x 1.25mm 44 N.m {4.5kgf.m, 33 rbtft) 10 x 1.25mm 54 N.m (5.5kgf.m, a0 lbf.ftl
(M/Tl: D16Y5. O16Y8 enginGs

REARSTIFFENER
10 x 1,25mm 44 N.m {4.5 kgl.m, 33 tbtft)
8 x 1.25mm 24 N.m 12.4 kgf.m, 17 lbtft) EXCEPTD16Y5, D16Y8 engines {M/T): STIFFENER Tighten boltson the stiffener the in the numbered sequence shown as ALTERNATOF BRACKET
10 x 1.25mm /t4 N.m {4.5kgf.m, 33 rbtft)
(O-O).
e)8x1.25mm 24 N.m(2.4 kg[.m. 17rbt.ftl
O 10 x 1.25mm 44 N.m {4.5 kgf.m. 33 rbf.ft)
10 x 1.25mm ,14N.m {4.5kgt m, 33 rbtftl 8 x 1.25mm 24 N.m {2.4kgf.m, 17 rbf.ft)
A/C COMPRESSOR BRACKET D16Y5. O16Y8 engine3lM/Tl: FRONT STIFFENER
8 x 1.25mm 24 N.m {2.4kgf.m, 17 tbf.ftl
10x 1.25mm 44 N.m (4.5kg,tm. 33 rbf.ft,
10x 1.25mm 44 N.m {i1.5 kgf.m, 33 tbtft)
c-tz
4 6
Engine Installation: Installtheenginein the reverse orderof removal. Reinstall mount bolts/nuts the followingsequence. the in Failure follow these procedures to may causeexcessive 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 n o u n t a n d b r a c k e t t h e n m , tightenthe boltson the frameside. NOTE: Do not tighten the bolts/nutson the transmissionside. CW:
Except Cw:
TRANSMISSION MOUNT 1 2x l 2 5 m m 64 N.m {6.5kgf.m, 17 tbt.ftl
kgf.m,28 lbf.ftl 38 N.m 13.9
2.
lnstall the upper bracket,then tighten the nuts in the numbered sequence shown (O - @).
(il 12 x 1.25mm 74 N.m 17.5 kg{.m, 54 rbf.ftl
(412x1.25mm kgt ?4N.m{7.5 m, 54 tbf.ftl
UPPER BRACKET
TNANSMISSION MOUNTBRACKET
(cont'd)
5-13
(cont'd) Installation
Install the rearmount bracket, then tightenthe bolts in the numbered sequence shown (O - @). 4 . T i g h t e nt h e b o l t / n u t s n t h e t r a n s m i s s i o n o u n t o m bracket the numbered in sequence shown (Ot- @).
cvT:
O 12 x 1.25mm 59 N.m (6.0kgJm,
(} rbtfrl Replace. mm 12x 1.25
O 12x t.25mm 74N.m{7.5 kg{.m, lbtft) 5il
kgt'm, 59 N.m 16.0 a:l lbt ft) Replace.
O 12 x 1.25mm kgJ 59 N.m 16.0 m, tbf.fr) Replace.
Except CVT: O 't2 x 1.25mm kg{.m. 59 N.m 16.0 $ tbt.ft) Replace.
12x 1.25mm 64 N.m (6.5 kgt.m, 47 tbtftl
5.
Tightenthe boltson the rightfront mounvbracket in the numberedsequence shown(O - O). CW:
O14xt.5mm tB N.m 18.5 kgf.m, 61 tbf.ftl Replace.
O to x t.zsmm 54N.m15.5 kgt.m, /r0 lbf.ftl
5-1 4
I
Except CVT:
7. Perform following: the and the Cleanthe areaswhere the driveshaft(s) (difintermediate shaft contactthe transmission ferential)thoroughlywith solvent or carburetor cleaner. and drv with compressed air. Check that the set rings on the ends of the driveshaftclickinto Dlace. shaftand intermediate CAUTION: Use new set rings. Adjustthe shift cable(seesection'14,. Adjustthe throttlecable(seesection11). Adjustthe cruisecontrolcable(seesection23). Refillthe enginewith engineoil (seepage8-5). Refillthe transmission with fluid (seesection13, 14). Refillthe radiatorwith enginecoolant(seepage 10-6). Bleedair from the coolingsystemwith the heater valveopen(seepage10-6). Cleanthe batterypostsand cableterminalswith to sandpaper. assemble them, then apply grease prevenr corroston. (seesection11). Inspect fuel Ieakage for the tuel line,turn on {ll)the igniAfterassembling the so tion switch(do not operate starter) that the two seconds fuel pump runs for approximately Repeatthis operaand the fuel line pressurizes. tion two or threetimes,then checkfor fuel leakage at any point in the fuel line.
a a a a a
10 x L25 mm kgf.m, a4 N.m 14.5 33 tbt f0
Tightenthe bolts/nuton the left front mount in the numbered sequence shown (O - O) O 1 2 x 1 . 2 5m m
83 N.m (8.5 kgl.m, 61
44 N'm 14.5 kgt.m, 33 rbf.ftl
@ 12 x 1.25mm 59 N.m 16.0 kgt.m, 43 lbf'frl Replace.
(cont'd)
5-15
Mount and Eracket Bolts/Nuts Torque Value Specifications:
A: 10x '1.25 mm 64 N.m (6.5 kgf.m,47 lbnft) B r 1 0x 1 . 2 5 m m 44 N.m (4.5 kgnm,33 lbift) C : 1 2x 1 . 2 5 m m 83 N.m (8.5kgf.m,61lbl.ft) D : 1 2x 1 . 2 5 m m 59 N.m (6.0kgt m, 43 lbl.ft) Replace.
SIDEENGINE MOUNT
RIGHTFRONT MOUNT
5-16
Tools Special
\
Rel. No.
Tool Number OTHAH PJTOl OB - 001010A 07JAA 07JAB- 0010204 . OTLAJ PR3O2OB 07NAB- 0010404 07NAJ- P07010A 07406 0020201 1A OTMAJ PY4O1 OTMAJ PY4O120 07406 0070300 07742 0010100
Description ValveGuideReamer, mm 5.5 Socket, mm 17 Holder andle H Air Stopper HolderAttachment, mm 50 Pressure GaugeAdapter A/'I PressureHose A"/T Pressure Hose,2.210mm A/T PressureAdapter A/f Low Pressure GaugeW/Panel V a l v e u i d eD r i v e r , 5 . m m 5 G
oty
PageRetsrsnce 6,43
o
@ @ @ @ @
6-8,10 6-4 6-4 6-4 6-4 6-4 6-41, 42
orO-1 andO-2 @
o o
e='T------_ts
\ - J
@ \ @
6-2
.;*'
VTECControl System
g Troubleshootin Flowchart
(DTC) toolindicates Diasnostic Trouble Code Pl259: problem theVTEC A in Pressure Switch circuit or ---tFl2Egl Il"-:1"". l e n o r d a l v e VItC So V
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)/powertrain control mod (see ule (PCM)ResetProcedLrre section 11). 2. Startthe engine. 3. Warm up the engine normal to operalingtemperature(coolingfan comeson). 4. Do the RoadTest.*
l s D T C P 1 2 5 9i n d i c a t e d ?
* RoadTest:
A c c e l e r a t en 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 i (D16Y5 engine) 6,000 or rpm (D16Y8 engine). Holdthat enginespeed at least for two seconds. lf the DTC P1259is not repeatedduring the first road test, repeat thistesttwo moretimes. Intermittent failure. system is OK at this time. Check tor poor conneqlionsor loose wires at VTEC oressure switch. VTECsolenoid valve and ECM/PCM. VTECPRESSURE SWITCH CONNECTOR
Test the VTECPresslre Switch: '1. Turnthe ignition switch OFF. 2. Disconnect the VTECPressure swrtchconnector. 3. Checkfor continuitybetween pressure VTEC switchconnector terminalNo. 1 and No. 2.
ls there continuity?
fleplace the VTEC pressrre switch.
SIDEOF MALE TERMINAL TERMINALS
vTM
T6st the VTEC Pressur Switch Wi16: 1. Turnthe ignition switch (ll). ON 2. Measure voltagbetween the pressure VTEC switchconnec' tor No. 1 and body ground.
fll \3-l
/Ta
{sr-ulelrt
I {9) Y
-L
Inspect for an open oa short to ground in the wir betweon tho VTECpressureswitch and ECM/ PCMtCls). It the wire is OK. sub3titute a known-good ECM/PCM rnd rech6ck.
WIFE SIOEOF FEMALE TERMINALS
ls thereapprox.12V? YES (To page6-4)
(cont'd)
6-3
VTECControlSystem
Flowchart(cont'dl Troubleshooting
(From page 6-3)
SWITCH VTECPRESSURE CONNECTOR
Tost the VTEC Pt.ssure Switch Wire: the Measure voltage across VTEC pressure switchconnector.
ls thereapprox.12V?
Ropair open in the wire batwe'n VTEC Dr66ureswitch and A10 or A23 ot tho ECM/FCM. ll the wire ia OK, 3ubstilut a known-good ECM/PCM .nd rochock.
WIRESIDEOF FEMALE TERMINAL
Test the VTECSolonoidValve: OFF. 1. Turnthe ignition switch 2 . R e m o v et h e V T E Cp r e s s u r e switch and installthe special tool as shown,then reinstall pressure switch. the VTEC (seesec3. Connect tachometer a 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 (cooling temperature operating fan comes on). at 6. Checkoii pressure the folD16Y5 lowing enginespeeds: e n g i n e :1 0 0 0a n d 3 0 0 0r p m , 3000and Dl6Y8 engine:1000, 5000rpm. ls pressurebelow 49 kPa {0.5kgflcm' ,7psi)?
A/T LOWPRESSURE W/PAiIEL 07406-0070300
LHOSE A/I PRESSURE 07i106 0020201 A/T PRESSURE HOSE, 2-210 mm 07MAJ - PY4O11A and A/T PRESSURE ADAPTER OTMAJ PY|{}l20
.-,,-t
t N O T E :K e e pm e a s u r i n g i m e a s s h o r t a s possible engineis runningwith no because load(less than one minute). PRESSURE GAUGE ADAPTER 07NAJ - P07010A
Insoectihe VTECsolenoidvalv6.
Test the VTECSolenoidValvel 1. Turnthe ignitionswitchOFF. 2. Disconnect VTECsolenoid the valveconnector. 3. Attach the baftery positiveter minal to the GFNIYEL termi' nal. the 4. Startthe engineand check oil pressureat the following D e e n g i n es p e e d : 1 6 Y 5 n g i n e engine5000 3000rpm, D16YB rpm.
07406-O070300
IOW PRESSURE GAUGE WPANEL
HOSE A/T PRESSURE 07406- 0020201 A/T PRESSURE HOSE, 2,210nn 07MAJ - PYlOltA .nd A/T PRESSURE ADAPTER OTMAJ PYO12O
ls the pressure above:D16Y5 kPa engine:250 (2.5kgvcm?, kPa enginer390 36 psi),D16Y8 (4.0kgf/cm' ,57 psi)?
In3oocttha VTECsolonoidvalve.
PRESSURE GAUGEADAPTER 07NAJ- P07010A
(Topage6 5)
6-4
lFrom page6-4)
ECMCONNECTORS c (3rP) A (32P1
T6t lhe VTECPr6.sure Switch: 1. Turn the ignitionswitchOFF. 2. Reconnectthe VTEC pressure swrtchconnector, 3. Staftthe engine. 4. With the batterypositiveterminal connected the VTEC to solenoidvalve,measure voltage betweenC15 and A'10or A.23 ls thsre approx. '12 above V 5,000rpm? WIRESIDEOF FEMALE TERMINALS Rplacthe VTECpressureswitch.
VTEC SOLENOID VALVE CONNECTON

Testth. VTECSolenoidValve: 1. Turn the ignitionswitchOFF. 2. Disconnect batterypositive the terminalfrom the VTECsolenoidvalve, 3. Checkfor continuitybetween the VTECsolnoid valve conneclorterminal 1 and body No. grouno. ls there14- 30 O?
l[-]f-r I I-L
I
TERMINAL SIDEOF MALE TERMINAL ReDlace VTECsolonoid valve. the VTECSOLENOID VALVE CONNECTOR ECMCONNECTOR A (32P1
tT------ I
Tosi tho VTEC Solenoid Valv Wi.e: Checkfor continuity betweenthe VTECsolenoid valve connector terminal No. I andA8.
ws
{GRN/YELI
ls therecontinuhy?
Rpair open in the wiro botweon the ECM/PCM{48} and VTECaotenoid valvoconnoclor.
WIRESIOEOF FEMALE TERMINALS VTECSOLENOID VALVE CONNECTOR
Tost tho VTEC Solenoid Valvo Whe: Checkfor continuity between the VTEC solenoidvalveconnector termin6lNo. 1 and bodyground.
r=
I
RoDair 3hort in the wire betwoon rho cM/PcM (A8land VIEC sotnoid valv6 connoctor,
t--l I
I
I r5' Y
ls therecontinuity?
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 the connectorfrom the VTECsolenoid valve. 2. Measureresistance betweenthe terminaland body grouno. Resistance: - 30 O 14 4. If the filter is not clogged,push the VTECsolenoid valvewith your fingerand checkits movement. . lf the VTECsolenoidvalve is normal,checkthe engineoil pressure.
6x1.0mm 12 N.m (1.2kgtm,8.7 lbtftl
lf the resistance within specifications, is removethe V T E Cs o l e n o i dv a l v e a s s e m b l y r o m t h e c y l i n d e r f 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 eh e e n g i n eo i l f i l t e r , t a n dt h e e n g i n e i l . o
VTECSOLENOID VALVEASSEMBLY
VTECSOLENOID VALVEFILTER Replace.
6x1.0mm 12 N.m {1.2 ksf.m,8.7 lbf.tr}
o-o
VTECRocker Arms
ManualInspection(D16Y5 engine)
1.
(D16Y8 ManualInspection engine)

'1. Setthe No. I pistonat TDC.
Setthe No. 1 pistonat TDC. Remove cylinderheadcover. the NOTE:Referto page 6-46when installing cylinthe der headcover. lvlove the intakesecondary rockerarm on the No. 1 c y l i n d em a n u a l l y . r Checkthat the intakesecondary rockerarm moves independently the primaryintakerockerarm. of
2.
2. Remove cylinderheadcover. the

NOTE:Referto page6-46when installing cylinthe der headcover.
3 . Pushthe intakemid rockerarm on the No, I cylind e rm a n u a l l y . Check that the intake mid rocker arm movesindependently of the primary and secondaryintakerocker arms.
MID ROCKER ARM
SECONDARY ROCKER ARM . Push pull. and
ROCKER ROCKER PBIMARY PBIMARY ARM ARM
SECONOARY ROCKER ARM
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. . lf the intake rocker secondary arm does not move, removethe primaryand secondary intakerocker armsas an assembly and check that the pistons in t h e s e c o n d a r y n d p r i m a r yr o c k e ra r m s m o v e a smoothly. . lf any rockerarm needsreplacing. replace prithe maryand secondary rocker armsas an assembly.
Checkthe intakemid rockerarm of each cylinderat TDC. . 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 , removethe mid, primary and secondaryintake rocker armsas an assembly check and thatthe pistons in the mid and primary rockerarms move smoothly. lf any rocker arm needs replacing,replacethe primary,mid, and secondaryrockerarms as an assemoly.
6-7
Arms VTECRocker
(D16Y5 engine) Inspection Using SpecialTools
CAUTION: . Eelore using the Valve Inspection Tool. make sure that the air pressuregaugs on the air compressor indicatesover iloo kPa {4 kgt/cm', 57 psil. a tnspectthe valve clearancebgfore rocker arm inspectlon. . Coverthe timing belt with a shop towalto protect the belt. . Checkthe intakepdmary rockerarm of eachcylinderat TDC.
1. 3. Remove the sealing bolt trom the inspection hole and connect the Valve Inspection Tool.
10 x 1.0mm BOLT SEALING 20 N'm {2 0 kgf'm, 14lbf'ft} AIR STOPPER OTLAJ- PR3O2OB
Remove cylinderheadcover. the the NOTE:Referto page6-46when installing cylinder headcover. tool. Plugthe reliefhole with the special
Y'
OTLAJ_ PR3O2OB
l0 x 1.0 mm ADAPTER
TNSPECTTON HOLE
VALVEINSPECTION TOOL (Commercially available)
. P u l l t hd i a a n d e l turnto adjust,
Loosenthe regulatorvalve on the valve inspection tool and apply specifiedair pressureto the intake rockera.m timing piston. SpecifiedAir Prossure: 250 kPa {2.5 kgt/cm,, 36 psil
6-8
5.
With the specified pressure air applied,push up the timing plate;the synchronizing piston will pop out and engage the intakesecondary rockerarm. Visually checkthe engagement the synchronizing of piston. NOTE: . The synchronizing pistoncan be seen in the gap betlveen secondary the and primaryrockerarms, . W i t h t h e t i m i n g p l a t ee n g a g e dn t h e g r o o v eo n i 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 pushedout position.
6.
Stop applyingair pressure and push up the timing plate;the synchronizing pistonwill snap backto its originalposition. Visuallycheckthe disengagement the synchroof nizingpistons. NOTE: . When the timing plate is pushedup, it releases the timing piston,lettingthe returnspring move pistonto its originalposition. the synchronizing . Replace intakerockerarms as an assembly the if eitherdoes not work correctlt.
TIMI]TG PLATE
TIMII{GPLATE TIMII{G PLATE SPRII{G --il. otL PASSAGE
ROCKER PRIMARY ARM

TIMINGSPRIIIIG
SECO'{OAFY ARII ROCKER
RETURIT SPRI G
SY CHRONIZING PISTON TIMING PISTO

SECONDARY ROCKER ARM
1.
Remove special the tools. After inspection, check that the malfunction indicator lamp (MlL)does not comeon.
A|R PNESSURE
PRIMARY ROCKEB ARM TIMING SYNCHRONIZI''IG PISTON TIMINGSPRING
6-9
I
VTECRocker Arms
Inspection Using Special Tools(D16Y8 engine)
CAUTION: . Before using the Valve Inspection Tool, make sure 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, . Cover the timing belt with a shop towel to protect the belt. . Checkthe intake primary rocker arm of each cylinder at TDC.
1.
3.
Removethe sealing bolt from the inspectionhole Tool. and connect ValveInspection the
1 0x 1 . 0m m SEALINGBOI-T 20 N.ln 12.0kgt.m, 14 lbf.ft)
Remove cylinderheadcover. the NOTE:Refer page6-46when installing cylinder to the neaocover. Plugthe reliefholewith the special tool.
Y '
HOLE RELIEF OTLAJ PR3O2OB
\
TOOL (Commercially available) . P u l l t h e i a la n d d turn to adlust,
6-10
4.
Loosenthe regulatorvalve on the valve inspection tool and apply the specifiedair pressureto the rocker arm synchronizingpistonAVB. SDecified Prsssure: Air 250 kPa {2.5 kgf/cm,. 36 psi) PRIMARY ROCKER ARM MIDROCKER ARM SECONDARY ROCKER ARM
Remove special the tools. 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 motionassembly throughits full movement. Replace any lost motion assemblythat does move smoothly.
TIMING PISTON
SYNCHRONIZING SYNCHRONIZING PISTON A PISTON B Make sure that the intake primary and secondary rockerarms are mechanically connectedby the piston and that the mid rockerarm does not move when pushed manually.
ASSEMBLY
After inspection, checkthat the MIL does not come on.
lf any intakemid rockerarm moves independently of the primary and secondaryrocker arms. replacethe rockerarms as a set.
6-11
Valve Clearance
Adjustment
NOTE: . V a l v e ss h o u l d b e a d j u s t e d n l y w h e n t h e c y l i n d e r o (38"C). is headtemperature lessthan 100"F . Alter adjusting,retorquethe crankshaftpulley bolt (seepage6-16). '1. Remove cylinderheadcover. the the NOTE;RefertopageG46wheninstalling cylinder neaocover. Remove uppercover(seepage5-19). the "UP" mark on the camSet the No. 1 pistonat TDC. shaft pulleyshouldbe at top, and TDCmarksshould align with the cylinderhead surface. 5. screw Loosenthe locknut, and turn the adjustment until the feeler gauge slides back and forth with a slight mount f drag. a o D16Y7 engine: CAUTIONT not overtighten the locknuts; the Do rockgrarms are madeol aluminum. VALVE INTAKE ExHAUST and LOCKNUTS
18 N.m (1.8kgt m, 13 lbf.ftl
"UP" MARK TOCMARKS D16Y5, Dl6Yg engines: INTAKEand EXHAUST VALVE LOCKNUTS 20 N.m 12.0kgf.m, 14 lbnft)
4.
Adiustvalveson No. 1 cylinder. Intake: 0.18- 0.22mm 10.007 0.009in) Exhaust: 0.23- 0.27mm (0.009 0.011inl
Adiusting 3crew locations:
INTAKE
No.4 No,3 o.2
"/
o-tz
t6
at^
6.
Tightenthe locknut,and checkthe clearance again. Repeat adjustment necessary. the if
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 t o e 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.
(camRotatethe crankshaft 180"counterclockwise shaftpulleyturns 90").The "UP" mark shouldbe on the exhaust side.Adjustvalveson No. 3 cylinder.
9.
Rotate crankshaft the 180"counterclockwise bring to No. 2 pistonto TDC.The "UP" mark should be on the intake side.Adjustvalveson No. 2 cylinder.
.UP'MARK
-UP" MARK
6-13
Valve Seals
(Cylinder head removalnot required) Replacement
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 procedure. shown below applieswhen usingthe inThe procedure 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 YA8845 2A7l8" attachment). 7. Alway wear approved eye protection when !@ usingthe in-carvalvespringcompressol. 1. 'l Turn the crankshaft that the No. and the No. 4 so pistonsare at top deadcenter(TDC). Remove cylinderheadcoverand the rockerarm the assemoty. NOTE: . 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. t W h e n r e m o v i n go r i n s t a l l i n gh e r o c k e ra r m h 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 t o l d e r , s 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 , p r i n g s and rockerarmson the shaft. Referto page 6-46 when installingthe cylinder headcover. 3. the and the wire harness. Remove fuel injectors with the tool, mount Uslngthe 8 mm bolts supplied 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 T c a m s h a l th o l d e r s . 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 cylinOIL PASSAGES
lntake Valve Sealsi 6, attachSelectthe 7/8 in diametershort compressor to ment,and fastenthe attachment the No. 4 hole of the leverarm with the speedpin supplied. lnsertan air adaptorinto the sparkplug hole.Pump air into the cylinderto keep the valve closedwhile springsand removingthe valve keepcompressing ers. Position the lever arm underlhe crossshaft so the leveris perpendicular the shaftand the compresto sor attachmentrests on top of the retainerfor the spring being compressed.Use the front position slot on the leveras shown.
COMPRESSOR SPRING IN-CAR
2.
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. comfrom pressthe valvespringand removethe keepers 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. the 1 0 . Remove valveseals(seepage6-38). 1 1 . Install valveseals(seepage6-43,. the in and the keepers 1 2 . Installthe springs,the retainers reverse orderof removal. ExhaustValve Seals:
t5.
15, Using a downward motion on the lever arm, compressthe valvespringand removethe keepers from 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 spnng. the 1 6 . Remove valveseals(seepage6-38). 1 7 . lnstallthevalveseals(seepage6-43). and the keepersin 1 8 . Installthe springs,the retainers reverse orderof removal. 1 9 . Repeat steps6 to 18 on the othercylinders,
attachSelect the 7/8 in. diametershort compressor to ment,and fastenthe attachment the No.2 hole of the leverarm with the speedpin supplied.
1 4 . Position the lever arm underthe crossshaft so the to leveris perpendicular the shaftand the compressor attachmentrests on top of the retainerfor the spring being compressed.Use the front position slot on the leveras shown. t 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 so prevent from fallinginto the cylinthe valvekeepers der head.
COMPRESSOR IN.CABSPRING
A 7/8 in SHORT
6-15
Crankshaft Pulleyand PulleyBolt

Replacement
W h e n i n s t a l l i n g n d tightening the pulley, follow the a procedure below, 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. O: Clean x: Remove any oil a: Lub.icate
CRANKSHAFT 1.
Tightenthe pulleybolt to the specified torque. Torque: 20 N'm (2.0 kgf.m, 14 lbf.ftl Use a felt tip pen to mark the pulley bolt head and wasner.
TIMING BELT GUIDE PLATE Crankshaftpully bolt siz and torque value: 14 x 1.25mm 20 N.m (2.0 kgf'm. lil lbf'ft] + 90" NOTE:Do not usean impactwrenchwhen installing. 3. }IOI.DER HANDII o'JAB- tD1020A
HOLDER ATTACHMENT. mm 50 07 AB - 00100A
EMBOSSING MARKS
Tightenthe pulleybolt an additional 90'.
SOCKET, mm 17 o'JAA - @1010Aot lComm.rcillly rv.ihbl.)
MARKING
o-to
L-
t^
at^
Timing Belt
lllustrated Index
NOTE: . Refer page to for 6-20 howto position crankshaft pulley the and before installing belt. the
. a . . . Mark the direction of rotation on the belt before removing. 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.
CYLINDER HEAD COVER Referto page6 46 when installing.
HEADCOVER GASKET Replace when leaking, damaged deterioraled. or Applyliquidgasket at the tour corners the of recesses.
@y
TIMINGBELT page Inspectaon, 6-18 page6-18 Adjustment, page6-19 Removal, page6,20 lnstaliation,
8 x 1.25mm 37 N.m (3.8 kg{.m.27 lbf.ftl Applyengineoil to the bolt threads. CRANKSHAFT FLUCTUATION SPEED ICKF)SENSOR page6'22 Replacement,
UPPER COVER
6x1.0mm 9.8 N.m 11.0 kgf.m, 1.2 tbl.trl RUBAER SEALS Replace when damaged or deterioratod. LOWER COVER RUBBER PLUG CRANKSHAFT PULIEY page6-16 Replacement, PULLEY BOLT 1a x 1.25mm 20 N.m {2.0kgl.m, lia lbf.ft) + 90' Replacement, page6-16 Do not use an impact wranchwhen installing. 6x1.0mm 9.8 N.m ll.0 kgf.m, 7.2 tbtftt
TIMINGBELT DRIVEPULLEY page6-16 Replacement, O.RING 6 x 1 . 0 m m 10r 1.25mm Replace.1 2 N m 1 1 . 2 k g l ' m , 4,1N.m {4.5 kgf.m, 33 lbtft) 8.7 lbf.ftl
6-17
Timing Belt
Inspection
1 . Remove cylinderheadcover. the . Refer page6-46when installing. to NOTE: . The tensioneris spring-loaded applytensionto the to after makingthe following adjustbelt automatically menr. . Alwavs rotatethe crankshaft when counterclockwise i v i e w e df r o m t h e p u l l e y s i d e .R o t a t i n g t c l o c k w i s e may result in improper adjustmentof the belt tension. . Inspectthe timing belt beforeadjustingthe belt tenston. 1 . Remove cylinderheadcover, the . Refer page6-46when instslling. to
TensionAdjustment
CAUTION: Always adiust the timing belt tension wiih th engine cold.
Remove rtppercover(seepage6-19). the

?
Inspect the timing belt for cracksand oil or coolant soaking. NOTE: . Replace belt if oil or coolantsoaked. the . Remove any oil or solventthat gets on the belt.
Remove uppercover(seepage6-19). the to five or six revolutions set Rotatethe crankshaft the belt. 4.
5.
Setthe No. 1 pistonat TDC(seepage6-2'1). Loosen adjusting the bolt 180'.
BOLT ADJUSTING 44 N.m {4.5kgf m, 33 tbtft) Rotatepulley belt. and inspect
After inspecting,retorque the crankshaftpulley bolt (seepage6-16).
counterclockwise three teeth Rotatethe crankshaft pulley. on the camshaft 7. bolt. Tightenthe adjusting pulleybolt the crankshaft After inspecting, retorque (seepage6-16).
Removal
NOTE: . Replace timing belt at 105.000 the miles{168,000 km) (normalconaccording the maintenance to schedule ditions/severe condition). lf the vehicleregularyis driven in one or more of the followingconditions, replace timing belt at 60,000 th miles(U.S.A.) 100,000 (Canada). km . In very high temperatures (over110'F, 43"C). . In very low temperatures {under-20"F,-29"C). . Turn the crankshaft pulley so the No. 1 piston is at top dead center(TDC)beforeremovingthe belt (see p a g e6 - 2 1 ) . . Inspectthe water pump before installingthe timing belt {seepage10-12). 1 . Remove splashshield(seepage5-7). the Loosen mountingbolt and lockbolt.then remove the (P/Sl pump beltand pump. the powe.steering
MOUNTINGEOLT 8 x 'l.25mm 24 N m {2.4 kgf.m, 17 lbt.ft) IDLER BRACKET 8 x 1.25mm 24 N.m l2.il kgf.m. 17 lbf.ft)
5.
Removethe dipstick, then removethe upper cover and idler pulleybracket. NOTE: Do not use the upper cover to store removed |tems.
UPPER COVER 6x1.0mm 9.8N.m {1.0kgf.m, 7.2
6.
(seepage6-29). Remove upperbracket the 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 BELT
7. 8.
pulley(seepage6-'16). Remove crankshaft the pipe. Remove lower coverand dipstick the NOTE: Do not use the lower cover to store removed tems.
8 x 1.25 mm 24N.m(2.4 m, 17lbnftl kgf
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) compressorbelt (seepage 5-6). Loosen mountingnut and lockbolt,then remove the the alternatorbelt.
ALTERNATOR BELT LOCKBOLT 8 x 1.25mm 2ir N.m 12.4 kgt.m, 17 tbt.ft)
LOWER
5xl.0mm 9.8Nm(1.0kgf.m. 7.2 tbt.ftl
MOUNTINGNUT 10 x 'l.25mm 44 N.m (4.5ksf.m, 33 tbtft)
(cont'd)
6-19
Timing Belt
(cont'dl Removal
9. Remove CKFsensor the from the oil oumo.
Installation
Install timing belt in the reverse the orderof removal; here. Only key pointsare described 1. Set the timing belt drive pulleyso that the No. 1 pisAlign the grooveon ton is at top deadcenter(TDC). the timing belt drive pulleyto the pointeron the oil oumo. TDCMABK
FOINTER
'i
12 N.m lr.2 kglm, 8.7 tbt.trl
1 0 . Loosenthe adjustingbolt 180".Pushthe tensioner 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 retighten adjusting the bolt.
TIMING BELT ORIVEPULLEY Clean. 2.
KEY
Set the camshaft pulley to TDC. Align the TDC marks on the camshaft pulley to the cylinder head surface.
ADJUSTING BOLT +l N.m 14.5 kgl.m, 33 tbtftt
11. Remove timing belt. the
a
3. Install timing belttightly in the sequence shown. the j@Adjusting oTiming belt drive pulley(crankshaft) pulley. pulley-)@Waterpump pulley'-r@Camshaft 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 camshaft are Dullev at TDC. pulley and camshaftpul9. Checkthat the crankshaft ley are both at TDC. CRANKSHAFT PULLEY:
(WHITEI PULLEY: CAMSHAFT

"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. pulley,then tightenthe pulley Installthe crankshaft bolt (seepage6-16). pulley about five or sjx turns Rotatethe crankshaft counterclockwise that the timing belt positions so on the pulleys. Adjustthe timing belt tension(seepage6-18).
7.
TOC MARK
'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 u l l e y i s n o t p o s i t tioned at TDC, remove the timing belt and adjust the positionfollowingthe procedure page 6-20. on Then reinstall timing belt. the ' It . After installation, adjustthe tensionof eachbelt. . . . belt tensionadjustSee section23 for alternator ment. See section22 fot NC compressorbelt tension adJustment. Seesection 17for P/Spump belt tensionadjustment.
6-21
SpeedFluctuation Crankshaft
(CKF) Sensor
Replacement
1. Remove cylinderheadcover. the NOTE:Refer page6 46 when installing. to pulley(seepage6 16). Remove crankshaft the ( 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). Disconnect CKFsensorconnector, the then remove the CKFsensor.
CKFSENSOR CONNECTOR
CKFSENSOR
6x1.0mm kgf.m, 12 N.m {'1.2 8.7 tbtftl
6.
InstalltheCKFsensorin reverse orderof 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 gaskets when reassembling.
6x1.0mm 9.6 N.m (1.0kgf.m,7.2lbtft) Applysoapsuds threads to and cylinder head contactsurfacewhen replacingthe rubber seal,then remove any soapsudsafter installing rubberseal. RUBBER SEAI. Replace when damaged or deteriorated. CYLINDER HEADBOLT 10 x 1:25mm 67 N.m 16.8 kgt.m, a9 lbf.ftl page&46 Tightening, Applyongin6 oilto the threads.
WASHER Replace when damaged or deteriorated. CYLINDER HEAO COVEB Beferto page6-46,when installing headcover. cylinder
HEADCOVER GASKET Replace when leaking, damagedor det6riorated. Apply liquidgasket at the four corners ofthe recesses.
OISTRIBUTOR Seesection23.
CYLINDER HEAD
8 x 1.25 mm 24 N.m {2.4 kqf.m, 17 tbf.ftl
CYLINDER HEAD GASKET Replace.
8 x 1.25mm 24 N.m (2.,0 kgf.m, 17 lbfft)
OOWEL PINS
{cont'd)
6-23
Cylinder Head
lllustratedIndex(cont'dl
Priorto.reassembling, cleanall the partsin solvent, them and applylubricant any contactparts. dry to D16Y7 engine:
I x 1.25 m m 20 N.m 12.0 kgf.m, 14 lbf.ftl Applyengineoil 10the 6x1.0mm 12 N.m (1.2kgf.m, 8.7 lbf.ft) Applyengineoil to the threaos.
ROCKER ARM ASSEMELY page6-30 Bemoval, page6-35 Inspection,
VALVEKEEPERS
c "
OIL CONTROL ORIFICE Clean. O-RING
Replace.
B
AKE VALVE SPRING AKEVALVESEAL ReplaceVALVESPRING SEAT INTAKEVALVE GUIDE
VALVEKEEPERS
RET SPRING EXHAUST VAL SPRING
EXHAUST VALVE SEAL Replace.

VALVESPRING SEAT EXHAUST VALVE GUIDE page6-39 Inspection, Replacement, page6-41 page6,43 Reaming, INTAKEVALVE page6-38 Removal, page6-43 Installation,
8 x 1.25mm 37 N.m (3.8kgtm, 27 tbt.ftl Applyengineoil to the threads.
EXHAUST VALVE
page6 27 Removal, Warpage,page 6-40 Valveseatreconditioning, page 6-40 page6 45 Installation,
6-24
D16Y5 engine:
8 x 1.25mm kg{.m, 14 lbf.ft) 20 N.m 12.0 Apply engineoilto the threads, 6x1.0mm 12 N.m {1.2kgf.m.8.7 lbf.ftl Apply engineoilto the threads,
ROCKER ARM ASSEMBLY page6-30 Removal, page6-34 Inspection,
CAMSHAFT page6-36 Inspection, 6x1.0mm 12 N.m 11.2 8.7 rbt.ftl
VALVEKEEPERS
SPBINGRETAINER
wEc solENoro
VALVE
VALVE INTAKE SPRING

INTAKEVALVESEAL Replace.
VTECSOLENOID VALVEFILTER Replace. OIL CONTROL ORIFICE Clean.
VALVE SPRING SEAT INTAKE VALVE GUIDE

CAMSHAFT PULLEY
VALVEKEEPERS
RETAINER SPRING EXHAUSTV SPRING EXHAUST VALVE SEAL Beolace. ' VALVE SEAT
Replace.
8 x 1.25mm kgf.m, 37 N.m 13.8 27 lbl-ltl Applyengineoilto the threads.
GUIDE page6 39 Inspection, page6-41 Replacement, page6-43 Reaming, EXHAUST VALVE INTAKEVALVE Removal,page6-38 page6-43 Installation, OIL SEAL Replace.
HEAD page6'27 Removal, 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, them and apply rubricant any contactparts. dry to
D16Y8 engine:
I x 1.25mm 2 0 N . m { 2 . 0k g f . m , 1 4 l b f f t l Apply engine oil to the threads.
LOSTMOTION ASSEMBLY
ROCKER ARM ASSEMBLY Bemoval, page6 30 Inspection, page6-34
6x1.0mm 12 N,m 11.2kgf m, 8.7 lbl ft) Applyengineoil to the threads.
6x1.0mm 12 N.m (1.2 8,7 tbf.fil
CAMSHAFT lnspection, page6 36
VAI-VEKEEPERS
"E
F WEC SOLENOID VALVEFILTER Replace.
SPRING RETAINEF
INTAKE VALVE SPRING

INTAKEVALVESEAL Replace. VALVESPRING SEAT INTAKEVALVE GUIOE
\$
OIL CONTROL ORIFICE Clean. VALVEKEEPERS SPRING RET EXHAUST VALVE SPRING
@
8 x 1.25mm 37 N.m 13.8 kgtm. 21 tbt.ftl A p p l ye n g i n e i l t o o the threads_
EXHAUST VALVE SEAL Replace. O-R|NG EXHAUST VALVE Reptace cUtDE lnspection, page6-39 Replacement, page6-41 page6-43 Reaming,
otL
Replace.
INTA(E VALVE EXHAUST CYLINDER HEAD Removal, page6 38 VALVE Removal, page6-27 Installation, page6,43 page6 40 Warpage, Valveseatreconditioning, page6'40 lnsta,'ation,page6-45
6-26
Removal
for Engineremovalis not required this procedure. Make surs lacks and safety stands are @ placed properly and hoist brackets are aftached to the corrcct positions on ihe engins, CAUTION: . Uso fonder covers lo avoid damaging painted surfacss. . Unplug the wiring conneqtorscarefully while holding 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 (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. . Inspect the timing belt before removingthe cylinder head. pulleyso thatthe No. 1 pistonis at . Turnthe crankshaft top deadcenter(seepage6-21). L Disconnect negative the terminalfrom the battery. Drainthe enginecoolant(seepage10-6). . Remove radiator the capto speeddraining. 8. Remove the throttlecableby loosening the locknut, then slip the cableend out of the throttlelinkage. NOTE: . Takecarenot to bendthe cablewhen removingit. Alwaysreplace kinked any cablewith a new one. (seesec. Adjustthe throftlecablewhen installing tion11). D16Y7 engine:
LOCKNUT
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) compressor belt (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 alternator belt (seepage6-19). 7. Remove P/Spump bracket the {seepage5-12).
{cont'd)
6-27
CylinderHead
Removal(cont'dl
(seesectionl1). 9. Relieve fuel pressure Do not smokewhile working on the fuel E@ systgm. Keep opn flame or 3park away from th9 work area. Drain tuel only into an approved containgr. 10. Removethe evaporativeemission (EVAP)control canister hose,fuel feed hoseand breather hose. D16Y7 engine: 11. Remove the brakeboostervacuumhose,fuel return hoseand vacuumhose(seepage5-4). 12. Removethe water bypasshose and positivecrank(PCV) caseventilation hose. D16Y7 engine:
WATEBBYPASS
BANJO BOLT 33 N.m{3.4kgf.m, 25tbtftl
BREAIHER HOSE
D15Y5, D16Y8 engines: BANJO BOLT 33 N.m 13.4 kgf.m, 2s tbf.ft) PCVHOSE
6-28
1 3 . R e m o v e t h e u p p e r radiatorhose, heater hose and water bypass hose.
1 5 . R e m o v e 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 t the cylinderhead. 16. Remove the upperbracket. NOTE: . 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 is upperbracket removed. . 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
WATER BYPASS HOSE UPPER RADIATOR HOSE
HEATER HOSE
c a 1 4 . R e m o v e h e e n g i n ew i r e h a r n e s s o n n e c t o r s n d t wire harness clampsfrom the cylinderheadand the intakemanitold.

a Fourfuel injector connectors ( a E n g i n ec o o l a n tt e m p e r a t u r eE C T ) e n s o rc o n s
17. Remove cylinderheadcover. the
nector a ECTswitchconnector a ECTgaugesendingunit connector a Throttlepositionsensorconnector ( p M a n i f o l da b s o l u t e 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 d x y g e ns e n s o r( p r i m a r yH O 2 S ) o 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 (D16Y7 HO2S) connector engine) (EGR) valve lift sensor Exhaustgas recirculation (D16Y5 connector engine) VTECsolenoid valve connector(Dl6Y5, D16Y8 engrnes) D16Y8 VTECpressure switch connector(D16Y5, engrnes, ldle air control(lAC)valveconnector
(cont'd)
',l
6-29
CylinderHead
Removal(cont'd)
1 8 . Remove timing belt (seepage6-19). the pulleyand backcover. 1 9 . Remove camshaft the
CAMSHAFT PULLEY when installing. Clean
Rocker Arms
Removal
1. Loosen adjusting the screws.
ADJUSTING SCREWS
6xl.0mm
8 x 1.25mm 37 N.m {3.8kgf.m, 2't tbftr)
f:,f'In:J$::'"''n"
2. (seepages and9-6). 20. Remove exhaust the manifold 9-5 21. Remove the intakemanifold(seepages9-2thru 4). 22. Removethe cylinder head bolts, then removethe c y l i n d eh e a d . r CAUTION:To prevnt warpage, unscrew the bolts in sequencel/3 turn at a time; repeat the sequence until allbolts are loossned. CYLINDER HEADBOLTSLOOSENING SEOUENCE: Unscrewthe camshaft holder bolts, then remove the rockerarm assembly. NOTE: . Unscrew camshaft the holderboltstwo turns at a pattern,to preventdamag time, in a crisscross ing the valvesor rockerarm assembly. . When removingthe rockerarm assembly, not do removethe camshaftholderbolts.The bolts will keep the camshaftholders,the springsand the rockerarms on the shaft. CAMSHAFT HOLDER SOLTSLOOSENING SEOUENCE:
6-30
Disassembly/Reassembly
NOTE: . ldentifypartsas they are removed ensurereinstallation originallocations. to in . Inspect rockershaftsand rockerarms (seepage6-35). . Rocker arms must be installed the samepositionif reused. in . When removingor installingtherockerarmassembly, not removethecamshaft holderbolts.The boltswill keepthe do holders, springsand rockerarmson the shaft. to Priorto reassembling, cleanall the partsin solvent, them and apply lubricant any contactpoints. dry
D16Y7 engine: Letter "8" is stamped on rockerarm. INTAKE ROCKER ARM B (4 pl.corl
INTAKE ROCKER ARMA

la pl.c$l
INTAKE ROCKER
I I
ROCKER SHAFT COLLAR 14placesl
ofr ffi* dT*,.\ft t G t I .l

"' r' lJll-No.3CAMSHAFT | No.2CAMSHAFTIl |
"
HoLDER
Lal HoLDER
[6]
UTU " l ^
SHAFT R(rcKER SPRING (4 plac.Bl
n] [n, ,d"h] H \d*hl

a A
B
I ru
(cont'd)
6-31
Rocker Arms
(cont'd) Disassembly/Reassembly
NOTE: . ldentify pansastheyareremoved ensure reinstallationoriginal to in locations. . Inspect page rocker shafts rocker and arms(see 6-34).
. Rocker arms must be installed the same positionif reused. in . When removingor installing rockerarm assembly, not removethe camshaft the do holderbolts.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 nc l , a n 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 o n yc o n t a cp o i n t s . ge a , a t SHAFT INTAKE ROCKER
D16Y5 engine:
ROCKER ARMS
ROCKER SHAFT COLLAR
No. 5 CAMSHAFT HOLOER
[u
Hlw l
'l I
I
EXHAUST ROCKER ARM 8 {4 placesl EXHAUST ROCKER SHAFT EXHAUST ROCKER ARM A 14placesl
IR SHAFT
Letter"8" is stamped on rocker arm.
Letter "A" is stamped
6-32
D16Y8 engine:
INTAKEROCKER SHAFT ROCKER SHAFT COLLAB ROCKER ARMS INTAK BOCKER ARM ASSEMBLY RUBBER AAND / coLLAR
"o,_.-o"
,mil
\
No. 4 CAMSHAFT HOLDER No. 3 CAMSHAFT HOLDEB
fla
H+nllf{ -
lu!4ut Etue
J
No. 2 CAMSHAFT HOLDER
tre / 0lluIJllt LF
rs,urtg
I
l-
,fxll^\ rvni<
NO,1 CAMSHNFT HI
H.LDER
l -t
r-{W
l-Jf
FOCKEB SHAFT SPRING (4 place3) ARM B
)rJfiF
t v t
\
XHAUST ROCKEB A8M {4 placesl
fll
-.\ EXHAUSTROCKER SHAFT
Letter
"B"
is stamped
Letter
"A"
is stamped
6-33
Rocker Arms and Lost Motion Assemblies

(D16Y5, Inspection D16Y8 enginesl
t N O T E :W h e n r e a s s e m b l i n gh e p r i m a r y r o c k e ra r m , o t a c a r e f u l l y p p l y a i r p r e s s u r eo t h e o i l p a s s a g e f t h e rocker arm. 1. Inspect rockerarm piston.Pushit manually. the - lf it does not move smoothly,replace the rocker arm assemory. D16Y5 engine: NOTE:Set the timing plate and returnspring as shown
\.
RETURN
D16Y5 engine:
PRIMARYROCKER ARM TIMINGPISTON
TIMI G SPRING
SYNCHRO ENG PISTOI{ CAMSHAFTHOI.DER
D16Y8 engine:
.{
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,replace it.
ARM MIOROCKEB
Pu!h
PRIMARYROCKER
MOTON ASSEMBLY LOST
sYt{cHRof$ztlrlc PISTON A NOTE: . Apply ojlto the pistons when reassembling. a Bundlethe rockerarms with a band to preventthem from separating.
6-34
RockerArms and Shafts

lnspection Clearance
Measure both the intakerockershaft and exhaustrocker shaft. 1. Measure the diameterof the shaftat the first rocke. tocauon. 3. Measure the insidediameterof the rockerarm and checkfor an out-of-round condition. RockerArm-to-Shaft Clearance: Standard lNew): Intake: 0.017 0.050mm (0.0007 0.0020 in) - 0.054mm Exhaust: 0.018 (0.0007 0.0021in) Service Limit:0.08mm (0.003 in)
2.
Zerothe gaugeto the shaftdiameter.

Inspect rocker arm
Reoeat thesemeasurements all the rockers. on - lf the cleara is overthe service it, replace nce lim the rocker shaftand all overtolerance rocker arms.
6-35
r,
Camshaft
Inspection
NOTE: . Do not rotatethe camshaft during inspection. . Remove the rockerarms and rockershafts. L Put the camshaftand the camshaftholderson the cylinderhead,then tightenthe boltsto the specified torque. Spocifiodtorqu: 8 mm bolts: 20 N.m 12.0 kgf.m 14 lbf'ft) Apply engine oil to the threads. 6 mm bolts: 12 N.m (1.2 kgf.m 8.7 lbf.ft) Apply engine oil to the th.eads. 6 mm bolts:@, @ @, @ Seatthe camshaftby pushingit toward the rear of the cylinderhead. Zerothe dial indicatoragainstthe end ofthe camshaft. Push the camshaftback and forth, and .ead the end olav. Camshaft End Play: Standard{New):0.05 0.15mm (0.002- 0.006in) ServiceLimit: 0.5 mm (0.02in)
'u
.g
Removethe bolts.then removethe camshaftholders from the cvlinderhead. - Lift the camshaft out 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 camshaftbearingsurfaces the cylinin der head,then set the camshaft backin place. - Place plastigage a strip acrosseachjournal. Install holders, and tightenthe boltsto the camshaft the soecified torque.
6-36
6.
Remove the camshaft holders,then measurethe widestportionof the plastigage eachjournal. on Oil Camshaft-to-Holder Cloarance: Standard {New}:0.050- 0.089mm {0.002- 0'004 in) Limit: 0.15mm (0.006 in) Sorvice
8.
Check cam lobe heightwear. the U n i tm m ( i n ) EXHAUST
Cam lobe heightstandard {New)
INTAKE
D 16Y7 engine D16Y5 engine PRI
sEc
(1.4678) 35.299 {1.3897) 37.281 ( 3 8 . 4 2 71 . 5 1 2 9 ) (1.5269) 38.784 32.193\1.267 4l 36.77411.44191 (1.5068) 38.008 (1.4964) 38.274 (1.45921 37.065
PRI D16Y8 MID engrne
PRI:Primary cam lobe,SEC: Secondary cam lobe. MID:Mid cam lobe,T/B:Timing belt. lN: Intake, Exhaust EX:
PRIMIDSEC
7.
is lf the camshaft-to-holder clearance out of toloil erance: - 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 , you must replace cylinderhead, the - lf the camshaft has not beenreplaced, first check on the total runout with the camshaftsuDDorted V-blocks. CamshaftToial Runout: Standard {Nw): 0.03 mm {0.001in) max. ServiceLimit: 0.0,t mm {0.002in)
,/a
EX
tN
EX
+ Dl6YS engine
IIB - D16Y8engine
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 tolerance,replace cylinderhead. the replace the lf the total runout is out of tolerance, lf is camshaftand recheck. the bearingclearance replace cylinderhead, still out of tolerance, the
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 in removedso that eachitem can be reinstalled its original position. 1. socketand plasticmalUsing an appropriate-sized to let, lightlytap the valve retainer loosenthe valve keepers beforeinstalling the valve spring compressor.
PLASTICIIIALLET
3.
Install valveguidesealremover. the
SEAL REMOVER
VALVEGUIDESEALREMOVER LISLEP/N 57900or KD3350

available)
VALVE SEAL
SOCKET
4. Remove the valve seal.
Compress the spring Installthe spring compressor. and .emovethe valvekeeper.
VALVE SPRING COMPRCSSOR SnlD-on CF7'lI or KD-383 rYlth t32 JAWS
6-3 8
ValveGuides
ValveMovement
Measurethe guide-to-stem clearance with a dial indicator while rockingthe stem in the directionof normal thrust (wobblemethod). Intake Vslve Stem-to-GuideClearance: Standard{Newl: 0.04- 0.10mm (0.002 0.004in) Service Limh: 0.16mm {0.006 inl ExhaustValve Stem-to-GuideClarance: StandardlNewl: 0.10- 0.16mm (0.00i1 0.fi)6 in) ServiceLimit: 0.22 mm {0.009inl
Valveextended mm out from seat. 10
Intake Valve Dimensions A Standard(New): 29.9- 30.1mm i { 1 . 1 8 1 . 1 9n l B Standard lNewl: 117.Q. 117.72 mm (4.623- il.635 in) C Standard {NBw): 5.'18 5.49 mm in) 10.2157 0.2161 C ServiceLimit: 5.,t5mm {0.2146in} D Standard (New): 0.85- 1.15mm {0.033- 0.045inl D ServiceLimil: 0.65 mm (0.026inl ExhaustValve Dimensions A St8ndard(Newl: 25.9- 26.1mm (1.02 1.03inl B Standsrd lNew): 114.60 114.90 mm - 4.521in1 14.512 C Standard {Newl: 5.45- 5.'16mm (0.2146 0.2150 inl C ServiceLimit: 5.42mm 10.213,[ in] D Standard (New): 1.05- 1.35mm l0.0il1- 0.053inl D ServiceLimit: 0.95mm (0.037 in) .
.:I
l f t h e m e a s u r e m e ne x c e e d s h e s e r v i c el i m i t . t t recheck usinga new valve. 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 limit,reassemble usinga new valve. l f t h e m e a s u r e m e ns t i l l e x c e e d s h e l i m i t . t r recheckusing the alternatemethod below. then replace valveand guide,if necessary. the
NOTE:An alternatemethod of checkingguide to stem clearance to subtractthe O.D.of the valve is stem, measured with 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 differencebet 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 measurement should not exceedthe limit, service Int8ke Valve Stem-to-GuideClearancs: Standard (Nsw): 0.02- 0.05 mm {0.001- 0.002inl ServiceLimit: 0.08 mm 10.003 in) ExhaustValve Stem-to-GuideClearance: Standard (New): 0.05- 0.08 mm (0.002- 0.003inl Service Limit 0.11mm 10.004 in)
6-39
GylinderHead
Warpage
( N O T E : l f t h e c a m s h a f t - t o - h o l d e ri l c l e a r a n c e s s e e o page6-36)are not within specification, cylinderhead the cannotbe resurfaced. lf the camshaft-to-holder clearances within sDecioil are fications. checkthe cylinderheadfor warpage. lf warpageis lessthan 0.05 mm (0.002 cylinin), der headresurfacing not required. is lf warpage is between 0.05 mm (0.002in) and 0.2 mm (0.008 resurface cylinderhead. in), the M a x i m u m r e s u r i a c ei m i t i s 0 . 2 m m ( 0 . 0 0 8i n ) l basedon a heightot 93 mm (3.66inl.
ValveSeats
Reconditioning
1. Renewthe valve seatsin the cylinderhead using a valveseatcuner. NOTE: lf the guides are worn (seepage 6-39), 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 valveseats.
VALVESEAT CUTTER available) lCommercially
s
/-.\O
o --\ .,o :-e>
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 concentric seat, 3. Bevelthe upperedge of the seatwith the 30'cutter and the lower edge of the seatwith the 60' cutter. Check width of the seatand adjustaccordingly. the Make one more very light passwith the 45" cutter to removeany possibleburrs causedby the other cutters. Valv Seat Width: Standard lNow): Intake: 0.85- 1.15mm 10.033 0.0,15 in) Exhaust 1.25- 1.55mm (0.0/l!'- 0.061in) ServiceLimit: Intake: 1.6 mm {0.06i1 inl Exhaust: 2.0 mm {0.079in)
Measure alongedges, and threeways across center.
Cylinder Head Height: Standard {Nowl: 92.95- 93.05mm (3.669- 3.66i1 inl
5.
After resurfacingthe seat, inspectfor even valve t B A s e a t i n g : p p l y P r u s s i a n l u ec o m p o u n d o t h e valve face, and insertthe valve in its originalloca tion in the head,then lift and snap it closedagainst times. the seatseveral
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 procedure can be done using the special tool and a conventional hammer. VALVE GUIDE DRIVER (Commercially available)
5.3 mm
VALVE SEAT PRUSSIAN BLUECOMPOUND
The actualvalve seatingsurface,as shown by the bluecompound, shouldbe centered the seat. on . lf it is too high (closerto the valve steml, you must make a second cut with the 60" cutter to move it down, then one more cut with the 45" cutter to restoreseat width. . lf it is too low (closer to the valve edge), you must make a second cut with the 30'cuuer to move it up, then one more cut with the 45'cutter to restoreseat width. NOTE:The final cut shouldalwavsbe madewith the 45' cutter. 7. Insertthe intakeand exhaust valvesin the headand measure valvestem installed the heioht. Intako. ExhaustStem Installed Height: Standard{Newl: 53.17 53.6i1mm 12.W3 2.112inl ServiceLimh: 53.89mm (2.122in) lf the valvestem installed height is over the service limit, replacethe valve and recheck. its still over lf 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.
t-
87 mm -]+| 13.43inl
s7 mm i'2,24 inl
tr_r
1 O . 8m m 10.42inl
or VALVEGUIDEDRlVEn,5.5 mm 077i+2 0010100 guides. Select properreplacement the and chillthem in the freezer section of a refrigerator for about an hour. Use a hot plate or oven to evenlyheatthe cylinder headto 300'F(150'C). Monitorthe temperature with a cooking thermometer.
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
(cont'd) Replacement
side.use the driver and Workingfrom the camshaft an air hammerto drivethe guideabout2 mm {0.1in} towards the combustionchamber.This will knockoff someoJthe carbonand makeremovaleasier. GAUTION: . 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 side of the head. the camshaft 7. Apply a thin coat of clean engineoil to the outside of the new valve guide. Installthe guide from the camshaftside of the head; use the specialtool to height.lf installed drivethe guide in to the specified you haveall 16guidesto do, you may haveto reheat the head,
Valvo Guide Installd Height: mm 10.703 0.722inl lntake: 17.85 18.35 mm (0.734 0.754in) 18.65 19.15 Exhaust:
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 damagthe cylinder head il the guide breaks. 6. one at a Removethe new guidesfrom the treezer, time, as vou needthem.
6-42
Valves
Reaming
NOTE;For new valveguidesonly. 1. Coat both the reamerand valve guide with cutting orl, Rotatethe reamer clockwisethe full length of the valve guide bore. 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 removingit lrom the bore, Thoroughlywash the guide in detergentand water to removeany cuttingresidue. Check clearance with a valve(seepage6-39). the Verifythat the valve slides in the valve guide without exenrngpressure.
Installation
l.
Coat valve stems with engine oil. Insertthe valves in the valveguides. NOTE: Make sure the valves move up and down smoothly.
2.
2. 3.
Installthespringseatson the cylinderhead. I n s t a l l 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 t installer. NOTE:Exhaust and intakevalvesealsare not interchangeable.
3.
4.
WHITE SPRING
BLACK SPRING
Turn reamerin clockwise direction INTAKEVALVESEAL REAMER
EXHAUST VALVE SEAL VALVE GUIDE SEAL INSTALLER

(Commercialtv KD2899 avaitable) NOTE:UsesmalltD end ot
o-.:) -c
REAMER. mm 5.5 OTHAH PJ'OIOB
(cont'd)
6-43
______---
Valves
lnstallation (cont'd)
t 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 , h e n Compressthe installthe valve spring compressor. springand installthevalvekeepers. NOTE:Place the end of the valvespringwith closely wound coilstowardthe cylinderhead.
Arms and Camshaft/Rocker Seal/Pulley Camshaft

lnstallation
CAUTION: . Mske sure that all rockers are in alignmnt with theil valves whon torquing ths rockor a3semblybolts. . Valve locknuts should be loosgngd .nd sdiusiing screws backed off belore installation. . To prevent the rocksr arm as3ombly tlom coming apart, leavs the camshaft holder bohs in the holde6. camshaftsealand 1. After wiping down the camshaft. 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 e o t h s u r b facesand installthe camshaft.
Clean and install the oil control orifice with a new O-ring. OIL CONTROL ORIFICE
SPRING COMPBESSOR VALVE available) {Commercially CF711 KD- 383 or Snao-on 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.
SEAL CAMSHAFT shouldbe dry. surface Sealhousing 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. (PartNo. 08718 0001or 08718 Apply liquidgasket 0003)to the head maling surfaces the No. '1and of No. 5 camshaft holders. - Apply liquidgasket the shadedareas. to Installthecylinderheadin the reverse orderof removal: NOTE: . 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 clea . n . " UP" markon the camshaft pulleyshouldbe at the top. . Turn the crankshaft the No. 1 pistonis at TDC(see so 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 instaltaton. No. 1
1 . Cylinder head dowel pins must be aligned.

CYLINDER HEAD
Set the rockerarm assemblyin place and loosely installthebolts. - Makesurethat the rocker arms are properlypositionedon the valvestems. Tighten eachbolt two turns at a time in the sequence shown belowto ensurethat the rockers not bind do 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, @, @, @
/6\
PINS
't
7.
Installthe backcover,then installthe camshaftpultey.
(cont'd)
6-45
CylinderHead
(cont'dl Installation
2. 3. (seepage6-20). Position camshaft the correctly Tightenthe cylinderhead bolts sequentially four in steps. lsr step: O - @ 20 N.m {2.0 kgt'm, 14 lbl.fr} 2nd step: G) - @ 49 N.m {5.0 kgf.m, 36 lbf.ftl 3rd srop: O - @ 67 N'm 16.8 kgf.m, 49 lbf ftl ,lth step: o, o 67 N.m (6.8 kgf.m, 49 tbt.ftl NOTE: . W e r e c o m m e n du s i n g a b e a m - t y p e o r q u e t wrench. When using a preset-type torque wrench, be sureto tjghtenslowlyand not to overtighten. . lf a bolt makes any noisewhileyou aretorquingit, loosen bolt,and retighten from the 1ststep. it the CYLINDER HEADBOLTSTOROUE SEOUENCE: 7 . Install timing belt lsee page6-20). the Adjustthe valveclearance {seepage6-12). 9. Installthe head cover gasketin the groove of the cylinder head cover. Seatthe recesses or the f camshaftfirst, then work it into the groove around the outsideedges. NOTEI . B e f o r ei n s t a l l i n g h e h e a d c o v e r g a s k e t , h o r t t oughlycleanthe sealand the groove. . When installing, make sure the head cover gask 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 recesses wrtn no gap. CORNERS OF THERECESS
HEADCOVER GASI(ET
rxe iicess
covER
1 0 . Apply liquid gasketto the headcover gasketat the four cornersof the recesses. NOTE: . Use liquidgasket, PartNo. 08718 0001or08718 - 0003. . Check that the matingsurfaces cleanand dry are beforeapplyingliquidgasket. . Do not installthe parts if five minutesor 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 r . Instead, reapplyliquid gasketafter removingold residue. o After assembly, wait at least30 minutesbefore fillingthe enginewith oil.
Installthe intakemanifoldand tightenthe nuts in a patternin two or three steps,beginning crisscross with the innernuts (seepages9-2thru 9-4). . Alwaysusea new intakemanifoldgasket.
Installthe exhaustmanifoldand tightenthe nuts in patternin two or three steps,beginning a crisscross 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 pipeA andthe bracket, exhaust then install cover, thd
6-46
11. When installingthe cylinder head cover, hold the headcovergasketin lhe grooveby placingyour fingers on the camshaft holder contacting surfaces (top of the semicircles). Settho sparkplug sealon the sparkplug pipe. 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 head,slidethe cover slightlybackand forth to seat the headcovergasket. NOTE: . Beforeinstallingthe cylinder head cover,clean w 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 s 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 installing cylinderheadcover. the . Visually check the sparkplug sealsfor damage. . Replace the washer when damaged or deteriorated.
12. Tightenthe nuts in two or three steps.In the final to step,tighten all bolts, in sequence. 9.8 N.m (1.0 kgf.m,7.2lbf.ft). NOTE: After assembly,wail at least 30 minutes beforefillingthe enginewith oil.
6x1.0mm kgf.m, 7.2 lbf.ftl 9.8 N.m 11.0

tl
After installation, check that all tubes, hoses and connectorsare installedcorrectly.
SEAL
6-47
Engine Block
Speciaf Tools .............7-2 lllustrated lndex ................................... 7-3 Flywheel and Drive Plate Replacement .........7-G Connecting Rod and Crankshaft EndPlay ................. 7-6 Main Bearings -7 Cfearance ..,,,,,,,,,....7 Selection ................ 7-8 Connecting Rod Bearings Clearance ............... 7-B ^ Selection ................ 7-9 |J Pistons and Crankshaft Removal ................. 7-9 Crankshaft fnspection ..............7-11 Pistons fnspection .,,,,.,,,....,7-12 Installation ............. 7-20 Cylinder Block lnspection .............. 7-13 BoreHoning ..........7-11 Piston Pins Removal ................. 7-14 lnstallation ............. 7-15 Inspection .............. 7-16 Connecting Rods Seleetion ................ 7-15 Piston Rings EndGap ................. 7-17 Repfacement .........7-11 Ring-to-Groove Clearance ............... 7-18 Alignment .............. 7-18 Crankshaft Oil Seal Installation ............. 7-19 Crankshaft fnstaffation .............7-2O Oil Pan fnstaffation .............7-22 Oil Seals lnstaffation .............7-24
SpecialTools
Raf. No.
Tool Numbor 07LAB PV00100 07749- 0010000 079i17 S800200 07948 S800101 07973- P800200 07973 PE00310 07973- PE00320 0t913 - PE00400 07973 S800100 07973- 6570500 07973- 5570600
DBcription RingGearHolder Driver SealDriver Driver Attachment PilotCollar PistonPin DriverShaft Piston Pin Driver Head Piston Pin Base lnsen Piston BaseHead Piston Base PistonBaseSpring
(Ny 1 1 1 1 1 I 1 1 1 1 1
Pag6 Rotorence 7-6 7 -19,25 7-24 7-'t9,25 7-1415 , 7-14.15 l-14,15 l-'14, 5 1 7- 1 4 , 5 1 7-'t4,15 7-'t4.15
@ @ @ @ @
o o
@ @ @
0
o o
c,
t-1
!
lllustrated lndex
D16Y7 engine: I Lrori""t" "tl internalpartswith engineoil during reassembly.
NOTE: . Applyliquid gaskettothe mating surfaces ofthe rightsidecover oil pumpcase and before installing them.
. . part No. 08718 0001or 08718 0003. Use liquidgasket. Cleanthe oil pan gasketmatingsurfaces beforeinstalling it.
DRAINBOLT 44 N.m (4.5 kgf.m, 33 lbf.ftl 6 x 1.0mm 12 N.m (1.2 kgt.m, 8.7 lbt.ft) OIL PAN Refetto page7-22 when installing. Apply liquidgasketto 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 check binding. lor 6 x 1 . Om m 12 N.m {1 .2 kgf.m, 8 7 lbt'ftl
.*"'" I
><-BL
"i'.'' Hii,ilJ ,::::T:Î y"::::ffi::: I
o[ rlt cnsrer
'y" \\ $5./ fR..r' gNliJ'J.f-%S
FLYwHEEL covER
,t/,oksf'm,87 rbt'ttr
@ff
OIL CRANKSHAFT SEAL lnstallation, pages 7-19and 7-25 \{ePlace 6 x 1 . Om m 1'l N.m (l .1 kgf.m, 8 tbt.ftl RIGHTSIDECOVER Apply liquidgasker to m6ting surface.
MAI
BEARINGCAP
MAIN BEARINGS Selection,page7-8 NOTE:New main bearings must be selectedby rnatchingcrank and block identilicationmarkings. CRANKSHAFT page7-'11 lnstallation, 6 x 1 . 0m m 1'l N.m (1.1 kgf.m, 8 lbf.ft) OII SCREEN 6 x 1.0 mm 1 1 N . m l 1 . 1 kgf.m, a lbt.tt)
OIL PUMP page8-9 Overhaul. Removal/lnspection, page8-10.
GASKET Replace. DOWELPIN
CRANKSHAFTSEAL /.\ lnstallation,pages7-24--rS) Replace. 6x1.0mm 1 1 N , m 1 1 1 kgt.ni, . 8 tbr.ftl
DOWELPIN
O-RING Replace.
BRATHINGPORT COVER MOUNT BOLTS 6 x 1 . Om m 11 N.m 11.1 kgf.m, I lbt.ft) Apply liquidgasketto the bolt threads.
WASHERS Groovedsides face outward. NOTE:Ihrusr washerthickness is fixed and must not be changed by grindingor shimming.
(cont'd)
7-3
lllustrated Index
(cont'dl
I . ! . rubricatealt internalpartswith engineoil duringreassembly.
NOTE:
Apply liquidgaskettothe matingsurfaces ofthe right sidecoverand oil pump casebeforeinstalling them. pan No. 08718 0001or 08718 0003. Use liquidgasket, Cleanthe oil pan gasketmatingsurfaces beforeinstalling it. DnAtNBoL, 39 N.m 14.0kgf'm,
29 tbf.f!) \ WASHER Apply liquid gaskerto these potnts,
D16Y5. Dl6Y8 engin"",
OII.PAN Reler page7-23 to wheninstalling.

FLYWHEELCOVER IM/T)
\ 6r1.omm
\,-, \%
12 N.m (1.2kgf'm, 8.7 lbf.trl 11x1.5 m m 51 N.m kgt 15.2 m, 38 lbf.{t) Applyengineoilto the bolt threads. NOTE:Aftertorquing each cap, turn crankshaft to check binding. lor MAIN BEARING MAIN BEARINGS page7-8 Selection, NOTE:New main bearings must be selectedby matching crank
12 x 1.0mm 1 1 8N . m (12.O kst.m, 87 lbl.ftl
\s
FLYWHEEL IM/TI
OIL PAN GASKET Replace.
DRIVE PLATE COVER lA/T or CVTI

1 2 x 1 . Om m 74 N.m (7.5 kgf.m, 54 lbf.ft)
(A/T or CVTI DRIVE PLAYE Check cracks. for

6 x 1.0 mm 1 1 N . m 1 1 . 1k g t . m , 8 tbf.frl CRANKSHAFTOIL SEAL pages 7-19and 7-25 Replace. RIGHT SIDE COVER Apply liquidgasket to mating surface. DOWEL PIN THRUSTWASHERS Groovedsidesface outward. NOTE:Thrust washerthickness is fixed and must not be changed by grindingor shimming.
6 x 1.0 mrn 1 1 N . m { 1 . 1 k g t . m ,8 l b f . f r l
OIL SCREEN GASKET Replace.

OIL PUMP Overhaul,page I 9 Removal/lnspection, page 8-10
Apply liquidgasket to mating surface.
CRANKSHAFT SEAL pages Installation, 7-24 a n d8 - 1 1 Feplace. '1 6 x .0 mm ' 1 1N . m 1 1 1 k g f . m , . I lbt.fr)
DOWEL PIN
BREATHINGPORT COVER MOUNT BOLTS 6 x 1.0mm 11 N.m {1.1 kgf.m, 8 lbf.frl Apply liquidgasketto the bolt threads.
7-4
NOTE:New rod bearingsmust be selected matchingconnecling by rod assembly and crankshaft identification markings (seepage7-9).
Lubricate all internal parts with engine oil during reassemblv. PISTONINSTALLATIONDIRECTION: EXHAUST
l o
4\A6\/A
o
v\y\7v
l t . -
t l
INTAKE
w, *al
@
PISTONPIN page7-14 Removal, page7-15 Installation, page7-16 hspection,
tl,^t
PISTONRINGS
pase olisnment, 7-18 )

PISTON page7-12 Inspection, NOTE: Belore removing piston, inspectthe top of the cylinder borefor carbonbuild,up or page 7-'10 ridge. Removeridge il necessary,
CONNECTING ROD End play, page7-6

S e l e c t i o n ,p a g e 7 - 1 5
ENGINE BLOCK page7-13 Cylinder boreinspection, page7-'13 Warpage inspection, Cylinder borehoning,page7'14
CONNECNNG ROD BEARINGS page 7-8 Clearance. Selection,page 7-9
Inspecttop of each cylinder bore or for c6rbonbuild-up ridge before removing piston. page7-'10 Removeridge if necessary,
CONNECTING ROOBEARING page7-20 lnstallation. NOTE: Installcaps so the bearing recessis on the same side as the recess in the rod.
RODCAPNUT CONNECNNG 8 x 0,75mm 3 1N m ( 3 , 2 k g f . m , 23 tbt.ft) Applyengineoil to the bolt threads. NOTE: After torquing each bearing to cap, rotatecrankshaft check binding. tor
7-5
Flywheel and Drive Plate

Replacement
Manual Transmission: Removethe six flywheel bolts, then separatethe flyw h e e l f r o m t h e c r a n k s h a f f l a n g e .A f t e r i n s t a l l a t i o n , t pattern. tightenthe bolts in a crisscross
RINGGEARHOLDER--4T-1 07LAB- PV00100
Gonnecting Rod and Crankshaft

EndPlay
ConnGting Rod End Play: Standard(New):0.15- 0.30mm {0.006 0.012inl ServiceLimit: 0.,[|)mm {0.016inl
Htr
ENGINEBLOCK 12 x 1.0mm 118 N,m 112.0 kgtm,87 lbl.ftl
RINGGEAR Inspect ring gear teeth for wear or damage.
I
. . ll out-of-tolerance, installa new connecting rod. lf still out-of-tolerance. replacethe crankshaft(see pages7-9 and 7-20).
Pushthe crankshaft firmly away from the disl indicator, and zerothe dial againstthe end of the crankshaft. Then pull the crankshaft firmly backtoward the indicator; dial readingshouldnot exceed servicelimit.
RINGGEARHOLDER 07LAB- PV(x'l00
Automatic Transmission: Remove six drive plate bolts,then separate drive the the platefrom the crankshaft flange.After installation, tighten the bolts in a crisscross oattern.
CrankshaftEnd Play: Stsndard {Nw): 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 thrustsurface the crankshaft. on pans as necessary. Replace
1 2x 1 . 0m m 74 N.m {7.5kgf m,54lblftl
NOTE:Thrustwasherthickness fixed and must not be is changed eitherby grindingor shimming. Thrust washersare installedwith groovedsidesfacing outward.
7 -6
Main Bearings
Clearance
1.
o 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 a li 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. acrosseach main jourPiaceone strip of plastigage nal. NOTE:tt the engineis still in the car when you bolt the the main cap down to checkclearance, weight and flywheelwill flattenthe plastiof the crankshaft 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 , 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 s c o u n t e r w e i g h t a n d c h e c ko n l y o n e b e a r i n ga t a s time. R e i n s t a ltlh e b e a r i n g sa n d c a p s ,t h e n t o r q u e t h e bolts. lst step: 25 N.m 12.5kgf'm, 18 lbf'ft) Final step: 51 N'm 15.2kgl.m, 38 lbf'ft) during inspecNOTE:Do not rotatethe crankshaft tton. Removethe cap and bearing again. and measure the widest pad of the Plastigage. Main Bearing-to-JournalOil Clearance: Standard lNew): No. 1,5 Journals: inl 0.018- 0.036mm (0.0007 0'001,+ i[ Jou]nals: No- 2, 3, 0.02/t- 0.0,[2mm {0.0009 0.0017in) Ssrvice Limit: 0-05 mm {0.002inl
too wide or too narrow, measures lf the plastigage (remove the engineif it's still in the carl. removethe and removethe upper half ol the bearcrankshaft, ing. Installa new, completebearingwith the same color code (selectthe color as shown on the next page), the and recheck clearance. CAUTION: Do not file, shim, or sqape the bearings or the caps to adiust clearance. 7. is shows the clearance still incorIt the plastigage rect,try the next largeror smallerbearing(thecolor listedaboveor belowthat one),and checkagain. cannot be obtained NOTE: lf the oroper clearance largeror smallerbearings' by usingthe appropriate and startover. the replace crankshaft
Main Bearings
Selection
CAUTION: lf the codes are indeciDherable becauseof an accumulationot dirt and dust, do not scrub them with a wire brush or scraper.Clean them only with solvent or detergent.
ConnectingRod Bearings
Clearance
1, 2. Remove connecting cap and bearinghalf. the rod 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 with a cleanshop towel. Place strip of plastigage a across rod journal. the R e i n s t a l 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 t nuts. Torque 31 N.m (3.2 kgf.m. 23 lbf.ftl NOTE:Do not rotatethe crankshaft during inspectton. Remove the rod cap and bearinghalf,and measure the widestpart of the plastigage. ConnctingRod Eearing-to-JouJnal Clearance: Oil StandardlNewl: 0.020 0.038mm (0.0008 0.0015 in) ServiceLimit: 0.05 mm (0.(X)2 in)
Crankshaft Bore Code Location

Letters have beenstampedon the end of the blockas a codefor the sizeof eachof the 5 mainjournalbores. Use them, and the numbersstamDed the crankshaft on (codes main journalsizel,to choosethe correctbearfor inos.
3. 4.
I
Main Joulnal Code Location(Numbers)
I
PLASTIGAGESTRIP
g Bearin ldentification
Colorcodeis on the edge of the bearing. crankoore B
lf the plastigage measures too 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 the clearance.
CAUTION:Do not lile, shim. or scrape the boarings or the caps to adiust clearance. 7. lf the plastigage shows the clearance still incoris rect,try the next largeror smallerbearing(the color 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 ance gain. a NOTE; lf the prooer clearance cannot be obtained by usingthe appropriate largeror smallerbearings, replace crankshaft the and stan over.
Smaller bearing {thicker)
Il f-i--l l --Jl
I
l
Red
Pink Gren Green
G.een Brown Black Elack
+ tn t +
Smaller main journ8l Smaller bearing (thicker)
t l t. .3 - lt t
Green
Brown
Blue
7-8
Pistonsand Crankshaft
Selection
becauseof CAUTION:lf the codes are indecipherable an accumulationol dirt and dust, do not scrub them with a wire brush or scraper,Clean them only with solvgnt or detorgent.
Removal
1.
Remove oil pan assembly. the Remove right sidecover. the
ConnectingRod Code Location

Numbershave been stampedon the side of each connecting rod as a code for the size of the big end. Use (codes them, and the lettersstampedon the crankshaft to for rod journalsize), choosethe correctbearlngs.
Halfof the numberis stampedon bearing capand the other hall is stamped the on rod. RIGHT SIDE COVER
connecting Rod Journal code Locations lLettersl

OIL SCREEN
Baring ldentif ication Colorcodeis on the

edge of the bearing.
Larger big end bore
bearing Smaller {thicker)
I F;.'l I
r I l D o , r lr+ r
Smaller rod iournal Smaller bearing (thicker)
l l B o r l l l l ll .-.------.ll I I Corlll | | l - l
Red Pink
Pink Green Green
Green Erown Black
O-RING RePlace 4. Remove the oil pump.
Brown
Black
Gren
Brown
Blue
7-9
Pistonsand Crankshaft
(cont'dl Removal
5. Remove the boltsand the bearingcap. CAUTION: To prev6nt warpago, unscrew the bohs in soquencel/3 turn at a tims; rgpoat the sequenco until 8ll bolts ara loosonsd. MAIN BEARING CAPBOLTSLOOSENING SEOUENCE Removethe upper bearing halvesfrom the connecting rods and set them asidewith their respective caps. Reinstall main capsand bearingson the engine the In properorder. '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's instructions. CAUTION: lf the ridgo is not removed, it may damage tho plstons as they are pushed out.
Removethe rod caps/bearings main caps/bearand ings.Keepall caps/bearings order in 7. Lift the crankshaft out of the engine,being careful not to damagejournals.
't1.
Use the wooden handle of a hammer to drive the pistonsout.
12. Reinstall connecting the rod bearings and capsafter removingeachpiston/connecting assembly. rod
CRANKSHAFT
1 3 . Mark each piston/connecting assemblywith its rod cylindernumberto avoid mixup on reassembly. NOTE:The existingnumber on the connectingrod does not indicateits position in the engine,it indicatesthe rod bore size.
7-10
Grankshaft
Inspection
. Cleanthe crankshaft passages oil with pipe cleaners or a suitablebrush. Checkthe keywav and threads. . Out-of-Roundand Tapel . . Measureout-o{-round the middle of each rod at and main journalin two places. The differencebetweenmeasurements each on journalmust not be more than the servicelimit,
Alignmont . 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.
. The differencebetweenmeasurements each on journalmust not be more than the service limit. CrankshaftTotal IndicatadRunout: Standard {Nowl: 0.03 mm 10.001 max. in} SorviceLimh: 0.04 mm 10.002 in)
Journal Out-ot-Round: Standard (Now): 0.0025mm (0.0001inl max. ServiceLimit: 0.005mm (0.0002inl
DIAL INOICATOR Rotate lwo complete revolutions.
round at middle.
Measure laPer at edges.
Suppon with lathe lype tool or V-blocks.
Measuretaper at edges of each rod and main journal. The differencebetlveenmeasurements each on journalmust not be more than the service limit.
JournalTaper: Standard{Newl:0.0025 mm (0.0001 max. in) ServiceLimit: 0.005mm 10.0002 in)
7-11
Pistons
Inspection
1.
Check the pistonfor distortionor cracks. NOTE:lf cylinderis bored,an oversized pistonmust be used.
3.
Calculatethe difference between the cvlinder bore diameter(seepage7-131 and pistondiameter. Piston-to-Cylindr Clearanca Standsrd {New): 0.010- 0.0i|()mm (0.000'l- 0.0016inl ServiceLimit: 0.05 mm {0.002inl
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 e t r o m t h e A bottom of the skirt. A: 5 mm (0.2in) Piston Diameter: Standard (Nw): 74.990- 74.990mm 12.9520 2.952itinl ServiceLimh: 7i1.970 mm {2.9516in}
SKIRTDIAMETER
lf the clearance near or exceeds is the servicelimit, inspectthe piston and cvlinderblock for excessive wear. OversizPiston Dismatel -75.21mn (2.9618 2.9622inl 0.25175.23 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 levels eachcvlinder shown. in as . lf measurements any cylinderare beyondthe in Oversize BoreService Limit,replace block. the lf the block is to be rebored.refer to PistonClear(see anceInspection page7 12)afterreboring.
NOTE;Scoredor scratched cylinderbores must be honed. ReboringLimit: 0.50 mm (0.020in) 2. Check top of the blockfor warpage. the Measurealong the edgesand acrossthe centeras shown.
SURFACES 8E MEASURED TO
Cylinder Bore Size Standard {New): 75.00- 75.02mm (2.953- 2.95,1 in) SrvicoLimit: 75.07mm {2.955inl OvsFize O.25t 75.25- 75.27mm (2.9626 2.963,[in] - 75.52mm 12.9721-2.9732in1 0.50:75.50 Bore Taper Limit (Differencebetwoen tirst and third measure. m6nt) 0.05 mm (0.002in)
Engine Block Warpage: Standard(New):0.07 mm (0.003 max. in) ServiceLimit: 0.10 mm 10.004 in)
PRECISION STRAIGHT EDGE
7-13
).
GylinderBlock
BoreHoning
l.
Piston Pins
Removal
1. Assemble the specialtool as shown.
Measure cylinder boresas shownon page7-13.lf the blockis to be reused, honethe cylinders and remeasurethe bores. Honecylinderboreswith honing oil and a fine (400 grit) stonein a 60 dagreecross-hatch pattern. NOTEi . Use only a rigid hone with 400 grit or tiner stone such as Sunnen, Ammco,or equivalent. . Do not usestonesthat are worn or broken.
PISTONBASEHEAD 07973- SB00100
f t
PISTONPIN BASE INSERT 07973- PE00a00
g
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 cylinder bores with hot soapy water, then dry and oil immediately preventrusting. to NOTE:Neverusesolvent, will only redistribute it the grit on the cylinder walls. lf scoring or scratches are still presentin cylinder bores after honing to the service limit. rebore the cylinderblock, NOTE:Some light vertical scoringand scratching is acceptable it is not deep enoughto catchyour finif gernailand does not run the full lengthof the bore.
CYLINDER BLOCK CYLINDER HONE
E.
2.
Assembleand adjust the length of the piston p t n driverand shaftto 53 mm (2.1in) as shown.
PIN HEAD PISTON DRIVER 07973 PE00320

Pres3
+
PISTON PIN DRIVER SHAFT 0?973- PE00310 PILOTOOLLAR 07973- PE00200
53 mm(21 in)
NOTE: . After honing,cleanthe cylinderthoroughlywith soapy waler. . Only a scoredor scratched cylinderbore must be noned.
press. NOTE|Usea hydraulic When pressing pin in or out, the makesure that the recessed ponionofthe pistonaligns with the lips on the collar.
Placethe piston on the specialtool and press the press. pin out with the specialtools and a hydraulic
7-14
Rods Gonnecting
Seleetion
Eachrod falls into one of four toleranceranges(from 0 to + 0.024mm (0 to + 0.0009in), in 0.006mm (0.0002 in) incrementsl depending the sizeof its big end bore.lt's on then stampedwith a number 11, 3, or 4l indicating 2, the ran9e. You may lind any combination l 1,2,3, or 4 in any o engine. Normal Bore Size: ,18.0 mm (1.89inl NOTE: Reference numbeG are for big end bore sizeand do NOTindicato positionof the rod in the engine, the Inspect connecting for cracks rod and heatdamage.
PistonPins
Installation
1. Usea hvdraulic Dress installation. for a When pressingthe pin in or out, be sure you position the rscessed on the piston againstthe lugs flat on the baseattachment,
The arrow must face the timing belt side ol the engineand the connecting rod oil hole must face the rear of the
PISTOI{ DRIVER P|r{ HEAD 07973- PEOO320
Adjust the length of the piston pin driver to in) 53 mm (2.09 PISTO PII{ DRIVERSHAFT 07973-PE00310
ffi--Z
PFroI{Prr{
PILOT COTLAR 07973- PEq)200
PISTOI{PINBASE I SERT 07973 - PCOO400 PISTOI{BASEHEAD 07973 - SB(xtl (xt
7-15
)
PistonPins
Inspection
'1. Measure diameter the pistonpin. the ot Piston Pin Diamcter: Standard (New): 18.994- 19.000mm (0.7,078 0.7{80 inl 18.997 19.003 OveIsiz: in) {0.7,u9 - 0.7,181 pistonpins are oversize. NOTE:All replacement 3. Measure pistonpin-to-piston the clearance. or NOTE:Check pistonfor distortion cracks. the is than 0.024mm lf the piston pin clearance greater ( 0 . 0 0 0 9n ) , r e m e a s u r e s i n g a n o v e r s i z e d i s t o n p i u pin. Piston Pin-to-PistonClsarance: Standard {Newl: 0.010- 0.022mm {0.0004 0.0009inl
betweenthe pistonpin diameCheckthe difference rod ter and the connecting smallend diameter, 2. Zerothe dial indicator the pistonpin diameter. to Piston Pin-to-Connecting Rod Intrferonc: Standard (New): 0.014- 0.040mm inl 10.0006 0.0016
7-16
PistonRings
EndGap
1 . Using a piston, push a new ring into the cylinder bore 15- 20 mm (0.6- 0.8 in) trom the bottom. Measure pistonring end-gap the with a feelergauge: . lf the gap is too small,checkto see if you have the properringsfor your engine. . lf the gap is too large,recheck cylinderbore the diameter against wear limits on page7-13. the lf the bore is over the servicelimit. the cvlinder blockmust be rebored. Piston Ring End-Gap: Top Ring St8ndardlNswl: 0.15- 0.30mm {0.006 0.012in) ServiceLimit: 0.60 mm 10.024 inl SecondRing Standard lN6wl: 0.30- 0.,l5mm {0.012 0.018inl ServiceLimit: 0.70 mm (0.028inl Oil Ring Standard lNewl: 0.20- 0.70 mm {0.008- 0.028inl SorviceLimit: 0.80 mm (0.031in) NOTE: . U s e a s q u a r e d ' o f f r o k e nr i n g o r r i n g g r o o v e b cleaner with bladeto fit pistongrooves. . Top ring grooveis 1.0mm (0.039 wide. in) . Secondring grooveis 1.2mm (0.047 wide. in) . O i l r i n gg r o o v ei s 2 . 8m m ( 0 . 1 Ii n )w i d e . . Filedown the bladeif necessary. CAUTION:Do not uso a wire brush to clean ring lands, or cut ring lands doeperwith cleaningtool. NOTE:lf the pistonis to be separated from the connectingrod, do not installnew ringsyet. Installnew rings in the proper sequence and position {seepage7-18). NOTE:Do not reuseold pistonrings.
RINGEXPANDER {Commercially available)
Replacement
1 . Usinga ring expander, removethe old pistonrings. 2. Cleanall ring groovesthoroughly.
15-20 mm {0.6 -O.8 inl
7-17
PistonRings
Clearance Ring-to-Groove
After installinga new set of rings, measurethe ring-togrooveclearances: Top Ring Clearance Standard lNew): 0.035- 0.060mm {0.0014 0.0024in} Limit: 0.13 mm (0.005inl Servic. SecondRing Clearance Standard (Now): 0.030- 0.055mm (0.0012 0.0022io) inl ServiceLimit: 0.13 mm 10.005
Alignment
1, Install the ringsas shown.
TOPBINGlchromo)
Piston Ring Dimensions:
r-T-
I I
| . - !
A
l r ' I '
Top Ring (Standatd): in} A: 2.6 mm {0.10 in) B: 1.0mm (0.0/t Second Ring {Standard): A: 3.0 mm (0.12inl B: 1.2mm (0.05inl NOTE: The manufacturingmarks must be facing upward.
,orrrno--"-@
RING.> SECONO
7-18
Oil Crankshaft Seal

lnstallation
2. Rotatethe rings in their groovesto make sure they do not bind. Position ring end gaps as shown the
1. any rrnggap DO NOTposition at pistonthrustsurfaces,
The sealsurfaceon the blockshouldbe dry. Apply a light coatof oil to the crankshaft to and the lio of the seal. Drivethe crankshaft seal into the right side cover oil usingthe special tools. NOTE:Drivethe crankshaft sealin squarely. oil
DRIVER 07749- 0010000
RINGGAP SECOND
Approx. 90"
TOP RINGGAP sny ring gaP DO NOTposition in linewith the pistonpin hole. OIL RINGGAP
Installseal with the part numberside facing oui.
Confirmequal clearance the way around with a all feelergauge. Clearance: - 0.8 mm {0.02 0.03inl 0.5
0 . 5- 0 . 8 m m
in) 10.02-O.03
NOTE:Referto pages'I-24and 8-11for installation oil of the oil oumo sidecrankshaft seal.
7-19
I
Pistons
lnstallation
the applya coat of Beforeinstalling pistons, engineoil to the ring groovesand cylinder bores.
1. lf the crankshaft is already installed:
Crankshaft
lnstallation
the apply a coatot Betoreinstalling crankshaft, engineoil to the main bearings and rod bearings,
1.
. Set the crankshaftto BDCfor each cylinder. . Removethe connectingrod caps.and slip short sectionsof rubber hose over the threadedends rod of the connecting bolts. . Installthe ring compressor, checkthat the bear ing is securelyin place,then positionthe piston 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 . o handle f a hammer. . Stop after the ring compressorpops free, and journal aligncheckthe connectingrod-to-crank ment beforepushingthe pistoninto place. and torquethe . Installthe rod capswith bearings, nutsto: ksl.m,23 lbf.ti) 31 N.m 13.2 Apply engineoil to the bolt threads. 2. is lf the crankshaft not installed: . R e m o v e 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 t then positionthe piston in the ring compressor, cylinderand tap it in usingthe woodenhandleof a hammer. . Position Distons top deadcenter. all at
The arrow must face the timing belt side of the engjne.
Installthe thrust washersin the No. 4 journal of the cylinderblock. Insertbearinghalvesin the cylinderblockand connectingrods. so Holdthe crankshaft the rod journalsfor cylinders No. 2 and No.3 are straightdown. into the block,seatingthe rod Lowerthe crankshaft j o u r n a l si n t o c o n n e c t i n go d s N o , 2 , N o . 3 . I n s t a l l r the rod capsand nutsfinger-tight.
l- ---1l t--l rrn )-'--tllf -l

ltll
THRUST WASHERS Groovedsidestace
clockwise. seat journals into Rotatethe crankshaft rods No. 1 and No.4. lnstallthe rod caps connecting and nutsfinger-tight. NOTE:Installthe caps so the bearingrecessis on in the sameside as the recess the rod. with plastigage(see Check rod bearing clearance page7-8).then torquethe capnuts.
RUBEER NOTE:Maintaindownwardforce on the ring comp 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 the entering cylinderbore.

RING COMPRESSOR (Commercially available)
Torque: 31 N.m (3.2 kgf.m,23 lbf,ft) Apply engineoil to the bolt threads. numbers on the connectingrod NOTE: Reference are for big-endbore toleranceand do not indicate the positionof the pistonin the engine.
\'
Lineup the markswhen rod installing connecting the cap.
7-20
7.
Installthemain bearingcaps. Checkclearanceswith plastigage(see page 7-7), then tightenthe bearingcap bolts in 2 steps. Fi6t st6p: 25 N'm (2.5 kgf'm. 18 lbt.ft) Secondstsp: 5t N.m (5.2 kgf.m, 38 lbf,ft) NOTE: Coat the thrust washer surfacesand bolt thresdswith oil. MAN BEAHNG CAP BOLTSTIGHTENING SEOUENCE
8.
Apply liquid gasketto the block mating surfaceof the right side cover, then install it on the cylinder block. NOTE: . Use liquidgasket, part No. 08718 0001or 08718 - 0003. . Checkthat the matingsurfaces cleanand dry are beforeapplyingliquidgasket . Apply liquidgasketevenly,b6ingcarefultocover allthe matingsurface. . To preventoil leakage. apply liquidgasketto the innerthreadsof the bolt holes. . Do not install the parts if five minutes or more haveelapsed sinceapplyingthe liquidgasket, Insteadreapplyliquid gasketafter removingthe old residue, . After assemblv, wait at least 30 minutes before fillingthe enginewith oil.
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
9. Apply liquid gasketto the oil pump mating surface 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. Apply grease the lipsof the oil seals. to t T h e n ,i n s t a l t h e o i l p u m p w h i l e a l i g n i n g h e i n n e r l r o t o r w i t h t h e c r a n k s h a f tW h e n t h e p u m p i s i n . place,clean any excessgreaseoff the crankshaft, then check that the oil seallips are not distorted.
O i l Pa n
Installation
O16Y7 enginc: 1. Apply liquid gasketon the oil pump and right side covermatingareasas shown below. NOTE: . Use liquidgasket, part No.08718 0001or 08718 - 0003. . Check that the matingsurfaces cleanand dry are beforeapplyingliquidgasket. . Apply liquid gasketas an even bead. centered between edgesof the matingsurface. the . lo preventoil leakage, apply liquid gasketto the innerthreadsof the bolt holes. . Do not installthe parts if five minutes or more h a v e e l a p s e d i n c ea p p l y i n g h e l i q u i d g a s k e t . s t Insteadreapplyliquid gasketafter removingthe old residue. . After assembly, wait at least30 minutes before fillingthe enginewith oil.
gasket Apply laquid alongthe broken
CYLINOER
Br_ocK
OIL PUMP HOUSING
Apply liquid gasket to these pornts.
NOTE: . Apply a light coat of oil to the crankshaft and to 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 .
6x1.0mm 11 N.m {1.1kgf.m, 6 x 1.0mm 11 N.m {1.1kgf.m, a tbt.{t} OII- SCREEN
DOWEL PIN
Apply liquid gasket to these pornts,
DOWELPIN 6 x 1.0mm 11 N.m {'l.1 kgl.m, 8 lbf,lt} O-RING Replace.
.,
r -zz
,.t ,.i
2.
t I n s t a ltlh e o i l p a ng a s k ea n d o i l p a n . NOTE: . Usea new oil pan gasket. . Install the oil pan no morethan five minutesafter applyingliquidgasket.
D16Y5, D16Y8 engines: 1. t I n s t a ltlh e o i l p a ng a s k eo n t h e o i l p a n . NOTE: . Use liquidgasket, part No. 08718 0001or 08718 , 0003. . Check that the matingsurfaces cleanand dry are beforeapplyingliquidgasket. 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 between edgesof the matingsurface. the . To preventoil leakage apply liquid gasketto the innerthreadsof the bolt holes. . Do not installthe parts if five minutesor more haveelapsed sinceapplying the liquidgasket. Instead, reapplyliquid gasketafter removingthe old residue. . After assembly, wait at least 30 minutesbefore filling the enginewith oil.
OILPAN
Apply liquid gasketto these poants.
OIL PAN PAN
GASKET points. to these 3.

Replace.
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.
Tighten boltsand nuts,starting from boltO, clockall wise in threesteps. NOTE:Excessive tighteningcan causedistonionof oil pan gasket and oil leakage. Torque:12 N.m (1.2kgl.m,8.7lbt.ft) (cont'd)
7-23
Oil Pan
2. Apply liquid gasketto the block mating surfaces, t h e n i n s t a l t 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 l shadedareas.
Oil Seals
Installation
NOTE: . Engineremovalis not required. . The crankshaft sealhousingshouldbe dry. oil Apply a light coat of greaseto the crankshaft and to the lips of the seals. 1. Usingthe special tool, drive in the timing pulley-end sealuntilthe driverbottomsagainst oil pump. the When the seal is in place,cleanany excessgrease and checkthat the oil seal lip is off the crankshaft not distorted.
OIL PAN
3.
Tighten the nuts finger{ight at six points as shown
L
07947-SB00200 lnstallseal with the part number side facingout.
4.
Tightenall boltsand nuts,starting from nut O, clockwise in threesteps. NOTErExcessive tighteningcan causedistortionof oil pan gasket and oil leakage. Torque:12 N.m (1.2kgf'm,8.7lbl.ft)
t-z+
2.
Measure the flywheel-end sealthickness and the oil seal housingdepth.Usingthe special tool. drive the flywheel-endseal into the rear cover to the point where the clearance betweenthe boftom of the oil seal and the right side cover is 0.5 - 0.8 mm (0.020.03in) (seepage7-191. NOTE:Align the hole in the driver attachment with the pin on the crankshaft.
07749-0010000
DRIVERATTACHMENT 07948-S800101 lnstallseal waththe part numberside facing out.
7-25
IHI
I
/
SpecialTools
t
Ref.No. I Tool Numbel 07746 0010400 07749 0010000 07912 611000' ] Description x Attachment.52 55 mm Driver Oil FilterWrench Oty 1 I 1 PageRoforance a-12 a-12 8-7
o
a2)
I
8-2
lllustrated Index
NOTE: o Usenew O-rings when reassembling. . Apply oil to O-ringsbeforeinstallation. . Use liquid gasket,Part No. 08718- 0001 or 087180003. . Clean oil pan gasket the matingsurfaces beforeinstallIn g .
CAUTION: Do not overtighten the drain bolt. ENGINE OIL PRESSURE SWITCH 18 N.m {1.8ksf m, 13 lbf.ft) (Eritish 1/8in. BSPT Standard PipeTaper) 2Slhreads/inch. Use properliquidsealant.
Apply liquidgasketto the recesses the oil pan gasof ket (seepage7-22).
D16Y7 engin:
OILPUMP page8-9 Overhaul, Inspectaon, 8-10 page Applyliquidgasket to the matingsurface of the block.
O-RING OIL BREATHER Replace. CHAMBER 6x1.0mm 1 1 N . m{ 1 . 1 kst.m, 8 lbl.fr)
OIL FILTER Replacement, page8-7
O.RING Replace. Apply liquidgasket to thesepornts.
6x1.0mm 11 N.m (1.1kgl,m, 8 tbf.ft)
GASKET Replace.
OILPAN GASKET Replace.

PAN Befertopage7 22 when installing.
6x1.0mm 1l N.m {1.1kgf.m, Apptvtiquidqasket ro 8lbf ft) rhesepoints.
6 x 1.0mm 12 N m (1.2kglm, 8.7tbf.ftl
DRAINBOLT 44 N.m 14.5kgf.m,33 lbtftl Do not overtighten.
(cont'd)
8-3
lllustrated Index
(cont'd)
NOTE: . Usenew O-rings when reassembling. . Apply oil to O-ringsbeforeinstallation. . Use liqu;d gasket,Part No. 08718- 0001 or 087180003. . Clean oil pan gasket the matingsurfaces beforeinstall, ing. D16Y5, D15Y8 engines: CAUTION: Do not overtighten the dlain bolt.
t.
ENGINEOIL PRESSURE SWITCH 18 N.m 11,8 kgf.m, 13 lbt.ft) (British 1/8in. BSPT StandardPipeTaper) 28 Threads/inch. Use properliquidsealant.
OILPUMP page8-g Overhaul, page8-10 DOWEL Inspection, plN Applyliquidgasket to the matingsurface of the block. 6x1,0mm 11 N.m 11.1 kgf.m, 8 tbf.ttl
6x1.0mm 11 N.m 11.1 m. kgt 8 tbf.ftl
page8,7 Replacement,
BAFFLEPLATE
SCREEN 6x1.0mm 11 N.m 11.1 kgf.m. 8 tbf.ft)
OILPAN GASKET Replace.
6x1.0mm 11 N.m 11.1 kgl.m, 8 tbf.ftl
OIL PAN Refer page7-23 to when installing.
I
39 N.m {,r.0kgl.m, 29 lbf.ft} Do not overtighten.
12 N'm 11.2kgl.m,8.7 lbf.ftl
urr.o-*tn
8-4
En g i neO il
Inspection
1 . Parkthe vehicle on level ground, and turn off the engine.Allow the oil a few minutesto drain back into the oil pan so the dipstickwill show the actual level. Make cenainthat the oil level indicated the dipon stickis between the upperand lower marks.
Replacement
CAUTION: Removo lhe drain bolt carfully whilo tho engine is hot; tho hct oil may cau36scalding, 1. Warm up the engine. 2. Drainthe engineoil.
BOLT DRAIN a,l N.m14.5 kgt'm, 33 lbf.ft) Do notovertighten. D16Y5.Dl6Y8 6ngines:
Beplace.
lf the level has droDpedclose to the lower mark, add oil until it reaches uooermark. the CAUTION:Insertthe dipstickcarefullyto avoid bending it.
DRAIN BOLT 39 N.m (,1.0 kgl'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 rcommendd oil. API ServiceGrade:Use an "Energy Conserving" gradeoil or an SJ "Energy Conserving SH gradeoil, ll" SAE 5W - 30 preferred. You can alsousean oilthat bearsthe API CERTIFICATION mark. D16Ytengine: 3.6f (3.8US qt, 3.2 lmp qt) at change,including filter. 3.3f (3.5US qt, 2.9 lmp qt) at change, without filter. 4 . 3 1 ( 4 . 5 S q t , 3 . 8l m p q t ) U afterengineoverhaul. Dl6Y5, D16Y8 engines: 3.3/ (3.5US qt. 2.9 lmp qt) at change, including filter. 3.0/ (3.2US qt, 2.6 lmp qt) at change. without filter. 3.7/ (3.9US qt,3.3 tmp qt) afterengineoverhaul. Every7,500miles (12,000 or km) 12 months(Normal Conditions). Ev6ry3,750miles(6.000 km) or 6 months (Severe Conditions).
API CERTIFICATION MARK
Requirement
Capacity
62\"'
API SERVICE LABEL
Change
NOTE:Under normalconditions, oil filter should be the replaced everyotheroil change. at Undersevere conditions, oil filter shouldbe replaced the at eachoil change. The numbersin the middle of the Apl Servicelabel tell you the oil's SAE viscosityor weight. Selectthe oil for your car according this chart: to
Fill the enginewith oil up to the specified level,run the enginefor more than three minutes, then check fof oil leakage,
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. Aftr the engine has been run, the exhaust pipe will be hot; be careful when working around the exhaust pipe. Be careful when loosening the drain bolt while the engine is hot. Burns can result becausethe oil tem. perature is very high.
1.
Afterthe rubbersealseats, tightenthe oil filterclockwise with the oil filterwrench. Tighten: 7/8 turn clockwise. Tightening torque:22N.m (2.2kgf.m,16lbt.ftl
Remove oil filter with the oil filter wrench. the Inspect threads the and 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 sysrem.
2.
Apply oil to rubberseal beforeinstalling.
8-7
Oil Filter
(cont'dl Replacement
Usethis procedure tightenthe filter if eight numto bers(1 to 8) are Drinted the surface on ofthe filter. 1) Makea markon the oil filterbaseunderthe num, ber that shows at the bottom of the filter when the rubberseal is seated. 2) Tightenthe filter by turning it clockwise seven numbersfrom the markedpoint. For example,if a markis madeunderthe number2 whenthe rubber seal is seated, filter shouldbe tightened the point. untilthe number1 comesup to the marked
Oil Pressure
Testing
lf the oil pressure warninglight stayson with the engine running,checkthe engineoil level.lf the oil levelis cor rect: 1. 2. Connect tachometer. a Remove engineoil pressure the switch, and install an gauge. orl pressure
ENGINEOIL PRESSURE SWITCH MOUNTINGHOLE
7, turn clockwise.
MARK Numberwhen rubber seal is seated, Numberaftertightening.
Numberwhen rubber sealis seated Numberaftertightening 8 2
4 3
5
4
6
5
at
ADAPTER {1/8'r28, BSPT} (Commercially avsilable)
OIL PRESSURE GAUGE lCommerciallv available)
CAUTION:Using any procedureolher than those shown could rsult in seriousengine damsge due to oil leakage. 5. Afterinstallation, the engine fill with oil up to the specifiedlevel, the engine morethanthreeminutes. run for then checkfor oil leakage. 4.
Stan the engine. Shut it off immediately the gauge if registers oil pressure. no Repair the problembefore contrnurng. Allow the engine reachoperating (fan to temperature comeson at leasttwice).The pressure shouldbe: EngineOil Temperature: 176'F(80.C1 EngineOil Pressure: Ar ldle: 59 kPa10.7 kgf/cm,,10 psi) minimum At 3,000rpm: 3,t0 kPa (3.5 kgt/cm,, 50 psi) minimum lf oil pressure within specifications, is replace the oil pressure switchand recheck. lf oil pressure NOTwithin specifications, is inspect p t h e o i l p u m p( s e e a g e8 1 0 ) .
8-8
Oil Pump
Overhaul
NOTE: a Usenew O-rings when 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 r 0 8 7 1 8 - 0 0 0 3 . , 1 . The rotorsmust be installed the samedirection. to . After reassembly, checkthat the rotorsmove without binding.
PUMPHOUSING 8-10 Inspection, Page Applyliquidgasket to mating surfaceof block the cylinder when installing. 6x1.0mm 7 N.m (0.7kgf m, 5 lbt'ft) OUTERROTOR page8_10 Inspection, INNERROTOR page8_10 lnspection,
DOWELPIN
PUMPCOVER O-RING Feplace.
6x1.0mm 11 N.m (1.1 kgt m. 8 lbt.ft)
OIL SEAL Replace. page8-1 1 Installation,
Valvemust slidefteely in hous,ng bore. it Replace scored.
SPRING
g
@ .Hwlsren
E
-
-/SEALING BOLT 39 N.- l{o kgf.m, 29 tbtftl
8-9
Oil Pump
RemovaUlnspection/lnstallation
'L 2.
D r a i n h ee n g i n e i l . t o Turn the crankshaft and align the white groove on pulley with the pointeron the lower the crankshaft cover. Remove cylinderheadcoverand uppercover. the R e m o v e h e p o w e r s t e e r i n g u m p b e l t ,a i r c o n d i , t p tioner beltand the aiternator belt. Remove crankshaft pulleyand removethe lower the cover.
1 0 . Removethe screwsfrom the pump hausing,then

separate housingand cover. the
1 1 . Checkthe inner-to'outerrotor radial clearance on
3. 4.
the pump rotor.lf the inner-to-outer rotor clearance e x c e e d s 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 t ourerrorors. Inner Rotor-to-OuterRotor RadialClarsnce Standard(New):0.02- 0.14mm {0.001 0.006inl ServiceLimit: 0.20 mm {0.008in) OUTER ROTOR
6. 7. 8.
Remove timing belt. the Remove drive pulley. the Remove oil pan and oil screen. the
DOWEL PIN
O.RING Replace.
1t
INNER ROTOR Cneclithe housing-to-rotor axial clearance the on pump rotor, lf the housing-to-rotor axial 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 Service Limit: 0.15mm {0.006 in)
OIL SCREEN
9.
Remove the oil pump.
ROTORS
8-10
13. Check housing-to-outer radial the rotor clearance. It the housing-to-outer rotor radialclearance exceeds the servjcelimit, replacethe set of inner and outer rotorsand/orthe pump housing Hoqsing.to.OutorBotor RadialClearance: Standard {New):0.10- 0.18mm (0.004- 0.007in) ServiceLimit: 0.20 mm (0.008in) HOUSING
' 1 7 .R e a s s e m b lte e h
o i l p u m p ,a p p l y i n g h r e a dl o c kt o t the pump housingscrews.
1 8 . Check that the oil pump turnstreely. 1 9 . Apply a light coatof oil to the seallip.
20. Installthe two dowel pins and new O-ringon the oil
pump. 2 1 . Apply liquidgasket the cylinderblockmatingsurto faceof the oil pump. NOTE: . Use liquidgasket, PartNo. 08718 0001or 08718 - 0003 . Check that the matingsurfaces cleanand dry are beforeapplyingliquidgasket. . Apply liquidgasketevenly,in a narrowbeadcen teredon the matingsurface. . To preventoil leakage, apply liquidgasketto the innerthreadsof the bolt holes. . 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 . Insteadreapplyliquid gasketafter removingthe old residue. . After assembly, wait at least 30 minutes before fillingthe enginewith oil.
1 4 . Inspect both rotorsand the pump housingfor scor-
partsif necessary. ing or otherdamage. Replace 1 5 . Remove old oil sealfrom the oil pump. the
to.
Usingthe special tool, gentlytap in the new oil seal until the driverbottomsagainst pump. the NOTE:The oil seal alone can be replacedwithout removingthe oil pump. DRtvER 0?7i190010000
Apply liquidgasket alongthe brokenline.
ATTACHMENT. 52x55mm 07746- 0010i100
(cont'd)
8-11
O il Pu mp
RemovaUlnspection/lnstallation (cont'd)
22. Install oil pump on the cylinderblock. the Apply grease the lip of the oil pump seal. to Then,installtheoil pump onto the crankshaft. Whenthe pump is in place, grease cleanany excess off the crankshaft and checkthat the oil seal lip is not distorted.
6x1.0mm 11 N.m 11.1 m, kgf I rbt.ftt
6 x'l.Omm 11N'm(1.1 kgtm, 8 tbt.ftl
11N.m(1.1 kgf.m, 8lbfftl
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 e i l p a n( s e ep a g e7 , 2 2 ) . o

NOTE:Clean the oil pan gasketmatingsurfaces.
8-12
IntakeManifold/Exhaust System
lntakeManifold Replacement .......... -............................ 9-2 Exhaust Manifold 9-5 Rep|acement ....................................... Exhaust Pipeand Muffler ....................................... 9-7 Replacement (TWC) ThreeWay Catalytic Converter Inspection ...................... 9-9 HeatedOxygenSensor{HO2S) Replacement ....................................... 9-9
IntakeManifold
Replacement
NOTE:Use new O-ringsand gaskets when reassembling, CAUTION: . Chckfor lolds or scratcheson the surtaceof the gasket. . Replacewith a new gasket if damaged. D16Y7 engine:
8 x 1.25mm 22 N.m 12.2kgl.m, 16lbfftl
INTAKEMANIFOLO Replace crackedor if it matingsurtaces are oama9eo,
8 x 1.25mm 23 N.m (2.3kgt.m, 1? tbt.ftl
INTAKEMANIFOLD ERACKET E x 1.25mm 2a N.m 12./t kgf.m, 17 lbtftl
g-2
D16Y5 engine:
6x1.0mm 12 N.m l'1.2kgt.m,8.7 lbtftl EGRCHAMBER
INTAKEMANIFOLD Replace crackedor if if mating surfacesarc oamageo.
8 x 1.25mm 21 N.m {2.1 kgf.m, 15 tbf f0
INTAKEAIR CONTROL IIAC}VALVE (M/TI
EXHAUST GAS RECIRCULATION {EGRIVALVE
8 x 1.25mm 22 N.m (2.2 kqf.m, 16 lbf.ftl
INTAKE MANIFOLD BRACKET 8 x 1.25mm 23 N.m 12.3kgf.m, 17 tbf.frl
8 x 1.25mm 22 N.m (2.2kgf.m, 16 tbt tr)
(cont'd)
9-3
Intake Manifold
NOTE:Usenew O-ringsand gaskets when reassembling. CAUTION: . Checkfor folds or scraichss on the surfaceof the gasket. . Replacewith a new gasket it damaged. D16Y8 engine:
INTAKEMANIFOLD Replaceit crackedor il mating surfacesare oamageo.
INTAKEAIR CONTROL {IAC)VALVE(M/T)
$"^
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
nutswhen reassembling. NOTE:Usenew gaskets and self-locking CAUTION: . Checkfor folds or scraicheson the surtace of lhe gasket. . Replacewith a new gaskei if damaged. D16Y7 D16Y5, engines:
I x 1.25mm 24 N.m {2,4 kgtm, 17 lbf,ft}
PRIMARY HEATED OXYGEN SENSOR HO2SI {PRIMARY 44 N.m (4.5kgf.m, 33 lbt.ft) page9 9 Replacement,
10 x 1.25mm 44 N.m 14.5 kgt.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,
6x1,0mm 11 N.m (1.1kgf.m,8lbtft)
MANIFOLD BRACKET
SECONDARY HEATED OXYGEN SENSOR ISECONDARY HO2S} 4zlN.m 14.5 kgf.m, 33 lbl.ftl page9-10 Beplacement,
{cont'd)
9-5
)
ExhaustManifold
Replacement(cont'd)
NOTE:Usenew gaskets and self-locking nutswhen reassembling. CAUTION: . Checktor lolds or scratcheson thg surfac6ol the gaskgt. o Replacewith a new gasket if damaged. D16Yg sngine:
8 x 1.25 mtn 2a N.m {2.4 kgf.m, t7 tbf.ft)
E x 1.25 mm 3l t&m13.2 kgf.m, 23 tbt'ftt Rplacs.
PNIMARY HO2S 14 N.m 14.5 kgt.m, 33 lbt.ft) page9-10 Replacement,
EXXAUSTMANIFOLD BRACKET
10 x 1.25mm 44 N.m (4.5kgf.m,33 lbf.ft,
9-6
ExhaustPipe and Muffler

Replacement
nutswhen reassembling. NOTE:Use new gaskets and self-locking D16Y7 D16Y5, engines:
EXHAUSTPIPNP MUFFI.ER
6 x 1.0 m.n 9.8 N.m {1.0 kgt.m, 7.2 lbf.ftl HEAT SHIEI.I)
"e*......------------
6xt.0mfi 9.EN.ft (1.0kst'm, 7.2 lbl'ftl
8 x 1.25mm 22 N.m 12.2 kgt.m. 16 tbf.frl Replace. Tighten boltsin the steps, alt.naling side-to-side.
8 x 1.25mm 22 N.m {2.2kgf.m, 16 |bfftl Replace. Tightenthe bolts in steps, side-to-side. akernating
------------->@ Replace.
GASKET Replace.
NUT SEI.f.LOCKING 10 x 1.25mm 33 N.m 13.4 kgtm, 25 tbt ftl Replace.
NUl SELF.I-OCKING 8 x 1.25mm 16 N.m (1.6kg .m. 12 lbf.tt) Replace.
(cont'd)
9-7
)
ExhaustPipe and Muffler

Replacement(cont'd)
NOTE: Use new gaskets and self-locking nuts when reassembling. Dl6Yg engine: MUFFLER
PIPE EXHAUST TIP
o.4/
GASKET Replace. -6r1.0mm 9.8 N.m {1.0kgf.m, 7.2 lbf.ftl
HEATSHIELD
8 x 1.25mm 22Nm12.2kgtm, 16 tbt.ft) Feplace. Tighten boltsin the stePs, alternating side-to side.
6x1.0mm 9.8 N.m {1.0kgf.m, 7.2 lbt.ftl
L
EXHAUST PIPE NUT SELF.LOCKING l0 x 1.25mm 33 N.m {3.4kgf.m, 25 tbt.ft) Replace.
SECONDARY H()2S a4 N.m (4.5kgf.m, 33lbf.ftl page9-10 Replacement,
GASKET Replace.
TWC page9-9 Inspection, GASKETS Replace. 8 x 1.25mm 22 N.m (2.2kgt.m, 16 lbf.ftl Replace. Tighten boltsin steps, the alternating side-to-side.
EXHAUST PIPE A
SELF.LOCKING NUT t0 x 1.25mm 54 N.m 15.5 kgtm,40 tbtftl Replace.
16 N.m {1.6kgl.m, 12lbt.ft) Replace.
9-8
TWC
Inspection
1. makea visualcheckfor plugging, Usinga flashlight, meltingand cracking the catalyst. of D16Y5, D16Y7 enginss:
HO2S
Replacement
Primary HO2S: 1. Remove primaryHO2S. the D16Y5, D16Y7 engines: a. Disconnect the primary HO2Sconnector, then removethe cover. mm 8 x 1.25 2ilNm12.4kgt'm,
a/)
D16Y8 engine:
FLASHLIGHT
b.
Remove the primaryHO2S.
I
A
I l
(cont'd)
PRIMARY H02S 44 N.m 14t kgf.m, 33tbtftl
9-9
HO2S
Dl6Y8 engine: a. Disconnect the primary HO2S connectorthen removethe primaryH02S. SocondaryHO2S: 1. Remove secondary the HO2S. 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 secondary HO25.
()2 SENSOR WRENCH (Commercially
PRIMARY HO2S 4,0N.m {4.5kgI.m, 33 lbt.ftl
2.
lnstall Drimarv the HO2Sin reverse orderof removal.
D16Y8 engine: a. Remove grommet, the and pullout the secondary HO2Sconnector,then disconnectthe secondary HO2Sconnector.
SECONDABY HO2S CONNECTOR
9-10
a
b. Remove secondarv HO2S. the
WRENCH 02 SENSOR 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
"." 10-2 lndex........... flfustrated Radiator "."...... ........................" " I 0-5 Replacement and Refilling Coolant Engine 10-6 ........"".......'.' Bleeding 10-8 ...........'....'..' CapTesting .'..'.10-8 Testing Thermostat " "......" ........................'.. 10-9 Replacement "....10-10 Testing TemPerature EngineGoolant (ECT) Switch ....'. 10-10 Testing WaterPump .. 10-11 Index .....".'. lllustrated .10-12 fnspection 10-12 .......................'.'.'.......'." Replacement
lllustratedIndex
!@@
when the system is under high pressure
engine is hot. To avoid danger of releasingscalding enginecoolant,removethe cap only when the engineis coor.
CAUTION:lf any engine coolantspills on painted portions ol the body, rinse it off immediately. NOTE: . Checkall coolingsystem hosesfor damage.leaksor if deterioration replace necessary. and . Checkall hoseclampsand retighten necessary. if . Use new O-rings when reassembling.
Total Cooling System Capacity ncluding heater and reservoir US {0.41 (0.,12 qt,0.35 lmp qt))l: M/I Afi CVT 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 4 . 3 f { 4 . 5U S q t , 3 . 8 l m p q t ) * '
4 . 3f 1 4 . 5 S q t . 3 . 8l m p q t ) U
* 1 :D 1 6 Y 7 n g i n e e x 2 :D 1 6 Y g n g i n e e BADIATOR CAP Pressure test, Page10-8 RADIATOR Engine coolantrefilling and bleeding, page10 6 Leak test,page10-8 jointsand Inspect soldered seams leaks, for Blowout dirt from between corefinswith compressed air. lf insects, etc.,are clogging radiator, washthem off with low pressure water,
6x1.0mm 9.8N.m (1.0kgt m, 7.2 tbt.ftl
\ \ \ \
-ECOOLANT RESERVOIR
UPPEN RADIATOR HOSE
5x0.8mm 5.4N.m {0.55 kgtm, 4.0lbffi}
6x1.0mm kgJ.m, 7.2N.m {0.73 5.3 tbf.f0
LOWER CUSHION DRAIN PLUG Refer sectionl4 to when installing. O-RING Replace.
10-2
EngineHose Connoction3: Dl6Y7 engin:
IACVALVE
HEATER HOSES
HEATER VALVE
(cont'd)
,.l
10-3
lllustratedIndex
(cont'dl
EngingHosgConnections: D16Y5, D16Y8 engines:
tAc vAtvE IA/T)
CONNECTING PIPE
Replace.
BYPASS WATER HOSE

IAC VALVE IM/T) O.RING Replace.
THEBMOSTAT HOUSING
\ \ \
rn
/
CONNECTING PIPE
O.RING Replace.
HEATEB VALVE
HATER HOSES
10-4
Radiator
Replacement
1 . Drainthe enginecoolant. 2. R e m o v e 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 , n d t a ATFcoolerhoses. Disconnect fan motor connector. the Remove the radiatorupper bracket, then pull up the raqtalor. 5, Removethe fan shroudassemblies and other parts from the radiator.
Install the radiatorin the reverse orderof removal: NOTE: . Setthe upperand lower cushions securely, . F i l l t h e r a d i a t o r i t h e n g i n ec o o l a n ta n d b l e e d w the air.
6x1.0mm 9.8 N.m (1.0kg[.m, 7.2 tbl.trl
3. 4.
RAOIA ATF COOLER HOSES {A/TI Referto section when installing. UPPER RADIATOR HOSE
6x1.0mm 7.2 N.m (0.73kgt.m, 5.3 tbl.fr)
RESERVOIR TANK
LOWEB CUSHION
DRAINPLUG
O.RING Replace. LOWER RADIATOR HOSE
10-5
Radiator
EngineCoolantRefillingand Bleeding
CAUTION:When pouring engine coolant, be sure to shut the rolay box lid and not to let coolant spill on the slcirical parts or thc paint. ll any coolant spills. rinse it off immdiatslv. 1. control lever to maxi Slide the heatertemperature mum heat. Make sure the engine and radiatorare cool to the touch, Remove radiator the cao. Loosen drain plug, and drainthe coolant. the
ORAINPLUG
Apply liquid gasketto the drain bolt threads,then reinstall the bolt with a new washer and tighten it securery. Tightenthe radiator drain plug securely. 7 . Remove,drain and reinstallthe reservoir.Fill the tsnk halfwayto the MAX mark with water,then up to MAX the markwith antifreeze.
2. 3.
4.
Remove drain bolt from the cvlinderblock. the
MAX MARK
</on
7E N.m 18.0kgl m, 58 lbf ft)
10-6
8.
Mix the recommended ntiJreezwith an equal a e amountof water in a cleancontainer. NOTEI . Useonly genuineHondaantifreeze/coolant. . For best corrosion protection,the coolant conc e n t r a t i o nm u s t b e m a i n t a i n e d e a r - r o u n d t y a 50% minimum. Coolantconcentrations than less 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 againstcorrosion freezing or . C o o l a n tc o n c e n t r a t i o n g r e a t e rt h a n 6 0 % w i l l s impair coolingefficiency nd are not recoma 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 10.42 qt, 0.35lm' qt)ll. US M/I 3 . 8{ { 4 , 0U S q t , 3 . 3l m p q t ) 3.7/ (3.9US qt,3.3 lmp qt)*' 3 . 9/ ( 4 . 1U S q t , 3 . 4l m p q t ) * , 3 . 9{ ( 4 . 1 S q t , 3 . 4l m p q t ) U
9. Pour coolantinto the radiatorup to the baseof the filler neck,and installthe radiator cap looselv.
1 0 . Startthe engineand let it run until it warms up (the

radiator comeson at leasttwice). fan
1 1 . Turn off the engine.Checkthe level in the radiator.
A/T
CVT *1:D16Y7 ngine e * 2 :D1 6 Y 8 n g i n e e
add coolantif needed. Put the radiatorcap on tightly,then run the engine againand checkfor leaks,
10-7
)
Radiator
CapTesting
1. Removethe radiatorcap, wet its seal with engine tester. coolant, then installit on the Dressure
Testing
'1.
Wait until the engine is cool, then carefullyremove 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. testerto the radiatorand apply Attachthe pressure a pressure 93 - 123 kPa(0.95- 1.25kgt/cm?,'14 of 18 osi).
RADIATOR ADAPTOR (for32 mm neck, low profile)
PRESSURE RAOIATOR TESTER (Commercially available)
ADAPTOR low {for32mm neck, Profile)
Apply a pressure 93 - 123kPa(0.95 1.25kgflcm' . of - 1 8p s i ) . 14 for Check a d.op in pressure. drops.replac cap. the lf the pressure
for Inspect enginecoolantleaksand a drop in pressure. 4. radiatorcap. Remove testerand reinstallthe the NOTE: Checkfor engine oil in the coolant and/or coolantin the engineoil.
10-8
Thermostat
Replacement
NOTE:Usea new O-ringwhen reassembling.
THERMOSTAT pin Installwith up.
RUEBER SEAL THERMOSTAT
THERMOSTAT HOUSING
TEMPERATURE IECTI
swtTcH
24 N.m 12.{ kgt.m, 17 lbl.ftl
6xl.0mm 12 N.m 11.2 kgf.m,8.7 tbtft)
10-9
Thermostat
Testing
if Replace thermostat it is open at room temperature. the To test a closedthermostat: 'L Suspendthe thermostatin a containerof water as shown.
ECTSwitch
Testing
Removingthe EcT switch while the engine @ is hot can causethe coolant to spray out, seriouslyscalding you. Always let the engine and radiator cool down betore removing the ECTswitch, NOTE:Bleedair from the coolingsystemafter installing the ECTswitch{seepage10-6}.
1. THERMOMETER
Removethe ECTswitch from the thermostathousing (seepage10-9). Suspendthe ECTswitch in a containerot water as shown.
THERMOSTAT
tl
Heat the water, and checkthe temperaturewith a thermometer.Checkthe temperatureat which the first opens.and at which it is fully open. thermostat CAUTION:Do not let the thermometertouch the bottom ot the hot container. w 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 t h e n f u l l y open. THERMOSTAT STANDARD Lift height: above8.0 mm (0.31in) (75"- 80"C) Startsopening: 169'- 176"F (90'C) Fullyopen: 194"F
4.
Heat the water, and checkthe temperaturewith a thermometer. CAUTION:Do not let lhe thormometertouch the bottom of the hot container. Measure the resistance betweenthe A and B terminalsaccording the table. to
Terminal
Op"r"ffi
ON SWITCH 196"- 203"F
O_
(3" 5" - 15.F - 8"C) O F F lower than the temperaturewhen I goeson
10-10
Fueland Emissions
SpecialTools
Component Location3
.............. 11-2
ldle ControlSystem
System Description ................. 11-122 TroublshootingFlowchart3 . . . . .1 1 - 1 2 4 . ldle Control System ldle Air Control Valve 11-126 ..11-130 Starter Switch Signal . AirConditioning 11-131 Signsl ................................. AlternatorFRSignal ...................................... t1-133
Brake Switch Signal 11-13i1
lndex . . .1 1 . 3 Systom Description Vacuum Connections 11.8 Electricrl Connaqtions 11-19 I 1.29 SystemConneqtors .........................,,.,..,...,.,. Troubleshooting Troubfsshooting 71.42 Procoduro!...............,........ EngineContlol Module/Poworftain Control Module Terminal Arrangement 11-'19 Diagnostic TroublCodeChart .................... 11-53 How to ReadFlowcharG............................... 1f -59
Power Stoaring PressurcSwitch Signal ......11.135 A/T Gear Position Signal .... 11-137 11-139 ClutchSwitch Signal .......... ldle SpeedSetting 11-141
PGM-FlSystem
Systom Description 11.60 TroubleshootingFlowcharts EnginoControl Module/Powrtrain Control Module 11.(x' Msnifold Absolute Pre3sure 11-67 Sen3or............. Intak Air TempraturoSensor 11-73 EngineCoolant TemperatureSensor ........... 1I-76 ThrottlePositionSensor ...............................9 11-7 Prim8ryHeatedOrygen Sensor(Sensor1) ... 11-8'l Socondrry Hoatd Orygon Sonsor 2)................ 11-95 lSensor HeatedOxygen Sensor Heatel 11-98 Fuel Supply System 11-103 Misfire Detectod in One Gylinder 11-105 Random Misfire 11-108 Knock Sensot 11-109 CKP/TDC/CYP 1 1 - 10 t Sensor.......................-....-.-..... VehicloSpesdSensor,......,...,....,.....,.,........... 11-'112 Barometric PressureSen3or 1t-113 11-115 ElectricalLoad Detectol CKFSensor 11-117 EGM/FCM InternalCircuit ............................. 11-120 A/T Sisnal[rvlA/TMB] .................................. 11-121
Fuel Supply System

Fuel Lines t 1-1i[5 F 11-117 Fusl Tube/Ouick.Connect ittin9s................,.... System Description........ 1t-150 11-150 Fuel PressurG.........,. 11-152 Fuel Iniectors ....... Regulator.....,.,.............,..,...,..,..... I 1-15i1 FuelPressure . . . . . . . . . . . . . . . . . . . .1.1 . . 1.5 . . ._. .5 Fuel Fiher . . . . . . . . . . . . . . . . . . . .1.1 . .1 5.6 . . - .. . Fuel Pump PGM-Fl Main Relay . . .1 1 - 1 5 7 FueTank................... l . . . . . . . . . . . . 1.1.-.1 6 0 . .
Intake Air System

System Description t1-161
Emission Control System

11-167 Systm Description 11-167 Tailpipe Emission Three Way Catalytic Converter 11-167 11-169 Exhaust GasRecirculation System ................... 11-171 PositiveCrankcase Ventilation System ..-......-.. I 1-178 Evaporative Emission Controls..........................
Speci a l To ols
t
SpecialTools
Rsl. No. Tool Number _ A973X-041 XXXXX 07JAZ- 0010008 07PAZ 0010100 07sAz - 0010004 07406- 0040001 07406- 0040304 Description 0 VacuumPump/Gauge, - 30 in.Hg 0 Vacuum/Pressure Gauge, - 4 in.Hg SCSService Connector Backprobe Set FuelPressure Gauge FuelPressure Adapter,6x 15 mm Oty
1 1 1 a 1 1
o
6
PageRefelnc 't1-171, 112,145, 186,188,192.193 1 1 - 1 9 2 ,9 3 1 11-42 11-44 1 1 1 - 1 5 0 ,5 r , 1 5 4 11 - 1 5 0
I
(^
./.
u
@
),
11- 2
ComponentLocations
lndex
D16Y5 engine:
THROTTLE POSITION ITPI SENSOR page11 79 Troubleshooting, EXHAUST GAS NECIRCULATION VALVEand EXHAUST {EGR) GAS RECIRCULATION IEGR} VALVE LIFTSENSOR pagel1 170 Troubleshooting, MANIFOLD ABSOLUTE PRESSURE IMAPI SENSOR page'l 1-67 Troubleshooting,
IDLE CONTROL AIR IIACIVAI-VE {M/TI page Troubleshooting, 11-126

EXHAUST GAS RECIRCULATION IEGR'CONTROL SOLENOID
INIAKE AIR TEMPERATURE IIAT} SENSOR page11-73 Troubleshooting, ELECTRICAL LOAD DETECTOR IELD){USA model) page11-1 Troubleshooting, 15 CRANKSHAFT POStTTON/ TOPDEADCENTER/
valvE tcwt
page11 I70 Troubleshooting, EVAPORATIVE EMISSION {EVAP}PURGE CONTROL SOLENOID VALVE pag11-190 Troubleshooting, POWER STEERING PRESSURE
swlTcH tPsP) {usal

1 = -
page11-135 roubleshooting, KNOCKSENSOR {KSI
CYLINDER POStTtON (CKP/TDC/CYP}

(Buikinrothe distributor) T r o u b l e s h o o t i n g ,g e1 1 - 1 1 0/ pa .
(cw)
page11-109 Troubleshooting,
VEHICLE SPEED SENSOR page1'l 112 Troubleshooting. ENGINE
CRANKSHAFT SPEED FLUCTUATION ICKFISENSOR page1'1117 Troubleshooting,
TEMPERATURE SENSOR {ECT) page Troubleshooting, 11-76
(IAC)VALVE IOLEAIR CONTROL
tcwt
page11-128 Troubleshooting,
WAY CATALYTIC
CONVERTER ITWC}
PRIMARY HEATED (PRIMARY SENSOR HO2SI 1) {SENSOR {M/Tt page1'1-88 Troubleshooting, PRIMARY HEATED OXYGEN SENSOR HO2S' {PRIMARY 1t {SENSOR {CWl page11-84 Troubleshooting,
paget 1-168 Troubleshooting,
SECONDARY HEATED OXYGEN SENSOR HO2SI ISECONDARY 2l {SENSOR page11-95 Troubleshooting,
(cont'd)
11-3
Component Locations
Index(cont'dl
D16Y8 engins:
THROTTLE POSITION ITP} SENSOR page11 79 Troubleshooting, INTAXEAIRTEMPERATURE IIAT} SENSOR -73 page1'1 Troubleshooting, MANIFOLO ABSOLUTE PRESSURE {MAPISENSOR page11 67 Troubleshooting, IOLEAIR CONTROL IIACIVALVE {M/T} page11-126 Troubleshooting,
EI."ECTRICAL LOAO DETECTOR (USAI {ELDI page Troubleshooting, I1-t15

CRANKSHAFT POStTtON/ TOPDEADCENTER/ CYLINOEF POStTtON (CKP/TDC/CYP} SENSOR l8uilt into the distributori page11'110/' Troubleshooting,
EVAPORATIVE EMISSION PURGE IEVAP) CONTROL SOLENOID VALVE

page11-185, Troubleshooting, 190 POWER STEERING PRESSURE {PSP|SWTTCH {USA) page11-135 Troubleshooting, KNOCKSENSOR {KSI page11-109 Troubleshooting,
VEHICI."E SPEED SENSOR page11-112 Troubleshooting,
CRANKSHAFT SPEED FLUCTUANON ICKFI SENSOR page 17 Troubleshooting, 11-'l IDLE CONTROL AIR IIACIVALVE IA/TI page Troubleshooting, 1'l 128
PRIMARY I{EATED OXYGENSENSOR (PRIMARY HO2SIISENSOR 1} page11-84 Troubleshooting, THREE WAY CATALYTIC CONVERTER {TWCI page1l'168 Troubleshooting,
TEMPERATURE
tEcTt sENson
page11 76 Troubleshooting,
t?\..==.--
- --L------
--- - ----:
SEOONDARY HEATED OXYGEN SENSOB HO2S}{SENSOR 2I ISECONDABY page11 95 Troubleshooting,
11-4
D16Y7 engin6:
THROTTLE POSITION ITPI SENSOR page11-79 Troubleshooting, VEHICLE SPEEO SENSOR {VSSI page1!-112 Troubleshooting,
MANIFOLO ABSOLUTE (MAP)SENSOR PRESSURE page11-67 Troubleshooting, INTAKEAIR TEMPERATURE {IATISENSOR page11 73 Troubleshooting, POWER SIEERINGPRESSURE SWTTCH {PSP) |USA} page11-135 roubleshooting,
ELECTRICAL LOAD DETECTOR IUSAI IELDI page Troubloshooting, 11''1'!5 CRANKSHAFT POStTtoir/ TOPDEAD CENTER/ CYLINDER POSTT|ON
SENSOR ICKP/TDC/CYPI {Builtintothe distributor) page11-110 Troubleshooting. i
--....-
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
CRANKSHAFT SPEED FLUCTUATION {CKF}SENSOR page TroLrbleshooting, 11 117 ENGINECOOLANT TEMPERATURE IECTISENSOR page11-76 Troubleshooting, EVAPORATIVE EMISSION CONTROL IEVAP)PURGE VALVE SOLENOID page'l1-190 Troubleshooting, SECONDARY HATED OXYGEN SENSOR HO2SI ISECONDARY 2t {SENSOR page11-95 Troubleshooting, PRIMARY HEATED OXYGEN SENSOR H02SI IPRIMARY
lsENsoR 1)
page11 84 Troubleshooting,
THREE WAYCATALYTIC CONVERTER {TWC) page Troubleshooting, I 1-168
CLUTCH SWITCH{D16Y5 6ngine M,/T)
PGM.FIMAIN RELAY page11-157 Relay Testing, pag11-158 Troubleshooting.
Procedures, Selt-diagnostic page 11-42
t2Pl Procedures, Self-diagnostic page11-42
ENGINE CONTROL MODULE IECMI/POWERTRAIN CONTROL MODULE{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: models,sedan:KL modell,'98-all all models:
FUELVAPORPIPE FUEL GAUGE SENDING UNIT FUELFEEO PIPE Testing, section see 23 FUELFILTER page11-155 Replacement. FUELPUMP page11-156 Testing, page11-156 Replacement,
EVAPORANVE EMISSION IEVAPI CONTROL CANISTER VENT S}IUT VALVE page'l Troubleshooting. 1-185
EVAPORATIVE EMISSION IEVAP)CONTROL CANISTER page11-1 Troubleshooting, FUELTANK page11-160 Replacement, APORATIVE EMISSION {EVAPIBYPASS SOLENOID 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 page11-152 Roplacement,
TIVEEMISSION
TWOWAYVALVE {EVAPI page Testing, 11-193 TANKPRESSURE

SENSOR page11-181 Troubleshooting,
FUEI
REGULATOR page'll-154 Testing,
R e p l a c e m e n t ,p a g e 1 1 - 1 5 4
FUEL
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) modls, hatchback:8ll modlsl. '97 D16Y8engine (sed!n: KA, KC modls): FUELVAPORPIPE FUEL FUEL FILTER page Replacement, 11155
EVAPORATIVE EMISSION IEVAPICONTROL CANISTER page11-190 Troubleshooting, FUEL PUMP page11 156 Testing, page I 1-156 Replacement,
FUELFILL CAP FUELTANK page11-160 Replacement,

TIVE EMISSION
IEVAP)TWO WAY VALVE page11 193 Testing,
TUBE/OUICK.CONNECT FUEL PRESSURE REGULATOR

page11-154 Testing, pageI 1-154 Replacement, FITTINGS page11-147 Precautions, page1'1147 Disconnection, page11 148 Connection,
11-6
D16Y5, D16Y8 engine: TITROTTLE BODY ITB} page Inspection, 11-164

AIR CLEANER IACL)
Replacement, p Removal, age11-165 D i s a s s e m b l y ,p a g e 1 l 1 6 6
THROTTLE CABLE Inspection/Adjustment, 11-'162 page page11,163 Installation,
VENTILATION VALVE {PCV} page I1-177 Inspection,
D16Y7 engine:
THROTTLE CABLE page Inspection/Adjustment, 1'l-162 page1l 163 Installation,
AIR CLEANER {ACL} page11-'162 Replacement,
RESONATOR
POSITIVE CRANKCASE VENIILATION{PCVIVALVE page'l1-177 Inspection.
THROTTLE BODY(TBI page'l1-16,4 Inspection, page11'165 Removal, page11 166 Disassembly.
11-7
SystemDescription
Vacuum Connections
D16Y5 engine{'96,'97 models):
To EvAPORATIVE EMISSION {EVAPI TWO WAYVALVE
MANIFOLO ABSOLUTE (MAPI PRESSURE SENSOR
EXHAUST GAS RECIRCULATION (EGRI CONTROL SOLENOIO VALVEIA/TI \ EMISSION EVAPORATIVE IEVAP)PURGE CANISTER CONTROL EXHAUST GAS RECIRCULA (EGRI VALVEand EXHAUST GAS VALVE RECIRCULATION {EGRI LIFTSENSOR (A/TI
\ \ ^
Tre)
-.'ry \
FRONT VEHICLE OF To CRUISE CONTROL DIAPHRAGM (withcruise controli
l.--
EVAPORA (EVAP} EMISSION PURGE CONTROL SOLENOID VAI-VE
REGULATOR
O: VacuumhoseNo.
11-8
D16Y5 ongine1,98 modell:
EVAPORATIVE EMISSION {EVAP) CONTROL CANISTER VENTSHUTVALVE
To EVAPORATIVE MISSION {EVAPI THREE WAYVALVE
To EVAPORATIVE EMISSION (EVAP} TWO WAYVALVE
EXHAUST GAS RECIRCULATION and GAS IEGRIVALVE EXHAUST IEGRIVALVE

LIFT SENSOR
tatfl
{CVTonlyl EXHAUST GAS RECIRCULANON {EGRICOiITROL SOLENOID
VALVE
EV
nvE
PURGE JOINT
EMISSION {EVAP} PURGE CONTNOL CANISTER
i,ff------\I M,
I SP
L..-..-..-..-r
lin.;rrdiollesolure
- --
PRESSURE tMAPI SENSOR
I I
EVAPORATIVE EMISSION {EVAP' PURGE CONTROL SOLENOID VALVE
To CRUISE CONTROL DIAPHBAGM (withcruisecontrol) FRONT VEHICLE OF
REGULATOR FUELPRSSURE
O: Vacuum hoseNo.
(conr'd)
11 - 9
SystemDescription
(cont'd) VacuumConnections
D16Y8 engine:
EVAPORATIVE EMISSION IEVAPI CONTROL CANISTER VENTSI{UT VALVE ('96 coup., 37 coup.: all models, '97 aed.n: KL model, 'g8-modelsl To EVAPOnATVEEMISSION WAY VALVE {EVAPITHFEE '97 l'96 coupo, coupo:all mod6b, '97 sedan:KL model, 'g8-modols) EVAPORATIVE EMISSION IEVAPI PURGE CONTROL CANISTER {'96coupe, 37 coupe:ell modek, 3edan:KL model)
To EVAPORATIVE EMISSION IEVAPI TWO WAY VALVE
FUEL PRESSURE REGULATOR
MANIFOLD AESOLUTE (MAP} PRESSURE SENSOR
EVAPORANVEEMISSION IEVAPIPURGE CO]TTROL CANISTER ('96 3.d.n, 37 r.drn: KA, KC mod.lrl
EVAPORATIVE EMISSION {EVAP} PURGE CONTROL SOLENOID 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:
EVAPORATIVE EMISSION IEVAP' PURGE CONTROL
FUEL PRESSURE REGULATOR
To EVAPORATIVE (EVAPI EMISSION TWOWAYVALVE
MANIFOLD AASOLUTE PRESSURE IMAP) SENSOB
To CRUISE CONTROL DIAPHRAGM {withcruiso control)
EVAPORATIVE EMISSION IEVAPI PURGE CONTROL CANISTER
FRONTOF vEHtcl-E
(cont'd)
11-11
r
SystemDescription
(cont'dl VacuumConnections
Dl6Y7 engine('97coupe:KL modcl,'97sedan:KL {LX)model,'98models}:
(EVAPI EVAPORATIVE EMISSION CONTROL CANISTER VENT SHUTVALVE
To EVAPORATIVE EMISSION IEVAPITHREE WAY VALVE
To EVAPORATIVE EMISSION IEVAP) TWOWAYVALVE

FUELPRESSURE REGULATOR
MANIFOLD AASOLUTE PRESSURE IMAPI SENSOR EVAPORATIVE EMISSION IEVAPI PURGE CONTFOL CANISTER
To CRUISE coNTROt DIAPHRAGM (withcruis control)

EVAPORATIVE (EVAPI EMISSION PURGECONTROLSOI."ENOID VALVE
FRONT VEHICLE OF
11-12
D16Y5 enginenl'95,'97 modelsl:
,r;---l
I i
l(D l+ |
ENGINEI COOLANTi
iLffii i -I]FnL l-r-
t/6r IUI t
i
I
l-,4
:l: Vacuum ho3oNo. ': CVT only
HOzS, OXYGEN SENSOR IPRIMARY o PRIMARYHCATED
1l SENSOR 6i SECONDARY HEATEO OXYGENSENSOR ISECONDARY HOzS.SENSOR 2l aal MANIFOLD (MAP}SENSOR ABSOLUTE PRESSURE TEMPERATURE IECTISENSON @ ENGINECOOLANT INTAKEAIR TEMPERATURE {IATISENSOR KNOCKSENSOR IKS} (CKFISENSOR CRAITIKSHAFT SPEED FLUCTUATION (IACIVALVE @ IDLEAIR CONTROL 6\ THROTTLE BOOY(TBI [E FUELINJECTOR FUELPULSATION DAMPER @ FUELFILTER REGULATOR @ FUELPRESSURE (0 FUELPUMP(FP) @ FUELTANK
a AIB CLEANER (D
RESONATOR
EMISSION IEVAP}VALVE @ FUELTANK EVAPORATIVE CRANKCASE VENTILAIION{PCVIVALVE @ POSITIVE IEGRICONTROL 0 EXHAUSTGAS RECIRCULANON SOLENOID VALVE
VALVE {EGRI @)EXHAUSTGAS RECIRCULANON EXHAUST GAS RECIRCULANON IEGRIVALVELIFT SENSOR EMISSION CONTNOL {EVAPIPURGE @ EVAPORANVE
o o
a
6
sottNotDvALvE
EVAPORATIVE EMISSION CANISTER {EVAPICONTROL THREE WAY CATALYTIC CONVERTEF ITWCI
EMISSION IEVAPITWO WAY VALVE @ EVAPORATIVE
(cont'd)
11 - 1 3
SystemDescription
D16Y5 enginel'98 model):
-: Vacuum hoaoNo. *: CW only
(PRIMARY HEATED O PRIMARY OXYGEN SENSOR HO2S. SENSOR 1l HEATED oxYGEN O SECoNDARY sENsoRISEGoNDARY HO2S. SENSOR 2) ABSoLUTE PRESSURE sENsoF O MANIFoLD |MAP} (' ENGINC COOLANT TEMPERATURE SENSOR ICCI) AIF O INTAKE TEMPERATUBE sENsoR {IAT} SENSOR G) KNOCK IKSI spEED FLUCTUAT|oN sENsoR O CRANKSHAFT tcKFt AIR VALVE @ IDI.E coNTRoL{IACI BoDYtrBl O THRoTTLE (O FUEL INJECToR PULSATION DAMPER O FUEL FILTER @ FUEL (} FUEL PRESSURE REGULAToR (} FUEL PUMP {FP) TANK @ FUEL TANKEvApoRATtvE EMtsstoN @ FUE|tEvaplvALvE @ AIRCLEANER @ RESoNAToR
SOLENOID VALVE GAs @ EXHAUST RECIBCULATIoN vALvE {EGRI @ ExHAUsrGAs REctRcuLATtoN valvE L|FT {EGRt SENSOR EMISSIoN @ EVAPoRATIVE PUnGE IEVAPI coNTRoL SOLENOID VALVE JOTNT 8] PURGE EMIsstoN @ EVAPoRATIVE coNTRoL IEVAPI CANISTER (EvAp) EMrsstoN @ EvApoRATtvE BypAsssoLENoD VALVE EMtssIoN{EVAP) THREE @ EVAPoRATIVE wAY vALvE EMISSIoN @ EVAPoRATIVE IEVAPI coNTRoLCANISTER VENT SHUT VALVE pREssuRE TANK @ FUE|sENsoR EMtsstoN two wAy valvE @ EVApoRATtvE tEvAp) wAY cATALYTIC @ THREE coNvERTER ITwcI
cRANKcasE vENnLATtoN vALvE @ posrnvE {pcvt GAs @ EXHAUST RECIRCULATIoN coNTRoL IEGn)
'97 '98 models): KL D16Y8 engine('96coupe,'97coupe:all models, sdan: model,
| - : - l i ( ' I
F@,
{M/T)
l
i
i liiffis r
:.. --''--I
{A/T) -
-l E-NGim
6)toofl'!
HEATED oxYGEN sENsoR Hozs, O PRIMARY IPRIMARY SENSOR 1l HEATED oxYGEN sENsoR{SECoNDARY ) SECoNDARY HO2S. SENSOR 2r ABSoLUTE PRESSURE sENsoR O MANIFoLD IMAP) TEMPERATURE SENSOR COOLANT IECTI @ ENGINE (IAT) AIR O INTAKE TEMPERATURE sENsoR @ KNocKsEt{soRtKs) (cKFlsENsoR FLUcruATroN spEED O CMNKSHAFT AtR @ |DLE coNTnoLltacl vALvE @ THRofiLEBoDYITB) INJEcToR @ FUEL FILTER O FUEL PRESSURE REGULAToR @ FUEL PUMP {FP) G) FUEL TANK @ FUEL (EVAP) TANKEVAPORATIVE EMISSION VALVE @ FUEL
(1-6)AIR CLEANER
o RESONATOR
CRANKCASE VENTILATION VALVE {PCV) @ POSITIVE EMISSION IEVAPIPURGE CONTROL @ EVAPORATIVE SOLENOID VALVE EMISSION {EVAP) CONIROLCANISTER @ EVAPORATIVE EMISSION SOLENOID IEVAPIEYPASS E1lEVAPORATIVE VALVE EMISSION IEVAPITHREE WAY VALVE @ EVAPORATIVE EMISSION {EVAPICONTROL CANISTER @ EVAPORATIVE VENT SHUTVALVE SENSOR @ FUELTANK PRESSURE EMISSION {EVAPITWO WAY VALVE c! EVAPORATIVE (TWC) CONVERTER adTHREEWAY CATALYTIC
(cont'd)
SystemDescription
(cont'dl VacuumConnections
Dl5Y8 engine ('96 sedan,'97 sedan: KA, KC modets):
IM/T)
I-@-l
'_._:_..i
ir'ffii
l,'
\
HEAIED OXYGEN SENSOR .' PRIMARY HO2S, IPfiIMARY SENSOn lt HEATED oxycEN sENsoRrsEcoNDABy ] sEcoNDARy HO2S. SENSOR 2l (MAPI ABSoLUTE PRESSURE sENsoB O MANIFoLD cooLANTTEMPERATURE sCNsoR O ENGINE tEcD AIR O INTAKE TEMPERATURE sENsoR IIATI @ KNocKsENsoR{Ksl spEED FLUcruATtoN O CRANKSHAFf {cKFtsENsoR AtR @ |DLE coNTRoLflActVALVE BODY O THROTTI.I ITBI INJECToR @ FUEL FILTER @ FUEL
FUELPRESSURE REGULATOR FUELPUMPIFPI FUELTANK FUELTANK EVAP,ORATwE EMISSION {EVAPIVALVE AIR CLEANER RESONATOR VENNIANON {FCV} VAIVE @ POSITIVECRANKCASE EMISSION @ VAFORATIVE CONTROL IEVAP}PURGE SOLENOID VALVE @ EVAPORATIVEEMISSON IEVAPI CONTBOLCANIS1ER (EVAP} EMISSION TWO WAY VAVE @ EVAPORATIVE @ IHREE WAY CATALYTICCONVERTER ITWC}
@ @ @ @ @
(x
11-16
-
D16Y7 enginel'96 models,'97coupe:KA, KC modets,'97 sedan: KA, KC,KL (DXl models,'97h8tchback: models): all
COOLANT
HEATED OXYGEN SENSOR O PRIMARY HO2S, {PRIMARY SGNSOR 1l HEATED oxyGENsENsoR(sEcoNDARy O sEcoNDARy HO2S. SENSOR 2) pREssuRE (MAptsENsoF ABSoLUTE O MAN|FoLD COOLANT TEMPERATURE SENSOR ) ENGINE {ECTI (IAT) AIR @ INTAKE TEMPERATURE sENsoR SPECD FLUCTUANON SENSOR @ CRANKSHAFT ICKF} AtR O |DLE coNTRoL{tActvALvE BoDYITBI @ THRoTTLE INJEcTon @ FUEL FTLTER @ FUEL PRESSURE REGULAToR O FUEL
FUELPUMPIFPI FUELTANK (EVAP) FUELTANK EVAPORATIVE EMISSION VALVE AIR CLEANER RESONATOR POSITIVE CRANKCASE VENTILATION VALVE {PCV) EVAPOMTIVEEMISSION IEVAPIPURGE CONTROL SOLENOID VALVE EMISSION @ EVAPORATIVE IEVAP)CONTNOL CANISTER EMISSION TWO WAY VALVE IEVAP} @ EVAPORATIVE THREE WAY CATALYTIC CONVERTER {TWC)
@ @ (} @ @ all @
(cont'd)
SystemDescription
D16Y7ongine l'97 coupe: KL modol, sed8n:KL (LX) model, g8.modols):
--[-
HEATED oxYGCN sENsoRIPRIMARY O PRIMARY Ho2s, SENSOR 1) HEATED oxYGEN sENsoR{SECoNDARY O SEGoNDARY HO2S, SENSOR 2l ABSoLUTE PBESSURE O MANIFoLD sENsoB IMAPI cooLANTTEMPERATURE sENsoR @ ENGINE tEcTI AIR O INTAKE IEMPERATURE sENsoR {IATI (CKFI SPEED FLUCTUATION SENSOR @ CRANKSHAFT AIR O IDLE CONTROL VAI.VE |IAC) BoDy tTBt @ THRoTTLE INJECToR O FUEL FILTER @ FUEL PRESSUFE REGULAToR O FUEL .IA FUEL PUMP {FP) TANK {9 FUEL Ii4 FUEL TANKEVAPORANVE EMISSION {EVAP} VALVE f,, AIRGLEANER
@ RESONATOR (PCVIVALVE VENTILATION @ POSMVECRANKCASE (EVAPIPURGE EMISSION @ EVAPORATIVE CONTROL

SOLENOID VALVE (EVAP) EMISSION @ EVAPORATIVE CONTROL CANISTER EMISSION @ EVAPORANVE {EVAPIBYPASS SOI.-ENOID VALVE (EVAP) EMISSION @ EVAPORANVE THREE WAY VALVE EMISSION @ EVAPORANVE IEVAPICONTROL CANISTER VENTSHUTVALVE SENSOR @ FUELTANK PRESSURE EMISSION @ EVAPORATIVE IEVAPITWO WAY VALVE WAY CATALYTIC CONVERTR @ THREE IIWC}
11 - 1 8
Electrical Connections
-9
lo C*iCA6OR
Cl,UlCtt FIAY
lo A./CPfiC8dUiE a|lrTCH
ECr SW'ICtl
CHEC|(
.2: AII (Dlovt, Dr6Y8.neln.l ra: AfI.nd OioYt.hgl.. r5: ElDt A/I.n<l Dr6Y7 ft9ir. r?: CVTlDi6Y5 ooln.l .nd O16Y3 .nsin. ra:96 Di6Yadgln. Ic@p.|, 37 Dl6Y3.t 96 Dl6Y3.n9ln. O i liIIEES UCHI n .ll mod.l." t d.n: XL mod.il '$ Ol6Y5 .n9in., O tAC( lr? lt.6 A,i lco!p.: tâ '10: M/I lD16Y5 mdn.l 11l: Eropt M/r OlaY5 .tr!4..1 .12: DiCY5, DltYgmdn. '15: '9t Dl6lt d9ln. (@qp.: K- mo.Ll, ..d.n: KL lLxl mod.ll, 16 D16rt .nein.
o xox tAtttl o rAt orct
N., 13fUEL tlr$t
lll Al
r: h ii.
t'|. rt &lEr|{AlOi A?*i.3oi tr.aAl llo. 3t 6ta8fEi stol{^t tt.6 at

lndr.lb.d lr-/nld 5.r
{cont'd)
11 - 1 9
System Description
(cont'dl Electrical Connections
T:I
.l
FUEL PACITST'R sEt{Bon
gEN90fi EGN
EGN
tnAt(Ctt{ltcH
lo f,lEnJOCK utrtt @fttiot VAIVE aorliloo A: EVA' tUiG clr||liol a: EvAr cotltioa c tr*slEi wm $(rr vavE qEv P av?ats aolEioo valvE O: CCi Coraliol Sotlltlolo VAIVE V IVE E: VIEC 6otli|oa IVE t: r,iEAns{r(EilOrOV c: LOO(.I P Ot Ltxt! SOt'lilOlO VAYE A lf,ot aot.iloD vAlvE I tt toc(.(t@ v^lvE A r SHfT @tvtioi, aottlllxt VAIVE ! J: at||f @lvriol8OlIiIXt 2; A/t lolart, Olava rCDl ra: AfI .nd Dlart ddn. 15: Espr A/T.nd Dttr, dsa.
- r------t Lll.J 1t!r!]J l' ? l l6 ' r r D 11 | t,'r,, st llll
.7: CVI iD'lav6milDl.nd DilV,.ndd r3: ga Ol6Y3 dct lcoup.), '97 DtaYS .|'|tu mort lr..d..: l(l n .Ul, ! DtaYE osl.., ldD...t 'ror M/r tDrat6 oCn l rll: Erc.pl M/T lDlaYt .nsl..l '12: D'laY5, DlaYa..dD rl5: It Oiart ddm ldrp.: IL h.d.l,..d.n: xL lL]xlhodJ','S Dlart odd
11-20
MAP Si60f,
cl'!t
EGi VAVE uF sENsoB
l""fi""-_
stu l__.!-sru/YEL
sivtcE cHEcx cot{NEcToi
a6scoNriol u r,
@l{t{cToi
(cont'd)
11-21
SystemDescription
Connections Electrical {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 .a: a/I .nd OlaYt .n!i.. .6 Esoi Art.d Dt6r, .n!ln. .7: CW (Oia\6 ociml.nd DI6YS.nciM .3:'94 OlaYl ncin. l.o{Fl, !7 ol6Ya 6ci.. Xtmod.ll,'9aOl6Y5.ngh, tcour:.amod.lr..d.n: .10: M/t lDl6YE osin.l .lr: Erc.rt MtI lot5Y5 min.l rl2: ol6Yt, Dl6Yaogin. .t5: 9? D16Ytdgi..ldp.: KL tFd.l. t d.n; lG ltxl mod.D,'93 O|6YT.nsim
\i
11-22
:rva --f|:F-l wtfii l-,1 /ffi|

| | 8LX'-1FJ
L__.dJ I I
LT GAiYWHT CAI'IISTEA VEM SHUTVALVE{.i$
N C D /- U
' ' _ _ _ - __ _ _
'''-'-
_ - _ __ __ -
F--+,
Ks"-I
-
aeo'-8rx-- Jl---l 1t+l
clurcH swrrcHn. {cont'd)
11-23
System Description
(cont'd) Connectors Electrical
.a
scr{90fi rDc stofi cr(?
H?,H,?,"iI
t30
BFN/IL(I
BLX
{
BRN/BIXI
BA/ alx1
r* ] &. l L t
lTop.l.tt-2al r1:USAmod .2: Arr tD'r6\r, Dr5Y3dsin. .3: C\/T tot6y6 net..l .a: A/I .nd Dl6r, .nC,. .E: Erc.ptA/T.nd Oi6Y'.ryin. .arA/t tDt6y8 dctn.t .7r CVt (Dl6V6 .nelal .nd DiOYs .ncin. '0:'96Dl5Y0.nc.{dp.l,37Di6Y3.nsim lcoup.:.llmod.L,..d.n:Klmod.ll,'9aot6Y5.nrin., .9i D'16Y5 mgim l0: Mfl lDl6Y5.rsitul .11: r..ct M/I lD'laY5 osim) r12: OtaY5, OtSYt .natr. .13: DltYa osin. rla: DlaYt.nlln. 116:t7 Dl6ft .n!Nm l@p. XL nod.l, ..d..: |(!tlxlh.d.ll,'!cDlaftosid
11-24
MAINSHAFI SPEED SENSOf,"
BtU'
t3
COUNT:RSHAFI SPIEDSENSOR-
c121
ll
l l
el 3
I
|
(cont'd)
11-25
System Description
(cont'dl Gonnectors Electrical
cr3r caa6
orrr c*,2
oll0
cSlta GRT/ATI: d YCL rr GFl{l ---Brx/Bru T I
T*-
w{F-
FEo
GRN --
uru,1
fi
a/r GE i fo6no|l swTcll
NtEn|-OCX coifliot uttr
;., cnr'--
--.1
l .lc
ilr
BLU/BEB-- -
t'i
-
mffimi#
arun:u--j' ro ^/c s$rcH
.10: Mlt loloY5.ncitul .i'l: Erc.Dr M/r ID|6Y5 ddn.l 'rA DiAY5,Dli\,t melm
U cr3r c/r46
'2: A/T (Dl6Y7,Dl6Y3.ngin.t .a: A/T .nd Di6rr.ncitu rt: Erc.pt Alt .nd Dl6Yt .nsi..
r15: 'et Dl6rt oslo loop.: KL mo.bl,..d.n: .t: Cw lol6Y5 6ein.l ..d D16YO .nsin. .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
(cont'dl Connectors Electrical
tT GRn GR /ALK'
o|or c555
ii
F
t-
YEUBI-U ITGRtsGA /a|.x AUUWHI 3LU'-
FED/ FED GRN VREFI
t:l t"-l TT
wxT/nED,
F F
F
[t
l " l
clit5 BEAXf,SWTTCX
Hiriffi+
.2: A/T {Or6Y?, Dl5Y8.nsin.l '3: Cvr {Dl6Y5.ngi.} .4: A/T .nd DlYr.ngin. .5: ExDt A/T tnd Dl6Y7.ngin. .5: A/T {D16Y8.ngln.l 17rCW tDtoYs!ngln.) lnd ol6YE .ngin. r8:'96 Dl5Y8.nsin. {coupol, Dl6Y8!.sin. 37 '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.
11-28
'15:,97 O'16Y7 .ngin.lcoup.r XL mod.l ..d.n: KL {LXlood.ll,'98 Dl6Yt msin.
SystemConnectors [FuelPumpl
c792+r.*'5
,
c565
c792r.,r1s
E ffi
@
IITYT!BLU-___l
I"TGRN/BLxf'li-BN' -
fr
tlr c793r3.rE *2: USA model A/T {D16Y7, D16Y8engine} *3: CvT {D16Y5enginel *4: A/T and Dl6Y7 engine *5: ExceptA/T and D16Y7enginc 16:A/T lDl6Y8ensine) *7: CVT {D16Y5engine}and D16Y8engine *8: '96 D16Y8 engine{coupel,'97 D16Y8 engine {coupe:all models,sedan:KL model), '98 D16Y5engine, '98 O'16Y7 engine '9: D16Y5 engine *10:M/T {D16Y5 enginel *11:Except M/T (D16Y5 engine) *12:D16Y5, D16Y8 engine *13:Dl6Ygengine '14: D16Y7.ngine *15:'97D16Y7 enginelcoupe:KLmod6l.sdan: KL {LX)modell,'98D16Y7 en9in6
NOTE:.
Different wireswith the samecolor havebeengivena numbersuffixto distinguish them (for example, YEUBLKI and YEUBLK, not the same). are O: Belated Fueland Emissions to System. - Connector (doubleoutline): with maleterminals View from terminalside - Connector with femaleterminals(singleoutline)r View from wire side (cont,d)
11-29
SystemDescription
(cont'dl SystemConnectors [EngineGompartmentl
D16Y8 sngine: D16Y5,
11 - 3 0
c101
c102
oo .",t
c104 (Canada,
c105
c106
F'fftt
ItrlwHr/RED,--l Fl8iNiB.,. I Ec" 16lBLrr,f 1
l- Irl
l.l.l
f'frf
.l lolwHr,nED" ttlBLvyEL ItlwHlBLrJ-
c10?
c109r.
cl10
c'|13+1
cl1a
r'ft]
16loRN---l
l)lYEUsrK' I bIBLX/BLtl-
ffiffi
c138r5
c136..
c137r'
C1,r2r'
fr
NOTE:.
Different wireswith the samecolor havebeengivena numbersuffixto distinguish yEUBLKT them (for example, and YEUBLK, not the same). are O: Related Fueland Emissions lo System. - Connector with maleterminals (doubleoutline): View from terminalsroe - Connector with femaleterminals{single outline): View from wire side
(cont'd)
11-31
System Description
(cont'dl SystemConnectors Compartmentl [Engine
D16Y8 D16Y5, engine:
c14113
c112
cl23
11-32
c111
c112
fr
ct15
c116
c117
r'tra
l
YEUBLKI
a 8LK i9, B L K '

ELKI 8LK'
FfBL{-l
i?l8L|(YEL I
G) Y E U B L K ' @ YEVE!KI
YEUBLII ,!] Y E V B L K ] YEUELK'
surwHr f3-l-
.!3 E L K I !l B L K '
SLK
fr
c118*'
cl20
c122
c123
ffi
o
YEVGAN 8LU5 YELI 5 tJ) RED5 BIK'
fr
c14{}*f
c124"
c125
ffi
ti|wHr FED.__l I]l fiTGRN/BLF l-3_ELK.YELl]]l I
--__l lDlGRr,P lEl-Lur-- -
BLU 10 ElxrYEL
lalir-r1wii'
c126r'
ffi
FT-wHr-7---l
lDlFEp. I
c121" -_Et_
F I'I
|6FED,--__-l l_l lSlwHl ;c;* l r l 2 l 3 l
fr
c12E.'
c139*
E
16lcRr.yYEL;_l
fr
clalrl
FT'I
I tilLr cnvwnl Il I-IBLKCi
l6lELU/vEL-l lETcRr^rHil
o l?lne ,
trTBLF---__-]
glnn
['lrl.)
tiT l
l 1l , I t f ; l L4 6l;I;l
l2lBtK l6lwHT I3 GFN,ELK' 7 BL(' 8lqED" l4lwHl'
l-t
16]wHrigLa_--l l?liFN/BIK,I ---1 ItrItEUBLU
It'|wHr/BLx_l
ll? GFN/BLKr I
----_--.l EBrx,r/yf,p I5T
lelBra-----l -1 F T _ -_j6FNF
I aTYELisLt -
l l2 wHTBLU I I3 ItH] GRN I 14 8-k I. *"' "co
l-T-
.-
wH si_l
c35{'1
o f6-wrr Rr
a w ' r TB . l r I l 2 9 WFTCFN I I1 10 | l! -1 BL-\/r| |u
f-Fr
6 BL'q^/rf__l
| I I
BtUl/vHT 7 WFIBLK S W H IG R N w H rB L K e wrrl l e rr c a r o
f---
-.l fclBtKi,,iHr loleLK--'-l l]l 1olGRNFEo

NOTEI. Different wireswith the samecolor havebeengivena numbersuffixto distinguish yEUBLKI them (for example, and YEVBLK, not the same). are O: Related Fueland Emissions to Svstem. o - Connector (doubleoutline): with maleterminals View from terminalside - Connector with femaleterminals(single outline): View from wire side (cont'd)
r'ft]
11 - 3 3
System Description
(cont'd) Compartment] SystemGonnectors [Engine
D16Y7 engine:
V., J
11-34
c10l
c102
9,''on
C'loil {C.nada)
c105
r,frt
lSlwHr/RED;_l 16TBuNsLKr--l _-l EfBLUmEo.
r+ l 2 l | 1
|jIJ
r'1rtr
-l 16lwHr/RED" ---1 ETBLX/vEr -'1 lTlwHrsru
ffi
c106
c107
c108
c112
ffi
ffi
Etr
ffi
c113*!
t=t
/ 1 \
\2
I6ERN--l ll Idfsr-r---
NOTE:o Different wireswith the samecolor havebeengivena numbersuffixto distinguish them (for example, YEUBLK1 and YEUBLK, not the same). are O: Related Fueland Emissions to System. a - Connector with maleterminals(doubleoutline): View from terminalside (cont'd) - Connector with femaleterminals(single View from wire side outline):
11-35
System Description
(cont'dl SystemGonnectors Compartment] [Engine
D16Y7 sngine:
11 - 3 6
c109
c'|10
r'ff;r
fSloRN---__l
IaIYEUBLK, I lb]-Bar<,jLu I
fr
c114
c115
cl16
BLK
.1) YEUELKI ttl Y E V B L K ' YEVBLK'
BLK' BLK' BLKI BLK' BLK' BLK'
o '|
YUBLK' YEUELK'
YEUBLK'
cI17
cl18 (A/Tl
cl23
r'frfl
lllBLr----l
lt ELK,YELI _-l I-TBLUIrvHT
ffi
ffi
c125 FF-' c126lA/T)
fiil RrD ,vHr-IdIGBIvBLK' I
ffi
fr
c127(A/Tl
c12A |dfil c141.r5
c12r lalf I
ffi
lrl2l
['l.l
ffi
l6lwHr'
l@lREo,
-t+-t IrI2l
-l
I YEL--I ITTTBLI l.afcrll-NlrHT,ll
I l'lz
lEl LicRN^,Hrl l6fsar<'EL I
I6liHT/REo'-_-l ftERN/Br-r;_-l lElYEL;---_-l lolREo,YEF-_-l lofBr-r</YEL I lSlBLK/wHTi-l
ItrlwHr'--__l
lOlBEp. I
c35{*' l 1 l 2 l 3 l
16lBL&l"Hr__-l l6lBLK I
lO cRNiREo I
NOTE:.
Different wireswith the samecolor havebeengivena numbersuffixto distinguish them (for example, YEUBLKT and YEVBLK' not the same). are O; Related Fueland Emissions to System. - Connector with maleterminals(doubleoutline): View from terminalside - Connector with femaleterminals(singleoutline): View from wire side
11-37
SystemDescription
SystemConnectors lDashand Floorl
11-38
6 l 7 l 8 l e 0 t 1 1 12 t
12 1 3
15
BLU,rvL
c'15
ottT'r
-r=l-
l[TTtT;ll
l l . | 5 | 6| 7I l
ll BL(vEr. I
,-F-
lr l, I
la FFo' I
|
I
TiTsuqv/ir---'l ---l ftl B.u,"Ep lOlwHr,Lr I

t.8lx I
litEli
tilwHr/6RN I
': scu.rYarrmsFtem
11 YEL
0125 ct|:|5 lwnhout crui! contolt (wtth ctuir controll -FF-
ffiffi
I !'IGRNAI/HF I ll WHI/GRN I 13 |
,| a 5 6 7 E 9 10 't2 1 3 t a 1 5 1 6 1 l 1E 20
't2 BLX'EL
I 1 LLT GiN 12 GnY lO cFNeHr'
I I I
f.T_
ltrlwHT/GRN1)
o
5
NOTE:.
Different wireswith the samecolor havebeengivena numbersuffixto distinguish them (for example, YEL,/BLK1 and YEUBLK, not the same). are O: Related Fueland Emissions to System. - Connector with maleterminals Vjew from terminalside {doubleoutline): (cont'd) - Connector with femaleterminals(singleoutline): View from wire side
11 - 3 9
SystemDescription
SystemConnectors [Dashand Floor](cont'dl
\
c412
C131 c446
C135
11-40
c130
t 't'l 12 l 3
5 6 7 I t0 l 5 1 6 1 7 ta 't9 20
lD16Y5, Dl6Ya.ngin6l
YEL
cr32 tEcM/PCM-A)
5 6 7 8
Ct33., (FCM-B) 9 t0 23
1l
cr3a{EcM/PcM-ct
12 t 3 lit t 5 l 6 t t I E t 9 2l 25 27
2a
2a 29 30
cr!5 tEcM/FcM-Dl
ffi
fiTwr/BrtTtltErnrx lfsri------l I]]l l -l
r'TftI;I
ItTniKrysr I-l I l-"rlcnN^v'tr Itmsrneo l f.. ErlwHr'--l
fr
rnwHr
flwHrnEF l I aaFlBa(
Cr|]lil
!
a l 5 't2 1 3
tl
E 9 't1 t 8 1 9
to
ffi
rfir
ITFI
l-tlwr/nEdI;TcRN^,Nr--l lrfttK,/,/H lilBrx,v/Hr l
NOTE:.
YEUBLK1 Different wireswith the samecolor havebeengivena numbersuffixto distinguish them (for example, and YEUBLK, not the same). are O: Related Fueland Emissions to System. - Connector wlth maleterminals(doubleoutline): View from termlnalside - Connector with femaleterminals(single outline): View from wire side
11-41
Troubleshooting
Procedures Troubleshooting
How To BeginTroubleshooting problem,usethe approprion. Indicator Lamp(MlL)has beenreported or there is a driveability Whenthe Malfunction belowto diagnose and repairthe problem. ate procedure A . W h e nt h e M I Lh a sc o m eo n : '1. Connect the 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'smanuals specific instructions. for operating . The scantool or testercan readthe Diagnostic TroubleCodes(DTC), freeze frame data,currentdata.and other EngineControlModule(ECM)/Powertrain ControlModule(PCM) data . Freeze frame data indicates engineconditions the when the first malfunction, misfireor fuel trim malfunctior when troubleshootino. was detected. can be usefulinformation lt problem,reterto the SymptomCharton page11-46. B . Whenthe MIL hasnot come on , but there is a driveability Indicator Lamp(MlL)with the SCSservice connector conc. DTCS be indicated the blinkingof the Malfunction will by nected. is as Connectthe SCS serviceconnectorto ServiceCheckConnector shown. (The 2P ServiceCheckConnector Turn the ignitionswitchON {ll}. located underthe dashon the passenger's of the vehicle.) side
OBD ll SCANTOOLor HONDAPGM TESTER
DATA LINKCONNECTOR {16PI
SERVICE CHECK CONNECTOR I2P}
SCSSERVICE CONNECTOR 07PAZ- 001011X'
11-42
ll.
Procedure Reset ControlModule(PCM) EngineControlModule(ECM)/Powertrain will resetthe ECM/PCM. Eitherof the followingactions . memorv. Usethe OBDll scantool or HondaPGMTesterto clearthe EcM's/PcM's for operating instructions. NOTE:Seethe OBDll scantool or HondaPGMTesteruser'smanuals specific fuse/relay box for 10 sec. Turn the ignitionswitch OFF,Removethe BACKUP (7,5A) fuse from the under-hood onds. Make note of the customer's the NOTE:Removing the BACKUP {7.5A) fuse cancels clockand the radio presets. oresets vou can resetthem. so
(thisprocedure must be done afterany troubleshooting) lll. FinalProcedure if Connector it is connected. 1, Remove SCSService the storedin the ECM/PCM, MIL will stay the is and there are no DTCS NOTE:lf the SCSservice connector connected on when the ignitionswitchis turned ON (ll). Reset Procedure, 2 . Do the ECM/PCM Turnthe ignitionswitchOFF. (cont'd)
11-43
Troubleshooting
(cont'd) Troubleshooting Procedures
lf the inspection a particular for voltageor resistance removethe right code requires checksat the ECM/PCM connectors, Removethe ABS control unit if so equipped.Unboltthe ECM/ kick panel.Pull the carpetbackto exposethe ECM/PCM. PCM bolt. Turn the ignition switch OFF,and connectthe backprobe sets and a digital multimeteras describedbelow. the for listedon the followingpages. Check systemaccording the procedure to described the appropriate code(s)
l
)
KICK PANEL
How to Use the BackprobeSets patchcords,and connect cordsto a multimeter. the Connect backprobe adapters the stacking to the Usingthe wire insulagently slidethe tip into the connector tion as a guide for the contoured of the backprobe tip adapter, trom the wire side until it comesin contact with terminalend of the wire.
BackproboAdapter BACKPFOBE SET 07SAZ- 001000AlTwo
OIGITAL MULTIMETER {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.
RUBBER SEAL
TESTERPBOBE
TERMINAL
{cont'd}
11-45
Troubleshooting
Troubleshooting Procedures {cont'd)
Symptom Chart Listedbeloware symptomsand probable causes problems for that DO NOTcausethe lvlalfunction indicator Lamp(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 n , g o t o p a g e ' 1 1 - 4 2 . o Troubleshoot eachprobable causein the order listedlfrom left to right)until the symptomis eliminated. The probable pagereference be found below. causeand troubleshooting can SYMPTOM Engine will not start Hardstaning Coldfast idle too low
Cold fast idle too high
PROEABLE CAUSE 4 , 2 , 3 , 5 , 2 01 4 ,1 , 2,4.11,16,13,'t9 7, 8, 6, 16 7 , 8 ,1 0 , 9 7 , 8 ,1 0 , 9 Troubleshoot misfireon pages11-105, tor 108 2 , 9 , 1 0 , ' t 2 1 1 ,1 6 ,1 8 ,2 0 , 2 , 4 , 1 1 , 7 ,2 0 ,A , 5 , 1 5
ldle speedtluctuates M i s f i r e r r o u g hr u n n i n g o Low power Engine talls s OtherProbable Causes an enginethat will not start: for - Compression - Startingsystem - Intake leakage - Overheating air - Enginelockedup - Battery - Timing belt ProbableCauseList (Forthe DTCChart, see page 11-531
\
ProbableCause 1 Page
I t-oJ
System EngineControlModule(ECM)/Powertrain ControtModule(PCM) Fuelpressure PGM-Fl main relay lgnitionsystem Crankshaft Position/Top DeadCenter/Cylinder Position sensorcircuit, CKFsensor circuit Intake Temperature Air {lAT)sensorcircuit ldle Air ControlValve(IACV) ldle speedadjustment Throttle body Thronlecable (MAP)sensor ManifoldAbsolutePressure (TP)sensor ThrottlePosition
1' t - 1 5 0 ,s 1 1
1I -157
4
Section 23 1 1 - 1 11 1 7 0,
6 7 8
9
11-73 11-'t26,128 11-141, 142, 143,144 1t-164 11-162 11-67 1' t-79 1 11 1 3
11 -1 3 4
10 't1
12
IJ
14
(BARO) pressure Barometric sensor Section 1'l-139 A/T gear posilionsignal(seepage'1'l-137) clutchswitchsignal 14, or Brake switchsignal AirCleaner Intake pipe air 1l-168 11-181 Three Way CatalyticConverter(TWC) Evaporative emission(EVAP) control
Contaminated fuel
11-162 11 18 19
20
11-4 6
ECM/FCMData variousdata can be By connecting OBD ll scantool or the HondaPGM Testerto the 16Pdata link connector(DLC), the practice. The retrieved from the ECM/PCM. itemslistedin the table belowconformto the SAErecommended by The HondaPGMTesteralso readsdatabevondthat recommended SAE. of failuresor engineproblems. this Understanding datawill helpto find the causes intermittent NOTE: and a The "operating valuesand may be differentdepending the environment on values" given below are approximate vehicle. the individual "at in . Unlessnotedotherwise, idle speed" meansidlingwith the enginecompletely warmed up, A//T pe5ition@ or @, turnedoif. M/T in neutral, and the A/Cand all accessories Data Diagnostic TroubleCode (DTC) Description Operating Value FreezeData
lf no problemis detected, lf the Ecl\4 a /PcM derects problem,it will storeit as a four numbers. thereis no output. of code consisting one letterand an code (P0xxx) Depending the problem, SAE-detined on code (P1xxx) be outputto the will or a Honda-defined rester. The ECM/PCM computes enginespeedfrom the signals sentfrom the Crankshaft Position sensor. This data is usedfor determining time and amountot the fuel injection. pulsesignals from the Vehicle The EClvl/PcM converts SoeedSensor(VSS) into speeddata
Nearly the same as tachometer indication.
YES
E n g i n eS p e e d
YES
Vehicle Speed
Nearlythe sameas speedometer indication With enginestopped: Nearlythe sameas atmosphencpressure At idle speed: 24 - 37 kPa(180- 280 0 m m H g ,7 . 1- ' 1 1 . i n H g ) With cold engine: Sameas ambienttemperatureand IAT With enginewarmedup: '176 194.F(80- 90"C) 0 . 0- 1 . 2 5 V At idle speed: a b o u t0 . 1- 0 . 9V
YES
pressure Manifold The absolute causedin the intakemanifoldby Absolute engineload and speed. (MAP) Pressure
YES
into voltEngineCoolant The ECTsensorconvenscoolanttemperature The Temperature age and signals the ECM/PCM. sensoris a thermistor (ECT) changes with coolanttemperawhose internalresistance usesthe voltagesignals from the ture.The ECM/PCM fuel. ECTsensor determine amountof iniected to the Heated OxygenSensor detects oxygencontent the Oxygen The Heated gasand sendsvoltagesignals the to Sensor(H02S) in the exhaust (Primary, con ECM/PCM. Basedon thesesignals, ECM/PCM the Sensor ) 1 trols the airfuel ratio.Whenthe oxygencontentis high (Secondary {thatis. when the ratiois leaner than the stoichiometric Sensor2) ratio), voltagesignalis lower. the Whenthe oxygencontentis low (thatis, when the ratio is richerthan the stoichiometric ratio), voltagesignal the is hioher.
YES
NO ( S e n s o1 ) r
(cont'd)
11-47
Troubleshooting
(cont'dl Procedures Troubleshooting
Data HO2S Feedback LoopStatus Description as "open" or "closed". Loopstatusis indicated deteroutput,the ECM/PCM Basedon the HO2S Closed: the minesthe airlfuelratioand controls amountof injected fuel. refersto sigOpen:lgnoringHO2Soutput,the ECM/PCM to nalsfrom the TP,MAP,and ECTsensors controlthe fuel. amountol iniected Operating Value closed At idle speed: FreezeData
YES
Shon Term F u e lT r i m
! 20% coefficient correcting for the The airfiuelratiocorrection is fuel when HO2Sfeedback in the amountof iniected Whenthe signalfrom the HO2Sis closedloop status. weak,shortterm fuel trim getshigher,and the ECM/PCM fuel.The airlfuelratio increases amountot injected the gets richer, gradually causinga higherHO2Soutput. and Consequently, shortterm lueltrim is lowered, the fuel. reduces amountot injected the the ECM/PCM This cvclekeeDs airlfuelratiocloseto the stoichiothe metricratiowhen in closedloop status.
YES
LongTerm FuelTrim
from shortterm fuel Longterm luel trim is computed in changes occurring the fuel supply trim and indicates systemover a long period. r o l f l o n gt e r mf u e lt r i m i s h i g h e t h a n 1 . 0 0t,h e a m o u n t f lf injected fuel must be increased. it is lowerthan 1.00, fuel must be reduced. the amountof injected into voltintakeair temperature The IATsensorconverts When intakeair temperaage and signals ECM/PCM. the of ture is low, the internalresistance the sensor increases, the voltagesignalis higher. and pedalposition, opening the Basedon the accelerator anqleof the throttlevalveis indicated. angleset by the lgnitiontiming is the ignitionadvance matches ignitiontiming to the ECM/PCM. ECM/PCM The drivingconditions. from the MAP data. CLVis the engineload calculated
+ 200/o
YES
InlakeAir Temperature (IAT) Throttle Position lgnition Timing Calculated LoadValue (CLV)
With cold engine: Sameas ambienttemperatureand ECT At idle speed: approx.10 % At idle speed:12't 2"
E' I UL Wtrn rne 5L5 Ser-
YES
YES
NO
viceconnector connected. At idle speed: 15-35% At 2,500rpm with no load: 12 - 30%
YES
Engine/Powertrain ControlModule Terminal Arrangement

ECM/PCMCONNECTOR {32P) A
1 2 a I N J 4 INJ3 INJ2 I N J l 1 2 't3 1 4 1 5
ACV
1 6 1 7 1 8 1 9 20 PCS FLR acc MIL AtTC tcM 25 21 2a E 30 vsv SLU
LG1 22 LG2
10 PGl
PG2
t1
IGPl
21 IGP2
Wiresideof femaleterminals
ECM/PCMCONNECTOR {32P1 A
NOTE:Standard battery voltage t s

Sig.al
YEL
2 3
BLU FED
88N
l N J 4 { N o a F U E LI N J E C T O B } l N J 3 ( N o . 3 F U E LI N J C T O R I lNJ2(No,2 fUEL INJECTOR) I N J I 1 N o .1 F U E L I N J E C T O F ) (SECONOARY SO2SHTC HEATED OXYGENSENSOFHEATER CON TSOL) PO2SHTC IPSIMARYHEATED OXYGENSENSOEHEATER CONTROL) E S O LI E G FC O N T R O L SOLENOIO ALVEI V E EGR WS (WC SOIENOID VALVE) L G 1( L O G I C 8 O U N D ) G PG1 (POWER GBOUNO) IGPl (POWER SOURCE) IACV(IDLEAIR CONTAOLVALVE) IACV N lIDLE AI8 CONTROL VALVE NEGATIVESID) IACV P (IDTEAIR CONTFOL VALVE POSITIVE SIDE) PCS {EVAPPUsGE CONTROL SOLENOIDVALVE) F L R{ F U E L U M PF E L A Y ) P A C C( A , / C L U T C H E L A Y ) C F MILlMALFUNCTION INDICATOR ALTC (ALTEFNATOB CONTNOL)
D r i v e s N o .4 i u e l n i e c r o r . Drives No. 2 fuel injecto.. O n v e sN o . 1 l u e l ' n t e c t o r Drives secondary hated oxygen sensor
W i t h e n g i n ef u n n n 9 : p u l s e s
BLI(WHT
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 y o t a g e v 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 : u t y c o n r f o t t e d d Wirh ignitio. swhch ON (ll): batery vohage 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 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 up engine: duty controlled W i l h E G Rn o r o p e r a t i n q : 0 V W i l l - F C F o p e r a f i n g u ' , n 9 d r ' v , rg w r h t u l l y w d n p d d ! p e n 9 r n ed u l y c o n t r o l l e d . r W l h E G Rn o t o p e r a t i n q : 0 V 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 Wilh enqine at hlqh enqine sD6ed:batre.vvokaoe L e s sl h a n I 0 V a t a r lr i m e s Wlth ignit on swilch ON (ll): batrerv vo taqe w i t h r g n n i o n w h c h O F F : 0V s W i l h e n g i n er u . n i n g : p u l s e s
BLK^/VHT
Drives prihary heated orygen s6nsor
Orives EGF conto solenoid valve.
FED*3
GBN/YEL 9 IO
ll
Drives VTECsoleno d valve. Ground for lhe ECi!4/PCM conlrolclrcuit. p G ' o u n d l o r t h e E C M / P C M o w e r( t r c ! f . Pow6rsource tor the ECM/PCMco.trol
BRN/BLK BLK
YEUBLK
SLVALU ORN
12"
Drives lhe IAC valve lnegai ve side). D ' i v e sI A Cv a l v el p o s r t r v r d e ) . s 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 (64'Cl: battery vohage Wilh engine running eng ne cocrant above 154'F {68'C): 0 V 0 v for ndo *(onds dier rJ .{ g 'gr't on sw ! h oN w r t h c o m p r e s s oO N : 0 V r Wth compressorOFF: battery vohaoe W i i h M l L r u r n e dO N : 0 V W i l h M l L t u r n e dO F F : b a t t e r y o h a s e v Wilh lully warmed up engine running: b.ftery voltsge Du.ingdrivingwilhsmallelectrcalload:0V With ignition switch ON (ll):baltery voltage 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 g n o L o s s t h a n. 0 V a r a l l i i m o s l Wirh igniiion switch ON (lll: banery vohage W i t h i 9 n i t i o n w i t c hO F F : 0V s W i t h i g n i t i o n w i t c hO N ( l l ) : a b o L t V s 5 W i t h l g n i l i o ns w i l c h O F F : 0V Wiih radiato. f8n running: 0 V Wirh radialor tan stopped: banery vohaoe 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 y o t r a g e v With ignilron swilch ON lll): battery vohage W t h i s n t i o n s w i i c hO N { 1 1 ) a nb r a ( e p e d a l d dpressed:batieryvohaae
BLVBLU
15 16 17 18 FEOTYEL GRNAEL BLK/FED G8N/ORN WHI/GFN
Drvestue pump relay. D r i v e s A , / Cl u l c h . e t a y . c
Sends alle.nator cohtrol signa
20 22 23
YEVGRN BRN/ALK BLX YE|JLK
rclvr 0GNrI|oNcoNTfloL t!'IODULE)

L G 2( L O G i C F O U N D ) G PG2IPOWER FOUND) G I G P 2( P O W E R O U F C E ) S ( VREF REFENENCE TTAGE) VO FANC iRAOIATOSFAN CONTFOL) 2WBS (EVAPBYPASS SOIENOID VALVE) VSV {EVAPCONTBOL CANISTEB VENI SHUT VATVE) (lNTEELOCK S!U CONTROL UNIT) Ground fof lhe EC^4/PCM conrrolcncuil p G r o u n df o r l h e E C M / P C M o w e f c i r c u i t . Powe. source fof rhe ECM/PCMcont.ol Provides rslerencevo ltage to TCM. Orives radiarorfan relay. Drives EVAP bypass sol6nord valve Drives EVAP control canisrer v6nish!t Derecb lnter ock convol unit sisnal.
25'3 27'r
WHf/BED
GRN 8LU
*2: A/T (D16\./. Dl6YSensine) * 3 : C W ( 0 1 6 Y 5e n g i n e ) 14: A"/Tand D16Y7 ensine '5:Except A/T and 016\./ engine 16: AtlTlD16Y8 engine) r T r C V T( O 1 6 Y 5 n q i n e ) n d D l 6 Y B e n s i n e o a '8:'96 016Y8ensine {oupel. 97 Dl6YSensine (coupe:all modols, sd.niKl '98 D'I6Y5 sngin,'98 016Y8 engine
r10:M/T(D16Y5 ngine) e . 1 1 : E x c e p lM / I ( 0 1 6 Y 5 n g i n e ) e i 1 2 : O 1 6 Y 5D 1 6 Y 8 n g i n e , e ' 1 5 : ' 9 t 0 1 6 Y 7e n g i n e( c o u p : L m o d e s e d a n r L K K lLXl modet), , '98 D16Y7 engine
{cont'd)
moder),
11-49
Troubleshooting
(cont'dl Engine/Powertrain ControlModuleTerminalArrangement
Wirg sideof female terminals
PCMCONNECTOR {25P)*' B
Telminal numoer
1
NOTE Standard battery voltage is l2 :

Terminsl De3cription Ground linear tor solenoid valve. Drives linearsolenoid valve. DrivesshiftcontrolsolenoidvalveA.
Signal
Wire color WHT
RED
BLU/YEL
LS- (LINEAR SOLENOID VALVE_ SIDE) LS+(LINEAR SOLENOID VALVE SIDE) + SHA(SHIFT CONTROL SOLENOID VALVE A}
With ignitionswitchON (ll):pulses With ignitionswitchON (ll):pulses With enginerunningin 2nd,3rdgears: batteryvoltage With enginerunningin 1st,4thgears: about0 V With lock-upON: batteryvoltage With lock-up OFF: V 0 With lock-up ON:battery voltage With lock-up OFF:0V InEposition:0V In any otherposition: battery voltaqe Wath enginerunningin 1st,2nd: baftery voltage With enginerunningin 3rd,4th:about0 V With ignitionswitchON (ll)and brake pedaldepressed: V 0 With D. indicator lighrrurnedON:batter), voltage With E indicator lightturnedOFF: V O
4 5 8 1t
GRN/BLK YEL PNK GRNA/VHT
LCB (LOCK.UP CONTROL SOLENOID VALVE B) LCA (LOCK.UP CONTROL SOLENOID VALVE A) ATPD3IA,/T GEARPOSITIONSWITCH) SHB(SHIFT CONTROL SOLENOID VALVE B)
Driveslock-rrp control solenoid valveBDriveslock-up controlsolenoid gear positionswitch Detects A,/T srgnat.
Drives shift control solenoid valve 8.
(INTERLOCK CONWHT/RED SLU GRN/BLK

14
Drives interlock controlunit. Drives indicator D4 light.
TROLUNIT} D4 IND(D4INDICATOR LIGHT)
WHT RED
WHT
17 22 8LU GRN BLU 24 YEL
NMSG(MAINSHAFT Groundfor mainshaftsoeedsensor. SPEED SENSOR GROUND) NM {MAINSHAFT SPEED Detectsmainshaftspeedsensor SENSOR) srgnal, ATPR{!VT GEARPOSIgear position switch DetectsAy'T TIONSWITCH} signal ATP2(A"/T gear position switch GEARPOSIDetectsAy'T TION SWITCH} srgnal, NCSG{COUNTERSHAFT Ground lor countershattspeed SPEED SENSOR GROUND) sensor. NC {COUNTERSHAFT Detectscountershaftspeedsensor SPEED SENSOR} srgnal. ATPD4{A"/T GEARPOSITION SWITCH) ATPNPiAlT GEAFPOSITIONSWITCH)
pulses With enginerunning: InEposition:oV In any otherposition: voltage battery InAposition:0V In any otherposition: battery voltage
With ignitionswitchON {ll),and front pulses wheelsrotating:
gear position switch DetoctsA./T In El position: V O srgnal. In any otherposition: V 5 gear position switch DetectsA.rT ln m orE position:V O 25 LT GRN srgnal. position: ln anyother battery voltage *1: USA model '9: 016Y5engine *2: A,/T{D16Yr,Dl6Y8 engine) *10:M/T lD16Y5 engine) *3: CVT(D16Y5 *11:Except engine) M/T (D16Y5 engine) *4: A*/T * 12:D16Y5, and Dl6Yl engine D'|6Y8 engine *5: ExceptA,rf and 016Y, ongine *13rDl6Y8engine *6r IVT {D16Y8ngine} i14: Dl6Y7engine *7: CW (D16Y5 *15:'97016Y7engine{coupe: model,sedan: (LX)model), engine) and D16Y8 engine KL KL '98D16Y7 * 8 : ' 9 6 D 1 6 Y 8 n o i n 6( c o u p e ) , ' 9 7 1 6 Y 8 e D ehgine {coupe:all engine '98 D16Y8 models. sedan:KL model),'98 D16Y5engine, on9ine
11 - 5 0
ECM/PCMCONNECTOR 131PI C
1 2 CKfP CKPP TIrcP
11
CKFM
12
13 21
ACS sTs scs 1 4 15 16 1 7 18 vTM ALTf vss 25 Wire sideof femaleterminals
9 10 TMA vBu
z)
lP+
30 TMB
ECM/PCM CONNECTOR {31PI C

Torminal numbot
l
NOTE:Standard batteryvoltageis 12 V,
Description Detects CKF sensor. Detects CKP sensor. Signrl W i t h e n g i n er u n n i n g :p u l s e s
T6rminal
2 3
5
6
BLU/RED BLU
GRN
CKFP{CKFSENSORP SIDE} ( CKPP CKP ENSOR SIDE) S P
pulses Withongine running:

With engine running: prils6s
YEL
BLU/RED BLU/ORN BRN
TDCP SENSOR SIDE} Detects P {TOC TDCsensor, CYPP {CYP SENSORSIDE) DetectsCYP snsor. P
ACS (P,/C SWITCHSIGNAL) STS {STARTER SWITCH SIGNAL) E S C S( S E R V I CC H E C K SIGNAL) ( K-LINE DLC) OetectsAy'C switch signal. Detects starter switch signal, Detectsservicecheck connector signal ( t h es i g n a l c a u s i n g D T Ci n d i c a t i o n ) a S e n d sa n d r e c e r v e s c a nt o o l s i g n a t , s D a t ac o m m u n i c a t i o n i t h T C M : E C M w c o n t r o l d a t ao u t p u t
pulss Withengine running:

With,!y'C switch ON: 0 V With ,y'C switch OFF: battery voltage With starter switch ON (lll): battery vollage With starler switch OFF: 0 V With the connector connected: 0 V With the connector disconn6ct6d: 5 V 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 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 8.ttery voltage at alltimos
1 8
LT8LU GRY
10
t1
VBU(VOLTAGE BACK UP) WHT/BLU WHT/RED

CKFI\4 {CKF SENSOB M SIDE) (CKPSENSORM CKPI\4 SIOE}
Power sourc6 for the ECM/PCM control circuit. Power source for the DTC memory G r o u n df o r C K Fs e n s o rs i g n a l . G r o u n df o r C K Ps s n s o rs i g n a l . G r o u n df o . T D C s e n s o rs i g n a l . G r o u n df o r C Y Ps e n s o rs i g n a l . DetectsVTEC pressure switch signal.
RED
14 BLK BLU/8LK ,I6
TDCM(TDCSENSOR M SIDE)
C Y P M( C K PS E N S O R V I SIDE)
VTM {VTEC PRESSURE
swrTcH)
With engine at low6n9in6 spdr0 V With engineat high enginspeed:batteryvoltEge At idle with steering wheel in sk6ight ahaad p o s i t i o n i 0V At rdle with st6ring whsel at full lock: battery voltage
GRN
( P S P S W P / SO I L P R E S S U R E Detects PSPswitch signal. SWITCH)
17 18
23'to
WHT/RED BLU/WHT BLK RED
ALTF(ALTERNATOE FR SIGNAL)
VSS(VEHICLEPEED EN. S S
Detects alternator FR signal,
Withfullywarmed 6ngine up running: 0V- battery voltage on {depsnding electrical

load)
soR)
DetectsVSS signal. C o n t r o l sH O 2 Sp u m p c e l l . R e f e r e n c e o l t a g es u p p l y , v DetectsVS cell voltage. gear position switch signal. Detectspy'T Detects clutch switch signal. D a t ac o m m u n i c a t i o n i t h T C M : w E C Mc o n t r o ld a t a i n p u t
l P +( H O 2 SP U M PC E L L+ ) IP-, VS- {HO2SCOMMON)
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 rotating:cycles0V-5V 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 With fully warmed up 6ngin6 at idle: about2.6-2.8 V 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
25* ta
LTGRN*3
29
BED*r0
VS+(VSCELL VOLTA6E) ATPNP GEAR POSI. {4,/T TroNswrTcH)

CLSW (CLUTCHSWITCH) TM8
InE orE position:0 V ln any otherposition: voltage battery With clutchpedalreleasd: about5 V With clutch oedaldeoressed: V 0
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
30
PNK
*1: USAmodl +2rAlT (Dl6Yl,D16Y8 engine) '3: CVT(D16Y5 engine) '4: A,/T and D16Y7 engine '5: Except and Dl6Yl engine A,/T *6: Ay'T (D16YB engine) *7: CVT(016Y5 engine)and D16YB engine *8:'96 D16Y8 (coupel,'97 (coupe: models, engine D16Y8 engine all sedan: model),'98 KL D16Y5 engine, D16YB 98 ongine
* 9 : D 1 6 Y 5e n g i n e r10: M/T {D16Y5 ngine) e * 1 1 : E x c e p tl v l / T( 1 6 Y 5e n g i n e ) ' 1 2 : D 1 6 Y 5 , 1 6 Y 8e n g i n e D * 1 3 : D 1 6 Y ge n g i n e '14: O16Y7 ngine e * 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 ) , '98D16Y7 engine
{cont'd)
11-51
Troubleshooting
Engine/Powertrain (cont'dl ControlModuleTerminal Arrangement
ECM/PCMCONNECTOR {16P) O
BXSW
lo
ECI
a
KS
13 11
15 EL
Wire sideof femaleterminals
ECM/PCM CONNECTOR (16P} D NOTE:Standard batteryvoltageis 12 V. Terminal

I
Wire RED/BLK
T.minal
Description
Signal
2 3
IPS (THROTTLE POSITION Detects sensor TP signal. SENSOR) (ENGINE COOLANT Detects ECTsensor signal. RED^^/HT ECT TEMPEFATURE SENSOB MAP (MANIFOLD ABSODetects MAPsensor signal. RED/GN B LUTEPRESSURE SENSOR) YEURED
With throttlefully open:about4.8V With throftle tully closed: about0.5V With ignition switchON(U): about0.1- 4.8V (depending engine on coolant temperature) With ignitionswitchON(ll): about3 V At idle:about1.0V (dopending enginespeed) on
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
vccl (SENSOR VOLTAGE) Powersource MAPsensor. for

EKSW(BRAKE SWTCH) Detects brakeswitchsignal. Detects signal. KS Detectsprimary heatedoxygen sensor 1) {sensor signal. Detects LABEL resistance. Detects sensor IAT signal. Detects EGFvalvelift sensor sional.
P r o v i d e ss e n s o r v o l t a g e ,
5
6*?
GRNîVHT
With brakeDedalreleased: V 0 With brakepedaldepressed: batteryvoltage With engineknocking: pulses With thronlefully opened from idlewith fully warmedup engine: above0.6V Withthrottlequicklv closed: below0.4V With enginerunning: about0.3- 4.9V With ignition switchON {ll):about0.14.8V (depending intake on airtemperature) At idlewithoutvacuum: about1.2V With 27 kPa(200mmHg,8 in. Hg):about4.3V With ignitionswitchON(ll): about5 V With ignitionswitchOFF: V 0
L e s s t h a n1 . 0V a t a l l t i m e s
RED/BLU KS (KNOCK SENSOR)

PH02S(PRIMARY HEAT ED OXYGEN SENSOR, S E N S O R) 1 LABEL IAT(INTAKE TEM, AIR BED/YEL PERATURE SENSOR} (EGR VALVE LIFT WHT/8LK EGRL SENSOR} (SENSOR VCC2 VOLTAGE)
8 9* 10
ll
YEL/BLU
12
(SENSOR GROUNDi (SENSOR GRNAr'VHT SG1 GROUND) (SECONDARY SHO2SG GRN/8LK+I' HEATED OXYGEN SEN. REDt/EL*14 SOF, SENSOR GROUND) 2 GRN/BLK
ground. Sensor Groundfor MAPsensor. Ground for secondaryheatedoxygen sensor 2), {sensor Detectssecondaryheatedoxygen sensor(sensor signal. 2)
Less than 1.0V at alltimes
14
(SECONDARY SHO2S WHT/RED HEATED OXYGEN SENSOR, SENSOR 2)

LT GRN
With throttle fully openedfrom idle with tully warmedup engine: above0.6V With thronlequicklv closed: below0.4V With fuel fill caDooend:about 2.5 V With parking lightsturnedon at idle:about With low beamheadlights turnedon at i d l e : b o u t1 . 5 - 2 . 5V a
(FUEL PTANK TANKPRES- Detects tankoressure fuel sensor, SURE SENSOR) EL (ELD) Detects ELDsignal.
16*,
GBN/RED
*1: USA model *2: IVT {D16Y7, D16Y8ensine) *3: CW (D16Y5 engine) *4: ,VTand D16Y7 6ngine +5:ExceptAy'T and D16W engine *6: A/T 1D16Y8 engine) *7: CW (O16Y5 engine) and 016Y8engine 1 8 : ' 9 6 D 1 6 Y 8 n g i n e( c o u p e ) , ' 9 7 1 6 Y 8 n g i n e( c o u p o : l l e D e a '98 D16Y8 m o d e l s , e d a n : L m o d e l ) , ' 9 8D 1 6 Y 5 n g i n e , s K engrne
r9: D16Y5 engine * 10rM/T (D16Y5 engine) *11:Excopt M/T (Dl6Y5engine) *12:D16Y5, D16Y8 engine *13:D16Y8 engane '14: Dl6Y7engine *15:'97 016Y7engine{coupe: model,sedan: (LX) KL KL modet), '98D16Y7 engine:
11-52
Diagnostic TroubleCode(DTC) Chart

DTC (MlLindicationr)
P0106*15 (5)
Dtection ltem ManifoldAbsolute Pressure C:rcuit Range/Performance Problem ManifoldAbsolute Pressure Circuit Low Input ManifoldAbsolute Pressure Circuit H i g hI n p u t Intake Temperature Air Circuit Range/Performance Problem Intake Air Temperature Circuit Low Input lntakeAir Temperature Circuit H i g hI n p u t Engine oolant C Temperature Circuit Range/Performance Problem EngineCoolant Temperature Circuit Low Input Engine oolant C Temperature Circuit H i g hI n p u t ThrottlePosition Circuit Low Input ThrottlePosition Circuit High Input PrimaryHeated OxygenSensor CircuitLow Voltage ( S e n s o1 ) r PrimaryHeated OxygenSensor CircuitHighVoltage (Sensor 1) PrimaryHeated OxygenSensor Slow Besponse {SensorI ) PrimaryHeated Oxygen SensorHealer CircuitMalfunction (Sensor'l)
ProbableCause
. Vacuum connection . MAP sensor
Page
1167
P0'107
(3)
Openor short in MAP sensorcircuit MAP sensor ECMiPCt\,4 TCM*I Open in MAP sensorcircuit MAP sensor ECM/PCM . IAT sensor
1169
P0108
(3)
11-71
1 { P 0 11 1 + r ,*4 . 5 1 0 )
11-73 Short in IAT sensorcircuit IAT sensor ECM/PCM Openin IATsensorcircuit IAT sensor ECM/PCM . ECTsensor . Coolingsystem Shortin ECTsensorcircuit ECTsensor ECM/PCM Open in ECTsensorcircuit ECTsensor ECM/PCM Openor shon in TP sensorcircuit TP sensor ECM/PCM TCM*1 Openin TP sensorcircuit TP sensor ECMiPCM Short in PrimaryHO2S{Sensorl)circuit PrimaryHO2S(Sensor 1) Fuelsupplysystem ECM/PCM Openin PrimaryHO2S(Sensor circuit 1) PrimaryHO2S(Sensor 1) ECtVr/PCM . PrimaryHO2S(Sensorl ) ' E x h a u s ts y s t e m . Openor short in PrimaryHO2S ( S e n s o1 ) h e a t e c i r c u i t r r . ECM
P01't2
(10)
1l-74
P01' t3
(10)
11-75
P0116
(86)
11-76
P0117
(6)
11-17
P0118
(6)
l1-78
P0'122
(71
11-79
P0123
t7l
I 1-81
P0131*'
(1)
11-84
PO132+'
(1)
11-86
P0133*'
(61)
11-8J
P0135*'
(41)
11,98
*: TheseDTCS will be indicated the blinkingof the Malfunction by IndicatorLamp (MlL)with the SCSserviceconnector connected * 1 : D l 6 Y 5e n g i n e C V T ) ( (cont'd) *2: Except Dl6Y5 engine(M/T) '97 model *14: * 1 5 : ' 9 6m o d e l *16:'98 model
11 - 5 3
Troubleshooting
TroubleCode(DTC) Diagnostic Chaft (cont'd)
DTC {MlL indication)
P0137 (63) Detection ltem
Probable Cause (Sensor circuit HO2S 2) Shortin Secondary HO2S 2) Secondary lSensor ECM/PCM Openin Secondary HO2S 2)circuit iSensor (Sensor HO2S Secondary 2) ECt\4/PCM
SecondaryH02S (Sensor2)
Page 11-95
Heated Oxygen Sensor Secondary Circuit LowVoltage (Sensor 2)

SecondaryHeatedOxygenSensor CircuitHigh Voltage (Sensor2)
P0138 P0139
(63) (63)
11-96
Heated Secondary Oxygen Sensor SlowResponse (Sensor 2)

SecondaryHeatedOxygen Sensor Heater CircuitMalfunction (Sensor2) SystemToo Lean
11-97 Open or short in SecondaryHO25 (Sensor 2) heatercircuit ECM/PCM Fuel supply system PrimaryH02S (Sensor1) lvlAPsensor fuel Contaminated Valveclearance Exhaustleakage Fuel supply system PrimaryHO2S(sensor1) MAP sensor Contaminated fuel Valve clearance
P0141
(65)
1 19 8
P0171
{45)
11-103
System Too Rich P0172 (45)
11,103
P0300*16 and someof P0301 P0302 P0303 l 7 3 l P0304 \741 P0301 P0302 P0303 P0304 P0325'3 P0335 P0336
Random Misfire
l#\
lgnition system Fuelsupply system MAPsensor EGR system IACvalve Contaminated fuel Lack fuel of
Fuel Injector Fuel Injectorcircuil lgnitionsystem Low compressron Valveclearance Open or short in KnockSensor(KS)circuit KnockSensor(KS) ECM/PCM Crankshaft PositionSensor PositionSensorcircuit Crankshaft ECM/PCM
11 -1 0 8
tr\
173 | \741
(23)
(4)
- Cylinder1 - Cylinder2 - Cylinder3 - Cylinder4 Misfire Detected KnockSensor(KS)Circuit Maltunction
11-105
11,109
{4)
Crankshaft Position Sensor Circuit Mallunction Position Crankshaft Sensor Range/Performance

ExhaustGas Recirculation lnsufficient Flow Detected
11-110
'1 -110 1
. Crankshaft PositionSensor . Timingbeltskipped teeth

. E G Rl i n e . Three Way Catalytic converter . SecondaryH02S
P0401.1
(80)
11-170
Catalyst System Efficiency Below Threshold *3r Dl6Y5engine (CVT) Dl6Y8engine and *4: D16Y5 engine *16:'98 odel m P0420 (67)
11-168
11-54
DTC (MlLindicationl
Detection ltem Evaporative EmissionControl System lnsufficient PurgeFlow
Probable Cause EVAPPurgeControlSolenoidValve Open or short in EVAPPurgeControl SolenoidValvecircuit EVAPControlCanister Vacuum lines ECM/PCM
Page
P0441*5
{92)
11-'190
P0452*6
(91)
FuelTank Pressure Sensor Circuit Low Input

FuelTank Pressure SensorCircuit H i g hI n p u t
P0453*6
(91)
Shortin Fuel TankPressure Sensor circuit Fuel TankPressure Sensor ECM/PCIV Openin Ful TankPressure Sensor cjrcuit Fuel TankPressure Sonsor ECM/PCM
VehicleSpeed Sensor VehicleSpeed Sensorcircuit ECM
11 -1 8 1
11 -1 8 3
P0500.1,
(17)
P0501*13 (17) P0505 (14)
Vehjcle Speed Sensor Circuit lvlalfunction Vehicle Speed Sensor Circuit Range/Performance
ldle ControlSystem Malfunction Automatic Transaxle
11-112
Vehicle Speed Sensor Vehicle Speed Sensor circuit PCM

. IAC valve . Throttle Body
1 1112 11-124
P0700*E and some of P0715 P0720 (70)* P0730 P0740 P0753 P0758 P0700*1 and {70)* P0725
Section 14
AutomaticTransaxle Section 14
P1107
(13)
Barometric Pressure Circuit Range/Performance Problem Barometric Pressure Circuit LowInput

Earometric Pressure Circuit H i g hI n p u t
. bCM/PCM (tsarosensorl
11 1'13
. ECM/PCM {8aro sensor}
'
'| 14
. ECM/PCM (Barosensor) 11-1't4
P1108
(13)
Pl121+M.+16 17) P 1 1 2 2 * 1 4* 1 5 l 7 l * P 1 1 2 8 * 1 4 '.6 ( 5 1
Throttle Position Lower Than Expected

ThrottlePositionHigherThan Expected ManifoldAbsolutePressure Lower Than Expected Manilold AbsolutePressure HigherThan Expected
. TPsensor . TPsensor
. MAP sensor . MAP sensor
11-82
11-83 11-72
11-72
*: The indicatorlight and the MallunctionIndicatorLamp (MlL) may come on simultaneously. LD.j *1: D16Y5engine (CVT) *5j '96 D16Y5engine,D16Y7engine,Dt6Y8 engine (sedanl,,97 O1dy5engine,O16y7engine (coupe:KA, KC models,sedan:KA, KC,KL (DX) models,hatchback: models),D16yg engine (sedan:KA;KC models) a *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
Chart(cont'dl Trouble Code(DTGI Diagnostic
DTC {MlLindication}
P1162*1 (48) Detection ltem PrimaryHeatedOxygenSensor (Senso1)Circuit r Mal{unction PrimaryHeatedOxygenSensor (Senso1)Circuit r Slow Response Probable Cause
Page
'1188
. Openor shortin Primary HO2S lsensor1 . Primary (Sensor l) HO2S

PrimaryHO25 (Sensor1)
P1163*'
(61)
11-87
P1164*'
i61)
Primary Heated Oxygen Sensor 'l (Sensor) Circuit Range/ Problem Performance
PrimaryHeatedOxygenSensor (Sensor'1)CircuitRange/ Prob em Performance PrimaryHeatedOxygenSensor (Sensor1) HeaterSystem Electrical Problem PrimaryHeatedOxygen Sensor (Sensor1) HeaterSystem Malfunction PrimaryHeatedOxygen Sensor (Sensor )LABEL owInput 1 L PrimaryHeatedOxygen Sensor 1 H { S e n s o r ) L A B E L i g hI n p u t VTECSystem Malfunction
. Primary (Sensor 1) HO2S

11-92 PrimaryHO2S(Sensor1) 11-92 Open or short in PrimaryHO2S(Sensor'l) heatercircuit PrimaryHO2S(Sensor1| ECM/PClvl
P1165*?
(61)
P1166*?
(41)
11-100
P1167*1
(41)
(Sensor liVS+ circuit in HO2S Open Primary (Sensor Heater 1) Primary HO2S (Sensor HO2S 1i Primary
. Shon in PrimaryHo2S (Sensor1) LABEL carcuit . Open in PrimaryHO2S(Sensor1) LABEL circuit . Short in ground circuit VTECSolenoidValve Open or short in VTECSolenoid Valve circuit v I tL Pressure Swttcn Switch Open or short in VTECPressure crrcurt ECM/PCM Load Detector Electrical Electrical Load Detectorcircuit ECM/PCrvl Load Detector Electrical Electrical Load Detector circuit ECM/PCIV
11-102
P1 1 6 8 * ?
(48)
P1169*7
(48)
'11-94
P1259*3
\22)
Section6
P1297*'
(20)
(20)
P1298*'
Electrical Load DetectorCircuit Low InPut Electrical Load DetectorCircuit H i g hI n p u t R a n d o mM i s f i r e
11-115
11-116
\ 74 l *7: D16Y5engine (M/T) *8: D16Y5,D16Y8engine *9: USA model * 1 4 r' 9 7 m o d e l ' + 1 5 r9 6 m o d e l
and someof P0301 P0302 P0303 P0304
prl
1 7 I1
l73l
lgnition system Fuelsupply system MAPsensor EGR system IACvalve fuel contaminated Lack fuel ol
11 -1 0 8
11 - 5 6
DTC lMlL indicrtionl P1336 P1337

(54)
Detoction hem Crankshaft Speed Fluctuation Sensor Intermift Interruption ent Crankshaft Speed Fluctuation Sensor No Signal . CKFsensor
Probable Cause
Page 11 117
(54)
P1359
P1361
(8)
(8)
Crankshaft Position/Top DeadCenter Sensor Disconnected

Top DeadCenter SensorIntermittent Interruptron Top Dead Center SensorNo Signal CylinderPositionSensor IntermiftentInterruption CylinderPositionSensor No Signal
CKF sensor CKF sensor circuit ECM/PCM CKP/TDC sensor circuit . TDCsensor
11 117
1 11 1 9
1 11 1 0
P1362 P1381 P1382
(8) (91
(9)
TDCsensor TDCsensor circuit ECM/PCM

. CYPsensor
11-110 11-' '10 ] 11 1 1 0
CYP sensor CYP sensor circuit ECM/PCM

F u e lf i l l c a p Vacuum connection Fueltank Fueltank pressure sensor EVAPbypasssolenoidvalve EVAP two way valve EVAPcontrol canistervent shut valve EVAPcontrol canister EVAPpurge control solenoidvalve Vacuum connection EVAPcontrol canister Fueltank pressure sensor EVAPbypasssolenoidvalve EVAP two way valve EVAPcontrol canistervent shut valve FuelTank EVAPpurge control solenoidvalve
Evaporative Emission Cont.ol (FuelTank System Leak Detected Area)

P1456*6 (90)
11-185
Evaporative Emission Control (EVAP SystemLeakDetected Control Canister Area)

P1457+6
(e0)
11,185
*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
Diagnostic TroubleCode(DTC) Chart(cont'dl
DTC lMlLindicationl
Detection ltem EGRValve Lift Insufficient Detected P1491*. l12l Probablc Cause EGRvalve (with lift sensor) EGRvalve lift sensorcircuit EGRcontrol solenoidvalve (4,/T) EGRcontrol solenoidvalve circuit EGRvalve circuit (M/T) ECIV P1498*. \12) EGRValve Lift Sensor High Voltage ldle Air ControlValve CircuitFailLrre ldle Air ControlValve C i r c u iF a i l u r e t EngineControl Module/Powenrain ControlModule lnternal (30) TMA,/TMB Sisnal Line Failure AutomaticTransaxle EGRvalve lwith lift sensor) EGRvalve lift sensorcircuit ECt\4 IAC valve IAC valve circuit ECM 11 - 1 7 6
Pags
11-171
P1508*'0
(14)
11-126
P1s09*11 114)
Open shon in IACvalvecircuit or IACvalve ECM/PCt\,,| . ECM/PCM
11'128
P1607
P1655*1 P1705 P1706 P1 7 5 3 P1758 P1768 P1785 P1790 P1791 P1793 P1870 P1873 P1879 P1885 P1886 P1888 P1890 P1891
11-120 Open or short in TMA/TMBcircuit 11-121
(70)*
Section14
*: The[D!] indicator lightandthe Mallunction Indicator Lamp(MlL]maycomeon simultaneously. *1: D'16Y5 (CVT) engine *4: D16Y5 engine 1N4/T) *10:Except andD'16Y7 A/T engine *11:A,/T D16Y7 and engine
11 - 5 8
How to ReadFlowcharts
A flowchartis designed be usedfrom startto final repair.lt's likea map showingyou the shortestdistance. beware: to But lf you go off the "map" anywhere but a "stop" symbol,you can easilyget lost.
ISTARN
{boldtype)
Describes conditions situation starta troubleshootinq the or to flowchart. Asksyou to do something; performa test.set up a condition etc. Asksyou aboutthe resultof an action,then sendsyou in the appropriate troubleshooting direction. The end of a seriesof actionsand decisions, describes final repairactionand sometimes a directsyou to an earlierpan ot the flowchart confirmyour repair. to
jAcroNl
QE!E]!!,
(bold type) NOTE:
fsro-l
The term "lntermittent Failure"is used in thesecharts.lt simply meansa systemmay have had a failure,but it checks out OK at this time. lf the Malfunction Indicator Lamp {MlL)on the dash does not come on, checkfor poor connectrons or loosewires at all connectors (seeillustration related the circuitthat you are troubleshooting to below). . Most of the troubleshooting flowchartshave you resetthe EngineControlModule (ECM)/Powertrain ControlModule the TroubleCode(DTC). the problemis intermittent {PC[/)and try to duplicate Diagnostic It and you can't duplicate the code,do not continuethoughthe flowchart. do so will only resultin confusion To and, possibly, needlesslv a reDiaced ECM/PCM. o "Open" and "Short" are common electrical terms.An open is a breakin a wire or at a connection. short is an acciA dentalconnection a wire to ground or to anotherwire. In simple electronics, of this usuallymeanssomethingwon't (likeECM'S/PCM'S), can sometimes work at all. In complexelectronics this meansomething works,but not the way it's suoDosed to. .
LOOSE
PGM-FI System
SystemDescription
INPUTS
CKP/TDC/CYP Sensor CKFSensor MAP Sensor ECTSenso. IATSensor TP Sensor EGRValveLiftSensor*1 Primary HO2S Secondary HO2S VSS EARO Sensor ELD*' KS*3 Starter Signal ALT FRSignal Air Conditionjng Signal A,/T GearPosition Signal (lGN.1) Baftery Voltage Srake SwitchSignal PSP SwitchSignal FuelTankPressure Ssnsor*a VTECPressure Switch*t Clutch SwitchSignal*6 Countershaft SpeedSensor*3 Mainshalt SpeedSensor*3
( E N G I N E O N T R OM O D U L EE C M ) i C L (PCM) POWERTRAIN CONTROL MODULE
OUTPUTS
FuelInjectors PGMFl Main Relay {FuelPump) MIL IAC Valve A,/C CompressorClutch Relay Radiator Relay*' Fan Condenser Relay Fan ALT*?
Tl.il g ""d Dr*i";l F*l |.r*a"r. E r""t'.','l" ldb c-o-l*il F,h*J--r---l Fr"*il]
rcM
EVAP PurgeControl Solenoid Primary HO25Heater Secondary H02SHeater EGRControl Solenoid Valve*7 EGRvalve*6 EVAPBypass Solenoid Valve*a EVAPControlCanisterVent Shut VTEC Solenoid Valve*5 DLC Lock-up Control Solenoid Valve*3 ShiftControl Solenoid Valv6*3 Linear Solenoid Valve*3
Effi;r"sc;;il
B""k,up Fr*,or'sl FcM/PcM
'1: D16Y5 engine *2:USAmodel *3rCW (D16Y5 engineland 016Y8 engine *4: '96016Y8 (coupe: models, engine D16Y7 engine KL sedan: {LX) KL model),'97 D16Y8 engine all sedan: KL {coupe},'97 {coupe: model, model).'98'all models 15:Dl6Y5, l6Y8 D engine *6:M/T(016Y5 engine) *7:CVT (D16Y5 engine) *8:A/T(D16Y7, D16Y8 ensine) *9:'96 Dl6Y5 (sedan),'97 (coupe: KCmodels, engine,'96 D16Y7 engine,'96 D16Y8 engine D16Y5 engine,'97 D16Y7 engine KA, sedan: (sedan: KCmodels) KA,KC, (LX) KL models, hatchback: models),'97 all D16Y8 engine KA, PGM-FISystem The PGM-Fi systemon this model is a sequential multiportfuel injection system. Fuol inisstor Timing and Duration The ECM/PCM containsmemories the basicdischarge for durationsat variousenginespeedsand manifoldair llow rates. The basicdischarge duration, afterbeing readout from the memory,is further modifiedby signalssentfrom varioussensorsto obtainthe final discharge duration. ldlo Air Control ldle Air ControlValve(lACValve) Whenthe engineis cold,the Ay'C compressor on, the transmission in gear,the brakepedalis depressed, P/Sload is is the is high,or the alternator charging, ECM/PCM is the controlscurrentto the IACValveto maintain correctidle speed. the lgnition Timing Co||trol . The ECM/PCM contains memorieslor basic ignition timing at various engine speedsand manifold air flow rates. lgnitiontiming is also adjusted enginecoolanttemperature. for *3 . A knockcontrolsystemwas adopted which setsthe idealignitiontimingfor the octaneratingof the gasoline used. Other Control Functions 1. StaningControl provides rich mixtureby increasing Whenthe engineis started, ECM/PCM tuel injectorduration the a 2. FuelPumpControl . When the ignitionswitchis initiallyturned on, the ECM/PCM suppliesgroundto the PGM-FI main relaythat suppliescurrentto the tuel pump for two seconds pressurize fuel system. to the . When the engine is running,the ECM/PCM suppliesground to the PGM-FI main relay that suppliescurrentto the fuel pump. . When the engineis not runningand the ignitionis on, the ECM/PCM cuts groundto the PGM-FI main relaywhich cutscurrentto the fuel pump.
11-60
FuelCut-offControl . Duringdeceleration with the throttlevalveclosed, currentto the fuel injectors cut off to improvefuel economyat is speeds overthe {ollowingrpm: . D16Y5 engine(M/T): 850 rpm . D16Y5 enginelCVT), D16Y8 engine(USAM/T)r920 rpm ' D16Y8 engine(USAA,/T), Dl6Y7 ensine(USAA"/T):910 rpm . D16Y8 engine(Canada M//T), Dl6Y7 engine(Canada):990 rpm . D'16Y8 engine(Canada M/T):1,000 rpm . Fuelcut-offactionalso takesplacewhen enginespeedexceeds 6,900rpm (D16Y5, Dl6Y7 engine;D16Y8engine: 7,000rpm),regardless the positionot the throttlevalve,to protect enginefrom over-rewing. of the Ay'C Compressor ClutchRelay When the ECM/PCM receives demandfor coolingfrom the air conditioning a system,it delaysthe compressor from beingenergized, enriches mixtureto assure and the smoothtransition the Ay'C to mode. (EVAP) 5 . Evaporative Emission PurgeControlSolenoid Valve+s Whenthe enginecoolanttemperature above '154.F (68"C). ECM/PCM is the controlsthe EVAPpurgecontrolsolenoid valvewhich controlsvacuumto the EVAPpurgecontrolcanister. (EVAP) Evaporative Emission PurgeControlSolenoid Valve*a Whenthe enginecoolanttemperature (68"Ci, above 154"F intakeair temperature above32"F(0"C)and vehictespeeo above 0 mile 10 km/h)or [A,/C compressor clutchon and intakeair temperature above 160"F141.C)1, ECM/PCM the controls EVAPpurgecontrolsolenoid the valvewhich controlsvacuumto the EVAPpurgecontrolcanister. (EGR) 6. Exhaust GasRecirculation ControlSolenoid Valve*? When EGRis required controlof oxidesof nitrogen(NOx)emissions. ECMcontrolsthe EGRcontrolsolenoid for the valvewhich supplies regulated vacuumto the EGRvalve. 7 . Alternator Control The systemcontrolsthe voltagegenerated the alternator accordance at in with the electrical load and driving mode, which reduces engineloadto improvethe fuel economV. the CM/PCMFail-safe/Back-up Functions 'L Fail-safe Function when an abnormalityoccursin a signalfrom a sensor,the ECM/PCN4 ignoresthat signsl and assumesa pre-programmedvaluefor that sensor that allowsthe engineto continue run. to 2. Back-up Function When an abnormality occursin the ECM/PCM itself.the fuel injectors controlled a back-up are by circuitindependent of the systemin orderto permitminimaldriving. 3. Self-diagnosis Function Indicator Lamp(MlL)] [r4alfunction When an abnormalily occursin a signalfrom a sensor, ECM/PCM the groundfor the MIL and storesthe DTC supplies in erasable memory.When the ignitionis initiallyturned on, the ECM/PCM suppliesgroundfor the MIL for two secondsto checkthe MIL bulb condition. 4. Two Trip Detection Method To preventfalse indications, Two Trip Detection the Methodis usedfor the HO2S, fuel metering-related, control idle system,ECTsensor.EGRsystem and EVAPcontrol systemself-diagnostic functions. When an abnormality occurs, the ECM/PCM storesit in its memory.When the same abnormality recursafterthe ignitionswitch is turned OFFand ON (ll) again,the ECM/PCM informsthe driverby lightingthe MlL. However, easetroubleshooting, functionis to this cancelled when you jump the servicecheckconnector. The MIL will then blink immediatelv when an abnormalitv occurs. 5. Two (or Three)DrivingCycleDetection Method A "DrivingCycle"consists startingthe engine,beginning of closedloop operation, and stoppingthe engine.lf misfiring that increases emissions detected is duringtwo consecutive drivingcycles, TWC deterioration detected or is during three consecutive drivingcycles, the ECM/PCM turns the l/lL on. However, easetroubleshooting, function to this is cancelled when you jump the servicecheckconnector. The MIL will then blink immediately when an abnormalitv occurs.
3.
(cont'd)
11-61
PGM-FI System
(cont'd) SystemDescription
LoanEurn Control(D16Y5 enginer CVT)
\.
SENSOR TDC/CKP/CYP
MAP SENSOR
CKFSENSOB
of Comparison currentair fuel ratio to target ratio
SelectionoI basicfuel iniection duration
ECM
which occursin increase crankshaft in angularacceleration The lean burn controlsystem is basedon the characteristic when the air-fuelratiogets leaner. falls lf angularacceleration below which is mountedon the crankshaft, monitorsenginespeed. crankshaft The CKFsensor, air-fuelratiolevel), amountof injected the fuel is reduced. a certainlevel(target this level.the amountof fuel is increased. lf crankshaft angularacceleration exceeds This system improvestuel economyand driveabilityby controllingthe amount of iniectedfuel in the lean burn range immediately startsto deteriorate, beforecombustion
11-62
EngineGontrolModule/Powertrain GontrolModule{ECM/PCM)
The Maltunction Indicato. Lamp {MlL) nover com.s on {even to. two secondsl .tter ignition i! tutned on. NOTE:lf this symptomis intermittent, check a looseluse No. 25 llrETER A) in the for 7.5 underdash fuse/relaybox, a poor connectionat ECN4/PCM terminal Al8, or an intermit, tent openin the GRN/ORN (Al8) and the gaugeassembly. wire betweon ECM/PCM the
Turnthe ignitionswitchON (ll). ls the low oil pressure light on? Try to stan the engine. ECM/PCMCONNECTOR (32P} A PGl {BLKI Rgpair short or open in tho wire betwo.n No. 25 (METER) (7.5A)fusc rnd gauge r$omblv. Repleco No.25 IMETERI 17.5
A)tu...
Ch6cklor an open in the wiros (PGlineslr 1. Turn the ignitionswitchON (ll). 2. Measurevoltage between body ground and ECM/PCM connector terminalsA10 and A23individually. Checkfor an open in th6 wire or bulb lMlL lino): 1. Turnthe ignition switchOFF. 2. Connecthe ECM/PCMon c nectorterminal 418 to body groundwith a jumperwire. 3. Turnthe ignitionswitchON (ll).
Wire sideof femaleterminals Repair opon in thc wi..l3) botwen ECM/PCM and c10l lloc.ted at tho tharmostat housinglthrt had more th.n 1.0V.
ls therelessthan 1.0V?
Substitute . known-good ECM/ PCM and rechock. lf 3ymptom/ indication goo3 away, rcplac6 tho o.iginal ECM/PCM.
ECM/PCMCONNECTOR {32PI A
ls the MIL on? -
Repai. open in tha wire3 betweon ECM/PCM(A181 .nd gaugc a$ombly. Reolace the MIL bulb.
Substituto a known-good ECM/ PCM and rechsck. lI symptom/ indicetion goo3 away, replaco the odgin.l ECM/PCM.
(cont'd)
PGM-FI System
(cont'd) ControlModule(ECM/PCMI EngineControlModule/Powertrain
The Malfunction lndicator Lamo lMlLl stays on or comos on after NOTE: . When there is no Diagnostic Trouble Code (DlC) stored,the MIL will stay on if the SCS and the ignitionswitch is on. serviceconnectoris connected . lf this svmptomis intermittent, check forl - A looseFl E/M{15A) fusein the underhoodfuse/relay box - A l o o s e o .1 3 F U E L P U M P f u s e ( 1 5 At)h e u n d e r ' d a sf h s e / r e l a y x u bo in N - An intermittent (C7)and the service check the shortin the wire between ECM/PCM T C h e c kt h e D i a g n o s t i c r o u b l e Code(DTC): 1. Connect scantool or Honda a PGMTester. 2. Turnthe ignition switch {ll). ON 3. Readthe DTC with the scan tool or HondaPGMTester. (A18)and the gauge An intermittentshort in the wire between the ECM/PCM
(D4l the An intermittent short in the wire between ECM/PCM and the MAP sensor the the An intermittent short in the wire betweenthe ECM/PCM {D10}, TP sensor, sensor ('96 EGRvalve lift sensor (D16Y5engine)and/or the Fuel tank pressure KL Dl6Y7 engine(coupei model,sedan:KL (LX)model), 016Y8engine(coupe),'97 '98-tllmodels) '97 D16Yg sedan: model), KL enginelcoupe: models, all - PGM-FI mainrelay . See the O8D ll scantool or HondaPGMTesteruser'smanuals specific for operating Instructrons.
Go to troubl6hooting procdures. pag611-53) {3ee
Ch6ckthe DTCby MIL indication: 1. Turnthe ignitionswitchOFF. 2. Connect SCSservice the con' n e c t o rt o t h e s e r v i c ec h e c k connector. 3. Turnthe ignition switch (ll). ON Rpair opon or short in wire between the EcM/PcM {c8) and Oata Link Connector. Go to troublashooting p.ocedure. (s6epage 11-531.
Doesthe MIL indicate any DTC?
C ECM/PCMCONNECTOR I31PI
scs (BRNI
Try to stan the engine.
Does enginestan? the terminals Wiresideof female (To page11-65)
C h e c kl o r a s h o r t i n t h a w i r e ISCSlinel: 'L Disconnectthe SCS service 2. Stop the engineand turn the ignitionswitchON (ll). 3. N4easure voltagebetween the ECM/PCM connector terminal C7and bodyground.
ls thereapprox. V? 5
Repair 3hoft to body ground in th wire botwoen ECM/PCM{C7) tnd se ice checkconnctor.
(Topage11-65)
11-64
(Frompage11-64)
Ch.ck to. . 3hort in the wirc {MlL linol: 1. Turnthe ignitionswitchOFF. 2. Disconnecr ECM,/PCi!4 the connectorA (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)
Inspect E/M ('10 fuse in the Fl A) undeFhood tuseJrelay box. R.prir 3hort in thc wi.. btw.en Fl E/M 115 A) luse and PGM-FIm.in iolay. Ropl.co Fl E/M (15 A)fu.e. Inspect No. 13 FUEL PUMP115 A) 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 115 luse. A)
Chcktor a short in a son3or: '1. Turn the ignition switch (ll). ON 2. Disconnect 3P connector the from eachsensor one at time: . TPsensor . EGRvalve litt sensor{Dl6Y5 engtne) . F u e lt a n k p r e s s u r e e n s o r s ('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 : l l m o d e l s .s e d a n : a KL model'98-all models)
(Topage11-66) {cont'd)
1-65
PGM-FI System
(cont'dl EngineControlModule/Powertrain ControlModule(ECM/PCMI
lFrompage11-651 ECM/PCMCONNECTOR {16PI D
Does the MIL go OFF?
Rapbce the ranaor thrt cau3od th6 light to go out,
VCC1(YEL/RED)
Chect tor r short in th6 wiras {VCClin.3l: 1. T{rrnthe ignition switchOFF. 2 . D i s c o n n e c tt h e E C M / P C M connector (16P). D 3. Checkfor continuitybetween body ground and ECM/PCM connectorterminals D4 and D10individually.
Check tor en opcn in th. wire3 llGP linosl: 1. Disconnect fuel inioctors the and IACvalveconnectors. 2. Turn the ignitionswitchON (ll). 3. Measurevoltage between body ground and ECM/PCM connector terminalsA11 and A24 individually.
Repair ahon to bodY g.ound in th. wire batwaon ECM/ PCMlD4l snd MAP s.n.or. 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 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 , 3odan: KL lLXl modcll, '97 D16Y8ongino lcoupc: all model3,seden:KL modol, '98all modobl,
A ECM/PCMCONNECTOR I32P}
,I IGP (YEL/BLK)
2
a
t5 t 5 1 1 t8 25 21 20 2A 29 30
a 22
l0
11
12 t 3
2a
IGP2 (YEL/8LKI Rapail opan in the srire{31 botwo.n ECM/PCM (A11. A24l .nd PGM-FI mrin roby. Check lor poor connaction3 or loo3. wirc! .t th. PGM-FI main ralay. Tert lho PGM-FImain r.lay l3ecpag611-1571. Wire sideof female terminals
Check for an opon in the wirg! ILG line.l: 1. Reconnect sensorconnecall rors, 2. Reconnect the ECM/PCM connectorD (16P). 3. Turn the ignitions,witch {ll). ON 4 . N 4 e a sru v o l t a g e b e t w e e n e body ground and ECM/PCM connectorterminals A9 and A22 individually.
LGl
IERN/ BLK}
a
12 t 3 t a t 5 t 6 7 7 t 8 t9 20
E !l
to 23
!l
2a
21
2A 23 3 0
LG2 IBRN/ BLKI
ls there lessthan '1.0 V?
Rapair op.n in the wiro(rl btween 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
(MAP)Sensor ManifoldAbsolutePressure
The scan tool indicatesDiagnostic problem (vacuumleak) in the Trouble Code (DTC)P0106: mechanical A (MAP)Sensor ManifoldAbsolutePressure svstem. The MAPsensorconverts pressure manifoldabsolute into electrical signalsand inputsthe ECM/pCM.
OUTPUI VOLTAGE
tvt3.5 3.0
2.5 2.O 1.5 1,0
o
The MIL has bo6nrponed on. OTCP0106is stored. Or from ProbableCauseUrt.
,5
lqt 2|x)
tq.
rs.
10
.25
30 lin. Hg) GAUGE
3(x) i(X,
5OO 600 7ql
READI'{G lln]n Hgl
Problemverilication: 1. Do the ECM/PCM ResetProcedure. 2. Start the engineand keep enginespeedat 1,000 rpm for one minutewith the transmis, sion in P or I position(M/T in neutral).
ls DTCP0106 indicated? C h e c kf o r v a c u u m l e a k a g eo r blockage betweenthe MAP sensor and throttle body.
Ch6ckthe MAP sensoroutput: 1. Turnthe ignitionswitchOFF. 2. Turnthe ignition switch lll). ON 3. Check the MAP with the scan tool.
ls there leakageor blockage?
Checkthe MAP sonso. outputr 1. Stopthe engine. 2. Turnthe ignitionswitchON (ll). 3. Checkthe MAP with the scan tool.
(To page11-68)
{To page11-68)
(cont'd)
(MAPISensor(cont'dl ManifoldAbsolutePressure
(Frompage11-67) lFrompagel1-67)
Check{or poor r6ponse: 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 E or E] position, M/T in neutral untilthe radiatorfan comes on, then turn the ignition switchOFF. 2. Stanthe engine. 3. Check th MAP with the scan tool.
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 engineat 3,000rpm with lVT in M/T in neu' E or E position, tral untiltheradiator comes lan on, then turn the ignition switchOFF. 2. Start the engine. 3. Checkthe MAP with rhe scan 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?
The MAP sensor is OK at this tims.
ls a MAPot40.0kPa{300mmHg, 12.0in.Hg) lessindicated within or one secondafterstartingthe engine?
Substitute a known-good ECM/ PCM and recheck.It symptom/ indication go6s awsy, roplace the originsl ECM/PCM.
11-68
The scan tool indicatesDiagnostic Trouble Code (DTC)P0107: low voltage (high vacuum) problem in the A (MAP)sensor. ManifoldAbsolutePressure
The MIL has b6n reooned on. DTC P0107 is stored.
Problemverilication: '1. Turnthe ignition switch (ll). ON 2. Check the MAP with the scan tool.
Intermittent f.ilure, svslem b OK at this tirne. Chock to. poor connactionsor loose wiroa at C111 IMAPsnsorland ECM/PCM.
Checkfo. an open or short in th MAP sensor: 1. Turnthe ignition switchOFF. 2. Disconnectthe MAP sensor 3P connector. 3. Turnthe ignition switch {ll). ON 4. Check the MAP with the scan tool.
MAP SENSOR CONNECTOR 3P ICTI'tI
vccl
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 sensorconnector No, 1 ter minaland No. 2 terminal.
{YEL/REDI
Wire sideof femaleterminals ls thereapprox.5V? Repair opeo in the wire btwoen ECM/PCM ltxl and MAP 3mor.
Checktor . short in the TCM: 1. Turnthe ignitionswitchOFF. 2. Disconnect 22Pconnector the 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). 4. Check the MAP with the scan tool.
(To page11-70)
(cont'd)
11-69
PGM-FI System
(MAPISensor(cont'd) ManifoldAbsolutePressure
MAP SENSOR CONNECTOR 3P 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. 2. Disco nect the ECM/PCM n connector (16P). D 3. Checkfor continuitybetween the MAPsensor connector 3 No. terminaland body ground.
MAP (RED/GRNI
Wire sideof female terminals
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 indicates Diagnostic TroubleCode (DTC)P0108: high voltage (low vacuum)problem in the A (MAP)sensor. ManifoldAbsolutePressure
Tho MIL has bn 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'T E or E position, in M/T in neutral) untilthe radiator fan comeson,then let h idle. 2. Check the MAP with the scan tool. ls 101kPa(760mmHg,30.0in.Hg) or higherindicated? Intormittont lailwo. 3yst6m ir OK at thia timc, Ch.ck tor poor connoctions or looaa wira! at Cllt (MAP!nrorl and ECM/PCIV|, MAP SENSOR CONNECTOR 3P {CI11I
Check for an open in the MAP 1. Turnthe ignition switchOFF2 . 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 the MAP sensor3P connector terminals No.3 andNo.2. 4. Turnthe ignitionswitchON llll. 5. Checkthe MAP with the scan tool. ls 101kPa{760mmHg,30.0 in.Hg} or higherindicated?
{RED/GRNI
JUMPR WIRE Wire sideof temale terminals
vccl (YEL/REDI
Check Ior an open in wirs (SGl linel: 1. Remove iumperwire. the 2. Measure voltagebetween the MAP sensor3P connector terminalsNo. 'l and No.2. ls thereapprox. V? 5 Repairopen in tho wir6 bctwaon ECM/PCM lDl2l .nd MAP sonror. CCM/PCMCO NECTOR I16PI D JUMPERWIRE Check for an open in lhe wire IMAPlinel: 1. Turnthe ignition switchOFF. 2 . C o n n e c tt h e E C M / P C M o n c nectorterminalsD3 and 012 with a iumPerwire. 3. Turnthe ignition switch (ll). ON 4. Check the MAP with the scan tool. ls 10'1 (760mmHg,30.0 kPa in.Hg) or higherindicated? R.pair opn in tha wir63 botwocn ECM/PCMlD3l .nd MAP.onsor. MAP IRED/GRNI
sG1
{GRN/WHTI Wire side of femaleterminals
Substitute a known-good ECM/ PCM .nd rechock.ll normal MAP is indicated, .oplace the originel ECM/PCM.
(cont'd)
11-71
PGM-FI System
(MAP)Sensor(cont'd) ManifoldAbsolutePressure
(MAP)lower than The scantool indicates Diagnostic TroubleCode (DTC)P1128; ManifoldAbsolutePressure expected.
The MIL hes been.eoorted on. DTC Pl128 is stored.
Problamvrific.tion: 1. Turnthe ignition switch lll). ON 2. Check the MAP with the scan
ls 54.1kPa(406mm Hg, 16.0 in. Hg)or higherindicated?
Intermittont tailurc, system b OK at thk time.
(MAP)higherthan The scantool indicates Diagnostic TroubleCode (DTC)P1129: ManifoldAbsolutePressure 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 engine at 3,000rpm with no load (A,/T E or E position, in M/T in neutral) untilthe radiator tan comes on, then let it idle. 2. Check the MAP with the scan tool.
ls 43.3kPa{325mm Hg, 12.8 in. Hg)or lessindicated?
lntermittent failure, 3y3temi3 OX at lhis time.
11-7 2
(lATlSensor IntakeAir Temperature

problemin the lntakeAir 1 TroubleCode (DTC)P01 1: A range/performance Diagnostic The scantool indicates (lAT)Sensor circuit. Temperature ot as resistor(thermistor). resistance the thermistordecreases the intake The dependant The IAT Sensoris a temperature increases shown below. as air temoerature
Th6 MIL has beenroportedon. DTCP011t is stored, O. from Probabl. C.us List.
RESISTAI{CE ft01
Problmvoritication: 1. Turnrhe ignitionswitchOFF. 2. Disconnect IAT sensor2P the connector, 3. Removethe IAT sensor. 4. Reconnect IAT sensor2P the connector. 5. Leavethe IAT sensorexposed to ambient temperature. switch (ll). ON 6. Turnthe ignition 7. Checkthe IAT with the scan tool,
-a 32 X rO. t1a 212 24a t.jl -20 0 20 /|o ao ao !00 t2o trcl
II{IAXE AIR TEI/IPERATURE
Reolace tho IAT sensor.
Checkthe IAT snsoroutput: 1. Warm the IAT sensorwith a hairdryer. 2. Checkthe IAT with the scan tool,
Didthe IATrise2"F(1"C) more or from the ambient temperature?
Interrnittentlailure, system is OK at this time.
Reolaco the IAT sensor.
(cont'd)
1-73
PGM-FI System
(lAT)Sensor{cont'd} IntakeAir Temperature
problemin the The scantool indicates Diagnostic TroubleCode(DTC) P0112: low voltage(hightemperature) A Intake Temperature Air circuit. {lAT)sensor
The MIL he3 b6en Eoortcd DTC P0112 b 3tor.d. on.
RESTSTANC ll0l lo to
I
Problamvo.ification: 1. Turnthe ignitionswitchON lll). 2. Checkthe IAT with the scan tool,
. aa aa ro. tra 2t2 a{ frt - 20 0 ro :|o ao ao t00 r20 tlcl
ITTAXE EMPERATURE AN
ls 302'F (150"C) higher (or or H-Limit*rlindicated?
Replace the IAT sensor.
Intormittent failurg, 3y3temis OK at thb tims. Chackfor Door conncctions or looac wi.as at C112 (lAT sonsorl .nd ECM/PCM. Checklor . .horl in the IAT s6nsot: 1. Oisconnect IAT sensorconthe nedot, 2. Checkthe IAT with the scan tool. ls 302'F (150'C)or higher (or H-Limit*1) indicated?
RoplacG IAT senio.. tho IAT SENSOR CONNECTOR 2P {Cl12I
Chockfor. short in the wiro llAT lin.l: 1. Turnthe ignitionswitchOFF. 2. Disconnect ECM/PCM the connector 116P). D 3. Checktor continuitybetween the IATsensor connector 2P terminalNo.2 bodyground. and Rgpairlhort in tho wire betweon ECM/PCMlDSl and IAT sensor.
--+-r l l l 2
l
IAT
@ IRED/YELI
=
rermtnats Wiresideof female
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 higherthan ambient temperature.
11-74
problemin the P0113: high voltage(low temperature) A TroubleCode(DTC) Diagnostic The scantool indicates (lAT)sensorcircuit. lntakeAir Temperature
The MIL has beenreportdon. DTCP0113is stord.
Ploblem veriticationi switch {ll). ON 1. Turnthe ignition 2. Checkthe IAT with the scan tool, Inte.mittent lailura, system is OK at this time. Checktor poor conneclionsor loose wires at C112 {lAT sensorl and ECM/PCM.
Checkfo. an open in the IAT sensor: 1. Disconnect IAT sensor2P the connector, 2. Connect IATsensor2P conthe n e c t o rt e r m i n a l sN o , ' l a n d No.2 with a jumperwire. 3. Checkthe intakeair temperature with the scantool.
(C112) IAT SENSOR CONNECTOR 2P
----F-t
sG2 ffi (GRN/BLn I I
I ' l r IAT l
JUMPER
(RED/YEL)
wtEE
Wire sideoI lemaleterminals
ECM/PCMCONNECTOR (16PI D Checklor an opn in the wires {lAT,SG2 lines): 1. Turnthe ignitionswitchOFF. 2. ConnectECM/PCM connector terminals gand Dl1 with a D ON 3. Turnthe ignition switch (ll). 4. Checkthe IAT with the scan tool.
IAT(RED/YELI
sG2
IGRN/8LK}
JUMPERWIRE Repairopen in th wires between ECM/PCM(D8, D11)and IAT senWire sideof female terminals
Substitute a known-good ECM/ PCM and recheck. It normal IAT is indicated. replace the o.iginal ECM/PCM. *r With HondaPGMTesterin Hondamode.
PGM-FI System
EngineCoolantTemperature Sensor {ECTI
The scan tool indicatesDiagnostic Trouble Code (DTC)P0116: range/performance A problem in the Engrne (ECT) Coolant Temperature Sensor circuit. The ECTSensoris a temperature (thermistor). resistance the thermistor dependant resistor The of decreases the enoine as coolanttemperature increases shown below. as
RESISTANCE tkol
THERMISTOR
a 3 2 6 E1 0 a1 a 0 1 7 6 t 2 2 a 8( . r ) 2 -20 0 20 ao o I to !20 Ic) ENGINE COOLANT TEMPERATURE
NOTE:lf DTCP0117and/or P0118 are storedat the same time as DTCP0116, troubleshoot those DTCS first, then troubleshoot DTCP0116. PossibleCausa . ECTsensordeterioration . Malfunction the coolingsystem in TroubleshootingFlowchart
The MIL has ben rcportodon. DTCP0116k stored.
Problemverification: 1. Start the engine.Hold the engine at 3,000rpm with no load {A"/T E or El position, in M/T in neutral) until the radiator 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
Ipfln7'l :
problemin the A The.scan Diagnostic TroubleCode(DTC) P0117: low voltage(hightemperature] tool indicates E n g i n e o o l a nT e m p e r a t u r e C Ts e n s o r c i r c u i t . {E ) C t
The MIL hes ben reooned on. DTC P0117 is sto.ed.
Problomveriticrtion: 1. Turnthe jgnition switch (lli. ON 2. Checkthe ECTwith the scan tool.
Intormittent failure,lvstem k OK at thi3 time. Checkfor poor connection3 or loo3o wirg! at Cl22 IECT3.n3or)and ECM/PCM. Chocktor a short in the ECTson1. Disconnect ECTsensor2P the 2. Checkthe ECTwith the scan tool.
(150"C) higher(or ls 302"F or H-Limit*)indicated? ECTSENSOR CONNECTOR 2P {C122I Chock tor a sho.t in the wire {ECTline): 1. Turnthe ignitionswitchOFF. 2. Disconnect ECM/PCM the connector (l6P). D 3. Checkfor continuitybetwoen the ECT sensor conneclor 2P ter 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 HondaPGMTester Hondamode. in
(cont'd)
11-77
PGM-FI System
(ECTI (cont'dl Engine Coolant Temperature Sensor
The scantool indicates Diagnostic TroubleCode{DTC) l8: A high voltage(low temperature) P0l problemin the (ECT) EngineCoolant Temperature sensorcircuit.
The MIL hrs boon reported on. DTC P0118 is stored.
P.oblemveritication: L Turnthe ignition switch (ll). ON 2. Checkthe ECTwith the scan tool. Intormittent tailuro, svstem is OK at this time. Chock tor poor connestions or loose wires at C122 sonsorland ECM/PCM. {ECT ECTSENSOR CONNECTOR 2P {C122I Checktor an opon in the ECTsen1 . D i s c o n n e c t h e E C Ts e n s o r 2P connector. 2 . C o n n e c tt h e E C Ts e n s o r2 P connector terminals No. 1 and No.2 with a j!mperwire. 3. Checkthe ECTwith the scan tool.
ECT {RED/WHTI WIRE JUMPEN sG2 IGRN/BLK)

Wiresideof female terminals
ECM/PCMCONNECTOR {16P) D JUMPERWIRE Checklor an opon in th6 wir6s SG2 linesl: {ECT, 1. Turnthe ignitionswitchOFF. 2. ConnectECNI/PCM connector t e r m i n a l s 2 a n d D 1 1w i t h a D 3. Turn the ignitionswitchON (ll). 4. Checkthe ECTwith the scan tool. ECT (RED/WHTI
L
t5
sG2{GRN/BLKI
---l l 3 l a l I 9 to
t6
12
l3
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
Diagnostic TroubleCode {DTC)P0122: low voltageproblemin the ThroftlePosition A scantool indicates .Tj_: t I l-l sensor crrcull. The TP Sensoris a potentiometer. is connected the throttlevalve shaft.As the throttlepositionchanges, throttle lt to the positionsensorvariesthe voltagesignalto the ECM/PCM. tFo-, -
The MIL has been reDortedon. DTCP0122is stored.
OUTPUTVOLTAGE {VI
5 4
Problomve.ification: 1. Turnthe ignition switch (ll). ON 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-
1 0
THROTTLE OPENING FULL THROTTLE
10%whenthe ls thereapprox. throttle is fully closedand approx.90%when the throttle is fullyopened?
Inlermittent tailure,system is OK et this time. Checklor Door connectionsor loose wires at Cl10 ITPsenso.land ECM/PCM.
TP SENSOF3P CONNECTOR {Cl1OI
sG2
IGRN/BLK}
vcc2
(YEL/BLU)
Ch6ck for an opcn in lhe wire (VCC2linell 1. Turnthe ignitionswitchOFF. 2. Disconnect TP sensor3P the connector. 3. Turnthe ignition switch (ll). ON 4. N,4easure voltage between the TP sensor3P connector terminals 'l andNo.3. No.
Ware sideof femaleterminals
D ECM/PCMCONNECTOR Il6PI
Checkfor an op6n in wire IVCC2 line): Measurevoltage betweenECM/ PCMconnector D10and terminals D1' ]. Checktor an open or 3hort in TP sensoa: 1. Turnthe ignitionswitchOFF. 2, At the sensorside, measure resistance betweenthe TP senNo. 1 and No. 2 sor terminals with the throttle fullyclosed.
SG2 (GRN/BLKI
Wire side of female terminals
Repairopen in lhe wire between ECM/PCM(D10)and TP sonsor.
(Topage11-80)
Substitute a known-good ECM/ PCM and rechock. It orescribed voltage is now available, replac the originel ECM/PCM.
Terminal sideof maleterminals
(cont'd)
PGM-FI System
ThrottlePosition(TP)Sensor(cont'dl
(Frompage1'1 79)
ls thereapprox. - 0.9k0? 0.5 YES CheckIor an open or short in the TP sensori Measureresistance betweenthe T P s e n s o rt e r m i n n a lN o . 2 a n d No.3 withthe throftle fullyclosed.
TP SENSOR CONNECTOR 3P
ls thereapprox.3.6 5.4kO?
Terminal sideoI maleterminals
Checklor an open in the ECM/ PCM{TPSline): 1 . R e c o n n e c t e T P s e n s o r3 p th 2. Turnthe ignition switch {ll). ON 3. Measurevoltage between ECM/PCM connector terminals D 1a n dD 1 l .
ECM/PCMCONNECTOR Il6PI O
TPS(RED/ BLKI
l f f" h i
7 I
sG2(GRN/BLKI
9 10 l l
12
13 l a
ta
ls thereapprox.0.5 whenthe V throttle is tully closedand approx.4.5 whenthe throttle V ;s fullyopened?
Sub3titute a known-good ECM/ PCM and recheck. It oroscribed voltago is now availabl6, aeplace the original ECM/PCM.
Wiresideof t6m6leterminals
(D16Y5 engine
f Checktor a short in rhe TCM: L Turnthe ignitionswitchOFF. 2. Disconnect 22Pconnector the from the TCM. 3. Turnthe ignition switch (ll). ON 4. Measure vohagebetweenECM c o nn e c t o rt e r m i n a l sD 1 a n d D11.
-l
TPS (RED/ BLKI
l tt" 1r
8 9 r0lrt l a 1 5 l lrG
sG2IGRN/BLKI
12
ls thereapprox.0.5V when the throule is fully closedand approx.4.5 whenthe throttle V is fullyopened? I Repairshort in the wire betwen ECM/PCM{Dll, TCM and TP s6n-
11-80
The scantool indicates Diagnoslic TroubleCode (DTC) P0123: high voltageproblemin the ThrottlePosition A (TP)sensorcircuit.
The MIL has been.eoorted on. DTC P0123 is stored.
Problemveritication: 1. Turnthe ignition switch (ll). ON 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 throttle fullyclosed is and approx. 90%whenthethrottle is fullyopened?
Intermittent failure, system b OK at this tim6. Checktor poor conneciionso. loose wires at C110 (TPsensor]and ECM/PCM.
TP SENSOR CONNECTOR lOI 3P ICl
sG2
(GRN/BLKI
vcc2 IYEL/BLU)
Checklor en open in the TP sen1. Turnthe ignitionswitchOFF. 2. Disconnect TP sensor3P the connector, 3. Turnthe ignition switch {ll). ON 4. At the harness side,measure voltagebetweenthe TP sensor 3P connecter terminalsNo. 1 a n dN o . 3 .
Replace thronle body. the ECM/PCMCONNECTOR I16P) D
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. V? 5 Repairopen in the wire between (D11) ECM/PCM and TPsensor.
Wire side of female terminats
Substitute a known-good ECM/ PCM and recheck. ll presc.ibed vohag is now available,replace the original ECM/PCM.
11 - 8 1
PGM-FI System
ThrottlePosition(TP)Sensor
p'I12j:Throttleposition(Tp)lowerthan exeected. P1121 | The scantool indicates Diagnostic TroubteCode(DTC)
The MIL has been reported on. DTC Pl121 is stord.
Problomve.ification: 1. Turnthe ignition switch (lll. ON 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 TP* % or higherindicated whenthe throttleis fully opened?
Intoimiftent tailure, systam i3 OK at this time.
* : 1 1 . 8D 1 6 Y e n g i n e i l 5 1 2 . 9 1 D 1 6 Yn g i n e ) e7 12.2(D16Y8 engine)
11-82
[Fil22-l
-
(TP)higherthan expecred. Th" """n tool indicates Diagnostic TroubleCode{DTC) P1122:Throttle Position
The MIL hes been reported on. DTC P1122 is stored.
P.oblemverification: 1. Turnthe ignition switchON {ll). 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 TP* % or lessindicated when the throttleis f!lly closed?
Intermittent tailurc, ay3tem is OK at this time.
*r 16.5{Dl6Y5,D16YB engine) 16.9{D16Y7 engine)
11-83
PGM-FI System
(Primary (Sensor (Except Primary Heated Oxygen Sensor HO2SI 1l Dl6Y5 (M/Tl) engine
The Heated OxygenSensor(HO2S) detects oxygencontentin the exhaustgas and signalsthe ECM/PCM. operation, the In the ECM/PCM receives signalsfrom the sensorand variesthe durationduring which fuel is injected. stabilize the To the sensor's output,the sensorhasan internalheater. The PrimaryHO2S(Sensor is installed the exhaustmanifold. 1) in HO25:
ztRcoNrA
SENSOR
VOLTAGE {VI
HEATER
TERMINALS
RICH. AIN- - LEAN FUL RATIO
TroubleCode (DTC)P0131: low voltageproblem in the Primary Heated A tFor3I The scantool indicatesDiagnostic Oxygen Sensor{H02S)(Sensor circuit. 1)
The MIL has bonreportedon. DTCP013'lis storod.
Problomveritication: 1. Do the ECM/PCM Feset Pro cedure. 2 . 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 (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 at this time. Checkfor poor connections or loos wires rt C123 l P r i m a r yH O 2 S ,. 6 n 3 o r 1 | a n d ECM/PCM,
Does the vohage stay at 0.1 V or less?
lTo page11-85)
\-
11-8 4
(Frompage11-84)
Chockfor a shon in the HOzS: 1. Turnthe ignitionswitchOFF. 2. Disconnect PrimaryHO2S the (Sensor 4P connector. 1l 3. Stan the engine and let it idle. 4. Check the Primary H02S lSensor1)outputvoltage with the scantool.
Doesit stayat 0.1V or less?
PRIMARY HO2S(Sen3or1l aP CONNECTOR lC123l
Check for a short in the wir line): IPHO2S 1. Turnthe ignitaon switchOFF. 2. Disconnect ECM/PCM the con, nectorD (16P). 3. Checkfor continuitybetween the PrimaryHO2S(Sensor1) 4 P c o n n e c t o tre r m i n a lN o . 1 andbodyground.
Pr{o2s T-{wHTrI- I--] f-l 1 2l 6 r l s l r l \z r__i_l
L
ls there continuityT
Rpairshort in the wire betwoan 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-FI System
HO2SI(Sensor {Except 1) D16Y5 PrimaryHeatedOxygenSensor(Primary (cont'dl engine {M/Tll
[FO13t : The scan tool indicates TroubleCode (DTC)P0'132: high voltageproblemin the PrimaryHeated A Diagnostic (Sensor circuit. HO2S) 1) OxygenSensor(Primary
The MIL hes ben reooned on. DTCP0132 b stored.
Problemvedfication: '1. Do the ECM/PCM ResetProcedure. 2 . 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 {A,/T E or E position, in M/T in neutral) untilthe radiator fan comeson, 3. Test drive with the Arr in E position (M/T in 4th gear). 4. Check the Primary HO2S (Sensor outputvoltage 1) with the scantool duringdeceleration using completelyclosed throttle. Doesthe voltagestayat 1.0V or more? Intermittent failuro, system b OK at this time. Checktor ooor connections or loose wires at C123 lPrimary HO2S,Sonsor 1) and ECM/PCM. PRIMARY HO2Slsensor 1l ,lP CONNECTOR
Chckfor an opn in the Primary H02S: 1. Turnthe ignitionswitchOFF. 2. Disconnect PrimaryHO2S the (Sensor 4P connector. 1l 3 . C o n n e c tt h e P r i m a r yH 0 2 S (Sensor1) 4P connectortermin a l sN o . ' l a n d N o . 2 w i t h a 4. Turnthe ignition switch (ll). ON 5. Check the Primary H02S (Sensor1l output voltagewith the scaniool. lsthere1.0V or more?
PHO2S {WHT)
sG2
{GRN/ BLKI
C h e c kt o r . n o p e n i n t h e w i r e line): IPHO2S 1. Turnthe ignitionswitchOFF. 2. ConnectECM/PCM connector terminalsD7 and D11 with a 3. Turnthe ignition switch lll). ON 4. Check the Primary H02S (Sensor1) output voltagewith the scantool. ls there1.0V or more? Repai. open in thc wire betwoen E C M / P C M ( D 7) e n d P r i m e r y HO2S{Son3or1} .
D ECM/PCMCONNECTOR {16PI JUMPERWIRE PHO2S(WHTI sG2(GRN/BLKI
ffi
I l0 1 1
12
t3
t6
Wiresideof femaleterminals Subltituto . known-good ECM/ PCM and roch.ck. lf 3ymptom/ indic.tion goe3 away, replace the originel ECM/PCM.
11-86
PrimaryHeatedOxygenSensor(Primary HO2SI(Sensor 1l
The TroubleCode(DTC) A tFols3-l scantool indicatesDiagnostic 1) circuit. P0133: slow responseproblemin the PrimaryHeated OxygenSensor(Primary HO25)(Sensor Diagnostic TroubleCode P1163 The scantool indicates l OxygenSensor(Primary HO25)(Sensor circuit. 1) (DTC) problemin the PrimaryHeated P1163: slow response A
DescriDtion By controlling airlfuelratiowith a PrimaryHO2S(SensorI ) and a Secondary the HO2S(Sensor the deterioration the 2), of PrimaryHO2S{Sensor1) can be evaluated its feedback period.When the feedback periodof the HO2Sexceeds cer, by a tain valueduringstabledrivingconditions, sensorwill be judgedas deteriorated. the Whendeterioration beendetected has duringtwo consecutive trips, MILcomeson and DTCP0133 P1'163* be stored. the or will NOTE:lf DTCP0131, P0132 and/orP0'135 storedat the same time as DTCP0133, are troubleshoot those DTCS first, then troubleshoot DTCP0133. DTCP1'162, lf P1168 and/orPl 169are storedat the sametime as DTCP1163, troubleshoot those DTCS first.then troubleshoot DTCP1163. PossibloCause . P r i m a r y O 2 S S e n s o1 ) D e t e r i o r a t i o n ( r H o PrimaryHO2SHeater (Sensor 1)Deterioration . Exhaust systemleakage TroubleshootingFlowchart
The MIL has beenreoortedon. DTC P0133and/o. P1163.is stored.
ProblemVorification: 1. Do the ECM/PCM ResetProcedure. 2. Connect scantool. the 3 . 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 no load (A"/T E or E position, in M/T in neutral) untilthe radiator fan comeson. 4. Connect SCSservice the connector. 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 readiness code comes
Intermittent tailur6, sysiom i! OK at this timo. Chgckfor pooa connections or loose wi.ss at C123 lC1/|5)*(PrimaryHOzS.Sensor1) and ECM/PCM.
*: P1163 engine tD16Y5 1M/T))
11-87
PGM-FI System
(Primary (Sensor (D16Y5 1l Primary Heated HO2SI engine Oxygen Sensor
(M/Tt)
Trouble Code lDTC)P1162: malfunctionin the PrimaryHeatedOxygen A The scan tool indicatesDiagnostic r y S e n s o ( P r i m a r H O 2 S ( S e n s o1 ) c i r c u i t . r ) Description over a wide airlfuelrange.The PrimaryHO2S The PrimaryHeatedOxygenSensor(PrimaryHO2S)(Sensor1) operates ( S e n s o1 ) i s i n s t a l l e id t h e e x h a u sm a n i f o l d . r n t
SENSOR ELEMENT
HEATER TERMINALS
SENSOR TERMINALS
first,then troubleshoot DTCP1167. NOTE:lf DTCP1162 storedat the sametime as DTCP1167, is troubleshoot DTCP1162
The MIL has been.eported on. DTC P1162 is stored.
Problomverilication: 1. Dothe ECMReset Procedure. 2. Startthe engine. 3. Wait at least two minutes.
ls DTC Pl162 indicated?
Test'drive severalmiles with for the transmission 3rd gear.Hold in the engine speed 1,500 at rpm. ls DTCP'l162 indicated? Intermittent tailure, system is OK at this time. Ch6ckfor poo. connections 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): 1. Turn the ignition switch OFF. 2. Disconnect ECM connector C ( 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
ECMCONNECTOR 131PI C PRIMARY HO2S 1} {SENSOR 8P (C1,15) CONNECTOR
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 telminal contact at the Primarv HO2S lsensor 1) connectorand ECM. lf terminal conlact is OK, replace the PrimaryHO2S(Sensor1). (Topage11'89)
11 - 8 8
(Frompage11-88)
ECMCONNECTORS
c {31P}
Chcck th. ECM input vohego {lP-/ VS- lino): 1. Turnthe ignition switchOFF. 2 Turnthe ignition switch {ll). ON 3. Measurevoltage between ECMconnector terminals C24 a n dD ' ] 1 .
o {16P}
sG2
{GRN/BLI(}
IP-/VS- {REDI
3 a
5 6
female terminals 1
9 l0 22 30
ls there more than 0.5 V?
Ch6ckthe ECM: 1. Turnthe ignitionswitchOFF. 2. Disconnect ECM connector C from the ECM. {31P) 3. Checkfor continuitybetween b o d y g r o u n da n d E C Mc o n nector terminal C24.
1 1 12
t 3 1a 15 l6 11 18 27 2t
23 21 25
z)
o-\ rP-/vs7 rneot

Repair open in the wire between ECM lc24l and Pri'l mary HO2S(Sensor I. Substitutea known-goodECM and .ach.ck. It symptom/indication goes awey, replacethe originalECM.
Chocktor s short in the wire (lP-l V9- linel: 1. Disconnect 8P connector the from the PrimaryHO2S(Sen' sor'l). 2. Checkfor continuitybetween body ground and ECMconnector terminalC24.
2 3 1 23 2a 25
t0
?2 30
1 1 l 2 1 3 1 4 1 5 1 6 1 7 1 8 ,/ 21 2A
fr) {RED}
R6pairshort in the wi.e between the Primarv HO2S{Sensor'l) and ECMtc24t. Repl.c. the Primary HO2S {Senso.1). Chock tho ECM output voltage IVS+linol: Measurevoltage between ECM connector terminalsC25and D'11.
ls theremorethan0.5V?
Checkfor a sho.l in tho wire {VS+ linel: 1. Turnthe ignition switchOFF2. Disconnect ECMconnector C (31P)from ECM. the 3. Check for continuity between b o d y g r o u n da n d E C M c o n nector terminal C25.
8 21
10
22 30
1 1 12 13 14 15 16 1 7 1 8
23 21 25
2a
O) vs*
! twHTt {cont'd)
(To page11-90)
(To page11-90)
11 - 8 9
I
System PGM-FI
PrimaryHeatedOxygenSensor(PrimaryHO2SI(Sensor1l (Dl6Y5 engine (M/Tl) (cont'dl
lFrompage11-89)
Substitut a known-good ECM and rccheck. lf symptom/indication goes away, replaco tho original ECM. Check for a short in tha wiro {lP+ linel: 1. Disconnect the 8P connector from the Primary HO2S (Sen 2. Check for continuity between body ground and ECM connector terminalC25. 9 l0 22
2 3
6 l5 t6 11
l 1 12
r3
r8
p lfi. w;,".ia"or r e m a r el e t m t n a I
Rpairshort in th6 wire between 1l HO2S{Sensor and the Primary ECMtC25).
ls therecontinuityT
Replacethe Primary HO2S {Sensor 11.
ls theremorethan 5.0V?
Checkthe EcM: 1. Turnthe ignitionswitchOFF. 2, Disconnect the 8P connector from the PrimaryHo2S {Sensor'l). voltagebetweenECM 3. Measure connector and D11. C25
Replace the Primary HO2S lSensor 11.
Checkthe ECMinput vohago(lP-/ vS- linel: 1 . 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 (M/T in neutral) until the radiatorfan comeson, then let it idle. 2. Measure voltagebetweenECM terminalsC24 and connector 01' j.
Substitut a known-good ECM and recheck. lf symptom/indication goes away, replacth6 originslECM.
ls there2.6- 2.8V?
1 t 2 3
5 t5 t 6
t rl
9 10
Check the ECM output voltage {VS+ line): Measure voltage between ECM connectorterminals C25 and D'11.
12 t 3
VS+ (WHT}
2 3
sG2
(GRN/8LKI to
tl
't2
( T op a g e1 1 - 9 1 )
( T op a g e1 1 - 9 1 )
t5
16
11 - 9 0
l F r o mp a g e1 1 - 9 0 )
lFrompage11-90)
ls thorelessthan 2.8V?
Roplacothe Primary HO2S (S6nsor 11.
Substitute a known-good ECM and recheck. lf symptom/indication gos away. replacethe original ECM.
c (3rP)
Check the ECM output voltage llP+line): Measurevoltage between ECM connector terminals C23and D'11.
D t16Pl
sG2
lP+ IBLK) ls theremorethan 0.4V? YES Substiluta a known-good ECM and recheck. It symptom/indication goes aw.y, rcplacethe o.iginalECM. (GRN/BLKI Wire side of femaleterminals
2 3 a
1 1 12
6 15 16 1 7 t8
t0 22
r3 t a
lP+
Checkthe ECM: 1. Turnthe ignition switchOFF. 2. Disconnect ECM connector C (31P)from ECM. the 3. Checkfor continuity between b o d y g r o u n da n d E C M c o n nector terminal C23.
23 21 25
I Check for an open in lh6 wire llP+line): 1. Turnthe ignitionswitchOFF. 2. Disconnect the 8P connector from the PrimaryHO2S(Sens o r1 ) . 3. Checkfor continuitybetween the PrimaryHO2S{Sensor1) 8P connectorterminal No. 7 and ECM connector terminal c23.
29 30
IBLK)
ECMCONNECTOR 13lPI C
PRIMARY HO2S tsENsoR 118P coNNECTOR tCl{st
lP+ IBLKI
lP+ IBLK}
femaleterminals NO
Wire side of female termrnats
Rpairopen 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+ linel: 1. Disconnect 8P connector the from the PrimaryHO2S(Sen sor'll. 2. Checkfor continuitybetween b o d y g r o u n da n d E C M c o n nector terminal C23.
Subsiitute a known-9ood ECM and rocheck. lt symptom/indica' tion goes eway, replacethe original ECM.
2 3
10
22
1 1 12 13 1 4 23 21 25 R.pair shon in th6 wirc btween th Primary HO2Slsonsor 1) and ECM{C23).
16 11 18 29 30
6\ jjl
lP+ {8LKl
Replecethe Primary HO2S ls6nsor 1).
{cont'd}
11-91
PGM-FI System
(Sensor (Dl6Y5engine (Primary 1) HO2SI Heated Sensor Primary Oxygen (M/T)l (cont'd)
lptrEl :
-
problem in the Primary A Trouble Code (DTC)P1164: range/performance The scan tool indicatesDiagnostic (Sensor circuit. (Primary HO2S) 1) Heated OxygenSensor
The MIL h.3 ben .sportod on. DTC Pl16il ii rtorcd.
ProblGm Verific.iion: '1. Do the ECMReset Procedure. 2 . 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 t l o a d u n t i lt h e r a d i a t o r a n 3. Connectthe SCS servicecon nector, 4. Tst-drivein 4th gear. Staning using at 1,600rpm, accelerate wide opnthrottlefor at least5 for seconds. Then decelerate at least 5 secondswith the throtclosed. tle complot6ly Intermittent frilurc. sy3tam b OK at this time. Chcktor poo. connections or loos6 wire3 at C145 {Prima.y HO2S,Sensor 1) .nd ECM.
ls DTCP]164indicated?
Rpl.c. tho Primary HO2S (Sen3or 11.
problem the Primary A The scan tool indicatesDiagnosticTrouble Code (DTC)P1165: range/performance (Primary (Sensor circuit. 1) H02S) Heated OxygenSensor
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 servicecon4 . 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 5th gear in - Untilreadiness cod comes Intormitteni failure, sy3tsm ia OK at thia tim6. Check tor poo. connections or looso wiroa at c145 lPrimary HO2S. Sentor 1l .nd ECM.
indicatod? ls DTCP1165
Rsplrc6 th6 Primary HO2S lsonaor 11.
11-9 2
The scan tool indicates Diagnostic TroubleCode (DTC)P]168:A low voltage problem in the PrimaryHeated lpi,';;l |gjgggg!ggg (Sensor LABEL OxygenSensor(Primary HO2S) 1) circuit.
The MIL has boon ..ported on. DTC Pl168 is stored.
Problemvedficalion: 1. Do the ECMReset Procedure. 2. Startthe engine. 3. Waitat least two minutes.
ls DTCP1168 indicated?
IntermittGotlailuro, 3yst.m is OK al this tim6. Chocktor poor connction3 or loo3e wiros at C145 {Primary HO2S, Sensor 1) and ECM. ECMCONNECTOR {16PI D LABEL{WHTI
Checkthe ECM: 1. Turnthe ignitionswitchOFF. 2. Disconnect the ECM connector D (16P). 3. Checkfor continuitybetween E C M c o n n e c t o t e r m i n a lD 7 r and bodyground. Substitute a known-good ECM .nd rcchack. lf aymptom/indication goes swsy. r6placeth6 original ECM.
LABEL IWHT}
Check for a short in the wires (LABEL lin.l: 1. Disconnect PrimaryHO2S the (Sensor 8Pconnector1) 2. Check for continuity betlveen ECM connector terminal D7 and body ground.
ls therecontinuity?
Replaceth6 Primary HO2S lsensor 11.
Ropair short in thg wir6 botweon tho Pfimary HO2S(Sensor1l and ECMtD7).
(cont'd)
11 - 9 3
)
PGM-FI System
(Primary Primary Heated HO2S) 1l Oxygen Sensor {Sensor (Dl6Y5engine (M/Tl)(cont'dl
[ti,r;ol L]g The scan tool indicates Diagnostic TroubleCode {DTC)P1169: high voltageproblemin the PrimaryHeated A Oxygen HO2S} 1)LABEL circuit. Sensor {Sensor {Primary
The MIL hs3 ben r6Dorted on. DTC P1169 is stor6d.
Problmveritication: 1. Do the ECMReset Procedure2. Startthe engine3, Wait at least two minutes,
PRIMARY HO2SISENSON 8P CONNECTOR 1} I145I Intormittent failure, system is OK at thi3 time. Checkfor ooor connections 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 opn in thg wiro linel: ILABEL 1- Turnthe ignitionswitchOFF. 2. Disconnectthe Primary HO2S (Sensor 8P connector. 1i 3. Turn the ignitionswitchON (ll). 4. Measurevoltage between Primary HO2S(Sensor1) 8P connector No. 4 terminaland bodyground.
D ECMCONNECTOF {16PI
,|
6
2
8
1 4 15
9 t0 1 l
16
12
sG2
IGBN/8LKI
(11 \9
ls thereapprox.5V?
Repai open in tho wirs bstwen the Piimary HO2Slsensor 1) and ECM(D71.
Check for an open in the wire lSG2line): 1. Turnthe ignitionswitchOFF. 2. Disconnect ECM connector D (16P) from the ECM. 3. Checkfor continujtybetween ECM connector terminal D11 and PrimarvHO2S(Sensor 1) 8P connector terminalNo. 3.
sideof le femaleterminals
_l
I
;G2 {GRN/8LK}
1
2 6
Repairopen in the wire betwen th. Primary HO2S(Sen3or1l and ECMtD11l.
11-94
SecondaryHeated Oxygen Sensor (SecondaryHO2S)(Sensor2l

Diagnostic TroubleCode(DTC) P0137: low voltageproblemin the Secondary A Heated scantool indicates lTol3ji]l lh" .: HO2SI(Sensor circuit. 2) OxygenSensor(Secondary
The MIL h.3 bo6n reported on. DTC P0137 is stored.
Problomveritication: '1. Do ResetPro the ECM/PCM cedure, 2 . S t a r tt h e e n g i n e .H o l d t h e engine at 3,000rpm with no load {A/Tin E or E position, M/T in neutral) untilthe radia tor fan comeson. 3. With the scan tool, checkthe H 2 S e c o n d a r y O 2 S( S e n s o r ) outputvoltage 3,000 at rpm. Intermittont failuro, sy3tem is OK at thi3 time, Checktor poor connections or loose wiao6at C131' (locrtod under right 3ide ot da3hl. C432r {located und.r middle of dashl, C125 (C782lt (Secondary HO2S)lsonlor 2l and ECM/PCM.
Does the voltage stay at 0.3 V or less?
Chck fol a short in the Second!ry HO2SI
Turnthe ignition switchOFF. Disconnect he Secondary HO2S(Sensor 4P connector. 2) Startthe engine. H C h e c kt h e S e c o n d a r y O 2 5 (Sensor outputwith the scan 2) tool.
SECONDARY HO2S(S.n.or 2l /aP CONNECTOR C7E2r) 1C125,
C h e c kl o l . 3 h o n i n t h . w i r o {SH()2Slinel: 1. Turnthe ignitionswitchOFF. 2. Discon ect the ECM/PCM n connector 116P). D 3. Checkfor continuitybetween the Sgcondary HO25 (Sensor 2) 4P connector terminalNo. 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. *: D16Y8 engine
(cont'd)
11 - 9 5
System PGM-Fl
2l HO2SI(Sensor (cont'dl HeatedOxygenSensor(secondary Secondary
Heated A P0138: high voltageproblemin the Secondary TroubleCode{DTC) Diagnostic The scantool indicates (Sensor circuit. (Secondary 2) H02S) OxygenSensor
The MIL has been reDorted on. DTC P0138 is stored.
Problemverification: Feset Pro1. Do the ECM/PCM cedure. 2 . 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 (A/Tin E or E position, M/T in neutral) untilthe radiaon, torfancomes 3. With the scantool, checkthe 2 H S e c o n d a r y O 2 S( S e n s o r ) 3,000rpm. outputvoltageat Intermittent failure, 3ystem b OK at this time. Checkfor poor connections or loose wires st C131' llocatedundor right side of dashl. C432i (localed undor middle ol da3h),C125 (C?82)*lsocondary HO2SSensor2) and ECM/PCM.
HO2S SECONDAnY lsontor2) C125 4PCONNECTOR (C782lr

JUMPERWIRE
Does the voltage stay at 0.6 V
sH02s IWHT/REOI
sH()2sG (YEL/RED}
(GRN/BLKIT
Checkior an opn in the Seclndary HO2S: 1. Turnthe ignitionswitchOFF. 2 . D i s c o n n e c tt h e S e c o n d a r y (Sensor 4P connector. HO2S 2) HO2S the 3. Connect Secondary (Sensor2) 4P connectorter_ N m i n a l s o . 1 a n dN o . 2 w i t h a iumperwire. ON 4. Turnthe ignition switch (ll). H 5 . C h e c kt h e S e c o n d a r y 0 2 S with 2) {Sensor outputvoltage the scantool,
D ECM/PCMCONNECTOR Il6PI
ls there0.6V or more?
sHo2sG (YEL/RED)
(GRN/BLKP I sHo2slwHT/REol I
JUMPERWIRE Wiresideof femaleterminals
Check tor an open in th wire (SHO25 line): 1. Turnthe ignitionswitchOFF. connector 2. Connect ECM/PCM Dl4 and D13with a terminals switch (lli. ON 3. Turnthe ignition H 4 . C h e c kt h e S e c o n d a r y 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 D14}and ECM/PCM {D13and,/or SecondarvHO2S{Sensor2).
ls there0.6V or more?
Substitute a known-good ECM/ PCM and recheck.It symptom/ indicaiion goes away. replace the original ECM/PCM.
*: Dl6Yg engine
u)t
11 - 9 6
a
problemin the Secondary The scantool indicates Diagnostic TroubleCode{DTC) P0139: slow response A Heated 2) OxygenSensor(HO2S) {Sensor circuit.
Thc MIL haa bccn rcponed on. DTCP0139i3 3iored.
P.obl6m vo.ificalion: 1. Do the ECM/PCM ResetProc60ure, 2 . 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 (A"/T E or E position, in M/T in neutral) untilthe radiator fan comes on, 3. With the scantool, checkthe SecondaryHO2S{Sensor2) outputat 3,000rpm. Intermittent lailure, system is OK at this time. Checkfor poor connections or loose wires at C13'l* llocatedunder right side ol dash), C432' {locatedunder middle of dashl C125 {C7821* {Secondary HO2SI{Sensor2l and ECM/PCM.
Doesthevoltage staywithin 0.3-0.6 V tor two minutes?
11-97
System PGM-FI
Heater HeatedOxygenSensor(HO2S)
fFor35l (Sensor Heater engine(M/T))' D16Y5 svstem{Except 1) HO2S) OxygenSensor(Primary lFot+ilThescan HO2S)(Sensor Heater (Secondarv circuat. 2)
The MIL haa bgon teDorted on. DTC m135, and/or P0141a.e stored.
\,, .a
problem in the Primary Heated An Trouble Code (DTC)P0135: electrical The scan tool indicatesDiagnostic OxygenSensor Heated P0141: problemin the Secondary A TroubleCode(DTC) Diagnostic tool indicates
Problomvorification: ResetPro1. Do the ECM/PCM cedure, 2. Startthe engine.
Checkfoi en opon or short in the HO2S: 1. Turnthe ignitionswitchOFF. the 2. Disconnect HO2S(Primary 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 terminalsNo. 3 4P connector a n dN o . 4 .
lntermittont failure, swtem i5 OK at thb time. Checkfot poor con' noction3 or loose wiros at 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.
HO2S{S.n.ot l)]|P CONNECTOR PRIMARY HO2s (S6nto12)4P CONNECTORT SECONDARY
sidoot maleterminals Terminal
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 b o d y g r o u n d a n d t h e H O 2 S4 P t c o n n e c t o r e r m i n a l sN o . 3 a n d No.4 individually.
(Cl23I 1) HO2SISENSOR 'P CONNECTOR PRIMARY lcl2s}* 2) sEcoNDARY HO2STSENSOR rP COI{NECTOR
sozsxrc i|iru I t z leozsxrc.

YELI Il - l T-IBLK/WHTI
_l=._1
L--Cp
Checkfoi an open or short in the lino): SO2SXTC* wire IPO2SHTC, switch (ll). oN 1. Turnthe ignition 2. Measurevoltage between the terminals HO254P connector No. 3 and No.4.
Wi16 side of f6male terminals
2l Ho2slsENsoR sEcoNoAnY
(C782)*. lP CONNECTOR
so2sHTc
(BLK/WHT)
tG1 {BLK/WHTI
(To page11-99)
*r P0141 (To page11-99) **: D16Y8 engine
Wire sideof lemaleterminals
\, I
11-98
PRIMARY HO2SISENSOR ilP CONNECTOR 1)
(cr23t
SECONDARY HO2S(SENSOR irP 2l coNNECTOR(C12s)r Checktor an open or short in the wire (lG1linell M e a s u r ev o l t a g e b e t w e e nt h e HO2S connector 4P term;nalsNo.3 ( D 1 6 Y g n g i n eN o . 4 )a n d b o d y e : ground-
lcl Ropair open or short in the wire between Prim.ry HO2S {Sensor1), (No. 15 ALTERNATOR SP SENSORI 17.5A) tuie and SoconderyHOzS,Scnsot 2l+, RoDlac.the No. 15 ALTEBNATOR SP SENSORl7.s Al tuso.
1 1 2 l - r l t 3t { l L_r__.r.____J
|BLK/ O) YELI Y
Wire sideot femaleterminals
Check fo. an open in the wire SO2SHTC* linel: {PO2SHTC, 1. Turnthe ignitionswitchOFF. 2. Reconnect HO2S4P conthe 3. Disconnect ECM/PCM the con nector (32P). A 4. Turnthe ignition switch (ll). ON 5. Measurevoltage between the ECM/PCM connector terminals 46 andA10(A5andA10)*. ls there0.1V or less?
SECONDABY HO2S 2I {SENSOR {P CONNECTOR tc782t*r
IGl -l. {BLK/WHTI
(v)
Repairopen in the wire betweon ECM/PCM{46, A5lt and HO2S {Primary,Secondary*1.
Wirosideof femaletorminals A ECM,/PCM CONNECTOR I32PI
Substituta a known-good ECM/ PCM and recheck.lt 3ymptom/ indication goes away, replace the original ECM/PCM. '11 {Frompage 98}
pozsxrc E/
IBLK/WHTI ^ so2sHrc r-----{vF I tBLK/wHn-J T-r
6
PG1 IBLK)
ll
rl lalglro
21 23
12 t 3
t5 t 6 27
ta t 0 20 2A a 3o
2a
Wire side ol female terminals Chock lor a short in lhe wire {PO2SHTC, SO2SHTC.lino): 1. Turnthe ignitionswitchOFF. 2. Disconnect ECM/PCM the connector {32P). A 3. Checkfor continuitybetween the ECM/PCM connector terminalA6 (A5)*and bodyground.
so2HTClBtX/WHTtr FO2SHTCIBLK/WlfTl
ls therecontinuity?
ReDair short in tho wi.s bstween ECM/PCM(46, As*l and HO2S lPrimary,S.condary.l.
Subslitute r known-good ECM/ PCM and recheck.lf symptom/ indication goes away. rplace the original ECM/FCM. *: P0141 **: D16Y8 engine
11 - 9 9
PGM-FI System
(HO2S) (D16Y5 Heater engine(M/Tll Heated Oxygen Sensor
An The scan tool indicatesDiagnostic Trouble Code (DTC)P1166: electricalproblem in the PrimaryHeated HO2S) Heater system. OxygenSensor(Primary
Th MIL h.3 bean reoon.d DTCP1165b stored.
Problomveritication: 1. Do the ECMReset Procedure. 2. Startthe engine. Intermittent tailur., 3vt.m is OK et thii time (te3i drive may bo nccossaryl. Chock for poor connoctions oa looie wkas bgtween C145 (Priftary HO2S,Sonsor 1) and ECM.
PRIMARY HO2SISENSOR 8P CONNECTOR 1}
Chockth6 Primery HO2S{S6nso1 'll re3btance: '1. Turnthe ignitionswitchOFF. 2. Disconnect PrimaryHO2S the 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 betweenNo. 1 and No. 2 ter mrnal.
Terminal side of maleterminals
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 betweenterminal No. 1 and terminalsNo.3, 4, 6, 7 and 8 individually.
Replacctho Primary HO2S (Scnsor 11,
( T op a g e1 1 - 1 0 1 )
11-100
(Frompage11-100)
1l8P CONNECTOR PRIMARY HO2SISENSOR {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 1 P r i m a r y O 2 S( S e n s o r i 8 P H terminalNo. 1 terconnector minaland bodyground. Chsck for en open'in th6 wire (PGlinel: Measure voltagebeNveen Primary ter' HO2S{Sensor1) 8P connector minalsNo. 1 and No.2. PO2SHTC (BLK/WHT)
ls theremorethan 5 V?
Ropairopen in the wire between thc HO2S.nd Gl01 llocated at thermostat housingt.
V
Check ror a 3hort in the wire (PO2SHTC linel: 1. Turntho ignitionswitchOFF. A 2. Disconnect ECNIconnector (32P) from the ECM. 3. Checktor continuitybetween E C M c o n n e c t o r e r m i n a l4 6 t and body ground.
Substitute a known-good ECM and .echock, lf symptom/indicelion goes rw.y, repl.c the originel ECM. ECMCONNECTOR A
6
PO2SHTC IBLK/WHTI
f)
9L 10
12 l 3 t a r5 l a
25
t 0 1 9 2\
221 23
2a
21
2a 4 30
|,-.'
Iemaleterminals Repair3hon in th6 wiae between the ECM (A6l and the Primary HO2Sls.nso.'l).
Check for an open in the wire (PO25HTC lin.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 connector terminal46 and the PrimaryHO2S(Sensor1) 8P connector terminalNo, 1, Repairopen in the wirc between ECM lA6l and the Prim.ry HO2S lsen3or 'l ).
Substiiuto . known-good ECM and r.ch.ck. lf symptom/indication 90e3.wry, ..pl.c the origin.l ECM.
(cont'd)
11 - 1 0 1
PGM-FI System
HeatedOxygenSensor{HO2S) Heater(D16Y5 engine(M/Tl) (cont'd)
scan tool in^dicates Disgnostic Trouble Code (DTC)P1167: system malfunctionin the PrimaryHeated A lTlLtl lh" .....-''.--....... Oxygen Sensor (Primary HO2S)(Sensor1) Heatercircuit.
The MIL he! bcofl ..oort.d DTC P1167 b stored. on.
Problomveffication: 1. Do the ECMReset Procedure. 2 . 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 1A,/T N or E position, in M/T in noulral) untilthe radiator fan comeson. ls oTC1167 indicated? Intermittent failure, systom k OK at this time. Checkfor poor connoctions or looie wi.es at C145 lPrimary HO2S, Sen3or 1l and ECM. PFIMARY HO2S(SENSOR 8P CONNECTOR 1) lClil5l
Ch6ck for an op.n in the wire {VS+lin.): 1. Turnthe ignitionswitchOFF. 2. Disconnect PrimaryHO2S the (Sensor'1) connector. 8P 3. Turnthe ignition switch {ll). ON 4. Measurevokage between the P r i m a r y O 2 S( S e n s o r l 8 P H 1 connector terminalNo, 6 and body ground. ls theremorethan5 V? check rhe EcM: M e a s u r ev o l t a g e b e t w e e nt h e ECMconnector terminalC25and body ground.
ECMCONNECTOR {3.IPI C
a 6 7 't3 t 4 1 5 1 1 6 1 l 8 1 1 12 1
1
r0
23 21 25
VS+ (WHT)
2i 30 Wire side of female terminals
Repairopen in thc wire ECM{C25} and PrimaryHO2Slsensor 11.
Sub3tilute a known-good ECM and recheck, lf symplom/indication goes eway, leplaceth original ECM.
11-1 0 2
PGM-FI System
HeatedOxygenSensor{HO2S) Heater(D16Y5 engine(M/Tl) (cont'd)
scan tool in^dicates Disgnostic Trouble Code (DTC)P1167: system malfunctionin the PrimaryHeated A lTlLtl lh" .....-''.--....... Oxygen Sensor (Primary HO2S)(Sensor1) Heatercircuit.
The MIL he! bcofl ..oort.d DTC P1167 b stored. on.
Problomveffication: 1. Do the ECMReset Procedure. 2 . 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 1A,/T N or E position, in M/T in noulral) untilthe radiator fan comeson. ls oTC1167 indicated? Intermittent failure, systom k OK at this time. Checkfor poor connoctions or looie wi.es at C145 lPrimary HO2S, Sen3or 1l and ECM. PFIMARY HO2S(SENSOR 8P CONNECTOR 1) lClil5l
Ch6ck for an op.n in the wire {VS+lin.): 1. Turnthe ignitionswitchOFF. 2. Disconnect PrimaryHO2S the (Sensor'1) connector. 8P 3. Turnthe ignition switch {ll). ON 4. Measurevokage between the P r i m a r y O 2 S( S e n s o r l 8 P H 1 connector terminalNo, 6 and body ground. ls theremorethan5 V? check rhe EcM: M e a s u r ev o l t a g e b e t w e e nt h e ECMconnector terminalC25and body ground.
ECMCONNECTOR {3.IPI C
a 6 7 't3 t 4 1 5 1 1 6 1 l 8 1 1 12 1
1
r0
23 21 25
VS+ (WHT)
2i 30 Wire side of female terminals
Repairopen in thc wire ECM{C25} and PrimaryHO2Slsensor 11.
Sub3tilute a known-good ECM and recheck, lf symplom/indication goes eway, leplaceth original ECM.
11-1 0 2
FuelSupplySystem
Diagnostic TroubleCode(DTC) P0171: The fuet systemis too lean. ]TO17il Th" """n tool indicates Diagnostic TroubleCode(DTC) P0172: fuel systemis too rich. The I P0172 The scantool indicates D6scription By monitoring the LongTerm FuelTrim, longterm malfunctions the fuel systemwill be detected. in It a malfunction beendetected has duringtwo consecutive trips,the MILwill come on and DTCP0171 and/orP0172 will be stored. NOTE:lf some ot the DTCS listedbeloware storedat the sametime as DTCP0171 and/orP0172, troubleshoot those DTCS first,then troubleshoot DTCP0171 andlotP0172. *5r P0106-8. P1128-9*3. MAP Sensor P0135: PrimaryHO2SHeater P0137-8: Secondary HO2S P0141: Secondary HO2SHeater P0401: EGRFlow lnsufficient*1 P0441: EVAP SystemInsuificient PurgeFlow*6 P1259: VTEC System*, P1491r EGRValveLift Insuflicient*l P1498: EGRValveLift SensorHighVoltage*1 * 1 ;D 1 6 Y 5 n g i n e e +,: D16Y5, D16Y8 engine *3:'97 model *a:'96 model *5:'98 model '96 *6:'96 Dl6Y5 engine,'96 D16Y7 engine, D16YB engine(sedan),'97 D16Y5 engine,'97D16Y/engine(coupe: KA,KC mod els,sedanKA.KC,KL (DX)models, hatchback: models),'97 all Dl6Y8engine(sedan: KCmodels) KA, PossibleCause D T CP 0 1 7 1 FuelPumpinsufficient flovpressure FuelFeedLineclogged, leaking FuelPressure Regulator stuckopen FuelFilterclogged FuelInjector clogged, inclusion air Gasoline doesn'tmeetOwner'sManualspec. PrimaryH02S (Sensor deteriorated 1) MAP Sensorrange/performance*a (too much flow)*1 EGRSystemmalfunction ValveClearance Exhaust leak FuelPressure Regulator clogged, stuckclosed FuelReturnPipeclogged FuelInjectorleaking Gasoline doesn'tmeetOwner'sManualspec. PrimaryH02S (Sensor deteriorated 1) MAP Sensorrange/performance+4 EGRSysteminsufticient flowrl EVAPPurgeControlSolenoid Valveleaking, stuckopened ValveClearance
DTCP0172
{cont'd}
11 - 1 0 3
PGM-FISystem
FuelSupplySystem(cont'dl
TroubleshootingFlowchart
The MIL has been reoortedon. DTCP0171and/or P0172are stored.
ls the fuel pressure OK? ls the luel pressure high too Chock the fucl p.caaure reguletor and fuel rcturn pip.
Checkthe P.imary HO2SI 1 . S t a r tt h e e n g i n e .H o l d t h e engine at 3,000rpm with no load (.A/T N or E position, in M/T in neutral) untilthe radia 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 ) u t p u tw i t h t h e o scantool. Doesit stayat lessthan 0.3V 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,applyvacuu 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 d a l v ef r o m t h e i n t a k e v manifold side.
Does it hold vacuum?
Checkthe fuel pump, luel fe.d pipe, fuel lilter, and fuel pressu.e regulator.
YES
Checkthe MAP sensoroutputl ON 1. Turnthe ignition switch ill). the l,4AP with the scan 2. Check tool, YES Check the response of the MAP Sensot: 1. Stanthe engine. 2. Check the MAP with the scan tool. ls a MAPof40.0kPa(300mmHg, within 12.0inHg)or lessindicated one secondafter startingthe engine?
L
Checkth6 valve clearance, Checkthe EGRswt6m (D16Y5 en9inel. It they are OK, replacethe luel inlecto.s.
11-104
Misfire Detectedin One Cylinder

Diagnostic TroubleCode(DTC) P030'1: Cylinder1 misfiredetected. I P0301 The scantool indicates I P0302 ths s636tool indicates Diagnostic TroubleCode(DTC) P0302: cylinder2 mistiredetected. 119393-.1 Th"""untool indicates Diagnostic TroubleCode{DTC) P03O3r Cylinder3misfiredetected. P0304 i ths 56sntool indicates Diagnostic TroubleCode{DTC) P0304: Cylinder misfiredetected 4 Description Mistiredetection accomplished monitoringthe crankshaft is by speedwith the crankshaft speedfluctuation(CKF) sensor which is attached the crankshaft. to lf misfiringstrongenoughto damagethe catalyst detected,lhe is MIL will blinkduringthe time ot its occurrence, DTC and P0301, P0302, P0303 P0304 or will be stored. Then,afterthe misfirehasceased, MIL will come on. the lf misfiringthat increases emissionsis detectedduring two consecutive driving cycles, the MIL will come on, and DTC P0301. P0302. P0303 P0304 or will be stored, NOTE:lf some of the DTCS listedbelow are storedat the sametime as a mislireDTC,troubleshoot those DTCS first,then troubleshoot misfireDTC. the P0106r MAP sensor P0131, P0132: HO2S P017'1, P0172t Fuelsupplysystem P0335, P0336: CKFsensor P0401, P1491, Pl498:EGRsystem purgeflow*6 P044'l: EVAP systemInsufficient P 1 3 5 9P 1 3 6 1P 1 3 6 2 : D Cs e n s o r , , T Pl381, l382: YP ensor P C s * 6 : ' 9 6D ' 1 6 Ye n g i n e , ' 9 6 1 6 Y 7 n g i n e , ' 9 6 1 6 Y B n g i n e s e d a n ) , ' 9D 1 6 Y 5 n g i n e , ' 9 7 1 6 Y 7 n g i n e c o u p eK A , ( 7 ( : 5 D e D e e D e KCmodels, sedanKA,KC,KL (DX)models, hatchback: models),'97 D16Y8 all engine(sedan: KCmodels) KA,
PossibleCause . Fuelinjector clogging, fuel leakage, leakage air . Fuelinjector circuitopenor shorted . Sparkplug carbondeposits, fouling,malfunction . lgnitionwires open.leaking . Distributor malfunction a Compression low . Valveclearance of spec out . VTEC systemmalfunction D16Y8 engine) {D16Y5, . HO2S . HO2S circuit
)/
(cont'd)
11 - 1 0 5
PGM-FI System
Misfirein Detected OneCylinder(cont'dl
TroublshootingFlowchart
The MIL hra boenreDortedon. oTc P0301,P0302,P0303,o. P0304i3 indicatsd.
Chocktho luol injector tunction: Slartthe engine,and listenlor a clicking soundat the fuel injector in the problemcylinder.
Check an openor shortin the for harnessbetweenECM/PCM and the fuel injector.
Repairopen or short in the wire.
Replace fu6l injoctoi. the 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, rcplactho originsl ECM/ PCM.
Problemvorilicationi 1. After checkingthe freezedata, do the ECM/PCM ResetProceoure, 2. Exchange sparkplug from the the problemcylinder with one of another cylinder. 3. Connect SCSservice the connector. 4. Test'drive the vehicleseveral times in the rangeofthe lreeze oala.
NOTE: 'lI thore is no lreezedata oI misliring, just clearthe DTC. . lf there is no freezedata of misfir;ng, test drives under various conditions
(To page11-1071
11 - 1 0 6
/
{Frompage11-106}
ls DTCP0301, P0302,P0303, or P0304indicated?
Intermittent mistire due to spark plug fouling, etc- lfiring is OK al this timel.
Doesthe misfireoccurin the othercylinder whosesparkplug was exchanged?
Replace faulty spark plug. lh6
Ch6ck for fuol injector malfunction: 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 minutes, 3. Test drive the vehicleseveral times in the rangeot the freeze data.
NOTE|It there is no lreezedata of mis f;ring,test drives under variouscondi tions are necessary,
ls DTCP0301, P0302,P0303, or P0304indicated?
Inte.mittont misfiro due to bad contact in the fuel injector connecto.lfiringis OK at this time).
Does the mislireoccurin the othercylinder whosefuel injector was exchanged?
Rplac the faulty luel iniector.
Chockfollowing items - Cylinderleak{own - Comoaession - Crank3heft soeed fluctuation ICKFI3ensor
11-107
PGM-FI System
RandomMisfire
*' [Fo3oo o' fFl3oo "nd P0301 l*' l*''
The scan tool indicatesDiagnosticTrouble Code (DTC) P 0 3 0 0 * s r P 1 3 0 0 + * 1 a n d s o m e o f P 0 3 0 1- P 0 3 0 4 : o 3 Randommisfire.
Dgscription Misfiredetectionis accomplished monitoringthe crankshaft by speedwith the crankshaft speedfluctuation(CKF) sensor which is attached the crankshaft. to lf misfiringstrongenoughto damagethe catalyst detected, MIL will blink duringthe time of its occurrence, DTC is the and P0300*5 or and some of DTCS P0301 through P0304 will be stored.Then,after misfirehas ceased. MIL will the c o m eo n . lf misfiringthat increases emissionsis detectedduring two consecutive driving cycles,the MIL will come on. and DTC *a P0300*5 P1300*3. and some of DTCS or P0301 through P0304 will be stored. NOTE:lf some of the DTCS listedbelow are storedat the sametime as a misfireDTC. troubleshoot those DTCS first,then troubleshoot misfireDTC. the MAP sensor P 0 1 3 1P 0 1 3 2 : O 2 S . H P0171, P0172t Fuelmetering P0401, Pl491,Pl498:EGRsystem*r P0505: ControlSystem ldle P1253; VTEC System*, Pl361.Pl362:TDCsensor Pl381.P1382: CYPsensor P1508: valve IAC PossibleCauso . Fuelpump insufficient fuel pressure, amountofflow . FuelIineclogging, blockage, leakage . Fuelfilter clogging . Fuelpressure regulator stuckopen . EGRsystemmalfunction*r . Distributor malfunction . lgnitioncoil wire open,leakage . lgnitioncontrolmodulemalfunction . MAP sensorrange/performance, response*1 poor . Valves carbondeposit . Compression low . IACvalvemalfunction*a ! VTECsystem malfunction*, . Fueldoes not meetOwner'sManualspec..lackoffuel . HO2S . HO2Scircuit
*1:D16Y5 ngine e *2: D16Y5, D16Y8 engine *3; '97 model *4: '96 model *5: '98 model
Troubleshooting By test-driving, determine the conditionsduring which misfireoccurs.Depending these conditions, on test in the order described the table below. in \ \, Possible cause ,;;; \
E GR * 1 system
Crankshaft Fuel Distributor and position(CKP) pressure lgnitionwires sensor section 6 11 - 1 5 0 , section 23
tcM
section 23
rAc
Clearance Valve section 6
MAP sensor
Condition Only low rpm and toao Onlyaccelerating

Only high rpm and toaq
1l-170
1't-126 11-67
o
ra\
@
@
o o
@ @ @
Not specific
NOTE:lf misfiredoesn'trecur,some possible causesare fuel that doesn'tmeet owner,smanual spec,lackof fuel, carbondeposits sparkplug,etc. on
11 - 1 0 8
(KS)(Dl6Y5engine enginel Knock Sensor and D16Y8 {CVTI

TroubleCode(DTC) P0325: malfunction the circuitof the KnockSensor A in The scantool indicates Diagnostic {KS).
Th MIL hes been reooned on. DTC m325 is stored.
Problemv6rification: 1. Do the ECM/PCM Reset Procedure2 . S t a r tt h e e n g i n e .H o l d t h e engine at 3,000rpm with no load (A/Tin N or E position, M/T in neutral) untilthe radiator 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 04,000 rpm for at least 60 seconds. Intormittenl tailure. system is OK at this time ltest drive mev be ls DTCP0325 indicated? Ch6ck lor poor conncclions or loose wi.es between C137(knock sensorlKSl) .nd ECM/PCM.
DIAPHRAGM
Checktoi a shon in the wir. (Ks linell 1. Turnthe ignitionswitchOFF. 2, Disconnect the knock sensor 2Pconnector, 3. Discon ect the ECM/PCM n connector {16P}. D 4. Checktor continuity between ECM/PCM onnector ermi c t nalsDOand body ground. Repairshort in tho wire between ECM/PCMlD6| and knock sensor. Chock lor an open in the wire (KSlinel: 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/PCM connector terminalD6 and knock sensor 2P connector terminalNo. 1. Rapairopen in the wire btwo6n ECM/PCMlD6) .nd knock sen-
D (16P1 ECM/FCM COtrl]\|CrOB KS IRED/ ALU)
Wir side of femal terminals
KS 2P CONNECTOR tcl37l KS
IRED/BLUI
ou1
s ide of
terlninit s l
fgm al
Substitutea known-goodknock sensor and recheck.
Replace originalknock s6nsor. tho
KS IREO/ BLU)
1 7
2 8
a 't0 1 1
16
12
13 1 a
Substitute a known-good ECM/ PCM and r.check. lf symptom/ indication goos away, 16plac6 thc originrl ECM/PCM.
11 - 1 0 9
PGM-FI System
position(CKp/TDC/Cyp) Grankshaft Position/Top DeadCenter/Cylinder Sensor
The position(CKp) A il'oggsl scantool indicatesDiagnosticTroubleCode(DTC)P0335: matfunctionin the Crankshaft sensorcircuit.
fFffi6l
The scantool indicates Diagnostic TroubleCode(DTC) P0336r range/performance A problemin the Crankshaft (CKP) Position sensor circuit.
pl36.l: lntermittent TroubleCode(DTC) interruotion the Top DeadCenter in tPr36r {TDC) tool indicatesDiagnostic I The scan circuit. sensor TroubleCode (DTC)P1362: signalin the Top DeadCenter(TDC) No sensor tn362l The scantool indicatesDiagnostic circuit. The TroubleCode{DTC)P1381: Intermittent interruption the Cvlinderpositaon in tFtu8Tl scantool indicatesDiagnostic (CYP) sensorcircuit. The Diagnostic Troublecode (DTC)P1382: signalin the cylinder position(cyp) sensor No tPJ382l scantool indicates circuit. Doscription The CKPSensordetermines timing for fuel injection and ignitionof eachcylinderand also detects enginespeed. The TDC Sensordetermines ignitiontiming at start-up{cranking) and when crankangle is abnormal. The CyF Sensordetects the positionof No. 1 cylinderfor sequential fuel injection eachcylinder. to 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,D16y8 ongin6:
Th. MIL hs. b..n roportld on. DTC P0335, P0336, Pl361. P1362, P1381 .nd/or P't382ero storod. CKP TDC SENSOR SENSOR CKP CYP SENSOR SENSOR ROTOR ROTOF
Problcmv.riticetion: 1. Do the ECM/PCM ResetProcedure. 2. Stan the engine, b DTCm35, P0336. P1361, P1362. P1381 and/orP1382 indicated?
SENSORROTOR ROTOR ROTOR
Intgrmittont failuro, systam is OK et this time. Chockfor Door connections or loose wires at C120 ldbtributo.l and ECM,/PCM.
DISTRIBUTOR lOP coNNECTOR tC120t TDCP
Chocktor an open in th. CKP/ TDC/CYP..nror: 1. Turnthe ignitionswitchOFF. 2. Disconnect distributor 10P the connector. 3. Measureresistance between th lerminals of the indicated (rseetable). sensor ls there 350 - 700 O? R.pt.ce the di.tributor ignition ho6in9 (3Ge soction23).
S E N S O R oTc CKP
CYPM{BLK)
SENSOR ECMPCM W I R E ERMINALIERMINAL COLOR
P0335 m36
P1361 P1362
2
6
c2 c12
8LU
TDC
3 7
GRN
cr3
c4
cl4
RED YEL BLK
11 - 1 0 1
-
CYP
P1381 P1382
v
( F r o m a g e1 1 - 1 1 0 ) p Chock tor e 3hort in the CKP/ TDC/CYP 3en3or: C h e c kf o r c o n t i n u i t y t o b o d y 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). DISTRIEUTOR 10PCONNECTOR tcl20l TDC P IGRNI
Replace the distributor ignition housing (see section 231.
CheckloJ an opgn in th6 wire3 linesl: ICKP/TDC/CYP 10P 1. Reconnect distributor the connecror, con2. Disconnect ECM/PCM the nector (31P). C between 3. Measureresistance the terminals the indicated of con sensoron the ECM/PCM nector('seetable).
TDC
Terminalside of maleterminals
ls there350- 7000?
Repai. open in the indicated sensor wiles ('see tabl).
ECM/PCMCONNECTORS {31P| C CKPP TDCP {BLUI IGRN} CYPP (YELI
\,
Chock tor a 3hort in the wires linosll {CKP/TDC/CYP C h e c kf o r c o n t i n u i t y b e t w e e n body ground and EcM/PcMconnectorterminalsC2, C3 and/or C4 individually.
M Ropair short in tho indicated 3onsor wiros ('see tablel.
ls therecontinuity?
{WHT)
Wiresid6of female terminals
Subitituto a known-good ECM/ PCM, and recheck. lt 3ymptom/ indicdtiongo6s away, replecothe origin!l ECM/PCM,
P TDC cYPP
CKP P IBLUI
T
11-111
PGM-Fl System
VehicleSpeedSensor(VSSI
The scan tool indicatesDiagnostic Trouble Code (DTC)P0500: malfunctjonproblem in the VehicleSDeed A (D16Y7, Sensor(VSS) circuitlexceptAy'T D16Y8 engine)].
LP@
The scan tool indicatesDiagnostic Trouble Code (DTC)P0501: range/performance problem in the Vehicle A (VSS) SpeedSensor circuitlA/T (D16Y7, D16Y8 engine)1.
The MIL has boonreDortedon. DTCP0500or P0501is stored.

Problem verificationi 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,
ECM/PCMCONNECTORS A l32P) lcl
IBRN/BLKI
1 12 l 3 t 5 15 E I
!
ls the correct speedindicated?
Intermittent f.ilure, 3ystem is OK at this time. Checktor Door connections or loose wircs at C117 (VSS)and ECM/PCM.
27
t 3 t 9 20 2A 4 30
t0 2a
ll
2a
CheckIor an open in the ECM/ PCM: r. r urn Ine rgnrt|on swrtch ut-t-. 2. Elockthe rearwheelsand set the parking brake. 3. Jack up the front ot the vehicle 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 ignition switch (ll). ON 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 6. Measure voltagebetween the ECM/PCM onnector ermi c t nalsC18and A9. pulse0 V Doesthe voltage and 5 V? Substituto a known-good ECM/ PCM and recheck. lf symptom/ indication90e3 .way, replacetho originalECM/PCM.
c t3lPt
I
I tro
1t 12 13 t a t 5 1 6 t t I E
VSS{BLU/WHTI
Wire side ot fma16 tgrminals
Check for a short in the ECM/ PCM: '1. Turnthe ignitionswitchOFF. 2 . D i s c o ne c t t h e E C M / P C M n connector (31P). C 3. Turnthe ignition switch (ll). ON 4 . B l o c kt h e r i g h t f r o n t w h e e l and slowly rotatethe left lront 5. Measure voltagebetween the ECM/PCM connectorterminals C18 andA9. pulse0 V Doesthe voltage and 5 V? NO Bepair 3hort in the wire betwen ECM/PGMlC18)and Substitute a known-good ECM/ PCM and rech6ck.lf symptom/ indication 9o6s away, replsco the original ECM/PCM.
LGl
(BRN/BLKI
6 I
12 t t
E
t 6 'It ! t 27
9 22
t0
2a
tt 21
2t 22 30
9 l0
t 1 1Z l 3 t a | l 5 ] t 6 i 1 7
ta
vss,TcM.
vss.
Repair open in the wire between ECM/PCM{C181 and lf wiie is OK. rest the VSS {seepag23-120).
vss (Btu/wHTl
11-112
(BarolSensor Barometric Pressure

problemin the Barometric A TroubleCode(DTC) 106: range/performance P1 The scantool indicates Diagnostic (Baro) Pressure Sensorcircuit.
Th6 MIL has been rooortod on. DTC P1106 b.tor.d.
Problemveritication: 1. Do the ECM/PCM resetprocedure, 2 . 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 (A/T in E or E position, M/T in neutral)until the radiator fan comes on, then let it idle. 3. Connect SCSService the connefior. 4. Test-drive with the A/T in E (M/Tin 4th gear). position 5. Acceleratefor live seconds usingwide openthrottle.
lntermitteni tailuro.system is OK st this timo.
Subslitute a known-good ECM/ PCM end recheck. ll symptom/ indication goss away. .cplaco the original ECM/PCM.
(cont'd)
11-113
PGM-FI System
Barometric Pressure {BarolSensor(cont'd}
lTilOil Th"""untool indicates Diag nosticTroubleCode(DTC) Pl107:Alowvoltage problemin the Barosensorcircuit. T h e s c a nt o o l i n d i c a t e s i a g n o s t i T r o u b l eC o d e( D T C ) 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 D c P : l P , il O C l crrcutl.
The MIL has beenreportedon. DTCPl107or Pl108is 3tored.
Problemveritication: 1. Do the ECM/PCM ResetPro 2. Turnthe ignition switch {ll). ON
ls DTCP1'107 P1108 or indicated?
Intermittent tailure, 3ystemis OK at this time.
Substitute e known-good ECM/ PCM and r6check. lf symptom/ indication gos away, replace the original ECM/PCM.
11-114
Electrical LoadDetector(ELDI
Load Trouble Code (DTC)Pl297; A low voltage problem in the Electrical The scan tool indicatesDiagnostic (ELD) circuit. Detector
DTCP1297is slored.
Problemverificationi ResetPro1. Do the ECM/PCM cedure, 2. Startthe engine. 3. Turnon headlights. ls DTCP1297 indicated? Intermittent feilure, svdam k OK at this time. Chckto. poor connoctions or looso wir.s at C131 {locatedunder right 3id ot dashl. Cil54{ELD}and ECM/PCM. EID 3P CONNESTOR {qtsill
Check for an opn in the wire {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, 3. Turnthe ignition switch (ll). ON 4. Measure voltagebetweenbody ground and the ELD3Pconnec' No. tor terminal 1. Ropairopen in the wire between No. 15 ALTERNATOR SENSOR SP 17.5Al tuse in thc undor-dash tuse/relaybox and ELD. Checktor short in the ELO: Measurevoltage between body groundand the ELO connector 3P t e r m i n aN o . 3 l
Wire sideof lemaleterminals
-T
L l l 2 l 3 l
f t ,
O) IGRN/RED}
ls thereapprox. V2 4.5
Checktor a short in the wi.e (EL linel: 1. Turnthe ignitionswitchOFF. 2. Disconnect ECM/PCM the connector (16P). D 3. Check{or continuitybetween b o d y g r o u n da n d E C M / P C M terminalD16. connector
D ECM/FCMCONNECTOR (16PI
ls therecontinuity?
Repairshort in the wire betwcon ECM/PCM{D161 and ELO.
Wire side of temale terminals
Substituter known-goodECM/ PCM and recheck. Ifsyrnptom/ indication goes away. roplace the original ECM/PCM.
(cont'd)
1 11 - 1 5
PGM-FI System
Electrical LoadDetector(ELDI {cont'd)
The scan tool indicates Diagnostic TroubleCode {DTC)P1298: high voltage problem in the Electrical A Load (ELD) Detector circuit.
Problemverification: 1. Do the ECM/PCM ResetPro cedure. 2. Startthe engine. 3. Turnon headlights. Intermittent failuro, 3y3tem is OK at thb time. Checklor ooor connection3 o. loose wire3 at C131 (locrted undcr right side of dashl, C354lEtDland ECM/PCM.
ELD3P CONNECTOF lc3sil,
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 c t e E L D3 P c o n , th necror, 3. Checklor continuitybetween body ground and the ELD 3P connector terminalNo, 2,
nepair opcn in the wirc between El-Dconnectorand G4l)2. YES Chackfor an opon in ihe wi.e (EL line): Checktor continuity between the ELD3P connector terminalNo. 3 and ECM/PCM connectortermi n a lD 1 6 .
EL {GRN/REO)
Repairopen in lhe wire betwon ECM/PCM and the ELO. {D16)
Wire sideol female terminals
Chcck a malfunction tho for in ELD:

1. Reconnectthe ELD 3P con2. 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).
ECM/PCMCONNECTORS
Wire sideof temaleterminals

Does the voltage drop?
Substitutea known-goodECM/ PCM and rch6ck. lf symptom/ indication goes away, replaco the original ECM/PCM.
11 - 1 6 1
L
(CKFI Crankshaft SpeedFluctuation Sensor

The scantool Diagnostic Intermittent interruption the Crankshaft in SDeeo tPtg36-lFluctuation indicates circuit. TroubleCode(DTC)P1336: (CKF) sensor Diagnostic TroubleCode(DTC) P1337: signalin the Crankshaft No (CKF) SpeedFluctuation tP-s37 The scantool indicates sensor circuit, Description The diagnostic systemhasa pulserrotor on the crankshaft and a pulsepick-up sensoron the engineblock.The ECM/PCM monitorsthe crankshaft speedfluctuation basedon the CKFsensorsignal,and judgesthat an enginemisfireoccurredif the fluctuation goes beyonda predetermined limit,
The MIL ha3 ten reDortodon. DTC P1336and/or P1337are ltored.
P.oblemvelitication: 1. Do the ECM/PCM Reset Procedure. 2. Startthe engine. Intermittont failure, system i3 OK at this time. Chack for poor connections or loose wires ai C102 (CKFsensorl and ECM/PCM,and mak6 sure CKF sensor mounting bolt is tigt|t. Checklor an open in the CKFsen301: 1. Turnthe ignitionswitchOFF. 2. Disconnect CKFsensor3P the 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 connector terminals No. 1 and No.3.
CKF SENSOR 3P CONNECTOR f' ----i l
iffil
1 1 l 2 1 3 l
cxrrrr f--fc*r
ls there1.6 3.2kO?
lwHrl L,,dJ g/
|BLU)
"
Terminal sideof maletermanals Checkfo. a rhort in tho CXFson3('t:
Check for continuity betwen body groundand the CKFsensor 3P connector terminals No. 1 and No.3 indavidually-
l--l
I-T--
-1
lll 2 3ll
CKF M {WHT)
.tX Y Y
I I
CKF P (8t_ul
( T op a g e1 1 ' l 1 8 )
{cont'd)
11-117
PGM-FI System
(CKFI Sensor(cont'dl SpeedFluctuation Grankshaft
p { F r o m a g e1 1 - 1 1 7 }
Chcck for an op.n in the wires (CKF lines): 1. Reconnect CKFsensor3P the con2. Disconnect ECM/PCM the nector (31P). C between 3, Measureresistance ECM/PCM onnectorermic i n a l s 1a n dC 1 1 . C Repeiropen in tho wire between (C1,Cl'll end the CKF ECM/PCM sensol. C ECM/PCMCONNECTOR {31PI CKFP (BLU/REDI
ls there1.6- 3.2k0?
IT
CKFM
10
1 2 1 3 1 4 1 5 l 6 1 7 '18
23 21 25
21 2a
z) 30
IWHT/RED}
Chck tor a short in the wire lin6): ICKF C h e c kf o r c o n t i n u i t y b e t w e e n conbody groundand ECM/PCM nector terminal C1.
Ropairshort in the wire between ECM/PCMlcl) and the CKFsen-
CKFP (BLU/REDI
Substitute a known-good ECM/ PCM, end rechck. lf 3ymptom/ indicrtion 90e3away, replacolhe origin.l ECM/PCM.
\.
\4
11-118
Crankshaft Position/Top DeadCenter/Cylinder Position(CKP/TDC/CYP) Sensor

Diagnostic TroubleCode (DTC) P'1359: problemin the Crankshaft A Position/Top Dead TD;aEol The scantool indicates Ll=!g Center/Cvlinder Position {CKP/TDC/CYP) sensorcircuit.
The MIL ha3 been roportad on. DTC P1359 is stored.
Problemverification: 1. Do the ECMReset Procedure. 2. Stan the engine. lftheengine won't start,Crank for at least it 10seconds,
Intermittem tailure, system is OK. 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 s r o loose wires betweenthe distributor and the EcM/PcM_
Substituto a known-good ECM/ PCM, and recheck. lf symptom/ indication go6s awaV, rgplace ths original ECM/PCM.
11-119
PGM-FI System
Internal Circuit ECM/PCM
Internal CircuitProblem. P1607: ECM/PCM An Diagnostic TroubleCode(DTC) I P1607 The scantool jndicates
The MIL has beenreportedon. is DTCP1607 stored.
Problemverilication: 1. Do the ECM/PCM ResetPro' cedure, 2. Turnthe ignition switch (ll). ON 3. Wait 10 seconds.
Substitute a known-good ECM/ PCM and recheck.lf syrnptom/ indicationgoes away, replacethe original ECM/PCM.
v
1-120
l/
A/T Signal(TMA/TMB) engine(CVT)) {D16Y5

Diagnostic TroubleCode(DTC) Pl631:TMMMB signallinefaiture. I P1655 iThe scantool indicates
ECMCONNECTOR {31P) C
TMA IGRY}
Problomverilication: 1. Dothe ECMReset Procedure. 2. Drive the vehiclefor several milesat varyingspeeds. Wire sideot temale termrnats
Intermittent failure,syslm is OK at this timo. Chockfor Door connections or loose wires at C131 (locatedunder right side of dash), C4:t8{TCMI,nd ECM.
Ch6ck tor an open in the wire {TMA linol: 1. Turnthe ignitionswitchOFF. 2. Disconnect ECM connector C from the ECM. {31P) 3. Turnthe ignition switch (ll). ON 4. Measurevoltage between E C M c o n n e c t o t e r m i n a lC g r and bodyground.
fcu22P CONNECTOR
ls there batteryvoltage?
Chcck lor a short in the wire ITMA line): Measurevoltage betweenTCM 22Pconnector terminalNo. 7 and body ground. ls there batteryvoltage? RoDair short in the wire between lhe ECM{C9land th6 TCM.
Chock tor rn open in tho wir (TMB line): 1. Turnthe ignitionswitchOFF. 2. Reconnect ECM connectorC (31P). 3. Disconnectthe 22P connector from TCM. 4. Turntho ignition switch (ll). ON 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.
Repairopen in the wire between the ECMlcg, and the TCM.
fcu 22P CONNECTOR
C h e c kf o . a 3 h o r t i n t h e w i r e {TMB line}: Measurevoltage between ECM connoctor terminalC30and body grouno.
{
23 21 25
10
11 1 2 1 3 l 4 1 5 1 6 1 7 l 8 Substitute r known-good ECM and rccheck. lt 3ymptom/indication goe3away, roplacelhe original ECM. 29 30
TMBT {PNK)
Repairshort in the wire between the EcM lc30) and the TcM.
Reprir open in the wi.e bstwen rhe EcM {c30) and rhe TcM.
11-121
ldle Control System

SystemDescription
by The idle speedof the engineis controlled the ldle Air Control(lAC)Valve. currentcontrolledby the to into the intakemanifoldin response electric The valvechanges the amount of air bypassing the properidle speed. lhe Whenthe IACValveis activated, valveopensto maintain ECM/PCM.
D16Ys, D16Y8 ensine(M/T):

I -
T r )
, :::/ __ BLK
_< *f,T.ir;tJ T MAINRELAY
VARIOUS SENSOnS
aLk
IROTARY} IACVALVE
EIVGINE COOLANT
(CVTI, D15Y8 engine(A/T): D16Y5
INTAKEMANIFOLD
;[i-
<l;litf,U''j
D16Y7 engine:
vARtous
SENSORS
11-1 2 2
a
1 . After the enginestarts,the IACvalveopensfor a certaintime, The amountof air is increased raisethe idle speed to about 150- 300rpm. When the coolanttemperature low, the IAC valve is openedto obtain the propertast idle speed.The amount of is bypassed is thus controlled relation the enginecoolanttemperature. air in to
IOLE SPEED lrpml
176 80
Et{Gt1{E TEMPERATURE COOLANT

(oF)
toc)
1.
When the idle speedis out of specification the scantool does not indicate and Diagnostic TroubleCode{DTC} P0505 or P1508, check followingitems: the . A d j u s t h e i d l es p e e d s e e a g e1 1 , 1 4 1 ) ( p . S t a r t es w i t c h i g n a ( s e e p a g e l l - 1 3 0 I r s l . A i r c o n d i t i o n i ns i g n a ( s e e a g e1 1 - 1 3 1 ) g p l . ALT FRsignal(seepage11 133) ' Brakeswitchsignal{seepage1'l-134) ' PSPswitchsignal(except Canada model)(seepage11-135) . A/T gear positionsignal(seesection'14, D16Y5 engine(CVT): p a g e1 l - 1 3 7 ) . Clutchswitchsignal(D16Y5 (seepage 11-139) engine(M/T)) . Hosesand connections . IACvalveand its mountingO-rings lf the aboveitemsare normal.substitute known-good a IACvalveand readjust idle speed(seepage 11-141). the (and the scantool does not indicateDTCP0505 P1508) lf the idle speedstill cannot be adlustedto specification or after IAC valve replacement, substilutea known-goodECM/PCM and recheck. symptom goes away, replacethe lf originalECM/PCM.
11-123
ldle ControlSystem
ldle ControlSystem
ldle P0505: controlsystemmalfunction. TroubleCode{DTC) Diagnostic lT05O5l Th" """n toot indicates first,then trouor troubleshoot DTCP1508 P1509 is or NOTE:lf DTCP1508 P1509 storedat the sametime as DTCP0505, bleshootDTCP0505. Possiblecause . IACvalvemechanical malfunction . Throttlebody cioggedport, improperadiustment r lntakemanifoldgasketieakage . Intake hoselooseleakage air . V a c u u me a k l . ECTsensorincorrect output . ThrottlePosition sensorincorrect output*1 Tloubleshooting Flowchart
Th6 MIL has beenreoortodon. DTC P0505is stored.
Problsm vorificationl 1 . 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 in load 1A,/T E or E position, radiator M/Tin neutrali untilthe fan comeson, then let it idle. *1 -Wi*i t2. tne scan toot, checLtt e-l posilion Throttle shouldbe 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., repair faultysenthe sol9!!9'llj:-.-.-.l 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 , radiator fan, and air defogger, conditioner not operating are (seepage11 139). -
ls the idlespeedOK?
Intermittnt failure, system is OK et this time.
ls it 550 rpm or less?
(Topage11-125) * 1 : ' 9 6m o d e l n l y o
{ T op a g e1 1 - 1 2 5 )
11 -1 2 4
{Frompage11-124}
(A,/T and D16Y7engine) I Checkthc IACvrlvo: Disconnect 3P connectortrom the the IACvalve.
' {Dl6Y5, D'|6Y8enginwith M/T) - - - - - - - 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.
Does enginespeed the drop or the enginestall?
_ l
Dl6Y5, Dl6Y8 ongin:

Adi6t thc lbasll idle 3pa6d ls6c p.9 11-1391. it'. impo$ible, ll cl6an th ports in tha throttle body. UPPER
lFrompage I1-124)
Putyour fingeron the upperport in the throttle body. Chack for vacuum laakr. make 3u.c th. throitla valvc is complctaly closrd, .nd ropair I necca3ary.
Dl6Y7 engine:
Doeslhe enginspeed drop?
Adiust tho idlo sp..d (3e pag. 11-139). it'5 impo$iblo, r.placo It tha IAC Yalve.
11-125
ldle GontrolSystem
ldle Air Control(lAClValve(Dl6Y5,Dl6Y8 enginewith M/T)
A Trouble Code (DTC)P1508: problem in the ldle Air Control(lAC)valve The scan toot indicatesDiagnostic 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 b6n reDortgd on. DTC P150a is stor.d.
Problomvorification: ResetPro1. Do the ECM/PCM cedure. 2. Startthe engine,and warm it up to normal operatingtemperature.
vat_vE
indicated? ls DTCP1508 lntc.mittent tailure, svslem i5 OK et thb time. Check for poor connoction3 or 10036wirg3 st C138 llAC v.lvel .nd ECM. IAC VALVE2P CONNECTOR ICl38}
Check to..n open in tho wi.o llGPl lin6l: 1. Turnthe ignitionswitchOFF. the IAC valve 2P 2. Disconnect connector, ON switch (ll). 3. Turnthe ignition 4. Measure voltagebetweenbody ground and the IAC valvo 2P No. connectorterminal 2.
t \
/T\'--'J rcpr
2 J -
rYCLrBtXl
r$, Y =
Wire sid6ot femaleterminals ls there batteryvoltage? Reprir opsn in the wiro bstwcen IAC valvo and PGM-FImain rcltY.
Chacklor rn open o. short in the wirc {lACv linel: 1. Turn the ignition switch OFF the IAC valve and reconnect connecror, the 2. Disconnect ECMconnector A (32P). 3. Turn the ignilionswitchON lll). 4 . M e a s u r ev o l t a g e b e t w e e n b o d y g r o u n da n d E C Mc o n A12. nector terminal
A ECMCONNECTORI32PI
12 l 3
5 6 1 5 i 6 't, t l
! 1 9 t9
to
ao
2a
2a
tAcv IBLK/ BLUI
lzsVlztl lz.lzelnl/l | .,'
(To page 11-127)
11 -1 2 6
(Frompage11-126)
ls ther batteryvoltage?
Ropairopen or short in the wiro b.twen ECM lA12l and IAC
Checkthe IAC valvelunction: MomentarilyconnectECM conn 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 trrhinals Doesthe IACvalveclickT
Substitute . known-good ECM and rocheck. lt 3ymptom/indication 906 away, .oplaco tho origin.l ECM.
11-127
ldle Gontrol System

ldle Air Control(lAClValve (A/T and Dl6Y7 engine)
lTi509l (lAC) TroubleCode(DTC) P1509:Aproblem inthe idleAirControl valvecircuit. Th""""ntool indicates Diagnostjc
v
BIMElAL
lo The (Rotary) IAC Valvechanges the amount ot air bypassing throttle body in response a currentsignaltrom the the
ECM/PCM in order to maintain the proper idle speed.
The MIL has beenreooned on. DTCPl 5'lx)is sto.ed. Problomverification: 1. Do the ECM/PCM ResetProcedure, 2. Turnthe ignition switch (ll). ON ls DTCP1509 iodicated?
SHAFT Intermittent failuro, svstem ia OK at lhis time. Check for poor connections or 10036wires at C109 {lACvalve) end ECM/PCM.
VALVE
STOP?ER
ECM/PCMCONNECTOR I32P} A Checkfor an open in the wires IPGlin6): Measurevoltage between body ground and ECM/PCM connector terminalsA10 and A23 individu PGl (BIK}
Repair op6n in lhe wires between ECM/PCM and G101 {locat6d ar the thermostat housing.l
\3
Wire sid ol temale terminals
Check the ECM/PCM inpul voltage: 1. Turnthe ignitionswitchOFF. 2. Disconnect ECM/PCM connector A (32P) from the ECM/PCM3. Turnthe ignition switch (ll). ON 4 . M e a s u r e v o l t a ge b e t w e e n body ground and ECM/PCM connector terminalsA14 and A13+individually. ls therebaftery vohage?
2 I 1 2 l 1 3 a 1 5 1 6 1 7 t8 t9 1 tAcv N {oRNt.
10
22 23
1'l
. l
O)
m
3o
2a
27
28 29
IACVP IBLK/BLU}
(Topage 129) 11
Check the IAC valve: 1. Turn the ignition switch OFF. 2. Disconnect the IAC valve 3P connector. 3. Measure resistance between IAC valve 3P connector termi' n a l N o . 2 a n d t e r m i n a l sN o . 1 and 3 individually.
IAC VALVE3P CONNECTOB
IACV N
IACV P
ls there16- 28 O?
IGP Terminal sideof male Iermtnals
Substiluto a known-good ECM/ PCM and rocheck.lf symptom/ indicalion goes away, replace the original ECM/PCM.
*: IACV N line
11 -1 2 8
p { F r o m a g e1 l - 1 2 8 }
IAC VALVE3P CONNECTOR {CIOI} Check tor an open in the wire (lGPline): 1. Turnthe ignition switchOFF. 2. Disconnect the IAC valve 3P connector. 3. Turnthe ignition switch (ll). ON 4. At the wire harness, measure voltage between IAC valve 3P connector terminalNo. 2 and body ground. ls therebattery vohage?
IGP {YEL/BLKI
Repairopen in the wire betweon lh6 IAC valvo and PGM-FImain relav.
Checkfor an open in tho wires (IACVP, IACV N' lines): 1. Turnthe ignitionswitchOFF. con 2. Disconnect ECM/PCM the nectorA (32P). 3. Checkfor continuitybetween IAC valve3P connector termi nal No. 3 and ECM/PCM con' n e c t o r t e r m i n a lA 1 4 ( a n d betweenIAC valve 3P connector terminal No. 1 and ECM/ A13)*. PCMconnector terminal Repairopn in tho wire bctwoen the IAC v.lve end ECM or PCM (A14, A13*1.
I
IACV N
toRNl*
' t 2
IACV P IBLK/BLUI ECM/PCM A CONNECTOR t32Pl IACV P (BLK/BLU)

E 9
Check tor a short in th wires (IACV P, IACV Nr linesl: Check tor continuity between 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* individually.
lo
tt
12 l 3 1 a t 5 l 6 1 7 ta t 9 2A 25 21
2a
2a
29 30
terminals Wire sideof female Repairshort in the wire between tho IACvalveand ECM/PCM 1A14. A13*).
3 a
a 9
t0
tl 24
Sub3titute a known-good ECM/ PCM and reched( lf syrYFtom/indication goes away, replacth6 o.igin.l ECM/PCM. ': IACVN line
t 2 t 3 lil
t 5 t 6 1 7 l a t 9 20
tacv N toRNl.
Lry,"*"YYO
l,
11-129
ldle ControlSystem
StarterSwitch Signal
This signalsthe ECM/PCM when rhe engineis cranking. NOTE: . A/T: Transmission or @ posnion. in E]
M/T: in neutral
ECM/PCMCONNECTORS Chockfor an open or ihort in the wire {STSlinol: Measurevoltage betweenECM/ PCMconnectorterminals Ag and C6 with the ignition switch in the start(lll)position.
A I:PPI LGl
I
c t3lPt
E 9 22 't0 1' |
sTstELu/oFNt
7 't8 t 9 t0
3
25 27
3 a
t t 12
5
t5 t6 1 l
t 2 l 3 t 4 1 5 1 6 t 7 ta r 9 20
23
2a
r3 t a
E
ut
29 30
2a 2a
29 30
Wire side ot female terminsls
Inspecttho No. 31 STARTER StG, NAL {7.5A) fuse in the undeFdash Iuse/relay box.
St.rior switch sign.l b OK. -
Raplir rhon in thc wiro b.tw..n the ECM lC6) and tho No. 31 STARTER SIGNAL (t.5 Al lu3. or th. PGM-FI main relsy. ReDhcotho No, 31 STARIR SIGNAL17.5 A1tu3..
Rapair open in tha wire batwatan tho ECM/PCM lC6|and th. No.31 STARTER SIGNAL17.5 tu!.. Al
\,
11-130
Air Conditioning Signal

This signals the ECM/PCM when there is a demandfor coolingtrom the air conditioning system.
A l32Pl LGl IBRN/BLK}

2 I 8 9 1 2 1 3 ta 't5 't6 1 7 t 8 1 9 a) 22
ECM/PCMCONNECTORS
c t3lPl ACSIBLU/REDI
l0 23
It
2a
1 I a 5 2 't'l 12 t 3 1 l t 5 t 5 1 7 t 8 23 2a 2a
9 10
Check lor a ahort in th6 wir {ACSlinel: 1. Turnthe ignitionswitchOFF. 2. Disconnect the A/C pressure switch 2P connector(see sect i o n2 2 ) . 3. Turn the ignitionswitchON (ll). 4. Measurevoltage between ECM/PCN4 nnector ermico t nalsC5 and A9.
25
27
2a xt 30
z, 30
Wiresideof lemaleterminals
ls thereapprox.5V?
Chockfo. a short in the wire IACS linol: 1. Turnthe ignitionswitchOFF. 2. Disconnect ECM/PCM the connector (31P). C 3. Checkfor continuitybetween body ground and ECM/PCM connector terminal C5,
ACS{BLU/RED}
Repairshort in the wire botwsn the ECM/PCM (Csl .nd the A/C pro3suraswitch.
Chock tor an open in the wire IACClin.l: 1. Turnthe ignitionswitchOFF. 2, Reconnect the A/C pressure switch 2P connector. 3. Turnthe ignilionswitchON (ll). 4. Momdntan'ly connect ECM/ PCM connectbr terminalsA9 and A17 with a iumper wire severaltimes.
Substitute a known-good ECM/PCM and rchock, lf proacribgd vohago i3 now aveil.ble, replace the original ECM/ PCM. See the sir condhione. inspction l.oc s.ction 22).
LGTIBRN/BLKI
1 2 3 a 12 l 3 t a 1 5 1 6 1 25 27
- r l ; l s l r Il s l s l ! o r r l l
(To page11-132)
ACC
w-z-
lnltslil/1zzl ze I z+ |
wlRE JUMPER {cont'd)
IBLK/REDI
1 1 131
ldle Control System

Air Conditioning Signal (cont'dl
( F r o m a g e1 1 - 1 3 1 ) p
ls therea clicking noiselrom the A,/C compressorclutch?
Check for an open in the wir {ACCline): Momentarily connect under-hood fuse/relay box 9P connector ter minal No. 5 to body groundwith a jumperwire several times.
UNDER.XOOD FUSE/RELAY BOX9P CONNECTOB tc3s2t
t
5 JUMPER WIRE
2
6 / 8
3 a
9
ACC IBLK/RI IBLK/REOI Wire side ot female side ot

tefmrnalS
ls therea clicking noisefrom the A/Ccompressor clutch?
See air conditioner inspection 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.
A (32Pt
Check tor the operation of the A/C: 1. Startthe engine. 2. Turnthe blowerswitchON. 3. Turn the A"/C switch ON.
ECM/PCMCONNECTORS
LGT
(BRN/ALKI
I 6
c (31Pt ACSIBLU/REDI
l0 23 tl
I 8 I
9 22
'to
12 1 3 t a t 5 t 6 1 7 I E 1 9 25 27
E
zo
30
2a
t t 12
t4 2a 2a
lf,
1 7 't8 29 30
WiresideoI femaleterminals Check for an open in the wire {ACSlin6): Measurevoltage betweenECM/ PCMconnector terminals and Ag
Air conditioningsign.l is OK. ls therelessthan1.0V?
Rprir open in tha wire bstween 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 conditionerinspection (seesection22).
11 -1 3 2
Alternator(ALT)FRSignal
(ALT)is charging. This signals ECM/PCM when the Alternator the
lnspectionot ALI FRSignal. A t32Pl LG1 (BRN/BLKI Ch6ck for a sho.t in the wire {ALT F line): 1. Disconnect 4P (3P)*conthe nectorfrom the ALT. 2. Turnthe ignition switch (ll). ON 3, Measu e voltage between r E C M / P C M o n n e c t o rt e r m i c nalsC'|7and A9. ECM/PCMCONNECTORS
c t31Pl
Wire sideot temaleterminals Check tor a short in the wire IALT F linel: 1. Turnthe ignitionswitchOFF. 2. Disconnect negativebat the tery cablefrom the battery. 3. Disconnect ECM/PCM the con nector (31P). C 4. Checklor continuitybetween b o d y g r o u n da n d E C M / P C M connector terminal C17.
ALT F {WHT/BEO) 5
6 l 7|
9 't0
1 1 12 1 3 l 4 1 5 l 6
rlrl/
ls thereapprox- V? 5
23 21
,/ / ,/ E 30
(wHr /FED) 0) ALrF
Checkthe operation ot the ALT: '1. Turnthe ignitionswitchOFF. 2. Reconnect the ALT 4P (3P)* connector the ALT. to 3 . 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 {A,/T E or E position, in M/T in neutral) untilthe radiator fan comes on, then let it idle. 4, Measue voltage between r ECM/PCM connectorterminals Cl7 andA9.
ls therecontinuity?
Repair shon in the wire between the the ECM/PCM {C17)end ALT.
Substitute a known-good ECM/ PCM and recheck. It prescribed voltage is now available,replace the originalECM/PCM.
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 Chec* lor an opeo in the wire IALT F lin): 1. Turnthe ignitionswitchOFF. 2. Disconnect 4P (3P)*con the nectorfrom the ALT. 3. Turnthe ignition switchON (ll). 4. Measurevoltage between the ALT 4P {3P}*connector termi n a l N o . 4 ( N o .1 ) * a n d b o d y ground. Repair open wire between the ECM/PCM {Cl7).nd the ALT. 3Pr
-+r1 1
ffi
2|
JUMPER WIRE
l 3 l ll rr-r r -lr JUMPER rwHr/(V) WIRE REot Y
ALT F (WHT/RED'
ls thereapprox- V? 5
':Canadamodel
11 - 1 3 3
ldle Control System

BrakeSwitch Signal
This signals ECM/PCM rne when the brakepedalis depressed.
Inspcctionol &ak Swhch Signal.
Are the brakelightson without depressingthe brakepedal?
Do the brakelightscomeon?
Inspect the HORN('15A) fu6e in 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: 1. Depress brakepedal. the 2. Measurevoltage betwoen ECM/PCN4 connectorterminals A9 and D5 with the brakepedal depressed. ECM,/FCM CONNECTORS
A t32P)
taRn u
10
23 tl 21
I
D tl6Pl 3
8 I
BKSW IGRN/ WHT}

5
1 2 t I 6 8 I 1 2 1 3 1 4 't5 l6 1 ' l8 t9 20 22 25 27 2A
a
10 1 1 16
12
30
13 t4 15
Rop.il open in the wi.6 botween tha ECM/PCMlDs) rnd thc b.ako lwitch,
Wir sid6 of lemale terminals
8r.ke 3witch 3ignal ia OK.
11-134
Switch Signal(USAI PowerSteeringPressure IPSP)

This signals ECM/PCMwhen the power steeringloadis high. the
lNpction of PSP3witch rignal. ECM/PCMCONNECTORS
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 E C M / P C M o n n e c t o r e r mi ' c t n a l s A 9 n dC ] 6 . a
Wire side of femalo terminals Chockfor .n opn in lhe wire (PSP SW linol: 1. Turnthe ignitionswitchOFF. 2. Disconnect PSPswitch2P the connecror, 3. Turn the ignitionswitchON lll). 4. At the harnessside, connect the PSPswitch 2P connector t e r m i n a l sN o . 1 a n d N o . 2 with a jumperwire. 5. Measurevoltage between ECM/PCM connectorterminals Ag andC16.
PSP 2P SW]TCH CONNECTOB PSP tcBf{l SW
ls therelessthan 1.0V?
JUMPER T-1 rJJ wrFE2/ GND IBLKI Wir sid6 of temale terminals
ls therelessthan 1.0V? -
Ch6ck thc opo.ation ot th6 PSP rwhch; 1. Stanthe engine 2 . T u r n s l e e r i n gw h e e l t o I u l l lock. 3. Measurevoltage between EC 4,/PCM connectorterminals Ag and C'|6.
Bepair opon in the wire betwocn th6 ECM/PCMlcl6l and the PSPswitch. Ropeir open in BLK wir btween the PSP 3wiich .nd G101.
ls there bafteryvoltage?
PSP .whch tignal i3 OK.
{ T op a g e1 1 - 1 3 6 )
(cont'd)
1 1 135
ldle Control System

(PSPISwitch (cont'dl PowerSteering Pressure Signal(USA)
(Frompage11-135)
C h e c kt o r s h o . t i n t h 6 P S P switch: 1. Turn the ignitionswitchOFF. 2. Disconnect 2P connector the from the PSP switch. 3. Turnthe ignition switch (ll). ON 4. Measu e voltage between r E C M / P C l v lo n n e c t o r e r m i c t n a l s 9 a n dC 1 6 . A
ECM/PCMCONNECTORS
Checkfor a shon in the wir6 {PSP SW linel: 1. Turnthe ignitionswitchOFF. 2. Disconnect ECM/PCM the connector (31P). C 3. Checkfor continuitybetween b o d y g r o u n da n d E C M / P C M connectorterminal C16.
9 10
1 t 12 13 14 15 1 6 1 7 18
23 21 25
30
\-
PSPSW {GRN}
ls therecontinuity?
Rep.ir short in th6 wire between the ECM/PCM{C16)and rhe PSP switch.
Substitute a known-good ECM/ PCM and recheck.lf p.escribed voltage is now available,replace the original ECM/PCM.
11 - 1 3 6
(CW) GearPositionSignal(D16Y5 engine) AutomaticTransaxle

s T h i ss i g n a l sh e E C Mw h e nt h e t r a n s m i s s i oi n i n E o r E p o s i t i o n . t
Check the ope.ation of th A/T gear position switch: 1. Turnthe ignition switch (ll). ON 2. Observethe A"/Tshift position indicatorand selecteach posi tronseparately.
Seethe A/T g6ar position indicator inspection{seesection 141.
ECMCONNECTORS Ch6ckfor a short in ihe wir (ATP NP linel: '1. Turnthe ignitionswitchOFF. 2. Disconnect 14Pconnector the from the gaugeassembly. the 26P connector 3, Disconnect lrom the TCM. 4. Turnthe ignition switch (ll). ON voltagebetweenECl/l 5. Moasure A c o n n e c t ot e r m i n a l s 9 a n d r
Wire sideof Iemaleterminals
ATP NP {LT GRN)
c29.
Checkfor a shon in the wire IATP NPline): 1. Turnthe ignitionswitchOFF. 2. Disconnect the ECM connec' t o rC ( 3 1 P ) . 3. Checkfor continuitybetween b o d y g r o u n da n d E C Mc o n nector terminalC29.
I
9 10
1 1 12 13 1 a 1 5 16 1 7 18
ls thereapprox.5V?
23 21
29 30
I ATP N P I ILT GRNI
Checklor .n open in th wiro IATP NP linel: 1. Turnthe ignitionswitchOFF. 2. Reconnect l4P connector the to the gaugeassembly. 3. Reconnect 26Pconnector the 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.
ls therecontinuity?
Repairshort in the wire between the EcM {c29)and rhe gau96 assemblv.
Substitute a known-good ECM and recheck.ll prescribadvoltege is now available,replacethe originalECM.
(Topage11-138)
(cont'd)
1 1-137
ldle Control System

(CWl GearPositionSignal(D16Y5 AutomaticTransaxle engine)(cont'd)
( F r o m a g e1 1 - 1 3 7 ) p Repair open in the wire btween the ECM lc29l and the gaugaa!3ombly. Repair open in the wire between the gaugo assembly rnd the A/T gear position switch.
l s t h e r e l e s s t h a n 1 . 0V ?
Checkfor a short in the wire IATP NP linel: Measurevoltage between ECM connector terminalsA9 and C29 with the transmission gear. in ATP NP ILT GRNI
Wire side ol female torminals ls there batteryvoltage? Repairshort in the wire between ECM(C291 and gauge assembly.
A/T gear po6ilion signel is OK.
11 - 1 3 8
ClutchSwitchSignal(Dl6Y5engine(M/Tll
This signals ECMwhen the clutchis engaged. the
Inapction of clutch .witch signal. A t32Pl Ch.ck for rn opcn in the wiro (CI..SW lin.l: oN 1. Turnthe ignition switch (lll. 2. Measure voltagebetweenECM connector terminalsC29 and A9. Wire sid6of femaleterminals (REDI ECM COITNECTORS LGl IBRN/BLK}
ls thereapprox.5V?
Checkth. clutch 3witch: 1. Turnthe ignitionswitchOFF. 2. Disconnect the 2P connector trom the clutch switch. 3. Turn the ignitionswitchON (ll). voltagebtweenECM 4. Measure connectorterminalsC29 and A9.
ls thereapprox.5V?
Chock tor an opcn in the wiro (CLSWlinel: 1. Depress clutchpedal. the 2. MossurevoltagebetweenECM connector termin6lsC29 and A9.
Check lor a shorl in tha wire (CLSWlinel: 1. Turnthe ignitionswitchOFF. 2. Disconnect the EcM connecthe tor C (31P)from ECM. 3. Checklor continuity between ECM connectorterminal C29 and body ground.
9 't0
t t l 2 ! 3 1 a l 5 t 6 l 7 1E
cLsw
(REDI
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 otiginrl ECM.
{cont'd)
11-139
ldle ControlSystem
ClutchSwitch Signal(Dl6YSengine(M/Tl) (cont'dl
(Frompage11,139) CLUTCHSWITCH2P OONNECTOR Chockthg clutch switch: 1. Turnthe ignitionswitchOFF. 2. Disconnect 2P connector the Irom the clutch switch. 3. Checktor continuitybetween the clutch switch connector terminals 1 and No.2 with No. the clutch pedaldepressed. Terminal sideof male terminals Adiu.t the clutch switch. Roplecothe clutch .witch.
ls voltage lessthan '1.0 V?
CLUTCH SWITCH CONNCCTOF 2P lcillTl
r-+-r
Checktor an opon in the wiro: 1. Turnthe ignition switch (ll). ON 2. Measure voltagebetween the clutch switch connectorterminal No. 1 and body groundwith the clutchpodaldepressed.
LJ_J
clsw (REDI 1;\ Y
I
Wire side of female terminals Rcpril opon in the wirc betwocn th6 EcM lc29) .nd tha clutch switch.
ls there approx. 5 V?
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 '96,'97 D16Y5,'96-'98 Dt6Y8engine{M/T} NOTE: . 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 items: - 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 then check that the headlights off. are engine. '1. Startthe engine.Hold the engineat 3,000rpm with in no load {transmission neutral)until the radiator fan comeson, then let it idle. a Connect tachometer. Disconnect IACvalveconnector. the Adjustthe idle speed,if necessary, removingthe by cap and turningthe idle adjusting screw. NOTE: After adjustingthe idle speed in this step, 23). recheck ignitiontiming (seesection the lf it is out of spec,go backto step4. IDLE
Turn the ignitionswitchOFF. 7 . Reconnect 2P connectoron the IAC valve,then the do the ECMresetprocedure. Restart and 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 . then checkthat the headlights are Startthe engine, off. ldle speed should be: 670 t 50 rpm {USA} 750 t 50 rpm lcanadal (Low) ldle the enginefor one minutewith headlights the ON.and check idlespeed. ldl8 spd should bo: 750 I 50 rpm 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 minute with heaterfan switch at Hl and air conditioner on,thencheckthe speed. idle ldle speed should be: 8101 50 rpm NOTE:lf the idle speed is not within specification, (cont'd) seeSymptomCharton page 11-46.
lf the enginestalls,restart the enginewith the accelStabilize rpm at the eratorpedalslightlydepressed. 1,000, then slowly release pedaluntil the engine the idles. Check idlingin no-load conditions: headlights, blower fan, rear defogger, radiatorfan. and air conditioner are not operating. ldl 3pdshould be: il50 t 50 rpm
11-141
ldle ControlSystem
ldle Speed Setting (cont'd)
'96, '97 Dt6Y5 engino {CvT), '96-'98 Dl6Y8 engine lA/T) rnd '96-'98 D16Y7engine Adjustthe idle speedusing a HondaPGM Testerif possible.lf not, usethe followingprocedure: NOTE: . Leave the 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 beenreported on. - l g n i t i o ni m i n g t - Sparkplugs - Air cleaner - PCVsystem
1.
D16Y5, D16Y8 engine:
Connect tachometer. a Startthe engine.Hold the engineat 3,000rpm with no load (A/T in N or E position, M/T in neutral) until the radiator comeson, then let it idle, fan Checkthe idle speedwith no-loadconditions: headlights,blower fan, rear defogger,radiatorfan, and air conditioner not operating. are 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: D15Y8 engine, D16Y7 engine: 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 , checkthe idle speedagain.lf it is out of spec,turn the idle adiusting screw1/2-turn again. NOTE: Do not turn the idle adjustingscrew more than 1/2-turn without checking idle speed. the 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 switch at Hl and air conditioner on, then checkthe idle soeed. ldle speed should be:
Dl6Y7 engine: NOTE:When you removethe ACL housing,do not disconnect IAT sensorconnector. the
MIT AIT
750t 50 rpm 750i 50 rpm {in E or E position)
Adjustthe idle speed,if necessary, removingthe by 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 g c r e w 1 / 2 - t u r n s clockwise counterclockwise. or
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 adjusting screwwhen the air conditioner on. is t lf the idle speed is not within specification, see SymptomCharton page 11-46.
11- 1 4 2
Inspection/Adiustmeni '98 D16Y5 engine(M/T) NOTE:Beforesettingthe idle speed,checkthe followIng trems; - The MIL hasnot beenreported on. - l g n i t i o ni m i n g t - Spark lugs p - Aircleaner - PCVsystem 1 . Startthe engine.Hold the engineat 3,000rpm with no load (transmission neutral)until the radiator in fan comeson, then let it idle. 2. Connect tachometer. a Disconnect IACvalve2P connector the and the EVAP purgecontrolsolenoid valve2Pconnector.
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 . After adjusting the idle speed recheck the ignition timing (see section 23). lf it is out of spec, go back to step 4. |DLE
Turn the ignitionswitchOFF.

7 . Reconnect the 2P connectors the IAC valve and to
the EVAPpurge controlsolenoidvalve,then do the ECMresetprocedure. and idle the enginewith no-loadconditions 8 . Restart for one minute,then checkthe idle speed.
EVAPPURGE CONTROL VALVE SOLENOID
ldle speedshouldbe: 6701 50 rpm NOTE:lf the idle speed increases 810 t 50 rpm, to this meansthe EVAPsystemis purgingthe canister. 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 pedal, speed above 1,000rpm with the accelerator the then slowly release pedal. 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 (Low)ON, and checkthe idle speed. ldle speedshouldbe: 750 I 50 rpm 1 0 . T u r n t h e h e a d l i g h t s f f . l d l e t h e e n g i n ef o r o n e o minute with heatertan switch at Hl and air conditioneron, then check the 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)
lf the enginestalls,restart enginewith the accelthe eratorpedalslightlydepressed. the Stabilize rpm at 1,000, then slowly release pedaluntil the engine the idles. Check idlingin no-load conditions: headlights, blower fan, rear defogger, radiatortan, and air conditioner are nor operalrng. ldle speed should be: 450 I 50 rpm
11-143
ldle ControlSystem
ldle Speed Setting (cont'dl
'98 D16Y5engine (CVTI Adjustthe idle speedusing a HondaPGM Testerif possible.lf not, usethe followingprocedure: NOTE: . Leave the 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. - l g n i t i o ni m i n g t - Sparkplugs - Air cleaner - PCVsystem l. Connect tachometer. a Startthe engine.Hold the engineat 3,000rpm with no load (transmission N or E position)until the in radiator comeson, then let it idle. lan 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, and air conditioner not operating. are ldle speed should be: 700 I 50 rpm . .
4.
6.
Removethe cap and turn the idle adjustingscrew 1/2-turn clockwise counterclockwise. or IDLE
1.
'll2-turn, Afterturningthe idle adjusting screw check the idle speedagain.lf it is out of spec,turn the idle adjusting screw1/2-turn again, NOTE: Do not turn the idle adlustingscrew more than 1/2-turn withoutchecking idle speed. the Turn the ignition switch OFF,Reconnect EVAP the purge controlsolenoidvalve 2P connector, then do the ECMresetprocedure. Stan the engine.ldlethe enginetor one minutewith heaterfan switch at Hl and air conditioner then on. check the idlespeed. ldl6 speed should be: 810 1 50 rpm (in @ or @ position) 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 SymptomCharton page 1l-46.
lf the idle speed is within the specification, the procedure complete. is lf the idle speedis out of specification, to step 4. go
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 EVAPsystem is purging the canister.To stop the purgingtemporarily, raisethe enginespeed above 1,000 rpm with the accelerator pedal.Slowly release the pedal,and recheck idle speed. the . lf the idle speed is within the specification, the procedure complete. is . lf the idle speedis out of specification, to step5. go Disconnect EVAPpurge control solenoidvalve the 2P connector.
SOLENOID VALVE
1 1-1 4 4
Fuel Supply System

FuelLines
NOTE:Checkfuel systemlines,hoses, tuel filter,and other components damage,leaksand deterioration, replace for and if necessarv.
22 N..n 12.2kgl.m, 16lbt.ftl engin:28 m N lD16Y5 2.8 kgl m, 21 lbf.fil
(conr'd)
11-145
FuelSupplySystem
FuelLines(cont'd)
NOTE:Check hoseclampsand retighten necessary. all if
FUEL TUBE/ 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 Do not smok while working on the ful @ systom. Kosp open tlamsg away from your work area. fittings assemblyconnects The fuel tube/quick-connect the in-tank fuel pump with the fuelfeed pipe.For removing or installing fuel pump and fuel tank, it is necesthe fittings. sary to disconnect connectthe quick-connect or Payattention tollowing: to . The fuel tube/quick-connect fittings assemblyis not h e a t - r e s i s t a nb;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 t procedures. weldingor other heat-generating Disconnection Do not smoke while working on the luel @ systgm. Keepopen tlames away from your work aroa. 1. 2. e 1 1 R e l i e v f u e lp r e s s u r ( s e ep a g e s 1 - 1 5 0 ,5 1 ) . e fittings for dirt, and Checkthe tuel quick-connect cleanif necessary. with one hand and pressdown Hold rhe connector the retainertabs with the other hand,then pull the connector off. NOTE: o Be carefulnot to damagethe pipe or other parts, Do not usetools. . lf the connector does not move,keepthe retainer pull and push tabs pressed down, and alternately the connector until it comesoff easilv. . Do not removethe retainerfrom the pipe; once removed,the retainermust be replacedwith a new one.
PAWL LOCKING
3.
o The fuel tube/quick-connect fittings assemblyis not acid-proof; not touch it with a shop towel which do Replace the was used for wiping batteryelectrolwe. tuel tube/quick-connect fittings assemblyil it came into contact with electroiyte something or similar. . t 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 gh e f u e l t u b e / q u i c k - c o n n e c i t t i n g s a s s e m b l y , e c a r e f u ln o t t o ft b Replace if damaged. it bendor twist it excessively.
quick-connect A disconnected fittingcan be reconnected, but the retaineron the mating pipe cannot be reused the once it has been removed from the pipe. Replace retainer when ! Replacing fuel pump. the . Replacing tuel feed pipe. the . lt hasbeenremoved from the Dioe. . lt is damsged. ACCESS PANEL
RETAIiIERTAA
CONNECTOR Press down.
Check the contactareaof the pipe for dirt and damage. . 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
FuelTube/Ouick-Connect Fittings(cont'dl
5. To prevent damage and keep out toreign matter, c o v e r t h e d i s c o n n e c t e d o n n e c t o ra n d p i p e e n d c with plasticbags. Connection 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 (lnsert into the connector.)
11 -1 4 8
Beforeconnecting new {uel tube/quick-connect a fitting assembly, removethe old retainer from the matingpipe.
4.
Make sure the connection is secure and the pawls are firmly lockedinto place;checkvisuallyand by pullingthe connector.
With the tabs pulled
apan,romove and discard the retainer
RETAIiIER
New FUELIUBE/ OUICK4ONNECT FTTTING ASSEMALY
Reconnect bafterynegativecable.and turn the the i g n i t i o n 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 s 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 . Repeattwo or three times, and checkthat there is no leakage the tuel supplysysten.. in
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 clicki 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 main relay, fuel filter, fuel pump, PGM-Fl high pressure and fuel delivery fuel pressure regulator. fuel injectors, p 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 s r e s s u r e - r e g u and cuts the fuel delivery latedfuel to the fuel injectors w h e nt h e e n g i n e s n o t r u n n i n g . i Inspeqtion 1. fuel pressure. Relieve bolt on the fuel filterwhile holdRemove service the ing the banjo bolt with anotherwrench.Attachthe tool. special
('96 FuelPressure model)

Relieving fuel pipes or hoses,releasepresBeforedisconnecting sure from the system by looseningthe 6 mm service bolt on top of the tuel filter.
FUEL PNESSURE GAUGE 07405 - 0040001
Do not smoke while working on the fuel system, Keep open flames or sparks away lrom your work area. . Be suie to relieve fuel pressurewhile the ignition switch is off, '1. Write down the frequencies the radio's preset for buttons. cablefrom the bat2. Disconnect batterynegative the tery negative terminal. 3 . R e m o v eh e f u e l f i l lc a p . t 4. Use a box end wrenchon the 6 mm servicebolt at l 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 a n j o b o l t with anotherwrench. bolt. 5. Place rag or shoptoweloverthe 6 mm service a 6. Slowly loosenthe 6 mm servicebolt one complete turn.
PRESSURE FUEL AoAPTER,6x15mm 07(}6 - 00{0304
NEGULATOB with the the Startthe engine.Measure fuel pressure engineidling and the vacuumhoseof the fuel presfrom the fuel pressure sure regulatordisconnected regulatorand pinched.lf the engine will not start, turn the ignition switch ON (ll), wait for two seconds, 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.
regulator. vacuumhoseto the fuel pressure Reconnect Pressureshould b: 200 - 250 kPa l2-0-2.5kgllcm2,28 - 36 psil first checkthe is lf the fuel pressure not as specitied, It fuel pump (seepage 11-'156).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 , for: inspect - Pinched cloggedfuel returnhoseor line. or - Faultyfuel pressure regulator(seepage 1l-'lg). inspect is lf the fuel pressure lowerthan specified, for: - Clogged fuelfilter. - Faulty (seepage11-154). fuel pressure regulato. - Fuelline leakage.
gaugecanbe attached the 6 mm at o A fuel pressure bolt hole. service . Alwavs reolacethe washer betweenthe service the serbolt and the specialbanjo bolt whenever vice bolt is loosened. . 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 removed.
11 - 1 5 0
('97 FuelPressure and later modelsl

Rlioving Betoredisconnecting fuel pipes or hoses,releasepress 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 g h e 1 2 m m b a n j o t bolt on toD of the fuel filter. Inspec'tior l 2. Do noi smok while working on tho tuel system, Keep open flames or sparks away from your work area. Bo surs to relieve tuel pressurewhile the ignition switch is oft.
1.
Relieve tuel pressure. 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 . Attach the specialtools.
Write down the frequencies the radio's preset for buttons, Disconnect batterynegative the cablefrom the battery negative terminal. Remove iuel fill cap. the
FUELPRESSURE ADAPTER BOLT,12 mm tgflDE - PD6- 0101
4.
Use a box end wrench on the 12 mm banjo bolt at the fuel filter while holdingthe fuel filter wirh another wrencn. Place rag or shoptowel overthe 12 mm banjobolt. a Slowfy foosenthe 12 mm banjo bolt one complete
IUIN.
REGULAIOA
12 mm EANJO BOLT
Stan the engine.Measure fuel pressure the with the engineidling and the vacuum hoseof the fuel pressure regulator disconnectedfrom the fuel pressu.e regulatorand pinched,It the enginewill not start, turn the ignition switch ON (ll), wait for two seconds, 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. Reconnect vacuumhoseto the fuel pressure regulator. Pressureshould bo: 200 - 250 kPa (2.0- 2.5 kgf/cm,, 28 - 35 psi) lf the fuel pressure not as specified, is tirst check the fuel pump (seepage 1'1156). rhe fuel pump is OK, lf check following: the . 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: - Pinched cloggedfuel returnhoseor line. or - Faulty fuel pressureregulator(see page 111541. . lf the fuel pressure lowerthan specified. is inspect for: - Clogged tuelfilter. - Faultyfuel pressureregulator(see page 11154). - Fuelline leakage.
N O T E :R e p l a c e l l t h e w a s h e r sw h e n e v e r h e 1 2 a t mm banjo bolt is loosened removed. or
11-151
FuelSupplySystem
Fuellnjectors
Replacement !@ Do not smoke when working on the luel system. Keep open flames away lrom your wotk alea.
(seepages11-150, 151), 1, Relieve fuel pressure the (D16Y7 the engine:Remove air cleaner). from the fuel iniectors the 2. Disconnect connectors regulator. Place shop towel overthe fuel returnhose,then disa 3. Disconnect vacuumhosesfrom the fuel pressure the Disconnect vacuum hosesand 2P connectorfrom the EVAPpurge the connectit from the fuel pressureregulator, D16Y8 engine). valve(D16Y5, controlsolenoid nuts on the fuel rail. 4. Remove retainer the the 5. Disconnect fuel rail. from the intakemanifold. the 6. Remove fuel iniectors D15Y5, D16Y8 engine: engine. NOTE:lllustration showsD16Y8 i D16Y5 nginessimilar. e
12 N.m kgf.m, 11.2 8.7 tbf.ft)
engine: D16Y7
'r2N.m kg{.m, 11.2 8.7tbtfr)
V
EVAP PURGE CONTROL SOLENOID VALVE
ffi ffi
g g
O-RING Replace. CUSHION RING Replace.
ffi ffi E
V
O.RING Replace. CUSHION Replace. SEAL RING Replace.
E Y
SEAL RING Replace.
7. 8. 9. 10.
Slidenew cushionringsonto the fuel injectors. with cleanengineoil, and put them on the fuel injectors. Coatnew O-rings into the fuel railfirst. Insertthe fuel injectors Coatnewsealringswith cleanengineoil, and pressthem intothe intakemanifold.
11 -1 5 2
11. To preventdamageto the O-rings,installthe tuel injectors the fuel rail first, then installthem in the intakemaniin fo ld.
't2. Installand tightenthe retainer nuts. 1 3 . Connectthe vacuum hosesand fuel return hoseto the fuel pressureregulator. Connect the vacuum hosesand 2P
connector the EVAPpurgecontrolsolenoid to valve(D16Y5, D16Y8 engine). (D16Y7 1 4 . Installtheconnectors the fuel injectors on engine:Install the air cleaner), Turn the ignitionswitchON (ll),but do not operate starter. the Afterthe fuel pump runsfor approximately seconds, two the fuel pressure the tuel line rises. in Repeat two or threetimes,thencheck this whetherthereis anyfuel leakage.
11 - 1 5 3
FuelSupplySystem
FuelPressure Regulator
Testing Do not smoke during the test. Keep open !@ tlamesaway lrom your work area. 1. Attachthe specialtool(s)to the servicepon on the f u e lf i l t e r( s e ep a g e s 1 ' 1 5 01 5 1 ) . 1 , Pressureshould be: 260 - 310 kPa {2.7- 3.2 kgf/cm', 38 - 46 psi} {with the fuel pressureregulator vacuum hose disconnectedand pinched) Replacement Do not smoke while working on fuel sys@ tem. Keepopsn llame away from your work area. 1. regulator, Place shoptowel underthe fuel pressure a (seepages11-150, 151). fuel pressure then relieve the Disconnect vacuumhoseand fuel returnhose. Removethe two 6 mm retainerbolts and the fuel pressure regulator.
2, 3.
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. riseswhen the vacuum Check that the fuel pressure is regulator disconnected hosefrom the fuel pressure a g an . I t l f t h e f u e l p r e s s u r e i d n o t r i s e .r e p l a c e h e f u e l d pressure regulalor.
Replace.
3.
and carefully Apply cleanengineoil to a new O-ring, installit into its properposition. r I n s t a l lt h e f u e l p r e s s u r e 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:
12 mm BAt{JO AOLT 33 N.m {3.4 kg{.m, 25 rbf.ftl
r!@ smoke while working on fuel systsm. K6op Do not

open fbme away from your work area. While roplacing th tusl filtar, be careful to keop a safo distance betwssn battGry tgrminals and any 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 d h e n e v e rt h e f u e l w pressure drops belowthe specified value 1260 310 kPa 12,7 3.2 kgtlcm,,38 - 46 psi)with the fuel pressure regu 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 a n d p i n c h e d la f t e r d making sure that the tuel pump and the fuel pressure regulator OK, are ' 1 . Place a shop towel underand aroundthe fuel filter. Relieve fuel pressure 151). {seepages11-150, Remove he 12 mm banjobolt and the tuel feed t pipetrom the fuel filter,while supponingit with the anotherwrench.as shown, Remove tuel filter clampand fuel filter. the 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 removal, and notetheseitems: . When assembling. new washersas shown. use . 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 thoroughlybeforereconnecting them.
9.8 N.m .0 lg{ m,
7.2rbt.ftt (3.8 ksf.m, 27 tbf.ftl
,97 AND LATERMODELS:
12mm BANJO BOLT 33 N.m (3.4 *gf.m, 25 tbf.ftl
37 N.m kgt 13,8 m, 27 tbtftl
N.m ll.0 kg(.rn, 1.2 tbt.trl
11 - 1 5 5
FuelSupplySystem
FuelPump
Testing Do not smoke during the test. Keep oPen @ tlame away trom you. work atea. a lf you suspect problemwith the fuel pump, checkthat the runs;when it is ON (ll),you will hear fuel pump actually somenoiseif Vouholdyour earto the fuelfill portwith the The fuel pump should run for two fuel fill cap removed, when ignitionswitchis first turnedON (ll).lf the seconds fuel pump does not make noise,checkit as follows: 1. 2. 3. the Remove seatcushion(seesection20). panelfrom the floor. Remove access the Make sure the ignition switch is OFF,then disconnectlhe fuel tank2P connector. termimain relay7P connector Connect the PGM-Fl nal No. 4 and No. 5 with a jumperwire. Rolacement Do not smoke while wotking on luel 3Y3!!@ tem, Koopopen tlams away from your work area. 1. 2. 20). Remove seatcushion(seesection the panelfrom the floor. Remove access the
ACCESSPANEL
4.
5.9N-m kgt 10.6 m. {.3 tbr.ftl
7P {C,a,|3) PGM-FI MAINRELAY CONNECTOR
\,
PUMP FUEL {YEL/ GRNI
IGN 1 (YEL/GRNI
JUMPERWIRE
torminals Wiresideof temale
betweenthe Checkthat batteryvoltageis available fuel pump connector terminalNo. 1 and body ground whenthe ignition switchis turnedON (ll).
CONNECTOR {c56sl
tr: I
I
El d,
Y
l----r
FUELPUMP (YEL/GRNI
3.
from the tuei pump. Disconnect 2Pconnector the Remove tuel pump mountingnuts. the Remove fuel pump from the fuel tank, the
4.
check tuel pump the lf battery voltageis available, ground.lf the groundis OK,replace fuel pump. the (see checkthe wire harness lf there is no voltage. p a g e1 ' l - 1 5 8 ) .
orderof removal. Installpartsin the reverse
5 11 - 1 6
PGM-FIMain Relay
Descliption The PGM-Fl main relay actuallvcontainstwo individual relays. This relay is locatedat the right side of the cowl. whenever ignitionis on which the One relayis energized power to suppliesthe batteryvoltageto the ECM/PCM, the fuel injectors, and power for the secondrelay.The for when the ignisecondrelayis energized two seconds tion is switchedON (ll),and when the engineis running, to supplypowerto the fuel pump.
Relay Testing NOTE: . It the engine starts andcontinues run,the PGM-Fl to

. main relayis OK. U s et h e t e r m i n an u m b e r s e l o w ; l b ignorethe terminalnumbersmoldedinto the relay.
FGM.FI MAITI RELAY
'1. Remove PGM-FI the main relay. 2. Attachthe batterypositiveterminalto the No. 2 terminal and the batterynegative terminalto the No. 1 terminal of the PGM-Flmain relay.Then checkfor the No. 5 terminaland No.4 tercontinuitybetween minalof the PGM-FI main relay. go . lfthere is continuity. on to step3. . lf there is no continuity. main replace PGM-Fl the relayand retest. No. 2
No.3 No. 1
FUELPUMP
No.
No.7 N o , 5 No. 6 To BAT @
To lGN.
To GROUND
To ECM,/PCM A24} {A1'1,
To ST. SWITCH
To ECM/PCM(A
To FUELPUMP
Attachthe battervDositive terminalto the No. 5 terterminalto the No, 3 minal and the batterynegative main relay.Then checkthat terminalof the PGM-FI there is continuitybetweenthe No, 7 terminaland No. 6 terminalof the PGM-FI main relav. . lf thereis continuity, on to step4. go . lf there is no continuity, main replace PGM-Fi the relayand retest. Attachthe batterypositive terminalto the No. 6 terminal and the batterynegative terminalto the No. 1 main relay.Then checkthat terminalof the PGM-Fl there is continuitybetweenthe No. 5 terminaland main relay. No. 4 terminalof the PGM-Fi . lf thereis continuity, PGM-Fl the main relayis OK. ll the fuel pump still does not work,go to Harness Testingon the nextpage. . lf there is nocontinuity,replacethePGM-Fl main relay and retest. {cont'd)
11-157
FuelSupplySystem
PGM-FI Main Relay(cont'dl
Circuit Troubleshooting
Engine will not siart. Inspection ot PGM-FI main relay and relay harness,
Check for an open in the wiro IGNDline): 1. Turnthe ignitionswitchOFF. 2. Disconnect the PGM-FImain relay7P connector. 3- Checkfor continuitybetween the PGM-FI main relay7P con' No. nectorterminal 3 and body ground. Repairopen in the wire betweon m.in relay and G101. the PGM-FI
7P PGM.FI MAINRELAY CONNECTOR lca,Bl
Checkfor an open or short in the wire (BATlinel: M e a s u r ev o l t a g e b e t w e e nt h e PGM'Flmain relay 7P connector terminalNo. 7 and body ground. Repair open or short in tho wire btw6n th6 FGM-FImain r6lsy and the Fl E/M 115Al fu3o. ReDleco Fl E/M l'15Alfus6 the in th6 undr-hood tuso/r.lay box.
Checkfor an open or short in th6 wir (lGl line): 1. Turnthe ignition switch (ll). ON 2. Measurethe voltage between the PGM-Fl main relay7P connectorterminal No.5 and body ground, Ropair open o1 short in thg wire bnrvon th PGM-FImain r6layand the No. 13 FUEL PUMP{15A} tusc. Roolac the No. 13 FUEL PUMP115 fus6 in th underA) dash fuso/rolay box.
ls there battery voltage? -
Checklor an open 01 short in the wi.e {STSline): 1. Turnthe ignitionswitchto the ( STARTlll) position. NOTE: . M/T: Clutch pedal must be depressed. . A"lT:Transmission E or in E position. 2, Measurethe voltage between t h e P G M - F I a i n r e l a y7 P m trminalNo, 2 and connector body ground.
sls IBLU/WHTI
3 a 5 E 7 2
( T op a g e1 1 - 1 5 9 )
11 - 1 5 8
(Frompage11-158| Fcprir opono.3hon in tho wirc baaw6.n the ftiu.Fl main 6lry .nd tho No. 31 STARTER SIGNAL 17.5 tuso. A Roplecotho No. 31 STARTER SIGNAL {7.5 A} fuse in tho undor-dalh fu3o/rclaybox.
7P PGM-FI MAIN RELAY CONNECTOR IC'4|II FLR
rcRNNEL]
1 2 6 3
o
FLR IGRN/YEL)
I 2 12 t l
Ch.ck to. an op6n in thG wir. IFLRlin6l: 1. Turnthe ignitionswitchOFF. 2. Oisconnect ECM/PCM the con, nectorA (32P). 3. Checktor continuitybetween the PGM-FI main .elay 7P connectorterminal No, 1 and ECN4/ PCMconnector terminalA16.
ECM/PCMCONNECTOR t32Pl A
ll
t 5 l 6 t 7 ta t 9 20l,/ 2A 4 l 3 0 l / 2t 21
22
23
2a
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 {lGPl. lGP2line3l: 1. Reconnect ECM/PCM the connectorA (32P). 2. Reconnect the PGM-Flmain relay connector. 3. Turnthe ignition switch (ll). ON 4. Measurvoltage between ECM,PCM connectorterminals 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 betw.n th. ECM/FCM {A11,A24l .nd thc PGM-FI main lolay. R.pleo. tho PGM-FImain relay.
PGl (BLKI
5 8 9
l2 t 3
t5 t6 1 1 tl
t 9 20 30
22
z tI r l
IGP2 IYEL/BLKI
2A 4
Ch.ck for sn opon in th. ECM/ PCM: '1. Turn the ignitionswitchOFF. 2. Measu e voltage between r ECM/PCM connectorterminals A16and A10whenthe ignition switchis firstturnedON (llltor two seconds. Sub.titut. ! known-good ECM/ PCM and ..check. lf orcacribod voltaga ii now rv.il.ble, rcplace thc origin.l ECM/PCM.
FLR IGRN/YEL)
2
12 I t
PGl IELK}
l s o l r l l e l e lr r
l a l 5 t6
21
11
ta l 9 20 2a 30
221 23
2a
ls there'1.0 or less? V
Ch.ck lhe PGM-FI main rel.y lroo pagc 11.1571.
11 - 1 5 9
FuelSupplySystem
FuelTank
Rsplacement
@
1. 2. 3. 4.
Do not smokewhile working on fuel system.Keepopanflame away from your work aroa.
(seepages11-150, Relieve fuel pressure 151). the Remove seatcushion(seesection20). the panelfrom the floor. Remove access the (96 D16Ygengine{coupe)'97 Dl6Y7 engine(coupe: model, Disconnect 2P (C565) and 3P (C564) connectors KL the (LX) model),'97D16Y8 (coupe: models,sedan:KL model '98-allmodels): sedan:KL engine all and 6P (C568) connectorl. 5. Disconnect hoseand quick-connect the fittings(seepages11-146, 147). 6. Jackup the vehicle. and supportit with jackstands. 7. Remove fuel tank cover('96.'97 model)orthefuel hosejoint protector. the 8. Bemovethe drain bolt, and drainthefuel into an approved container. 9. Disconnect hoses(seepage 11-146). the Slidebackthe clamps, then twist hosesas you pull,to avoiddamaging them, 10. Place jack,or othersuppon.underthe tank, a 11. Removethestrap nuts,and let the strapsfall free. 12. Remove fuel tank, lf it stickson the undercoat lly the appliedto its mount.carefu pry it off the mount. 13. Install the drain bolt with a newwasher,thencoatthedrain bolt with Noxrustl24B,Allowthe Noxrustdryfor20 minutes. partsin the reverse 14. Installtheremaining orderof removal.
BASE GASKET
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
(ACL), intakeair duct,Throttle The systemsuppliesair for all engineneeds.lt consists the intakeair pipe,Air Cleaner of in additional silencing A Body {TB),ldle Air Control(lAC)Valveand intakemanitold. resonator the intakeair pipe provides as air is drawn into the svstem. Dl6Y5, Dl6Y8 angine (M/Tl
YEL/ BLK _ - From PGM-FI MAIN RELAY
VARIOUS SENSORS
BLK IROTARYI ENGINE IACVALVE COOLANT
D15Y5 engine{CWl, D16Y8 enginelA/T)' lrutne umrrrolo
YEL/ BLK
- From PGM-FI I MAIN RELAY
D16Y7 sngin:
ORN BLK/
8tu
VARIOUS SENSORS
BLK
(ROTARYI IAC VALVE
RESONATOR
11 - 1 6 1
lntakeAir System
(ACLI Air Cleaner
NOTE; Do not cleanthe ACL elementit with compressed (except type). air dry Dl6Y5,D16Y8 engino:
ACL ELEMENT Normal conditionsi Replacg cleanerelement every air 30,000milos (48,000 kml or 24 months whichovercomes first. Sova.c conditionr: (Usenormalschedule except in dusty conditions) Replace every 15,000 miles (24,000 km) or '12months whichevercomesfirct.
ThrottleCable
Inspection/Adiustmont 1. Startthe engine.Hold the engineat 3,000rpm with no load(ly'Tin E or @ position, Mff in neutral) until the radiator comeson,then let it idle. fan 2. Check that the throttlecableoperates smoothlywith no bindingor sticking. Repair necessary. as 3. Checkcable free play at the throttle linkage. Cable deflection shouldbe 10- 12 mm l3/8- 1/2in.l. D16Y5. D16Y8 engine:
CABLE
DEFLECTION 1 0 - 1 2m m 13l8- 112inl HOUSING Dl6Y7 engine:
Dl6Y7 engine:
LOCKNUT
AIUUSTING
DEFLECNON 10-12mm B l a - 1 1 2^ l i
ACL ELEMENT Normrl condhion3: Replace cleaner air element every 30,000 mil6s(48,000 or 24 km) months whichevercomes first. Sovorocondhion3:
(Usenormal schedule except in dustyconditions) Replace every'15,000

whichever comesllrsl.
It de{lection is not within specs, loosen the locknut, turn the adjusting untilthe deflection as specinut is fied,then retighten locknut. the With the cableproperlyadjusted, checkthe throttle valve to be sure it opens fully when you push the pedalto the floor. Also checkthe throtaccelerator tle valve to be sure it returnsto the idle position you release accelerator whenever pedal. the
11 -1 6 2
lnstallation 'L Openthe throttlevalvefully.then installthe throttle , c a b l ei n t h e t h r o t t l el i n k a g e a n d i n s t a l lt h e c a b l e housingin the cablebracket.
4.
A 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 . d j u s t t h e nut adjusting so that its free play is 0 mm. Removethe cablesheathfrom the throttle bracket, nut resetthe adjusting and tightenthe locknut.
5.
D16Y5, D16Y8 engine: CABLE LOCKNUT
engin: Dl6Y5,D16Y8
NUT ADJUSTING
D16Y7 ngine:
ADJUSTING NUT
9.8 N.m {1.0kgf.m, 7.2 tbt'ttl
Startthe engine.Hold the engineat 3,000rpm with until M/T in neutral) no load(A,/T E or E position, in fan the radiator comeson, then let it idle. Hold the cablesheath,removingall slackfrom the caore.
11-163
IntakeAir System
ThrottleBody
Doscription side-draft type The throttlebody is eithera single-barrel { D 1 6 Y 5 D 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 , engine). The lower portionof the throttlevalve is heated 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 regulates bypassair is locatthe ed on the top of the throttlebody. Inspection 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 without bindingor sticking. It thereare any abnormalities, checkfor: . Excessive wear or play in the throftlevalveshaft. . Stickyor bindingthrottieleverat the fully closed position. . Clearance betweenthrottlestop screwand throttle leverat the fully closedposition. D16Y5,Dl6YB engine:
THROTTLESTOP SCBEW {Do not adiust.}
D16Y7 engine:
{Do not adiust.)
play in the Replace throttlebody it there is excessive the throttlevalveshaftor if the shaftis bindingor sticking.
11-1 6 4
Removal D16Y5, D16Y8 engine:
D15Y7 engine:
IAT SENSOR
AIF CTEANEF IACLI MAP SENSOB
22Nm 12.2*gl.m, 16tbf.ftt
GASKET Repl6ce.
CAALE THROTTLE
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
kgf.m,2.5lbtftl 3.5N.m 10.35
D16Y7 engine:
2.1 N.m kgf.rn, 10.21 1.5lbt.ft)
MAP SENSOR p6ge11-67 Troubleshooting,
11 - 1 6 6
Emission ControlSystem
SystemDescription
The emissioncontrol system includesa Three Way Cata(TWC), lytic Converter ExhaustGas Recirculation {EGR) Ventilation(PCV) system*, PositiveCrankcase system and Evaporative Emission Controlsystem.The emis{EVAP) sion control system is designedto meet federaland state emission standards. *: D16Y5 engine
ThreeWayCatalytic Converter
(TWC)
Description The Three Way CatalyticConverter(TWC) is used to (HC),carbonmonoxide(CO), and conven hydrocarbons oxides of nitrogen(NOx) in the exhaustgas to carbon (Nr)and watervapor. dioxide(CO?), dinitrogen Dl6Y5, Dl6Y7 engine:
ENGINE SIDE
TailpipeEmission
Inspection Do not smoke during this procodure.Kep E@ any open flam away from your work area. 1. Stan the engine.Hold the engineat 3,000rpm with no load (Ay'T E or E position, in N4/T neulral) in until the radiator comeson. then let it idle. fan Connect tachometer. a D16Y8 engine: Checkand, if necessary. adjustthe idle speed (see p a g el l - 1 4 1 ) . Warm up and calibrate CO meteraccording the the to metermanufacturer's instructions. heater blower, Checkidle CO with the headlights. rearwindow defogger, cooling fan,and air conditioner 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 headlights are off. CO metershouldindicate 0.1%maximum. NOTE:'98 D16Y5 engine- lf the idle speedincreases to 810 f 50 rpm, this meansthe EVAPsystemis purgingthe c8nister. stop the purgingtemporariTo ly. raisethe enginespeedabove 1.000rpm with the pedal. accelerator then slowly release pedal. the (cont'd)
HOUSING
11-167
(TWC) (cont'dl ThreeWayCatalytic Converter
Diagnostic TroubleCode(DTC) PO42O: Catalyst systemefficiency belowthreshold. ] P0420 I tne scantool indicates Description This systemevaluates catalyst's the capacity meansof the HO2S(Primary by and Secondary) outputduringstabledriving conditions. deterioration beendetected lf has duringtwo consecutive drivingcycles, MIL comeson and DTCP0420 the will be stored. NOTE:lf some of the DTCS listedbelow are storedat the same time as DTCP0420, troubleshoot those DTCS first, then troubleshoot DTCP0420. P0137, P0138: Secondary HO2S(Sensor 2) P0141: Secondary H02S (Sensor Heater 2) PossibleCause . TWC Deterioration . Exhaust systemleakage TroubleshootingFlowchart
The MIL hes beenreoortedon. DTC P0420b stored.
Problgmverfficationi 1. Do the ECM/PCM ResetProce' dure. 2 . S t a r tt h e e n g i n e .H o l d t h e engine at 3,000rpm with no load (A/Tin E or E position, M/T in neutral) untilthe radiator fan comeson. 3. Connect SCSservice the connector. 4. Test-drive 0 - 55 mph for 4 a p p r o x .t w o m i n u t e s .T h e n decelerate at least 3 sec for 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.
11 - 1 8 6
System(Dl6Y5enginel Exhaust GasRecirculation {EGR)

Description to exhaustgasthroughthe EGR The EGRsystemis designed reduceoxidesot nitrogenemissions {NOx)by recirculating chambers. is composed the EGRvalve,EGRvacuumcontrolvalve, lt of valveand the intakemanifoldinto the combustion EGRcontrolsolenoid valve,ECMand varioussensors. The EGRvalve lift sensordetects The ECMcontainsmemoriesfor ideal EGRvalve litts for varyingoperatingconditions. it to the amountof EGRvalvelift and sendsthe intormation the ECM.The ECMthen compares with the idealEGRvalvelift betweenthe two, the ECMcuts curlf which is determined signalssentfrom the other sensors, there is any difference by vacuumaoolied the EGRvalve. to rent to the EGRcontrolsolenoid valveto reduce EGR CONTROL VALVE SOLENOIO cVT.
BLK
EGRVALVELIFTSENSOR
BLK
I
1-16 9
(EGR) Exhaust GasRecirculation System(D16Y5 engine){cont'dl
The scantool indicates Diagnostic TroubleCode(DTC) P0401: Insufficient flow in the Exhaust GasRecirculation (EGR) svstem. DescriDtion (clogging, Deterioration leakage, etc.)in the EGRline or EGRvalve is detectedby meansof the changesin MAP before and afterthe operation the EGRvalve. of It deterioration has been detectedduring two consecutive driving cycles,the MIL will come on and DTCPO4O1 be will stored. PossibleCauses . Clogging, leakage the EGRline in . FaultyEGR valve TroubleshootingFlowchart
The MIL has been.eoortadon. DTC P0401b stored.
Problomveriticetion: 1. Do the ECMReset Procedure. 2. Connect SCSservice the connector, 3. Testdriveunderthe following conditions. - Withoutany electdcal load - Deceleratfrom 55 mph e {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 passaginside the EGR valve with carburetor cleanerot toplacthe velve.
11-170
in Gas Recirculation P1491: malfunction the Exhaust A TroubleCode (DTC) Diagnostic The scantool indicates (EGR) system. CvT (M/T seepao 11-174):
Tha MIL h'3 boan.eDortedon. DTCP1,191 sto.od. is
Probl.m verificstion: 1. Do the ECMResetProcedure. 2. Connctthe SCS serviceconnector. 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 '1,70O2,500 rpm range. Intermittgnt failure, systom is OK at thb tirno. Checktor Door conngctions or looaa wire3 at, C144 vrlvol and ECM, {EGR
YES
Ch.ck tor vacuum to the EGR 1. Dsconnectthe 16hosetrom No. th EGR valve. 2 . C o n n e c ta v a c u u m p u m p / gauge the hose. to 3. Stanthe engineand let it idle.
EGR VALVE LIFTSENSOR
#16 HOSE
Ch.ck tor a mrlfunction in tho EGRcomrcl lolonoid v.lv.: 1 . D i s c o n n o ctth e E G Rc o n t r o l solenoid valve2Pconnector. 2. Rcheck the No. 16 hose for
l T o p a g e1 1 - 1 7 2 )
PUMP/GAUGE,0-30 in.Hg A973X-fi1 -XXXXX
ls there6ny vacuum?
Check vacuum hose .outing ot the entirs EGR 3y3tom. lf hose routing is OK, .eplsce the EGR control solenoidvrlve. VALVE
Subrtitute a known-good ECM .nd rcheck.lf lymptom/indication goar aw.y, r.placa th6 oJiginll ECM.
(cont'd)
11-171
(EGR) Exhaust GasRecirculation System(D16Y5 engineGWI (cont'dl
( F r o m a g e1 1 - 1 7 1 ) p
#16HOSE
VACUUM Check tor a malfunction in the EGRvalve: 1. Movethe vacuumpump/gauge to the EGR valve. 2. With the engineat ;dle,apply 26.7kPa{200mmHg,8.0 in.Hg) ofvacuum theEGR to valve.
- 30 PUMP/GAUGE,0 in.Hg A973X-041-XXXXX *nj-
,w;
Doesthe engine stallor run roughand doesthe EGRvalve hold vacuum?
Checkthe vacuum routing: 1. Reconnect vacuumpump/ tho gaugeto the No. 16 hose. 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 connectorterminal 1, No, 4 . W h i l ew a t c h i n g h e v a c u u m t g au g e , c o n n e c tt h e b a t t e r y negative terminalto the EGF controlsolenoid valve2P connectorterminal No.2.
\
EGRCONTROL SOLENOIO VALVE 2P CONNECTOR
li;El
E el lo
Terminal sideol maleterminals Checkthe vacuum ho3a: 1. Turnthe jgnitionswitchOFF. 2 . I n s p e c t e N o . 1 6 a n d N o .1 0 th hosestor leaks,restrictionsor mrsrout|ng.
ls thereapprox. 26.7kPa(200 mmHg,8.0 in.Hg) vacuum of whhin l second?
\
(Topage11-173)
11-172
( F r o m a g e1 1 1 7 2 ) p EGRCONTROL SOLENOID VALVE2P CONNECTOR {Cl42I Checkfor an open in the wire {E SOLlinel: 1. Turn the ignitionswitchOFF. the 2. Disconnect 2P connector from the EGRcontrolsolenoid the 3. Disconnect ECMconnector A (32P)Irom ECM. the 4. Checkfor continuitybetween l E C M c o n n e c t o t e r m a n a4 7 r 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 of female terminals ESOL IFEDI
ECM CONNECTOR A t32Pl
ESOL IREDI
Repeirop6n in lhe wire b'twen the EGR control 3olenoid valv6 and the ECM lA?).
Wire side oI female terminals
Chck tor a short in the wir (ESOL line): between the Check continuity lor EGRcontrolsolenoid valve2P 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,
Bopair open in the wir betwoen tho EGR control solnoidvalve and G101.
GND {8LKI
Substitute e known-good ECM and recheck. lf symptom/indication goes away, replacethe originalECM.
(cont'd)
1 1-173
Exhaust GasRecirculation SystemlD16Y5 enginel(cont'd)
M/T:
The MIL has benroportodon, OTCPl{)l is stord.
Probl6mvorification: 1. Do the ECMReset Procedure. 2. Connect SCSservice the connector. 3 . S t a r t t h e e n g i n e .H o l d t h e engane 3,000rpm with no at load (transmission neutral) in untilthe radiatorfan comeson. 4. Drive the vehiclo on the road for approx. 10 minutes.Try to keepthe enginespeedin the 1,700 2,500rpm rang, Intermittont frilur., ry3tem i! OK at this timo. Checktor poor conn.c{ion3 or looa6 wiros at Clil4 IEGRvllve) lnd ECM.
EGR VA|V: 6PCOI{NECTOR lC14,a)

1
l s D T C P 1 4 9 1i n d i c a t e d ?
3 6 PNK IE.EGNI
1 G101 IBLKI
Check tor r mallunction in the EGRvalve: L Startthe engine and let it idle. 2. Measurevoltage between th6 EGRvalve 6P connector termi nal No. 4 and No. 6.
Wire side of mal torminals
rr-
EGRVALVE 5P CONNECTOR Chockthe EGRv.lv.: 1. Turnthe ignitionswitchOFF. 2. Disconnect EGRvalv6 6P the connector. 3. Connectthe battery positive terminalto EGRvalve6P con' nector terminal No,6. 4. Stan the engineand let it idle, then conn6ctlh battery negative terminalto EGRvalve 6P connectorterminal No. 4. Wire side of fem.lo terminrls
Sub3titute r known-good ECM and rcch.ck. lf symplom/indication goe3.wey, replaceth original ECM.
\
( T op a g e1 1 - 1 7 5 )
11-174
(Frompage11-174)
EGR VALVE 6PCONNECTOR tcla,al

1
a
Chockfor an op6n in the wire {E EGRlinel: 1. Turnthe ignitionswitchOFF. 2. Disconnect ECMconnector the A (32Plfrom ECM. the 3. Checkfor continuitybetween E C M c o n n e c t o t e r m i n a l4 7 r and the EGRvalve6P connector terminalNo.6.
I E.EGF
IorurrWire side
E-EGR IPNKI
of lemale tsrminals
t32Pl 2
_j
8 3 a 12 1 3 1 4 t 5 t6 1 7 1 8 1 9 20 22 n a 30 25 21 Repairopon in tho wir6 betwcon tho EGRvalvc and tho ECM lA7l.
't0 23
11
21
Chock lor rn opgn in tho wir6 IGNDlinol: Checklor continuity betveen the EGRvalve6P connector terminal No.4 and body ground. ls therecontinuity? Repsir opn in the wir btwen th. EGR control 3olnoid v.lve and G101.
0) ter-xt
G101
Subrtituta r known-good ECM .nd rcchock. lt 3ymptom/indicalion go.3 away, .apl.ca tha origind ECM.
(cont'd)
1-1 75
Exhaust GasRecirculation System(D16Y5 engine) {cont'dl
The scan tool indicatesDiagnostic Trouble Code (DTC)P'1498: high volrage problem in the ExhaustGas A (EGR) Recirculation valvelift sensorcircuit.
The MIL has boen reportedon. DTCP14)8 is sto.ed.
Problemvs.iticstionl 1. Do the ECMBeset Procedure. 2. Startthe engine. lntermittfi failuro. 3y3tem i3 OK at thL tim.. Chcck to. ooor connoctions o. loo3. wire3 at Cl/14 valv.l and ECM. IEGR Check tor an op6n in the EGR valve lift sonso.: 1. Turnthe ignitionswitchOFF. 2. Disconnect EGRvalve lift the sensor3P {M/T:6P)connector. 3. Turnthe ignition switch (ll). ON 4, Measurevoltage between the EGRvalve lift seosor 3P (M/T: 6P)connector terminals No. 3 a n dN o . 2 .
VALVE LIFTSENSOR lM/T: SPlCONNECTOR EGR 3P {Ct14l
cw:
vcc2 IYEL/BLUI
SG2IGRN/BLKI
ls thereapprox, V? 5
sG2 (GRN/ BLK}

Chock tor opcn in the wire lSG2 linel; Measurevoltage between ECM connector terminals D10and D11.
vcc2
(YEL/ ALUI
Ropairopon in th. wirg bctwoon ECM(D11) and EGRvalv.litt.cnsor.
Wiro side of female teaminals
cM CoNNECTORtl6Pl O
Substitute a known-good ECM and recheck. ll symptom/indication goe3away, replacthe original ECM.
vcc2
(YEL/BLUI
sG2
(GRN/BLKI
Wire side of female te.minals
11-176
Positive Crankcase Ventilation(PCV) System

Dscription T h e P o s i t i v eC r a n k c a s e e n t i l a t i o n( P C V )s y s t e m i s V designedto preventblow-by gas trom escaping the to atmosphere.The PCV valve contains a spring-loaded plunger. When the enginestarts, the plungerin the PCV valve is lifted in proportionto intakemanifoldvacuum and the blow-by gas is drawn directly into the intake manifold. O16Y5, D16Y8 engine:
Inspgqtion 1.
Check the PCVhosesand connections leaksand for clogging. At idle,makesurethere is a clickingsoundfrom the PCVvalve when the hose betweenPCVvalve and intakemanifoldin lightly pinchedwith your fingers or olters.
D16Y5, D16Y8 ongine:
Gentlypinchhere.
PCVVALVE
D16Y7 engine: D16Y7 engine:

Gently pinch here.
:: ELOW-BY VAPOR e: FRESH AIR VALVE
l f t h e r e i s n o c l i c k i n g o u n d ,c h e c kt h e P C Vv a l v e s grommetfor cracksand damage.lf the grommet is OK,replace PCVvalveand recheck. the
11-177
Emission GontrolSystem
(EVAP) Evaporative Emission Controls
Dsscripiion The evaporative emissioncontrolsare designed minimizethe amount of fuel vapor escaping the atmosphere. to to The systemconsists the followingcomponents: of A. EvaporativeEmission (EVAP)Control Canister An EVAPcontrolcanister usedtor the temporarystorageof luel vapor until the fuel vapor can be purgedfrom the is EVAPcontrolcanister into the engineand burned.
B. Vapor PurgeContfol System EVAPcontrolcanister purgingis accomplished dr6wingfreshair throughthe EVAP by controlcanister and into a pon on the intakemanifold. The purgingvacuumis controlled the EVAPpurgecontrolsolenoid by valve. EVAPPURGE CONTROL SOLENOID VALVEDUTYCON. TROLLED AFTER STARTING ENGINE e D I ' 9 6O 1 6 Y 5 n g i n e , ' 9 6 1 6 Y 7 n g i n e , ' 9 6 1 6 Y 8 e D 7 e n g i n e( s e d a n ) , ' 9 D 1 6 Y 5 n g i n e , ' 9 7 ' 1 6 Y 7 e D engine (coupe:KA, KC models,sedan: KA, KC, K L ( D X ) m o d e l s ,h a t c h b a c k : l l m o d e l s ) , ' 9 7 a D16Y8 engine(sedan: KA, KCmodels)l '97 D16Y7 l ' 9 6 D 1 6 Y 8e n g i n e ( c o u p e ) , engine ( 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 D16Y8 engine(coupe: models.sedan:KL model, all '98-allmodelsll
ENGIN COOLANT TEMPERATURE ABOVE154'F(68"C)
ENGINE COOLANT TEMPERATURE ABOVE154"F I68"C) INTAKE TEMPERATURE AIR ABOVE 32"F(O'C) ano VEHICLE SPEED ABOVE MILE(0 km/h) 0 or A./C COMPRESSOR CLUTCH ON and (41"C} INTAKE TEMPERATURE AIR ABOVE160"F
C.
FuelTank Vapor Control System Whenfuel vapor pressure the fuel tank is higherthan the set valueof the EVAP in two way valve,the valveopensand regulates flow of fuel vaporto the EVAP the controlcanister.
11-178
'96 D16Y8 engine lcoupe), '97 D16Y8 engine {coupe: all models, sedan:KL model). '98 Dt6Y5 engine (all models}, '98 D16Y8 engine(allmodelsl:
9:I'
FUEL TANK PRESSURE SENSOR
r
tLl
7'
THREE
VAL
VAPCONTROL VENT SHUT VAI
EVAPPURGE CONTROL VALVE SOLENOID
From No. 15 ALTERNATOR SP SENSOR
(7.s a)
YEL/ BLU
. . LT GRN GRN/ BLK
\
EVAP BYPASS SOLENOID VALVE
BLU
LT GRN/
EVAP TWOWAY VALVE
WHT RED/ YEL

BLK
FUEL TANK
INTAKE MANIFOLD
'97 Dl6Y7 engine
{coupe:KL model, sedsn: KL ILX) mod6l},'98 D16Y7engine:

YEL/ BLU LT G' GRN/ BLK
9ii
'-<
From No. 15 ALTERNATOR SP SENSOR t7.5Al
FUEL TANK PRESSURE SENSOR
BLU
LT GRN/ WHT
EVAP BYPASS SOLENOID VALVE
RED/ YEL
BLK EVAPCONTROL CANISTER FUEL FILL CAP
EVAP TWOWAY VALVE
FUELTANK
(cont'd)
11-179
Emission Controls(cont'dl Evaporative
'97 '96 D16YS '96 enginelsedan: KA, KC models): enginelsedanl, D16Y5 engine,'97 D16YB engine, D16Y8
EVAP PURGE CONIROL
EVAP TWO WAY VALVE
sot_ENotD
VALVE
MANIFOLD
'96 D16Y7engine,'97 D16Y7engine (coupe:KA, KC mod6ls, sedan: KA, KC, KL IDX) models, hatchback:all models): From
EVAP PURGE CONTROL SOLENOID VALVE
i:1"
-----
No. 15
ALTERNAToR
SP SENSOR
VARIOUS SENSORS
BLK
J-
\,*ro..
MANIFOLD
11 - 1 8 0
FuelTank Pressure Senso. I'96 D16Y8engine {coupe),'97D16Y7ngine (coupe:KL mod6l, sedan:KL (LXl modet),'97 D16Y8 engins(coupe: allmodels,sodan:KL model,'98-all models)l:
The scan tool indicates Diagnoslic Trouble Code (DTCI P0452:A low voltage problem in the Fuel Tank Pressure sensor.
The fuel tank pressure sensorconverts luel tank absolute pressure into electrical signalsand inputsthe ECM/PCM. OUTPUT VOLTAGE
tv)
4.5
Th6 MIL has ben .eported on. DTC P0452 b stored,
0.5
Chckthe vacuurnlinos: C h e c kt h e v a c u u ml i n e s o f t h e fueltankpressure sensor misfor r o u t i n g ,l e a k a g eb r e a k a g e n d , a clogging. Are the vacuumlinesOK? -7 kPr (-50 mmHg, -2 in.Hgl +t kP8 (50 mmHg, 2 in.Hgl PRESSURE
Problemvorilication: 1. Do the ECM/PCM Reset Proce' dure. 2. Remove fuel fill cap. the 3. Turnthe ignition switch (ll). ON 4. Monitorthe FTPSensorvolta 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 b e t w e e nb o d y g r o u n d a n d ECM/PCM terminalD15. ls thereapprox. V? 2.5
ECM/PCMCONNECTOR Il6PI D
Chockfor an opon in wire {VCC2 linel: 1. Turnthe ignitionswitchOFF. 2. Reinstall fuelfill cap. the 3. Disconnect fuel tank presthe suresensor connector. 3P 4. Turnthe ignition switch (ll). ON 5, Measurevoltage between the fuel tank pressure sensor3P connector No, 1 terminaland No.2 terminal. ls thereapprox.5V? YES (Topage11-182)
Intermittent tailur6,systom is OK at thb time. Checktor ooor connections or loose wire3 at C131 {locatedunder right sid6 of dashl, C401 (located above unde.-daah tuse/relay boxJ. C568 llocatod under acce3s prnel), C792 (tuel tank pre33uresonsorl and ECM/ FCM.
PTANK {LTGRN' Wiro side ol temale terminals
FUELTANK PRESSUBE SENSOB 3P CONNECTOR tC792)
vcc2 (YEL/BLU)
Wire sideof femaletrminals Repairopen in the wire belween tho tueltank pre3sur6sen3o.and the ECM/PCM lD10l.
(cont'd)
11 - 1 8 1
EmissionControl System
Controls(cont'dl Evaporative Emission
p { F r o m a g e1 1 - 1 8 1 } FUELTANK PRESSURE SENSOR 3P CONNECTOR {C7921 PTANK (LTGRN)
C h e c kt o r a s h o r t i n t h e w i r e line): IPTANK M e a s u r ev o l t a g e b e t w e e nt h e 3P fueltank pressure sensor connectorNo. 3 terminaland No. 2 rermtnat,
sG2 {GRN/BLK)
ls thereapprox. V? 5 Wire sideof female terminals
Check for a Short in the wire (PTANK line): 1. Turn the ignitionswitchOFF. con 2. Disconnect ECM/PCM the nectorD (16P). 3. Checkfor continuitybetween sensor the fuel tank pressure No. 3 terminals 3P connector and body ground.
ReoairShort in the wire between the fueltank oressurcsensorand ECM/PCM tD15).
Sub3titut6 a known-good ECM/ PCM and recheck.ll symptom/ indicationgoes away, replacethe orisinal ECM/PCM.
11-1 8 2
FuelTank Pressure Sensorf96 D16Y8ongine {coups),'97D15Y7ongins lcoupe:KL model, sedan:KL (LX} model},,97 D16Y8 enginelcoupe:all models, s6dan:KL model,'98.all modelsll: The scantool indicates Diagnostic TroubleCode(DTC) P0453: high voltageproblemin the FuelTankPressure A 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 pressure sensor misfor routing, leakage,breakageand cloggrng. Are the vacuumlinesOK? ECM/PCM CONNECTORD (T6P} Problcmverificetion: 1. Do the ECM/PCM Reset Procedure, 2. Remove fuelfill cap. the 3. Turnthe ignition switch (ll). ON 4. Monitor the FTPSensorvolt, age with the HondaPGM 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 ECM/PCM terminal015. ls thereapprox.2.5 V?
PTANK ILTGRNI
Intermittont tailu.e, sy3tem b OK at this tim6. Chcck to. poor connoctions or loo.g wiros at C131 {locatodunder right side ol d.!h}, C401 llocrtod abovo und.r-dash tuse/rolay boxl, C56Ellocatod undor accossD6ncl),C792 (fuel tank prossurc s6n3or) and ECM/ FCM.
Wiresidsof f6mals terminals
FUEL TANK PRESSUAE SENSOR 3PCONNECTOR tC792)
Chock for rn opon in the wire lSG2linol: 1. Turnthe ignitionswitchOFF. 2. Reinstall fuelfill cap. the 3. Disconnect fuel tank presthe suresensor connector, 3P 4. Turnthe ignition switch (ll). ON 5, Measure voltagebetween the fuel tank pressuresensor3P connectorterminals No. 1 and No.2. ls thereapprox.5V?
vcc2
(YEL/3LUI
sG2 IGRN/BLKI
Wir6 side of temale terminals Repai. opn in thc wirc botwcn the tuel tank pa633ure 36nsorend (D111. ECM/PCM
Check tor an open in the wiro (PTANK linal: M e a s u r ev o l t a g e b e t w e e nt h e fuel tank pressure sensor con3P nector No. 3 terminaland No. 2 termanal. ls thereapprox. V? 5
3 PTANK IGRN/NEDI
sG2 IGRN/BLKI
(To page11-184)
(cont'd)
11 - 1 8 3
ControlSystem Emission
Emission Controls(cont'd) Evaporative
(Frompage11 183)
Check for an open in the wire {PTANKline}: Measurevoltage betweenECM/ 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 .
D ECM/PCMCONNECTOR (16PI
ls thereapprox.5V?
Rcp.ir open in th6 wir6 betweon E C M / P C M D 1 5 )a n d f u e l t a n k { pt033utesensol.
PTANK ILT GRNI
SG2IGRN/BLK)
Wire side of fsmal terminals
Sub3litute a known-good ECM/ PCM .nd rechck.lf symptom/ indicationgoes away, replaceth6 originalECM/PCM.
11-1 8 4
['96 Dl6Y8 engine(coupe],'97 Dl6Y7 sngine{coupe: model,sedan:KL {LX}modeU.'97Dl6Y8 engine(coupe: modKL alt els, sedan:KL model, '98-all modolsll: tool Diagnostic (EVAP) TroubleCode(DTC) P1456: Evaporative Emission conlrolsystemteak tPEs6l The scan(fuelindicates detected tank system). The tool indicates Diagnostic TroubleCode tPl45?-l scan(EVAP detected controlcanister system). PossibloCauso . Fuelfill cao . VacuumConnections . FuelTank . EVAP ControlCanister VentShutValve . EVAP ControlCanister VentShutValveCircuit o EVAPPurgeControlSolenoid Valve . EVAPPurgeControlSolenoid ValveCircuit . EVAPBypass Solenoid Valve . EVAPBvDass Solenoid ValveCircuit . FuelTankPressure Sensor . FuelTankPressure SensorCircuit . EVAPControlCanister . Throttle Body TroublshootingFlowchart
Th. MIL has bo.n reDoned DTCP1456or P1457i. storcd.
(DTCIP1457: (EVAp) Evaporative Emission controlsystemreaK
VACUUM PUMP/GAUGE,0-30in.Hg 4973X 041-
xxxxx
EVAP CONTROL CANISTER VENT SHUT VALVE O.RING Replace.
Ch6ck the EVAP control c.nbtet v.nt lhut valva: 1. Disconnect vacuum hose the 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 canister vent shut valvelrom the canister. 3. Turnthe ignition switch (ll). ON 4. Applyvacuum tho hose. to Doesthe valve hold vacuum?
Chock tor a short in the wiro {VSV linol: Disconnect 2P connectorfrom the the EVAPcontrol canister vent Rop.ir 3hort in the wirc betwen lh6 EVAP control caniste. vnt shut valvo and the EcM/PcM la29l. ECM/PCMCONNECTOR I32P) A
I 2 12 t 3 6
Doesthe valve hold vacuum? Check tho EVAP control crnialc. vont 3hut valvo: 1. Turnthe ignitionswitchOFF. 2. ConnectECM/PCM connector terminal429 to body ground with a jumperwire. 3. Turnthe ignition switch (ll). ON 4. Applyvacuumto the hose. Doesthe valvhold vacuum?
Roplrce the EVAP control cani.tcr vont rhut valvo,
a
t5 t3 t t
to 23
ll
21
r8 t 3 20 a 4t 30 I
2a
{LT GRN/WHTI
JUMPERWIRE
Wiresideof lemaleterminals
(cont'd)
{To page11-186) (To page 1l-186)
11 - 1 8 5
Emission GontrolSystem
Evaporative Emission Controls(cont'dl
(Frompage11-185) (Frompage'1'l-185)
EVAP CONTROL CANISTER VENT SHUT VALVE2PCONNECTOR {Cl41I

Check lor an op.n in th. wi.e (lG1linel: 1. Turnthe ignitionswitchOFF. 2. Disconnect the 2P connector from the EVAPcontrolcanister v0nt shutvalv. 3. Turnthe ignition switch (ll). ON 4. Measurevoltage betwen the EVAPcontrolcanister vent shut valve 2P connectorterminal No.2 and bodyground.
tGl IBLK/YEL)
Wire side of fmale torminal6
Rcpair opon in tha wirc batwoon tho EVAP control crnirtor vont lhut vdw rnd tho No. 15 ALTERNATORSP SENSOR {7.5Al tu!..
Ch.d( ior an op.n in tho wirr IVSV lin l: 1. Turnthe ignitionswitchOFF. 2. Roconnect the 2P connector to the EVAPcontrol canister vent shutvalve. 3. Turn the ignitionswitchON (ll). 4 , M e a s u r ev o l t a g e b e t w e e n ECM/PCM onnctor 6rmi t c nalsA29and A10.
A ECrir/FcM @NNECTOfi {32P1 PGl (BLK)

2 12 l 3
'|
t5
rrlrrlllll @ l / l z l a l u l
I ' l ' l I' l r l r l r o I r r I ,JAA_]{

Wiro sid ot lomsle t6rminals
-J-
vsv (LTGRN^Vlff)
Rapairop6n in thc wh6 batwaan iho EVAP control caniatar vant shut vrlvo end th. ECM/PCM tA29t. Raolaccth6 EVAP cont.ol canister vant rhut valva.
Ch6cktho vacuumwhan cold: 1. Disconnect vacuum hos6 th shown from the EVAPcontrol canrster and connecta vacuum gaugeto the hose. 2. Stan the engineand allow it to idle. N O T E :E n g i n ec o o l a n tt e m peraturemust bo below 154"F (68'C)or Iy'Cswitch OFF. 3. Ouicklyraisethe engine spegd to 3.000rpm.
VACUUM PUII'P/ GAUGE,030in.Hg A973X
041 xxxxx
(Topage11-187)
8 11 - 1 6
(Frompage11-186) Ch.ck the EVAP purge control robnoid velvol 1. Disconnect the 2P connector from the EVAPpurge control valve. solonoid 2. Orricklyraisethe enginespeed to 3,000rpm. Inspectv.cuum hoaerouting. lf OK, replaco lho EVAP purge contrcl solonoidvalve. Chcck tor a short in the wir. {PCSlincl: 1. Turnthe ignitionswitchOFF. 2. Disconnect ECM/PCM connector A 132P). 3. Check for continuity botween the EVAPpurge controlsole' noid valve 2P connector terminal No. 2 and body ground. EVAPPURGE CONTROL SOI:NOID VALVE2P OONNECTOR lC11,al
Chacktha vrcuum whcn hoti 1. Turnthe ignitionswitchOFF. 2. Block the rear wheels and set the parkingbrak. 3. Jack up tho front ot the vehicle and support it with salety slands. 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 loed {A/r in E or E position, untilthe radiator WT in neutral) lan comeson, then let it idle. 5. Ch6cktor vacuum at the vac' uum hos6 with lransmission in ge6r {A/T in B position, M/T in 1st gear) after starling the ngine. 6. Ouicklyraisotho ongine sp66d to 3,000rpm.
Wiro side ot temale trmrna|s Repairshort in the wira bgtween the EVAP purga control solonoid valvo and rhe EcM/PcM lA15l.
Sub3titut. a known-good EGM/ PCM lnd r.ch.ck. lf symptom,/ indication eoo3 away, raplacc th. o.iginrl ECM/FCM.
Chock th6 EVAP purg. control .olonoid valvoi l. Turnthe ignitionswitchOFF. 2. Disconnect 2P connector the from the EVAPpurgo control solenoid valve and worm it up to normal operatingtom peratureagain it necessary. 3. Startthe engine. 4. At the ha.ness side. 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 . ls there batteryvohage?
PCS {RED/YELI
Intpct vacuum hoa! routing. It OK, roplace EVAP purg6 control solonoidv6lvo.
Chcck for an opcn in th6 wire llcl linoll At the harnossside.measurcvoltago btwoenthe EVAPpurge control solenoidvalve 2P connector terminal No. 1 and body ground.
tGl IBLK/YEL}
Ropai. open in the wiro lrotwean EVAPpurga control 3olcnoid valv. ANdthC NO. 15 ALTERNATOR SP SENSOR {7.5Al fu36.
(cont'd)
{Topage11-188) (To page11-188|
11-187
ControlSystem Emission
Controls{cont'd} Emission Evaporative
( F r o mp a g e ' 1 1 ' 1 8 7 )
|5
A ECM/PCMCONNECTOR {32P) PGI {BLKI
(Frompage11 187)
Check for an open in the wire {PCSline}: switchOFF. 1. Turnthe ignition to 2. Reconnect 2Pconnector the the EVAPpurge controlsole_ noidvalve. switch {ll). ON 3. Turnthe ignition 4, Measurevoltage between ECM/PCM connectorterminals A 1 5a n dA 1 0 .
PCS {RED/YELI
wire sid ot female !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/indication 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 . Repl.cthe EVAPtwo way v.lve.
PUMP/ -30 GAUGE.0 in.Hg 4973X 041-
xxxxx
EVAPBYPASS SOLENOID VALVE
Checkthe EVAP bypa$ solenoid 1, Disconnect vacuum hose the from the EVAPtwo way valve and connecta vacuumpump to the hose. swhchON (lli. 2. Turnthe ignition 3. Applyvacuumto the hose. Doesthe valvehold vacuum?
U
Check tor a short in the wi. I2WBSline): lrom the Disconnect 2P connector the EVAPbypasssolenoidvalve. O.RING Replace.
EVAP TWOWAYVALVE
Rooair3hort in tho wirc botween EVAP bypass 3ol.noid valve and rhe EcM/PcM {A281.
Does the valve hold vacuum?
l T o p a g 61 1 - 1 8 9 1
11-188
(Frompage11-188)
Checkthe EVAP bypasssolenoid 1. Turnthe ignitionswitchOFF. 2. ConnectECM/PCM connector terminal A28and bodyground with a iumperwire. 3. T!rn the ignition switch (ll). ON
ECM/PCMCONNECTOR I32PI A
I 1 9 2A
lo 23
'12 t 3
r5 t 6
25 27
It
tl
2a
Check for an opon in tha wire llGl linel: 1. Turnthe ignitionswitchOFF. 2, Disconnect 2P connector the from the EVAPbypass sole 3. Turnthe ignition switch (ll). ON 4. Measure voltagebetween the EVAP bypasssolenoidvalve 2 P c o n n e c t otre r m i n a lN o . 1 and body ground.
2A 29 3 0
2WBS IBLUI
JUMPER WIRE
Does valve hold vacuum?
Wire sid of femal6 terminals
SOLENOID EVAPBYPASS VALVE2P CONNECTOR {C79i}l tG1 (BLK/WHTI
Wire sido of lemale terminals
Ropai. open in the wirc botwoon EVAPpurg6 control solonoid valve snd the No. 15 ALTERNATOR SP SENSOR 17.5 tu36. A)
A ECM/PCMCONNECTON (32PI Check for an open in the wire {2WBSlin6l: 1. Turnthe ignitionswitchOFF. 2. Reconnect the 2P connector to the EVAPbypasssolenoid 3. Turnthe ignition switchON (ll). 4, Measurevoltage between ECM/PCM connectorterminals A28andA10. 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: ' tucl till c.p . luel tank . tuel vapor pipe . EVAPtwo wav vslve . EVAPbypasssolenoidvalve . Iuel tank pressuresensoa . EVAPcontrol cenkter . EVAPcontrol canistcr vant shut valve . EVAP pu196 control solenoid . vacuum hososand connoctions PGl (BLK}
=
12 l 3
6
t6 1a 1 1 tt 21
l r l l . l e l r oI i r I tolal.lal za l yl
-J--
2WBSIBLUI
wirs side of female l6fmrn6ls
Ropai. opon in the wiro between tha EVAP byp.33 3olenoid valv. .nd tho ECM/PCM lA28|,
(cont'd)
11 - 1 8 9
Evaporative Emission Controls{cont'd}
'96 Dl6Y5 engine,'96Dl6Y7 engine,'96Dl6Y8 engine enginelcoupe:KA, KC modDl6Y5 engine,'97D16Y7 {sedan},'97 els, sedan: KA, KC, KL (DX)models, hatchback:all models),'97 Dl6Y8 ngine (sedan:l(A, KC models): The scan tool indicatesDiagnostic Trouble Code (DTC)P0441: Evaporative Emission(EVAP) control system I P0441 | ;n"r11;";.nt ouroeftow. Description By monitoringthe purge line vacuum with the MAP sensor,the ECM/PCM can detectinsufficient EVAPcontrol system purgeflow. PossibleCause . EVAPPurgeControlSolenoid Valve . EVAPPurgeControlSolenoid ValveCircuit . EVAP ControlCanister . Vacuum ines L . ECM/PCM TroubleshootingFlowchart
Tho MIL has b6onreportedon, DTCP(X4t is stored.
Problsmve.itication: 1 . S t a r tt h e e n g i n e .H o l d t h e engane 3,000rpm with no at load (A,/Tin N or E poskion, M/T in neutral) untilthe radia' tor tan comeson. 2. Do the ECM/PCM ResetProceoure, 3. Connect SCSservice the connector. 4. Test-drive underfollowingconditionson 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') 15 mph 124 to km/h) ls oTC P0441indicated? Intorrnittenttailu.e, 3wtem i3 OK at thi3 timo. Chock for poor connctions or 10036wir$ at C144 (EVAP purge control solenoid valve)andECM/PCM. EVAPPURGE CONTROL SOLENOIO VALVE2P CoNNECTOR tctla)
Chck for an opn in the wir (lcl linell 1. Turnthe ignitionswitchOFF. 2 . D i s c o n n e ctth e E V A Pp u r g e controlsolenoid valve2P connector, 3. Turn the ignitionswitchON {ll). 4. Measure voltagebetweenbodv g r o u n da n d t h e E V A Pp u r g e control solenoidvalve 2P connectorterminal 1. No. Ropair open in th wiEs botwoon the EVAP purgo control rolenoid valve and th. No. 15 ALTERNA. TORSP SENSOF17.5 fuse. Al { T op a g eI 1 - 1 9 1 )
r+_r' l ' l
lrci
rv)
Y
oixrv..r
wir6 side of lemslo terminals
11 - 1 0 9
p { F r o m a g e1 1 - 1 9 0 }
D CONNECTOR(32PI ECM/PCM PG1 IALK)
Chock tho EVAP purge control 30lenoidvalv6: '1.Reconnec t h e E V A Pp u r g e valve2P con controlsolenoid nector. 2. ConnectECM/PCI, connector terminals A'15and A10 with a
WRE JUMPER
Wire sideoI tomaleterminals
Does the solenoid valve click when the jumper is connected?
Chockfol rn op6n or 3hort in th6 wirc IPCSlin6l: Measurevoltage betweenECM/ PCMconnector terminalA15 and bodyground.
PCS{RED/YELI
ls therebaneryvoltage?
t
ReD.ir 3hort in the wire! bdtween the EVAP purge control 3olgnoid (415). vtlve .nd ECM/PCM
Ch6ckfor a shon in the wire IFCS lin): 1. Turnthe ignitionswitchOFF. 2. Disconnect ECM/PCM the connector {32P). A 3 . D i s c o n n e ctth e E V A Pp u r g e valve2P concontrolsolenoid nector. 4. Checkfor continuitybetween body ground and ECM/PCM terminal A15, connector
ls therecontinuity?
Chocktho vacuum lines: Checkthe vacuumlinesof EVAP systemIor misrouting,leakage. breakage clogging. and
Ropair opon in the wires bstwson the EVAP purge control solenoid valveand ECM/PCM {Al5}.
Ar the vacuumlinesOK?
6 I E I 2 12 l 3 'l'a t 5 l 6 1 7 I E t 9 20
10 23
ll
21
25
27
26 A
30
t
{To page11-192)
O) Pcs {RED/YEL}
(cont'd)
11 - 1 9 1
Evaporative Emission Controls(cont'd)
p l F r o m a g e1 1 - 1 9 1 )
D16Y5 engine:
ngine D15Y7, D16Y8
Check the EVAP purge control solenoidvalve: 1. Disconnect vacuum hose the from the EVAP controlcanister. 2. Connect vacuumpump to the the hoseandapplyvacuum.
VACUUM PUMPI GAUGE,

0-30 in.Hg 4973X 041 -
VACUUM PUMP/ GAUGE, 0 - 30 in.Hg A973X- 041 -
xxxxx
xxxxx
Doesit holdvacuum?
EVAPCONTROL CANISTER
Checkthe EVAPcontrol canister: 1, Reconnect vacuumhoseto the the EVAP control canister. 2, Connect vacuum/pressure the to 9auge the purgeair hose. 3. ConnectECM/PCM connector terminals 415 and 410 with a 4. Start the engine. 5. Check vacuum. the
ECM/PCMCONNECTOR I32P} D PG1IBLKI
JUMPERWIRE Wire sideof femaleterminals
D16Y7, Dl6YBengine:
Check the EVAP two way valve lseepage11 193).
0oesthe EVAP two way valve
Replace EVAPtwo way valve. the
D16Y5 engine:
Substitute a known-good ECM/ PCM and recheck.lf svmptom/ indicationgoes away, replacethe original ECM/PCM.
VACUUM/ PRESSURE GAUGE 4 in.Hg 007JAZ- 0010008
VACUUM/PRESSURE GAUGE
0 - il in.Hg
07JAZ 0010004
11-192
(EVAP) Evaporative Emission Two Way ValveTesting Dl6Y8 engine{coupel,'97Dl6Y7 engine(coupe: KL I'96 model,sedan:KL (LX)model),'97 D16Y8 engine{coupe: all models,sedan: model,'98-all KL modelsll: 1 . R e m o v eh e f u e lf i l l c a p . t 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 g a u g e n d a v a c u u m u m pa s s h o w n . p a
f96 D16Y5engine,'96D16Y7engine,'96D16Y8engine (sedanl,'97 D16Y5 engine(coupe: KA. engine.'97D16Y7 KC models,sedan:KA, KC, KL (DX) models.hatchback: engine(sedan: KA. KC models)l: all modelsl,'97D16Y8 1. 2. R e m o v eh e f u e lf i l l c a p . t 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 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/ PFESSURE GAUGE, 0 -4 in.Hg o?JAZ- 0010008
VACUUM/PRESSURE GAUGE 0 - 4 in.Hg 07JAZ- 0010008 VACUUM PUMP/GAUGE, 0 - 30 in.Hg A973X-041-XXXXX
T.F|rTING
T-FITTING
while watch3. Applyvacuumslowlyand continuously ing the gauge. The vacuumshouldstabilize moment a r i l ya t 0 . 8- 2 . 1k P a( 6- 1 6m m H g , . 2 0 . 6i n . H g ) . 0 ( 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 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 ( 1 6m m H g , 0 . 6n . H g )i,n s t a la n e wv a l v ea n d r e t e s t . i l
4.
3.
A p p l y v a c u u ms l o w l ya n d c o n t i n u o u s l y h i l e w w a t c h i n g 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 m o m e n t a r i la t 0 . 7 2 . 0k P a( 5 - 1 5 m m H g , 0 . 2 0 . 6 y i n .H g) . ( 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 )b e l o w 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 5 m H g ,0 . 6i n . H g )i,n s t a la n e wv a l v ea n d r e t e s t . m l Move the vacuum pump hose from the vacuumfitfitting, and move the vacuum ting to the pressure gauge hose from the vacuum side to the pressure side as shown. f-Ei
Move the vacuumpump hosefrom the vacuumfitfitting, and move the vacuum ting to the pressure gauge hose from the vacuum side to the pressure sideas shown.
4.
5. Slowly pressurize vapor line while watchingthe the gauge.The pressure shouldbe stabilize momentaril y a b o v e 1 . 0k P a( 8 m m H g , 0 . 3n . H g ) . i ( . 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 b o v e 1 . 0 k P a ( 8 m m H g , 0 . 3i n . H g ) t h e , valveis OK. . lf the pressure stabilizes below 1.0kPa(8 mmHg, 0.3 in.Hg), installa new valveand retest.
the Slowly pressurize vapor line while watchingthe gauge.The pressure at shouldstabilize 1.3- 4.7 kPa ( 0 - 3 5 m m H g ,0 . 4 1 . 4i 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 s v a l v e l '1.4 o p e n s ) t 1 . 3- 4 . 7 k P a( 1 0- 3 5 m m H g ,0 . 4 a in. Hg),the valveis OK. . ll the pressure stabiljzes below 1.3kPa(10 mmHg, 0.4 in.Hg)or above4.7 kPa(35 mmHg, 1.4in.Hg), install new valveand retest. a
11 - 1 9 3
Transaxle
Clutch 12-1 "n M a n u aT r a n s m i s s i o . ' . . . . . ' . . . " " " " ' 1 3 - 1 l ...'..."""""' 14-1 Transmission Automatic 15-1 Differentia..... l 16-1 Driveshafts
Clutch
"".--- 12-2 S p e c i aT o o l s . . . . . . . . f ."' 12-3 I f l f u s t r a t e dn d e x . . . . . . . . clutch Pedal ..."""'.-"" 12'4 Adjustment Clutch Master Cylinder '." 12-5 Removal/lnstallation Slave Cylinder "" 12-6 Removal/lnstallation PressurePlate -'." 12-7 Removal/lnspection Clutch Disc .'." 12-8 Removal/lnspection Flywheel ' 12-9 Inspection .t . R e p l a c e m e n . . . . ." . . . . ." . . . . ' . . . . . .".. 12 - 9 Clutch Disc, PressurePlate ...".....'.'...12-10 . Installation ReleaseBearing ..." 12-11 Removal/lnspection 12-12 lnstallation
rf,'
l l ,
SpecialTools
Ret. No.
Tool Number
Dscliption Clutch AlignmentDisc Clutch AlignmentShaft Ring Gear Holder Attachment, 32 x 35 mm Driver Handle
Oty 1 1 1 1 1 1
I P89e Reference
o
l /6
@
,A
1A OTJAF_PM701 OTJAF_PM7O124 OTLAB PVOO or 1OO o7924-PD20003 07746-0010100 07749-O010000 07936-3710100
't2-7 1 2 - 7 A , 1 0 ,1 1 , 1 2 - 7 S , 1 0 ,1 1 , 12-10 12-10 1 2 - 7 8 , 1 0 ,1 1 ,
12-2
lllustratedIndex
NOTE: a Wheneverthe transmission removed,clean and greasethe releasebearingslidingsurface. is a It the parts markedwith an asterisk(*) are removed,the clutch hydraulicsystem must be bled (see page 12-6). and twisting. a Inspectthe hosesfor damage,leaks,interlerence,
@
ASSTST
/6t-^
@ *REsERvorR r
t= ov / g*______-__=
Fn
*CLUTCHLIN 15 N.m {1.5kgl.m, 11 tbt.Ir)
,,'
W.*ra
TCLUTCH LINE 19 N.m ll.9 kgl'm, 14 rbt.ttl PEDALPIN
\F
fl \
'CLUTCH MASTERCYLINOER '12 5 Removal/lnstallation, Page CLUTCH PEDAL Adjustment,page 12-4 I x ' 1 . 2 5m m 25 N.m (2.6 kgf.m, 19 tbf.fi)
RELEASE BEARING page 12-11 Removal/lnspection, page 12'1 2 lnstallation,
FLYWHEEL page12'9 Inspection, page Replacement, 12-9

CLUTCH DISC page 12_8 Removal/lnspection, page 12-10 Installation, 1 2 x 1 . Om m 118 N.m {12.0 kgf.m, 86.8 lbf.tt} PRESSURE PLATE page 12 7 Removal/lnspection, page 12-10 Installation,
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 Removal/lnstallation, *CLUTCHLINE 15 N.m {1.5kgl.m.11 lbf.{r)
12-3
Clutch Pedal
Adjustment
NOTE: a To check the clutch interlock switch and clutch switch, see section 23. a The clutch is sell-adjusting compensate wear. for to CAUTION: ll thefe is no clearance between the master cylinder piston and push rod, the leleaso bearingis held against the diaphragm spring, which can resultin clutch slippageor other clutch problems, '1. Loosenlocknut A, and back off the clutch switch (or adjustingbolt) until it no longertouchesthe clutch oedal. Loosenlocknut C, and turn the push rod in or out to get the specified stroke(@)and height(O) at the clutch pedal. Tighten locknut C. Threadin the clutch switch (or adjusting bolt) until it contacts the clutch pedal assjyear.lc -@{
{P/N PUSH ROO CLUTCH MASTER CYLINDER
5. Turn the clutchswitch {or adjusting bolt) in an additional 3/4 to 1 full turn. 6. Tighten locknut A. 7. Loosenlocknut B on the clutch interlockswitch. the betweenthe floor boardand 8. Measure clearance clutch pedal with the clutch pedallully depressed. '15-20 mm (O.59 9 . R e l e a s t h e c l u t c hp e d a l e 0.79 positionand hold it there. in) from the tully depressed switch so Adjustthe positionof the clutchinterlock that the engine will startwith the clutchpedalin this postuon. '10. in Threadthe clutch interlockswitch an additional 3/4 to 1 full turn.
2.
3. 4.
1 1 . T i g h t e nl o c k n u tB .
LOCKNUT 8 9.8 N.m (1.0 kgt.m,7.2 lbf.ttl

INTERLOCK SWITCH
CLUTCH SWITCH {or ADJUSTING BOLTI
A LOCKNUT 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 )
: a @ ( S T R O K E t P E D A L )1 3 0 - 1 4 0 m m 1 5 . 1 2 - 5 . 5 1 i n ) PLAYI:12-21 mm 1o.47-0.83 in) includethe pedalplay 1-1o mm {0.o4-0.39 in) {fOrll Clufcx PEDALFREE ) 165 mm (6.50 in) to the flool ao |CLUTCHPEDALHEIGHT): 83 HEIGHT): mm 13.27 in) minimumto the floor o) {CLUTCHPEDALDISENGAGEMENT
12-4
Clutch Master Cylinder

Removal/lnstallation
CAUTION: 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. hose from Disconnect the clutch line and reservoir the clutch master cylinder.
CLUTCHLINE 1 9 N . m( 1 . 9 k g t ' m , 14 tbI.ft)
4.
Removethe clutch mastercylinder.
CLUTCHMASTERCYLINDER
5 . Installthe clutch mastercylinderin the reverseorderof 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: a Do not spill brake fluid on th vohiclo; it may damagc the paint; it brake fluid doos contact tho paint. wash it ott immsdiatoly whh water. a Plug the end of the clutch line with a shop towel to prevent brake tluid from coming out. -.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 grease. '1. Disconnect the clutch line lrom the slavecylinder. 3. Install the slave cylinder in the reverseorder ol removat. on NOTE: Make surethe boot is installed lhe slave cylander. CLUTCH LINE 15 N.m (1.5 kgf.m,1'l lbt.ttl
SLAVECYLINDER
(P/N 08798 -9002)
-C.
8 x 1.25mm 22 N.m 12.2 k9l.n, 16 tbf'ttt
.:;?L. -=-s!!rqil (Brake Assembly Lubel Bleedthe clutch hydraulicsystem. a Attach a hoseto the bleeder screw, and suspend the hose in a containerof brake fluid. a Make surethere is an adequate supplyof 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. Using a non-Honda brakefluid can causecorrosion and dec.easethe liJeof the system. a Contirmclutch operation, and check for leaking fluid.
2.
Remove slavecylinder the from the clutch housing.
12-6
PressurePlate
Removal/lnspection
1 . Inspect Jingers the diaphragm the springfor wear of at the releasebearingcontact area. Check the diaphragm spring tingers tor height using the specialtools and a feelergauge. StandardlNew): 0.6 mm (0.02 inl max. ServiceLimit: 1.0 mm (O.O4in)
FEELR GAUGE
platesurlacefor weaf, cracks, the pressure Inspect and burning. 6. Inspectfor warpageusinga straightedge and feeler gauge. plate at three NOTE: Measureacrossthe pressure points. Standard(New): O.O3mm (0.0O1inl max. SrvicoLimit: 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.
PRESSUBE PLATE
service limit,replace the lf the warpageexceedsthe pfessureplate.
RING GEAR HOLDER 071A8-PV00100 ot 07924-PD20003 ENGINE BLOCK
OTJAF_PM7012A HANDLE
07936-3710100
GEARHOLDER 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. Rivet Depth: (New):1 .3 - 1 .9 mm {0.O5-O'O7in} min' Standatd Limit: O.2 mm (O.01 inl Srvice
CLUTCH DISC
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 dN e w ) : 8 . 5 - 9 . 1 m m ( 0 . 3 3 - 0 . 3 6 i n l l ServiceLimit: 5.5 mm (0.22 in)
CLUTCH DISC
the lI the depthis lessthan the servicelimit,replace clutch disc.
limit,reolace lf the thickness lessthan the service is the clutch disc.
12-8
Flywheel
Inspection
1. 2. Inspectthe ring gear teeth tor wear and damage. Inspect the clutch disc mating surface on the flywheel for wear, cracks, and burning. 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 measured with engineinstalled. Standard{Now}: O.O5mm (0.OO2in) max. ServicaLimir: O.15 mm (0.006 inl
Replacement
tool. 1. Installthe sDecial
FLYWHEEL
3.
,
FLYWHEEL
MOUNTING BOLTS RI[{G GEAR HOLOER 071A8 -PV00100 ot 07924-PO20003
2 . Remove flywheelmountingbolts in a crisscross the

patternin severalsteps as shown, and removethe flywheel. lf the runout exceedsthe servicelimit, reolacethe flywheel. Turn the innerraceof the ball bearingwith your finger. The ball bearingshouldturn smoothlyand quietly. 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.replace ball bearing. the Removethe ball bearingfrom the flywheel.
FLYWHEEL
BALL BEARING
{cont'd)
12-9
ClutchDisc,
Flywheel
Replacement(cont'dl
4. Drivethe new ball bearinginto the flywheel using the sDecial tools as shown.
PressurePlate
Installation
1. Installth specialtool.
L
clurcH olsc
07936-37ioioo
ON|vER 07749-OOtO(xX)
ATTACHMENT, 32x35mm 07746-0010r00
FLYWI{EEL
(P/n 08798-90{'21
RING GEAR HOLDER 07LAB-PVOOIOO ot 07924-PD20003 CI.UTCH ALIGNME T SHAFT OTJAF_PM7012A
BEARII{G
5 . Align the hole in the flywheel with the crankshaft dowel pin and installthetlywheel.Installthemounting bolts fingertiqht.
o.
lnstallthe clutch disc using the specialtools. Installthe pressureplate.
Install the specialtool, then torque the flywheel mountingbolts in a crisscrosspattern in severalsteps as shown.
BOLTS MOUNTING k 1 1 8N . m 1 1 2 . 0 s t ' m , 87 tbf'ft)
YWHEEL
RINGGEARHOLDER oTLAB-PVOO100
ol
07924-PD20003 RINGGEARHOLDER oTLAB-PV00100

ol
O7JAF.PM70l2A HANDLE 07936-3710100
07924-PD20003
12-10
ReleaseBearing
Removal/lnspection
4. patternas Torquethe mountingbolts in a crisscross shown. Tighten them in severalsteps to prevent warping the diaphragmspring. 1 . Remove the release fork boot from the clutch housing. the release Remove fork from the clutch housingby the fork set springwith pliers.Resqueezing release move the releasebearing.
BOLTS @ MoUNTING 8 x 1 . 2 5m m 25 N'm 12.6kgf.m,19 tbt.ft)
RLEASEFORK
it bearing play by spinning by for 3 . Checkthe release hand. CAUTION: The lelease bearing is packed with grease. Do not wash it in solvent
RINGGEARHOLDER CLUTCHALIGNMENT oTLAB-PVOo100 OTJAF_PM7O12A

ol
o7924,PD20003
HANDLE 07936- 3710100
play, replace lf there is excessive the release bearing with a new one.
12-11
Release Bearing
Installation
NOTE: Use only Super High Temp Urea Grease (P/N 08798 9OO2). 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.
3.
fork rightandlelt to makesurethat Movethe release bearing, and that it fits properlyagainstthe release the releasebearingslidessmoothly.
29 N.m 13.0 kgf.m, 22 lbl.fr)
--6i
oa798-9002)
4.
Install release the fork boot;makesurethe boot seals aroundthe releasefork and clutch housing.
(P/N 08798-9002) 0 . 3- 0 . 9 g { 0 . 0 1 - 0 . 0 3o z }
fork with the release 2 . Align the detentoJ the release fork overthe release {ork bolt,then pressthe release lork bolt sequarelv.
12-12
ManualTransmission
Tools ......... 13-2 Speciaf Maintenance T r a n s m i s s i o ni l . . . . . . . . . . . . . . . . . . . .1 .3 - 3 . . O Back-upLight Switch ....... 13-3 Replacement Troubfeshooting ..... 13-4 Transmission Assembly . . . . . . . . . . . .1 3 - 5 . Removal ...... ... 13-8 lnstallation 1. . l l l u s t r a t e n d e x . . . . . . . . . . . . . . . . . . . . . . .3.-.1 0 ld Transmission Housing . . . . . . . . . . .1 . - 1 2 .3 Removal R e v e r s e h i f tH o l d e r S n n .3 C l e a r a n cIe s p e c t i o . . . . . . . . . . . . . . . .1 . - 1 3 Reverse ldler Gear . . . . . . . . . . . .1 3 - 1 4 . Removaf Mainshaft, Countershaft,Shift Fork Disassembly . . . . . . .1 3 - 1 4 Mainshaft Assembly I n d e x. . . . . . . . . . . . . . . . .1 3 - 1 5 1. C l e a r a n cIe s p e c t i o . " . . . . . . . . . . . . . . . 3 - 1 6 n n . . . . . . .1 3 - 1 7 Disassembly Inspection .........13-18 . Reassembly . . . . . . . .1 3 - 1 9 CountershaftAssembly fndex............. .... 13-20 e f . .. C f a r a n c en s p e c t i o n. . . . . . . . . . . . . . .1 3 - 2 1 . ... ... 13-22 Disassembly ....... ... 13-23 lnspection Reassembly ..... ... 13-23 Shift Fork Assembly Index............. ....13-25 n . .3 C l e a r a n cle s p e c t i o n. . . . . . . . . . . . . . .1 . - 2 6 MBS Shift PieceInspection ......... 13-27 SynchroSleeve.SynchroHub Inspection/lnstallation ................ 13-27 Synchro Ring, Gear .........13-28 . Inspection Shift Rod . . . . . . . . . . .1 .3 - 2 9 . Removal Differential . . . .1 3 - 3 0 l n d e x. . . . . . . . . . . . . I . .. B a c k l a s hn s p e c t i o n. . . . . . . . . . . . . . . .1 3 - 3 0 .. . B e a r i n g e p l a c e m e n t . . . . . . . . . . . . .1.3 - 3 1 R .... FinalDrivenGear Replacement 13-31 T h r u s tS h i mA d j u s t m e n t. . . . . . . . . . .1 3 - 3 2 . Clutch Housing Bearing . . . . . . .1 3 - 3 4 Replacement Mainshaft Thrust Shim . . . . . . . .1 3 - 3 6 . Adjustment Transmission . . . . . . . .1 3 - 3 9 Reassembly OilSeals . . . . . . .1 3 - 4 3 Replacement GearshiftMechanism . . . . . . . . . . .1 3 - 4 4 . Overhaul
Ref. No.
Tool Number
Description MainshaftHolder Collar MainshaftBase AdjustableBearingPuller,25 Attachment,42 x 47 mm Attachment. 52 x 55 mm Driver, 0 mm l.D. 4 Attachment, 30 mm LD. Attachment, 35 mm LD. Driver Driver Attachment Pilot, 26 x 30 mm Seal DriverAttachment
Oty 1 1 1 1 I I I I 1 1 1 1 1
I Page Relerence
o @ o .@
,3)
@
(j) (q) )
oTGAJ-PG20110 oTGAJ-PG20120 07GAJ-PG20130 07736-AO10004 o7746-0010300 o7746-0010400 o7746-0030100 o7746-0030300 o7746-OO30400 o7749-O010000 07JAD-PH80101 07JAD-PH80200 07947-6110501 07947-6110500
40 mm
@ (, @ @
13-38 13-37 13-37 13-34,35 13-34, 5 3 13-34, 5 3 13-19,24, 31,32 13-19,24 13-19,24 13-3435,43 , 13-43 13-43 13-43
n Must be used with commercially available3/8 " -'1 Slide Hammer. 6
ll
(1]
at\
\,
/;i
\ @ (9
13-2
Maintenance
Transmission Oil
oil NOTE:Checkthe transmission with the engine OFF and the vehicleon levelground. 1. Removethe oil fille. plug, then check the leveland conditionof the oil. OILFILLER PLUG 44 I{.m (4.5 kgt.m, 33 lbl.ftl
ProperLevel
Back-upLight Switch
Replacement
NOTE: To test the back-uplightswitch, seesection23. 1. Disconnect connector, the then remove the back up light switch connectorlrom the connectorclamp. Removethe back-uplight switch.
2.
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 reinstall the oil filler plug with a new washer. lf the transmission is dirty, removethe drainplug oil and drain the oil. Reinstall drainplug with a new washer,and refill the the transmission with the recommended to the oil properlevel. NOTE: The drainplugwashershouldbe replaced at every oil change. Reinstall the 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 causestiffershifting becauseit does not contain the proper addittves.
25 N'm 12.5 kgf'm, 18lbt.tt)
Replace.
3 . Installthe new washer and back-uplight switch.

Connectthe back-uplight switch connector.
13-3
Troubleshooting
Reverse Gear Noise ReductionSystem
Wheneverthe clutch pedal is depressed shift into reverse, to the mainshaftcontinuesto rotate becauseof its inertia. The resultingspeed differencebetween mainshaftand reverseidler gear producesgear noise. gearnoisereduction shift holder.When shifting The reverse systememploysa cam platewhich was addedto the reverse into reverse, the sth/reverse to shift piece,connected 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. gear noise reductionsystem. NOTE: This system is not a fully-synchronized 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 shifting into reverseafler lhe engine rs slarleo.
ls the gear noisepfesentwhen shilting into sth gear?
Replacetho sth synchto hub and sEeve as a sel.
Measurethe clearance between 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
Transmission Assembly
Removal
6.
Make sure jacks and satety stands are placed properly, and hoist bracksts are attached to correct pos;lion on the engine. Apply parking brsko and block rea. wheels so cal will nol ,oll oft stands and lall on you whils working under it. CAUTION: Use fender covers to avoid damaging painted surlacas.
Disconnect vehiclespeedsensor(VSS)connecthe tor.
vss
CONNECTOR
1 . Disconnectthe negative(-) cable first, then the
positive(+ l cable from the battery. Draintransmission (seepage13-3). oil Removethe intakeair tube, intakeair duct and air (seesection5). cleanerhousingassembly Disconnect the starter motor cables,transmission groundwire and back-up light switchconnector, 7. Removethe clutch line bracket,clutch line clamp, and slavecylinder. CAUTION: a Do not operate the clutch pedal once the slave cylinder has been removed. a Take care not to bend the clutch line.
6xl .O mm 9.8 N.m (1.0 kgt.m, 7.2 lbf'ft)
b
ARTER 8t1.25 mm 8.8 N.m (0.9kgf.m,6.5lbl.ttl
5.
Remove wire harness the clamos.
(cont'd)
13-5
Assembly Transmission
Removal(cont'd)
8. Removethe driveshafts(seesection 16). finished with sur{aces NOTE: Coatall the precision Tie cleanengineoil or grease. plasticbags over the drivesha{tends.
SET RING
10. Removethe shitt rod and extensionrod.
SHIFTROD
DRIVESHAFT
1 0 x 1 . 2 5m m 43 N.m (4.4 kgl.m,
8x22mm SPRING PIN Replace.
\
1 l. Removethe enginestiffenersand clutch cover' Dl6Y5, Dl6Yg onginos:
COTTERPIN 12 x '1.25mm Replace. 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.
Replace
10 x 1.25mm 44 N.m {4.5 kgl.m,
33 tbhlrt
8 r 1.25mm 24 N.m (2.4 kgf.m 17 tbt.trl
COVER
ruur.-@ sELF-LocKrNG
EXHAUST Replace. PIPEA I x 1 . 2 5m m NUT SELF-LOCKING 1 6 N . m 1 1 . 6k g t ' m , Replace. 12 tbf.ftl D16Y5, Dl6Y7 engins: NUT 1 0 x 1 . 2 5m m SELF.LOCKING Replace. 33 N.m (3.4 ksl'm, 25 lbI'ttl 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}
8 x 1.25mm 24 N.m (2.4 kgl'm, '| 7 tbl.trl
13-6
O16Y7 engine:
1 4 . R e m o v e h e r i g h t l r o n t m o u n tb r a c k e t . 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 chainhoist to the bolts,then lilt the engineslightly to unloadthe engineand transmission mounts. CHAIN HOIST 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. Remove transmission the mountbracketand mount.
TRANSMISSION MOUNT TRANSMISSION RIGHTFRONT MOUNT/BRACKET
64 N.m (6.5 kgt.m,47 lbt.ttl
' 1 2x 1 . 2 5 m m
BRACKET
13. Bemove he splash hield. t s
SPLASHSHIELD
(cont'd)
13-7
Assembly Transmission
Removal(cont'd)
17. Remove threeuppertransmission the mounting bolts and the lower starter mountingbolt.
Installation
in orderol Installthetransmission assembly the reverse removal. a Beforeinstalling, check that the two dowel pins are i n s t a l l e dn t h e c l u t c hh o u s i n g . i a When installing startercable,make surethat the 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 eo r k a n d r e l e a s e e a r i n g . f b NOTE:Use only Super High Temp Urea Grease ( P / N0 8 7 9 8- 9 0 0 2 ) .
STARTER MOUNTING BOLT 1 0 x 1 . 2 5m m 44 N.m {4.5 kgl.m, 33 tbt.trl
TRANSMISSION BOLTS MOUNTING 1 2 x 1. 2 5 m m 64 N.m (6.5kgf.m,47 lbt,tt)
RELEASE FORKEOLT 1 2 x 1 . 2 5m m 29 N.m {3.0 kgt.m,
N tPi 08798-9002)
22 tht.trl
1 8 . R e m o v eh e r e a rm o u n tb r a c k e b o l t sa n dt r a n s m i s t t sion mountingbolts spEcrAL BoLT Replace. ' l . 5m m 14 x

a 4 N . m { a . Sk g f . m , 6 1 t b f , t t l 12 x 1.25mm 6 4 N . m 1 6 . 5k g f . m , 4 7 l b f . f t )
RELEASE FORK BOOT
\
{P/N08798 RELEASE FORK 9002)
lP/N08798-9002) 0 . 3 0 . 9s { 0 . O- 0 . 0 3 o z ) 1
WASHER
SPECIAL BOLT 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 shown. A 1 2 x 1 . 2 sn m 64 N.m {6.5 kgf.m, a ) 1 2 x 1 . 2 5m m 64 N.m (6.5 kgf.m, 47 tbI.tt)
a Apply greaseto the slave cylinderpush rod. NOTE: Use only Super High Temp Urea Grease ( P / NO 8 7 9 8 9 0 0 2 ) .
6 x 1.0mm 9.8 N'm (1.0kgt.m, 7 .2 tbt.ltl
CLUTCH PIPE
@ 1 2 x 1 . 2 5m m 74 N'm17.5 gf.m, k 54 lbt.tt) a Check that the bushingsare not twisted or offset. a Installthe clip as shown.
SHIFTROD 8 x 1 . 2 5m m 22 N.m 12.2 kgt,m, 16 lbt.ftl
tP/N08798_9002) 16 tbt.fl) Turn the breather cap so that the "F" mark pointsat the front of the car as shown.
8 x 1.25mm 22 N.m 12.2 kgl.m,
FRONT
gx22mm SPBING PIN

Replace.
BOD ,// EXTENSTON
I -/:'.G
/.t***rrm"'i@
,z-s;c,r oown ).,,
a Turn the boot so the hole is facing down. a Make sure the boot is installedon the shift rod.
Retill the transmission with the recommended oil (seepage 13-3). Connect the positive (+ ) cable first, then the negative {- ) cable to the battery. a Check the clutch operation. a Shift the transmission and check for smooth operation. '18). Check the front wheel alignment (see section
lllustratedIndex
disassembly/reassembly Referto the drawing below for transmission ail Cleanall the parts thoroughlvin solvent and dry with compressed I LuOricate the parts with oil belore reassembly. all
NOTEI use a This transmission usesno gaskets betweenthe maiorhousings; liquidgasket{P/N0871 I - 0001 or 08718 - OOO3) ( s e ep a g e 1 3 - 4 ' l ) . housingis disassembled. a Always clean the magnet@ wheneverthe transmission a Inspectall the bearingsfor wear and operation.
;- 6
d b +
+v
\"
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) (*1I O BALLBEARING ANGULAR BALL EEARINGIT2) @ sTH sYNcHRo HUB O 5TH SYNCHRoSLEEVE SPRING @ SYNCHRO RING @ SYNCHRO @ 5TH GEAR @32xazxz:.5mm NEEDLE BEARING coLLAR @ SPACER @3lx3gxz3mm NEEDLE BEARING @ 4TH GEAR O SYNCHRoRING SPRTNG @ SYNCHRO @ 3RD/4THSYNGHRoSLEEVE @ 3RD/4THsYNcHRo HUB @ 3RD GEAR @34x39x27.5mm NEEDLE BEARING @ MAINSHAFT @ WASHER WASHER @ SPRING @ BALL BEARING Check wear and for operalron. @26x42x7mmOlLSEAL Replace. @ 28 mm PLUGBOLT 54 N.m {5.5 kgt.m, 40 lbf.ft) SPRING @ 1ST/2NDSELECT L. 36.26mm (1.428 inl @ SHIFTARM SHAFT @ CLUTCHHOUSTNG GUIDEEoLT @ INTERLoCK 39 N.m 14.0kst.m, 29 lbf.ft) SHIFTHOLDER @ REVERSE IDLERGEAR @ REVERSE TDLER GEARSHAFT @ REVERSE @ 5 x 22 mm SPRINGPIN Replace. @ 3RD/4THSHIFI PIECE @ sTH/REvEnsESHIFTPIECE @ MBS SH|FTP|ECE @ lsT/zNo SHIFI FoRK r 1 : D l 6 Y 7 n g i n . 12: D16Y5.D16Y8engines 3RD/.TH SHIFr FoRK 5TH/REVERSE sHIFT FoRK 52 mm SNAP RING 65 mm THBUST SHIMl*11 70 mm THRUSTSHIM l*21 page 13-36 Selection, @ OIL GUIDEPLATE @ WASHERReplace. @ @ O @ SH|M t'1) @ 72 mm THRUST 80 mm THRUSTSHIM {*2) page 13-33 Selection, ASSEMBLY @ DIFFERENTIAL Seepage 13-30 @ 14 x 25 x 17.5mm OtLSEAL Replace. @35x56x8mmOlLSEAL Replace.
LrcHT @ BAcK.uP swrrcH

@ sETscREw
25 N.m (2.5 kgt'm, 18 lbf.ft) 22 N.m (2.2 kgt.m, 16lblftl WASHER Replace. SPRING L.31.6mm (1.24in) STEELBALL (5/16 in) BACK.UPLIGHT SWITCHHARNESS STAY HANGER @ TRANSMISSION @ 32 mm SEALINGBOLT 25 N.m (2.5 kgf.m, 18 lbt,ft) @ OIL SEAL Replace. @ OII DRAINPLUG 39 N'm {4.0 kgf.m, 29 lbf.ftl @ WASHERReplace. PLUG @ OIL FILLER 44 N.m (4.5 kgf.m. 33 tbf'ft) Reptace. @ WASHER HOUSING @ TBANSMISSION PIPESTAY @ RELEASE @ OIL GUTTERPLATE LocK cAM @ REVERSE SELECT SPRING @ REVERSE L. 63.4 mm l2.i6 in) SELECT RETAINER @ REVERSE @ SHIFTARM c @ SHIFTARM B @ INTERLOCK @ COLLAR @ SHIFI ARM A @ SPBINGWASHER @ MAGNET @ SETEALL SPRINGBOLT 22 N.m (2.2 kgl.m, 16 lbf.ft) PIN @ r4 x 20 mm DOWEL @ @ @ @
RoD @sHrFr @ BOOr

PLATE @ oIL GUIDE @30xlzx2tmm ('1} NEEDLE BEARING 30x55x21 m m NEEDLE EEARING IT2) @ COUNTERSHAFT m @ 3 6 x 4 1x 2 5 . 5 m NEEDLE BEARING Check wearand for
ooeralton.
@ lsT GEAR DAMPER @ FRICTION @ sYNcHRoR|NG SPRTNG @ sYNcHRo sYNcHRoHUB @ 1ST/2ND GEAR @ REVERSE SPRTNG @ SYNCHRO FING @ SYNCHRO DAMPER @ FRICTION @ SPACER @39xllx2zmm NEEDLE BEARING @ 2NDGEAR @ 3RDGEAR @ 4THGEAR @ 5THGEAR {*1) @ EALLBEARTNG NEEDLE BEARING I*2I BEARING @ BALL WASHER @ SPRING Reptace. @ LoCKNUT + 108 0* 108 .m N k f r r . o* o * 1 1 . 0 g f . m , l tbtft | lrs.e* o- 79.6
13-11
Housing Transmission
Removal
NOTE:Placethe clutch housingon two piecesof wood f 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 t r o m h i t t i n g t h e workbench. 1. 2. the light switch. Remove back-up transmission hanger. Remove
TRANSMISSION HAt{GER
housingattachingbolts in Loosenthe transmission pattern in severalsteps.then remove a crisscross them. 5. Remove 32 mm sealingbolt. the ball Expandthe snap ring on the countershaft bearing, and remove it from the groove using a pair of snap ring pliers. BOLT 32 mm SEALING
SNAP RIIIG
Removethe setting screws,washers,springs,and steelballs.
housingfrom the clutch the transmission Separate housing, and wipe it cleanol the sealant. Remove thrust shim,oil guide plate,and oil gutthe housing. ter plate{rom the transmission
STEELBALLS D.5/16in SPRING L . 3 1 . 6 m m 1 1 . 2 4I n l
TRANSMISSIONHOUSING
13-12
ReverseShift Holder
Inspection Clearance
1 . Measure clearance the between reverse the shiftfork
3.
and sth/reverseshift Dieceoin. S t a n d a r d : 0 . O 5 - O . 3 5 m m ( O . O O 2 - 0 . O 1 4n ) i ServiceLimit: 0.5 mm {0,02 inl
Measure clearance the between reverse the idlergear a n d t h e r e v e r s e h i f tf o r k . s Standardr 0.5-1.1 mm {O.02-0.04 in} S e . v i c e i m i t :1 . 8 m m ( 0 . 0 7 i n t L IDLEB REVERSE GAB
REVERSE
REVERSE SHIFTFOBK
2 . lf the clearances more than the service limit, are

measure widths of the groovein the reverse the shift fork. Standard:7.15- 7.35 mm (0.281- 0.289inl
lf the clearance morethan the servicelimit,measis ure the width of the reverseshift 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 ) :
REVERSE SHIFTFORK
SHIFTHOLDER REVERSE REVERSE SHIFTHOLOEB
lf the widths of the grooves are not within the standard, replacethe reverseshift holderwith a new one. lf the width of the groovesare within the standard, replacethe sth/reverse shift piece with a new one.
lf the width is not within the standard,replace the reverse shift holderwith a new one. lf the width is within the standard,reDlace the reverse idler gearwith a new one.
13-13
Reverseldler Gear
Removal
1. Remove the reverse shift holder. REVERSE SHIFT HOLDER
Mainshaft,Countershaft, Shift Fork

Disassembly
1 . Remove the interlock guide boh trom under the clutch housing. SHIFT ARM8 ATTACHING EOLT
SPRING WASHER
CLUTCH HOUSING
the idlergearshatt and reverse idler 2. Remove reverse geat. BOLT II{TERLOCK GUIDE
2 . Removethe shift arm B attachingbolt.

REVERSE IDLER GEARSHAFT
Removethe mainshalt and countershaft assemblies with the shift lork trom the clutch housing. NOTE: Belore removingthe mainshalt and counterto tape the mainshaft splines proshaft 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 installed with a press. . Install angularball bearing with the thin-edge the outer racefacingthe sth synchrohub. . Installtheball bearing with the bsll cagefacingup. Priorto reassembling. cleanall the partsin solvent. them and applylubricant all contactsurfaces 3rd/i[th dry to the and sth svnchrohubs,
Ball cage faces up.
3RD/4THSYNCHRO SLEEVE p a g e1 3 2 7
BALLBEARING {T1} ('2I ANGULARBALLBEARING Check wearand operation. for Note the directionof installation.
SYNCHRO HUB
sTH SYNCHRO SLEEVE page13 27 lnspection,

SYNCHRO SPRING SYNCHRO RING Inspection, p a g e1 3 - 2 8 SPRING RING SYNCHRO page 13'28 Inspection, 5TH GEAR p I n s p e c t i o n ,a g e 1 3 - 1 7 NEEOLE BEARING Checkfor wear and operation. SPACER COLLAR page 13-'t6 Inspection, 34x39x23mm NEEDLE EEARING Check for wear ano operalton. 4TH GEAB p I n s p e c t i o n ,a g e 1 3 - 1 6 RING page 13-28 Inspection, SPRING
3RO GEAB page 13'16 Inspection, 34 x 39 x 27.5 mm NEEDLE BEARING Checkfor wear ano operalron.
CHAMFER
MAINSHAFT I n s p e c t a op a g e 1 3 - 1 8 n,
D16Y7 engine D16Y5, D16YB engines
13-15
MainshaftAssembly
NOTE: lI replacement required,always replacethe is svnchrosleeveand hub as a set. 1. Measure clearance the between2nd and 3rd oears. Standaid: 0 . 0 6 - O . 2 1 m m { O . O 0 2 - O . O Oi8 } n Ssrvice Limit: O.33 mm (O.O13inl 3. Measurethe clearance between 4th gear and the soacercollar. inl Standard: 0.06-o.19 mm (O.OO2-O.OO7 ServiceLimit: O.31 mm {0.012 in}
4TH GEAR
t l,-
--,
q l \ \-,l-LJ
[nI
/ /hm
2ND GEAR
r[Jl] i r
\- cltl-l
tl-lll
3RD GEAB
5TH GEAR
is lf the clearance morethan the seryicelimit,measure 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 clearance morethan the servicelimat. is measure the thicknessof 3rd gear. 30.22-30.27mm { 1 . 1 9 0 - 1 . 1 9 2i n l S e r v i c e i m i t :3 0 . 1 5 m m ( 1 . 1 8 7 i n l L Standard:
4TH GEAR
stoE
SPACEB COLLAR
3RO GEAR
lf distance@ is lessthan the servicelimit, replace the spacercollar with a new one. lf distance is within the service limit,measure the @ thicknessof 4th gear. 3O.12 30.17 mm 1 1 . 1 8 6 -1 . 1 4 8i n ) Ssrvicelimit: 30.05 mm {1.183 in) Standard:
4TX GEAR
a lf the thicknessot 3rd gear is lessthan the service limit, replace3rd gear with a new onea lf the thicknessof 3rd gear is within the servrce the limit,replace 3rd/4thsynchrohub with a new one.
lf the thicknessof 4th gearis lessthan the service 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. Measure clearance the between spacer the collarand sth gear. i S t a n d a r d : O . 0 6 - O . 1 9 m m ( 0 . 0 O 2 - O . O O 7n l S6rvicelimit: O.31 mm (0.O12 in) p 1 . R e m o v e h e b a l l b e a r i n g s i n ga b e a r i n g u l l e ra s t u shown.
PULLER BEARING (Commercially available)
4TH GEAR DIAL INDICATOR
--t
*3'4>
sTH GEAR 1 . lf the clearance morethan the service is limit.measure distance@ on the spacercollar. 23.53-23.56mm (0.926-0.928 inl Servics Limit:23.51 mm (0.926 in) Standard:
stoE
sTH GEAR 2.
CAUTION: Remove the synchrohubs usinga piess and steel blocks as shown. Use of a.iaw-type puller can causedamageto the gear teeth, 4th Support gearon steelblocks,andpress main' the shaft out of the sth synchro hub as shown.
lf distance@ is less than the servicelimit, replace the sDacer coliar with a new one. lf distance@ is within the servicelimit, measure thicknessof sth gear. 28.42-28.47mm ( 1 . 1 1 9 -1 . 1 2 1 n l i ServiceLimit: 28.35 mm l1 . l 16 in) Standald: sTH GEAR
It the thicknessof sth gear is lessthan the service limit, replace5th gear with a new one. lf the thicknessof sth gear is within the service limit,replace 5th synchrohub with a new one. the
} {cont'd
13-17
MainshaftAssembly
(cont'dl Disassembly
3. Supportthe 3rd gearon steelblocks,and pressthe mainshaltout of the 3rd/4thsynchrohub as shown.
Inspection
I. Inspectthe gear surtaceand bearingsurfacefor wear the mainshaftat points and damage,then measure A, B, C, and D. 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 } Standard:
tor Check wearanddamage is lf any part of the mainshaft lessthan the servicelimit, it replace with a new one. 2. Inspecttor runout. O.O2mm {O.0O1in} max. Standald: 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 with a new one. mainshaft
13-18
Reassembly
CAUTION: When installing the 3rd/,lth and 5th synchro hubs, support the shaft on steel blocks. and instsll the synchro hubs using a press. for sequence. NOTE:Refer page 13-15 reassembly to 1. Support 2nd gear on steel blocks,then install the 3rd/4thsynchro hub using the specialtools and a press,
40 DRIVER, mm l.O. 07746 - 0030100 ATTACHMENT, 30 mm LD. o7746-0030300 HUB sTH SYNCHRO 40 ORIVER. mm l.D o7746 -0030100
3.
Installthe sth synchrohub using the specialtools ano a oress.
ATTACHMENT, 35 mm LO. o7746 -OO30400
2ND GEAR
tools and a Install the ball bearingusingthe special press.
2.
I n s t a l l 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 t and hub. stopsof the 3rd/4thsynchrosleeve NOTE:After installing,checkthe operationof the 3rdl4thsynchrohub set.
SYNCHRO SLEEVE
*1: D'16Y7 engine *2r D16Y5, D16YB engines
13-19
Gountershaft Assembly
Index
NOTE: 3rd, 4th,and sth gearsare installed The with a press,
Prior_to reassembling, cleanall the partsin solvent, them and apply lubricant all contactsurfaces dry to exceptthe 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) (*2) BEARTNG I NEEDLE Check for wear and operation. GEAR 4TH GEAR 3RO GEAR 2ND GEAR lnspection, page 13-21, 28 39x44x27 mn NEEDLE BEARING Checktor wear and operation. SPACER COLLAR Inspection, page 13-21 FRICTION DAMPER SYNCHRO RING Inspection, page 13-28 SYNCHRO SPRING REVERSE GEAR page 13-27 lnspecta.on, 1ST/2NDSYNCHRO HUB
SYNCHRO SPRING
SYNCHRO RING page 13-28 Inspection, FRICTION DAMPER lST GEAR p l n s p e c t i o n ,a g e 1 3 2 1 , 2 8
36 x 41 x 25.5 mm NEEOLE BEARING

Check for wear and operation.
I n s p e c t i o n ,a g e 1 3 - 2 3 p
*1: D16Y7 engine '2: D16Y5, D16Y8 engines
13-20
is NOTE: lf replacement required,always replacethe synchrosleeveand hub as a set. b t 1 . M e a s u r e h e c l e a r a n c e e t w e e nt h e c o u n t e r s h a f t and lst geaf. m S t a n d a l d : O . O 3 - O . 1 O m ( 0 . 0 O 10 . 0 O 4 i n ) ServiceLimit: 0.22 mm {0.0O9 in} 3. M e a s u r eh e c l e a r a n cb e t w e e n n d a n d 3 r d q e a r s t e 2 S t a n d a , d : O . O 4 - O . 1 2m m ( 0 . 0 0 2 - 0 . 0 0 5 i n ) ServiceLimit: 0.24 mm {0.009 in)
3RD GEAR
FEELER GAUGE
SPACER COLLAR
2NO GEAR
is lf the clearance morethan the servicelimit,measure the thicknessot the spacercollar. Standard: GAUGE 2. lf the clearance morethan the servicelimit,measis urethe thickness f 1st gear. o Standard: 30.41-30.44mm { 1 . 1 9 7 - 1 . 1 9 8i n } S e r v i c e i m i t : 3 0 . 3 6m m ( 1 . 1 9 5i n ) L
3 2 . 0 3 - 3 2 . 0 6m m .261- 1.262 inl 11
ServiceLimit: 32.01 mm l1 .260 inl
SPACER COLLAR
1 S TG E A B
5 . lf the thickness lessthan the service is limit. reDlace the spacercollar with a new one. lf the thicknessis within the servicelimit, measure the thicknessof 2nd gear. 31.91 31.96mm inl 11.256 1.258 S.rvicoLimit:31.85mm (1.25i1in) Standard:
Af
/-?:-
2rlDGEAR t
-
-N/
/
l
L'rz::---h_l
i I t h e t h i c k n e s s f 1 s t g e a ri s l e s st h a nt h e s e r v o i c e l i m i t ,r e p l a c e s t g e a r w i t h a n e w o n e . 1 lf the thicknessof l st gear is within the service limit,replace 1st/2ndsynchrohub with a new the one.
lf the thicknessot 2nd gear is lessthan the servi c e l i m i t ,r e p l a c e n d g e a rw i t h a n e w o n e . 2 lf the thicknessof 2nd gear is within the service limit,replace 1st/2ndsynchrohub with a new the one.
13-21
Assembly Gountershaft
Disassembly
CAUTION: Remove the gears using a pr6ss and stel blocks as shown. Use of a iaw-type pullor can damage the gear toeth. a 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 t s s e m b l yi n a benchvisewith wood blocks. 2. Raisethe locknuttab from the groove of the countershaft,then remove the locknut and the spring wasner. 4. Suppon4th gearon steelblocks, and press counthe tershaft of sth and 4th gearsas shown. out
4TH GEAR
Support 1st gear on steel blocks,and pressthe countershaftout of 3rd gear as shown.
WOODBLOCKS 3, R e mo v e t h e b e a r i n g s s i n g a b e a r i n gp u l l e ra s u shown.
BEARINGR'LLER
13-22
Inspection
t. for Inspectthe gear surfacesand bearingsurfaces wear and damage,then measurethe countershaft at pointsA. B. and C. Standard: A: 30.000- 30.015mm 7 { 1 . 1 8 1-1 1 . 1 8 1 i n l B: 35.984- 36.000mr' {1.4167 1.4r73inl mm C: 24.980- 24.91t3 10.9835 0.9840in) SrviceLimh: A: 29.950mm (1.1791in) B: 35.930mm (1.41i[6in] mm (0.9815inl C: 2/+.930
Reassembly
CAUTION: . Prcssthc 3rd. 4th, and 5th gelrs on thc cour*crshaft whhoul lubrication. . When installing the 3rd, 4th, and sth gea.5, support the shaft on 3te6l blocks and install the gas.r uring a prass. NOTE: Referto page 13-20for reassemblysequence. 1. Installtheneedlebearingon the countershaft.
36 x 41 x 25.5 rnm NEEDLEBEARII{G
COUNTERSHAFT
Check oil passages for clogging.
2.
Assemblethe Dartsbelow as shown. NOTE:Check that the fingersof the frictiondamper are securelyset in the groovesof the 1sv2ndsynchro hub.
lf anv oart of the countershsftis less than the it service limit, replace with a new one.
2 D GEAR 39r44x27mm I{EOLE BEARIIIG SPACERCOLLAB FRICTIOII DAMPER SY'{CHRO RING SYI{CHROSPNING REVERSE GEAB lST/21{D SYNCHNOHUB SY]TCHRO SPRING SYNCHRORING FRICTIONDAMPER 1ST GEAR
2.
lnspect runout. for Standard: 0.02 mm {0.001in) max. in, SorviceLimh: 0.05 mm 10.002
lf the runout is more than the servicelimit. replace with a new one. the countershaft
3.
Installthe oarts on the countershaft. (cont'd)
Assembly Countershaft
(cont'd) Reassembly
4. SuoDort countershaft a steelblockas shown the on and install 3rd gear using the specialtools and a oress, 7. Installthe bearings the direction in shown usingthe specialtools and a press. CAUTION: Install the barings with a maximum prssureof 7.8 kN (8m kd. 5.786lbf).
40 DRIVER, mm l.D. o7746-0030100 ATTACHMENT, 35 mm LO. 07746 -OO30400
w
*1: D16Y/engine +2:D16Y5, D16Y8 engines TH GEAR
Snapring faces up,
Ball cage faces up.
5.
Install4th gear usingthe special tools and a press.
DRIVER,40 lnm
07746-0030100 ATTACHMENT,
35 mm l.D. 07746-OO3O/IOO
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 t s s e m b l yi n a a 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 specialtools and a press.

DRlvER,40 mm l.O. 07746-0030100 ATTACHMENT, 30 mm l.O.
07746-0030300
sTH GEAR
Installthe spring washer,tighten the locknut,then stakethe locknuttab into groove.
13-24
Shift Fork Assembly

lndex
---'rl 'f to dry erlorto reassembling, all the partsin solvent, them,andapplylubricant anYcontactparts clean
3RO/4THSHIFTFORK
5TH/REVERSE SHIFTFORK
1ST/2NDSHIFTFORK
MBS SHIFT PIECE
5TH/REVERSE PIECE SHIFT
3RO/4lH SHIFTPIECE
'13-25
Shift ForkAssembly
Clearance Inspection
NOTE:The synchrosleeveand the synchrohub should be replacedas a set. 1. Measure the clearance betweeneach shift fork and its matchingsynchrosleeve. Standard: 0.35- 0.65 mm (0.014- 0.026in) ServiceLimit 1.0 mm (0.0{ in) 3. Measurethe clearancebetweenthe shift oiece or shiftfork and the shift arm B. Standard: 0.2 - 0.5 mm (0.008- 0.02 in) ServiceLimit: 0,62 mm {0.024ifin)
ARMB SHIFT
".
lf the clearance more than the servicelimit, meais surethe thickness the shiftfork finqers. of Siandard; 3rd/,fth: 7.4 - 7.6 mm {0.291- 0.299in) lst/2nd, 5th: 6.2 - 6.,f mm (0.244- 0.252in)
lf the clearance more than the servicelimit, meais surethe grooveof the shift pieceor shiftfork. Stsndard:13.2- 13.4mm {0.520 0.528in}
SHIFTFORK
lf the thicknessof the shift fork fingers is not within the standard, reDlacethe shift fork with a new one. lf the thickness the shift fork fingers is within of the standard.replacethe synchrosleevewith a new one.
lf the groove of the shift piece or shift fork is not within the standard, replacethe shift pice or shift fork with a new one. lf the groove of the shift piece or shift fork is within the standard, reDlace shift arm B with the a new one.
13-26
Sleeve, Synchro Hub Synchro

MBS Shift PieceInspection
1. Measurethe width of the MBS shilt piece. 6.9-7.1 mm (O.272-O.2aO in) Standard: 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
lnspection/lnstallation
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
lf the width of the MBS shift pieceis lessthan limit, replace MBS shift piece. the service
the synchrosleeveand synchro When assembling hub, be sureto matchthe three sets of longerteeth (120 degrees apart)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.
TEETH LONGER
13-27
Synchro Ring,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 . 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
SYNCHRO
GOOOWORN C: Inspectthe synchro sleeve teeth and matching teeth on the gear for wear (rounded off).
oo
GOOO WORN D: Inspect gear hub thrustsurface wear. the for E: Inspect cone surface wear and roughness. the for 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 g e a r .R o t a t e h e g t synchroring, makingsurethat it does not slip. M e a s u r e h e c l e a r a n c e e t w e e nt h e s y n c h r or i n g t b 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 evenl y w h i l em e a s u r i n t h e c l e a r a n c e . g Synchro Ring-to-Gear Clearance 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 cie l e s st h a nt h e s e r v i c ei m i t ,r e o l a c e s l the synchroring and synchrocone.
/\... ,,-\. \---l (rl
13-28
shift Rod
Removal
N O T E :T h es t e e b a l l s a r e ao lf t h e s a m e s i z e ( 5 / 1 6 i n ) . l l 1. 2. Removethe diff;rential assemory. Removethe 28 mm plug bolt and 1st/2nd select spring. b 7 . R e m o v e h e s h i f t a r m A a t t a c h i n g o l t ,t h e s e t b a l l t a s p r i n gb o l t , s e t s p r i n g , n d s t e e lb a l l . t 8 . R e m o v eh e s h i f tr o d ,t h e n r e m o v e h e s h i f ta r m A . t 6 . R e m o v e 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 s r e m o v et h e r e v e r s e e l e c ts p r i n ga n d r e t a t n e r . s
3 . Removethe shitt arm C attachingb o l t .

9 . Removethe reverselock cam. Removethe shilt arm shalt. 1 0 .Removehe magnet. 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
,Y/
SHIFTARM B INTERLOCK L. SPRING 21.4 mm {0.843 in) SHIFTARM A COLLAR 14x20
RETAINER REVERSE SELECT SLECT SPRING L. 63.4 mm (2.50 inl
\s
SET BALL SPRING BOLT SPRING L . 2 5 . 6 m m 1 1 . 0 1i n )
DOWELPIN
CLUTCH HOUSING
ASSEMBLY DIFFERENTIAL
6p*
\
^s*
\
ssrrrinru spnrr "r..", "r*,*o
OIL SEAL Replace. SHIFTBOO
\ ',)r,r*o
L . 3 6 . 2 6 m m { 1 . 4 2 8i n l
\ 28 mm PLUG BOLT
13-29
Differential
Index
Backlash Inspection
1. Placedifferential assemblyon V-blocks,and install both driveshafts.
PINIONGEARS
:'ylT'Y:-1.91"*4w checktorwear^;Ul
2 . Measurebacklashof both pinion gears.
BALL AEARING Check lor wear and damage. 10x 1.0 1 0 1 N ' m 1O.3 kgl.m, 74.5 tbt'ft1 Left-hand threads
Standard {Newl:0.05-O.15 mm (O.0O2-O.006in)
3 . It the backlashis not within the standsrd,reolace

the ditterentialcarrier.
13-30
BearingReplacement
NOTE: Check bearingsfor wear and rough rotation. the bearingsare OK, removalis not necessary.
1. Remove the ball bearings using a bearing puller as
Final Driven Gear Replacement

't . Remove the bolts in a crisscross pattern in several steps, then remove the final driven gear from the differential carrier. NOTE: The final driven gear bolts have left-hand threads.
PULLER (Commercially available)
FINALDRIVEN GEAR diameterol Chamferon anside final drivengear faces carrier.
BALL BEARING
2.
Installnew ball bearingsusing the specialtool as shown. NOTE: Drivethe bearingssquarelyuntil they bottom againstthe carrier.
40 DRIVER, mm l.O.
1 0 x 1 . 0m m B O L T 101 il.m (10.3kg{'tn,74 5 lbl'tt) threads. Left-hand
7746- 0030100
2.
Installthe final driven gear by tighteningthe bolts pattern in severalsteps. in a crisscross
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 a ls s e m b l ym a k i n g u r ei t b o t a , s t o m s i n t h e c l u t c hh o u s i n gu s i n g h e s p e c i a l t o o l s , t a sh o wn . housing(seepage 13-41). 3 . Installthe transmission NOTE: Do not applyliquidgasketto the matingsurtace 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 differentialassembly in the clutch housing.
DRIVER, mm l.D. 40 07746 -0030100
I n s t a l t h e t h r u s ts h i m . l N O T E : I n s t a l t h e s a m es i z et h r u s ts h i m t h a t w a s l removed.
6.
betweenthrust shim and bearMeasureclearance i n g o u t e r r a c ei n t r a n s m i s s i oh o u s i n g . n
13-32
7.
ll the clearance more than the standard,selecta is t 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 g a b l e . measured step 6 is within in NOTEr lf the clearance t h e s t a n d a r dg o t o s t e p 1 O . , S t a n d a r dO - 0 . 1 O m m l 0 - 0 . O O 4 i n ) :
8 0 m m T H R U S T H I M :D 1 6 Y 5 ,D l 6 Y 8 e n g i n e s S Part Numbe? Thickness i 1 . 0 m m ( O . O 3 9 4n ) 1 1 m m ( O . 0 4 3 3i n ) 1 .2 mm lO.O472in') n 1 . 3 m m ( O . O 5 1 i2 ) n 1 . 4 m m { O . O 5 5 i1 ) '1.5 i m m ( O . O 5 9 1n ) i 1 . 6 m m ( O . 0 6 3 0n ) 1 . 7 m m ( 0 . 0 6 6 9i n l 1 . 8 m m ( 0 . 0 7 0 9i n ) 3 1. O 5 m m ( 0 . 0 4 1 i n ) 1. 15 m m ( O . O 4 5 3n ) i 1 . 2 5 m m ( O . O 4 9 2n ) i i 1 . 3 5 m m ( O . O 5 3 2n ) 1. 4 5 m m { O . 0 5 7 1i n ) 1 . 5 5m m { 0 . 0 6 1 0i n ) 1 . 6 5 m m { 0 . 0 6 5 0i n ) 1 . 7 5 m m ( 0 . O 6 8 9n ) i
4r441-PL3-800
41442-PL3 BOO 41443 PL3 800 41444-PL3-800 41445 PL3 800 41446- PL3 800 41441 PL3 BOO 41448- PL3 BOO 41449-PL3- 800 41450 PL3-800 4 1 4 5 ' t- P L 3 - B O 0 41452 PL3-BO0 4 1 4 5 3 - P L 3- B O O 41454 PL3-BO0 41455 PL3-BO0
72 mm THRUSTSHIM: Dl6Y7 engine Part Number 4t441 41442 PL3 AOO PL3 AOO Thickness i 1. 0 m m ( O . O 3 9 4n ) ( O . O 4 3 3n ) i 1. 1 m m 1.2 mm lO.0472 tn) n 1 . 3 m m { O . 0 5 ' 1i2 ) 1 . 4 m m ( O . O 5 5 i1 ) n 1 . 5 m m { 0 . 0 5 9 1i n ) i 1.6mm (0.0630n) 1 . 7 m m ( 0 . 0 6 6 9i n ) 1 . 8 m m ( 0 . 0 7 0 9i n ) 1. 0 5 m m ( 0 . 0 4 1 3 i n ) 1. l 5 m m ( O . O 4 5 3n ) i 1 . 2 5 m m { O . O 4 9 2n ) i ' 1 . 3 5m m ( O . O 5 3 2n ) i '1 . 4 5 m m { O . O 5 7 'i1 ) n i 1. 5 5 m m ( 0 . 0 6 ' 1 0 n ) 1 . 6 5 m m { 0 . 0 6 5 0i n ) '1 . 7 5 m m ( O . 0 6 8 9i n )
41443-PL3-A00 41444 PL3-AOO 41445-PL3-AOO 41446-PL3-AOO 41447 PL3 AOO 41448-PL3-AOO 41449-PL3,AOO 41 450- PL3- AOO , 4 1 4 5 ' 1 P L 3- A O O 4 14 5 2 - P L 3- A O O 41453-PL3-A00 41454-PL3 A00 41455-PL3-AOO 4 14 5 6 - P L 3- A O O 41457 PL3 A00
41456 PL3,B00
41457 PL3 BO0
housing. 8 . Removethe bolts and transmission 9 . Replacethe thrust shim selectedin step 7. then recheckthe clearance. 'lO. Remove housing.Apply the bolts and transmission housliquidgasketto the surface the transmission o{ ing and reassemble.
13-33
Clutch HousingBearing
Replacement
Mainshafl 1 . R e m o v e h e b a l l b e a r i n g s i n gt h e s p e c i atl o o l a s t u s h o wn . 3. Drivethe new oil sealinto the clutch housingusing the sDecial tools as shown.
\J
ATTACHMENT, 42 | 47 mm 07746-0010300
\ '
ADJUSTABLE EEARING PULLER, 25-40 mm 07736-A01000A
Drivethe ball bearinginto the clutch housingusing the specialtools as shown.
Remove the oil seal trom the clutch housing.
CLUTCH HOUSING
Replace.
13-34
J
Countershatt 1. tool as bearingusingthe special Remove the needle shown, then removethe oil guide plate. 2. p , b t I n s t a ltlh e o i l g u i d e l a t e t h e nd r i v e h e n e e d l e e a r u i n g i n t o t h e c l u t c hh o u s i n g s i n gt h e s p e c i atl o o l s as shown.
BEARING NEEDLE
)
GUIDEPLATE
25-40 mm PULLER. 07736-AOtOOOA
* 1 : A T T A C H M E N T ,2 x 4 7 n n 4 07746-0010300 *2: ATTACHMENT. x 5s mm 52 o7746 -0010400
OIL GUIDEPLATE *1: Dl6Y7 ngin6 +2: D16Y5, Dl6Yg onginos
13-35
MainshaftThrust Shim
Adjustment
I. Remove thrust shim and oil guideplatetrom the the t r a n s m i s s i oh o u s i n g . n
THRUSTSHIM
5.
s o S e l e c t h e p r o p e r h i mo n t h e b a s i s f t h e f o l l o w 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 ( B a s i c o r m u l) F a ( B ) + ( C ) - O . 9 5 = s h i mt h i c k n e s s
:.____
OIL GUIDE PLATE
1)/t' i':
''7
TRANSMISSION HOUSING
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 ( s u b t r a c t h e s p r i n g a s h e r e i g h t 0 . 9 5m m ) = t h e w h f e q u i r e dh r u s ts h i m ( 1. 14 m m ) t 65 mm THRUSTSHIM: Dl6Y7 engine

Part Numbet 23931 PL3 A10 B Thickness 0.60 mm {0.0236 in} 0 . 6 3 m m 10.0284 in) O . 6 6m m { 0 . 0 2 6 0 ; n } 0 . 6 9 m m { 0 . 0 2 7 2i n } 0 . 7 2 m m ( 0 . 0 2 8 3i n ) 0 . 7 5 m m ( 0 . 0 2 9 5i n ) 7 O . 7 8 m m ( O . O 3 Oa n l O . 8 1 m m ( 0 . 0 3 1 9i n ) i O . 8 4 m m 1 0 . 0 3 3 1n ) 0 . 8 7 m m 10.0343 inl O . 9 0m m 1 0 . 0 3 5 4 n ) i O . 9 3 m m { 0 . 0 3 6 6i n } O . 9 6 m m ( O . O 3 7 8n ) i O . 9 9m m ( O . O 3 9 O in 1 . O 2m m ( O . O 4 Oi2 n 1 . 0 5 m m ( 0 . 0 4 1 3i n ) 1 . 0 8 m m ( 0 . 0 4 2 5i n ) 1 . 11 m m ( 0 . 0 4 3 7i n ) 1 4 m m O.0449 in) 1 . 1 7m m 1 0 . 0 4 6 1n ) i 1 . 2 0 m m ( 0 . 0 4 7 2i n ) l 2 3 m m l O . O 4 8 4n ) i L 2 6 m m { 0 . 0 4 9 6i n ) L 2 9 m m { 0 . 0 5 0 8i n )
2 . Installthe 3rd/4th synchro hub, spacercollar, 5th

synchrohub, ball bearing, and thrust washeron the mainshaft.Installthe assemblyin the transmission housrng.
c
HUB @ gnolcru sYncHRo
THRUSTWASHER SPACERCOLLAR D E
F H
23932 PL3 410

23933 PL3 A10 23934 PL3 A10
23935 PL3 Ar0

2 3 9 3 623937 23938 23939 PL3 A 10 PL3 A10 PL3 A10 PL3-A' t O
J K L
M N
2 3 9 4 0 -P L 3 A 1 0
23941 PL3 A10 2 3 9 4 2- P L 3 A 1 0 23943 PL3 A10 23944 PL3 A10 23945 PL3 ArO 23946 PL3 A10 23947 PL3 A10 23948 PL3-A10 23949 PL3-A10 23950 PL3 A10 23951 PL3 A10 23952 PL3 A10 23953 PL3 A10 23954- PL3 A 10 23955 PL3 A10 23956 PL3 A 10 2 3 9 5 7- P L 3 A 1 0 2 3 9 5 8- P L 3 A t O 23959 PL3-A10 23960-PL3 A10
23961-PL3-A10
5TH SYNCHRO HUB
o
BALL EEARING
o
R T
3 . Measurethe distance@ between the end of the

transmission housingand thrust washer. NOTE: a Use a straight edge and verniercaliper. a Measure at three locations and average the readings.
4.
1 . 3 2m m { 0 . 0 5 2 0n } i
1 . 3 5 m m { O . O 5 3 Ii n ) 1 . 3 8 m m ( 0 . 0 5 4 3i n ) 1 . 4 1 m m { 0 . 0 5 5 5i n } 1 . 4 4 m m 1 0 . 0 5 6 7n ) i 1 . 4 7 m m ( 0 . 0 5 7 9i n ) . 5 0 m m ( O . 0 5 9 1n ) i - 5 3 m m 0 . 0 6 0 2i n ) . 5 6 m m ( O . 0 6 1 4n l i . 5 9 m m ( O . 0 6 2 6n ) i L 6 2 m m ( 0 . 0 6 3 8i n ) ' t . 6 5m m 0.0650 in) L 6 8 m m { 0 . 0 6 6 1i n } 7 l m m 0.0673in) 1 . 7 4 m m { 0 . 0 6 8 5i n i 1 . 7 7 m m ( 0 . 0 6 9 7i n ) 1. 8 0 m m ( 0 . 0 7 0 9' n )
Measure distance between the the surfaces the ot @ clutch housingand bearinginner race. NOTE: a Use a straightedge and depth gauge. a Measure at three locations and average the readlngs. ENDOF CLUTCHHOUSING
AB
AC
AD
AE AG AH
AK
AO
2 3 9 6 2- P L 3- A 1 0 23963 PL3 A10 23964- PL3-A 10 23965 PL3-A 10 2 3 9 6 6- P L 3 , A 1 0 23967-PL3-A10 2 3 9 6 8- P L 3 A 1 0 23969 PL3 A10 23970 PL3 A10 23971 PL3 A10
INNERRACEOF EALL BEARING
13-36
70 mm THRUSTSHIM: D16Y5. D16Y8 enqines

A Part Number 23931 PL3 BOO 23932 PL3- BOO 23933-PL3 BOO 23934 PL3 800 Thickness 0 . 6 0 m m { 0 . 0 2 3 6i n } 0 . 6 3 m m { 0 . 0 2 8 4i n i O . 6 6 m m { 0 . 0 2 6 0' n ) 0 6 9 m m ( 0 . 0 2 7 2i n )
7. Installthe thrust washer and spring washer in the mainshaft.
a
D E F G
H
23935 PL3 800

23936 PL3 800 23937 PL3 B00 23938 PL3 800 23939 PL3 800 2 3 9 4 0- P L 3 B O O 23941-PL3 BOO 23942 PL3 BOO 23943 PL3 BOO 23944 PL3 BO0 23945 PL3 800 23946 PL3- 800 23947 PL3 800 23944 PL3 800 23949 PL3 800 23950 PL3-800 23951 PL3 800 23Ss2 PL3 BOO 23953 PL3 800 23954 PL3-BOO 23955 PL3- 800 23956 PL3- 800 23957 PL3 800 23958 PL3-800 2 3 9 5 9- P L 3 - 8 0 0 23960 - PL3- 800 23961 PL3 800 23962 PL3 800
0 . 7 2m m ( 0 . 0 2 8 3n ) i
0 . 7 5 m m ( 0 . 0 2 9 5I n ) 0 . 7 8 m m ( 0 . 0 3 0 7i n ) 0 . 8 1 m m ( 0 . 0 3 1 9n ) i 0 . 8 4 m m ( O . 0 3 3 1n ) i 0 . 8 7 m m ( 0 . 0 3 4 3i n ) O . 9 0m m ( O . 0 3 5 4 n ) i O . 9 3m m { O . 0 3 6 6 n ) i O . 9 6m m { 0 . 0 3 7 8i n ) 0 . 9 9 m m { 0 . 0 3 9 0i n } LO2 mm {0.0402 inl 1. O 5 m m ( 0 . 0 4 1 i n ) 3 1 . O 8m m { 0 . O 4 2 5 n ) i 1 . 11 m m ( 0 . 0 4 3 7 n ) i ' ] 1 4 m m ( O . O 4 4 9n ) i 1 . 1 7m m ( 0 . 0 4 6 1 n ) i 1 . 2 0 m m ( 0 . 0 4 7 2i n ) L 2 3 m m { O . O 4 8 4n } i 1 . 2 6 m m { 0 . 0 4 9 6I n ) l 2 9 m m { 0 . 0 5 0 8i n } THRUSTWASHER WASHER SPRING
M N
8 . Installthe mainshaftin the clutch housing. 9 . Placethe transmission housingover the mainshaft and onto the clutch housing. housingswith 1O. Tightenthe clutch and transmission severalI mm bolts. NOTE: lt is not necessaryto use sealing agent between the housings. I x 1 . 2 5m m 27 N'm (2.8 kgf.m. 20 lbf.ftl 1 1 . T a p t h e m a i n s h a fw i t h a p l a s t r c a m m e r . t h in 12. Checkthe thrust clearance the mannerdescribed below. shouldbe made at room CAUTION: Measurement temperalute. a. Slidethe mainshaftbase and the collarover the mainshaft.
o o
R
S
z
AB AC AD AE AG AH
1 . 3 2m m { 0 . 0 5 2 0n l i
1 . 3 5 m m ( 0 . 0 5 3 1i n ) 1 . 3 8 m m 1 0 . 0 5 4 3n ) i 1 . 4 1 m m ( 0 . 0 5 5 5i n ) 1 . 4 4m m ( O . 0 5 6 7n ) i 1 . 4 7 m m ( O . 0 5 7 9n ) i L 5 0 m m ( 0 . 0 5 9 1i n ) L 5 3 m m { 0 . 0 6 0 2I n ) . 5 6 m m { 0 . 0 6 1 4i n } 1 . 5 9 m m { 0 . 0 6 2 6i n } L 6 2 m m { 0 . 0 6 3 8i n ) 1 . 6 5 m m 1 0 . 0 6 5 0n l i 1 . 6 8 m m ( 0 . 0 6 6 1i n ) . 7 ' l m m ( O . 0 6 7 3n ) i 1 . 7 4m m ( O . 0 6 8 5n ) i 1 . 7 7 m m 1 O . 0 6 9 7n ) i 1 . 8 0 m m ( O . 0 7 0 9n ) i
23963-PL3-800
23964 PL3- BO0 23965- PL3- BO0 23966 PL3 800 23967 - PL3 BOO 23968-PL3 BOO 23369 PL3 800 23970- PL3,800 23971 PL3 800
AK
AN
AO
6. Installthe oil guide plate and selectedthrust shim in the transmission housing. NOTE: a Clean thrustwasher,spring the washerandthrust shim thoroughlybefore installation. a Install the thrust washer, spring washer and thrust shim properly.
THRUSTSHIM O I LG U I D E PLATE TRANSMISSION HOUSING
CLUTCH HOUSING
:---.._
a',/ ,
---[
{cont'd}
I "): i, '"9
MAINSHAFT BASE 07GAJ- PG20't 30 COLLAR oTGAJ-PG20120
13-37
--
MainshaftThrust Shim
Adjustment (cont'd)
b. Attach the mainshaltholderto the mainshaftas lollows: NOTE: holderbolt and loosenthe the Back-out mainshaft 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. holder'slip aroundthe groove Align the mainshaft then tighten splines, at the insideof the mainshaft the hex bolts.
MAINSHAFTHOLDER EOLT
e. Zero a dial gauge on the end of the mainshalt
HOLDEF MAINSHAFT -PG20t 10 07GAJ

f . Turn the mainshalt holderbolt clockwise;stop
MAINSHAFT HOLDR
07GAJ-PG20110
its turningwhen the dialgaugehas reached maximum 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 transmissioo.
on Seat the mainshaftfully by tappang the end with a Dlastichammer. d . Threadthe mainshalt holderbolt in until it just base. contactsthe wide surfaceof the mainshaft
the is s . lf the reading withinthe standard, clearance rs correcr. recheck lf the readingis not within the standard, the shim thickness. n S t a n d a . d O . 1 1 - O . 1 8 m m { O . O O 4 - 0 . O Oi7 ) :
13-38
Transmission
Reassembly
N O T E :T h es t e e b a l l s a r e ao lf r h e s a m e s i z e ( 5 / 1 6 i n ) . l l 1 . I n s t a l t h e m a g n e ta n d r e v e r s eo c k c a m . l l 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. 6 . Insertshift arm shatt in the clutch housing 7 . Install the collar,spring,and steelballinto the case. Compressthe ball and insert the shift arm shaft. 8 . Install shift arm C in shitt arm A, then insertthe shift arm shalt.
3 . Installthe springwasherand shitt arm A attaching

bolt. Installthe steelball,spring,and set ball springbolr.
9 . Installthe reverseselectretainer and reverse select

spring onto shitt arm shaft.
1 0 .lnstallthe differentialassembly.
5 . Installshitt arm B in the interlock, then set it on the clutch housing.
A:8x'l.Omm 31 N.m 13.2 kgf.m, 23 lbf.ft,
SHIFTARM C
6 x 1 . 0m m 1 5 N . m { 1 . 5 k g t . m ,1 1 l b l . f t l
sHtFTARM " ___\..TNTERLOCK,\ INTERLOCK.
f!ir"--10.843 in) SHIFTARM A
-.-.-.-...uK,
COLLAR
-b
REVERSE LOCKCAM REVERSE SELECTRETAINER REVERSE SELECTSPRING L. 63.4 mm 12.50inl MAGNET
SET BALL SPRINGBOLT 22 N.m 12.2 kgt.m, 16 lbf.ltl 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
(cont'dl Reassembly
11. Position 36 mm springwasherand washeronto the the mainshaftbearing.
MAINSHAFT/COUNTERSHAFT SHIFTFORKASSEMBLIES
15. lnstallthe reverseidler gear and reverseidler gear shaft.
IDLER REVERSE GEAR SHAFT

Tape the mainshaft splrnes. WASHER
1 2 .Installthe mainshaft,countershaft.and shift fork

assemblies. NOTE: Align the finger ot the interlock with the groove in the shitr fork shaft. Installthe springwasher and shi{t arm B attaching bolt. 8 x 1 . 0m m 31 N'm 13.2kgl'm, 23 lbl'ltl
SPRING 1ST/2NOSELECT i L. 36.26 mm 11.428n)
GEAR
16. Installthe reverseshift holder.
REVERSE SHIFT
28 mm PLUGEOLT 54 N.m {5.5 kgl.m, 40 tbf.Irl
GUIDEEOLT 39 N.m 14.0 ksf.m,29 lbf.ftl
s 2 1 4 . I n s t a ltlh e 1 s t / 2 n d e l e c t p r i n g , 8 m m p l u g b o l t . s and interlockguide bolt. 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 of 08 7'l I 0003) to the threads the 28 mm plugbolt and interlockguide bolt.
6x1.Omm 15 N.m {1.5kgl'm, 11 lbI.fr)
13-40
1 7 . I n s t a l t h e o i l g u t t e rp l a t e l
2O. lnstallthedowelpinsand the transmission housing. 21. Lower the transmission housingwith the snap ring pliers,and set the snap ring into the groove of the countershaftbearing. NOTE: Checkthat the snap ring is securelyseated in the groove of the countershaftbearing.
32 mm SEALING EOLT 25 N.m {2.5 kgf.m, 18lbf.ttl
OIL GUTTER PLATE
1 8 . Installthe oilguideplateandthrustshimon the transmissionhousing. 1 9 . Apply liquidgaskel to the surfaceof the transmission housing mating with the clutch housing as shown. NOTE: . Use liquid gasket (P/N O8718-OOO1 or o8718-O003). a Removethe dirty oil from the sealingsurface. a lf 5 minutes have passedafter applying liquid gasket. reapplyit and assemble housings. the a Allow it to cure at least20 minutesafter assembly before tilling the transmission with oil.
4.6 -8.3 mrr| 10.18 0.33 in)
Liquid gasker
2 2 . I n s t a lt h e 3 2 m m s e a l i n g o l t . l b
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 08718-OOO3) o the threads. t

(cont'd)
13-41
I -
Transmission
(cont'dl Reassembly
housingattachingbolts in 23. Tightenrhe rransmission the numberedsequencein several steps shown oetow. 8 x 1. 2 5 m m Totqnet 27 N'm (2.8 kgf.m, 20 lbl'fr) 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 hanger.
8 x 1 . 2 5m m 27 N.t 12.8 kgt.m, 20 lbf.frl
BACK,UP LIGHTSWITCH HARNESS STAY
le
24. Installthe steel balls,springs,and set screws.
25 N.m {2.5 kgl'm, 18 lbf,ftl
SPRING L . 3 1 . 6 m m ( 1. 2 4 i n l SETTING SCREW 22 N.m l'2.2 ksf.m, 16 lbt.tt)
13-42
Oil Seals
Replacement
Transmission Housing: L Bemovethe oil sealfrom lhe transmission housing. Clutch Housing: 1. Removethe oil seal from the clutch housing.
2 . Installthe oil sealinto the transmission housinqusing the specialtools as shown.
Installthe oil seal into the clutch housingusingthe soecialtools as shown.
DRIVER SAL DRIVER ATTACHMENT 07947-6110501 ot 07947-6110500 OIL SEAL Replace. DRIVERATTACHMENT oTJAD-PH80101
otL sEAt
neplace.
T
13-43
GearshiftMechanism
Overhaul
NOTE: parts. replace worn or damaged any partsfor wearanddamage a Inspect whendisassembling; rubber a Install clip as shown. the
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
SHIFTLEVER KNOB 7.8 N.m (0.8 kgl.m,5.8 lbf.ftl
iiJ?t
xx'tt" cuEr fl ffi

U &_ e:---g
EXTENSION
exrrfusror noo
I .,,,"1"
i!l,1t'^-
ExrENsroN END BUsHrr{c
3$i^\@ :r'.n Y
ENocoLLAR cL'P
r*H d""A'?''" ,, _ - _ lii,i"r**,*tlp;t{^ -' % se^LB fi+L-w^sHER \o Boor I 1 REARJo,Nr",i""YEo aÂ ;#""*,\** iKlp-dffi :rr,'"'iyss. \
5ii_-.ry @
r.,or.rr, I ffiW
NUr sELF.LocKrNG
Replace.
\ f Ant;:n;r ,:1i",""""""",, \\ exr.zs.- ,._, sH,FrRoD J exrertror,r o.n^c\\
ffi)'o"o*h--:l+:l Y9 ,-,r:- \\
6 x 1 o mm
9.8 N.m l1.Oksf.m,7.2 lbt.frl
/oown \ \a[ffi= :"

CLIP
sinttc ptt't
neoraci.
HOLE
13-44
AutomaticTransmission
."' AutomaticTransmission.'.'......'.".... 14-1 VariableTransmission Continuously
(cwl ..........
14-161
Automatic Transmission
Special Toofs .............-.-....-......14-2 ATF Pump Description .............,.,.,..,......,.. 14-3 Inspection .......................... 14-109 PowerFlow ........................ 1i1.6 Main ValveBody Elestronic ControlSystem ..,............................. 14.13 Disassembly/lnspection/Rea$embly ......,......, 14-110 Hydraulic Control .............. 14-18 SecondaryValve Body Hydraufic F|ow...... .,.....-..... 14-23 Disassembfy/lnspection/Reassembly ......-.-..-.. 11-112 Lock-up System .-......-....-.-. 1+32 RegulatorValv Body EleqtricalSystem Disassembly/lnspction/Reassembly .......,....,. 13 1{-'t Component Locations.......,..,....,.,......... ................. 1i1"39 Servo Eody PCMCircuit Diagram Disassembly/lnspection/Beassembly .............. 14 14.1 1il.40 {A/T ControlSysteml ......................................... 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 Electrical System .....,.....,.,. 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 lllustroted Index ................ 1+13/t Repfacement ...................... 1+77 t Backlash Inspection .......... 14-135 Hydraulic Systcm Baring Replacement .............,.........,........,........ lil-l35 Symptom-to-ComponentChart Ditferential Carrier Replacement ..........,........... 1il.136 Hydraulic System ...........-.11-78 Oil SalRemovsl ............... 14.137 RoadTest ................................ 14-82 Oil SealInstallation/Side Clea.anc ................. 14-137 Stall SDeed Torque Converter Housing Bsarings Test ...................... ............. 1/t-85 Mainshaft Bearing/OilSal Replacement........1,t-1,m Fluid Level CounteEhaftBearing Replacemsnt ................. lil-li[f Checking/Changing .......... lil-86 TransmissionHousing Bearings Pressure Testing ......,.............. 1il-87 Mainshaft/CountGrshaft Bearings Transmission Repfacement -..........,.,.,, 11-112 Transmission Reverseldlr Gear R e m o v a. . . . . . . . . . . . . . . . l . . . . . . . . . .1 . .. 9 0 .4 Installation ..,,.................,.,. l+t/*l lllustrated Index Parking BrakeStop Transmission/Right Cover ..............,..,.,.... Side 1+g4 Inspection/Adiustment ..,.......................,,...,...... lil-li(| Transmis3ion Housing....,......,........................,.. Transmission 14-96 TorqueConverter Housing/Valve Body ..,....,... 14-98 Rea$embly........... ............. 14-144 Right Side Cover TorqueConvrter/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 . . 0 .{ .6. alve ATF Cooler Hoses
SpecialTools
v
Ref. No. I Tool Number 07GAB PF50101 07GAE PG40200 07HAC PK40' l0A 07JAD- PH80101 07JAD- PH80200 07LAE PX40100 07PAZ 00'10100 07sAz - 0010004 _ OTMAJ PY4O11A 07MAJ- PY40120 07406- 0020400 07406- 0070300 07736 A010004 07746 0010500 07746 0010600 07746 0030100 07749 0010000 07947-611501 Description Oty 1 1 1 I I 'l 1 I Prgo Reforenc. 14- 01, 48 1 1 't 4-128,'t31 14-103 14-139 '14139 14-124,131 l4-45 14-46 't 4-47 14-87 14-87 14-87 14-140,14' 1 14-140, 141,142 14-'t40,142 '14-121. 137, 135, 138 14-139,140,141,'142 14-139 Mainshaft Holder ClutchSpringCompressor BoltAssembly ar HousingPuller DriverAttachment @ Pilot,26 x 30 mm ClutchSpringCompressor Attachment @ SCSService Connector @ Backprobe Set @ A"/T Pressure Oil Hose,2210 mm A,/TOil PressureHose,Adapter @ A,/TOil PressureGauge Set w/panel @ Ay'T Low PressureGaugew/panel @ Adjustable Bearing Puller, - 40 mm 25 @Attachment,62 x 68 mm @ Attachment, x 75 mm 72 @ Driver40 mm l.D. @ Driver @ DriverAttachment, mm 68 @ *Must be usedwith commerciallv-available - 16 slidehammer. 3/8"
I 1 1 1 I 1 I 'I
I
\,
Edttltr-
\l
6,
14-2
Description
controlled electronically is torque convenerand a dual-shaft The automatictransmission a combinationof a 3-element 4 forwardand 1 reverse. transmission which provides speeds automatic Torque Converter,Geats and Clutches in to The torqueconverter consists a pump.turbineand stator,assembled a singleunit.They are connected the engine of so crankshaft they turn togetheras a unit as the engineturns.Around the outsjdeof the torque converteris a ring gear The entiretorqueconverter assembly servesas a which mesheswith the starterpinionwhen the engineis being started. powerto the transmission mainshaft. flywheelwhile transmitting The mainshaftis in line with the engine has two parallelshafts:the mainshaftand the countershaft. The transmission gearstor 2nd, 4th, reverse and 1st (3rd gear is integral The mainshaftincludes the 1st,2nd and 4th clutches, crankshaft. includesthe 3rd clutch,and while the reversegear is integralwith the 4th gear).The countershaft with the mainshaft, mesh with those on the counare gearsfor 3rd, 2nd. 4th, reverse, and parking. 1st The gearson the mainshaft in constant from the are engagedby clutches,power is transmitted of tershaft.When certaincombinations gears in transmission to mainshaft the countershaft providep, E, E, and E positions. to ElectronicControl The electroniccontrol system consistsof the PowertrainControl Module (PCM),sensors,a linear solenoid and four The PCMis controlled comfonable for driving underall conditions. solenoid valves.Shiftingand lock-upare electronically side. locatedbelowthe dashboard, underthe front lower panelon the passenger's HydraulicControl valvebody,the servobody and the valvebody,the regulator The valvebodiesinclude the main valvebody,the secondary plates, housing. Theyare boltedon the torqueconverter separator lock-up valvebody throughthe respective
Pressure the manualvalve,the 1-2shift valve,the 2nd orificecontrolvalve,the CPB(Clutch The main valve body contains valve valve,the modulatorvalve.the servocontrolvalve,the reliefvalve,and ATF pump gears.The secondary Back-up) valveand the CPC(Clutch body contains 2-3shift valve,the 3-4shift valve,the 3-4 orificecontrolvalve,the 4th exhaust the valve,the torque convenercheckvalve. the pressure regulator valve.The regulator valve body contains Pressure Control) with the the controlvalve.The servo body contains servovalvewhich is integrated the coolerreliefvalve,and the lock-up The lock-upvalve body containsthe lock-upshift valve and the lock-uptiming reverse shift fork, and the accumulators. housing, are valve.The linearsolenoidand the shift controlsolenoidvalveAy'B boltedon the outsideof the transmission housing.Fluidfrom regulator and the lock-upcontrolsolenoidvalve!y'B is boltedon the outsideof the torque converter fluid from their respective ieed pipes passes The clutchesreceive throughthe manualvalveto the variouscontrolvalves. or internalhydraulic circuit. Shift Control Mechanism valvethe PCMwill activate. which shift controlsolenoid located throughoutthe car determines Inputfrom varioussensors a a valvechanges modulatorpressure, causing shift valveto move.This pressurizes line Activating shift controlsolenoid a gear.The shift controlsolenoid valvesA and B are conengaging that clutchand its corresponding to one of the clutches, trolledby the PCM. Lock-uoMechanism fluid is drainedfrom the backof the torqueconverter In E position, 3rd and 4th, and in E positionin 3rd, pressurized in the cover.As this takesplace, causing the lock-uppistonto be held againstthe torque converter through a fluid passage, the Together with hydraulic control.the PCMoptimizes timing of mainshaft rotatesat the same as the enginecrankshaft. valvesA and to controlsolenoid The lock-up valvescontroltherangeof lock-upaccording lock-up the lock-upmechanism. The lockchanges. the When lock-up controlsolenoidvalvesA and B activate, modulatorpressure B, and linearsolenoid. are by valvesA and B and the linearsolenoid controlled the PCM. uo controlsolenoid
t
(cont'd)
14-3
Description
(cont'd)
Gear Selction The shift leverhassix positions: PARK, REVERSE, NEUTRAL, 1stthrough 4th gear ranges, 1stthrough3rd E E E E E gear ranges, 2nd gear. P Position Description parkingbrakepawl engaged Frontwheelslocked; with parkinggearon countershaft. clutches All reteaseq, gear Reverse; reverse selector engaged with countershaft.everse and 4th clutchlocked. All clutches released. General driving;stansoff in 1st,shiftsautomatically 2nd.3rd,then 4th, depending vehicle to on Downshift speedand throttleposition. through3rd,2nd and 1ston deceleration stop.The Iock-up to mechanism comesinto operation E positionin 3rd and 4th gear. in Usefor rapidacceleration highway at speeds and general driving; up-hill and down-hill driving; starts off in 1st,shiftsautomatically 2nd,then3rd,depending vehicle to on speed andthrottleposition. Downshifts through2ndto 1ston deceleration stop.The lock-up to mechanism comesintooperation in 3rd gear. Usefor enginebrakingor bettertractionstartingoff on looseor slipperysurfaces; staysin 2nd gear,does not shift up and down,
E PARK E REVERSE E NEUTRAL E] DRIVE (1st 4thl through E DRIVE (1st through 3rd)
E SEcoND
Startingis possible neutral-safety only in E and N positions throughthe useof a slide-type. switch. Automatic TransaxlslA/T) Gear Position Indicatot gear positionindicatorin the instrument panelshowswhich gear has beenselected The Ay'T without havingto look down at the console,
Clutchs gears. The four-speed automatic transmission useshydraulically-actuated clutches engageor disengage transmission to the When hydraulicpressure introduced is into the clutchdrum, the clutchpiston moves.This presses frictiondiscsand the steel platestogether.lockingthem so they don't slip. Power is then transmitted through the engagedclutch packto its gear.Likewise, pressure bledfrom the clutchpack, hub-mounted when the hydraulic is the pistonreleases frictiondiscs the and the steelplates,and they are free to slide past each other. This allowsthe gear to spin independently its shaft, on transmitting power. no . 1st Clutch just behindthe right sidecover. The lst clutchengages/disengages gear,and is located the end of the mainshaft, lst at pressure its ATFfeed pipewithin the mainshaft, The 1stclutchis suppliedhydraulic by 2nd Clutch The 2nd clutchengages/disengages gear, and is locatedat the middle of the mainshaft. 2nd The 2nd clutch is joined pressure back-to-back the 4th clutch.The 2nd clutchis suppliedhydraulic to throughthe mainshaft a circuitconnectby ed to the internalhydraulic circuit. 3rd Cluich The 3rd clutchengages/disengages gear, and is locatedat the end of the countershaft. 3rd clutchis supplied 3rd The pressure its ATFfeed pipe within the countershaft. hydraulic by 4th Clutch gear,and is located the middleof the mainshaft. The 4th clutchengages/disengages gear,as well as reverse 4th at The 4th clutch is joined back-to-back the 2nd clutch.The 4th clutch is suppliedhydrauiicpressure its ATF feed pipe to by within the mainshaft.
14-4
One-way Clutch gearsplined the gear,with the parking to 1st between countershaft gearand the parking the The one,way clutchis positioned The onethe inner racesurface. and the parkinggear provides the outer racesurface, The lst gear provides countershaft. '1st 1st from the mainshaft gear to the countershaft gear.The 1st clutch way clutch locksup when power is transmitted and gearsremainengagedin the 1st,2nd,3rd, and 4th gear rangesin the E, E or @ position when the 2nd,3rd, or 4th clutches/gears appliedin the D., o or E position. are However, one way clutchdisengages the "speedrange" of the overrides locking the rotational This is because increased the speedof the gearson the countershaft with the 1stclutchstill engaged. the one-wayclutch.Thereafter, one-wayclutchfree-wheels
2ND CLUTCH 4TH CLUTCH
1STCLUTCH MAINSHAFT
COUNTERSI{AFT
ONE-WAY CLUTCH
PABKING GEAR
3AD CLUTCH
OF OUTSIDE ONE.WAY CLUTCH INSIDEOF ONE,WAY CLUTCH Splined wilh counter shaft
The sprags engage/ disengageoutside and inside of the one way clutch.
LOCKING CONDITION
OVER.FIDING LOCKING SPEEO CONDITION
14-5
tDescription
PowerFlow
1STGEAR 2ND GEAR 3RD GEAR TOROUE 1sT 2ND 3RD CONVERTER CLUTCH CLUTCH CLUTCH
4TH GEAR CLUTCH REVERSE PARKING GEAR GEAR
POSMON\.
\enr
E E E
D-a 3 R O
4TH
2ND
[o]
2ND
3RD
o o o o o o o o a o o
o
4,2 o*i
o o o o o o o
o*,
o*!
o*, o*' o*'

o*1
x: O: Operates, Doesn'toperate. *1: Althoughthe 1stclutchengages, driving power is not transmitted the one-wayclutchslips. as *2: The one-wayclutchengages when accelerating, slipswhen decelerating. and
,,
I
14-6
El Position pressure not appliedto the clutches. to Poweris not transmined the countershaft. is Hydraulic E Position to pressure not appliedto the clutches. Poweris not transmitted the countershaft is Hydraulic the is The countershaft lockedby the parkingpawl interlocking parkinggear.
TOROUE CONVERTER
1ST CLUTCH
FINALDRIVE GEAR
3RD CLUTCH
(cont'd)
14-7
Description
Power Flow (cont'd)
position) lst Gear {lP!lor .D3l tn [D.] lal position, optimum gear is automatically or the from 1st,2nd,3rd and 4th gears,according conditions selected to suchas the balance between throttleopening(engineload)and vehiclespeed. 1. pressure appliedto the 1st clutch,which rotatestogetherwith the mainshaft, Hydraulic is causingthe mainshaftlst gear to rotate. Poweris transmitted the countershaft gear,which drivesthe countershaft the one-wayclutch. to lst via
2.
3. Poweris transmitted the final drivegear,which drivesthe final drivengear. to
TOROUE CONVEETER
MAINSHAFT1ST GEAR
1ST CI-UTCH
MAINSHAFT
ONE-WAYCLUTCH FINAI.DRIVEGEAR PARKING GEAR COUNTERSHAFT 1ST GEAR
FINAL DRIVEN GEAR
14-8
Znd Gear {[0!, or or @ positionl is E Position providedto drive only 2nd gear. '1. Hydraulic pressure appliedto the 2nd clutchon the mainshaft, via and power is transmitted the 2nd clutchto the is mainshaft 2nd gear. 2. 2nd gear, which drivesthe counterto Powertransmifted the mainshaft2nd gear is conveyedvia the countershaft shaft. to Poweris transmitted the final drive gear,which drivesthe final drivengear. that pressure also appliedto the 1st clutch.but sincethe rotationspeedof the 2nd gear exceeds is NOTE:Hydraulic of 1stgear,powerfrom 1stgear is cut off at the one-wayclutch. TOROUE CONVERTER
2ND CLUTCH
3.
MAIIISXAFT
COUNTERSHAFT 2ND GEAR
(cont'd)
14-9
Description
PowerFlow {cont'dl
3rd Gear ([ll or lg.l position) '1. Hydraulic pressure appliedto the 3rd clutch.Powerfrom the mainshaft is 3rd gear is transmitted the countershaft to 3rd gear. 2. Poweris transmifted the final drive gear,which drivesthe final drivengear. to pressure also appliedto the 1stclutch,but sincethe rotationspeedof 3rd gear exceeds NOTE:Hydraulic is that of 'lst gear,powerfrom lst gear is cut off atthe one-wayclutch.
TOROUE CONVERTER
MAINSHAFT3RD GEAR
MAINSI{AFT
COUNTERSHAFT
3RD GEAR 3RD CLUTCH
FINALORIVNGEAB
I
14-10
4th Gear {[t] position) 1. 4th causingthe mainshaft pressure appliedto the 4th clutch,which rotates togetherwith the mainshaft, is Hydraulic gear to rotate. 4th Poweris transmitted the countershaft gear,which drivesthe countershaft. to Poweris transmitted the final drive gear.which drivesthe final drivengear. to that of 1st pressure alsoappliedto the 1stclutch.but sincethe rotationspeedof 4th gear exceeds is NOTE:Hydraulic gear,powerfrom 1stgear is cut off at the one-wayclutch.
TOROUE 4TH GEAR
2.
4TH CLUTCH
MAINSHAFT
COUNTERSHAFT
FINALDRIVEN GEAR
(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 reverse shift fork engages with the reverse selector, reverse selectorhub, and the counte.shaft gear. reverse Hydraulicpressureis also appliedto the 4th clutch.Power is transmittedfrom the mainshaftreverseoear vta the reverse idler gearto the countershaft gear. reverse The rotationdirection the countershaft gear is changed the reverse of reverse via idlergear.
4.
Poweris transmitted the final drive gear,which drivesthe final drivengear. to TOROUE
MAINSHAFT
COUNTERSHAFT
COUNTERSHAFT REVERSE GEAR
REVERSE SELECTOR HUB REVERSE SELECTOR REVERSE SHIFT FORK
FINALORIVEN GEAR
SERVO VALVE
14-12
Electronic ControlSystem
a sensors, linearsolenoidand four solenoid ControlModule{PCM), of controlsystemconsists a Powertrain The electronic The PCMis located driving underall conditions. for controlled comfortable valves.Shiftingand lock-upare electronically side. the front lower panelon the passenger's under belowthe dashboard.
PGM-FI Conirol Sy3tem
A/T Control SFtem
Shift Control
Control Lock-uD
(cont'd)
14-13
Description
Electronic ControlSystem(cont'dl
Shift Control The PCM instantaneously which gear should be selected varioussignalssent from sensors, determines by and actuates the shift controlsolenoid valvesA and B to controlshifting. Also,a GradeLogicControlSystemhas beenadoptedto control shiftingin io.rposition while the vehicleis ascending descending slope,or reducing or a speed. Position Gear 1st
Dr Dr Shil't Control Solenoid Valve A
Shift Control Solenoid Valve B ON ON

OFF
OFF ON ON
OFF
2nd 3rd
4th
rq!
l
OFF ON
2nd Reverse
ON
ON E*See page 14-30for reverse inhibitorcontroldescription. Lock-uoControl From sensor input signals,the PCM determines whether to turn the lock-upON or OFF,and activates lock-upcontrol solenoidvalveA and/orB accordingly. The combination driving signalsto lock-up of controlsolenoidvalvesA and B and the linearsolenoidpressure shown in the table below. is Lock-up Conditions Lock'upOFF H Lock-up, alf Lock-up,ull F
LOCX-Up
Lock-up Control Solnoid Valve A

OFF
Lock-upControl Solenoid Valve B OFF Dutyoperation OFF- ON ON Dutyoperation O F F* O N
Linear Solenoid Pressure

High
ON ON
H i gh
duringdeceleration
ON
Low
14-14
SYSTEM LOGICCONTROL GRAOE
How it works: in memorized the PCM,basedon the input trom the with drivingconditions actualdrivingconditions The PCMcompares sensor, pressure the sensor, enginecoolanttemperature positionsensor. barometoric the the vehiclespeedsensor, throttle a or and the shift lever positionsignal.to controlshiftingwhile a vehicleis ascending descending the brakeswitchsignal speed. slope,or reducing
SIGNALSOETECTED
Judgemenl ot Controlling ArGa OrivingRt3ktrncc
{Fuzzylogicl ' GradualA3cendingmode ' Steop Ascondingmode . D6cnding mode . GradualOosconding mode . Siep Odcending mode
(cont'd)
14-15
Description
Electronic ControlSystem(cont'dl
. AscendingControl
When the PCMdetermines that the vehicleis climbinga hill in El position, the systemextendsthe engagement area of 2nd gear and 3rd gear to preventthe transmission from frequentlyshiftingbetween2nd and 3rd gears,and between3rd and 4th gears,so the vehiclecan run smooth and have more power when needed. Thereare two ascending modeswith different 3rd geardrivingareasaccording the magnitude a gradientstoredin the PCM. to of NOTE: . The PCMmemorycontains shift schedules between2nd and 3rd gears,and between3rd and 4th gearsthat enablethe PCM'sIuzzylogicto automatically gearaccording the magnitude a gradient select the most suitable to of . Fuzzylogic is a form of artificialintelligence that lets computersrespondto changingconditionsmuch like a human m i n dw o u l d . . DescendingControl
When the PCM determines that the vehicleis going down a hill in E position,the shift-upspeedfrom 3rd to 4th gear when the throttleis closedbecomes fasterthan the set speedfor flat roaddrivingto widenthe 3rd geardrivingarea. This, in combinationwith engine brakingfrom the deceleration lock-up,achieves smooth driving when the vehicleis descending. Thereare two descending modeswith differentdownshift(4 - 3) schedules according the magnitudeof a to gradientstoredin the PCM.When the vehicleis in 4th gear,and you are decelerating a gradualhill. or when you are on applying the brakes a steephill,the transmission downshift 3rd gear.Whenyou accelerate, transmission on will to the will then returnto 4th gear.
ASCENDING MODE
DESCENDING MOOE
,lTH SHIFTING CHARACTERISTICS CONTROL AREA
ir'.ff}",
vehicre speod
ir'.111,",
v.hicre3ped
DecelerationControl
Whenthe vehiclegoes arounda corner,and needsto first decelerate then accelerate, PCMsetsthe datafor deceleration and the controlto reduce the numberof timesthe transmission shifts. When the vehicleis decelerating from speeds above26 mph (41km/h), PCMshifts transmission the the from 4thto 2ndearlier than normal copewith upcoming to acceleration.
14-1 6
and TerminalLocations CircuitDiagram

IGNITION SWITCH
PG2
LOCK-UPCONT8OL OVALVE A SOLENO
IGPl IGP2
vcc2
TPS sG2
LOC( UPCONTFOL SOLENOIDVALVEB
SNIFTCONTSOL SOLENOIDVALVEA
SHIFICONTFOL VALVE B SOLENOID
LNEIFSOLENOID
POSITON F
14-17
Description
Hydraulic Control
The hydraulic controlsystemis controlled the ATF pump.valves,accumulators, electronically by and controlled solenoids. The ATF pump is drivenby splineson the end of the torqueconverter which is attached the engine.Fluidfrom the ATF to pump flows throughthe regulator valveto maintainspecified pressure throughthe main valve body to the manualvalve, directingpressure each of the clutches. to The valve body includesthe main valve body, the regulatorvalve body, the lock-upvalve body, the secondary valve body, the servo body. the linear solenoid, the shift control solenoidvalve Ay'B assembly, and the lock-up controlsolenoid valveA,/B assembly. The shift controlsolenoid valveA,/B assemblv and the linear solenoidare bolted on the outsideof the transmission housing,The lock-upcontrol solenoidvalveAy'B assemblyis boltedon the outsideof the torqueconverter housing.
SHIFTCONTROL SOLENOID VALVEA/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 modulator 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 CONTROL 2NOORIFICE VALVE
1.2 SHIFTVALVE V MOOULATOF
VE
V RELIEF
VE
MANUALVALVE
MAIN V BODY
CONTROL VALVE
SecondaryValve Body valvebody houses 2-3 shift valve,the 3-4 the The secondary valvebody is locatedon the main valve body.The secondary valveand CPCvalve shift valve,the 3-4 orificecontrolvalve,the 4th exhaust
3.4 SHIFTVALVE 2-3 SHIFTVALVE
VALVE 4TH EXHAUST
CPCVAL
CONTBOL 3.4 ORIFICE VALVE
VALVE
(cont'd)
14-19
Description
HydraulicControl (cont'd)
RegulatorValve Body The regulatorvalve body is locatedon the main valve body.The regulator valve body consistsof the regulator valve,the torqueconverter checkvalve,the coolerreliefvalve,and the lock-uocontrolvalve.
REGULA VALVE
RELIEF VALVE COOI.ER
VALVE CONTROL Lock-upValve Body The lock-up valvebody with the lock-up shift valveand the lock-up timing valveis located the regulator on valvebody.
SHIFTVALVE LOCK-UP
TIMINGVALVE
BODY
14-20
Valve Regulator control system,while from the ATF pump to the hydraulic The regulatorvalve maintainsa constanthydraulicpressure The fluid from the ATF pump flows through B and B'. fluid to the lubricating systemand torqueconvener. alsofurnishing of The fluid entering from B flows throughthe orificeto the A cavity.This pressure The regulator valve hasa valveorifice. valve uncovers fluid port the pushesthe regulator valveto the right side,and this movementof the regulator the A cavity and the reliefvalveand regulator and the reliefvalve.The fluid flows out to the torqueconverter, to the torque converter pressure valve through B, the positionof the regulator to valve movesto the left side.According the levelof the hydraulic maintaining the This operationis continued, changesand the amountof the fluid from B' through D and C also changes. ltnepressure. direction the illustration on below. NOTE:When used,"left" or "right" indicates
ENGINE NOTRUNNING RUNNING ENGINE CONVERTER Lubrication To TOROUE STATOBSHAFTARM
Stator ReactionHydraulicPressureControl valve using the statortorque reaction pressure to increases according torque,are performedby the regulator Hydraulic springcap.When the and its arm end contacts regulator The statorshaft is splinedwith the statorin the torqueconverter. the Range), statortorque reactionacts on the statorshaft,and or the vehicleis accelerating climbing(TorqueConverter The statorreacto springcap in the directionof the arrow in proportion the reaction. the statorarm pushesthe regulator by which is regulated the regulator the line pressure valve movesto increase and tion spring compresses, the regulator reaches maximum. its reaches maximumwhen the statortorque reaction its valve.The line Dressure
TOROUE CONVERTER
VALVE REGULATOR
TORSPRING CAP
'..- _..-7
3f
STATOR SHAFT ATORSHAFTARM
{cont'd)
14-21
Description
Control(cont'd) Hydraulic
Servo Body with the servovalvewhich is integrated valve body.The servo body contains The servo body is locatedon the secondary the reverse shift tork,and the accumulators
2ND ACCUMULA
SERVO BODY
lST ACCUMULATOR
3RDACCUMULATOR
SERVO VALVE/SHIFT FORKSHAFT
14-22
.J
Hydraulic Flow
Genr8lChart of Hydraulic Pressure ATFPumpRegulator Valve -; LinePressure -ModulatorPressure ; LClutch Pressure LinearSolenoid
l L
TorqueConverter Pressure Lubrication Pressure
Distribution of Hvdraulic Prssure . Regulator ValveTorqueConvenerPressure Lubrication Pressure f L To requlate LinePressure . . ManualValve-ModulatorValve To selectLinePressu.e ModulatorPressure l . . . Il]l l ClutchPressure ClutchPressure Valves Shift ControlSolenoid Valves Lock-up ControlSolenoid LinearSolenoid
1-2 Shift Valve 2-3 Shift Valve 3-4 Shift Valve
NO. '1
DESCRIPTION PRESSURE N O . OF LINE 6B
DESCRIPTION PRESSURE N O . OF
DESCRIPTION PRESSURE OF 4THCLUTCH
MODULATE (SHIFT CONTROL SOLENOID 4 1 VALVE B) MODULATE (LOCK-UP CONTROL SOLENOID VALVE A)
LINE
LINEAR SOLENOID
1"
LINE
6D
MODULATE (LOCK-UP CONTROL SOLENOID VALVE B)

MODULATE (LOCK-UP CONTROL SOLENOID VALVEB) LINE LINE/CPC LINE 1STCLUTCH 2ND CLUTCH 2ND ACCUMULATOR LINE 3 R DC L U T C H 4TH CLUTCH
90
TOROUE CONVERTER
LINE LINE LINE LINE LINE LINE
6D'
7 8 10
91 92
TOROUE CONVERTER
TOROUE CONVERTER
ATF COOLER TOROUE CONVERTER LUBRICATION TOROUE CONVERTER
93
94 96 97 99 X
20 204
25 30 40
4'
LINE
TOROUE CONVERTER
SUCTION DRAIN
cPc
MODULATE 6A MODULATE (SHIFT CONTROL SOLENOID VALVEA)
(cont'd)
14-23
Description
Flow (cont'dl Hydraulic
N Position fluid (ATF)is drawn from (99)and disAutomatictransmission As the engineturns,the ATF pump also startsto operate. (1) (1) the line pressure The line pressure is regulated chargedinro (1).Then,ATF flowing from the ATF pump becomes through the lock-up (94)of the torque converter {92)enters by t;e regulatorvalve.The torque converterinlet pressure pressure from rising' the checkvalveprevents torque converter The torqueconverter into (90). shift valveand discharges pressure not appliedto the clutches' is the Underthis condition, hydraulic "|eft" or "right" indicates circuit' on direction the hydraulic NOTE:When used,
14-24
E Position (1)flows to the manualvalveand the modulatorvalve.The line pressure changes (1) The line pressure the line pressure (4) and (25)at the manualvalve,and changes the modulatorpressure the modulalo.valve.But the modulatorpresto at sure (6) does not flow to each shift valve because shiit control solenoidvalvesA and B are turned ON by the PCM.The (4) (5), line pressure passes through the CPBvalveand the CPCvalve,and changes the line pressure then flows to the to (5) pressure from the 1-2shift valvechanges the 2nd clutchpressure 1-2shift valve.The line to {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 (10)also flows to throughthe 1-2shift valve and the orifice,and changes the 1st clutchpressure, The 1st clutchpressure no the 1stclutch.However, power is transmitted because the one-wayclutch. of NOTErWhen used,"|eft" or "right" indicates direction the hydraulic on circuit.
(cont'd)
14-25
Description
Flow (cont'd) Hydraulic
El or lOi Position
1. lst Gear flows to the manual The line pressure circuitis sameas in N position. The flow of fluid throughthe torque converter (6) valveand to changes the modulatorpressure at the modulator to valve.The line pressure valveand the modulator (6) (4) the line pressure at the manualvalve.The modulatorpressure flows to the left end of the 1-2shiftvalveand the valveA is turnedOFFand B is turnedON by the PCM.The l-2 shift valve shift controlsolenoid 3-4 shift valvebecause 'lst (4) at to clutchpressure right side.The line pressure changes the 110) the 1-2shift valve and the is movedto the ('t0)is appliedto the lst clutchand the 1st accumulator; the consquently, vehiclewill orifice.The 1st clutchpressure move as the enginepower is transmitted. "right" indicates on circuit. direction the hydraulic NOTE:When used,"|eft" or
2.
2nd Gear As the speedof the vehiclereaches prescribed the value,shift controlsolenoidvalveA is turned ON by meansof the (64l in the left end of the 1-2 shift valve is released turning shift control solenoid PCM.The modulatorpressure by (5) valveA ON. The 1-2 shift valve is moved to the left side and uncovers the pon to allow line pressure to the 2-3 (5) (20)at the 2-3 shift valve.The 2nd clutchpressure shift valve.The line pressure changes the 2nd clutchpressure to (20)is appliedto the 2nd clutch,and the 2nd clutchis engaged. Fluid flows bv wav of: - Line Pressure - CPBValve- LinePressure - 'l-2ShiftValve- LinePressure - 2-3 ShiftValve (4) (5) (5) - 2nd ClutchPressure (20)t 2nd Clutch pressure The hydraulic alsoflows to the 1stclutch.However, power js transmitted no because the one-wayclutch. of NOTE;When used,"|eft" or "right" indicates directionon the hydraulic circuit.
(cont'd)
14-27
Description
Flow (cont'd) Hydraulic
3. 3rd Gear valve B is turned OFFby meansof the value,shift controlsolenoid the As the speedof the vehiclereaches prescribed 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 (5) to {68),The 2-3 shift valvecoversthe port to stop line pressure to the 2nd clutchand uncovers the 3-4 shift valve (30)at the 3-4 (5) the 3rd clutchpressure as the 2-3 shift valve is moved to the right side.The line pressure becomes (30)is appliedto the 3rd clutch,and the 3rd clutchis engaged. shiftvalve.The 3rd clutchpressure Fluidflows by way of: (5) (5) - Linepressure - CPBValve- Line Pressure - 1-2ShiftValve- LinePressure + 2-3 Shift Valve (4) (30} - LinePressure - 3-4 Shift Valve- 3rd ClutchPressure * 3rd Clutch {5) of because the one-wayclutch pressure also flows to the 1st clutch.However,no power is transmitted The hydraulic i n 2 n dg e a r . as "right" indicates circuit. directionon the hydraulic When used,"left" or
14-28
i*.
4th G6ar ( qr Positionl Asthe speedofthevehicle reachesthe prescribed value,shiftcontrolsolenoid valveA is turnedOFFby meansof the PCM.Shift control solenoidvalv6 B remainsOFF.The modulatorpressure(6) flows to the left end of the 1-2 shift (64) in the left end of the 1-2shift valveequals valve and the left end of the 3-4 shift valve.The modulatorpressure (68) in the right end of the 1-2 shift valve,the 1-2shiit valve remainsat left side by the tenthe modulatorpressure sion of the valvespring. (5A).The 3-4 shift valvecoversthe port to the The 3-4 shift valveis movedto the right side by the modulatorpressure port to the 4th clutchas this valveis movedto the right side.The 4th clutchpressure (41) 3rd clutchand uncovers the 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 - CPBValve- LinePressure + l-2 Shift Valve- LinePressure - 2-3 ShiftVarve (4) (5) (5) - LinePressure * 3-4 ShiftValve- 4th ClutchPressure + ManualValve- 4th ClutchPressure (5) (41) (40) + 4th Clutch The hydraulicpressure alsoflows to the 1stclutch.However, power is transmitted no because the one-wayclutch of as in 2nd and 3rd gear. NOTE:When used,"|eft" or "right" indicates direction the hydraulic on circuit.
(cont'd)
14-29
Description
Hydraulic Flow(cont'dl
lll Position (1) The line pressure changes the to circuitis the same as in E position. The flow of fluid through the torque converter (3') (3) (3) to pressure and flows to the 1-2shift valve.The line pressure changes the line pressure at the 1-2shift valve line the rangeposition) and uncovers pon to and flows to the servovalve.The servovalve is movedto the right side (Reverse (3') (3") to the manualvalve.The line pressure from the 1-2shift valveflows throughthe servovalveto allow line pressure (40)is appliedto the 4th clutch,and the 4th clutchpressure {40).The 4th clutchpressure the manualvalve and changes the 4th clutchis engaged. ReverseInhibitor Control the PCMoutputsthe while the vehicleis movingforwardat speedsover 6 mph (10 km/h), Whenthe E positionis selected shift controlsolenoid valveA is turnedOFF, valvesA and B; shift controlsolenoid 1stspeedsignalto shift controlsolenoid {3') valve B is turned ON. The 1-2 shift valve is moved to the right side and coversthe port to stop line pressure to the (3') is not appliedto the servovalve,and the 4th clutchpressure {40)is not appliedto the servo valve.The line pressure direction. to 4th clutch,as a result.power is not transmitted the reverse "right" indicates on circuit. direction the hydraulic NOTE:When used,"|eft" or
14-3 0
E Position (11 The line pressure changes the to circuitis the same as in E position. The flow of fluid through the torque converter (3') (3) (3) to line pressure and flows to the 1-2shift valve.The line pressure changes the line pressure at the 1-2shift valve rangeposition) and uncovers port to the and flows to the servovalve.The servovalve is movedto the right side {Reverse (3")from the servovalveis intercepted by (3")to the manualvalveas in E position. The line pressure allow line pressure pressure not supplied the clutches, to and the power is not transmitted. hydraulic is the manualvalve.However, on circuit. direction the hydraulic When used,"left" or "right" indicates
14-31
Description
Lock-up System
Lock-up Clutch 1. (clutchon) Operation pistonis drained With the lockup clutchon, the fluid in the chamber between torqueconverter the coverand the lock-up pressure off,and the converter fluid exerts throughthe pistonagainst torqueconverter the cover. a result, convertAs the placing vehicle directdrive. er turbineis locked the converter to cover. The effectis to bypass converter, the thereby the in
LOCK-UP PISTON The power flows by way of: Engine TOROUE CONVERTER COVER SPRING DAMPER
I plate Drive
t
Torque convertercover
t
Lock-uppiston
t
Damper spring
t
Turbine I lvlainshaft
MAINSHAFT
(clutchoff) Operation 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
Engine
TOROUE COVER
t
Driveplate { Torqueconvenercover
t
Pump
t
Turbine
To ATF coolel
t
lvlainshaft
MAINSHAFT
14-32
position in 3rd, In igd position,in 3rd and 4th, and D3pressurized fluid is drainedfrom the back of the torque causingthe lock-up converterthrough a fluid passage, pistonto be held againstthe torque converter cover.As the mainshaft rotates the same speed at this takesplace, Together with the hydraulic as the engine crankshaft. t c o n t r o l ,t h e P C M o p t i m i z e d h e t i m i n g o f t h e l o c k - u p the lock-upclutch is system. Under certain conditions, in appliedduring deceleration, 3rd and 4th gear. systemcontrolsthe rangeot lock-upaccordThe lock-up ing to lock-upcontrol solenoidvalvesA and B, and the linearsolenoid. When lock-upcontrol solenoidvalvesA 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 by housing, and are controlled the PCM. Lock-up Conditions/Lock-up Control Solenoid Valves/ Linear Solenoid Pressure Lock-upControl Solenoid Valve A Lock-up OFF Lock-up, Half Full Lock-up, LOCX-Up during deceleration
MODULATOR PRESSURE RELIEFVAL
TOROUE CONVERTER
Lock-up Conditions
B
OFF
Linear Solenoid Pressure

High
OFF ON ON
Duty operation OFF- ON ON Duty operation OFF- ON High
ON
IOROUECONVERTER VALVE CHECK
LOCK.UP TIMING VALVE
",
<RELIEF VALVE .X,COOLER
PRESSURE LINEARSOLENOID
ATFPUMP
(cont'dl
14-33
Description
Lock-upSystem(cont'dl
No Lock.up . . . Lock-uo ControlSolenoidValveA: OFF Lock-uo ControlSolenoidValveB: OFF LinearSolenoidPressure: High
TOROUE CONVERTER
The pressurized fluid regulated the modulatorworks by shift valve.Underthis condion both ends of the lock-up tion, the pressures working 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 that is, side of the lock-up clutchto the torque convener; the lock-uo clutchis in OFFcondition. NOTE:When used,"left" and "right" indicates direction circuit. on the hvdraulic
-r TOROUE CONVERTER I
CHECK VALVE
RELIEF VALVE
MOOULATOR PRESSURE
LOCK-UP TIMING VALVE
LINEARSOLENOID PRESSURE $ I L--r COOLER RELTEF VALVE
ATFPUMP
Half lock-up . . . Lock-up ValveA: ON ControlSolenoid ValveB: DutyOperation Lock-up ControlSolenoid OFF* ON Low LinearSolenoidPressure:
TOROUE CONVERTER
LOCK,UP CONTROL SOLENOID VALVE
t
TOBOUE CONVERTEF I CHECK VALVE
the The PCMswitches solenoidvalveA on to release the modulatorpressurein the left cavity ot the lock-upshift valve.The modulatorpressure the right cavity of the in lock-upshift valve overcomes the spring force;thus the lock-upshiftvalve is movedto the left side. The line pressureis then separatedinto the two passagesto the torque convener: I : T o r q u eC o n v e r t e r 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 clutch sideto engagelock-up Torque Converter BackPressure: entersinto left side lock-up clutch to disengage The back pressure(F2)is regulatedby the lock-upcontrol valve, whereas the position of the lock-uptiming and by valve is determined the linearsolenoidpressure tensionof the valvespring.Also the positionof the lockof up control valve is determinedby the back pressure pressure regthe lock-upcontrolvalve,torque converter checkvalve,and modulaulatedbv the torque converter by tor pressure determined the lock-upcontrolsolenoid control solenoid valve B. The PCM switchesthe lock-uD undercertain valve B on and off rapidly(duty operation) the backpressure conditions regulate to {F2)to lockthe properly. torqueconverter direction NOTE:When used,"left" and "right" indicates on the hydraulic circuit.
MODULATOR PRESSURE
RELIEF VALVE
LOCK.UP TIMING VALVE
,.
^r
LINEARSOLENOID PRESSURE
RELTEF VALVE r* cooLER
ATFPUMP
(cont'd)
14-35
Description
Lock-up System(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 linearsolenoid controlled the PCM. by 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
TOROUE CONVERTER
LOCK-UP CONTROL VALVE
Under this condition, the modulatorpressure the left in 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 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 released fully, causingthe lock-upclutchto be engaged fully. NOTE:When used,"|eft" and "right" indicats direction on the hvdraulic circuit,
LOCK.UP CONTROL SOLENOID VAI.VE
MODULATOR PRESSURE RELIEF VALVE
LOCK-UP TIMING VALVE
^ cooLERRELTEF vALvE 1,,__.r'
LINEARSOLENOID PRESSURE
ATFPUMP
14-36
DecelerationLock-up . . . ValveA: ON Lock-up ControlSolenoid ValveB: DutyOperation ControlSolenoid Lock-up OFF- ON Low LinearSolenoidPressurer
The PCM switchessolenoidvalve B on and off rapidly . u n d e r c e r t a i nc o n d i t i o n sT h e s l i g h t l o c k - u pa n d h a l f so lock-upregionsare maintained as to lock the torque properly. converter
TOROUE CONVEATER
"right" indicates direction NOTE:When used,"left" and circuit. on the hydraulic
LOCK-UP CONTROL VALVE SOLENOIO
"otua"rlil ,o*oua
CHECK VALVE
MODULATOR PFESSURE RELIEF VAL
TIMING LOCK.UP VALVE
PRESSUBE LINEAR SOLENOID s ^r RELIEF VALVE ---r'1 COOLER
ATF PUMP
14-37
ComponentLocations
CONTROL POWERTRAIN MOOULEIPCM}
TICTRANSAXLE IA/TI SWITCH GEARPOSITION
COUNTERSHAFT SPEED SENSOR
i:.
(-
i\ \.i.'.
tr',\i,
V'.:t
',
VALVE SOLENOID ASSEMBLY VALVE SOLENOID ASSEMBLY
14-39
PCM Circuit Diagram(A/T ControlSystem)

-HOODFUSE/REIAY UNOEfl BOX
(80A) No.42 No.41 l40A)

N o . 4 7{ 7 . 5 ) A
( N o . 1 3l 5 A )
UNOER DASH FUSE/RELAY BOX
/8tu c10
BtK
A10
BLK 423
L
ArpNp l o r ^ o ] s L ul n r r n lSlt l6lt lor*
824 l88 I817 YEL96:GRN BLU '96: BLU/RED '97,'98: GRN/BLK
G A U GA S S E M E L Y E
A/TGEAR POSITION INDICATOR
',u, f ,,,tro "I wHT ,at BLKETU

38-'cFN/BLK
FBIK/BLU |--wHT I-GRN
YEL
T T T
GRN BLU
NorE:rf :To 5v T rTo 2V 1
D,
14-40
VEHICLE SENSOR SPEEO
l. '1Fr
rlP
CONNECTOR SERVICE CHECK
BLUMHT
I I
RED/WHT 02
RED/BtK YEUBTU
010 D1
l.',
REO
l"'
t
s23
BLU GRN
I RED
I"
83
|811
BLU/ryEL GRN,4A/HT
I I GRN/BLKBRN/BTK
l"
122
I
T lT t
Lcl
l
MAINSHAFT SPEED SENSOR
_l__L f_l_ _l__l_l__l_
TTTT p*8
SPEoSENSoR L|NEARSOLENo|D
I T T T
-UP LOCK CONTROL VALVE SOLENOIO ASSEMBLY
Locations rcM TeminBl
14-41
PCMTerminal Voltage/Measuring Conditions

A/T ControlSystem
The PCMterminalvoltageand measuring conditions shown for the connector are terminalsthat relateto the A,/T control system. The other PCN4 terminalvoltageand measuring conditions described section1L are in
A l32P)Connector
I (25PlConncrol
C (3lPlConnector
D {16P)Connector
PCMCONNECTOR {32P} A
TerminalNumber
41 to A8
Signal
Description
Measuring Condiiions/Terminal Voltage

see section 11 -
A9 A't0 411 A.12 421 ro 422 423 424 A25 to A32
LGl PGl IGPl
Ground Ground Powersupplysystem With ignitionswitchON (ll):Battery voltage With ignitionswitchOFF: V 0 - seesection11-
LG2 PG2 IGP2
Ground Ground Powersupplysystem With ignitionswitchON (ll):Battery voltage With ignitionswitchOFF:0V - seeseclion11
PCMCONNECTOR {25PI B TerminalNumber Signal LSLS+ SHA Description Linearsolenoidpower supply negative electrode Linearsolenoidpower supply positiveelectrode
Shift control solenoid valve A control
Measuring Conditions/Telminal Voltage l g n i t i o n w i t c h N { l l } :P u l s i n g i g n a l s O s

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
B1
82
In 2nd gear and 3rd gear in id, Ei position, and in El, E position: Battery voltage In lst gearand 4th gear in D3l, position: V Bll O When full lock-up: Battery voltage W h e nh a l fl o c ku p : P u l s i n g i g n a l s When lock-upis ON: Battery voltage With no lock up: 0 V position: V In .[D;] 0 In otherthan D3lposition: Battery vortage
B4 B5 86 to 87 B8 89to 810
LCB LCA
Lock-up controlsolenoid valve B control Lock-up controlsolenoidvalveA control

Not used
ATP D3
gear positionswitch !c posiAy'T tion signalinput Not used
14-42
B PCMCONNECTOR (25P)(cont'd) Terminal Numbel

811 Signal SHB
Description valveB Shift controlsolenoid control lnterlock control D4 Indicator light control
Measuring Conditions/TerminalVoltage In 1stgear and 2nd gear in El, E position, voltage Battery and in E position: 0 In 3rd gearand 4th gear in E, lp! position: V When ignitionswitchis ON (ll).brakepedal pedalreleased: V 0 and accelerator depressed When ignitionswitchis first turnedON (ll): Battery voltage for two seconds Battery voltage In iDaposition: Always:0 V Depending enginespeed:Pulsingsignal on 0 When engineis stopped: V InEposition:0V Battery voltage In otherthan E position: InEposition:0V Battery voltage In otherthan E position: Always:0 V on Depending vehiclespeed:Pulsingsignal 0 Whenvehicleis stopped: V position:0V In -Drl 5 In otherthan E! position: V 0 In E and El positions: V In other than E and N positions:Batteryvoltage
SLU
B13
D4IND
814
NMSG NM
Mainshaft speedsensorground Mainshaft speedsensorsignal Input A,/Tgear position switch @ positionsignalinput A/T gear positionswitchP position signalinput Not used speed sensorground Countershaft speedsensorsignal Countershaft Inpur A/T gear position switch Pj position signalinput A/'f gear positionswitchE and N positionsignalsinput
B16
817
ATP R AJP 2
8 1 8t o 8 2 1
B22 B23
824 B25
NCSG NC ATP D4 ATP NP
C PCM CONNECTOR {31P) Terminal Number Cl to C6 Signsl Description MeasuringConditions/Terminalvoltage - seesection11 checksignal Service With ignition switch ON (lll and servicecheck open:5 V connector With ignition switch ON (ll) and servicecheck with special tool: 0 V connected connector - seesection11Always battery voltage - seesectionI I -
c7
C8 to C9
c10
Cl 1 to C31
VBU
power system Back-up
D PCM CONNECTOR (16P) TerminalNumber D1 to D4 Signal Description Measuring Conditions/TerminalVoltage - seesection1 l STOPSW Brakeswitchsignalinput Battery voltage Brakepedaldepressed: 0 Brakeoedalreleased: V - seesection11-
D5
DO o D16 t
14-43
Troubleshooting Procedures
Checking Diagnostic the TroubleCode{DTC) with an OBD ll Scan tool or Honds PGM Testel When the PCM sensesan abnormality the input or output systems, in the ql indicatorlight in the gaugeassemblywill blink When the 16PData Link Connector (DLC)ilocatedunder the dash on the driver'sside) is connected the oBD ll to ScanTool or HondaPGM Testeras shown,the scantool or testerwill indicate the Diagnostic TroubleCode (DTC) when t h e i g n i t i o n w i t c h s t u r n e dO N I ) . s i when the E ] indicator light has been reported connectthe oBD ll scan Tool conforming SAEJ197gor HondapGM on, to Testerto the DLC(l6P). Turn the ignitionswitchON {ll), and observethe DTCon the screenof the OBD ll ScanTool or HondaPGMTester' After determining DTc, referto the electrical the systemSymptom-to-component chart on pages14-48 and 14-49. NOTE:Seethe OBD ll ScanTool or HondaPGMTesteruser,smanualfor specific instruction.
OBD ll SCANTOOLor HONDAPGM TESTER
(16P} DATA LINKCONNECTOR
14-44
Checkingthe DiagnosticTroubleCode (DTC) with the ServiceCheckConnestorand SpecialTool will light in the gaugeassembly blink the in an Whenthe pCM senses abnormality the inputor outputsystems. itj indicator tool as with the special side) is connected (locatedunderthe dash on the passenger When the ServiceCheckConnector (DTC) when the ignitionswitchis turnedON (ll). TroubleCode light will blinkthe Diagnostic shown,the lD1indicator tool. with the special Connector Check the on, light has beenreported connect Service Whenthe @ indicator light the [o! indicator ON (ll)the ignitionswitchand observe Thenturn
ASSEMBLY GAUGE
.-.=-.-..--- . .
\.....-,-..-.""r
a:
.'
'i''
.-
c ,
CHECK SERVICE CONNECTOR I2P}
07PAZ (x)'10t00
CONNECTOR
by short blinks.codes 10 and aboveare indicated a seriesof long and short by codes 1 through9 are indicated individual the code After deterblinks.one long blink equals10 short blinks.Add the long and short blinkstogetherto determine and 14-49' Charton pages14-48 Component systemSymptom-to miningthe code,referto the electrical
Short blink {once}
See DTC 1
See DTC2
Long blink
Short blinks lfive times)
See DTC 15
(cont'd)
14-45
{cont'd)
1. 2.
Remove the kickpanelon the passenger's side (seesection20). Remove PCM,and turn the PCMover. the
Inspect circuiton the PCMaccording the troubleshooting the llowchartwith the special to tools and a digitalmultimeter as shown. How to Use the BackprobeSet Connect the backprobe adapters the stackingpatchcords,and connectthe cords to a multimeter. to Using the wire gently slidethe tip into the connector insulation a guide for the contoured of the backprobe as tip adapter, from the wire side until it comesin contact with the terminalend of the wire.
EACKPROAE
BACKPROAE SET 07sAz- 001000A (tworequired)
OIGITAL MULTIMETER (Commrcially available)
-aHM-32-003
or equivalent
14-46
. 1. 2.
PCM RasetProcadure Turnthe ignitionswitchoff. to box for 10 seconds resetthe PCM' fuse/relay the Remove BACKUP fuse (7 5 A) from the under-hood NOTE: the radio presetstationsand clock setting.Make note of the radio . Disconnecting BACKUP fuse also cancels the presets beforeremovingthe 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 1. 2. 3. Turn the ignitionswitchOFF. the Reset PcM. tool from or the Disconnect OBD ll ScanTool or HondaPGMTesterfrom the DataLinkConnector, removethe special CheckConnector. the Service and clocksetting Turn the ignitionswitchON (ll),and set the radiopresets
4.
14-47
Symptom-to-Component rt Cha
Electrical System
Diagnostic TroubleCode El Indicator Light (DTC)* Symptom Lock-up clutchdoes not engage. Lock-up clutchdoes not disen gage. Possible Cause Disconnected lock-up controlsolenoid valveA connector Shortor open in lock-up control solenoid valveA wire Faultylock-up controlsolenoid valveA Disconnected lock-up controlsolenoid valveB connector Shortor open in lock-up control solenoid valveB wire Faultylock-up controlsolenoid valveB . Short in Ay'T gear positionswitchwrre . FaultyA4 9"", Oosition switch Disconnected gear positionswitch A/T connector gear positionswilchwire Open in A"/T FaultyAy'T gear positionswitch Disconnected shiftcontrolsolenoid valveA connector Shortor open in shift controlsolenoid FaultyshiftcontrolsolenoidvalveA Failsto shift (stuckin 1stor 4th gears). Blinks Disconnected shiftcontrolsolenoid valveB connector Shon or open in shiftcontrolsolenoid valveB wire Faultyshift controlsolenoid valveB Disconnected countershaft speedsensor connector Shon or open in countershaft speed sensorwrre Faultycountershaft speedsensor Referto Page
P1753 (1)
Blinks
l4-50
Lock-up clutchdoes not engage. P1758 t2l Blinks
14-52
P1705
(s)
Blinks
P1706 (6)
OFF
. Failsto shiftotherthan 2nd - 4th gears. . Lock-up clutchdoes not engage. . Fails shiftotherthan 2nd - 3rd to - 4th gears. . Lock-up clutchdoes not engage. . Failsto shift (between1st- 4th, o r 2 n d- 3 r d g e a ro n l y ) . . Failsto shift (stuckin 4th gear).
14-54
14-s6
P0753 t7I
Blinks
r4-58
P0758 (8)
'14-60
. Lock-up clutchdoes not engage. PO1 20 (9) Blinks
14-62
(DTC)*: The DTcs in parentheses the numberof the E indicatorlight blinkswhen the service are checkconnecror conrs nected with the special tool (SCS service connectorl.
14-48
Diagnostic Indicator TroubieCode E Light (Drc).
Symptom
Possible Cause mainshaft speedsensor Disconnected connector speedsenShortor open in mainshaft sor wtre Faultymainshaft speedsensor linearsolenoid connector Disconnected wire Shortor open in linearsolenoid Faultvlinearsolenoid or Disconnected loosedPGterminal . Faultylock-up controlsystem . Faultvshift controlsystem
Referto Page
clutchdoes not engage. '96,'97 models . Lock-up
P07r5 (1 5 )
OFF '98 model Blinks . Transmission jerkshardwhen shifting.stuckin 4th gear. . Lock-up clutchdoes not engage. . Lock-up clutchdoes not engage. Failsto shift (between1st- 2nd, 1st- 4th. 2nd - 4th,znd - 3rd, 3rd - 4th, 1st- 2nd - 3rd, 1st-3rd 4th or 2nd - 3rd - 4th gearsonly). Failsto shift (stuckin 1stor 2nd gears).
14-64
P1 7 6 8 (16) P0740 (40)
Blinks
14-66
14-68
P0730
(41)
OFF
14-69
P0700 (none)
problem, Any automatic transmission probtroubleshoot other automatictransmission the To eliminateDTCP0700, indicated. lem(s)according the DTC(S) to
is checkconnector con(DTC)*: light blinkswhen the service are The DTCS parentheses the numberof the E indicator in (SCSservice connector). with the sDecialtool nected controlsysfor transmission the DTC(S) the automatic NOTE:When the OBOll ScanTool or HondaPGMTesterindicate Code P0700meansdetectionof some automatic code P0700simultaneously. tem, the scan tool or tester also indicates transmission oroblemon the PGMFl controlsystem. to according the table below. light does not blink,performan inspection lf the self-diagnostic indicator Ei!] Symptom after ignition light does not come on tor two seconds E indicator switchis first turnedON (ll). (not blinking) whenever the ignition light is on constantly E indicator switchis ON (ll). Shift levercannotbe movedfrom E positionwith the brakepedal oeoresseo, Inspection Ref. page 14-70 't 4-12 Inspection 14-13
(6), the to the NOTE:lf a customer describes symptomfor code P1706 it will be necessary recreate symptom by test-driving,then recheck DTC. the
14-49
Electrical Troubleshootin g
Troubleshooting Flowchart Lock-up GontrolSolenoidValveA
. OBD ll ScanTool indicatesCode P1753. . Sell-diagnosi3 i-tl indicatol light blinks once. PossibleCsuso . Disconnectedlock-up cont.ol solenoid valve A connector . Short or opon in lock-upcontrol 3olenoidvalve A wire . Faulty lock-up control solenoid valvo A PCMCONNECTORS
Checkfor e Short to Power: 1. Turnthe ignitionswitchOFF. 2. Disconnect A {32P)and B the ( 2 5 P )c o n n e c t o r sf r o m t h e PCM. 3. Turn the ignitionswitchON (ll). 4. Measurethe voltage between the 85 and A9 or A22 terminals. WIRESIDEOF FEMAI.f TERMINALS
Ropairshort to power in the wirc betweon the 85 terminal and the lock-upcontrol solenoidvalve A.
Measur Lock-upControl Solenoid Valve A R*istanc: 1. Turn the ignitionswitchOFF. 2, Measure the resistance betweenthe 85 and Ag or A22 terminals.
ls the resistance - 25 0? 12
Check tor loose P1CM connectoJs. It necossary, substituto a knowngood solenoid v.lvo assomblyor PCM and r6chock.
To page14-51
14-50
From page14-50
PCMCONNECTORS
Check Lock-up Control Solenoid Valve A for a Shon Circuh: 1, Disconnect the 2P connector from the lock-up controlsolenoid valveassembly. 2. Checkfor continuitybetween the 85 and Ag or A22 terminals,
A (32P)
TERMINALS WIRESIDEOF FEMALE Repair3hort to ground in the wire between the 85 t6rminal and the lock-uD conttol solenoid vahre A. CONTROL LOCK.UP CONNECTOR SOLENOID
ls therecontinuity?
*T
. - F
ItrTt
M6asu.e Lock-uo Control Solonoid Valve A Rosistance at lho SolenoidConnector: Measure the resistancebetween the No. 2 terminalof the lock-up control solenoid connectorand body ground.
(o)
YEL
TERMINAL SIDEOF MALETERMINALS
ls the resistance - 25 0? 12
Check for open in the wire btwen the 85 terminel .nd the lock-upcontrol solenoid valve A.
Replece the lock-up control solenoid valve assembly.
14-51
Troubleshootig Electrical n
Troubleshooting Flowchart Lock-upGontrolSolenoidValveB
OBD ll Scan Tool indicli.. Code P1758. Selt-disgnolb E indicltor light blinks twice. Po..iblo C!u& . Diaconnacted lock"up control rolanold valv. B connector . 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. 2. Disconnact A (32P)and A the ( 2 5 P )c o n n e c t o r sf r o m t h e PCM. 3. Turn the ignitionswitchON (ll). 4. Measurethe voltagg btween the 84 and A9 or A22 terminals,
A t32P)
TENMNALS WIRESIOEOF FEMALE
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 Solenoid Valvo B Rcrictlncc: 1. Turnthe ignitionswitchOFF. 2. Measure the resistance b e t w e e nt h e B 4 a n d A g o r A22terminals.
ls the resistance - 25 O? 12
Ch.ck tor loo.. PrCi, conn.c'lor3, It n6ca3t!ry. subttihrta r knowngood 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: 1. Disconnect the 2P connector trom the lock-upcontrol solenoid valve assembly. 2. Check for continuity between the 84 and A9 or A22 terminals, TERMINALS WIRESIDEOF FEMALE Rapair3hort to ground in th wir betwaen the 84 torminal and th lock-up control solenoid valvo B.
CONTROL LOCK-UP CONNECTOR SOLENOID
Mea3ura lock-up Control Solenoid Vrlvc B Ro3irtrnc. at the SolonoidConnoc{or: Measure the resistancebetween the No. 1 terminalof the lock-up control solenoid connectorand bodyground.
IFT']
t-
cnNreLxI (o)
T I
SIDEOF TERMINAL MALETERMINALS
12 ls the resistance - 25 0?
Chock for opon in the wir botwon th. 84 torminal and the lock-up control aolonoidvalva B.
R.phc. tha lock-up cont.ol solonoid valvc $!.mbly.
14-53
Electrical Troubleshooting
Troubfeshooting Flowchart- AIT GearPositionSwitch (shortl
. OBD ll ScanTool indicatesCode P1?05. . SelI-disgno3is indicrror light E blinks tive tim6. PossibleCause . Shorl in A/T 96ar position switch . FaultyA/T geal po3ition switch NOTE:Code Pl705 (5) is causedwhen the PCMreceives wo gear position t ,nputsat the sametime-
Observeth6 A/T Gear Po3ition Indicator: 1. Turnthe ignition switch {ll). ON 2. Observethe A,/Tgear position indicator, nd shilt to each a posttlon.
Do any indicators stayon whenthe shiftleveris not in thosepositions?
The system is OK at this time. Check the wile harnessfo. damage.
PCMCONNECTORS
MeasureATP R Voltage: 1. Shittto all positions otherthan 2. Measure voltagebetween the the 816 and Ag or A22 terminals, Check for short in the wire betweenthe Bl6termineland the A/T gear position swilch or A/T gear position indicator. lf wire is OK, check lor loose PCM connectors. It noceasary, substitute a known-goodPCMand recheck. MeasureATP NP Voltage: 1. Shiftto all positions otherthan Nor@. 2. Measure voltagebetween the the 825 and Ag ot A22 te(mi nals, WIRESIDEOF FEMALE TERMINALS
E.
ls therebattery voltage?
MeasureATP 04 Voliage: 1. Shiftto all positions otherthan O.. 2. Measure voltagebetween the the 824 and A9 or A22 terminals.
Check tor short in the wire btweentho 825 terminal and the A/T goar position indicator, o. a shon in the wiaes beiween the A/T gear position indicator and the A/T gear posilion switch. It wires are OK, check for loose PCM conneclors. lf necssarv, substitute a known-good PCM end rechock,
Check for sho.t in the wiro betweenthe B24terminaland the A/T ge.r position switch. lf wire is OK, check lor loose PCM GonnectoE. 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 2. Measurethe voltage between the 88 and A9 or A22 terminats. TERMINALS WIBESIDEOF FEMALE Ch6ck for short in tho wire batwen tho 88 terminel and the A/T gear position switch ot A/T gea. position indicator. It wire i3 OX, check for loos6 PCM conneclors. lf neces3ary, substitute a known-good PCMand techeck. BRN/ALK Morsure ATP2vohage: otherthan 1. Shiftto all positions 2. lvleasuro the voltage between the 817 and A9 or 422 termi nats.
E.
tr.
BRN/BLK
Check for sho.t in the wire btwenthe 817 terminal .nd thc A/T goar position switch or A/T gear position indicalo.. tf wire is OK. check for loos6 PICMconnecsubstitute a tors. lf necessary, known-goodPCM.nd racheck.
Chockfor loo3o PCMconnGctors, lf nccossrry, 3ubsthuto a knowngood PCM tnd r6chock.
14-55
Troubleshooting Flowchart A/T GearPositionSwitch (Openl
. OBD ll ScanTool indicat$ Code P1706. . Self-di.gnosisq indicatorlight blinks six iim*. PGsibl. Causo . DisconnectodA/T goal po3iilon 3witch connector . Open in A/l gear position awitch . Fauhy A/T go.r position switch PCMCONNECTORS Me8ure ATP R Voltage: 1. Turnthe ignition switch (ll). ON 2. Shiftto E position. 3, Measure voltagebetween the the 816 and A9 or A22 terminals,
BRN/BLK
BRN/BLK
WIRESIDEOF FEMALE TERMINALS Bepair open in the wile bstwaton the 816 torminal and tha A/T goar po3hion switch.
BRN/BLK
MeasureATP NP Voltage: 1. Shiftto N orE position. 2. Measure voltagebetween the 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: 1. Shiftto E position. 2. Measure the voltagebetween the 824 and Ag or A22 termi-
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 betwen the 88 and A9 or A22 terminats.
TERMINALS WIRESIDEOF FEMALE 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 tsrminals.
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 ! knowngood FCM .nd r.ch.ck.
14-57
g Electrical Troubleshootin
Troubleshooting Flowchart Shift ControlSolenoidValveA
. OBD ll ScanTool indicatosCode m753. . Sof-di.gno.is D; indicrtor llght blinks 36v6ntimes. PossibleCeuse . Disconngcled shift cont.ol solenoid valve A connoctot . Short or open in shift control solenoid valve A wire . Faulty shift control 3olenoid valve A PCMCONNECTORS BLU/YEL Ch.rckfo. a Short to Powel: 1. Turn the ignitionswitchOFF. 2. Disconnect A {32P)and B rhe ( 2 5 P )c o n n e c t o r sf r o m t h e PCM. 3. Turnthe ignition switchON (ll). 4. Measlre the voltagebetween the 83 and Ag orA22 terminals.
BRN/BLK TERMINALS WIRESIDEOF FEMALE
Ropairshort to power in the wire between the 83 t6.minal and tho shift control3olenoid valve A.
Mssure Shift Control Solenoid Vrlve A Rosidance: 1. Turnthe ignitionswitchOFF. 2. Measure the resistance betweenthe 83 and Ag or A22 Iermrnats.
Chocktor loose PCM connoctors. It nace33ary, substitut a knowngood 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. Disconnect the 2P connector from the shift control solenoid valve assemblv. 2. Chgck for continuity between the 83 and Ag or A22terminals.
A {32P)
WIRESIDEOF FEMALE TERMINALS
Ropairlhort to ground in the wire betweon the lIt torminal and lho rhift control solenoid v6lvo A. SHIFTCONTROL SOLENOID CONNECTOR
Me.sure Shift Control Solonoid Valv. A R6btanco .t the Solonoid Connoctor: Measure the resistancebetween the No. 1 terminal oI the shitt control solenoid connectorand body ground.
BLU/YEL
Chack lor opon in lhe wire betwoen the 83 termin.l and tho rhift control solenoid valv6 A.
14-59
g ElectricalTroubleshootin
Troubleshooting Flowchart Shift ControlSolenoidValveB
. OBD ll ScanTool indicatosCode P0758. . Selt-diagnosis indicator ligln Ei blinks oight time6. Possibl6Cause
. Disconnoctod shift contlol solenoid velve B connector . Short or ooen in shift control solenoid valve B wire
. Faulw shift control solenoid valve B
PCMCONNECTORS
Chockfo. a Short to Power: l. Turnthe ignitionswitchOFF. 2. Disconnect A {32P}and B the (25P)connectors from the PCM. 3. Turnthe ignition switch (lli. ON 4. Measure the voltagebetween the 8'11and Ag or A22 termi nals.
l32Pl
TERMINALS WIRESIDEOF FEMALE
Repairshort to power in th6 wire between the 811 termin.l and the shift conlrol solenoidvelve B.
Measure Shift Control Solenoid Valve B Resistance: 1. Turnthe ignitionswitchOFF. 2. Measure the resistance b e t w e e nt h e 8 1 1 a n d A g o r A22terminals.
ls the resistance 25 0? 12
Ch6ckfor looso PCMconnectors. lf nocessary, 3ubitituta a knowngood 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 Valve B tor a Short Circuit: 1. Disconnect the 2P connector lrom the shift control solenoid valveassembly. 2. Checkfor continuitybetween the 811 and A9 or A22 terminars,
BRN/BLK
BRN/BLK WIRE SIDE FEMALE OF TERMINALS
ls therecontinuity?
Repairshort to ground in the wira betweenthe 811 ierminal and the shitt control solenoidvalve B. SOLENOID SHIFTCONTROL CONNECTOR
li; tt
I GRN,/WHT Measure Shift Control Solenoid Velve B Resistanceat the Solonoid Connec'tor: Measure the resistancebetween the No.2 terminal ofthe shiftcontrol solenoid connector and body oround,
(o) Y I I
SIDEOF MALETERMINALS TERMINAL
l s t h e r e s i s t a n c el 2 - 2 5 0 ?
Check for open in the wire between the Bll terminal and the shift control solenoid valve 8.
14-61
Troubleshooting Flowchart Countershaft SpeedSensor
. OBD ll Scrn Tool indicats Code PO720. . Solt-diagnosis Dj indicator light blinks ninc times,
Po$ible C.u3o . t"a* ". t*rlty ""."""t1* botwoen the PCM .nd c.r harnoss . Disconnectodcountarshaft soeodson3orconnector . Short or open in countorsh.ft sp6ed sensor wirc . F ulty count.shrft speod 3en-
ls the countershaftspeedsensor properly? installed COUNTERSHAFT SPEED SENSOR CONNECTOR
Measure Countorsh.ft Soeed Sensor R6istanc al ths Senror Connectot: 1. Disconnect the 2P connector from the countershaft sDeed sensofconnector, 2, Measure the resistance the oI countershaftsDeedsensor,
t'-tt TT 9 ll t
L I
TERMINAL SIDEOF MALETESMINALS
ls the resistance 400- 600 0?
PCMCONNECTOR {25P) B
Chack Coume6hatt Spod Sensor for a Short Circuit: 1. Disconnect e B (25P) on th c nector from 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. TERMINALS WIRESIDEOF FEMALE Repairshort in the wires belwen the 823 and 822 torminals and the countershaft soeed sensor.
To page14-63
14-62
Frompage14-62
PCMCONNECTOR {25PI B Maasure CruntoFhaft Speod Sonsor Rosbtrnce: 1. Connect the countershaft speedsensor connector. 2P 2 . M e a s ur e t h e r e s i s t a n c e between the 823 and B22 le'' minals,
SIOEOF FEMALE TERMINALS ls the resistance 400- 600 O? Ropair loose terminal or open in tho wiies bstw66n tho B23 and 822 termin.ls and tha countorshaft speodsensor.
Check tor loos6 PICMconnectors. lf necass{ry, substihJtg a knowngood PCMrnd roch.ck.
14-63
Troubleshooting Flowchart MainshaftSpeedSensor
. OBD ll ScanTool indicatosCode P0715. . Selt-diagnosis E indicatol light indic.t6 Cod 15. Posible Ceuse ' DI*.""."1"d -"l".h"ft .*.d 3en30t connctot . Short or op6n in main3hatt speed sensorwire . Faulty mainshaft speodsensol
N O T E : C o d e P 0 7 1 5 ( 1 5 )o n t h e P C M doesn't always mean there's an electrical problem in lhe mainshafl or countershaft ) 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 a t also indicatea mechanicalproblem in the transmtsston.
Check mainshaft the and counter' shaftspeed sensorinstallation.
Are the mainshaft and countershaft properly? speedsensorinstalled MAINSHAFT SPEED SENSOR CONNECTOR
MeasureMainshrft SpeedSensor Resistanceat the Sensor Connector: 1. Disconnect the 2P connector from the mainshaft speed sen' sor connector. 2. Measure the resistance the of majnshaft speedsensor.
TERMINAL SIDOF MALETERMINALS
ls the resistance 400- 600 {}?
PCMCONNECTOB I25P} 8 Check MainahaftSpeed Sensot for a Short Circuit: 1. Disconnect B (25Piconnecthe tor from the PCM. 2. Checkfor continuitybetween bodygroundand 815terminal and the 814 terminalindividn-
ls therecontinuity?
ReDairshort in the wires between the 815 and Blil terminals and lhe meinshrft soeedsensor.
To page14'65
14-64
Frompage14-64
PCMCONNECTOR (25PI 8 MeasureMrinshaft SpeedSensor Resistance: speed 1. Connect the mainshaft 2P sensor connector, 2 . M e a s ur e t h e r e s i s t a n c e the 8'15and 814 terbetween mt n a l s .
ls the resistance - 600o? 400
Run iho Elect ical Troubleshooling Flowchart code m720 l9l. for Checktor loose PCM connectors. It ncossary, substitute a knowngood PCMand recheck.
MAINSHAFT SPEED SENSOR CONNECTOR
CheckNM Wire Continuity: 1. Disconnect the 2P connector from the mainshaft speed sensor connector. 2. Checkfor continuitybetween the 815terminal and the No. 1 terminal of the mainshaft speedsensorconnector,
ls therecontinuity?
Repairopen in the wire between the 815 terminal and the main' shaft speedsensor.
CheckNMSG Wire Continuity: Check continuity for between the 814 terminal and the No. 2 terminal of the mainshaftspeedsensor
ls therecontinuity?
Bepair op6n in th wire between th 814 terminal and the main3haft sDeedsnsor.
Checklor loos PCMconnectors. It nocessarv, substitute a knowngood PCMand recheck.
14-65
g Electrical Troubleshootin
Troubleshooting Flowchart LinearSolenoid
. OBD ll ScanTool indicat6 Codo P176a. . Self-diagnosis [d indic.tol light indicatesCode 16. Po$ible C.Ge . Oisconnectedlinar solonoid . Short or op6n in linear solonoid . F.uhy linorr 3olonoid LINEAR SOLENOID CONNECIOR
Msasure Linoar Solanoid Rosi3tanco at tho SolonoidConnector: 1. Turnthe ignitionswitchOFF. 2. Disconnect the 2P connector from the linearsolenoidconnector, 3. Measure tho resistance ofthe linearsolenoid.
trTt -r-r
rdl t_i
Y Il t
TERMINAL SIDEOF MALE TERMINALS
ls the resistance aoorox. 0? 5.0 PCMCONNECTOR (25P) B
WHT
Ch6ckLinor. Sol.noid for a Short Circuit: l Disconnect B (25P)connec, the tor from the PCM. 2. Checktor continuity between the body ground and the 81 terminaland 82 terminalindividually.
RED
TERMINALS WIRESIDEOF FEMALE Repairsho.t in the wire3 bgtwoon tho 81 and 82 termin.ls rnd th6 lineal solonoid.
Me.iuie Linoar Solenoid Rcai3tance: 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. Masure the resista ce n between the 81 and 82 terminals,
ls the resistance approx.5.0O?
Ropair loo3o terminsl or open in tho wirgs bgtween the B1 and 82 torminrl! rnd the linoar sol6noid.
To page14-67
14-66
Frompage14 66
PCMCONNECTOR I32P} A 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 . . R6pair loo3o junction connector. . Ropairpoor ground (G1011.
Chgckloi loo3a PCMconnecto.s. lf necellrry, 3ubstituto a knowngood PCMand rochock.
14-67
Troubleshooting Flowchart Lock-up ControlSystem
OBD ll Sc{n Tool indicatss Code m740. Self'diagnosis ErJ indicdor light indicatB Code /U). Poitible Cru.. Faulty Lock.up control ryitcm
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 ri g h t l indicates another code.
Doesthe OBDllscantoolor the E! indicator l;ghtindicate another code?
Perform tho Troubla3hooting Flowch.rt tor tho indic.t.d Codols). Rocheck tol codo P0740 l40l after troublG.hooting. NOTE:Do not continuewith this troubleshootino until th causes any of other DTCS have beencorrected.
Test Lin Piessure: M e a s u r eh e l i n e p r e s s u r es e e t { page14-87 and 14-88).
ls the linepressure withinthe service limit?
Repai. tho hydrrulic sy3tom a. 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 eh e l o c k - u p o n t r o l t c 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-hood fuse/relay box tor more than '10seconds. 3. Using the scan tool, checkto be sure that the enginecoola n t t e m p e r a t u r es i n 1 7 6 " F i {80'C)and above. 4. Drive the vehicle at 55 mph (88 km/h)constantly more for than one manute. (40). 5- Recheck codeP0740 for
DoestheOBDll scantool (401? indicate codeP0740
The syltom ii OK at thb timo.
14-6 8
Troubleshooting Flowchart Shift GontrolSystem

' OBD ll Scan Tool indic.t6 cod. m730. ' s.lf-di.gno.i. E indicator lig]|t Indicat . Code 41. PorsibleCauso F.ulty shitt contol systom
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.
Doe3the OBD ll scantool or indithe E indicaro.light cste anothercode?
Parform the Troubl.shooting Flowchrrt tor th6 indicatod Codo(s).Rochockfor cod! m730 {41| rft ol troubl.ihooting. until the causesof any NOTE:Do not continuwith this troubleshooting 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 the servicelimit?
Rcpair tha hvdraulic aystom ra 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 e h e l i n o a rs o l e n o i d t assembly(seepage 14-771. 3. Turn the ignirionswitch OFF and rsset th PCMmemory by romovingthe BACKUP (7.5A) {use/ fuse in the under-hood 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 seconds [8d oosition. at (41). for 5, Recheck code PO73O
Do6sthe OBD ll scantool or the E indicator light indicate code P0730(41)?
Tho sydem b OK rt this time.
14-69
ElectricalTroubleshooting
Troubleshooting Flowchart
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.)
D.lndicatorLight DoesNot GomeOn
Checkthe ServiceCheckConnector: Make sure the specialtool (SCS SetuiceConnector) not connectis ed to the service checkconnector.
(SCS ls the specialtool Service Connector) connected the serto vice checkconnector?
Disconnectthe soecial tool from the se.vice chock connoctor and rachock.
Checkth E indicator Light: Shiftto E position.
Checkto. loose PCM connectors. lf necasary, substitute a known. good PCMend iecheck.
PCMCONNECTOR (32P) A Checklhe Ground Circuit: 1. Turnthe ignitionswitchOFF. 2. Disconnect A (32P) the connec' tor fromthe PCM. 3. Checkfor continuitybetween 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.
WIRESIDEOF FEMALE TERMINALS Repair opon in the wires botwoen tho A9 or A22terminalsand G101. poor ground(Gl01). Repair
T o p a g e1 4 7 1
14-70
Frompage14-70
A PCMCONNECTOR I32P}
Moasure Powo. Supply Circuit Voltage: switchON (ll). 1. Turnthe ignition 2. Measureth voltage between A terminals g andA11 and 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 terminals,the PGM-FImain .elay, aod the fu3e box.
MoasuroD4 IND Voh.ge: 1. Turnthe ignitionswitchOFF. 2. Connectthe A (32P)connector to the PCM. 3. Connecta digital multitester to the 813 and A9 or A22 termtnals, switchON (ll) 4. Turnthe ignition and makesure that the vokage for is available t\ivoseconds.
BRN/8LK
'96: BLU/RED '97, '98: GRN/BLK
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
Troubleshooting Flowchart E IndicatorLight On Constantly
The E indic.tor light b on con3lently {not blinking}whenever the ignition switch b ON {lll.
Me.sure Dil IND Voltage: 1. Turnthe ignitionswitchOFF. 2. Disconnect B (25P)connecthe tor from the PCM. 3. Turnthe ignition switch (ll). ON 4. Measure voltagebetween the t h e 8 1 3t e r m i n a a n d b o d y l ground.
PCMCONNECTORI25PI B
WIRESIDEOF FEMALE TERMINALS Repairshort to power in the wire betweon the 813 terminal and the gauge a$embly.
MeasuraATP D{ Voltage; 1. Turnthe ignitionswitchOFF. 2. Connect B (25Piconnector the to the PCM. 3. Turnthe ignition switch {ll). ON 4. Shiftto any position otherthan
D;.
5. Measure voltagebetween the 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
Flowchart BrakeSwitch Signal Troubleshooting

Symptom Shift lav6r crnnot be movod liom E porition whh the bt.ko Pedal
Ch.ck Brr*. Light Op.r.tion: Oeoress brakepedal. the
Are the braklights ON?
Rapairtaulty brake switch circuit l3oorction 231.
PCMCONNECTORS M.arur. STOP Sw voh.gc: 1. Turnthe ignitionswitchOFF. 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 betwen the D5 and Ag or A22 terminals with the brake peclal depressd.
TERMINALS WINES|DEOF FEMALE
ls there battoryvoltsge?
Rop.ir opan in thc wiro btwcen 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
1. Disconnect 2P connectorfrom the lock-upcon the trol solenoid valveAy'B assembly. TERMINAL OF SIDE MALE TERMINALS
Replacement
NOTE:Lock-up controlsolenoid valvesA and B must be removed/replaced an assembly. as 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 solenoid valveA,/B assembly.
6 x 1.0mm 12 N.m {1 .2 kgt.m, 8.7 lbl.ltl
FILTER/GASKET Replace.
LOCK.UP CONTROL SOLENOID VALVE A/B ASSEMBLY 2. Measure the resistance betweenthe No. 2 terminal ( s o l e n o i d a l v eA ) o f t h e l o c k - u p o n t r o ls o l e n o i d v c valveconnector and body ground,and betweenthe No. 1 terminal{solenoid valveB} and body ground. STANDARD: - 25 O 12 R e p l a c eh e l o c k - u p o n t r o ls o l e n o i d a l v ea s s e m t c v bly if the resistance out of specification. is lf the resistance within the standard, is connectthe No. 1 terminalof the lock-upcontrolsolenoidvalve connector the bafterypositive to terminal. clickjng A soundshouldbe heard. Connect No.2 terminal the to the batterypositive terminal. clicking A soundshould be heard.Replace lockup controlsolenoid the valve assembly no clicking if soundis heard.
Clean mountingsurface the and fluid passages.
Cleanthe mounting surfaceand fluid passages of t h e l o c k u p c o n t r o ls o l e n o i d a l v e a s s e m b l ya n d v , installa new lock-up controlsolenoid valveA,/B with a new filter/gasket. Checkthe connector rust,dirt or oil, and reconfor nectrt securely.
Shift ControlSolenoidValveA/B Assembly

Test
1. from the shift control the Disconnect 2P connector valveA'lBassembly. solenoid
Replacement
NOTE: Shift control solenoidvalves A and B must be as removed/replaced an assembly. 1. solenoid the Remove mountingboltsand shiftcontrol valve4!/Bassembly.
6x1.0mm 12 N.m {1.2ksl.m,8.7 lbt'ft}
BRACKET CONNECTOR
CONTROL SHIFT A/8 VALVE SOLENOID ASSEMBLY '1 betweenthe No. terminal Measure the resistance (solenoid valve valveA) of the shift controlsolenoid and body ground,and betweenthe No. 2 connector valveB) and body ground terminal(solenoid 12 STANDARD: - 25 O Replace shift controlsolenoidvalve assemblyif the is the resistance out of specification. connectthe is lf the resistance within the standard, v 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 d a l v e terminal.A clicking to connector the batterypositive the No. 2 terminal sound should be heard.Connect A t t o t h e b a t t e r yp o s i t i v e e r m i n a l . c l i c k i n gs o u n d the should be heard.Replace shift control solenoid sound is heard. if valveassembly no clicking
FILTER/GASKET the Clean mountingsurface Replace. and fluid passages.
2,
2.
of Cleanthe mounting surfaceand fluid passages 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 with a installa new shift controlsolenoidvalveA,/B and new filter/gasket the clamp bracket. for Checkthe connector rust, dirt or oil, and reconnectit securely.
3.
14-75
Linear Solenoid Assembly

Test
1. Disconnect linearsolenoid the connector. 6.
LINEAR SOLENOID 7.
I
lf not, removethe linearsolenoid assembly. Check that the linearsolenoid fluid passage dust for or qrn. 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 connector the batterypositiveterminaland con to nectthe No. 1 terminalto the batterynegative termi, nal.Check that the valvemoves. Disconnect one of the batteryterminalsand check that the valvereleases. NOTE: You can see the valve movement through the fluid passage the mountingsurfaceof the linin ear solenoid assembly.
8.
LINEAR SOLENOID
2.
Measurethe resistance betweenthe No. 1 and the N o .2 t e r m i n a l o f t h e l i n e a r o l e n o i d o n n e c t o r . s s c STANDARD: approx. 5 O lf the resistance out of specification, is replacethe linearsolenoidassembly. Connect No. 2 terminalof the linearsolenoid the connectorto the batterypositiveterminaland connect the No. 1 terminalto the batterynegative terminal. A clicking soundshouldbe heard.
,.-,.
VALVE
9.
lf the valve binds. or moves sluggishly, or the linear solenoid does not operate, replacethe linear solenoid assemory.
14-76
Mainshaft/Countershaft SpeedSensors
Replacement
1. Remove the mounting bolts and the linear solenoid assemDly.
Replacement
1. speed Removethe 6 mm bolt and the countershaft sensorfrom the right sidecover
6x1.0mm 12 N.m {1.2kgJ.m, COUNTERSHAFT 8.7 rbr.frl SPEED SENSOF 5x1.0mm 12 N.m (1.2kgf.m, 8.7 tbf.ftl O.RING Replace. MAINSHAFT SPEED SENSOR
the mountingsurface Clean and fluid passages.
@ @
GASKET LINEAR SOLENOID ASSEMBLY
SPEED MAINSHAFT WASHER SENSOE engine) {D16Y7 6x1.0mm 12 N.m 11.2 kgl.m, 8.7 tM.ft)
of and fluid passage the Cleanthe mountingsurface housing. and transmission assembly linearsolenoid Installa new linear solenoidassemblywith a new gasket. the NOTE:Do not pinch the gasketwhen installing is that the gasket installed makesure linearsolenoid; properlyin the mountinggroove of the linearsolenord. 4. for Checkthe linearsolenoidconnector rust,dirt or oil, and connectit securely.
s 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 t p e e d housing. senso.from the transmission the Repiace O-ringwith a new one beforeinstalling speed or speedsensor the mainshaft the countershaft sensor. washeron speedsensor NOTE:Installthemainshaft the mainshaftspeed sensor.The mainshaftspeed w s e n s o r 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.
14-77
Symptom-to-Component Chart
Hydraulic System
\
SYMPTOM Engineruns,but vehicledoes not move in any gear. Vehiclemovesin p. E, but not in pel,@, position. Vehiclemovesin E, E, E. but not in E position. Vehiclemovesin E, E, E, but not in E position. Vehiclemovesin E position. Excessive vibration. idle Pooracceleration; flareson starting in ro.. @ position off Stallrpm high in lDl, E, El position. Stallrpm high in E, l,- position. Stallrpm high in E position. i Stallrpm is in specification. Stallrpm low. No shift Failsto shift in @, @ position; from 1stto 3rd gear pl, @ position; Failsto shift in from 'lsrto 4th gear Erratic upshifting. 1-2upshift, upshift.3-4 2-3 upshift 1-2upshift
2-3 uDshift
Check theseitemson the PROBABLE CAUSE LiSt 1,2,3,5,6,'t,36,38 6, 8, 9, 10,30, 54 6,11,12,24 4 , 6 ,1 4 ,1 5 10, 12,13,14,16,29, 33,34. 35 1 , 2 , 1 9 , 3 2 , 3 64 5 ,4 7, 4 8 , 1 , 2 , 3 , 6 , 3 A4 ' l , 6, 8, 10 6,12
14
Check theseitemson the NOTES List K,L,R,S
c,M,o
C,L
c,L,o
C,D
B.K.L K.L,R
C,D C,D
N R G,L
17, 32, 45,47. 48 't9,20,40, 48,49 22, 49 22, 23, 4A 58 21, 48 22, 49 23, 48 1 2 ,1 9 ,2 0 , 2 9 , 0 , 5 1 , 5 , 5 8 5 1 13,19,20,24,21,29,50,51,57,58 14, 19,20,25,28,29,50,51. 57,58 1 9 , 2 0 , 2 44 3 ,5 4 , 5 75 8 , , 12,'19,20,25, 43,55,57 58 , 13, 19,20,26, 43,56,57,5A 1 3 ,1 9 ,2 0 , 2 4 , 7 , 5 1 2 14, 19, 20, 25, 2A,5'l 13,19,20,24,27, 43,50,51, 58 14, 19,20,25,28,43,50,51 58 , 1 0 ,3 0 4,14,21,53 2,37 17 6, 39 19,48, 49
_ Harshupshift{1,2). Harshupshift{2-3). Harshupshift(3-4). Harshdownshift(2-1) Harshdownshift(3-2). Harshdownshift(4-3). Flares 2-3 upshift. on Flares 3-4 upshift. on Excessive shockon 2-3 uDshift. Excessive shockon 3-4 upshift. Lateshift from E positionto E or lE! position. Lateshift from E positionto E positron. Noisefrom transmission all shift leverpositions. in Vehicledoes not accelerate morethan 31 mph (50 km/h). Shift leverdoes not operatesmoothly, Failsto shift;stuckin 4th gear.
3-4 upshift
\
C,D,E,H,L
C ,D ,E ,I , L
o
C,D.E,H C, D, E, I E,L,N E,L,N E.L,N M
o
K,L,O P P D.K.O
F I
Transmission not shiftintoparking will gearin E] position. 6, 18.39 Stallrpm high; all clutchpressures in specification. are 41 Lock-up clutchdoes not disengage. 19, 44,45,46,47,50,51, 58 '19,4't, Lock-up clutchdoes not operate smoothly. 44, 45, 46,47, 50, 51, 58 't9, Lock-up clutchdoes not engage. 41,44,45,46,47,50. 51,57, 58 Vibrationin all positions 36
E,L
14-78
.
PROBABLE CAUSE 2 ATF pump worn or binding.

Regulator valve stuck.
42 43
44
5 6 7 I 10 l1
14
tc
Servo valve stuck. worn/damaged. Mainshaft of Shiftcablebroken/out adjustment. Finalgearsworn/damaged. clutchworn/damaged. One-way {sprag) (2 1stgearsworn/damaged gears). 1st clutch defective. (2 2nd gearsworn/damaged gears)2nd clutch defective. 3rd clutchdefective. 4th clutch defective. (3 gearsworn/damaged gears). Reverse ATF Excessive one-wayclutchdefective. Torqueconverter defective. Paking mechanism defective. Linearsolenoidassembly CPCvalve stuck. 1-2shiftvalvestuck. 2-3 shiftvalvestuck. 3-4 shift valve stuck. defective. 2nd accumulator defective. 3rd accumulator 4th accumulatordefective. stuck. 2nd orificecontrolvalve 3-4 orificecontrolvalvestuck. Foreignmaterialin main orifice.
Foreign material in 1st orifice.
45 46 47 48 49
5U
52
53
54
16 17 18 19
58
plate. Foreignmaterialin separator CPBvalvestuck. Lock-up timing valvestuck. Lock-up shift valvestuck. controlvalvestuck. Lock-up pistondefective. Lock-up valveA defective. Shiftcontrolsolenoid valveB defective. Shiftcontrolsolenoid valveA defective. controlsolenoid Lock-uD valveB defective. Lock-uo controlsolenoid Servocontrolvalvestuck. defective. 1staccumulator orifice. Foreignmaterialin 2nd exhaust orifice. Foreignmaterialin 3rd exhaust orifice. Foreignmaterialin 4th exhaust sDeed sensordefective. Mainshaft sensordefective sDeed Countershatt
20
21
27
28 29
30 31
32
33
34
38
orifice. Foreignmaterialin reverse Engineoutput low, worn/damaged. Needlebearing Thrustwasherworn/damaged. incorrect. Clutchclearance misasplatedefective transmission or Drive sembly. housingor transmlsslon Torqueconverter worn/damaged. housingbearing clogged. ATFstrainer or Joint in shift cableand transmission body valvestuck. Modulator
40
(cont'd)
14-79
Symptom-to-Component Ghart
Hydraulic System (cont'dl
The followingsymptomscan be caused by improperrepairor assembly Vehicle creepsin N position. Vehicle does not move in .S or @ position. Transmission locksup in E position Excessive drag in transmission. Excessive vibfation,rDm related,
Noise with wheels moving only.
\ Check these items the on PROBABLE CAUSE DUETO IMPROPER REPAIR List
R 1 ,R 2 R4 R 3 ,R 1 ' 1 R6 R7 R5 R8 R 9 ,R 1 O
Items on the NOTES List
K,R
Main sealpops out. Variousshiftingproblems.
PROBABLE CAUSE DUETO IMPROPER REPAIR R1 R2. R3. R4. R5. R6. R7. R8. R9, R10. R11 lmproperclutchclearance.
lmproper gear clearance.
Parking brakeleverinstalled upsidedown. (sprag) One-way clutchinstalled upsidedown. Reverse selector hub installed uDside down. A T Fp u m pb i n d i n g . Torqueconverter fully seatedin ATF pump. not
Main seal improperly installed.
Springsimproperlyinstalled. Valves improperlyinstalled. Shiftfork bolt not installed.
14-80
NOTES page14-155 and 156. Seeflushingprocedure, 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. lf the large clutch piston O-ring is broken, inspect the piston groove for rough machining'
c.
D.
E.
for the worn, inspect otherclutches wear,and checkthe orifice or lf the clutchpackis seized is excessively lor controlvalves,CPCvalveand linearsolenoid free movement for the lf the linearsolenoidis stuck,inspect clutches wear. has will closed, transmission not upshift lf stuckopen,the transmission the lf the l-2 shift valveis stuck no lst gear. for the lf the 2nd oriticecontrolvalveis stuck,inspect 2nd and 3rd clutchpacks wear. the It the 3-4orificecontrolvalveis stuck,inspect 3rd and 4th clutchpacksfor wear' will closed, transmission not shift out of 1stgear' the controlvalveis stuck lf the clutchDressure The housingmay causeATF pump seizure. or lmproperalignment main valvebody and torqueconverter squeaktickingnoiseor a high-pitched symptomsare mostlyan rpm related
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.
H.
t.
J,
K.
L.
N.
o.
P,
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 sbpeeacrtitn g b a l l he The the housing.lf oK, replace right sidecoveras it is dented. movementin the transmission for excessive worn O-ringunderthe guide is probably lf , Replace mainshaft the bushing the 4th feed pipeis looseor damaged. the 4th feedpipeis damfor if the the agedor out of round,replace rightsidecover. . Replace mainshaft the bushing the 1stfeed pipeis looseor damagedll the 1stfeedpipeis dam for if the it. agedor out of round,replace _ while in spragclutchis mostlya resultof shiftingthe transmission iD1or lDaposition A worn or damaged the suchas rocking vehiclein snow. the wheelsrotatein reverse, the Inspect lrame for collisiondamage. for Inspect damageand wear: gearteethchamters selector 1. Reverse gear' 4th oI teethchamlers countershait and reverse 2. Engagement 3. Shifttork for scuffmarksin center. pinionshaftfor wear underpiniongears 4. Differential 5. Bottomof 3rd clutchfor swirl marks grindingor whirringnoise, makesa clicking, lf items1, 2, 3 and 4 if worn or damaged. transmission Replace to 4th idlergear,and countershaft gearin addition 1,2,3 or 4' 4th mainshaft gear,reverse afsorepface and ATFstrainer, thoroughly and replace assembly, differential pinionshaftis worn, overhaul lf differential coolerand lines Ilushtorqueconverter, clean transmission, and the gearnoise, replace countershaft finaldriven makes lf bottomof 3rd clutchis swirledandtransmission gear. You the housingwhen replacing main ball bearing. Be very carefulnot to damagethe torqueconverter pump when you torquedown the main valvebody.This will resultin ATF pump may alsodamagethe ATF Usethe propertools. if seizure not detected. lf housing. you push it into the torqueconverter Install the main sealflush with the torqueconverter and resultin damage' housinguntil it bottomsout, it will blockthe fluid returnpassage
o.
S.
14-81
RoadTest
NOTE:Warm up the engineto normaloperating (the radiatorfancomeson). temperature '1. Apply parkingbrake and block the wheels.Start the engine,then shift to E positionwhile depressing the brake pedal.Depress accelerator pedaland release suddenly. the it The engineshouldnot stall. Repeat sametest in E position. Test-drive vehicleon a flat road in the E] position. the Check that the shift pointsoccurat approximate speeos snown on a flat road.Also checkfor abnormalnoiseand clutchslippage. NOTE:Throftlepositionsensorvoltagerepresents throttleopening. the a. Unboltthe PCMfor roadtesting;referto page 14-46. b Set the digital multitester checkvoltagebetweenD1 (+) terminaland A9 {-) or A22 l. l terminalof the pCM for to the throttlepositionsensor.
2.
BACKPROBE ADAPTER
BACKPROBE SET 07sAz- 001000A Itwo requiredl
DIGITAL MULTIMETER lCommerciallyavailablel KS-AHM-32-003. or equivalent
PCMCONNECTORS
B {2sP)
c {31P)
&l Position: Dl6Y7 engine Upshift Throttle Opening Throttlepositionsensor voltage: 0.75V Throttlepositionsensor v o l t a g e : 2 . 2V 5 Fullyopenedthrottle Throttlepositionsensor voltage:4.5V Downshift Throttle Opening throttle Fully-closed Throttlepositionsensor voltage:0.5V throttle Fully-opened Throttlepositionsensor voltage:4.5V -9. Position: D16Y8engine Upshift Throttle Opening Throttlepositionsensor voltage:0.75V Throttlepositionsensor voltage: 2.25V throttle Fully-opened Throttlepositionsensor 4.5 voltage: V
Downshift
Unit of speed
mpn km/h
lsl + 2nd
znd * 3rd
1t _ a'f
3rd -
ilth
Lock-upON 2 1- 2 4
9-12 15- 19 21-25 34-40 40-45 65-73
28-32
45-52 59-65 9 5- 1 0 4 101- 112 102- 115 163 180
34-39
99 - 108 99 - 109 ' t76 159-
mph km/h mph

km/h
33-38
53-61
Unit of sDeed
mpn km/h
Lock-upOFF 19-22 30-35 9 5- 1 0 5 1 5 3- 1 6 9
4th * 3rd 1 7- 2 0
3rd + 2nd
2nd * lst
6-9(3rd-1st) 10- 15 (3rd* 1st)
mph km/h
85-95 137 153
54-61 87-98
25-30 40-48
Unit of speed mph

km/h mph km/h mph
lst * 2nd 9-12 15-l9 34-40
2nd + 3rd
3rd + 'lth
Lock-upON
20-23 32-37
40-45 65-73 62-70
28-32 45-52 9 5- 1 0 4 '107 96 155- 172
2't- 24 34-39
62-67 99 - 108 9 5- 1 0 6 1 5 3- 1 7 0
km/h
52-60
100 113
Throttle Opening Fully-closed throttle Throttlepositionsensor v o l t a g e : 0 .V 5 throttle Fully-opened Throttlepositionsensor voltage:4.5V
Unit of speed
mph
Lock-upOFF
ilth - 3rd
3rd - 2nd
2nd - lst
19-22 30-35
91 101 1 4 7- 1 6 3
1 1- 2 0
6-9(3rd- 1st) ' 1 0 1 5 ( 3 r dlstl
km/h mpn
km/h
85-95 1 3 7- 1 5 3
54-61 87-98
25-30
40-48
NOTE: v o L o c k - u O N : T h el o c k - u p c o n t r s o l e n o i d a l v eA t u r n sO N . ol p va . Lock-uo lock-up controlsolenoid lve A tu rns OFF. OFF:The
(cont'd)
14-83
RoadTest
(cont'dl
Accelerate about 35 mph (57 km/hl so the transmission in 4th, then shift from E to is vehicleshouldimmedistely beginslowingdown from enginebraking. positionto @ position. The
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. Check abnormalnoiseand clutchslippage the followingpositions for in E (2nd cear) Position a. Accelerate trom a stop at full throttle.Check that there is no abnormalnoiseor clutchslippage. b. Upshifts and downshifts shouldnot occurwith the selector this oosition. in Position E (Reverse) 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. Release brake; vehithe the 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 lver whils raising th sngine spoed. . Bs sure to rsmove ths pressuregauge beforg lgting stall sPeed. '1. Engage parkingbrake,and blockthe front wheels. the 2. 3. 4. 5. 6. to a Connect tachometer the engine.and startthe engine Makesurethe IVCswitchis OFF. fan temperature {the radiator comeson), shift into E position. Afterthe enginehaswarmed up to normaloperating and noteenginespeed' for the Fullydepress brakepedaland accelerator 6 to 8 seconds, then repeatthe test in E and E positions. Allow two minutesfor cooling, NOTE: purposes only . Stallspeedtestsshouldbe usedfor diagnostic . Stallspeedshouldbe the same in E, E and E positions. Stall Speed RPM: Spocmcation:2,700rpm ServiceLimit: 2,550- 2,850rpm TROUBLE stall rpm high in ld, El and E positions CAUSE PROEABLE Low tluid levelor ATF pump output ATF strainer Clogged valvestuckclosed Pressure regulator Slippingclutch . Slippage 4th clutch of . Slippage 2nd clutch of . Slippag lst clutchor 1stgear one-wayclutch of . Engineoutputlow ' Torqueconvenerone-wayclutchslipping
Stallrpm high in E position Stallrpm high in E position Stallrpm high in E position stall rpm low in E, E and E Positions
14-85
FluidLevel
Checking/Changing
CAUTION: While checking 8nd changing, bo sure not to allow du3t and other foreign particles to nter into the transmission.
Changing
CAUTION: Keop all of the toreign particles out of the transmiasion, 1. Bringthe transmission to operating up temperature 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 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:lf a coolerflusheris to be used,seepage 141 5 5a n d 1 5 5 . 2. Reinstall drain plug with a new sealingwasher, the then refill the transmission with the recommended fluid* to the uppermark on the dipstick. Automatic Transmi$ion Fluid Capacity: 2.7 I 12.9 qa,2-1lmp qt) at chang. US 5.9 / {6.2 US $, 5.2 lmp qt} at overhaul RecommendedAutomatic Transmisrion Fluid: Genuine Honda Prmium Formula Autometic TransmissionFluid (ATF).. TRANSMISSION RIGHT SIOE COVEF
Checking
CAUTION: Keep all of th loreign particles out of th transmission. NOTE:Checkthe fluid level with the engine at normal operating temperature fan {the radiator comeson}. l. 2. Parkthe vehicleon level ground. Turn off the engrne. Removethe dipstick(yel low loop) from the transmission,and wipe it with s cleancloth.
I
\ \ \
\\ l V l
0OIPSTICK LOOPI IYELLOW 4.
tl
UPPER MARK LOWER MARK
3 . Insertthe dipstickinto the transmission.

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 between the upperand lower marks. lf the levelis belowthe lower ma.k, pour the recommendedfluid+ into the filler hole to brino it to the uppermarK. Insertthe diDstick back into the trsnsmission the in direction shown. FRONT
DRAIN PLUG 1 8x 1 . 5m m 49 N.m {5.0kgf.m,36lbttr)
SEALING WASHEE Replace.
* Alwaysuse Genuine HondaPremiumFormula AutomaticTransmission Fluid (ATF). Usinga nonHonda ATF can affect shift qualitv.
Installthe dipstick the extent in ol the direction shown.
Testing Pressure
@ tosting, be careful of the rotating tront wheels . While

. 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. 2. 3. the Raise vehicle(seesection1). then stop the engineand connecta tachometer. Warm up the engine, gaugesto eachinspection hole. the Connect oil pressure 18 TOROUE: 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 PRESSUBE GAUGE SETWPANEL 07406 - 0020400
HOSE A/T OIL PRESSURE ADAPTER 07MAJ - PY,(}l20 (4 roquirodl
GAUGE A/T LOWPRESSUBE SET WPANEL 07'r()6 0070300
HOSE A/T OIL PRESSURE 2.10 mm 07MAJ - PYiOllA {{ rsquirodl
pressure follows as the Startthe engine,and measure respective a Line Pressure . 1stClutchPressure . 2nd.3rd and 4th ClutchPressure torque. hole,and tightento the specified Installa new washerand the sealingbolt in the inspection 18 TOROUE: N.m (1.8kgf.m,13 lbf'ft| washers washers; alwaysreplace NOTE:Do not reuseold sealing
(cont'd)
14-47
Pressure Testing
(cont'd)
a Line Pressure/1stClutch PressureMeasurement 1. 2. 3. Setthe parkingbrake, and blockboth rearwheelssecurely. Runthe engineat 2,000rpm. line pressure, Shiftto E or E posltion, then measure may be indicated measurements made in shift leverpositionsotherthan E or fl posiif are NOTE:Higherpressure tion. 4. lst Shiftto E position, then measure clutchpressure.
PRESSURE 1STCLUTCH HOLE INSPECTION (Marked with "L")
LOCK.UP CONTROL VALVE SOLENOID A/B ASSEMELY
VALVEA/B ASSEMBLY
PRESSURE Line
SHIFTLEVER POStTtON
FLUIDPRESSURE SYMPTOM No {or low) lrnepressure
CAUSE PROBABLE
Standard Torqueconverter, ATF pump, pressure regulator, torqueconverter checkvalve 1 s tC l u t c h 830 - 880 kPa (8.5- 9.0 kgf/cm' , 1 2 0- 1 3 0p s i ) SrvicLimit 780 kPa {8.0kgf/cm,,110psi)
Eo.E
'1st Clutch
Noor low 1st pressure
14-88
2nd, 3rd rnd 4th Clutch Ptassurc Mclrurcmanl
LINEARSOLENOID
1 . Set the psrking brake,and block both tear wheels

sscurely.
2. Disconnect linsarsolenoidconnector. the 3. Startthe sngine,and run the engineat 2,000rpm.

4. eachclutchpresShift to E position,and measure sure, Connectbattery voltage and ground lo the linear solenoid connectrtgrminals,then msasure each clutch pr6ssure. 1THCLUTCH
INSPECTIONHOI.I (M.rkedwith "4")
5.
PRESSURE CLUTCTI
HOLE INSPECTION PRESSURE
PfiESSURE
2nd Clutch
SHIFT I.EVER POSmON
FLUID PRESSURE SYMPTOM

No or low 2nd pressure
PROBABI.E CAUSE
Standard 2nd Clutch 800 - 850 kPa (8.2- 8.7 kg7cm', 120- l2il psi) with the linearsolenoid disconnec'ted 0- 150kPa (0-1.5kgflcm' , 0 - 21 psi) with the linearsolenoid connectedto battery voltageand ground 810- 860 kPa (8.3- 8.8 kgflcm', 1 1 8- 1 2 5p s i ) with the linearsolenoid disconnected 0 - 150kPa (0-1.5kgf/cm' , 0 - 21 psi) with the linearsolenoid connectedto battery voltageand ground
ServiceLimit 760 kPa (7.7kgf/cm,,110psil with the linearsolenoid disconnected
Above 150 kPa {1.5kg?cm,,2l psi) with the linearsolenoid connectedto battery vollage and ground 765 kPa (7.8kgf/cm' ,111psi) with the linearsolenoid disconnected
3rd Clutch
No or low 3rd pressure
3rdClutch
ilth clurch
No or low 4th pressure
4th clutch
ts
Servo Valve or 4th Clutch
Above 150 kPa (1.5kgf/cm' . psi) 21 with the linearsolenoid connectedto battery voltage and ground
14-89
Transmission
Removal
@ suie lifts, Make
4.
iacks and safety stands are placed properly, and hoist bracket are aftached to the colrect 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.
groundcable,and disconRemove transmission the nectthe lock up controlsolenoid connector.
CAUTION: Use fender covers to avoid damaging painted surfaces. 1. ( D i s c o n n e c t 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 th the battery, then removethe positive(+)terminal. Remove intakeair duct. the D16Y7 engine: Remove intakeair duct and resonator. the D16Y8 engine: R e m o v eh e i n t a k e i r d u c ta n dt h e a i r c l e a n e h o u s t a r ing assembly. R e m o v e 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 t the startermotor. 5.
MOTORCABIE VEHICLE SPEED
2.
Disconnect vehiclespeedsensor(VSS)connec, the tor and the countershaft speedsensorconnector.
MOTOECABLE
14-90
6.
Removethe transmissionhousing mounting bolts and the rearenginemountingbolt.
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 f t r a n s m i s s i o nl 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 sealing washer.
DRAINPLUG 1 8x 1 . 5m m 49 N.m (5.0 kgf.m,36 lbf ftl
7.
the Disconnect shift controlsolenoid, linearsolethe sDeed sensorconnectors. noid.and the mainshaft
9. SHIFTCONTROL SOLENOIO CONNECTOR LINEARSOI.ENOID CONNECTOR Remove the splash shield.
SPLASH SHIELD CONNECTOR BRACKET
(cont'd)
14-91
Transmission
(cont'dl Removal
10. Removethe cotter pins and castlenuts.then separate the balliointsfrom the lowerarms(see section 18).
DAMPER PINCH BOLT
16. Remove the shift cablecover,then removethe shift cableby removingthe controllever. CAUTION: Take care not to bend the shift cable.
SHIFTCABLE
:\
NUT FORK FORK BOLT COTTER PIN Replace.
CONTROL SHAFT
1 1 . R e m o v e 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 t r i g h td a m p e r o r ka n d d a m p e r . f 12. Prythe rightand leftdriveshafts of the differential. out j P u l lo n t h e i n b o a r do i n ta n dt h e r i g h ta n d l e f td r i v e shaftslseesection16). 1 4 . Tie plasticbagsover the driveshaft ends. NOTE:Coatall precision finished surfaces with clean engine il. o Remove exhaustpipeA. the N O T E :D ' 1 6 Y 8 n g i n e i s s h o w n ; D 1 6 Y 7e n g i n ei s e s i mi l ar .
WASHER
1 1 . Remove the rightfront mount/bracket. 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 lines.Turn the ends of the ATF cooler hosesup to preventATF from flowing out, then plug the ATF coolerhosesand lines. 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 e t t h e h o s e a joints.
ATF COOLER LINE
Y;
"): ,
*S9e,
SELF.LOCKING NUT Replace. A EXHAUSTPIPE
Replace.
RIGHTFRONT MOUNT/BRACKET
HOSE
14-92
a 1 9 . R e m o v e h e e n g i n es t i f f e n e r n d t h e t o r q u ec o n t vertercover.
and raise the 23. Placea jack under the transmission, just enoughto take weight off of the transmission mount. mounts,lhen removethe transmisslon TRANSMISSION MOUNT BRACKET
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
pulley. while rotating the crankshaft 2 1 . Remove distributor. the to 2 2 . Attacha hoistingbracket the engine.then lift the s engine lightly. 2 4 . R e m o v e h e t r a n s m i s s i o h o u s i n gm o u n t i n gb o l t s t n m b a n dt h e r e a re n g i n e o u n t i n g o l t s . away from the engine until it 25. Pull the transmission the 14 mm dowel pins, then lower it on the clears transmission iack.
REARENGINE MOUNTINGBOLTS Replace.
HOUSING TRANSMISSION MOUNTINGBOLTS
removethe torque convener and the 26. lf necessary, stanermotor.
14-93
lllustrated lndex
Transmission/Right Cover Side
(, @ O @ O @ O @
ROLLER COLLAR o-RtNGReplace. FEEDPIPEFLANGE o-RINGReplace. SNAPRING 3RDcLUTcH FEED PIPE LOCKNUT NUT) COUNTERSHAFT {FLANGE 23 x 1.25mm Replace. RepIace, SPRING WASHER O CONICAL GEAR @ PARKING @ ONE-WAYCLUTCH 1ST @ COUNTERSHAFT GEAR BEARING @ NEEDLE 1ST @ COUNTERSHAFT GEARCOLLAR o-RlNGs Replace. @ Rep|ace. SIDECOVER GASKET @ RIGHT @ DowEL PINS BRAKEPAWLsToP @ PARKING Reptace. @ LocK WASHER part BRAKE STOPSelective @ PARKING BRAKELEVEB @ PARKING ERAKELEVERSPRING @)PARKING @ DRAINPLUG WASHER RepIace. @ SEALING o-RINGReplace. @ SENSOR SPEED @ COUNTERSHAFT BRAKEPAWL @ PARKING BRAKEPAWLSPRING @ PARKING PARKING BRAKEPAWLSHAFT @ ASSEMBLY @ LINEARSOLENOTD RepIace, SOLENOID GASKET @ LTNEAR
@ @ @ @ @ @ @ @ @ @ @ @ @ @ @ @ @ @ @ @ @ @ @
RIGHT SIDECOVER PIPE lsT cLUTcHFEED o-RlNGsReplace. FEEDPIPEFLANGE SNAPRING NUTI21 x 1.25mm MA|NSHAFT LoCKNUT(FLANGE Replace. WASHER Replace. CONICAL SPRING lsT cLuTcH ASSEMBLY o-RlNGs Replace. THRUSTWASHER THRUST NEEDLE BEARING NEEDLE BEARING MAINSHAFTlST GEAR MAINSHAFTlST GEARCOLLAR LINE ATF COOLER SEAL|NG wAsHERs Reptace. JoINT BoLT ATF DTPSTICK ATF COOLER LINE JOINT BOLT WASHERS Reptace. SEAL|NG VEHICLE SPEED SENSOR O.RING Replace.
TOROUESPECIFICATIONS Bolt/Nut No. 6A 6B 8F 12A' 18D 21M Torque Value 12 N'm (1.2kgim,8.7 lbf.ft) '14 '10 N'm (1.4kgf.m, lbf'ft) 22 N.m (2.2kgim, 16 lbf.ft) 28 N.m (2.9kgf.m,21lbf.ft) 49 N.m (5.0kgf.m,36lbf.ft) 78 N.m (8.0kgim,58 lbf.ft) k l 1 0 3N . m( 1 0 . 5 g n m , 7 5 . 9b f . f t ) Size m 6x 1.0 m 6x1.0mm '1.2mm 5 8x 1 2x 1 . 2 5 m m 1 8x 1 . 5m m m 2 1x 1 . 2 5 m 2 3x 1 . 2 5 m m Remarks
Joint bolt D r a i np l u g Mainshaft locknut: Left-hand threads Countershaft locknut: Left-hand threads
14-95
lllustratedIndex
Transmission Housing
6A
I o
14-96
b
WASHER Replace. ill LOCK (A REVERSE FORK SHIFT REVERSE GEARCOLLAR @ couNTERSHAFT REVERSE GEAR .' COUNTERSHAFT BEARING @ NEEDLE (O REVERSE SELECTOR HUB SELECTOR O REVERSE 4TH @ COUNTERSHAFT GEAR BEARING O NEEDLE part COLLAR, mm Selective 28 @ DISTANCE 2ND @ COUNTERSHAFT GEAR NEEDLE BEARING @ THRUST 3RD [3 COUNTERSHAFT GEAR (iI NEEDLE BEARING 3RD .(3 COUNTERSHAFT GEARCOLLAR (D THRUST NEEDLE BEARING (' SPLINED WASHER @)3RD cLUTcH ASSEMBLY @ o-RlNGsReplace. @ COUNTERSHAFT @ SNAPRING WASHER @ THRUST NEEDLE BEARING @ THRUST 4THGEAR/REVERSE GEAR @ MAINSHAFT BEARINGS @ NEEDLE NEEDLE BEARING @ THRUST ) MAINSHAFT4TH GEARCOLLAR @ 2ND/4THcLUTcH ASSEMBLY @ o-RlNGsReplace. part WASHER, 36.5x 55 mm Selective @ THRUST THRUSTNEEDLE SEARING 6] 2ND GEAR @ MAINSHAFT BEARING @ NEEDLE
NEEDLE BEARING 89 THRUST @ MAINSHAFT RINGS, mm 35 60 SEALING RING, mm 29 6DSEALING BEARING 6!) NEEDLE @ SETRING VALVEA/B ASSEMBLY CONTROL SOLENOID @ SHTFT HARNESS CLAMPBRACKET @ FTLTER/GASKET Reptace. SOLENOTD 6DsHtFT CONTROL BRACKET @ CONNECTOR HANGER .O TRANSMISSION cAP @ BREATHER sPEED sENsoR @ MAINSHAFT SPEED SENSOR WASHER ENgiNEI {O16Y7 @ MAINSHAFT @ o-RINGReplace. @ SNAPRING TRANSMISSION HOUSING BEARING @ MAINSHAFT (5] COUNTERSHAFT TRANSMISSION HOUSING BEARING IDLER GEARSHAFTHoLDER ASSEMBLY @ REVERSE BEARING D NEEDLE 6, olL SEALReplace. part 80 @ SETRING, mm Selective HOUSTNG d]TRANSMISSION IDLER GEAR @ REVERSE @ DOWELPINS Reptace. @ TRANsMtssloNHoustNG GASKET ASSEMBLY @ DIFFERENTIAL @ olL SEALReplace. 62TOROUE CONVERTER HOUSING
TOROUE SPECIFICATIONS Bolt/Nut No. 6A 6B 10A TorqueValue '12 N.m 1l.2kgf.m,8.7lbf.ft) '14 k . N . m( 1 . 4 g f . m 1 0 l b n f t ) 44 N m (4.5kgnm,33lbnft) Size 6x1.0mm 6x1.0mm 1 0x 1 . 2 5 m m Remarks
14-97
lllustrated Index
Body Housing/Valve TorqueConverter
'98 mod.l
i lll iH
t -
14-98
\
T) O @ @ .'
ATF FEEDPIPE ATF STRAINER BODY SERVO PLATE sERVo SEPARAToR SECONDARY VALVE BODY
DowEL PrNs a6)

PLATE SEPARATOR O SECONDARY BASE @ SERVODETENT PIPES O ATF FEED (o) ATF FEEDPIPES O SHAFTsToP @ coNTRoL SHAFT (} DETENT ARM SPRING (D DETENT ARM ARM SHAFT @ DETENT Replace. @ FILTER BALLS O CHECK CHECK VALVESPRING [o) TOROUECONVERTER CONVERTER CHECK VALVE @ TOROUE PINS @ DOWEL VALVEBODY @ LOCK-UP LOCK.UP PLATE SEPARATOR @ VALVE BODY @ REGULATOR
@ ATF MAGNET TOROUE HOUSTNG CONVERTER @ COUNTERSHAFT BEARING @ ATF GUIDEPLATE HOUSING CONVERTER Q] TOROUE @ olL SEALReplace. (.} MAINSHAFT TOROUE CONVERTER HOUSING BEARING @ olL SEALReplace. CONTROL SOLENOID FILTER/GASKET @ LOCK.UP Replace. @ LocK-UPcoNIRoL SoLENoIDVALVEA/B ASSEMBLY BMCKET @ CONNECTOR
PrNs @ DowEL
RELIEF VALVE SPRING @ COOLER RELIEF VALVE @ COOLER @ o-RINGReplace. @ STATORSHAFT @ STOPSHAFT PIPE @ ATF FEED @ MAIN VALVE BODY GEARSHAFT O ATF PUMPDRIVEN @ ATF DRIVENGEAB PINS @ DOWEL @)ATF PUMPDRIVEGEAR PLATE @ MAIN SEPARATOR PIPE COLLAR @ SUCTION
a
Size 6x1.0mm Remarks
TOROUE SPECIFICATIONS Bolt/Nut No. 6A TorqueValue

1 2 N . m { 1 . 2k g f . m , 8 . 7l b f . f t )
14-99
Right Side Cover

Removal
NOTE: . Clean parts all thoroughly solvent carburetor in or cleaner, drywithcompressed and air. . Blowoutall passages.
. When removingthe right sidecover,replace following: the O rings - Mainshaft and countershaft locknuts - Conical springwashers - Rightsidecovergasket Lockwasher Sealing ashers w
RIGHTSIDE COVEB
ARAKE LEVER
WASHER
lST GEABOOLLAR
JOINT BOLT
COUNTERSHAFT
SEALING WASHERS
14-100
'13 1 . Removethe bolts securingthe right side cover. then removethe right sidecover. as Slipthe special tool onto the mainshaft shown.
5. Removethe specialtool from the mainshaftafter removingthe locknuts. lst 6. Remove 1stclutchand mainshaft gearassem the l bly and mainshaft st gearcollarfrom the mainshaft. 7 . Remove the parkingbrakepawl.springand shaft. 8 . R e m o v e 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 t shaft. two jaw puller,removethe parking Usinga universal 1 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 t s t g e a r assemoty.
HOLDER MAINSHAFT o'GAB- PFs0'101
PULLER (Commercially availablel
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. and countershaft Cut the locktabs of the mainshaft locknutsusing a chisel as shown, then removethe locknuts and conicalspringwashers. CAUTION: Keep all of the chisoled particles out of tho transmiS3ion. NOTE: . Mainshaftand countershaftlocknutshave lefthandthreads. . Always wear safety glasses. '10. R e m o v e 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 t 1stgearcollarfrom the countershaft.
1 1 . Remove the ATF coolerlinesand ATF dipstick.
CHISEL
LOCKNUT
LOCKTA8
14-101
Transmission Housing
Removal
HOUSING TRANSMISSION MOUNTINGEOLTS 18 Bolts TRANSMISSION HANGER
MAINSHAFT SUB.ASSEMBL
MAINSHAFT SENSOR WASHER (D16Y7 engine)
SPEED SENSOR
TRANSMISSION HOUSING GASKET
TOROUE CONVERTER HOUSING
14-102
-
NOTE: 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 air. and dry with compressed cleaner, . Blow out all passages. h . 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 n o u s i n g ,r e p l a c e the following: - O-ring - Transmission housinggasket * Lockwasher ' t . Remove speedsensorfrom the transthe mainshaft missionhousing. 2. Removethe transmissionhousing mounting bolts ano nanger. Align the spring pin on the control shaft with the housinggrooveby turning the control transmission shaft,
gear with the colreverse Remove the countershaft lar and needlebearing. Removethe lock bolt securingthe shift fork. then removethe fork with the reverseselectorfrom the countershaft. 7. a t R e m o v et h e c o u n t e r s h a fs u b - a s s e m b l y n d t h e together. mainshaft sub-assembly
MAINSHAFT SUB,ASSEMBLY
COUNTERSHAFT SU8-ASSEMBLY
8.
Removethe differentialassemblyfrom the torque housing. converter
PULLER HOUSING 07HAC PKa010A housing, tool on the transmission lnstallthe special 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/Valve Body
Removal
6x1.0mm
1
ATF FEEDPIPE x 1.0mm 2 Bolts
PIN VAL LOCK-UP BODY IOCK-UPSEPARATOR PLATE 6x1.0mm SEBVODETENT BASE ATF FEED CONTROL SHAFT OETENT ARM SHAFT
TF STRAINER
REGULATOR VALVEBODY
DOWEL COOLER RELIEF VALVE
x 1.0mm 7 Bolts
TOROUE CHECK VALVE
DETENT ARM
SERVOSODY SERVOSEPARATOR PLATE
ATF FEEO PIPE 6x1.0mm 5 Bolts MAIN VALVE 6x1.0mm 3 Bolts SHAFT STOP
BODY
ATFPUMP GEARSHAFT ATF PUMP DRIVEN MAIN SEPARA PLATE
VALVEBODY
PIN
ATF PUMP ORIVE GEAR
SECONDARY SEPARATORPLATE
14-104
NOTE: o Clean all parts thoroughly in solvent o. carburetor air. cleaner, and dry with compressed . Blow out all passages. . When removingthe valvebody, replace O-ring. the 1. Removethe ATF feed pipes from the servo body, valvebody and main valvebody. secondary 2, Remove the ATF strainer and servo detent base (two bolts). 3. Removethe servo body and servo separatorplate (seven boltsl. valve body, shaft stop and Removethe secondary plate(threebolts). secondary separator plate Remove the lock-upvalve body and separator bolts), {seven Remove the regulator valvebody {one bolt).
t 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 r h o r air, oughly with compressed then checkthat it is in good condition, and the inletopeningis not clogged.
INLETOPENING
1 4 . Test the filter by pouring clean ATF fluid through
7 . Removethe stator shaft and stop shaft, Remove detentspringfrom the detentarm. then the remove the control shaft from the torque converter housing. Removethe detentarm and detentarm shaft from the main valvebody.
i t t h e i n l e t o p e n i n g .R e p l a c eh e A T F s t r a i n e r f i t i s or clogged damaged. NOTE:The ATF strainercan be reused if it is not croggeo.
1 0 . Remove main valvebody (fivebolts). the

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 . Remove ATF pump driven gear shaft,then remove the 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 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 valve body. Caps with a projected tip on each end are installed with the smaller tiD toward the inside oI the valve 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 .
Capswith hollow ends are installed with the hollow end awayfrom the insideof the valvebody. CaDs with notchedends are installed with the notch towardthe insideof the valvebody. Capswith llat ends and a holethroughthe centerare i n s t a l l e d 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 w 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 installedwith the tip toward the inside of the valve body.The tip is a springguide.
Capswith flat ends and a groovearoundthe cap are installed with the groovedside toward the outsideof the valvebodv.
Toward outside of valv6 bodv.
---'gJfr
Toward outside ol valve body.
GROOVE
./
\:7
Sectional view. Toward insideot valve bodv Toward inside ol valve body.
14-106
E.
Valve Body
Repair
if NOTE:This repair is only necessary one or more ot the valvesin a valve body do not slidesmoothlyin their to bores.You may use this procedure free the valvesin the valvebodies. 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 about30 minutes. v C a r e f u l l ya p t h e v a l v eb o d y s o t h e s t i c k i n g a l v e t dropsout of its bore. t C A U T I O N :l t m a y b e n e c e s s a r y 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. 5. Removethe #600 paper and thoroughly wash the entire valve body in solvent,then dry it with compressed arr. Coatthe valvewith ATF,then drop it into its bore. It should drop to the bottom of the bore under its own weight.lf not, repeatstep4, then retest.
6.
2.
3. Insoect valvefor anv scuff marks.Use the ATFthe

soaked#600 paper to polish off any burrs that are on the valve,then wash the valvein solventand dry it with compressed air. paper,and insen Roll up half a sheetof ATF-soaked valve. it in the valvebore of the sticking Twistthe paperslightly, that it unrollsand fits the so 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 paperas you push it in and out. CAUTION: The valve body is aluminumand doesn't require much polishing to remove any burrs.
VALVE EODY
ffiFS'
7. Remove the 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 reassemble using ATF as a lubricant.
ATF-so6ked #0OO abrasivo papet
14-107
Valve
Assembly
NOTE: Coatall partswith ATF beforeassembly. . I n s t a l t 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 l body and secure with the roller. . Set the spring in the valve and i n s t a l i t i n t h e v a l v e l 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.
ROLLER
SPRINGSEAT SPRING VALVE BODY
\
VALVE BODY
ROLLER VALVE BODY
Install valve,springand cap in the valvebody. the P u s h h e c a p ,t h e ni n s t a ltlh e c l i p . t
VALVE
SPRING
CAP
14-108
ATFPump
lnspection
'L lnstallthe ATF pump gears and ATF pump driven gear shaftin the main valvebody. NOTE: . Lubricate partswith ATF during inspection. all . I n s t a l l t h e A T Fp u m pd r i v e rg e a rw i t h i t s g r o o v e d r sidefacingup as shown. and chamfered
GEAR ATFPUMPDRIVEN s and chamfered cie Grooved
2.
of Measurethe side clearance the ATF pump drive and drivengears. ATF Pump Geais Side (Radiallclearance: Standard (New): ATF Pump Drive Gear 0.105- 0.1325mm {0.00/t- 0.005in) ATF PumpDrivenGear in) mm (0.0014 0.0025 0.035 0.0625
MAIN VALVEEODY
ATF PUMP ATF PUMP DRIVEGEAB Inspect teethfor wear and damage.
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 of the thrust clearance the ATF pump driven gearto-valvebody. ATF Pump Drive/D ven GoarThrust lAxial)Clearance: Standard (Newl: 0.03- 0.05 mm 10.001 0.002inl in) ServiceLimit: 0.07 mm 10.003
MAIN VALVE BODY
14-109
Main Valve Body

Disassembly/lnspection/Reassembly
NOTE: . Cleanall partsthoroughlyin solventor carburetor cleaner. and dry with compressed Blow out all passages. air. . Replace valvebody as an assembly any pans are worn or damaged. the if . Check valvesfor free movement. any fail to slidefreely,seeValveBody Repair page 14-,|07. all lf on . Coatall pans with ATF duringassembly. CAUTION: Do not uss a magnet to remove the check balls; it may magnetizethe balls.
1-2 SHIFTVALVE VALVECAPCLIP
{*4
MOOULATOR VALVE
2ND ORIFICE CONTROL VALVE
CHECK BALLS,8
1STACCUMULATOf, CHOKE
du:
VALVE
RELIEF VALVE
MAIN VALVEBODY Inspect wear,scratches for and scoring.
SERVOCONTROL VAL
VALVECAP
14- 1 1 0
CHECK BALL
CHECK BALLS
CHCKBAI.LS
SPRING SPECIFICATIONS Standard (Newl

No.
U n i t :m m ( i n )
Springs Reliefvalvespring valvesprang Modulator CPBvalvespring '1-2 shiftvalvespring 2nd orificecontrolvalvespring Servocontrolvalvespring
Wire Dia.
o.D.
8.6 (0.342) 9.4 {0.374} 8 . 1( 0 . 3 2 2 ) 7.6 (0.302) 6.6 (0.262) 8.1 (0.322)
FreeLength 3 7 .t { 1 . 4 6 1 ) 3 5 . 0( 1 . 3 7 8 ) 47.2{1.858) ( 41.3 1,626) 34.8(1.370) ( 52.1 2.051)
No. of Coils 13.4 10.9 18.3 16.3 22.0 20.8
o
\9/
( 1.1 0.043) ( 1.4 0.055) 0.9(0.035) 0.9(0.035) 0.7(0.028) 1.0(0.039)
14-111
SecondaryValve Body
Disassembly/l nspection/Reassembly
NOTE: o Cleanall pans thoroughlyin solventor carburetor cleaner, and drywith comp.essed Blow outall passages. air. . Replace secondary the valvebody kit, P/N27700 P4R- 305 (Thesecondary valvebody kit includes linearsolenoid the assembly) any partsare worn or damaged. if . Checkallvalvesfor free movement. anyfail to slidefreely,seeValveBody Repaironpage'14-107. lf . Coatall partswith ATF duringassembly. . The CPCvalveis installed the secondary in valvebody, held in placeby the lockbolt.
2.3 SHIFTVAI.VE
3.4 SHIFTVALVE
LOCKBOLT CAUTION: Oo not move.
SECONOARY VALVEBODY Inspect wear,scratches for and scofing. 3-4 ORIFICE CONTROL VAL
VALVE
ROLLER
SPRING SPECIFICATIONS
Standald lNewl
No.
Springs Wire Dia. 3-4 shift valvespring 2-3 shift valvespring 4th exhaust valvespring 3-4 orificecontrolvalvespring
o.D.
7.6 (0.302) 7.6 (0.302) 6.1 (0.242) 6.6 10.2621
Free Lenglh
No. oI Coils 26.8 26.8 19.5 24.6
o 6,
@
0.9(0.035) 0.9{0.035) 0.9(0.035) 0.7(0.028)
51.0 12.2441 51.0 \2.244) 3 6 . 4( 1 . 4 3 3 ) 3 7 . 5( 1 . 4 7 6 )
14-1 1 2
ValveBody Regulator
NOTE: air. and dry with compressed Blow out all passages. cleaner, . Cleanall partsthoroughlyin solventor carburetor if any partsare worn or damaged . Replace valvebody as an assembly the on It . checkall valvesfor free movement. any {ail to slidefreely,seevalve Body Repair page 14-107. 1. the release sprang springcap in placewhile removingthe stop bolt. Oncethe stop bolt is removed, Holdthe regulator cap srowry. CAUTION: Thc regulator spring cap can pop out when the stop bolt is removed' 2. procedure orderof the disassembly is Reassembly the reverse NOTE: . Coatall partswith ATF duringassembly. springcap with the hole in the valve body,then pressthe springcap into the valve . Align the hole in the regulator body,and tightenthe stoPbolt.
STOPBOLT 6x1.Omm 1 2N . m( 1 . 2
VALVEBODY REGULATOR Inspectfor wear, scratches and scortng, REGULATOR VALVE
SPECIFICATIONS SPRING Standard(New) No. Springs valvespringA Regulator valvespringB Regulator spring Statorreaction Coolerreliefvalvespring checkvalvespring Torqueconverter controlvalvespring Lock-up Wire Dia. 1 . 8( 0 . 0 7 1 ) 1 . 8( 0 . 0 7 1 ) 4 . 5( 0 . 1 7 7 ) 1 . 0( 0 . 0 3 9 ) 1.0(0.039) 0.7 {0.028)
o.D.
14.7(0.584) 9 . 6( 0 . 3 8 1 ) 3 s . 4( 1 . 4 0 7 ) 8.4 (0.334) 8.4 {0.334) 6.6 (0.262)
Free Length
No. of Coils 1' I.0 1.9 8.2 8.2 14.1
o
@
87.8(3.457) 44.0l'1.7321 3 0 . 3( 1 . 1 9 3 ) 33.8 1.331) { 3 3 . 8( 1 . 3 3 1 ) 38.0(1.496)
14-113
ServoBody
NOTE: . Cleanall partsthoroughlyin solventor carburetor cleaner, and dry with compressed Blow out all passages. air. . Replace valvebody as an assembly any partsare worn or damageo. the if . Coatall partswith ATF duringassembly. . Replace O rings. the
SERVOBOOY lnspect wear,scratches scoring. for and
"----.-'g
2ND AccuMULAroR ==p
-^'":::#,
3RDACCUMULATOR PISTON 4TH ACCUMULATOB PISTON SNAPRINGS
g;li:':-Y
O-BING Beplace.
1STACCUMULATOR PISTON
SPRINGSPECIFICATIONS U n i t :m m ( i n ) No. Springs Wire Dia. 1staccumulator spring 4th accumulato. springA 4th accumulator springB 3rd accumulator springA 3rd accumulator springB 2nd accumulator springC 2nd accumulator springA 2nd accumulator springB Standard (New)
o.D.
16.0{0.636) 17.0(0.676) 10.2{0.402) 17.5(0.695) 31.0 1.220) { ( 14.5 0.576) 2 9 . 0( 1 . 1 5 2 ) 9.0 (0.358)
FreeLength 89.1(3.508) 87.0(3.425) 5 1 . 6( 2 . 0 3 1 ) 89.3(3.516) 35.1(1.382) 68.0(2.677) 39.0(1.535) 20.7(0.815)
o
A)
lJl
No. of Coils 16.2 14.2 13.8 15.6 2.4

1? O
2.1(0.083) 2 . 6( 0 . 1 0 2 ) 2 . 3( 0 . 0 9 1 ) 2 . 8( 0 . 1 1 0 ) 2.2(0.087) 2.2(0.087) 2.4(0.094) ( 1.6 0.063)
2.9
14-114
Lock-upValve Body
NOTE: air, and dry with compressed Blow out all passages. . Cleanall partsthoroughlyin solventor carburetor cleaner, . Replace valvebody as an assembly any partsare worn or damaged. iJ the on . Checkall valvesfor free movement. any fail to slidefreeiy,seeValveBody Repair page14-107. lf . Coatall pans with ATF duringassembly.
LOCK.UP SHIFTVALVE
LOCK-UP VALVE BODY Inspect wear, for scratches

ano sconng,
VALVECAP
LOCK.UP TIMINGVAL
\uo.*.or.,-,,
SPRING SPECIFICATIONS Standard (New) No. Springs Wire Dia. Lock-up shiftvalvespring Lockup timing valvespring
U n i t :m m { i n )
o.D.
7.6(0.302) 8 . 1{ 0 . 3 1 9 )
Free Length
No. of Coils
0.9(0.035) 0.9(0.035)
73.1|'2.902) 80.1 t3.1771
32.0 45.8
14-115
t-
Mainshaft
NOTE: . Lubricate partswith ATFduring reassembly. all .Inspectthethrustneedlebearingsandtheneedlebearingsforgallingandroughmovement. . Beforeinstalling O-rings. the wrap the shaftsplineswith tapeto preventdamaging O-rings. the . Locknuthas left-hand threads.
SNAP RING
(FLANGE LOCKNUT NUTI 2 1 | 1. 2 5 n f i 78 N.m 18.0 kgl.m,58 lbl.ftl Replace. Lelt-hand threads CONICAL SPRINGWASHER Replace.
lST CLUTCH ASSEMBLY THRUST WASHEN THRUSTNEDLE BEARING 4TH GEAR MAINSHAFT Check splinestor excessive wear and damage. Check bearingsurfacefor scoring, scratches and excessive wear. NEEDI-E BEARINGS
O.FINGS Replace. THRUST WASHER THRUST NEEDLE BEARING BEANING ,IST GEAR
THRUSTNEEDLE EEARING TRANSMISSION HOUSINGEEARING
4TH GEAR COLLAR 2ND/4TH CLUTCH ASSEMBLY
O.BINGS Replace. THBUST WASHER, 36.5 r 55 mm

part. Selective
THRUSTNEEDLE BEARING SEALING RINGS, 35 mm Inslallthe sealingring matlng faces as shown, RING, 2ND GEAR BEARING NEEDLE BEARING
lti
29 mm NEEDLEBEARING SET RING
14-1 1 6
L.
Inspection
. Measurement Clearance 3. Torquethe mainshaftlocknutto 29 N'm (3.0 kgf'm, 22 lbf.ft). threads. locknuthas left-hand NOTE:Mainshaft 1. Removethe mainshaftbearingfrom the transmission housing(seepage l4-142). the Assemble partsbelow on the mainshaft. the O-ringsduring inspecNOTE:Do not assemble tion. NOTE:Lubricate partswith ATF during assembly. all
2.
LOCKNUT
WASHER CONICALSPRING ,IST CLUTCH ASSEMELY
Hold 2nd gear againstthe 2nd clutch,then measure between2nd gear and 3rd gear with a the clearance feelergauge. in NOTE:Take measurements at leastthree places, as and usethe average the actualclearance. 0.05- 0.13 mm {0.002- 0.005in) STANDARD:
THRUST WASHEB 1ST GEABCOLLAR TRANSMISSION BEARING HOUSING THRUSTWASHER 4TH GEAR COLLAR
SNAP RING
2ND/4TH CLUTCH ASSEMBLY THRUSTWASHER 36.5 x 55 mm Selective part. TI{RUST NEEDLE BEARING 2ND GEAR NEEOLE BEARING THRUSTt{EEDLE BEARING
MAINSHAFT
(cont'd)
14-117
Mainshaft
(cont'd) Inspection
5. l f t h e c l e a r a n c e s o u t o f t o l e r a n c e ,r e m o v et h e i thrustwasherand measure thickness. the
6.
Select and installa new washer. then recheck.
THRUST WASHER 36.5x 55 mm

No. 1
Part Number 9044' - P4P 010 t 90442-P4P-010 90443-P4P-010 90444-P4P-010 90445-P4P-010 90446 P4P, 010 90447-P4P-010 90448-P4P-010 90449-P4P-010
Thickness
4 . 0 0m m ( 0 . 1 5 7 n ) i
4 . 0 5m m ( 0 . 1 5 9n ) i 4 . 1 0 m ( 0 . 1 6 i1 ) m n 4 . 1 5m m ( 0 . 1 6 3n ) i 4 . 2 0m m { 0 . 1 6 5n ) i 4 . 2 5m m ( 0 . 1 6 7n ) i 4 . 3 0m m ( 0 . 1 6 9n ) i 4 . 3 5m m ( 0 . 1 7 1n ) i 4 . 4 0m m ( 0 . 1 7 3n ) i 4 . 4 5m m ( 0 . 1 7 5n ) i
4 5 6 1 8 10 7.
90450-P4P-000
A f t e r r e p l a c i n g 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 t clearance within tolerance. is
14-1 1 8
Gountershaft
NOTE; . Lubricateall parts with ATF before reassembly. .Inspectthethrustneedlebearingsandtheneedlebearingsforgallingandroughmovement. . Beforeinstalling O-rings, the wrap the shaitsplineswith tapeto preventdamagingthe O-rings. . Locknuthas left-hand threads.
NUTI LOCKNUT(FLANGE 23 x 1.25mm 103 N.m {10.5 kgf.m, 75.9 lbI.ft) Replace. Left-hand threads SPRING CONICAL WASHER Replace-
GEAR REVERSE
BEARING NEEDLE
SELECTOR
HUB 4TH GEAR BEARING NEEDLE DISTANCECOLLAR, 28 mm part. Selective 2ND GEAR THBUSTNEEDLE EEARING 3RD GEAR BEARING
ST GEARCOLLAR
COUNTERSHAFT Checksplines{or excessive wear and damage, Check bearingsurfacefor scoring, wear. and excessave scratches
BEARING NEEDLE 3RD GEARCOLLAR BEARING THRUSTNEEOLE SPLINEDWASI.IEB 3RD CLUTCHASSEMBLY
Replace.
14-119
Gountershaft
1. Using a hydraulicpress,pressout the countershaft 4th while supporting gear. NOTE: Placean attachment between the press and to the countershaft preventdamageto the shaft. CAUTION: Do not allow the countershaftto fall and hit the ground when Pressdclear. 2. as Assemblethe parts on the countershaft shown Delow. NOTE: . Lubricate pans with ATFduring assembly. all . Beforeinstallingthe O-rings,wrap the shaft splines with tapeto preventdamagingthe O-rings.
4TH GEAR NEEOLE BEARING DISTANCECOLLAR, 28 mm Selective part.
2ND GEAR THRUST NEEDLEBEARING
3RD GEAR
NEEDLEBARING
3RDGEARCOI.LAR AEABING TI{RUST NEEDIE SPLINED WASHER ASSEMBLY 3RDCLUTCH
14-120
lnspection
3. lnstallthe reverseselectorhub on the countershaft sub-assembly, and then pressthe reverseselector hub usingthe special tool and a pressas shown. a Clearance Measurement NOTE:Lubricate partswith ATFduringassembly. all 'L Removethe countershaftbearingtrom the transmissionhousing(seepage 14 142). Install the partsbelowon the countershaft usingthe specialtooland a pressas described this page. on the O-ringsduring inspec NOTE:Do not assemble tron.
2.
DRIVER 40 mm l.D. 07746 -OO30tOO
REVERSE SELECTOR HUB 4TH GEAR BEARING NEEDLE DISTANCECOLLAR, 28 mm part. Selective 2ND GEAR THRUSTNEEDLE BEARING 3RD GEAR NEEDLE BEARING 3RD GEARCOLLAR BEARING THRUSTNEEDLE SPLINED WASHER 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 fs u b , t 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 kgf.m,22blf.ft). NOTE:Countershaft locknuthas left-hand threads. 4. M e a s u r eh e c l e a r a n c e e t w e e n h e 2 n d g e a ra n d t b t the 28 mm distance collarwith a feelergauge. NOTE:Takemeasurements at leastthree places, in and usethe average the actualclearance. as STANDARD: - 0.18mm (0.004 0.007inl 0.10
Left-hand threads SPRING CONICAL WASHER PARKING GEAR/ONE-WAY CLUTCH/1ST GEAR ASSEMELY NEEDLE EEARING OISTANCE COLLAR. mm 28 1ST GEAECOLLAR TRANSMISSION HOUSING BEARING
REVERSE GEAR COLLAR
COUNTERSHAFT SUB-ASSEMELY
5.
lf the clearance out of tolerance, is removethe 28 mm distance collarand measure width. the 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.
6.
DISTANCE COLLAR. mm 28 No. PartNumber 90503-PCg-000 90504 PCg, 000 90505 PCg 000 90507-PCg-000 90508-PCg-000 90509-PCg,000 90510-PCg-000 90511 PCg 000 90512-PCg-000 width 3 9 . 0 0 m ( 1 . 5 3 5n ) m i 3 9 . 1 0 m ( 1 . 5 3 9n ) m i 3 9 . 2 0 m ( 1 . 5 4 3n ) m i 3 9 . 3 0 m ( 1 . 5 4 7n ) m i 3 9 . 0 5 m ( 1 . 5 3 7n I m i 3 9 . 1 5 m ( 1 . 5 4i1 ) m n 3 9 . 2 5 m i 1 . 5 4 5n ) m i 3 8 . 9 0 m ( 1 . 5 3 1n ) m I 3 8 . 9 5 m ( 1 . 5 3 3n ) m i
,]
2 3
4
5 6
7 8
9 1.
A f t e r s e l e c t i n g n e w d i s t a n c e o l l a r ,r e c h e c kh e a c t c l e a r a n ca n 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 . e
14-122
One-way Clutch
nspection/Reassembly Disassembly/l
1. S e p a r a t e o u n t e r s h a f1 s t g e a r f r o m t h e p a r k i n g c t 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. 3. Inspect partsas followsl the
PARKING GEAR
Inspectthe parkinggear
for wear and scoring,
PARKING GEAR
COUNTERSHAFT lST GEAR
ONE-WAYCLUTCH Inspectthe one-way clutch for damageand faultVmovement.
2.
Remove the one-wayclutchby prying it up with the end of a screwdriver. ONE.WAY CLUTCH NOTE: Install this direction. in
.IST GEAR Inspectcountershall'l for wear and scoring,
COUNTERSHAFT GEAR 1ST
4.
Afterthe partsare assembled, hold countershaft 1st 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 ,I COUNTERSHAFT ST GEAR
COUNTERSHAFT GEAR lST SCREWDRIVER
14-123
Clutch
Transmissionl lllustratedIndex(A4RA, B4RA
3RDCLUTCH
CLUTCH DRUM
O-RINGS Replace.
C L U T C Hp t S T O N DISC SPRING
CLUTCH PLATES Standard thickness: 2 . 0m m ( 0 . 0 7 i9 ) n CLUTCH END PLATE
SNAPRING
lST CLUTCH
END CLUTCH
TE cLurcsorscs
Standard thickness: '1.94 mm {0.076 in)
SNAPRING SPRING RETAINER RETURN SPNING DISCSPRING
I
CLUTCH PLATES Standard thickness: 1.6mm 10.063 in)
o-"'"cs !,L"urlcf tleptace. I

CLUTCH DRUM
CHECK VALVE
14-124
2ND/4TH CLUTCH
SNAPRING
CLUTCH PLATES
PISTON CLUTCH SNAP RETAINEB SPRING RETURN SPRING DISCSPRING
O.RINGS Replace.
DRUM 4TH CLUTCH PLATES CLUTCH Standardthicknessr O-RINGS in) 2.0mm {0.079 Reptace.
END PLA CLUTCH SNAPRING
14-125
Clutch
lllustrated Index(M4RA Transmissionl
3RDCLUTCH CLUTCH ORUM
PISTON CLUTCH OISCSPRING
CLUTCH END PLATE
1STCLUTCH CLUTCH END
SNAPRING
SNAPRING
rll
VALVE CHECK
14-126
g
SNAPRING
2ND/4TH-CLUTCH
VALVE
CLUTCH PLATES Standardthickness: 2.0 mm (0.079 in)
\--2ND CI-UTCH
DNUM
PISTON CLUTCH
SPRING RETURN O-RINGS Replace.
SNAPRING
\---
SNAPRING
14-127
Clutch
Disassembly
1. Removethe snap ring, then removethe clutch end plate.clutchdiscsand olates.
SCREWORIVER
3.
Install the specialtools shown. as

CLUTCHSPRING COMPRESSOR ATTACHMENT 07LAE- PX40100
SNAP RING
;=
_=:_-.-----
2.
Remove the discspring. NOTE:Except 2nd clutch.

CLUTCH
CLUTCH SPRING COMPRESSOR ATTACHMENT 07LAE- PX40100

ol
07HAE- P150100
OISCSPRING
COMPRESSOR BOLT ASSEMBLY 07GAE PG40200

ol
OTGAE PGIO2OA
CLUTCHSPRING COMPRESSOR ATTACHMENT 07LAE- PX40100
CLUTCHDRUM
li ll
CLUTCH SPRING COMPRESSOR ATTACHMENT 07LAE- PX40100 CLUTCH SPRING COMPRESSOR BOLTASSEMBLY 07GAE- PG40200
OI
07HAE- P150100
_ OTGAE PG4O2OA
14-128
g -
CAUTION:It eitherend of the special tool issetoveran area of the spring retainer which is unsupported by the return spring, the retainer may be damaged. Be sure the specialtool is adiusted to have tull contact with the spring retainer.
5.
the tools, Remove snap ring.Thenremove special the springretainer return and spring.
SPECIAL TOOL
6.
Wrap a shop rag aroundthe clutchdrum. and apply to to air pressure the ATF passage removethe piston. P l a c e 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 a r rp r e s s u r e . OSHA-APPROVED
SPRING RETAINER
4.
Compress returnspring. the
PISTON
14-129
Glutch
Reassembly
NOTE: . Clean all parts thoroughly in solvent or carburetor cleaner, and dry them with compressed ajr. . Blow out all passages. . Lubricate partswith ATF beforereassembly. all 1. Inspect checkvalve;if it's loose,replace the the piston, 3. Install the pistonin the clutchdrum. Apply pressure and rotateto ensureproperseating. NOTE:Lubricate the piston O-ringwith ATF before installing. CAUTION: Do not pinch th8 O.ring by installing the 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 n d , positionthe snap ring on the retainer.

O-RINGS
SNAP RING
SPRINGRETAINR
RETURNSPRING
CLUTCHDRUM
PISTON
14-130
5.
lnstallthe soecial tools as shown.
CLUTCHSPRING COMPRESSOB ATTACHMENT 07LAE- PX40100
CAUTION:ll either end ot the special tool is set over an ar6a of the spring retainer which is unsupported by the return spring, the retainer may be damaged. Be sure the specialtool is adiusted to have tull contact with the spring retainsr.
SPRING
SPRING CLUTCH COMPRESSOR ATTACHMENT 07LAE- PX40100 ot 07HAE- PL50'100
Do not s6t hore.
OTGAE PG4O2OA
SPECIAL TOOL
CLUTCHSPRING COMPRESSOR ATTACHMENT oTLAE-PX40100
6.
SPRING CLUTCH COMPRESSOR ATTACHMENT 07LAE- PX40100 CLUTCH SPRING COMPRESSOR BOLTASSEMBLY 07GAE- PG40200 ot OTGAE PG4O2OA 07HAE- PL50100
(cont'd)
14-131
Clutch
(cont'd) Reassembly
7. lnstallthe snap ring. '10. Soak the clutchdiscsthoroughlyin ATF for a minimum of 30 minutes.
1 1 . staning with a clutch plate, alternatelyinstall the
clutch platesand discs.Installthe clutch end plate with flat sidetowardthe disc. NOTE:Beforeinstalling the platesand discs,make sure the insideof the clutch drum is free of din or otherforeignmatter.
CLUTCH EI{D PLATE Installin this direction.
SNAP RING
8. 9.
Remove special the tools. Install the 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. Install the snap ring.
SCREWDRIVER
SNAP RIIIG
!tf
14-132
-
the clutchend plate 13, Measure clearance the between Zero the dial indiand top discwith a dial indicator. cator with the clutch end plate lowered and lift it up to the snap ring. The distancethat the clutch end olatemovesis the clearance between the clutchend plateand top disc, in NOTE:Takemeasurements at leastthree places, and usethe average the actualclearance. as Clutch End Plate-to-TopDisc Clearanco: Clutch 1st 2nd 3rd 4th 0.650.650.400.40Sowico Limit 0.85mm (0.026 0.85mm (0.026 (0.016 0.60mm mm (0.016 0.60 0.033in) 0.033in) 0.024in) 0.024inl
END CLUTCH PLATE A,[RA, B4RA Transmission:

Plste No.
1 Part Numbe.
Thicknoss 2.1mm (0.083 in in 2,2 mm (0.087 i 2 . 3m m ( 0 . 0 9 1n 2 , 4m m { 0 . 0 9 4n i 2.5 mm (0.098 in i 2 . 6m m ( 0 . 1 0 2n i 2 . 7m m ( 0 . 1 0 6n i 2 . 8m m ( 0 . 1 1 0n i 2 . 9m m ( 0 . 1 1 4n
6 7 8 I
22551 P4R- 003 22552- P4R,003 22553-P4R-003 22554-P4R-003 22555-P4R-003 22555-P4R-003 22557-P4R-OO3 22558-P4R-003 22559-P4R-003
M4RATransmission: Plaie No. 1 2 Part Number 22551- PCg- 000 22552-PCg-000 22553-PCg-000 22554-PCg-000 225ss-PCg-000 22556-PCg-000 22557-PCg-000 22558-PCg-000 22559-PCg-000 22s60-PCg-000 22561 PCg- 000 22s62-PCg-000 22563-PCg-000 22574-P4V- 003 22561 P4V- 003 22562 - P4V- O03 22563-P4V-003 22564-P4V-003 Thicknoss in 2.4mm (0.094 in 2.5mm {0.098 i 2 . 6m m ( 0 . 1 0 2n 2 . 7m m { 0 . 1 0 6 I n 2 . 8m m ( 0 . 1 1 0n i 2 . 9m m ( 0 . ' 1 1i 4 n n 3 . 0m m ( 0 . ' 1 1i 8 3 . 1m m ( 0 .1 2 2 n i i 3 . 2m m ( 0 . 1 2 6n i 3 . 3m m ( 0 . 1 3 0n in 2.'l mm (0.082 2.2mm (0.086 in in 2.3 mm (0.090 i 3 . 4m m ( 0 . 1 3 4n i 3 . 5m m ( 0 . 1 3 8n i 3 . 6m m ( 0 . 1 4 2n i 3 . 7m m ( 0 . 1 4 6n in 3.8 mm (0.150
DIAL INDICATOR tl
CLUTCHEND PLATE
CLUTCHDISC
Clearance
6 7 8 9 10 11 12 '13 14 15 16 17 18
i 1 4 . l f t h e c l e a r a n c e 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 , select a new clutch end plate from the following table. NOTE; lf the thickesiclutch end plate is installed, replace but the clearance still over the standard, is the clutchdiscsand clutchDIates.
15. After replacing clutchend plate,make sure that the is the clearance within tolerance.
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 excessive wear. Installin this dlrection.
lnspectlor taulty movement.
CARRIER DIFFERENTIAL Insoectlor cracks.
DRIVE SPEEDOMETER GEAR Installin this direction.
5x 10mm
SNAP RING Installin this direcrion.
BALL EEARING Inspectfor faulty movement.
14-134
Inspection Backlash
1. Placedifferentialassemblyon V-blocksand install both axles.
BearingReplacement
NOTE: Checkbearingsfor wear and rough rotation. bearings OK. removalis not necessary. are 1. usinga bearingpuller. Removebearings
PULLER BEARING (Commercially availablel
of Checkbacklash both piniongears. Siandard(Ncwl:0.05- 0.15mm (0 002- 0.006in) replacethe differenis lf backlash out of tolerance, tial carrier. tool as shown. usingthe special Install new bea.ings
2.
40 DRIVER mm l.O. 07746-OO30100
14-135
Differential
Differential CarrierReplacement
1. Removethe final driven gear from the differential carner. NOTE: The final driven gear bolts have left-hand threads.
Hooked end
Align the hookedend of the snap ring with the pinion shaft as shown,then installthe snap ring in the differential carriergroove.
SNAP RING Installin this direclion.
2.
Prythe snap ring off differential carrier, then remove the speedometer drivegearand 5 x 10 mm roller.
SNAP RING
PINIONSHAFT
SPBING
Installthe final drivengear,then tightenthe boltsto the specified torque, TOROUE:101 N.m 110.3 kgf.m, 74.5 tbf.ft) NOTE: The final d.iven gear bolts have left-hand threads. 3. Installthe5 x 10 mm rollerin the differential carrier.
BOITS 10 x t.0 mm 1Oi N'm 11O.3 kgl.m, 74.5 tbf.ttl Left-hand threads
SPEEDOMETER DRIVEGEAR Installin this direction.
FINAL ORIVEN GEAR Installin this direction.
Frlr
tril
4.
Installthe speedometerdrive gear with its chamfered side facingthe carrier. Align the cutout on the bore of the speedometer drive gear with the 5 x lO mm ro er,
OIFFERENTIAL CARRIER
7.
Install a new ball bearing (see page'14-'l3S).
14-136
Oil SealRemoval
1, 2, assemblv. Remove differential the housing, Remove oil sealfrom the transmission the
Clearance Oil SealInstallation/Side

1. in) Installa 2.50mm (0.098 set ring,80 mm in transmissionhousing. NOTE:Do not installthe oil sealvet.
RING,80 mm OIL SEAL 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.
assemblyinto the torque conInstallthe differential tool as shown. verterhousingusingthe special
TOROUE CONVERTER HOUSING h I n s t a l lt h e t r a n s m i s s i o n o u s i n ga n d t i g h r e n t h e and 14-147). bolts(seepage 14-146
(cont'd)
14-137
Differential
(cont'd) Oil Seal Installation/Side Clearance
4. Tap on the transmission housingside of the differentialassemblv with the soecial tool to seatthe differential assembly the torqueconverter in housing. 5. Measure the clearance betweenthe 80 mm set ring and outer race of the ball bearingin the transmiss i o nh o u s i n g . STANDARD: - 0.15mm (0 - 0.006inl 0
DRIVER mm LD. 40
-0030100
6.
lf the clearance more than the standard, is selecta new set ring from the table,and insta : SETRING, mm 80 Part Number 90414 689- 000 90415 689 000 90416-689-000 90417 689- 000 90418-689-000 90419 PH8 000 Thickness 2.50mm (0.098n ) 2 . 6 0m m ( 0 . 1 0 2 ) n 2 . 7 0m m ( 0 . 1 0 6 ) n 2.80 m (0.'110) m n 2 . 9 0m m ( 0 . ' 1 1 4 ) n 3 . 0 0m m ( 0 . ' 1 1 8 l n
NOTE:lf the clearance measuredin step 5 is standard,it is not necessary performsteps7 and 8. to 7. 8. Remove transmission the housing. Replace 2.50mm (0.098 80 mm set ring wjth the in) the one of the correct thickness selected step6. in
ti{
14-138
9. lnstallthe new oil seal flush with the transmission tools as shown. housingusing the special
ORIVER 0?7/tg- 00'10000
PILOT, 26x30mm 07JAD- PH80200
DRIVER ATTACHMENT, mm 68 07947 6110501
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 tools as shown. verterhousingusingthe special
DRIVER 07749 0010000
14-139
TorqueGonverter Housing Bearings

MainshaftBearing/OilSeal Replacement
1. R e m o v e h e m a i n s h a t t e a r i n ga n d o i l s e a l u s i n g t b the special tools as shown. 2. Drivein the new mainshaftbearinguntil it bottoms in the housingusingthe special tools 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
ADJUSTABLE EEARING PULLER,25 40 mm 07736 A01000A
ATTACHMENT, 62x68mm 077{6 - 0010500
3.
Install the new oil seal flush with the housinq u s r g n the soecial tools as shown.
l;'.r
fri
ATTACHMENT, 72 x75 tnm 07746- 0010600
14-140
g Bearin Replacement Countershaft

1. bearingusing the special Removethe countershaft tools as shown.
HAMMER 3/81T6SLIDE (Commercially available)
AOJUSTABLE BEANING PULLER, 25-40mm 07736- A01000A
t
2. 3. A I n s t a l l t h e T Fg u i d ep l a t e . 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 special tools as shown.
0 - 0.03mm in) {0 - 0.001 ATF GUIDEPLATE
1+141
Transmission Housing Bearings

Mainshaft Bearings /Countershaft Replacement
1. To removethe mainshaft and countershaft bearings from the transmission housing,expand each snap ring with snap ring pliers,then push the bearingout usingthe special tools and a pressas shown. 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 necessary cleanthe groovesin the housing. to
PRESS
Expandeach snap ring with snap ring pliers,insert 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 the specialtools and a press as shown. Installthe bearingwith the groovefacingoutsidethe housing. NOTE:Coatall parrswith ATF. Release pliers.then push the bearingdown into the t h e h o u s i n g n t i l t h er i n gs n a p s n p l a c e r o u n di t . u i a
07749- 00r0000
ATTACHMENT, 62x68mm
07146 -
MAINSHAFT BEARING DRIVER 07749- 00r0000 ATTACHMENT
ATTACHMENT . Mainshaft Bearir|gRemovaluse: ATTACHMENT, x 75 mm 72 07745- 0010600 . CountershaftBearing Removal use: ATTACHMENT, x 58 mm 62 07746 0010500 4. After installing bearing the verilythe following: . . The snap ring is seatedin the bearinqand housIng grooves. The ring end gap is correct.
ENOGAP:0-7mm {0 - 0.28inl
ATTACHMENT . Mainshaft B6aring Installation use: ATTACHMENT, x 75 mm 72 077'16 0010600 . CountershaftBearing Installation use: ATTACHMENT. x 68 mm 62 07745- 0010500
SNAPRING
14-142
Reverse ldler Gear

Installation
1. idler gear. Install the reverse
ParkingBrakeStop
Inspection/Adjustment
1. 2.
Set the parkingbrakeleverin the E posrrron. t b M e a s u r e h e d i s t a n c e 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 72.9- 73.9 mm (2.87- 2.91 inl STANDARD:
'2:\
Measuring
idler gear shaft holderand needle Install the reverse housing.then tighten bearinginto the transmission the bolts.
6 x 1.0mm 12 N.m (1.2kgf.m, 8.7 tbf.ftl
-.
BRAK PARKING PAWLSHAFT
is lf the measurement out of tolerance,selecl and parkingbrakestop from the installthe appropriate table below.
PARKINGBRAKE STOP
PARKING BRAKESTOP Mark

I
Part Number
Lr
L2
2 3
m 24537-PAg-003 1 1 . 0 0 m (0.433 in) '10.80 mm 24538-PAg-003 ( 0 . 4 2 5n ) i m 24539-PAg-003 10.60 m ( 0 . 4 1 7n ) i
11 . 0 0 m m (0.433 in)
10.65 m m ( 0 . 4 1 9n l i 10.30 mm (0.406 in)
After replacingthe parking brake stop. make sure is the distance within tolerance.
14-143
Transmission
Reasembly
NOTE: . Coatall partswith ATF. . Replace followingpans: the - O-rings - Lockwashers - Gaskets - Mainshaft and countershaft locknuts and conicalspringwashers - Sealing washers TOROUE: N.m (1.2kgf.m,8.7tbf.ft) 12
6x1.0mm 7 Bolts
ATF FEEDPIPE: A 6x1.0mm 2 Bolts
LOCK-UP VALVE BOOY LOCK-UP SEPARATOR PLATE REGULATOR VALVE EODY DOWELPINS.2 CONTROL SHAFT DETENT ARM SHAFT DETENT ARM ATF FEEO PIPES: B ATF STRAINER
9 or l il
li lf: ln l
Yl l
SERVODETENT BASE
cooLER RE FvALVe -----------E LrE

TOROUE CONVERTEB CHECK VALVE STATORSHAFT O-RING STOPSHAFT ATF FEEDPIPE: H 6x1.0mm 5 Bolts MAIN VALVEEODY ATFPUMP GEARSHAFT ATF PUMPDBIVEN GEAR MAIN SEPARATOR PLATE DOWELPINS, 2
6x1.0mm 7 Bohs SERVOBODY SERVOSEPARATOR PLATE SECONDARY VALVE BOOY
i l
, ATFFEED PIPES:
PINS,2
\l
SECONDARY SEPARATOR PLATE CONTROL SHAFT ('98model)
14-144
1 . lnstallthe ATF magnetand suctionpipecollarin the housing.if necessary. tgrqueconverter 2 . lnstallthe main seoaratorDlateand the two dowel housing. pins on the torqueconverter 3 . Installthe ATF pump drive gear, ATF pump driven gear and ATF pump driven gear shaft on the torque convenernousrng. 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 groovedand chamfered sidefacingdown.
ATF PUMP GEAR
r t 8. I n s t a l l h e s e r v o b o d y a n d s e p a r a t o p l a t eo n t h e valvebody (sevenbolts). secondary L lnstall the servo detent base and the ATF strainer Itwo bolts). 1 0 . Tightenthe five bolts on the main valve body to l2 N.m (1.2kgim, 8.7 lbf.ft). Make surethe ATF pump drive gear and ATF pump drivengear shaftmove smoothly.
1 l . It the ATF pump drive gear and ATF pump driven
ATF PUMPDRIVEN GEARSHAFT ATF PUMP DRIVEN Grooved and chafitered side faces separalot plate.
gear shaft do not move freely,loosenthe live bolts the on the main valve body. and disassemble valve bodies. Realign ATF pumpdrivengearshaftand reassemthe the bolts to the then retighten ble the valve bodies, torque. specified CAUTION: Failureto slign lhe ATF pump driven gear shaft correctly will result in a seizedATF pump drive gear or ATF pump driven gear shaft.
MAIN SEPARATOR PLATE
Looselyinstallthe main valve body with five bolts. smoothly Makesurethe ATF pump drivegearrotates and the ATF pump direction in the normaloperating driven gear shaft moves smoothly in the axial and normaloperating directions. Install the secondaryvalve body, separatorplate and two dowel pins on the main valvebody. NOTE: Do not installthe bolts. Installthe controlshaft in the housingwith the control shaftand manualvalvetogether. 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 to valve body, then hook the detentarm sprang the detentarm.
PLATE SEPARATOR SERVO
7.
ATF PUMP GEAR DRIVEN
DRIVEN GEAR SHAFT
12. Install the statorshaftand stop shafi 1 3 . lnstallthe bolts and the shaftstop on the secondary valvebody,then tightenthe bolts (threebolts). checkvalve,coolerrelief 1 4 . lnstallthe torqueconverter valvebody, valveand valvespringsin the regulator r t h e n i n s t a l lt h e r e g u l a t o v a l v e b o d y o n t h e m a i n valvebody (one bolt).
DETENTARM SHAFT
DETENT AFM SPRING ARM OETENT
valve Installthe lock-upvalvebody on the regulator body (sevenbolts). 1 6 . Installthe ATF feed pipes in the main valve body, valveand the threeATF feed pipesin the secondary the four ATFfeed pipesin the servobody. (cont'd)
MANUAL VALVE
14-145
I Transmission
Reassembly(cont'dl
I
TRANSMISSION HANGEB
TRANSMISSION HOUSING MOUNTINGBOLTS 1 0x 1 . 2 5 m m 44 N.m (4.5 kg{.m,33 lbf.trl TRANSMISSION HOUSTNG
MAINSHAFT SUE.ASSEMBLY
MAINSHAFT SPEED SENSOR WASHER (D16Y7 engine) MAINSHAFT SPEED SENSOR
COUNTERSHAFT SUB.ASSEMELY
DIFFERENTIAL ASSEMBLY
TRANSMISSION HOUSING GASKET TOROUE CONVERTER 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 ( p h o l d e r s e e a g e1 4 - 1 4 3 ) . 1 8 . Installthe differentialassemblyin the torque convener housrng. 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 y n d t h e a th c o u n t e r s h a fs u b - a s s e m b l y , e n i n s t a l lt h e m t housing. togetherin the torqueconverter
2 1 . Install the needle bearing, countershaft reverse gear

and reverse gear collar on the countershaft.
2 2 . Align the spring pin on the control shaft with the

transmission housing groove by turning the control shaft. SPRING PIN CONTROL SHAFT
COUNTERSHAFT SU8-ASSEMBLY
Installthe two dowel pins and a new gasketon the housing. torqueconverter 24. Placethe transmission housingon the torque convener nousrng. CAUTION: Make sule that the mainshaft speed snsor is not installed on the transmission housing before installingthe transmissionhousing on the torque converter housing. 25. I n s t a l lt h e t r a n s m i s s i o n o u s i n gm o u n t i n g b o l t s h a l o n gw i t h t h e t r a n s m i s s i o n a n g e r . h e n t i g h t e n h t the bolts in two or more steps in the sequence as snown. TOROUE: N.m {4.5 kgf.m, 33 lbt.ft, 44
TRANSMISSION HANGEB
20. Turn the shift fork so the large chamferedhole is facing the fork bolt hole, then install the shift fork with the reverseselector, and torque the lock bolt. Sendthe locktab against the bolt head.
SHIFTFORK LOCKWASHER Replace. 6 x 1 . Om m 14 N.m (1.4 kgf.m, '10 lbf'ft)
a -&)H@
V G '
Large chamfered hole
| "fl:
@
-_F
1+117
Transmission
Reassembly(cont'd)
26. Slip the special tool onto the mainshaft shown. as
MAINSHAFT HOLOER
- PF50101
' 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. 32. Wrap the shaft splineswith tape to preventthe Orings,then installnew O-ringson the mainshaft.
33. Assemble thrust washer.thrust needlebearing, the

n e e d l eb e a r i n g a n d m a i n s h a f 1 s t g e a r i n t h e 1 s t , 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. 28. Assemble the one-wayclutchand the parkinggear with the countershaft gear{seepage 14 '|.23). 1st 29. Installthe countershaft gear collar,needlebear 1st ing, and the countershaft st gear/parking ear g 1 assembly the countershaft. on lSTCLUTCH PARKING ASSEMBLY GEAR PAWL
COUNTERSHAFT LOCKNUT Left handrhreads.
MAINSHAFT LOCKNUT Left-hand threads
CONICAL SPRING WASHEBS Install thisdirectionin 35. Tightenthe locknuts the specified to torque. 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, . Mainshaftand countershaftlocknuts have lefthandthreads. TOROUE: MAINSHAFT 78 N.m {8.0 kgt.m, 58 lbl.ft} COUNTERSHAFT N.m {10.5kgt'm, 75.9 lbt ft) 103
30. Installthe parking brake pawl shaft, spring, pawl, and pawl stop on the transmission ousingthen h , 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.
14-148
36. Removethe special tool from mainshaft,then stske eachlocknutusinga 3,5 mm punchas shown.
40. Installthe right side cover with two dowel pins and bolts). I new gasket(thirteen TOROUE:12 N'm 11.2kgt.m, 8.7 lbt'ft)
RIGHT SIDE COVER 3 7 . Set the parkingbrakelever in the E position,then verifythat the parkingbrakepawl engages parkthe ing gear. lf the pawl does not engagetully, checkthe parking (seepage 14-143). brakepawl stop clearance Tightenthe lockbolt and bendthe locktab. 4 1 . Insrallrhe ATF cooler lineswith new sealingwashers. TOROUE: N'm (2.9 kgt.m, 21 lbf.ft) 28 Install ATF dipstick. the
6 r 1 . Om m 1 4 ' m 1 1 . 4k g t . m , 10 lbt'frl
PAR(ING BRAKE PAWL
14-149
TorqueConverter/Drive Plate
\
m 6x 1.O 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 on Flushthe ATF cooler as described page 14-155 and 14-156. with assemblysecurely Installthe torque converter a new O-ringon the mainshaft.
45 N.m 14.5kgf.m, STARTERMOTOR
6.
mount bracket. lnstallthe transmission
2,
1a mm DOWELPIN
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 housing,then installthe tlvo 14 mm dowel pins in housing. the torqueconverter on Placethe transmission a iack,and raiseit to the level. engineassembly 5. to Aftach the transmission the engine,then install housingmounting bolts and two two transmission rearenginemountingbolts. REAR ENGINE MOUNNNG BOLTS 14x 1.5mm
kg 83 N.m 18.5 'm, G1lbtft) Replace.
12 x'l.25 mm 7il N.m (7.5kgl.m, 54 tbf.ftt 7.
MOUNT
housingmountlnstallthe remainingtransmission rearenginemountingbolt. ing boltsand remaining
WASHEB REARENGINE MOUNTINGBOLT 14 x 1.5rnm 8i] N.m 18.5kgt'm, 61 rbf.n) Replace.
WASHER
TRANSMISSION HOUSING MOUNTINGBOLTS 12 x 1,25 mm 47 tbf.ftl 64 N.m 16.5
ENGINE MOUNTING BRACKET
HOUSING MOUNTINGBOLTS 12 x 1.25mm 64 N.m (6.5kgf.m, 47 lbf.ftl
8.
JACK
Remove the transmission iack.
{cont'd)
14-151
Transmission
9. Attachthe torque converter the drive plate with to eight drive plateboltsand torqueas follows: Rotate pulleyas necessary tighten the crankshaft to the bolts to 1/2 of the specified torque,then to the finaltorque,in a crisscross pattern. After tighteningthe last bolt, checkthat the crankshaft rotatesfreely. TOROUE:12 N.m (1.2 kgf'm, 8.7 lbf.ftl
10 x 1.25mm 44 N.m 14.5 kgl.m, 33 lbf.ft)
14. Installthe control lever with a new lock washerto the controlshaft,then installthe shiftcablecover. CAUTION: Tako care not to bend the shift cable.
SHIFTCABLE
LOCK WASHER Replace.
6x1.0mm 12 N.m {'1.2 kg{.m, 8.7 tbf.ftl
8 x 1.25mm 22 N.m {2.2 ks{.m, 16lbf.ftl SHIFTCABLE COVER 6x 1.0mm
8 x 1.25mm 24 N.m {2.4kgf.m, 17 tbf.ftt COVER
1{ N.m11.l kgf.m, 10tbtftt

CONVERTER
15. Install the exhaustpipeA. NOTE:D16Y8 engineis shown;D16ft engineis similar.
1 0 . I n s t a l l h e t o r q u ec o n v e r t e c o v e ra n d t h e e n g i n e t r stiffener. pulley bolt, if necessary (see 1 1 .Tightenthe crankshaft section6). 1 2 . Connect ATFcoolerhoses the ATFcoolerlines the to (seepage14-160).
ATF COOLER LINE
J
Replace.
1 0 x 1 . 2 5m m
,4
"
44 N.m {4.5kgt.m, 33 lbf.f0 RIGHTFRONT 12 x 1.25mm MOUNT/BRACKET64 N.m {6.5 kgf.m, 47 lbI.ft)
GASKET Replace. NUT SELF.LOCKING Reolace. 8 x 1.25mm 22 N.m (2.2kgt.m. 16lbf.ft)
NUT SELF.LOCKING Replace. 10 x 1.25 mm 5,1N.m 15.5kgf.m, 40 rbf.ftl NUT ReDlace. 8 x 1.25mm 16 N.m ('1.6 kgf.m, 12 tbf.ftt
13. Installtherightfront mounvbracket.
14-152
16. lnstalla new set ring on the end of eachdriveshaft. (seesection16). 17. Installtheright and left driveshafts CAUTION:While inslalling the driveshaftsin the difforGntial,be sure not to allow dust and olher foroign particlos to enter into the transmission. NOTE: . Cleanthe areaswherethe driveshafts the contact thoroughly with soltransmission(differential) v e n t o r c a r b u r e t oc l e a n e ra n d d r y w i t h c o m r , prssed atr. . Turn the right and left steeringknuckle fully outinto the differenward, and slide eachdriveshaft tial until you teel its set ring clip engagethe side gear. 18. Install the damperfork,then installthe right and left ball jointsto the eachlower arm with the castlenuts and new cotteroins.
DAMPER PINCHBOLT 10 x 1.25mm a3 N.m {4.4 kd.m, 32 tbnft)
the 20, Connect mainshait the speedsensor, linearsolenoid and the shiftcontrolsolenoid connectors.
SHIFT CONTROL SOLENOID CONNECTOR
LINEAR SOLENOIO CoNNEcToR

5x1.0mm 12Nm(1.2kgf.m, 8.7 rbf.ft)
CONNECTOR ERACKET
MAINSHAFT SPEED SENSOR CONNECTOR
2 ' t . Connect countershaft the speedsensorand the vehicle speedsensor(VSS) connectors. VEHICLE SPEED SENSORCONNECTOR VSS
\
SELF-LOCKING NUT 12 x 1,25mm 6ir N.m (6.5 kgf.m, il7 lbf.ftl Replace. COTTER NUT CASTLE Replace. 1 2\ 1 . 2 5 n n 49 - 59 N.m (5.0- 6.0 kgf.m, 36 - $ lbtftl
Install splashshield, 19. lnstall the solash shi the
SHIELD 6r1.0mm 12 N.m (1.2kgt'm,8.7 lbf'ft)
COUNTERSHAFT SENSOR SPEED CONNECTOR
(cont'd)
14-153
Transmission
22. Connect lock-up the controlsolenoid connector, and installthe transmission groundcable. 6x1.0mm 12N.m{1.2 kgtm,8.7 lbtftl 24. Installtheintakeair duct. D16Y7 engine: Installtheint6keair duct and the resonator. D15Y8 engine: Installthe intakeair duct and the air cleanerhousing assembly. Refillthe transmission with ATF (seepage 14-86). Connectthe positive(+) cablefirst. then the negative {-) cableto the battery. 27. Check ignitiontiming {seesection23). the Stan the engine.Setthe parkingbrake, and shiftthe transmission through all gears.three times. Check the shift cableadjustment {seepage14-158). Check front wheelalignment the {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 g e m p e r a t u r e t h e t cooling fan comes on) with the transmission E in or E position,then turn it off and checkthe fluid levet. 3 1 . Roadtest as described pages14-82 on thru 14-84. N O T E :W h e n i n s t a l l i n gh e s t a r t e rc a b l et e r m i n a l , t makesurethat the crimpedside of the ring terminal is facingout (seesection23),
Connect startercableson the startermotor, and the install cableholder. the
6xl.0mm 12 N.m 11.2 kgtm,8.7 lbt.ft) {0.9 kgf.m.7 lbI.ft}
STARTER CAALE
lllri
lltl
14-154
CoolerFlushing
To prevent iniury to lace and eyes, always @ wear safety glassesor a face shield when using the transmissionllusher. NOTE:This orocedure shouldbe oerformedbetorereinstallingthe transmission. 1 . Checktool and hoses for wear and cracksbefore using.lf wear or cracks found,replace are the hoses beforeusing, Usingthe measuring cup,fill the tankwith 21 ounces ( a p p r o x i m a t e l2 / 3 I u l l l o t b i o d e g r a d a b lfeu s h i n g y l fluid {J35944 20).Do not substitute with 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 e n t h e f l u i d o container.
7. With the water and air valves off, aftach the water and air suppliesto the tlusher. (Hot water if available.)
3 . Secure flusherfiller cap,and pressurize tank the the

with compressed to between550- 829 kpa {5,6air 8.45kg?cm' ,80 - 120psi). NOTE:The air line shouldbe equipped with a water trap to ensurea dry air system. 4. 5. H a n g h et o o l u n d e r h e v e h i c l e . t t Attach the tank's dischargehose to the return line of the transmission coolerusinga clamp. Connect drain hoseto the inlet line on the transthe m i s s i o n o o l e r s i n ga c l a m p . c u IMPORTANT: Securely clampthe opposite ofthe drainhoseto a end bucketor floor drain. Depress triggerto mix the flushing the fluid into the waterflow. Usethe wire clipto holdthe triggerdown. 1 0 . W h i l ef l u s h i n g i t h t h e w a t e ra n d f l u s h i n g l u i df o r w f two minutes,turn the air valve on for five seconds every 15- 20 seconds createa surgingaction. to AIR PRESSURE: MAX 845 kpa (8.45kgf/cm,, 120psi)
1 1 . Turn the water valve off. Release the trigger,then
8 . Turn on the flusherwater valve so water will flow throughthe coolerfor 10 seconds. NOTE:lf water does not flow throughthe cooler,it plugged,cannotbe flushed,and must is completely be replaced.
reverse the hosesto the coolerso you can flush in the opposite direction. Repeat steps8 through 10. 1 2 . Release trigger,and rinsethe coolerwith water the 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 leaving the drain hose. CAUTION: Residualmoisture in the cooler or pipes can damagethe transmission. {r water
TRANSMISSION COOLER FLUSHER (Commercially availablel Kent-MooreJ38405-A or oquivalent
Remove the flusherfrom the coolerline.Attachthe drain hoseto a container. I n s t a l t h e t r a n s m i s s i o n ,n d l e a v et h e d r a i n h o s e l a attached the coolerllne. to (cont'dI
BUCKET
14-155
Transmission
CoolerFlushing(cont'd)
1 1 . Makesurethe transmission in the E position. is
\,
TOOL MAINTENANCE 1. Emptyand rinseaftereachuse.Fillthecanwith water and pressurize can. Flushthe dischargeline to the ensure that the unit is clean. lf discharge liquiddoes not foam,the orificemay be blocked. To clean,disconnect plumbingfrom the tank at the thelarge oupling ut. c n
F i l lt h e t r a n s m i s s i ow i t h A T F ,a n d r u n t h e e n g i n e n f o r 3 0 s e c o n d s r u n t i la p p r o x i m a t e0y 9 5I ( 1 . 0U S o l. q t . ,0 . 8l m p q t . ) i sd i s c h a r g e d . 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 s r e t u r n o s et o t h e t r a n s m i s s i o(n e ep a g e' 1 4 ' 1 6 0 ) . h '19. Refillthe transmission with ATF to the proper level ( s e e a g e1 4 - 8 6 ) . p
2.
3.
FILLER CAP
FILTER
COUPLING I{UT
\ \
- 0 - - \D
O-RING
I I
-sq
I
\
ORIFICE
4.
Remove in-linefilterfrom the discharge the side and cleanit necessary. The fluid orificeis locatedbehindthe filter. Clean it with the pick stored in the bottom of the t a n k h a n d l e o 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 parts. all
5.
14-156
Shift Gable
f!!@
1. 2.
Makesure lifts are placedproperly(see

5.
Remove shift cableholder. the Remove shift cablecover. the R e m o v e 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 , t then removethe shift cable.Takecare not to bend the cablewhen removing/installing it.
8 x 1.25mm 22 N.m kgt.m, 12.2 16 tbf.ftl
section11. Remove front console(seesection20). the 6. Shift to N position, then removethe lock pin from the adjuster.
SHIFTCABLEHOLDER SHIFTCABLE
SHIFTCABLE COVER
LOCKWASHER Replace. 6x1.0mm 14 N.m (1.4kgf.m.10lbtft)
6x1.0mm 12 N.m {1.2kgf.m, 8.7 tbt.ftl
CONTROL LEVER
SHIFTCABLE
7. 8.
7 N.m
Install the shift cable in the reverse order of removal. Check the cable adjustment on reassembly (see page 14-158).
ksf.m. lbt.ft) s 10.7 3. Remove shift cablebracket. the
SHIFTCABLE BRACKET
6x1.0mm 9.8N.m kgl.m.7.2lbf.ft) 11.0
14-157
Shift Cable
Adjustment
!@ section1). 1. 2. 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 T a l i g n e d 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 . h e r ea r e w two holes in the adjuster.They are positioned90' 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.
Remove front console(seesection20). the Shift to E position, then removethe lock pin from the adiuster.
Cable Too Shorl
Cable Too Long
Exact Alignment
4 . lf the hole is not perfectly aligned,loosenthe lock-
and adjustas required. nul on the adjuster to 5 . Tightenthe locknut 7 N.m (0.7kgf.m,5 lbf.ft). l 6 . I n s t a l t 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 and must be readjusted. out of adjustment
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 follows the automatic transshift positionindicator 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 (g t t r o u b l e s h o o t i n s e ep a g e1 4 - 7 8h r u 1 4 - 8 1 ) . 1 0 . Insertthe ignition key into the key cylinderon the panel,and verifythat the Aft gear positionindicator shift lockleveris released.
7 N m 1 0 . kgf.m, 7 5lbtft)
Ir
t'l
14-158
Shift Lever
PUSHKNOBSPRING LEVERKNOB SCREW N.m {0,3 kgnm. 2 lbI.ft) Applynon hardening threadlocksealant.
SILICONE GREASE
SCREW 3 N.m (0.3kgf.m, 2 lbl.ft)
GEANPOSITION INDICATOR PANEL COVER BUSHING LAMP SHIFTINDICATOR SHIFTLOCK LEVER SCREW 3 N.m {0.3
-Gt
SILICONE GREASE LEVER ASSEMBLY
2/'o"*"'
,@__-----Gar \oo.,rar.*
5x1.0mm 9.8 N.m 11.0 kgf.m, 7.2 tbt.fr) A/T GEARPOSITION PI-ATE
A/T GEARPOSITION SWITCH
SHIFTI-EVER ERACKET BASE
SHIFTLEVER BASECOLLAR 6x1.0mm 9.8 N.m (1.0kgl.m,7.2lbf.h)
14-159
Shift Indicator Panel

Adjustment
1 . C h e c k h a t t h e i n d e xm a r k o n t h e i n d i c a t o a l i g n s t r with the E mark on the shift indicatorpanelwhen t h e t r a n s m i s s i oi n i n N E U T R A L . s
INDEXMARK
ATFCoolerHoses
Connection
l. Connect ATFcoolerhosesto the ATFcoolerlines the and ATF cooler,and securethem with the clips as shown. TRANSMISSION CLIP
3 N'm (0.3 kgf.m,2lbf.ft)
PANEL
ATF COOLER
lf not aligned.removethe front console(seesection 201. Removethe shift indicatorpanel mounting screws and adjustby movingthe panel. NOTE:Whenever shiftindicator panelis removed. the reinstall panel described the as above.
HosEs
aoo'itoa
2-4 mm 1 0 . 1 - 0 . 2i n )
f "
14-160
-
(CVT) Transmission Variable Continuously

. . . . . . . . . . . .. . . 1 4 - 1 6 2 S p e c i aT o o l s l '14-163 ..................... Description Brake/Planetary Clutches/Reverse . . . . . . . . . .1 4 - 1 6 6 Gear/Pulleys . . . . . . . . . . . . . . 1.4.1 6 8 . . .. Power low F . . . C l E l e c t r o n i co n l r oS y s t e m . . . . . . . . . . . . . . . . . . . 1.4 1 7 1 ...... 14-173 H y d r a u f iC o n t r o l c ......... 14-177 H y d r a u l iF f o w c . M P a r k i nB r a k e e c h a n i s .m. . . . . . . . . . . .... . . .1 4 ' 1 8 7 g ElectricalSystem L . . - t8 . C o m p o n e n t o c a t i o n s , . . . . . . . . . . . . . . , . . . . . ... . . .1.4 . .' . . .9 ..... 14-190 t T C MC i r c u iD i a g r a m TCM TerminalVoltage/ .. . . 1 M e a s u r i n g C o n d i t i o.n s. . . . . . . . . . . . . . . . . . . . . 1.4 .-.' . 9 2 ...... Procedures . . ... . . .. ..... . 14 194 Troubleshooting Chart Symptom-to-Component 1 . . . . . . . . . .4 - 1 9 8 E l e c t r i c a ly s t e m S Troubleshooting Electrical 1. . Fl T r o u b l e s h o o t i n go w c h a r t.s . . . . . . . . . . . . . . . . . 4.- 2 0 0 Solenoid LinearSolenoids/lnhibitor ........14-223 T e s t. . . . . . . . . . . . . . . . . . . . . . . . . Gear Pulley/Secondary DrivePulley/Driven ShaftSpeedSensors '14'224 ...... .......... Replacement StartClutchControl Procedure........... 14-225 Calibration StartClurch System Hydraulic Chart Symptom-to-Component ..... . .14'226 System Hydraulic . . . . . . . . . . . . . . . . . . . .1 4.-.2.2 . .. . . 4 T Road est StallSpeed ........14'230 T e s t. . . . . . . . . . . . . . . . . . . . . . . . . FluidLevel .. ..14'231 Checking/Changing ............14-232 P r e s s u rT e s t i n g e LowerValveBodyAssembly . . . . . . . . . ... . 1 4 ' 2 3 4 Replacement ATF Filter R e m o v a l / l n s t a l l a t i o n . . . . . . . . . . . . . . ...............1 4 - 2 3 5 .. Transmission Transmission ........14-236 R e m o v a.t. . . . . . . . . . . . . . . . Index lllustrated ValveBody Transmission/Lower 1 . . . . . . . . . .. . . .4 ' 2 4 0 Assembly Housing/ Transmission . F l y w h e e l H o u s i n.g. . . . . . . . . . . . . . . . .....,.,.... 1 4 - 2 4 2 RightSide Cover/ 1. . H l n t e r m e d i a t eo u s i n 9 . . . . . . . . . . . . . . . . . . . . . . 4.-.2 4 4 Housing/ Transmission LowerValveBodyAssemblY .....'14-246 . R e m o v a l. . . . . . . . . . . . . . Housing Housing/Flywheel Transmission ........14-244 R e m o v a.l. . . . . . . . . . . . . . . . Housing RightSideCover/lntermediate ........14-250 R e m o v a.l. . . . . . . . . . . . . . . . M a n u aV a l v eB o d y l ....... Disassembly/lnspection/Reassembly 14'252 ForwardClutch n . 4 .. . . l l l u s t r a t eld d e x . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 . . - 2.5.3 . . . . . . . . . . . . . . . . . .1 4 - 2 5 4 Disassembly . . . . . . . . .... . . . . 1 4 ' 2 5 6 Reassembly GearShaft Secondary 25 x 35 mm ThrustShim Selection. . ..... . . 14 260 Differential 1 l d l f l u s t r a t en d e x. . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 2 6 1 . .,..14-261 Inspection Backlash .t .4 . R B e a r i n g e p 1 a c e m e.n . . . . . . . . . . . . . . . . . . ..... . .1 . . '.2 6 2 . . Cla r r i eR e p l a c e m e n.t. . . . . . . . . . .1'4 - 2 6 2 r Differentia 14-263 ........... Oil SealRemoval ...14-263 e de O i l S e a ll n s t a l l a t i o n / S iC le a r a n c . . O I H F l y w h e e l o u s i n gn p u tS h a f t i l S e a l . . . . . . . . . . .1 4 - 2 6 5 Replacement B H T r a n s m i s s i o no u s i n g e a r i n g s DrivenPulleyShaftBearing 1 . . .. R e p l a c e m e . . t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.-.2.6 6. . . . . . n. GearShaftBearing Secondary . . . . . . . .. 1 4 - 2 6 1 Replacement B H Flywheel ousing earing GearShaftBearing Secondary 1 .- .. R e p l a c e m e . . t . . . . . . . . . . . . . . . . . . . . . . . ......... . .4 . .2 6.7 n. R i n gG e a rB e a r i n g . . . . . . . . . . . . .1 4 - 2 6 8 . Replacement ControlShaftAssembly ....14-268 Removal/lnstallation Transmission . . . . . . .. . . . . . 1 4 - 2 1 0 Reassembly 1 F l y w h e e l / D r i Pea t e. . . . . . . . . . . . . . . . . . . . . . ...' . ......... .4 - 2 7 9 vl Transmission . . . . . . . . . . . . . . .1.4 - . . 8 0 . .. 2 lnstattaton . . . . . . . . . .1 4 - 2 4 4 CooleFlushing r Shift Cable .'.,.14-246 Removal/lnstallation .. .............:.....:................. . .. . ... 14-2aj Adjustment . . . . . . . . . . . . . . . . . . 1.4 . .2 . 8 . . - .8 s h i f tL e v e r Panel Shift Indicator . . . . . . . . . . . . . . 1.4 - 2 8 9 . Adjustment ATFCooler/Hoses ........ 14-289 .............. lnstallation
SpecialTools
\
Ref. No. I Tool Number 07GAE PG40200 07JAD- PH80200 07LAE PX40'100 07PM- 0010100 07sAz - 0010004 07TAE P4V0110 07TAE P4V0120 07TAE P4V0130 _ OTMAJ PY4OI lA 07MAJ- PY40120 07406 0020400 - 0070300 07406 07736 A010004 07746 0010100 07746 0010500 07746 0010600 07746 0030100 07749 0010000 07947 611050't 07941 - 6340201 Description ClutchSpringCompressor BoltAssembly Pilot,26 x 30 mm ClutchSpringCompressor Attachment SCSService Connector Backprobe Set Reverse BrakeSpringCompressor Start ClutchRemover Start ClutchInstaller A/T Oil Pressure Hose,2210 mm A,rIOil Pressure Hose. Adapter A,/T Pressure Oil GaugeSet Wpanel A,/T Low Pressure Gaugew/panel Adjustable Bearing Puller, - 40 mm 25 Attachment,32 35 mm x Aftachment, x 68 mm 62 Attachment, x 75 mm 72 Driver40 mm l.D. Driver DriverAttachment, mm 68 DriverAttachment, x 72 58 (hy
,l 1 1 1
PageReferenco 14-254,257 14-254,25'l 14-195,225 14-196,228 14-251,271 14-249 14-274,275 14-232 14-232 14-232 14-232 14-261 14-265, 268 14-267 14-266,261 14-262,263 't4-265,266, 267, 14-265 14-265
o o
@
p,
2
'l 1 1 4 1 1 1 I 1 1 1 '1
o o 6r
@ @ @ @-
(D
@ @ @ @ @
(D
I I
*Must be usedwith commercially-available - 16 slidehammer. 3/8"
E.!rnt!!---
g
l,
\ l
@ fi
@ @ @
(9
\ @)
14-162
Description
(CVT) a electronically The Continuously Variable Transmission is controlled automatic with drive and driven transmission pulleys, and a steelbelt.The CVTprovidesnon stagespeeds forwardand one reverse. The entireunit is positioned line in 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 transmission four parallel has shafts: the input shaft,the drive pulleyshaft,the drivenpulleyshaft and the secondary gearshaft.The input shaft is in linewith the enginecrankshaft. drive pulleyshaftand the drivenpulleyshaftconsistof The movableand fixedface pulleys. Eoth pulleysare linkedby the steelbelt. The input shaft includes sun gear.The drive pulleyshaft includes torwardclutchwhich mountsthe carrierassemthe the bly on the forwardclutchdrum.The carrierassembly includes piniongearswhich meshwith the sun gear and the ring the gear.The ring gear hasa hub mountedreverse brakedisc. The driven pulleyshaft includes startclutchand the secondary the drive gear whjch is integralwith the parkinggear.The gear shaft is positioned secondary gear shaft betweenthe secondary drive gear and the final drivengear.The secondary includes secondary the driven gear which servesto changethe rotationdirection, because drive pulleyshaft and the 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 n o m b i n a t i o n o f p l a n e t a r y e a r si n t h e t r a n s m i s s i o a r e g . c s n engagedby the clutches and the reverse brake,power is transmitted from the drive pulleyshaftto the driven pulleyshaft to provideE, E, d, and E. Electronic Control The electronic controlsystemconsists the Transmission of ControlModule (TCM), sensors, three linearsolenoids, and a inhibitorsolenoid. Shjftingis electronically controlled underall conditions. The TCM is locatedbelowthe dashboard, behindthe kickoanelon the driver'sside. Hvdraulic Control The lower valve body assembly includes the main valve body,the Pressure Low (PL)regulator valve body,the shift valve body, the start clutch control valve body, and the secondary valve body. They are positionedon the lower pan of the t r a n s m i s s i oh o u s i n g . n The main valvebody contains Pressure the High (PH)controlvalve,the lubrication valveand the pitot regulator valve. The secondary valve body contains the PH regulatorvalve,the clutch reducingvalve,the start clutchvalve accumulator and the shift inhibitorvalve.The PL regulatorvalve body containsthe PL regulatorvalve and the PH-PL control valve which is joined with the PH-PL control 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 s 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 t solenoid. The stan clutchcontrolvalve body contains the start clutchcontrolvalve,which is joined with the start clutch controllinearsolenoid. The linearsolenoids and the inhibitorsolenoidare controlled the TCM.The manualvalvebody by which contains manualvalveand the reverse the inhibitorvalve,is boltedon the intermediate housing. The ATF pump assembly located the transmission is on housing,and it is linkedwith the input shaft by the sprockets and the sprocket chain.The pulleysand the clutchreceive fluid from their respective Ieed pipes,and the reverse brakereceives f l u i df r o m i n t e r n ah y d r a u l ic i r c u i t . l c 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 d 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 s h i c h l i n e a rs o l e n o i d h e T C M w i l l a c t i v a t e . t w t Activating the shift control linearsolenoidchanges the shift controlvalve pressure, causingthe shift valveto move.This pressurizes drive pulley pressure the drive pulleyand the driven pulley pressure the driven pulleyand changes the to to pulleyratio.Activating startclutchcontrollinearsolenoidmovesthe startclutchcontrolvalve.The start their effective the clutchcontrolvalveuncovers port, providingpressure the startclutchto engageit. the to
(cont'd)
14-163
I
Description
(cont'd)
Gear Selction The shift leverhassix POSitiONS:PARK, REVERSE, NEUTRAL, DRIVE, SECOND, E LOW. E F] ANd E E E Position Description Frontwheelslockedj parkingbrakepawl engaged with the parkinggearon the drivenpulleyshait. The startclutchand the forwardclutchreleased. Reverse; reverse brakeengaged. Neutral; startclutchand the forwardclutchreleased. the General driving;the transmission automatically adjusts keepthe engineat the bestspeedfor to drivingconditions. For rapidacceleration highwayspeeds; transmission at the shiftsinto a lower rangeof ratiosfor betteracceleration increased and enginebraking. For enginebrakingand powerfor climbing;the transmission shiftsinto the lowestrangeot the rataos.
E PARK E REVERSE E NEUTRAL {d DRrvE E] SECOND E LoW
Staningis possible only in @ and N positjons rhroughthe useof a slide-type, neutral-safety switch. Automatic Transaxle{A/T) Gear Position Indicator The A/T gear positionindicatorin the instrument panelshowswhich gear has beenselected without havingto look down at the console.
14-164
L )/
BING GEAR
FLYWHEEL
STEEL BELT
STARTCLUTCH
INPUTSHAFT
PULLEY DRIVE
FORWARD CLUTCH REVERSE BRAKE ARY GEARSET
ATF FILTER
14-165
Description
Clutches/Reverse Brake/Planetary Gear/Pulleys
Clutchs/Reverse Brake 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 tce u t c h e s n d b r a k et o e n g a g eo r d i s e n g a g eh e t r a n s m i s s i o n e a r s .W h e n ld a g t pressure introduced hydraulic is into the clutchdrum and the reverse brakepistoncavity,the clutchpistonand the reverse brakepiston move.This presses frictiondiscsand the steel platestogether,lockingthem so they don,t slip. power is the t h e n t r a n s m i t t e dh r o u g ht h e e n g a g e d l u t c hp a c kt o i t s h u b - m o u n t e g e a r ,a n d t h r o u g he n g a g e d i n g g e a rt o p i n i o n t c d r gears. Likewise, when the hydraulic pressure bledfrom the clutchpackand the reverse is brakepistoncavity,the prstonreteases the frictiondiscsand the steelplates, and they are free to slidepast each. This allowsthe gearto spin independently its on shaft,transmitting power. no Start Clutch The stan clutch,which js located the end of the drivenpulleyshaft,engages/disengages secondary at the drive gear. The stan clutchis suppliedhydraulic pressure its ATFfeed pipeswithin the drivenpullevshaft. by Forward Clutch The forwardclutch, which is located the end of the drive pulleyshaft,engages/disengages sun gear. at the The forwardclutchis suppliedhydraulic pressure its ATFfeed pipewithin the drive pullevshaft. by ReveFe Brake The reversebrake,which is locatedinsidethe intermediate housingaroundthe ring gear,locksthe ring gear in @ position The reverse brakediscsare mountedto the ring gear and the reverse brakeplatesare mountedto the intermediate housing. The reverse brakeis suppliedhydraulic pressure a circuitconnected the internalhydraulic by to circuit. PlanetaryGear gearconsists a sun gear,a carrierassembly, The planetary of and a ring gear.The sun gear is connected the Inputshaft to with splines The pinion gearsare mountedto the carrierwhich is mountedto the forward clutch drum. The sun gear inputsthe enginepower via the input shaftto the planetary gear,and the carrieroutputsthe enginepower.The ring gear is only usedfor switching the rotationdirection the pullevshafts. of In @, $, and E positions(forwardrange), the pinion gears don't rotate and revolvewith the sun gear, so the carrier rotates ln S position(reverse range), the reversebrakelocksthe ring gear and the sun gear drivesthe prntongearsto rotate.The pinion gearsrotateand revolvein the oppositedirectionfrom the rotationdirectlonof the sun gear,and the carrierrotates with piniongear revolution. Pulleys Eachpulley consistsof a movabletace and a fixed face, and the effective pulley ratio changeswith enginespeed.The drive pulleyand the drivenpulleyare linkedby the steelbelt. To achievea low pulley ratio, high hydraulicpressure works on the movableface of the driven pulley and reduces the effective diameterot the drive pulley,and a lower hydraulicpressure works on the movableface of the drive pulleyto eliminate steelbelt slippage. achieve high pulleyratio,high hydraulic the pressure To a works on the movableface of the drive pulleyand reduces effective the diameterof the drivenpulley,and a lower hydraulic pressure workson the movable faceof the drivenpulleyto eliminate steelbelt slippage. the
14-166
ATF PUMP SPROCKET DRIVEN RING GEAR FLYWHEEL
ATFPUMP DRIVEPULLEY REVERSE BRAKE PISTON FORWARD CLUTCH REVERSE BRAKE CARRIEB RINGGEAR
DRIVEPLATE PLANETARY PINIONGEARS INPUTSHAFT
ATFPUMP DRIVECHAIN
ATF PUMP DRIVESPROCKET
STARTCLUTCH GEAR FINALDRIVE GEAR SECONDAFY SHAFT
DRIVEN PULLEY SHAFT
ORIVEN PULLEY
STEEL EELT
ORIVE GEAR SECONDARY
a'-
PARKING GEAR
14-167
Description
PowerFlow
E Position . Start Clutch: released
. ForwardClutch:released a Reverse Braket released pressure not appliedto the startclutch,forwardclutch,and the reverse Hydraulic is brake.Poweris not transmatted the to secondary drive gear. E Position . . . Stan Clutch: released ForwardClutch: released Reverse Brake: released
Hydraulic pressure not appliedto the stan clutch,forwardclutch,and the reverse is brake.power is not transmitted the to secondary drive gear'The secondary drive gear is lockedby the parkingbrakepawl interlocking parkinggear. the
FLYWHEEL
FORWARD
INPUTSHAFT
SUN GEAR
STARTCLUTCH DRIVENPULLEY
FINAL DRIVE GEAR
SECONDARY GEAR SHAFT
i{ B$
PARKING GEAR
14-16A
FINALORIVEN GEAR
E, E, 8nd E PGitions (Forward Range) . . . 1. engaged StartClutch: engaged ForwardClutch: ReverseBrake:released The hydraulicpressureis appliedto the forward clutch and the stan clutch,and the sun gear drives the forward clutch. The forwardclutchdrivesthe drive pulleyshaft,which drivesthe drivenpulleyshaftlinkedby the steelbelt. drive gear,via lhe sta.t clutch. The drivenpulleyshaftdrivesthe secondary drivengear.which drivesthe final drivengear. to Poweris transmitted the secondary
2. 3. 4.
on pressure the movablefaceof eachshaftdepends the throttleopeningposition. on NOTE:The workinghydraulic

FLYWHEEL
PULLEY DRIVE
CLUTCH
SUN GEAR
START CLUTCH
DRIVEN SECONDARY GEAR
(cont'd)
FINAL DRIVEN GEAR
14-169
Description
Power Flow (cont'd)
E Po$ition . . . 1. StartClutcht engaged ForwardClutch:released Reverse Brake: engaged pressure appliedto the reverse The hydraulic is brakeand the startclutch.The sun gear drivesthe pinrongears,and the piniongearsrevolvearoundthe sun gear.The carrierassembly rotatesin the oppositedirection from tne rotatron direction the sun gear. of The carrierassemblydrivesthe drive pulleyshaft via the forward clutchdrum, and the drive pullevshaft drivesthe drivenpulleyshaft linkedby the steelbelt. The drivenpulleyshaftdrivesthe secondary drive gearvia the startclutch. Poweris transmitted the secondary to drivengear,which drivesthe final drivengear.
DRIVEPULLEY DRIVE PULLEY STEELBELT BEVERSE BRAKE CARRIER ASSEMBLY
3. 4.
INPUTSHAFT
STARTCLUTCH
FINAL DRIV SECONDARY DRIVEN GEAR
!il
FINALDRIVEN GEAB
14-170
ControlSystem Electronic
and a three ljnearsolenoids, sensors, ControlModule (TCM), of controlsystemconsists the Transmission The electronic underall conditions controlled Shiftingis electronically inhibitorsolenoid. behindthe kickpanelon the driver'sside belowthe dashboard, The TCM is located when the vehicleis to The TCM controlsthe transmtsston reduceenginespeedand retainthe engine'scoolingefficiency drivenwith full throttleacceleration p t t t, y 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 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 nh e T C M r e g u l a t e sh e p u l l e yh y d r a u l i c r e s s u r eo After coolingefficiency. the designed speedand retains the increase pulleyratio,which, as the result,reduces engine the the the vehiclehasbeendrjvenat a lowerenginespeedfor a while,the TCM increases pulleyratioto the originalratio clutch{if the IVC is on} and the TCM sendsa signalto the ECMto cut off the A,/C in the E position, For smooth starting is increases enginespeedto 900 rpm when the transmission shiftedto the E position the the TCM regulates To The start clutchfunctionsto make smooth startingpossible. let the start clutchfunctionproperly, in pressure memorized the E position. pressure basedon the engine'snegative hvdraulic the startclutch
=
I
E z 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
SIAFTCLUICN CONTsOL LINEAFSOLENOID
SC1
6 F
TXD/NXD
SIlIFTCONTROL L]NEARSOLENOID
=
I
rM8
sNAKE SWIICN
l\__
+B
8RA(EL]GHT
i\-
rcr
2 14
3 16 11
10 t l 12 23 25
1 12
2
'14
s to
20
20
1 7 l8
14-172
Control Hydraulic
The ATF pump is drivenby the by controlsystemis controlled the ATF pump,the valves,and the solenoids. The hydraulic The inhibitor input shaft.The ATF pump and the input shaft are linkedby the ATF pump drive chain and the sprockets. controlledby the TCM. Fluidfrom the which are locatedon their valve body, are solenoidvalveand the linearsolenoids, pressure the drive pulley,the driven pulley,and to valveto maintainspecified ATF pump flows throughthe PH regulator valve. the manual valve body,the shift valve body,the start the main valve body,the PL regulator includes The lower valve bodv assembly valvebody. clutchcontrolvalvebody,and the secondary Main ValveBody valve. valve,and the pitot regulator the the The main valvebody contains PHcontrolvalVe, lubrication PH Control Valve (HLC), and supcontrolpressure (PHC) accordance with the PH-PL in The pH controlvalvesuppliesPHcontrolpressure PH it At PH plies pH control pressure the PH regulatorvalve,which also regulates pressure. kick-down, increases to inhibitor the This shonensthe shift speedby releasing reverse the which increases high (PH)pressure. controlpressure valve. pressure from the inhibitorsolenoid lRl) LubricationValve pressure. Whenthe preslubrication pressure eachshaft and maintains to valvecontrolsthe lubrication The Iubrication passage. valveand opensthe fluid leak This movesthe lubrication sureis too high,the spring is compressed. Pitot RegulatorValve when the electron with the enginespeed, {SC)in accordance the valvecontrols startclutchpressure The pitot regulator ic controlsvstemjs faulty.
VALVEBODY LOWER ASSEMELY
TION VALVE
1+173
Description
Hydraulic Gontrol(cont'dl
SecondaryValve Body The secondary valve body contains valve,the clutchreducingvalve,the start ciutchvalve accumulator, the PH regulator and the shift inhibitorvalve. . PH Regulatol Valve The PH regulatorvalve maintainshydraulicpressure to suppliedfrom the ATF pump, and suppliesPH pressure the hydraulic is valve by the PH control controlcircuitand the lubrication circuit.PH pressure regulated the PH regulator at (PHC) pressure from the PHcontrolvalve. Clutch ReducingValve The clutchreducing valve receives pressure PH from the PH regulator valveand regulates clutchreducingpressure the (CR) the manualvalveand the startclutchcontrolvalve,and The clutchredLrcing valvesupplies clutchpressure to lCR). pressure supplies signalpressure the PH-PL valve. to controlvalve,the shift controlvalve,and the inhibitorsolenoid Start Clutch Valve Accumulator pressure The startclutchvalveaccumulator stabilizes hydraulic the that is supplied the startclutch. to Shift lnhibitor Valve The shift inhibitorvalveswitches fluid passage switchthe startclutchcontrolfrom electronic the to controlto hydraulic (CR) the pitot regulator controlwhen the electronic controlsystemis faulty.lt alsosuppliesclutchreducingpressure to pipe. valveand the pitot lubrication
VALVE STARTCLUTCH
VALVE SECONDARY BOOY
VALVE SHIFTINHIBITOR
VALVE REDUCING CLUTCH VAL PH REGULATOR
fi 1i
1 4- 1 7 4
L
PL RegulatorValve Body controlvalve,which is joined with the PH-PL valve and the PH-PL the PL regulator valve body contains The pL regulator valvebody The inhibitorsolenoidis boltedon the PL regulator controllinearsolenoid. PL RegulatorValve (PL) the pulleyto eliminate steelbelt slippage' to low pressure valvesupplies The PL regulator (HLC). controlpressure by is The PL pressure controlled the PH-PL PH-PLControl Valve controlvalve supplies to valve according enginetorque.The PH-PL The pH-pLcontrolvalve controlsthe PL regulator conThe PH-PL pH-pLcontrolpressure higherthan PL pressure. (HLC) the PH controlvalveto regulate pressure PH to by which is controlled the TCM' controllinearsolenoid, by trol valveis controlled the PH-PL lnhibitorSolenoid controlsPH inhibitorvalveby turningon and off, Also,the inhibitorsolenoid the reverse The inhibitorsolenoidcontrols (Rl) pressure to the PH controlvalve The inhibitorsolenoidis con(PHC) applyingreverse inhibitor by controlpressure trolledby the TCM. Start Clutch Control Valve Body the The startclutchcontrolvalve body contains start clutchcontrolvalve.Both are ioinedto the startclutchcontrollinear solenoid. . Start Clutch Control Valve to according the throttleopening.The start clutchconThe startclutchcontrolvalvecontrolsstartclutchengagement by which is controlled the TcM. by trol valveis controlled the stan clutchcontrollinearsolenoid,
CONTROL STARTCLUTCH LINEARSOLENOID
CONIROL STARTCLUTCH VALVE
SOLENOID INHIBITOR
PL REGULATOR
VALVEBODY
VALVEBOOY LOWER ASSEMBLY
PL REGULATOR VALVE
PH.PLCONTROL LINEARSOLENOID
(cont'd)
14-175
)
Description
Hydraulic Control (cont'dl
Shift Valve Body The shiftvalvebody contains shift valveand the shift controlvalve.Bothare joined the to the shift controllinearsotenoid. e Shift Valve The shift valve is controlledby shift valve pressure (SV)from the shift control valve.The shjft valve distributes pH pressure and PL pressure drive pulleyand the drivenpulley,to shift the transmission. to . Shift ControtValve The shift controlvalve controlsthe shift valve in accordance with the throftleopeningand 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 regulator pressure the startclutch. to
SHIFTCONTROL
LOWER VALVEBODY
ASSEMBLY
CONTROL VALVE
VALVEBODY
Manual Valve Body The manualvalvebody contains the manualvalveand the reverse inhibitorvalve.The manualvalvebody is boltedto the intermediate using. ho . ManualValve The manualvarvemechanicaty uncovers/covers fruid passage the according the shift reverposition. to ReverseInhibitor Valve The reverseinhibitorvalve is controlledby the reverseinhibitorpressure (Rt).lt intercepts hydraulic the circuitto the reverse brakewhile the vehicleis movingforwardat speeds over approximately mph (10km/h). 6
REVERSE INHIBITOR
MANUALVALVE
BODY
14- 1 7 6
HydraulicFlow
GeneralChart of Hydraulic Pressure
. Shift Valve . Shiftlnhibitor Valve
,,/
SHIFTVALVE
PL REGULATOR VALVE
PH REGULATOR VALVE
NO.
DESCRIPTION PRESSURE OF CONTROL CLUTCH
NO.
PP PR RCC RI RVS
DESCRIPTION PRESSURE OF PITOT PIPE PITOT REGULATOR RECIRCULATION INHIBITOR REVERSE REVERSE BRAKE CLUTCH START
coL
CR
ATF COOLER R CLUTCH EDUCING PULLEY DRIVEN DRIVEPULLEY FORWARD CLUTCH PH-PL CONTROL LUBRICATION PRESSUREGH HI PHCONTROL PRESSURE LOW
DN DR FWD
HLC LUB PH PHC PL
sl
SUC SV X
I S H I F TN H I B I T O R SUCTION SHIFT VALVE LEAK
(cont'd)
14-177
L
Description
Hydraulic Flow (cont'dl
llj Position As the engineturns,the ATF pump also startsto operate. Fluidfrom the ATF pump flows to the PH regulator valveand the clutchreducing valve.The PH regulator valveregulates (pH),and send,it to the shift valveand the pL reguhigh pressure lator valve.The high pressure (PH)flows to the movableface of the driven pulleyvia the shift valve,and turns into low (PL)at the PL regulatorvalve.The low pressure pressure (PL)flows to the movableface of the drive pulleyvia the shift valve.At this time, the pulleyratio remainslow. (PH)becomes clutchreducingpressure The high pressure the {CR)at the clutchreducing valve.The clutchreducingpres_ sure{CR) flows to the startclutchcontfolvalve,the manualvalve,the PH-PL controlvalve,and the shift controlvalve,and is intercepted thosevalves. by Underthis condition, pressure not appliedto the clutches hydraulic is and reverse brake.
1 4-1 7 A
E position, at low speed range The valve is the same as in E position. The flow of fluid up to the drive pulley.the drivenpulley,and the clutchreducing {PL). (PH), low pressure pressure and the drive pulieyreceives high the pulleyratio is low because drivenpulleyreceives (CR)flows throughthe manualvalveto the forwardclutch,then forwardclutchis engaged. in" "tut"t reducingpressure The forwardclutchthen drivesthe drive pulleyshaft,which drivesthe drivenpulleyshaft' pressure(CC). Also, clutch reducingpressure(CB)flows to the start clutch control valve, and becomesclutch control (SC)is (SC)at the shift inhibitorvalve.Start clutchpressure (CC)becomesstart clutch pressure Clutchcontrol pressure clutch the start to aoolied the startclutchto engage
(contd
14-179
Description
HydraulicFlow (cont'dl
lll position, at middle sped range As the speedof the vehiclereaches prescribed the value.the shift controllinearsolenoidis activated the TCM.The shift by controllinearsolenoidcontrolsthe shift controlvalveto activate (SV).Clutchreducingpressure (CR) shift valve pressure from the clutchreducing (SV)at the shift cont.olvalve.Shift valvepressure valvebecomes (SV)flows shift valvepressure to the left end of the shift valve,the shift valveto the right side and positioning in the middleof its travel.The shift valve it (PH)to the pulleys.and uncovers coversthe port to stop high pressure (PL)to the pulleys. the port leadinglow pressure (PL). this time, the pulleyratiois in the middle. The drive pulleyand the drivenpulleyreceive low pressure At Pressure remainsto applythe forwardclutchand the stan clutch. NOTE:When used,"left" or "right" indicates direction the hydraulic on circuit.
$
14-180
E position, at high speed range value,the shift controllinearsolenoidmovesthe shift controlvalveto the As the speedof the vehiclereaches prescribed (SVl at the left end of the shift valve.The shift valve movesto the right side compared its to increase shift valvepressure (PH)to the drive pulley and the port leadinghigh pressure positionat the middle pulteyratio.The shift valve uncovers (PH)and the driv(PLlto the driven pulley.The drive pulleyreceives high pressure uncovers pon leadinglow pressure the (PL). The pulleyratio is high low pressure en pulleyreceives Pressure remains applythe forwardclutchand the startclutch. to "|eft" or "right" indicates circuit directionon the hydraulic NOTE:When used,
(cont'd)
14-181
Description
lll position The flow of fluid up to the drive pulley,the driven pulley,and the clutchreducing valve is the same as in E position. The pulleyratio is low because drivenpulleyreceives (pH)and the drive pulleyreceives the high pressure (pL). low pressure The manualvalve is shiftedinto the E position,and it uncovers the port that leadsreverse (RVS) the brakepressure to reverse inhibitorvalve.The inhibitorsolenoid turns off by meansof the TCM,and reverse (Rl)is applied inhibitorpressure to the right end of the reverse inhibitorvalve.The reverse inhibitorvalvemovesto the left side,and uncovers pon that the (RVS) the reversebrake.Clutchreducingpressure leadsreversebrakepressure (CR)becomesreversebrakepressure to at {RVS) the manualvalve,and flows to the reverse brake. The reverse brakeis engaged, and it locksthe ring gear. NOTE:When used,"1eft"or "right" indicates direction the hvdraulic on circuit.
14-182
Lll position FeveBe lnhibitor Control while the vehicleis moving forward at speedsover 6 mph (10 kmlh),the inhibitorsolenoid lf the E positionis selected (Rl) is not appliedto the reverseinhibitorvalve as the inhibitorpressure doesn,tturn off by meansof the TCM. Reverse valve is kept on the right side, and coversthe port to stop reverseinhibitor solenoidturns on. The reverseinhibitor (RVS) not appliedto is brakepressure (RVS) the reversebrakefrom the manualvalve.Reverse to reverse brakepressure direction. to brake, and Doweris not transmjtted the reverse the reverse "right" indicates circuit. on direction the hydraulic NOTE:When used,"left" or
(cont'd)
14-183
Description
Hydraulic Flow(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. (CR)flows to the stan clutchcontrolvalve,th manualvalve,and the shift controlvalve.and is Clutchreducingpressure intercepted thosevalves. by Underthis condition, pressure not appliedto the clutches hydraulic is and reverse brake.
14-144
E po3ition. when the electroniccontrol system is taulty. is usesthe pitot pipe pressure When the electronic controlsystem(linearsolenoids and sensors) faulty,the transmission (PP) allow the vehicleto drive. to controlsystem,clutchreducingpressure When all linearsolenoids and sensors off because a faulty electronic are of {CR) flows to the startclutchcontrolvalve,the manualvalve,the PH-PL controlvalve,and the shift controlvalve.Clutchreduc(SV)is appliedto (CR)becomesshift valve pressure (SV)at the shift controlvalve,and shift valve pressure ing pressure the left end of the shift valve and the right end of the shift inhibitorvalve.The shift valve movesto the right side,and (PL)to (PH)to the drive pulleyand uncovers the port that leadslow pressure uncovers the port that leadshigh pressure pulley.At this time, the pulley ratio is high. The shift inhibitorvalve movesto the left side,and uncovers the the driven (Sl)to the pitot lubrication port that leadsshift inhibitorpressure pipe and the pitot regulator valve.The pitot lubrication pipe discharges fluid entersinto the pitot pipe and it is appliedto the left fluid insideof the pitot flange,and discharged the pon that leadspitot valve.The pitot regulator valve movesto the right side,and uncovers end of the pitot regulator (SC)at the (PR) the shift inhibitorvalve.Pitot regulatorpressure pressure start clutchpressure regulator to {PR)becomes (FWD)is is engaged. The forward clutch pressure shift inhibitorvalve.and is appliedto the start clutch.The start clutch This allowsthe vehicleto drive. appliedto the forwardclutch,and the forwardclutchis engaged. NOTE:When used,"left" or "right" indicates direction the hydraulic on circuit.
(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 uncovers (RVS) the the port that leadsreversebrakepressure to reverse inhibitorvalve.Reverse (Rl)is appliedto the right end of the reverseinhibitorvalve because inhibitorpressure of a faulty inhibitorsolenoid.The reverseinhibitorvalve moves to the left side, and uncoversthe port that leadsreverse brakepressure(RVS) the reversebrake.Clutchreducingpressure(CR)becomesreversebrakepressure(RVS) the to at manualvalve,and flows to the reverse brake. The reverse brakeis engagedand locksthe ring gear.This allowsthe vehicle to drive in reverse. NOTE:When used,"left" or "right" indicates direction the hydraulic on circuit.
14-186
Mechanism Brake Parking

by locksthe transmission engagingthe parkingbrakepawl with the parkinggear which is The parkingbrakemechanism drivengear which engages with the secondary drive gear engages secondary drive gear.The secondary integralwith the with the final drivengear. at the parkingcone (installed the end of the parkingbrakerod) to pressthe parkingbrake Shiftingto E positioncauses gear. Even it the end of the parkingbrakepawl rides on the top of the parkinggear teeth,slight pawl onto the parking movementof the vehiclewill causethe parkingbrake pawl and the parkinggear to mesh with each other completely the because parkingbrakecone receives tensionfrom the parkingbrakerod spring.The parkingbrakepawl receives the the the tension(whichactsto separate parkjngbrakepawl from the parkinggear)from the parkingpawl spring.
ART CLUTCH
PARKING GEAR
PARKINGBRAKEROD PARKING BRAKE PAWL PARKING BRAKE RODSPRING
14-187
ComponentLocations
a
BRAKESWITCH
AUTOMATIC TRANSAXLE {A/T) SWITCH GEARPOSITION
SECONOARY GEARSHAFT SENSOR SPEED
MANIFOLD ABSOLUTE PRESSURE {MAP)SENSOR THROTTLE POSITION ITPI SENSOR
INHIBITOR SOLENOID STARTCLUTCH CONTROL LINEAR SOLENOID SHIFTCONTROL LINEAR SOLENOID

PH-PL CONTROL L I N E A RS O L E N O I D
14.1A 9
TCMCircuitDiagram
\
UNDER-HOOD FUSE/RELAY BOX
N o . 4 18 0 A ) N o . 4 7 ( 7 . 5 A ) l
PARKING BRAKE SWITCH
IGNITION IL CO
UNDER-DASH FUSE/RELAY BOX
Y I I
V
I I I
BLU
I I I
oul
To12v lGl 5V REGULATOS
G A U GA S S E M B L Y E A/I GEAR POSITION INDICATOR
L TG R N 8LK/8LU
_ RED GRN/8LK -GflN_ BLU
BLK
[,
I:
14-190
I I
G401 G404
8l,K BRN/BL( | I BRN/BLK I
l A 4 l A 1 7l A 1 3 l A 2 6
RED/BLU I
T T I J , T*t* I *-I*T*^,T,*;i, T ,,t,,. ?t T l 'lFr 'i Fl --l+--++ ;I. T T lTI T T T T.,^T,,T T".T"T 1P 1ts I | | | | I I I t.lt I i LOJ L C @ @ @ @ l F l ,rr,r,.o,
wHT I WHT/REDI PNK/8LK I PNK/BLU I GRNTYEL I GRN/BLK
t t a
L--.1 L---l
I BLK
P K/BLK I
PNK/8LU I
GRNIYEL I
G8N/BLK
8RN/BLK
BLK
SECONDARY PH_PT DNNE PULLEY DRIVEN PUI-LEY CONTROL GEAR SHAFT SPEEO SENSOR SPEED SENSOR SPEED SENSOR LINEAR SOLENOID
START CLUTCH CONIROL LINEAR SOLENOID
SHIFT CONTROT I.INEAR SOLENOID
s0LEN0r0 | t
_o
:
_o_
:
G101
L l
G101
Locations TCMTerminal
,,
10 23
11
,l t,
2 13 14
t 5
6 16
7 18
10
14 1 5 l6 1 7
TCM A {26P)Connctor
20
2 5 26
20
T C M - Bl 2 2 P ) C o n n e c l o r
14-191
TGM TerminalVoltage/Measuring Gonditions
--r-
TCM Torminal Locations
a 6 7 20 10
1 7 l8
3 4
la 15 16 11
1 I 20
r0i11 12
23,/
26 1 2
14 15
L)
TCM-A(26P1 Connoctor TCM CONNECTOR A {26P} TerminalNumbor
TCM.Bl22PlConnector
Measuring Conditions/Terminal Voltage Start clutch control linearsolenoid PH PL control linear solenoidpower Shift control linear solenoidpower E n g i n ei d l i n g , p o s i t i o n : E Aoorox. 0.4 V Engineidling,lll positionl Approx.0.7 V Enginedling, l positionl i E
inerunningPulsing ignal : s gear positionswitch L! position Ay'T In i!.1position:0 V In other than E position:
410 411
0 I nE Jp o s i t i o n :V ln otherthanE position: Approx. V 1O 0 gearposition A,/T switch position I nL l l p o s i t i o n :V E In otherthanE position: Approx. V 1O gear positionswitchE or E Ay'T I n E o r E p o s i t i o no V r A/Tgearposition switch position lg
s i g n a li n p u t gear positionswitch E position A,,/T
In other than N or E position:Approx. 1OV I n L Ep o s i t i o n : 0 V I : 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 A15 A16 417 A18 A19 E indicatorlighr control indicatorlight comes on: Approx. 10 V indicatorlight OFF:0 V PH-PL control linearsolenoidDower Shift control linearsolenoidpower Enginedling, i Enginedling, i Aoprox.5.0 V E n g i n ei d l i n g , ADorox.6.0 V
posation:
Always banery voltage 424 With ignitionswitch ON (ll): Batteryvoltage With ignition switch OFF|0 V 426
14-192
{
B TCM CONNECTOR (22P)
Terminal Number Me6suring Conditions/Terminal Voltag With inhibitorsolenoidONr Batteryvoltage O s W i t h i n h i b i t o r o l e n o i d F F : 0V V W i t h i g n i t i o n w i t c hO N ( l l ) :A p p r o x . 2 . 5 s With engine idling: Approx. 1.0V (dependingon s engine peed) With ignitionswitch ON (ll) and throttlefully open: 4 . 1 4- 4 . 4 2V With ignitionswitch ON (ll) and throttlefully closed:0.44- 0.56V With ignitionswitch ON (ll) and rotatingfront wheelsi0-SVcycle With ignition switch ON (ll):Pulsingsignal With ignition switch ON (ll)rPulsingsignal
B1 82 B3 B4
(MAP) Manilold AbsolutePressure sensorsignal input
Throttle PositionlTP) sensorsignal input
B5 B6 B7 B8
Driven pulley speedsensorsignal 810 B tl Drive pulley speedsensorsignal Data communicationwith ECMI control data oLltput Transmission Datacommunicationwith EcM: PGIM-Fl control data input
: s 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 g i g n a l ln other than position;Pulsingsignal
812 813
814 SCS
Brakeswitch signal input
Batteryvoltage With brakepedal depressedr V released:0 With brake
v switch (ll):Approx.5.0 oN with ignition

I Servicechecksignal With ignition switch ON (ll) and servicecheckcon nectoropen: Approx. S V With ignition switch ON (ll) and servicecheckconwith specialtool: 0 V nectorconnected Depending vehiclespeed:Pulsingsagnal on When vehicleis stopped:0 V
815
816
817 818 819
Secondarygear shaft speedsensor s i g n a li n p u t Secondarygear shaft speedsensor
Parkingbrakeswitch signal input
p a r k i n g r a k el e v e rp u l l e d : 0V b rkinq brakelever released: A s W i t h i g n i t i o n w i t c hO N ( l l ) : p p r o x . 5 .
voltage
820 821 822
14-193
Procedures Troubleshooting
l. How To Begin Troubleshooting procedurebelow to diagnoseand repairthe When the E indicatorlight has been reportedon, use the appropriate
proorem.
light hascome onl A. Whenthe E indicator (DLC)locatednearthe left 1. Connect the HondaPGM Testeror an OBD ll ScanTool to the 16PData Link Conneclor k i c kp a n e l . 2. Turn the ignitionswitchON (ll). 3. Checkthe DTC and note it. Also checkand note trame data. the freeze Referto the DiagnosticTrouble Code Chan and begintroubleshooting.
o0\-/oo
INOICATOR LIGXT
instructions. operating NOTE:SeetheOBDll ScanToolor HondaPGMTesteruser'sman uals for specific the the PGM-Fl system,disconnect problemswill also makethe E indicatorlight come on. After repairing Some PGM-Fl TCM memory,then recheck. to fuse/relay for more than 10seconds resetthe box BACKUPfuse (7.5A) in the under-hood the NOTE:Disconnecting BACKUP tuse also cancelsthe radio presetstationsand the clock setting,Make note of the beforeremovingthe fuseso you can resetthem. radiopresets
TOoL or OBDtl SCAN HONDA PGMTESTER
I16PI OATALINKCONNECTOR
14-194
Connect connector connected. will be indicated the blinkingof the E indicatorlight with the SCSservice by B. DTCS (2P)is located as the SCS serviceconnectorto ServiceCheckConnector shown. (The ServiceCheckConnector Turn the ignitionswitchON (ll) side of the vehicle.) underthe dashon the passenger's
CONNECTOR I2PI
07PAZ @101tX)
CONNECTOR
by by short blinks.Codes10 and aboveare indicated a seriesof long and shon Codesl through9 are indicated individual the code.After deterblinks.One long blink equals10 short blinks.Add the long and shon blinkstogetherto determine Charton pages14-198 and 14-199. systemSymptom-to-Component miningthe code,referto the electrical
Shon blink {onc.l
S.. DYCI
S.c DlC2 Long blink Sho.t blinkt {fiv. tim6l
S.c DTC15
the the PGN4-Fl system,disconnect problemswill also makethe E indicatorlight come on. After repairing Some PGM-Fl to fuse/relav box for more than 10 seconds resetthe TCM memory,then recheck. BACKUP fuse (7.5A) in the under-hood
(cont'd)
14-195
(cont'd)
C. lf the inspection a particularcode requiresvoltageor resistance for checksat the TCM connectors, removethe driver'sside kickpanel.Unboltthe TCM.Turn the ignitionswitchOFF,and connect the backprobe setsand a digital multimeter described as below.Check systemaccording the procedure the to described the appropriate for code(s) listedon the followingpages.
How to use the BackprobeSet Connect the backprobe adapters the stackingpatchcords,and connectthe cordsto a multimeter. to Usingthe wire insulation a guide for the contoured of the backprobe as gently slidethe tip into the connector tip adapter, from the wire side untilcomesin contact with 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. y A 2 . R e m o v eh e B A C K Pf u s e( 7 . 5 ) f r o m t h e u n d e rh o o df u s e / r e l ab o 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 . t U NOTEI . Disconnecting BACKUP fuse also cancels radio presetstationsand the clocksetting.Makenote of the radio the the presets beforeremovingthe fuse so you can resetthem BACK UP (7.5 FUSE A)
. The TCM can also be cleared usingthe OBDll ScanTool or HondaPGMTester. by

OBO ll SCAN TOOL ol
PGMTESTER
LINK CONNECTOB DATA I16P) lll. FinalProcedure must be done afterany troubleshooting. NOTE:This procedure 1. Turn the ignitionswitchoff. 2. Reset TCM. the (16P), removethe special or tool the 3. Disconnect OBD ll ScanTool or HondaPGMTesterfrom the DataLink Connector Connector. from the Service Check and clocksetting. 4. Turn the ignitionswitchON (ll),and set the radiopresets
14-197
Symptom-to-Component Chart
ElectricalSystem
Diagnostic Indicaror Trouble Code E Lig t h (DTC)* Symptom
E n g i n er p m d o e s n o t i n c r e a s e . Transmission does not kick-
\
Possible Cause Disconnected throttleposition(TP) sensorconneclor Shortor open in TP sensorwire Faulty sensor TP Disconnected vehiclespeedsensor (VSS) connector Shortor open in VSSwire Faulty VSS Shortin A/T gear positionswitchwire gear positionswitch Faulty A"/T Disconnected gear positionswitch A/T connector gear positionswitchwire Openin A,/T Faulty Aft gear positionswitch Disconnected ignitioncoil connector Shortor open in ignitioncoil wire F a u l t yg n i t i o n o i l i c Disconnected pres, manitoldabsolute sure(I/AP) sensorconnector Shon or open in MAP sensor wire FaultyMAP sensor Disconnected solenoidharness connecror Shortor open in shift controllinear solenoid wire Faultyshift controllinearsolenoid Disconnected solenoidharness connector S h o no r o p e ni n P H - P L o n t r o l i n e a r c solenoid wire FaultyPH-PL controllinearsolenoid Disconnected solenoidharness con nector Shortor open in startclutchcontrol linearsolenoid wire Faultystartclutchcontrollinear solenoid Disconnected solenoidharness connector Shon or open in inhibitor solenoid wtre F a u l t yn h i b i t os o l e n o i d i r Refer to Page
P1790 (3)
Blinks
Transmission does not change to higher ratio.
14-200
. No specific symptomappears. P1791 (4) P'1705 15) P'1706 (6) Blinks . Transmission shiftssameas E positionin any positions. . Transmission shiftssameas @ positionin any positions.
14 201
Blinks
14 202
OFF
14-204
P0725 (1 ) 1
Blinks
Pooracceleration, flareson starting off. No specitic symptomappears.
14-206
P1793 \121
Blinks . Pooracceleration, flareson startingoft. Blinks
14-207
P1870 (30)
14-208
P1873 (31 )
Pooracceleration, flareson staningoff. Blinks
't4-209
Pooracceleration, flareson startingoff. P1 8 7 9 (32) Blinks
't4-210
No specific symptomappears. P1882 (33) Blinks
't4-2't 1
The DTCS parentheses the numberof the E indicatorlight blinkswhen the service in {DTC)*: are checkconnector conis nected with the special tool (SCSService Connector).
14-198
Diagnostic E Indicator Trouble Code Light (DTCT
Symptom flareson Pooracceleration, startingoff.
Cause Possible drive pulleyspeedsenDisconnected sor connector speed Shon or open in drive PulleY sensotwire Faultydrive pulleyspeedsensor drivenpulleyspeedsenDisconnected sor connecror speed Shon or open in drivenPUlley wire sensor Faultydrivenpulleyspeedsensor gear shaft secondarY Disconnected connecror speecl sensor gearshaft Shortor open in secondary speedsensorwtre gearshaftspeed Faultysecondary sensor Shortor open in TMA wire between 87 terminaland ECIVI Shon or open in TMB wire between86 t e r m i n aa n d E C M l FaultyECM TCM Faulry . Faultyshift controlsystem Faultystartclutchcontrolsystem
Referto Page
P1885 (34)
Blinks
14-212
P1886 (35)
. Pooracceleration, flareson starting off. Blinks
14-213
. Poor acceleration,flares on starting off.
P1888 (36)
Blinks
14-214
. Poorcreeping powerwith brake pedalreleased. P1655 l31l Blinks
14-215
P1890 \421 P1891 (43)
Blinks Blinks
flareson Pooracceleration, off. starting

Poor acceleration,flares on starting otf.
14-217 14-214
checkconneclorrs con(DTC)*: are in The DTCS parentheses the numberol the E indicatorlight blinkswhen the service Connector). tool (SCSService with the special nected to according the table below lighr does not blink,performan inspection lf the self-diagnostic indicator E SymPtom afterignitionswitch light does not come on lor two seconds E indicaror is firstturn on {ll). (not blinking) the ignition whenever light is on constantly @ indicator switchis on (ll). Inspection
Ref. page
14-220
14-222
NOTE: (5),it will be necessary recreate symptom by test driving, lhe to the . It a customerdescribed symptomfor code P1706 the then recheck DTC. lf lamp (MlL)may come on simultaneously. so, repairthe Indicator light and the Malfunction . Sometime E indicator the p G M - F ls y s t e ma c c o r d i n go 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 t Drivethe vehiclefor severalminutesat a speedover 30 mph (50 km/h),then fuse/relay box for more than 10 seconds. the recheck DTC.
14-199
)
TroubleshootingFlowchart - Throttle Position (Tp) Sensor
. OBD ll ScanTool indic.les Code P1790. . Sef-diagnosisE indicaior light blinks threo times. PossibleCause . Disconnoctdthrottle Dosition (TP)sensorconnecior . Short or open in TP sensorwire . FaultvTP sonsor
CheckIor Anothe. Code or MIL Blinking: '1. Turn the ignition switchON (ll). 2. Checkwhetherthe OBD scan tool indicates anothercode or the Malfunction Indicator Lamp (see lMlL)blinks section 11).
Doesthe OBDllscan tool indicate anothercode isthe MILblink or ing?
Repairthe PGM-Flsystem lse section111.
MeasureVREFVohage: 'L Turn the ignitionswitchOFF. 2. Disconnect A (26P)and B the P 1 2 2 ) 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 n w i t c hO N s flr). 4. Measure the voltagebetween the 820 and A13 or 426 terminals,
TCM CONNECTORS l26Pl
WHT/RED WIRESIDEOF FEMAI-E TERMINALS
Repair op6n or short in the wir6 betweenthe 820 terminal and the ECM.
Measu.e TPS Voltagel Measurethe voltage between the B4 and A13 or A26 terminals.
RED/BLK
ls there0.4-0.6V?
Repairopen in the whe betwoen the 84terminal and the TP sensor.
Chocklor loos6 TCM connectoB. ff necossary, substitute a knowngood TCM and recheck.
Flowchart VehicleSpeedSensor(VSSI Troubleshooting

. OBD ll Scan Tool indicare. Codo P1791. . Sor-di.gnotb E indhttor light blink3lour tim.i PossibleCause . Di3connected vehicls sPeed ienaor (VSSIconnectol . Short or ooan in VSS wile . Faulty VSS
Refol to s.ction 23 tor vehicle spood 3ensor {VSSI t6t.
check rh. vss voh.go: the 1. Raiso vehicle. 2. Shift the transmissionto E posrt|on. and B 3. Disconnectthe A 126P) ( 2 2 P )c o n n e c t o r sf r o m t h e TCM. ON switch lll) 4. Turnthe ignition 5. Rotate the tront wheel and checkfor the voltage between the 85 and A13 or A26 terminals.Blockthe otherwheelso it does not turn.
. Mak6 3ure lifts, iacks,and salety stands aro plsced properly lseo section 1l . Set tho pa*ing brake socurgly,and block the rear wh6el3. . Jack up the front of the vehicl,and supPort it with salety 3tands' TCM CONNECTORS
Check lor open in the wiro botwean tho 85 torminal and the vehiclo speod sen30r (vSSl. lf wire is OK, chock the VSS (see 3ction23).
Chack for loo3o TCM connoctoG. ll nacaaarry,aubltituto t known' good TcM rnd rechock.
14-201
Troubleshooting Flowchart A/T GearpositionSwitch (Shortl
. OBD ll ScanTool indicatesCodo P1705. . Selt-diagnosis indicator tight @ blinksfive timos. PossibleCause .Short in A/T gear position switch wire . FeuttyA/T gear pGition switch NOTE:Code5 is caused when the TCM recerves two gear posilioninputsat the
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. Observe A/T gear position the a n d i c a t o ra n d s h i f t t o e a c h , position separately.
Do any indicators stay on when the shift lever is not in that position?
The syslem is OK at this tim. Checkthe wire harnesstor demage.
TCM CONNECTOR I26P} A
Mersure ATP R Voltagel 1. Shittto all positions othe.than 2. Measure the voltagebetween the Al 1 and A13or 426 terminals. Check for short in lhe wi.e betwoenthe A11terminal and tho A/T gear position switch or A/T gear position indicator. ll wire is OK, check for loose TCM connoctors. lf nocessary, substitute a known-goodTCM and .echeck.
tr.
WIRESIOEOF FEMALE TERMINALS
ls thereapprox.10V?
Measure ATP NP Voltagei 1. Shift to all positions other
t h a nE o r E . 2. Measure voltagebetween the the 410 and A13 or 426 termi, nals,
ls thereapprox.l0 V?
Check for short in th6 wiro between lhe A10 terminal and the A/T gar position indicator. or a short in tho wires botween th A/T gear position indicator and the A/T gear position switch. lI wires are OK, check for loose TCM connectors. ll necessary, substilute a known-good TCM and rochck.
MeasureATP D Vohago: 1. Shiftto all positions otherthan 2. Measure voltagebetween the the A9 and A13 or 426 rerminals. Check for short in the wire bstwoon the Ag terminal and the A/T gear position switch. ll wiro is OK, check lor loose TCM connectoG. lf neces3ary,substitute a known-goodTCM and rcheck.
E,
ls thereapprox.10V?
To page14'203
14-202
Frompage14-202
A TCM CONNECTOR (26P}
M.ssur6 ATP S Vohage: otherthan 1. Shjftto all positions 2. Measurethe voltage between the Ag and A13 or A26 termi nals. TERMINALS WIRESIDEOF FEMALE Check lor sho* in the wire between tho A8 tolminal and the A/T 9o.r po3ilion switch or the A/T goar position indicrtor. lf wirc is OK, check for loose TCM connctors. ll necessery,substitute a known-goodTcM and rochck
ts.
ls thereapprox.10V?
MoasureATP L voltager otherthan 1. Shittto all positions 2. Measurethe voltage between the A7 and A13 or A26 terminats, Check for short in the wile betwoen the A? terminal and the A/T gear po3ition switch or the A/f gear pGition indicttor. lf wile is OK, check for loo3o TCM connectors. lf nocasi.ry.subditute a known-goodTCM and rc.ch.ck.
E.
ls thereapprox.10V?
Checktor looso TCM connoctors. It neco$ary, substitute a known_ good TCM and rechock.
14-203
Troubfeshooting Flowchart- AIT Gear positionSwitch (Open)
. OBD ll Scan Tool indicatesCode P1706. . Self-diagnosis indicator tight E blinks six times. PossibleCause . Oisconnected A/T geer position switch connector . Openin A/T gearpositionswitch . Faulty A/T gear position switch
MeasureATP R Voltage: 1. Turnthe ignition switch (ll). ON 2. Shiftto E position. 3. Measure the voltagebetween t h eA 1 1a n dA 1 3o r 4 2 6 t e r m i nals, WIRE SIDE FEMALE OF TERMINALS Repairopen in the wire botween lhe A11 terminaland the A/T gear position switch.
MeasureATP NP Voltage: 1. Shiftto E or E position. 2. Measure the voltagebetween 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: 1. Shiftto E position. 2. Measure the voltagebetween 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 TCM CONNECTOR {26P}
MeasuroATP S Voltage: 1. Shittto E position. the voltagebetween 2. Measure the Ag and A13 or A26 termi_ nals. TERMINALS WIRESIDEOF FEMALE
Repairopen in lhe wire between the A8 terminal and the A/T gear oo3iiion swilch.
MeesureATP L Voltage: 1. Shiftto E position. the 2. Measure voltagebetween the A7 and A13 or A26 termi_ nals.
Repairopen in the wire between the A7 termin.l and th A/T goar oosition switch.
Checkfor loose TCM connectors. sub3titute a known' lf necessary, good TCM and recheck.
14-205
TroubleshootingFlowchart - lgnition Goil
. OBD ll ScanTool indicatsCode P0725. ' Selt-diagn6is E indicaior tight indicat6sCod6 'l 1. PosFibls Cause . Oisconnectedignition coil conngctor . Short or op6n ignition coil wire . Faulty ignition coil
Maasu.oNE Voltag6: 1. Disconnect the A l26p) connector from the TCM. 2. Startthe engine. 3. Measurethe voltage between 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 knowngood TCM and recheck.
Ii
14-206
(MAP)Sensor Flowchart ManifoldAbsolutePressure Troubleshooting

. OBOll ScanTool indicat$ Code P1793. . Self.diagno.i3E indicator light indicat* Cods 12. Po$iblo Causo . Dilconnoctodmanitold absolute prG3u.a {MAP} sensor connoc_
lol
. Short or opan in MAP 3on3o.

MAP snsol
Check tor Anolhor Coda or MIL Blinking: ON switch (ll). 1. Turnthe ignition 2. Checkwhetherthe OBOll scan tool indicatesanother code or IndicatorLamP the Malfr.rnction (see (MlL) 11). blinks section
OBDllscantool indicate Doesthe another codeoristhe MILblinking?
Repair PGM-Fl syltem 13663ec' tion 111.
TCM CONNECTORS Mca3uroVREFVohtge: l. Turnthe ignitionswitchOFF the 2. Disconnect A (26P)and B ( 2 2 P )c o n n e c t o r sJ r o m t h e TCM, 3. Turn the ignitionswitchON (ll). 4. Measurethe voltage between the 820 and A13 or A26 terminals.
WHT/REO WIRESIOEOF FMALETERMINALS
5 ls thereapprox. V?
R6pai. opon ot short in ths wire botw.on the 820 tolminal and rhe ECM.
Moasur. MAP (PBlvoltago: Measurethe voltage betweenthe 82 and A13or 426 terminals.
3 ls thereapprox. V?
Repair open or shon in the wire botween tho 82 terminal and tho MAP snsor.
Chcktor loo3eTCM connectors. lf n6ce$ary, 3ubstitut6 a known' good TCM and rech6ck.
14-207
TroubleshootingFlowchart - Shift Control Linear Solenoid
. OBD ll ScanTool indicatesCode P1870. . Selt-diagnosis indicator light E indicetesCod 30. PossiblCau3e . Disconnectedsolenoid harness connector . Short or op6n in shift cont.ol linear solonoidwire . Faulty shift control linear solcnoid
SOLENOID HABNESS 8P CONNECTOR 8LU/WHT
Measure Shift ControlLine.r Solenoid Resistance lhe Solenoid at Harness Connector: 1. Disconnect 8P connector the fromthe solenoid harness connector. 2, Measu e the resistance r beNveen No. 3 and the No. the 7 terminals ofthe solenoid har nessconnector.
GRN/YEL TERMINAL SIDE MALETERMINALS OF
ls the resistance 3.8 6.8O?
TCM CONNECTOR I26PI A
o
I
GRN/YEL
3 a
BLU/YEL
9 l 0 1 1 12
Check Shift Control Linear Solenoid for a Shon Circuit: 1. Disconnect e A (26P) on th c nector from the TCM. 2. Checkfor continuitybetween body ground and the 43 term i n a la n d t h e A 1 6 t e r m i n a l individually.
11 l5 16 1 7
20
23
26
o
WIBESIDE FEMALE OF TERMINALS
ls thereconlinuity?
Repairshorl in the wi.es be'tween the A3 and A16 terminals and the body ground. GRN/YEL
M a a s u r eS h i f t C o n t r o l L i n e a r SolenoidR6istance: 1. Connectthe 8P connectorto the solenoidharness connec tor. 2. Measure the resistance rJetween A3 and A16 terthe mt n a l s . Repair loose terminal or open in the wires between the A3 and A16 terminals and the solenoid harnessconnector.
'' 11 2
t'Ft
17 BLU/YEL
1 0 1 t 1 2 13 23 25 26
ls the resistance - 6.8g? 3.8
Checklor loose TCM connectors. ll nece$ary, substitute a knowngood TCM and recheck.
14-208
ControlLinearSolenoid Flowchart PH-PL Troubteshooting

OBD ll ScanTool indicatsCodo P1873. Self-diagnosis indicrtor light E indicatsCodo 31. Po$ib16Cau3e . Disconnectedsolonoid hatn8s connectol . Short or opon in PH_PL contol linear 3olenoidwire . FaultyPH-PL control linear sole_ noid
Mgasure PH-PLControl Lineet Solenoid Rgsistancaal th6 SoleConn6ctor: noid Harne3s the 8P connector 1. Disconnect confrom the solenoidharness nector. 2. Measu e the resistance r betweenthe No. 2 and the No. ha. 6 terminals the solenoid of nessconnector.
HARNESS SOLENOID 8P CONNECTOR GRN/WHT
PNK/BLK TERMINAL SIDE MALETERMINALS OF
3.8 ls the resistance - 6.8 0? A TCM CONNECTOR (26P)
o
Check PH-PLControl Linoar Sol.noid tor a Short Circuit: the A (26P)con1. Disconnect nectorfrom the TCNI. 2. Checkfor continuitybetween body ground and the A2 ter_ minaland the A15terminal iodividually. 1
PNK/BLK 1 11 5 8 I 1 0 1 1 12 1 3
11 15
20
23
25 26
o
R6pair 3hort in the wires between the A2 and 415 torminals and the body ground.
LGRN/WHr
TERMINALS OF WIRE SIDE FEMALE
_J()l-
Mea3ure PH-PLControl Linear Solsnoid Ro3istance: 1. Connectthe 8P connectorto connecthe solenoidharness tor. 2. Measure the resastance betweenthe A2 and A15 termanals,
- l PNK/BLK
t , t . 3 a
u1l] 16 1 7
GRN/WHT
20
8 9 t 0 11 12 1 3 25 26 23
3.8 ls the resistance - 6.80?
Ropair loosa terminel or opon in ihe wires between the A2 and A'15torminals and the solonoid conn6ctor. haJness
Ch.ck for loosa TCM connectors. It nece$ary, substhuto a known_ good ICM and rechck.
14-209
Troubleshooting Flowchart Start ClutchControlLinearSolenoid
. OBOll Sc.n Tool indicst$ Code P1879. . Selt-diagnosis indicator light E indicatesCode32. PossibleCrule . Disconnectodsol.noid harno33 connoctot 'Sho.l or opan in 6tart clutch control lineff solonoidwire . Faulty 3tart clutch control lineat solenoid SOLENOID HARNESS 8P CONNECTOR
Measuro Slan Clutch Control LinarSolenoidRosistance the at Solenoid Harness Connoqtor: 1. Disconnect 8P connector the from the solenoidharness connector, 2. Measure the resistance betweenthe No. 4 and the No. 8 terminals ofthe solenoid harnessconnector.
YEL
PNK/BLU TERMINAL SIDEOF MALETERMINALS
ls the resistance - 6.8 O? 3.8
TCM CONNECTOR I26P) A Check Start Clutch Control Linear Solonoidtor a Shori Circuitr 1. Disconnect the A (26P)connectorfrom the TCM. 2. Checkfor continuity between body ground and the A1 terminaland the A14terminal individually.
o
1
PNK/BLU
2 3 I 1 a t5 1 6
20
E 9 1 0 1 1 12 1 3 23 25 26
0)
R6pair short in the wir6s betwoen th6 Al and A1{ lerminals and the body grcund.
IYEL
Measu.6 51.n Clutch Cont.ol LinoarSolenoidRo3istance: 1. Connectthe 8P connector to the solenoidharness connector. 2. Measure the resistance betweenthe A1 and 414 termrnals. Repair looae tormin.l o. open in ih. wir6s botwoen th Al snd 414 terminals and tho solenoid htanos3connectot.
PNK/BLU
F Jr
2 3 il 5 a 15 1 6 1 7
8 9 10
20
I YEL
23
12 1 3 25 26
ls the resistance - 6.8 O? 3.8
Checkfor loos TCM connsctors. lf necossary, substitute a knowngood TCM and rechock.
14-210
TroubleshootingFlowchart - lnhibitor Solenoid

. OBD ll ScanTool indicatesCode P1882. . Self-diagnosis indicator light E indicatesCode33. Po$ible Cause . Disconnectedsolenoid harn6s3 connectol . Short or open in inhibitor sol.' noid wi.e . F.ultv inhibhor solenoid HARNESS SOLENOID 8P CONNECTOR
MasureInhibitorSolenoidRe3ist' a n c e a t l h e S o l e n o i dH a r n e s s Connector: the 8P connector 1. o;sconnect f r o m t h e s o l e n o i dh a r n e s s connector. r 2. Measu e the reslstance the between No. 5 terminalof connec_ the solenoidharness tor and body ground-
11.7 lsthe resistance - 21.0A?
B TCM CoNNECTOR l22p) Check Inhibitor Solenoid for a Short Circuit: th 1 . D i s c o n n e c t e I ( 2 2 P )c o n from the TCM. nector 2. Checkfor continuitybetween t h e B ' 1t e r m i n a la n d b o d y ground. TERMINALS WIRES|OEOF FEMALE
Repair3hort in the wire between the B1 and the body ground.
Measure lnhibhorSolenoidResisl' ance: 1. Connectthe 8P connectorto connec_ the solenoidharness IOr. r 2, Measu e the resistance betweenthe B1 and body ground.
11.7 ls the resistance -21.0{l?
ReDairloose terminal or open in the wire between the Bl and the solenoidharnessconnectoa.
Checktor loose TCM connectors. lI necessarv, substitute a knowngood TCM and recheck.
14-211
TroubleshootingFlowchart - Drive pulley Speed Sensor
. OBD ll ScanTool indicatosCode P18a5. . Selt-diagnosis indicator tight El indicat$ Codo3{. Po$iblo Cause . Dbconnectod drivo pulloy lpocd 30n301connectot . Shon or op.n in diiv. pulley tpasd sonaorwire . Faulty drivr pull.y sp..d ronsoa
ls the drivepulleyspeedsenproperly? sor installed
ORIVE PULEY SPEED SENSOR CO NECTOR 2P
Measurc D.iv6 Pulloy Sped Sensor Rasistlnce st the SorBor ConnctoJ: 1. Disconnect 2P connector the from the drive pulley speed sensor connector, 2. Measure the resistance ofthe drivepulleyspeedsensor.
t|;Trl *r-r
LJ
t9
\
RED/BLU
TERMINAL SIDEOF MALE TERMINALS ls the resistance 350 - 600 O? TCM CONNECTOR (22P} B Check Driv6 PullGySpood S.nsor for s Short Ci.cuit: 1. Disconnect B (22p)connecthe torfromtheTCM. 2. Checkfor continlity between body groundand the Bl0 tr, m i n a la n d 8 1 7 t e r m i n a i n d i l vidually.
2 4 5 6 , E 9 t0 12 t3 1 1 t5 1 6 1 ' 1 8 m
GRN
t,
nepair shon in th. wiags botween the B10.nd 817 torminals 6nd the driv6 pulley spd 3onso..
MeasuroDrivo PulloySpood Sensor R6ktanco; 1. Connect drive pulleyspeed the sensor2P connector, 2. Measure the resistance between the 810 and 817 terminals. RepaL looro toiminal or open in tha wiro3 betw6on tho Bto rnd 817 t.rminak .nd the driv6 oullay !p6od an3or.
REO/BLU 2 a 5 12 1 3 1 a t5 16
I
iTiT;f;Fdz
,I,ElVdVV
ls the resistance 350 - 600 0?
GRN
Chock lor looso TCM connestor. lf necessary. sub3titute e knowngood TCM and rechock.
14-212
Troubleshooting Flowchart - Driven Pulley Speed Sensor

' OBD ll ScanTool indicatsCode P1846. . Solt-diagnosis indicator light E indicatesCode 35. PossibleCause . D i s c o n n e c t e dd t i v e n P U l l e y 3pegdsensorconnec'tor . Short or open in driv6n PulleY so6dson3orwire . 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 ,
ls the drivenpulleyspeedsenproperly? sor installed
SPEED DRIVENPULLEY 2P SENSOR CONNECTOR

tr-_- l
Measure DrivenPulloySpeedSenat sor Resistance the SensorConnector: 1. Disconnect the 2P connectol speed from lhe driven PUlleY sensor connectorof the resistance the 2. Measure drivenpulleyspeedsensor,
-T-r l @ t l t_.1
l t1 | 2 |
lL +
SIDEOF MALETERMINALS TERMINAL
350 6000? ls the resistance B TCM CONNECTOR (22P) WHT
Check Driven Pulley Speed Snsor for a Short Citcuit: connec' the 1. Disconnect B (22P) torfromtheTCM. 2. Checkfor continuitybetween body ground and the 88 ter minaland 89 terminalindividuaIy. Reoairshort in the wirs bgtween th 88 .nd 89 terminals and the driven pulley spoedsensor.
8 20
10
12 13 14 15 1 6 1 7 1 8
ls therecontinuity?
MeasuleDrivenPulloySpeodSonsor Resistance: 1 . C o n n e c t h e d r i v e nP U l l e Y 2P speedsensor connector. 2 , M e a s ur e t h e r e s i s t a n c e the 88 and Bg termi between nals, Eepair loose trminal or opon in th wires botween the 88 and Bg lerminals and the driven Pulley soeedsensoJ,
RED/BLUI WHT
Al
\j/
10
12 1 3 1 4 1 5 1 6 1 7 1 8
20
350 600O? ls the resistance
Check lor loose TCM connector. substitute a known' lf necessarv, good TcM and recheck.
14-213
TroubleshootingFlowchart - SecondaryGear Shaft Speed Sensor
. OBD ll ScanTool indicatesCod P1884. . Self-diagnosis indicalor light E indicatesCode36. PossibleCause . Disconnecled3econdarygea. shaft speedsonsorconnctot . Short or open in scondarygear shaft speedsonsorwire . Faulty secondary 9ea1 3haft
Check the secondary gear shatt speed sensor installation.
ls the secondary gearshattspeed properly? sensorinstalled
SECONDARY GEARSHAFTSPEED SENSOR CONNECTOR 2P
lT- T ---1
MeasurSecondaryGear Shaft Speed Sonsor Resistanceat the Sensor Connectoa: 1. Disconnect the 2P connector from the secondary gearshaft speeosensor connector. 2. Measure the resistance ofthe secondarygear shaft speed
t l l 2 l -T--T-
ta
L__l
ls the resistance - 600O? 350 TCM CONNECTOR (22PI B Ch6ck Countrsheft Speed Sensor for a Short Circuitl 1. Disconnect B (22P)connec, the tor from the TcM. 2. Checkfor continuitybetween body groundand the 815 term i n a la n d 8 1 6 t e r m i n a i n d i l vidually. Ropairshort in the wires betwoen the 815 end 816 terminals and the socondary g6ar 3haft speed sensor.
1 a 5 6 8 9 10 12 1 3 '14 1 5 1 6 1 7 1 8 20
WHT/REDT '1 ORN/BLU
o) (o
MeasureSeconderyGoar Shaft SpedSensorResistance: 1 . C o n n e ct h e s e c o n d a r y e a r g shaftspeedsensor connec2P tor, 2. Measure the resistance between the 815 and 816 termtnals. Bepair loose terminal or oDen in the wires btween the 815 and 816 terminals and the secondery gearshaft speedsensor.
10
12 13 14 15 16 1 7 l8 WHT/REI
20
A I
ORN/BLU
ls the resistance - 600O? 350
Check tor loose TCM connector. It nocessary, substitute a knowngood TCM and recheck.
14-214
Flowchart- TMA and TMB Signals Troubleshooting

. OBOll ScanTool indicate3Code P1665. . Seff-dirgnosisE indicator light indicstosCod37. Po$ible Csuse . Short or open in TMA wire between B? terminal and ECM . Short or oDenin TMB wire beiwoen 86 terminal and ECM . Faultv ECM ' F.ultv TCM
I
B TCM CONNECTOR I22P) GRY
o
I
CheckTMA Wire ContinuitY: 1. Turnthe ignitionswitchOFF. the B (22P)con2. Disconnect nector from the TCM. 3 . D i s c o n n e ctth e C ( 3 1 P )c o n nector from the ECM. 4. Checkfor continuitybetween 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 ECM.
6 t 7 8
10
1 2 't3 1 a 1 5 1 6 1 7 1 8
20
C ECMCONNECTOB 131P) GRY 2 3 1 1 1 12 t 3 t 4
sJs;lI
16 17lle/t./
22
//
Rpairopen in the wiro between the TCM and the ECM.
//
l2s
WIRESIDEOF FMALETERMINALS
GRY ChockTMA wite lor a Shorl Ci.cuiti the lor between Check continuity 87 terminalof the TCM or the Cg t e r m i n a lo f t h e E C M a n d b o d y ground.
I
8 I
10
12 13 1 4
1 6 1 7 18
20
C ECMCONNECTOR {31P)
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 to connector the TCM. {22P) switchON (ll). 2. Turnthe ignition 3. Measurethe voltage between t h e c 9 t e r m i n a lo f t h e E c M and body ground.
1 2
5 6 7
10
11 12 1 3 1 4
t 5 1 7r 8
t/
4r 30
ls thereapprox.10V?
Checkfo. loose ECM connectors. substitute a known' ll necessary, good ECMand rcheck.
To page14-216
{cont'd)
14-215
TroubleshootingFlowchart - TMA and TMB Signals (cont'dl
ftom page 14 215
CheckTMB Wire Continuity: 1. Turnthe ignitionswitchOFF. 2. Disconnect C 13'1P) the connec tor from the ECM.and the B con {22P) neclorfrom the TCM. 3. Checkfor continuitybetween t h e 8 6 t e r m i n a lo f t h e T C M a n d t h e C 3 0t e r m i n a lo f t h e ECM.
TCM CONNECTOR I22P} B

PNK
o
I | 9 10
12 1 3 1 4 l 5
17 18
20
ECMCONNECTOR {31P} C 1 2
Repeir open in the wi.o between the TCM and th6 ECM.
sl67
16 1 1
9 10
1 12 t 3 l 4
ls therecontinuity?
LA WU 14+
PNK I
81/r,/)/
WIRESIDEOF FEMALE TRMINALS CheckTMB Wire tor a Short Circuit: Check continuity for between the 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.
PNK
o
7 8
10 20
1 2 1 31 a 1 5 1 6 1 7 1 8
ls therecontinuity?
check th6 TcM: 1 . R e c o n n e ctth e B ( 2 2 P )c o n nectorto the TCM, and the C (31P) connector the ECM. to 2. Turnthe ignition switch {ll}. ON 3, Measurethe voltage between t h e 8 6 t e r m i n a lo f t h e T C M and bodyground.
PNK
4 6 1 8 9 't0 '15 1 6 1 7 l 8 12 1 3 11 20 1
CheckIor loose TCM connectors. lf nece3sery, substituto a knowngood TCM and rcheck.
14-216
Flowchart Shift ControlSystem Troubleshooting

. OgD ll Sc.n Tool indiclt6 Codo P1890. . S.lt diagno.b E indicator ligl|t indic.tG Codo 42. Poasibla C.uta . Faulty shitt control rystom
Ch6ckfor Anoth.r Cod.: check whther the E] indicator light indicatessnother code.
light indilsthe E indicator cato anothercod6?
Parlorm lha Troubl63hooting Flowch.rt tor thc indicttcd 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 stallsoeedblow 2,000rPm?
T.!l-drivo .nd Ch.ok Engina Spa!d: t. Driv the vehicle at 30 mPh (50 km/h) constantly for several minutes, sps6d. the 2. Check engine
ls th6 engino speedwithin tho spocification(se6 page 14-228 and 1+229)?
14-217
TroubleshootingFlowchart - Start Clutch Gontrol System
. OBD ll ScanTool indicatesCode P1891. . Selt-diagnb E indicator tight indicatesCode43. PossiblG Cause . Feulty start clutch control system
Checkfor Another Code: C h e c k h e t h e rt h e E i n d i c a t o r w light indicates another code.
ls the E indicator tightindi cateanother code?
P e r l o r mt h e T r o u b l e s h o o t i n g Flowchart for the indicatod Code(sl.
Test Start Clutch Operationl 1. Turnthe ignitionswitchOFF. 2. oisconnectthe 8P connector from the solenoid harness con3. 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
Replaco stan clutch,assemblv. the
CheckCreepingSpeed: 1. Turnthe ignitionswitchOFF. 2. Reconnect 8P connector the to the solenoidharness connec, 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: Measure stallsooedRPM(see the page14-230).
ls the stall sDeedover 3,500rpm?
Warm Up Eogine and Rochck 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 fan lthe radiator comeson). whetherthe startclutch 2. Check problemappears again.
The syst6m k OK rt this time.
a
14-219
Troubleshooting Flowchart 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 ServiceChockConnectot: 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 servicecheckconnector,
ls the special tool (SCSService Connector) connected the serto vicecheckconnector?
Disconnsctth6 sDecialtool trom the sgrvice chgck connector and recheck.
Checkth E Indicator Light: Shiftto E position.
Does the E indicator light
Chocktor loosc TCM connector3. ff n6cess6ry, 3ubstituta e knowngood TCM and rachock. TCM CONNECTOR (26P) A
BLI i r ( [ ,
Checkthe Ground Circuit: 1. Turnthe ignitionswitchOFF. 2 . D i s c o n n e c t e A ( 2 6 p )c o n th nector from the TCM. 3. Checkfor continuitybetween t h e A 1 3 t e r m i n a la n d b o d y ground and the 426 terminal and body ground.
a
20
8 9 1 0 t 1 12
14 15 16 1 7
23
25
a a
l-
BLK (o
WIRE SIDE OF FEMALE TERMINALS
. Repair opan in the wi.s botwean lho A13 or A26 terminalsand G101. . Repairpoor ground ic101).
Io page 14 221
From page 14 220
A TCM CONNECTOR (26PI BLK/WHT I BLK
Measure Power SuPPIYCircuil Voltege: ON switch (ll). 1. Turnthe ignition the 2. Measure voltagebetween t e r m i n a l A 1 2a n dA 1 3 a n d s b e t w e e nt e r m i n a l sA 2 5 a n d 426.
(v) Y I
25 26
'10 l t 1 2 23
t a 15 16 1 7
20
)
BLK/WHT
TERMINALS WIRESIDEOF FEMALE Repairopen or short in the wiro between the Al2 and/or A25 terfuse minals and the undeFdash box.
BLK
ls Ihere banery voltage?
MeasureO IND Voltag6: 1. Turnthe ignitionswitchOFF. connec' 2. Connectthe A 126P) tor to the TCM. 3. Connecta digital multilester 10the A20 and A13 or A26ter mrnals. ON switch (ll), Turnthe ignition and makesure that the voltage fortwo seconds is available Check tor oDen in the wire btween the A20 terminal and lhc gauge assembly. lf the wire is OK, check for a faulty El indicator lighl bulb or a faulty gauge assomblyprinted circuit boa.d CheckD IND lor an Short Ci.ctlit: 1. TLrrn ignitionswitchOFF. the c th 2. Disconnect e A (26P) on nector from the TCM. 3. Checkfor continuitybetween andthe No.I the A20terminal terminalof the gaugeassem23). bly connector lseesection Repairopen in the wire between the A20 terminal and the gauge essemblY,
GRN/BLK
A TCM CONNECTOR (26P}
TERMINALS WIEESIDEOF FEMALE Checktor loose TCM connectors. C h e c kt h e A / T g e . r p o s i t i o n substitute a switch. lf necessary. known-good TCM and recheck.
14-221
Troubleshooting Flowchart El IndicatorLight On Constantly
Tho llj indicator light b on constantly {not blinking}whenev.r the ignition switch b ON (ll).
TCM CONNECTOR I26PI A Mea3ureD IND Voltag6: 1. Turnthe ignitionswitchOFF. 2. Disconnect e A (26P) onth c nector from the TCM. 3. Turn the ignitionswitchON {ll). 4. Measurethe voltage between t h e 4 2 0 t e r m i n a la n d b o d y ground. 1 2 3
9 10 t l 12 13
t4 15 1 5 1 7
20
23
25 26
GRN/8LK
WIRESIDEOF FEMALE TERMINALS Repairshort to powsr in the wir. botwoon tha A20 t6rminal .nd lhs gaug essombly.
Me.3ur6 ATP OVohage: 1. Turnthe ignitionswitchOFF. 2. Connectthe A (26P)connector to the TCM. 3. Turn the ignitionswitch ON (ll). 4. Shiftto any position otherthan 5. Measurethe voltage between t h e A S t e r m i n a la n d b o d y ground.
2 3
E.
ta
l5 1 6 1 1
20
E 9 l0 I t 12 1 3 23 E 26
Chock tor a short lo ground on the wire. It wiro i3 OK, roplaco the A/T goar pGition indic.tor.
rd
14-222
Linear Solenoids/lnhibitor Solenoid

Test
'L
Disconnect 8P connector from the solenoidharthe nessconneclor. M e a s u r e h e r e s i s t a n c o f t h e s h i f t c o n t r o ll i n e a r t e solenoidbetweenthe No. 3 and No. 7 terminalsof the solenoidharness connector. lMeasure resistance the PH-PL the of control linear solenoidbetween the No. 2 and No. 6 terminals. Measurethe resistance the start clutch control of linearsolenoidbetweenthe No. 4 and No. 8 terminals. STANDARD: - 6.8 o 3.8 M e a s u r e h e r e s i s t a n c e f t h e i n h i b i t o rs o l e n o i d t o between the No. 5 terminaland body ground. STANDARD: - 21.00 11.7
7.
2.
lf all of the resistances within the standard,a are c l i c k i n g 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 s the batteryterminalsto the solenoidharnesscon nectorterminalsbelow: . Shift control linear solenoid positive No.3: Batterv terminal No.7: Battery negative terminal PH-PL control linear solenoid No.2: Bafterv oositive terminal No.6: Battery negative terminal Start clutch control linear solenoid No. 4: Battervoositive terminal No. 8: Batterynegative terminal lnhibitorsolenoid positive No. 5: Battery terminal Bodyground:Battery negative terminal
3.
HARNESS CONNECTOR SOLENOID
SOLENOID HARNESS CONNECTOR TERMINAL SIDEOF MALETERMINALS
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 y e p l a c e r ment is required, see Lower Valve Body Assembly Replacement 4-234). {page'1
ATF DIPSTICK
6.
Replace lowervalve body assembly any of the the if resistance beyondthe standard. is solenoids
14-223
Sensors
Drive Pulley/DrivenPulley/Secondary Gear Shaft Speed

Replacement
CAUTION: While replacingthe speed sensor,be sure not to allow dust and other loreign particles to enter into the ttansmission. 1. 2. Disconnect drive pulley,the drivenpulley,or the secondary the gear shaftspeedsensorconnector. Removethe 6 mm bolt from the transmission housing,and removethe drive pulley.the driven pulley,or the secondarygear shaftspeedsensol. Replace O-ringwith a new one beforereinstalling drive pulley,the driven pulley,or the secondary the the gear shaft sDeed sensor.
\ ,
3.
6x1.0mm 12 N.m {1.2kgf.m, 8.7 lbl.ftl
DRIVEN PULLEY 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, TCM the must memorizethe teedback signalfor the start clutch control. o . . . . '96 TCM Transmission assembly Startclutchassembly Lowervalvebody assembly Engineassembly overhaul or
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 negative pressure in memory, let the engine idle in E or E position for one minute under the following conditionsl . . . . . With the brake pedal depressed. With the A,/Cswitch OFF. Wilh the combination light switch OFF. With the heater fan switch OFF. Turn OFF all other electrical systems.
Modl Only
NOTE: Start step 5 w;thin 60 seconds after the radiator Ian goes off. Shift into E position, and let the engine idle lor two minutes to store the feedbacksignal in memory under the same conditions as in step 5. 7. Connect the Honda PGM Tester. Check that the TCM has completed the start clutch calibration.
CAUTION:Do not use this procedure on'97 -'98 mod. els or you will damagethe transmission. On'97 -'98 models, the TCM memorizes the feedbacksignals when you drive the vehicle. 1 . E n g a g e 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 t wheelssecurely. 2. Connectthe SCS serviceconnectorto the Service C h e c kC o n n e c t o r s s h o w n . ( T h e S e r v i c eC h e c k a ( 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 passenger's side of the vehicle.)
NOTE:
o The TCM will not storethe feedback signalwhen is the CVTfluid temperature below 40'C (104'F) even il the engine coolanttemperaturereaches the normaloperating temperature. a R e p e a t h e s e p r o c e d u r e s n t i l t h e s t a r tc l u t c h u calibration completed. is 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 Service Check Connector. '97 - '98 Models The TCM memorizes feedback the signalwhen 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 comes n). o Shift into E position. a Turn OFFall electrical systems. 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). 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 ) , release accelerator 5 seconds. the for
(2PI CONNECTOR
CONNECTOR 07PAZ- 0010100
Start the engine,and warm it up to normal operat (the radiator comeson twice). ing temperature fan 4. Fullydepress the brakepedaland accelerator 20 for seconds the E position. in
14-225
Symptom-to-Gomponent Chart
HydraulicSystem
SYMPTOM Engineruns,but vehicledoes not move in anv position. Vehicle does not move in @, [, S positions. Vehicle does not move in B position. No shift to higherratio.
Poor acceleration. F l a r e so n m o v i n g .
Check theseitemson the PROBABLE CAUSE List 1 , 2 , 3 , 4 , 5 , 6 , 1 , 8 ,, 1 0 , 0 ,3 4 ,3 5 ,3 6 ,3 8 ,4 1 9 2 10,11,12,20,41 5 , 1 0 ,1 1 ,1 2 ,1 1 1 a ,1 9 , 2 0 , 3 94 1 , , 9 , 1 3 ,1 4 ,1 5 ,1 6 ,3 5 , 3 7 4 0 , 9 , 1 3 ,1 4 ,1 s ,1 6 , 2 0 , 3 5 , 3 7 , 3 a , 4 0 9, 10,20,21,35,36, 38, 40,42 9 , 1 0 ,2 0 , 2 1 , 3 5 , 3 6 , 3 8 ,2 4 9, 20,21, 35,36,3A 9, 17, 18,19,20, 35,36,38 10,22,23 10,11,12,22,41 ' t 1 ,1 2 , 1 7 ,1 A , 2 2 , 4 1 9, 10,20,35,37,3A2 4, 9, 18,19,20,25, 26.35,31,38,42 5 , 1 1 1 8 ,1 9 ,2 5 , 2 6 , 2 , 3 ,8 , 2 1 2 8 , 2 , 3 ,1 9 , 2 4 , 2 5 , 2 A 16,35,37,38
Excessive shockwhen depressing and releasing pedal. accelerator Noengine raking. b Vehicle does not accelerate E position. in Vehiclemovesin N position. (Shiftcableadjustment proper). is Lateshiftfrom @ positionto D position, and from @ position E position. to Lateshiftfrom N position E position, to and from E position @ position. to Enginestopswhen shiftedto @ positlon from N position. Engine stopswhen shifted E position to from E position. Noisefrom transmission E position.*1 in Excessive vibration. idle Noisefrom transmission E and E positions. in Hunting ngine peed. e s
Vibration in all position.
a, 2a
11,29, 'l 4
Shift leverdoes not operatesmoothty. Transmission not shift into E positionor transmiswill sion cannotbe removedfrom p position. Vehicle does not accelerate more than a certainsDeed. to Excessive shockon staningoff.
Flareson acceleratingat low speed.
11 29,30,31,32,33 ,
9 , 1 0 ,1 4 ,1 5 ,1 6 , 2 0 , 3 5 , 3 1 38, 42 20,21,34,42 20,21,3A,42 2 0 , 2 1 , 3 84 2 , 1 0 ,2 0 , 3 8 9 , 2 0 ,2 1, 3 7, 3 a 20,43
Excessive vibrationin @, p, p, @ posirions. Low enginespeedin [, [, p, @ positions. S t a l ls p e e d i g h . h Stallspeedlow.

Judder on starting off.
*1: Somegear noiseis normalin the
gear actton. E positiondue to planetary
4-226
a
LIST PROBABLE CAUSE 1 Low CVTfluid tevel Foreignmaterialin ATF pump. ATF pump worn. AT gearsworn or damaged. pump sprocket worn or damaged. ATFpump chain/ATF
I n p u t s h a f tw o r n o r d a m a g e d . 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 .
2
3
4
5 1 8 9 10
11
drivengearworn or damaged. drive gear/secondary Secondary plateworn or damaged. Flywheel/drive housingassembly worn or damaged. Intermediate
Forward clutch defective. Shift cable broken/out of adiustment.
12
t5
M a n u a l e v e rp i nw o r n . worn or damaged. ATFfeed pipe (pulleypressure) pulleyspeedsensordefective. Drivepulleyspeedsensor/driven speedsensordefective. Vehicle TCM defective.
14
17
Reverse brake defective.
18 19
partsworn or damaged. Reverse brakepistonand related P l a n e t a rg e a rw o r n o r d a m a g e d . y Start clutchdefective. worn or damaged. ATFteed pipe lstartclutchpressure)
brake clearance incorrect. Clutch clearance/reverse Reversebrake return spring/retainerworn or damaged-
20
21 22 23 24
Needlebearingon input shaftworn or damaged. o r T h r u s t e e d l e e a r i n g n c a r r i ew o r n o r d a m a g e d . n b Thrustwasheron carrierworn or damaged.

E n g i n eo u t p u t l o w . Flywheel assembly def ective. C o n t r o ll e v e rw o r n o r d a m a g e d .
25
,1
2a
29 30 32 34 35
brakepawl shaftworn or damaged. Parking brakepawl/parking worn or damaged. brakerod assembly Detentlever/parking
Parking gear worn or damaged.
brakepawl springworn or damaged. Parking filter clogged. ATFstrainer/ATF

Lower valve bodv assemblv defective.
36 37
38 40
41
(PL defective). valvebody assembly defective regulator Lowervalvebody assembly defective). defeclive Lowervalvebodv assemblv lshiftvalvebody assembly (startclutchcontrolvalvebody assembly defective). detective Lowervalvebodv assemblV defective). defective Lowervalvebodv assemblv linhibitorsolenoid
Solenoid harness worn or damaged. 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
systemdelective, PBfeedback CVTfluid deteriorated.
43
RoadTest
NOTE:Warm up the engineto normaloperating temperature fan {the radiator comeson). 1, Apply the parkingbrakeand block the wheels.Start the engine,then shift to the E positionwhile depressing the brakepedal.Depress accelerator pedaland release suddenly. the it 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.Release brake;the the vehicleshouldnot move. Test-drive vehjcleon a flat road in the positionshown in the table,Check the that the enginespeedsmeetthe approximatevehiclespeeds shown in the table. NOTET Throttlepositionsensorvoltagerepresents throttleopening,To monitorthe throttlepositionsensorvoltthe age,useone of the followingmethods: A. Connect HondaPGMTester, the and go to the PGM-FI DataList.
OBo ll SCANTOOLoI HONOAPGMTESTEB
3.
B.'!. Remove kickpanelto exposethe TCM for roadtesting;referto page 14-194. the 2. Setthedigitalmultitester check voltagebetlveen 84 (+)terminalandA4(-) or A17 (-)terminaloltheTCM to the for throttlepositionsensor. TCM
84 T6rmin.l
I I
I
[''
BACKPROBE AOAPTER
BACKPROBE SET 07sAz- 001000A {two raquirad}
DIGITAL MULTIMETER lCommelcielly.v.ilabl.) KS-AHM-32-003 or oquivilont
l
I
14-228
STACKINGPATCH CORD TCM CONNECTORS
E position: Engine Speedrpm Vehicle Soeed ThrottleOpening 0.75V Throttlepositionsensorvoltage: 2.25V Throttlepositionsensorvoltage: 4.5 Throttlepositionsensorvoltager V Fullthrottleposition 25 mph (40 km/h) 1,250 1,650 2,500 3,r 00 3,950 4,550 2,6s0 3,250 4,650 5,250 2,700 3,300 5,200 5,800 37 mph (60km/hl 62 mph 1100 km/hl
E position:EngineSpeed.pm Vehicle Speed

Throttle Opening
2s mph (40 km/h) 1,800- 2,200 2,950 3,550 4,100 4,700
37 mph 160 km/hl
62 mph (100km/hl 3,550 4.150 4,050- 4,650 5,900 6,500
0.75V Throttlepositionsensorvoltage: 2.25V Throttlepositionsensorvoltage: 4.5 Throttlepositionsensorvoltage: V p Fullthroltleositaon . E position:EngineSpeedrpm
2,200- 2,AOO
3,250 3,850 5,100 5,700
Vehicle SDeed
Throttle Opening voltage: 0.75V Throttlepositionsensor

Throttle position sensor voltage: 2.25 V
25 mph (40km/hl 3,' l00 3,700 3.500 4,100 4,100 4,700
km/h) 37 moh 160 3,650 4,250 4,050- 4,650 5,100 5,700
62 mph (100km/hl 4,450 5,050 4,800 5,400 5,900 6.500
4.5 Throttlepositionsensorvoltage: Fullthrottleposition
14-229
Stall Speed
Test
CAUTION: . To preventtransmission damage, notteststall speedfor more than 10 seconds a time. do at . 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 eh e p a r k i n g r a k ea n d b l o c k h e f r o n tw h e e l s . t b , t 2. 3. 4. 5. 6. Connect tachometer the engine,and startthe engine. a to Makesurethe IVC switchis OFF After the enginehaswarmed up to normaloperating (the radiator comeson),shift into E position. temperature fan Fullydepress brakepedaland accelerator 6 to 8 seconds, the for and note enginespeed. Allow two minutesfor cooling, then repeat test in E, E, and E positions. the
Stall SpeedRPMin @ position: Specilication:2,500rpm ServiceLimit: 2,350- 2,650rpm Stall SpeedRPMin p. I and @ positions: Specification: 3,000rpm Service Limit:2,800 3,100lDm TROUBLE 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 PROBABLE CAUSE Low fluid levelor ATF pump output Clogged ATF strainer PH regulator valvestuckclosed Slippage forwardclutch of Faulty stan clutch Slippage reverse of brake Faultystart clutch E n g i n e u t p u tl o w o Faultystart clutch Stuckshift valve
S t a l lr p m h i g hi n @ p o s i t i o n Stallrpm low in Dl, p, [, and @ positions
14-230
FluidLevel
Checking/Changing
be and changing, sure not to while checking CAUTION: allow dust and other foreign particles to enter into the transmission,
Changing
1. temup Bringthe transmission to normaloperating perature(the radiatorfan comes on) by driving the v e h i c l e 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 ,a n d . turn oif the engine. Remove drain plug,and drainthe CVTfluid. the NOTE:ll a coolerflusheris to be used,see page14'14-285. 284 and 3. Reinstall drain plug with a new sealingwasher, the w t h e n r e f i l l t h e t r a n s m i s s i o n i t h G e n u i n eH o n d a CVTFluidto the uppermarkon the dipstick. FluidCapacity: AutomaticTransmission 3.9? 14.1 qt, 3.4 lmp qtl at changing US 6.4{ (6.8US qt,5.5lmp qtl at overhaul Fluid: AutomaticTransmission Recommended GenuineHondaCVTFluid. H C U s eG e n u i n e o n d a 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 life. transmission reduce
Checking
NOTErCheckthe fluid level with the engine at normal operatingtemperature(the radiatortan comes on iust 1. 2. 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 engine. Removethe dipsrick(yellow loop) from the transmission, and wipe it with a cleancloth. n N O T E :C h e c kt h e t r a n s m i s s i o f l u i d 6 0 t o 9 0 s e c onds aftershuttingoff the engine. 3. into the transmission. Insenthe dipstick
DIPSTICK {YELLOW LOOPI
2.
l
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 the upperand lower mark. shouldbe between
Interval: Change kml 30,000miles(48,000 NormalCondition: kml, but if Severe Condition:30,000miles {48,000 you drive at high speedsin high and abovel temper' t90"F {32"C1 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 should be changed every 15'000 km). miles {24,000
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 C o G e n u i n e o n d a V TF l u i d n l y . H into the transmission. Insenthe dipstick
DRAINPLUG 1 8x 1 . 5m m kgI 49 N.m 15.0 m, 36lbfttl
WASHER SEALING Replace.
14-231
Pressure Testing
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. 2. Raise front of the vehicle, the and supportitwith safetystands(seesectionI). Setthe parkingbrake, and blockboth rearwheelssecurelv.
3. Allow the front wheelsto rotatefreely.

Warm up the engine(the radiator comeson),then stop and connecta tachometer. fan 5. Connect specialtool each inspection the to hole. TOROUE: N.m (1.8kgf.m,13 tbf.ft) 18 CAUTION: ' Connectthe oil pressureg.uge securely,be sure not to allow dust and other toreign particles to enter the inspection 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: . Drivepulleypressure may be above3,430kPa(3.43MPa,35.0kgf/cmr,498 psi)when there is a transmission problem that causes TCM to go into the fail safemode. the . U s e a c o m m e r c i a l la v a i l a b l e i l p r e s s u r e a u g et h a t m e a s u r e s , 9 0 0k p a ( 4 . 9 0M p a , 5 0 . 0k g t c m r ,7 1 1 p s i ) y g o 4 or more,and the A,/T Pressure Oil Hose, j0 mm (071\itAJpy40j 1A). 22
A/T OIL PRESSURE GAUGE SETw/PANEL 07406- 0020400 FORWARD CLUTCH PRESSURE INSPECTION
(Marked ith "F") w
A/T LOW PRESSURE GAUGE W/PANEL 07406- 0070300 DRIVEPULLEY PRESSURE INSPECTION HOLE with "DR") lMarked
A/T PRESSURE HOSE ADAPTER 07MAJ - PY40120 (4 Requirad)
A/T PRESSURE HOSE 2210 rnfi OTMAJ PY4O11A (4 Bequired)
REVERSE BRAKEPRESSURE INSPECTION HOLE
oJ..
LUBRICATION PRESSUBE DBIVEN PULLEY PRESSURE INSPECTION HOLE INSPECTION HOLE "LUB") ( M a r k ew i t h d (Ma.ked with "DN")
ATF OIPSTICK STARTCLUTCH PRESSURE INSPECTION HOLE (Marked with "SC")
14-232
Stan the engine. rpm. at the shift leverpositionas in the table,and measure followingpressures 1,500 7 . shift to the respective . . . . ForwardClutchPressure Reverse BrakePressure DrivePulleyPressure DrivenPulleyPressure
pressure. 3.000rpm at the and measure lubrication 8 . Shiftto E position, SHIFTLEVER POStTtON
PRESSURE FLUID
SYMPTOM No or low forward clutch pressure No or low reverse brake pressure No or low drive pulley pressure Drivepulley pressure too h i gh CAUSE PROBABLE
Forward Clutch
PRESSURE
Forward Clutch Reverse Brake Drive Pulley
Standard/ServiceLimit '1.4 1.75MPa (14.3 17.8kgtcm' , 203- 253psi) M 1 . 4- 1 . 7 5 P a (14.3 17.8kgf/cm' , 203- 253psi) 0.2- 0.7 MPa (2 - 7.1 kgflcm' ,28- 101psi)
E E E
Reverse Brake
)a
Driven Pulley
ATF pump,PH regulatorvalve,PL valve, regulator Shiftvalve valve, PH regulator valve, PL regulalor Shiftvalve,Shift controllinear solenoid ATF pump,PH reg' ulatorvalve,Shift valve.Shiftcontrol linearsolenoid valve PH regulator
No or low drivenpulley pressure Drivenpulley pressure too h i gh
1 . 5- 2 . 3M P a (15.3 23.5kgficm' ,218- 334Psi)
Lubrication
No or low lubrication pressure
ATF pump, valve Lubrication
Above0.2 MPa (Above2 kgf/cm' , psi) 30
testing. tool afterpressure the Disconnect special
lorque hole,and tightento the specified washerin the inspection the 1 0 . Install sealingbolt with a new sealing 18 TOROUE: 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 !@ are placed properly {seesection 11. C A U T I O N : 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 W valve body assembly.be sure not to allow dust and other toreign particlesto enter into the transmission. 1. Raisethe front of the vehicle,and suoDortit with safetystands{seesection1}. Set the parkingbrake,and block both rear wheels securely. 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 e d r a i np l u g w i t h a n e w s e a l i n g a s h e r l w (seepage14-231). CAUTION: Keep all ol other foreign particles out of the transmission.
4.
7. 8. 9. 10. 11.
Remove ATF cooleroutletpipe. the Remove ATFcoolerDipebracket the bolt. Remove ATF pan (fourteen the bolts). (two bolts). Remove ATF strainer the R e m o v eh e o n e b o l ts e c u r i n gh e s o l e n o i d a r n e s s t t h 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 bolts).
SEALING Replace. ATF COOLEE OUTLETPIPE JOINT BOLT 28 N.m (2.9 kgtm, 2l lbf.ft)
O.RING Replace SOLENOID HARNESS CONNECTOR DOWELPIN
Disconnect 8P connector the from the solenoidhar nessconnector. 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 pipes,Turn the ends of the ATF cooler hosesup to preventATF from flowing out, then plug the ATF cooternoses. CAUTION: Keep all of other foreign particles out ot the transmission.
O-RING ATF Replace. STRAINER
6x1.0mm 12 N.m {1.2kgl.m, 8.7 tbf.tt) LOWER VALVE BODYASSEMBLY 6x1.0mm 12 N.m 11.2 kgf.m, 8.7 tbtft)
6.
Remove right front mounvbracket. the

'10 1.25mm x 44 N.m (,1.5 kgtm, 33 lbnftl 6x1.0mm 12 N.m 11.2 m, kgt 8.7 rbtftl DOWELPIN RIGHT FRONT MOUNT/BRACKET
ATF PAN GASKET Replace. ATF COOLER INLET PIPEBRACKET BOLT I x 1.25mm 26 N.m (2.7kgt.m, 20 tbl.ft)
/
ATF COOLER PIPE ATF PAN
6x1.0mm 12 N.m (1.2kgf.m,8.7 lbl.ft)
'10 1.25mm x 54 N.m (5.5kgt.m, 40 tbt.ft)
l14-234
ATF COOLER HOSE
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. NOTE: . Replace followingparts: the - 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 and the ATFstrainer - ATF pan gasket Sealing ashers w . 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 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 n r o c e d u r e n p o p a g e1 4 2 2 5 .
ATFFilter
Make sure lifts, iacks, and safety stands @@ are placedproperly lsee section 11. CAUTION: While removing and installing the ATF filter, be sure not to allow dust and other foreign particles to enter into the transmission. 1. Raisethe front of the vehicle,and support it with saletystands(seesection1). Ser the parkingbrake,and block both rear wheels rely. secu 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 . the Reinstall drain plug with a new sealingwasher (seepage'14 231). CAUTION: Keep all of other foreign particles out of 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 Turn the ends of the ATF cooler hosesup to Di9es. preventATF from flowing out, then plug the ATF coolerhoses. CAUTION: Keep all of othet loreign particles out ot the transmission.
5.
Remove ATF cooleroutletpipe the bolt. Remove ATF coolerpipe bracket the the Remove ATF pan (founeenbolts). Remove the ATF coolerinlet pipefrom the ATF pan bolts). {three the 10. Remove ATFfilter,and cleanit. 11. Check that the ATFfilter is in good condition the 12. Replace ATFtilter if it is clogged. 6. 7. 8. 9.
JOINT BOLT kgl 28 N.m 12.9 m, 2'l lblftl SEALING Replace.
2.
3.
ATF COOLER OUTLET 'l.0mm 6x 12 N.m (1,2kgf m, 8.7 tbtft)
ATF COOLER INLET PIPEBRACKET BOLT I x 1.25mm 26 N.m (2.7kgt m,
DOWEL
Remove rightfront mounvbracket. the

m 1 0x 1 . 2 5 m 44 N.m (4.5kgt'm,33lbfftl ATF P GASKET Replace. O.RING Replace.
RIGHTFRONT MOUNT/BRACKET
ATF PAN
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 54 N.m (5.5 kgf'm, 40 rb{ft1 CAUTION: Keep all foreign particles out of the transmission. NOTEI . Replacethe O-rings, the ATF pan gasket and sealing washers. . lf the ATF cooler inlet pipe bracket is bent or warped, put it back to the original position.
HOSE ATF COOLER
14-235
Transmission
Removal
@@ Make
4.
sure lifts, iacks, and safety stands are placed pfoperly, and hoist bracket are attached to the correct position on the engine (seeseqtion 1). Apply parking brake and block rear wheels, so the vehicle will not roll off stands and fall on vou while working under it.
Disconnect solenoid the harness connector, drive the pulleyspeedsensor connector, the groundcable and terminals.
GROUNDCABLE TERMINAL
GROUND CABLE
CAUTION:Use fender coversto avoid damaging painted surfaces.

'L
Disconnect the battery negative(-) terminal from lhe battery. then removethe positive{+)terminal. R e m o v e h e i n t a k e i r d u c ta n d a i r c l e a n e h o u s i n g t a r assemDty. R e m o v e 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 t the startermotor.
2.
3.
DRIVEPULLEY SPEED SENSOR CONNECIOR SOLENOIO HARNESS CONNECTOR
STARTER MOTON
5.
Remove the clip,then separate shift cablefrom the the controllever. GAUTION:Take care not to bend the shift cable.
SHIFICABLE
WASHER
WASHER
STARTER CABLE
Ft
14-236
LEVER CONTROL
6.
Disconnect vehiclespeedsensor(VSS)connecthe and tor, the driven pulleYspeedsensorconnector, gear shaftspeedsensorconnector. the secondary
PULLEY DRIVEN SENSOR SPEED CONNECTOR
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 . washer' Reinstall drainplugwith a new sealing the while installingthe drain plug, be sure CAUTION: not to allow dust and other foteign particles to enter into the transmission
GEAR SECONDAFY SHAFTSPEED SENSOR
F(A --
,fi . ' - 1(VSSt SENSOR CONNECTOR DRAINPLUG 18x 1.5mm irg N.m {5.0kgl m.36lbt'ft) WASHER SEALING Replace.
7.
housingmountingbolts. Remove transmission the
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. Remove cotterpinsand castle the nuts,then separate the balljointstrom the lowerarm (seesection 18).
16. Remove the right front mount/bracket.
TF COOLER PIPE
ATFCOOLER HOSE 1 t . Removethe right damper fork bolt, then separate r i g h td a m p e r o r ka n d d a m p e r . f 1 2 . Prythe right and left driveshafts of the differenout tial. Pullon the inboardjoint and the right and left drive, shafts(seesection16). 't 4. Tje plasticbagsoverthe driveshaft ends. NOTE:Coatall precision finished surfaces with clean engine il. o
t5,
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 pipes.Turn the ends of the ATF cooler hosesup to preventCVT fluid from flowjng out, then plug the ATFcoolerhosesand pipes. NOTE: Checkfor any sign of leakageat the hose joints. Remove enginestiffeners the flywheel the and cover.
Remove exhaust the pipe A.
r")
SELF-LOCKING NUT Beplace. SELF-LOCKING NUT Replace. EXHAUSTPIPE A ENGINE STIFFENER
r9. Remove the eight drive plate bolts one at time while
rotating the crankshaft pulley.
14-238
the 20. Remove distributor.

t1
h t 2 3 . R e m o v e h e t r a n s m i s s i o n o u s i n gm o u n t i n gb o l t and rearenginemountingbolts.
REAR ENGINE MOUNTING BOLT
to Attacha hoistingbracket the engine,then lift the engine lightly. s

HOUSING TRANSMISSION MOUNTINGBOI-T
lP.WASHER
and raise the 22. Placea jack under the transmission, just enoughto take weight off of the transmission mountbracket the mounts, then remove transmission MOUNT TRANSMISSION
away from the engine until it 24. Pull the transmission clearsthe 14 mm dowel pins, then lower it on the transmission iack.
14-239
lllustratedIndex
Valve Body Assembly Transmission/Lower
\
14-240
O) ATF DIPSTICK @ o-RINGReplace. CONNECTOR HARNESS O SOI-ENOID O LowER vALvE BODYASSEMBI-Y O DowEL PIN O JoINT aoLT SOLT INLETPIPEBRACKET ) ATF COOLER ASSEMBLY INLETPIPE @ A'F COOLER Replace. WASHER o SEALING PIPE OUTLET G, ATF COOI-ER @ o-RING Replace. Ci)ATF FILTER @ o-RINGReplace. G) ATF PAN (9 DOWELPtN Replace. @ O-RING ) ATF STRAINER G} ATF MAGNET @ ATF PAN GASKETReplace. ) ATF MAGNET @ DRAINPLUG WASHER BepIace, @ SEALING
SPECIFICATIONS TOROUE Boh/Nut No. 6A 8F 12J 18D Torque Value 12 N m (1.2kgf.m,8.7lbf'ft) 26 N.m (2.7kgf.m,20lbf.ft) 28 N.m (2.9kgf.m,21lbi'ft) 49 N.m (5.0 kgnm, 36 lbf.ft) Sizs 6x1.0mm m 8 x 1.25 m '12 1.25mm x 1 8x 1 . 5m m Remarks
Joint bolt Drainplug
14-241
lllustratedIndex
Transmission Housing/Flywheel Housing
8G
14-242
Replace. af O-RING le oll sEAl- Replace. HOUSING :O FLYWHEEL Replace. HOUSING GASKET i4l FLYWHEEL DIFFERENTIAL ASSEMBLY .1'ATF PASSAGE PIPE ASSEMBLY G,I ?l o-RINGReplace. i8')DOWELPIN .' ATF PUMPASSEMBLY iio DOWELPlN, 18 x 10 mm Replace. ll O-RING OOWEL PlN, 22 x 10 mm a1a O ATF PUMPoRIvE CHAIN .iOSNAPRING pan sHlM,22x 28 mm Selective i9 THRUST (10) PUMPDRIVESPROCKET ATF .1I PITOTFLANGE HUB .O ATF PUMPDRIVESPROCKET WASHERS i!i) THRUST 6i PIToT PIPEBRACKET PITOT LUBRICATION PIPE iz:i, PIPE ., PITOT ag OILSEALReplace. ari SET BING,80 mm Selectivepart ASSEMBLY PIPEHOLDER 29 ATF PASSAGE
Replace. !d O-RING LA STARTCLUTCH ATF FEEDPIPE e3 o-RING Feplace. PIPEFLANGE 8 FEED .O SNAPRING BRACKET @ CONNECTOR A BALI BEARING @ SNAPRING RETAINER @ COTTER 25.5 mm Selectivepart @ COTTERS, ASSEMBLY @ STARTCLUTCH DRIVEGEARASSEMBLY 6I SECONDARY Replace. @ o-RINGS COVER @ DIFFERENTIAL @ THRUSTsHlM, 25 x 35 mm selecrivepart GEABSHAFT .4i SECONDARY BRAKEPAWLSHAFT 6DPABKING BRAKEPAWLSPRING @ PARKING 'O PARKING BRAKEPAWL RepIace. WASHER @ TONGUED BRAKERODHOLDER {3 PARKING I BALLBEARING io o-RINGReplace. .4!) VEHICLE SPEDSENSOB 60 OILSEALReplace.
TOROUE SPECIFICATIONS
Bolt/Nut No. 6A 8A 8F 8G
TorqueValue 12 N.m ('1.2 kgim,8.7 lbf'ft) 22 N.m 12.2 kgf.m,16lbf.ft) 26 N.m (2.7kgf.m,20lbnft) 29 N.m (3.0kgtm,22 lbf.ft)
Size 6x1.0mm 'l.25 m m 8x m 8 x 1.25 m 8 x 1.25 m m
Remarks
14-243
lllustratedIndex
Right Side Cover/lntermediate Housing
8B
tr
.i) RIGHTSIDECOVER (.] ATF FEEDPIPE PIN i3. DOWEL O O-RINGReplace. PIPEFLANGE i5) FEED PIPEFLANGPLATE ] FEED Ol'RoLLER ASSEMBLY HOUSING iq,]INTERMEOIATE SHAFTASSEMBLY O CONTROL HouSlNG TRANSMISSION 1_oI BRACKET .11) SHIFTCABI-E CAP iO BREATHER O olL SEALReplace. (4 CONTROILEVER (3 LOCKWASHER Replace. SENSOR ii6-i GEABSHAFTSPEED SECONDARY Ji DRIVEN SENSOR PULLEY SPEED (8_' O-RINGReplace. t!9 SNAPR|NG DRIVEN PULLEY HOUSING .9 TBANSMISSION BEABING SHAFTROLLER FEPIACE. 2i RIGHT GASKET SIDE COVER (2?j O-RINGReplace. POMANUALVALVEBODYLINEA .]i MANUALVALVEBODYLINE8 a3 o-RINGReplace. SPRING ,! DETENT !]) ATF FEEDPIPE Replace. Q0O-RING EI MANUAL VALVEBODY 13o] DOWELPIN PLATE MANUALVALVEBODYSEPARATOB 51) 34 SNAPRING ASSEMBLY CLUTCH $) FORWARD gl o-RINGFeplace. 69 SNAPBING (30 ASSEMBLY SPRING RETAINEB/RETURN SPRING BRAKEPISTON O REVERSE (381 O-RINGReplace. r SNAPRINGRETAINER ATF FEEDPIPE .4!)
(t TRANSMISSION GASKETReplace HOUSING @}DOWELPIN PIPE @ ATF FEED Replace. @ O-RING 6t o-RING Replace. SENSOR SPEED DRIVEPULLEY .45) (? TRANSMISSION HANGER (O SNAPRING pa( SHIM,25x 31 mm Selective e0 THRUST 6i BALLBEARING GEAR O RING 69 SNAPRING BRAKEEND PLATESelectivepan 6l REVERSE BRAKEDISC @IREVERSE BRAKEPLATE 69 REVERSE 6! D|SCSPRTNG WASHER @ THRUST BEARING 6J'THRUSTNEEDLE WASHER 63 THRUST ASSEMBLY @ CARRIER 6) THRUSTWASHER BEARING @ THRUSTNEEDLE @ SUN GEAR @ SEALINGRINGReplace. BEARING 69 NEEDLE @ INPUTSHAFT BEARING @ NEEDLE RINGReplace. @ SEALING Replace. RINGIRUBBER) 69 SEALING PIPE @ ATF FEED
TOROUE SPECIFICATIONS
Bolt/Nut No.
TorqueValue 12 N.m (1.2kgf.m,8.7lbf'ft) 1 4 N . m( 1 . 4 g n m ,1 0 l b i f t ) k 37 N.m (3.8kgim,27 lbf'fti kgf.m,20lbf.ft) 26 N.m 12.7 29 N.m (3.0kgf.m,22lbnft)
Size 6x1.0mm 6x1.0mm m 8 x 1.25 m m 8 x 1.25 m m 8 x 1.25 m
Remarks
6A 6B 8B 8F 8G
14-245
Transmission Housing/Lower ValveBodyAssembly

Removal
NOTE: o Cleanall partsthoroughlyin solventor carburetor cleaner, and dry with compressed air. . Blow out all passages. . When removingthe lowervalvebody, replace following: the - O-rings - ATF pan gasket - Sealing washers
O.BING Replace. SOLENOID HARNESS CONNECTOR OOWEL PIN 6 x 1.0mm BOLT
LOWER VALVEBODY ASSEMBLY
6 x 1.0mm EOLT
ATF PAN GASKET Feplace.
ATF STRAINER
ATF COOLER INLETPIPE BRACKET BOLT 8 x 1.25mm ATF COOLER INLETPIPE
6 x 1.0mm BOLT
6 x 1.0mm EOLT ATF PAN
14-246
1. 2. 3. 4. 5.
Remove ATFcoolerinletpipe bracket bolt. the Remove ATFcooleroutletpipe. the Remove ATF pan (founeenbolts). the (two bolts). Remove ATFstrainer the Remove the one bolt securing the solenoidharness then pushthe connector, connector, Remove lowervalvebody (eightbolts). the thoroughly Clean inletopening the ATFstrainer the of with compressed air, then checkthat it is in good condition, the inletopeningis not clogged. and
6. 7.
ATF STRAINES
if or Replace ATFstrainer it is clogged damaged. the NOTE:The ATF strainercan be reusedif it is not clogged.
14-247
Housing/Flywheel Housing Transmission

Removal
NOTE: . Cleanall partsthoroughlyin solventor carburetor air. cleaner, and dry with compressed . Blow out all passages. . When removingthe transmission housingflywheel housing, replace followingl the - O-rings - Secondary drive gear assembl, - Stan clutchassembly - Flywheel housinggasket
ATF PASSAGE PIPE HOLOER ASSEMBLY CONNECTOR BRACKET 8 x 1.25mm BOLT
fl
O.RING Replace.
HOUSING FLYWHEEL
fl
DOWEL PIN
ASSEMBLY OIFFERENTIAL SNAPRING COTTER RETAINER COTTERS, 25.5 mm Selectivepart STARTCLUTCH ASSEMBLY Replace. THRUSTSHIM, 25x35mm Selectivepart O-RING Replace. HOUSING GASKET FLYWHEEL Reolace, ATF PASSAGE PIPE ASSEMBLY 6 x 1.0 mm BOLT O-RING Replace. ATF PUMPDRIVECHAIN SNAPRING THRUSTSHIM,22 x 28 mm Selectivepart 6 x 1.0mm BOLT ATF PUMP DRIVE SPROCKET PITOTFLANGE ATF PUMPDRIVE HUB SPROCKET THRUSTWASHERS
SECONDARY GEARSHAFT SECONDARY DRIVE GEARASSEMBLY Replace. PARKING BRAKE PAWLSI{AFT PARKING BRAKEPAWL SPRING
INPUTSHAFT PARKING BRAKEPAWL
ORIVEN PULLEY SHAFT
14-248
pipe holderassembly. 1 . Remove ATF passage the Remove flywheelhousing(twentybolts). the (onebolt). pipe assembly Remove ATF passage the Remove the ATF pump drive sprocket(threebolts), then removethe ATF pump drivecharn. Move the pitot flange toward its cutout, then remove the pitot flange.
and attach the 10. Setthe special tool on the startclutch, pawl of the special tool to the parkinggear securely as snown. CAUTION: . Do not place the pawl ol the special tool on the start clutch guide. lf the pawl of the special tool contacts the slart clutch guide. the start clutch guide may be damaged. . Be sure not to allow dust and other toreign particles to enter into the driven pulley shaft.
STARTCLUTCH REMOVER 07TAE- P4V0120
STARTCLUTCH ASSEMBLY Replace.
PITOT PIPE
d 1 1 . R e m o v e 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 y r i v e t gear assemblyusing the specialtool, then remove gearshaft. the secondary the Remove the snap ring securing ATF pump drive sprockethub, then remove the 22 x,28 mm thrust shim,the ATF pump drive sprockethub and the thrust washers. 7. Remove difterential assembly. the Removethe parkingbrake pawl shaft,the parking brakepawl spring,and the parkingbrakepawl. then Remove snap ring securing startclutch, the the remove the cotter retainerand the cotters.
START CLUTCH REMOVER 20 07TAE- P4V01
PARKING GEAR
14-249
)
Housing RightSideGover/lntermediate
Removal
NOTE: air. . Cleanall partsin solventor carburetor cleaner, and dry with compressed . Elow out all passages. housing.replace followingparts: the . When removing the right sidecover/intermediate - O rings - Rightsidecovergasket - Transmission housinggasket - S e a l i n gi n g s r - Sealing ashers w
SNAPRING REVERSE BRAKE END PLATE 8 x 1.25mm BOLT 6 x 1.0mm BOLT
Dtsc
PLATE DISCSPRING SNAP THRUSTSHIM. 2 5 x 3 1m m pan Selective RINGGEAR THBUSTWASHER THRUSTNEEOLE BEARING THRUST WASHER CARRIER ASSEMBLY THRUSTWASHER THRUSTNEEDLE SEARING SUN GEAR INPUTSHAFT SNAPRING CLUTCH END PLATE FORWARD CLUTCH ASSEMBLY
{u
RIGHTSIDECOVER GASKET Replace. PIN DOWEL
8 x 1.25mm BOLT
TRANSMISSION HOUSING GASKET Replace,
RING(BUBBER} SEALING Beplace. SNAPRING SPRING RETAINER/ RETURN SPRINGS
DOWELPIN
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 , eleven8 mm bolts). the 2. Remove manualvalvebody linesA and B. 3 . Removethe snap ring securingthe ring gear,then gear. removethe thrustshim and the rang b t R e m o v e h e s n a pr i n g s e c u r i n gh e r e v e r s e r a k e t brakeend then removethe reverse discsand plates, plate,brakediscs,brakeplates, and discspring. Remove the carrierwith the thrust washersand the from the forwardclutch. thrustneedlebearing, 6 . Removethe sun gear and the input shaft as a sub assembly pullingir. by The sun gear is pressfittedtightly into input shaft. 7 . Removethe snap ring securingthe forward clutch, the and remove snapringsecuring forwardclutch the then remove forwardclutchend plate. the end plate, 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 secure the carrierwith the snap ring on the forward ciutchend plate. 9 . R e m o v e 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 t together. 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 the reversebrakereturnspring retaineras securing snown. BRAXE REVERSE COMPRESSOR SPRING 07TAE P4V01r0
the then removethe snap 11. Compress returnsprings. ring. 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 Be damaged. sure the spring retainertab is not on the piston.
SPECIALTOOL
RETAIiIER SPRING TAA l 12. R e m o v et h e s p e c i a t o o l , t h e n r e m o v et h e s p r i n g retainer/return springassembly. the reversebrake Remove the sealingbolt securing pressure hole. inspection hole to remove to 1 4 . Apply air pressure the inspection brakepiston. the reverse
SPRNG RETAINER/ SPRING RETURN ASSEMBLY BRAKE REVERSE PISTON
o-Rt Gs
Replace.
REVERSE BRAXE PRESSUR INSPECNON HOIT
SEALING WASHER Replace. 8 x 1.25 mm 18 N.m {1.Ekgl.m, 13 lbf.ftl
from the drive pulley 15. Remove the snap ring retainer shaft. 16. Remove manualvalvebody (fivebolts). the '17 Remove roller, and Dush controlshaftassemthe the housing, bly toward the outsideof the transmission (fourbolts). housing then remove the intermediate
14-251
ManualValveBody
NOTEI air. cleaner, and drywith compressed Blowoutall passages, . Cleanallpartsthoroughlyin solventor carburetor o Coatall partswith CVTFluidduringassembly,
SEAT SPRING INHIBITOR RVERSE VALVESPRING
INHIBITOR REVERSE VALVE
N'
MANUAL VALVE
BODY VALVE MANUAL for Inspect wear,scratches andscoring.
14-252
ForwardGlutch
lllustrated Index
ORUM CLUTCH
\ \ \ _
SPRING RETURN RETAINER SNAPRING PLATES CLUTCH thickness: Standard in) 2.00mm (0.079 DISCSPRING
END PLATE CLUTCH PISTON CLUTCH
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 plate, clutch discs, and plates.
3.
Install the special tools as shown.

CLUTCH SPRING COMPRESSOR ATTACHMENT 07LAE- PX40100
SNAP RING
CLUTCH SPRING COMPRESSOR ATTACHMENT OTHAE PLsO,IOO
2.
Remove the 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 contact with the spring retsiner.
Do not st hre.
SPECIAL TOOL
SPRING RETAINER
14-254
4.
6.
Wrap a shop rag aroundthe clutchdrum, and apply air pressure the fluid passage remove piston. to to the Place fingertip on the otherend while applying air a pressure.
OSHA.APPROVED 30 p3i NOZZLE
5.
the tools, Remove snapring.Then remove special the and springretainer, returnspring.
SPRING RETAINER
14-255
Clutch Forward
ReassemblY
NOTE: . Clean all parts thoroughly in solvent or carburetor alr' and dry them with compressed cleaner, . Blow out all Passages. all . Lubricate partswith CVTFluidbeforereassemDly' 1. the prsthe Inspect checkvalve;i{ it's loose'replace ton. CHECKVALVE 3. pressure lnstallthe pistonin the clutchdrum Apply and rotateto ensureproperseatlng' CVT Fluid NOTE: Lubricatethe piston O-ring with beforeinstalling the CAUTION: Do not pinch the O-ring by installing piston with too much lorce
PISTON
2.
Installnew O-ringson the clutchpiston'

O.RINGS
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 ' retainer' positionthe snap ring on the
SNAP RING
SPRINGRETAINER
SPRING RETURN
CLUTCHDRUM
PISTON
14-256
5.
Installthespecial tools as shown,

CLUTCHSPRING COMPBESSOR ATTACHMENT OTLAE PX4OlOO
6.
CLUTCHSPRING COMPRESSOR ATTACHMENT oTHAE-P150100 CLUTCHSPRING COMPRESSOR EOLTASSEMBLY 07GAE-PG40200 7. I n s t a l l t h es n a p r i n g .
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 contact with the spring retainer.
SNAP RING
8.
Sot here. Do not set hre. TOOL SPECIAL
Remove special the tools.
RETAINER
(cont'd)
14-257
/
Forward Clutch
(cont'dl Reassembly
9 . I n s t a ltlh e d i s cs p r i n g . shown. NOTE: Installthe discspringin the direction 1 2 . I n s t a ltlh e s n a pr i n g .
DISC SPRING
SNAPRING
".urr* o.r*
1 0 . Soakthe clutchdiscsthoroughlyin CVT Fluidfor a o minimum f 30minutes. 1' ]. Starting with a clutch plate, alternatelyinstall the clutch platesand discs.Installthe clutch end plate with flat sidetoward the disc. the platesand discs,make NOTE:Beforeinstalling sure the insideof the clutch drum is free of dirt or otherforeignmatter.
13, Verifythat the snap ring end gap is correct.

CLUTCH DRUM
i 7 M i n i m u m . 9m m { 0 . 3 1n )
CLUTCHEND PLATE
14-254
I
i I
14. Measu.e clearanc the between the clutchend plate andtop discwith a dial indicator. Zerothe dial indicator with the clutch end plate lowered,and lift it up to the snap ring.The distance that the clutchend plate moves is the clearancebetweenthe clutch end Dlate andtop disc. in NOTE:Takemeasurements at leastthree places, and usethe average the actualclearance. as Clutch End Plate-to-TopDisc Clearance: STANDARD: - 0.8 mm (0.024- 0.031in) 0.6
15. lf the clearance out of tolerance, is select new clutch a end plate from the following table. thenrecheck. but NOTE:It the thickest clutchend plateis installed replacethe the clearance still over the standard, is clutchdiscsand clutchplates.
PLATE I{UM8ER
Thicknoss
CLUTCH END PI-ATE
FORWARD CLUTCHEND PLATE

Plale No. Part Numbel
Thickness
1or15 2ot16 3or17

4ot18
22561 P4V- 003 3 . 5m m ( 0 . 1 3 8n ) i i 22562-P4V-003 3 . 6m m ( 0 . 1 4 2n ) 2 2 5 6 3 - P 4 V - 0 0 33 . 7m m ( 0 . 1 4 6n ) i 2 2 5 6 4 - P 4 V - O O 33 . 8m m ( 0 . 1 5 0n ) i i 2 2 5 6 5 - P 4 V - 0 0 33 . 9m m ( 0 . 1 5 4n ) 2 2 5 6 6 - P 4 V - 0 0 3 4 . 0 m m ( 0 . 1 5 7i n ) 22561 -P4V OO3 4 . 1m m ( 0 . 1 6 1n ) i i 2 2 5 6 8 - P 4 V - 0 0 34 . 2m m ( 0 . 1 6 5n ) 2 2 5 6 9 - P 4 V - 0 0 3 4 . 3m m ( 0 . 1 6 9n ) i 22510 P4V OO3 4 . 4m m ( 0 . 1 7 3n ) i , OO3 4 . 5m m ( 0 . 1 7 7n ) 225't1 P4V i 2 2 5 - 7 2 - P A V - O O 3 . 6 m m ( 0 . 1 8 1i n ) 4 22573 - P4V - OO3 4 . 7 m m ( 0 . 1 8 5i n )
5 or
'19
6or20
7ot21
8ot22 9or23 '10 24 or 1 1o r 2 5 or or
After replacing clutchend plate,make surethat the is the clearance within tolerance.
r'
14-259
Secondary GearShaft
25 x 35 mm Thrust Shim Selection
1. Measure distance the between the flywheelhousing surfaceand the ball bearing as shown, then note (Measurement the measurement A).
FLYWHEEL HOUSING --"i<t=''
4.
Calculate x 35 mm thrust shim thickness fol25 bv lowingformula. FORMULA: 25 x 35 mm Thrust Shim Thickness = Measurement A - Measurement B + Flywheel HousingGasketThickness: mm (0.020 0.5 in) ExamDle: Measurement A:32.7mm (1.287 in) Measurement B:30.1mm (1.185 in) 25 x 35 mm Thrust Shim Thicknss = 32.7mm 11.287 -30.1 mm {1.185 inl in} + 0.5 mm (0.020 in) = 3.1 mm 10.122 in) Select 25 x 35 mm Thrust Shim D.
\ oi.r".." I fi-i"r*,.g
5.
Selectthe 25 x 35 mm thrust shim from the following the table. THRUST SHIM,25 x 35 mm
BALL BEARING
FLYWHEEL HOUSING
No.
Part Number P 9 0 5 5 '-1 4 V - 0 0 0
Thickness 2 . 8m m ( 0 . 1 1 0n ) i
Installthe secondary gear shaft in the transmission housrng. 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 gear shaft as shown,then surfaceof the secondary notethe measurement B). {Measurement
SECONDARY GEARSHAFT
9 0 5 5 2 - P 4 V - 0 0 0 2 . 9m m { 0 , 1 1 4n ) i 9 0 5 5 3 - P 4 V - 0 0 0 3 . 0m m ( 0 . 1 1 8n ) i 9 0 s 5 4 - P 4 V - 0 0 0 3 . 1m m ( 0 . 1 2 2n ) i 9 0 5 5 5 - P 4 V - 0 0 0 3 . 2m m { 0 . 1 2 6n ) i 9 0 5 5 6 - P 4 V - 0 0 0 3 . 3m m ( 0 , 1 3 0n ) i
c
E F
9 0 5 s 7 - P 4 V - 0 0 03 . 4m m ( 0 , 1 3 4n ) i
H
9 0 5 5 8 - P 4 V - 0 0 0 3 . 5m m ( 0 . 1 3 8n ) i 9 0 5 5 9 - P 4 V - 0 0 0 3 . 6m m ( 0 . 1 4 2n l i 9 0 5 6 0 - P 4 V - 0 0 0 3 . 7m m ( 0 . 1 4 6n ) i 90561 P4V- 000 3 . 8m m { 0 . 1 5 0n ) i
14-260
Differential
lllustratedlndex
AOLTS 10 r 1.0mm 101N.m {10.3kgf.m. 74.5 |bfit) Left'handthreads
BacklashInspection
1. Place differential the assembly V-blocks, install on and both axles. Check backlash both piniongears. the of Standard(Newl:0.05- 0.15mm {0.002 0.006inl
2.
PINIONGEARS
FINALORIVEN GEAR
BALLBEARING
lf the backlash out of tolerance, is replace differthe entialcarrier.
14-261
Differential
BearingReplacement
NOTE:Checkthe bearings wear and rough rotation. for lf the bearings OK, removalis not necessary. are 1. Remove ball bearings the usinga bearingpuller,
DifferentialCarrier Replacement
1. Removethe final driven gear from the differential carrier. 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
BEARING BALL
Installthe new ball bearingsusing the specialtool with a pressas shown. 2.
DIFFERENTIAL CARRIEN Installthe final driven gear with its chamfered side on the innerborefacingthe differential carrier. Torquethe boltsto the specified torque in a crisscross panern. TOROUE: N.m {10.0kgf.m, 72 lbf.ftl 98
p
14-262
BALLBEARING
Oil Seal Removal

1. 2. assembly. Remove differential the housing. Remove oil sealfrom the transmission the
Clearance Oil Seal Installation/Side

i 1 . I n s t a l l 2 . 5 0m m { 0 . 0 9 8 n ) t h i c k8 0 m m w i d e s e t a n r i n gi n t h e t r a n s m i s s i oh o u s i n g . NOTE:Do not installthe oil sealyet.
SETRING, 80 mm Seleclivepart
TRANSIflSStON HOUSING TRANSMISSION HOUSING 3. OIL SEAL Replace.
Remove the oil seal from the flywheel housing.
Installthe difterentialassemblyinto the transmistool as shown. sion housingusingthe special
HOUSING (cont'd)
14-263
,l
Differential
(cont'd) Clearance Oil Seal Installation/Side
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.
betweenthe 80 mm set ring the clearance Measure i r a c eo f t h e b a l l b e a r i n g n t h e t r a n s m i s and outer s i o nh o u s i n g . 0 STANDARD: - 015 mm (0 - 0 006 inl
8 x 1.25mm 29 N m (3.0kgtm,22 lb{ft}
u f H s
FLYWHEEL HOUSING
FLYWTIEEL GASKET HOUSING
lf the clearance is more than the standard, select a new set ring from the table, and install it. SET RING, 80 mm
PartNumber 90414-689-000 90415 689 000 90416-689-000 90417-689-000 90418-689-000 90419-PH8-000
Thickness i 2 . 5 0m m ( 0 . 0 9 8n ) i 2 . 6 0m m ( 0 . 1 0 2n ) n 2 . 7 0m m 1 0 . 1 0i6 ) i 2 . 8 0m m ( 0 . 1 1 0n ) n m 2 . 9 0 m ( 0 . 1 1i4 ) n 3 . 0 0m m 1 0 . 1 1i8 )
measuredin step 4 is stan NOTE|lf the clearance to dard.it is not necessary performsteps7 and 8 6. 1. the Remove flywheelhousing. in) the Replace 2.50mm (0.098 set ring,80 mm with in selected step5 thickness the one of the correct
h
14-264
FlywheelHousing
InputShaftOil Seal
Replacement
8. housingusing the oil seal in the transmission Install tools as shown. the sDecial DRIVER 07749 0010000 1. Removethe input shaft oil seal from the flywheel houstng.
Installthe oil seal in the flywheelhousingusingthe soecial tools as shown.
Installrhe oil seal in the flywheelhousingusingthe special tools as shown.
FLYWHEEL
DRIVER x ATTACHMENT,5E72 mm 079{?- 6340201
PILOT, 26r30mm 07JAD- PH80200
Installed depth: 2.5 - 3.5 mm
,"rf fo"rrr'l,i.ttl,
t@
ATTACHMENT, 32x35mm 07746- 0010100
14-265
Transmission Housing Bearings

Driven Pulley Shaft Bearing Replacement
'1. To removethe driven pulleyshaft bearingfrom the t r a n s m i s s i o n o u s i n g , x p a n dt h e s n a p r i n g w i t h h e 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 pressas shown. NOTE:Do not removethe snap ring unlessit's necessaryto cleanthe groovein the housing. Expandthe snap ring with snap ring pliers. insert the new bearing part-way into the housing using the specialtools and a press as shown. Installthe bearingwith the groovefacingoutsidethe housing. N O T E :C o a ta l l p a n sw i t h C V TF l u i d . Release pliers.then push the bearingdown into the the housinguntil the ring snaps in placearound it, u s i n g h e s p e c i a l t o o la s s h o w n . t s
07749- 0010000
BEARING
ATTACHMENT, 72x75mm 07746 - 0010600
GBOOVE
SNAPRING
ATTACHMENT. 72x75mm 07746- 0010600
4.
After installing bearingverifythe following: the . . . The snap ring is seatedin the bearingand housIng gfooves. The snap ring operates properly. The ring end gap is correct.
ENDGAP:0-9mm (0- 0.35in)
BEARING
HOUSING
SNAPRING
14-266
FlywheelHousing
Bearing
SecondaryGear Shaft Bearing Replacement
1. gear shaft bearingusingthe Remove the secondary s p e c i a l t o o la s s h o w n . s
GearShaft Bearing Secondary Replacement

1. gear shaft bearingusingthe Remove the secondary soecial tool as shown,
HAMMER 3/8" - 16 SLIDE lCommerciallyavailablel
GEAR SECONDARY
BEARING ADJUSTABLE - ,10 PULLER,25 mm 07?36 4010004
SHAFT BEARING
ADJUSTABLE BEARING PULLER.26 40 mm 07736- A01000A
gear shaft bearinguntil it Installthe new secondary housing,usingthe spebottomsin the transmission a cialtools sshown.
gear shaft bearinguntil it lnstallthe new secondary bottoms in the flywheel housing,using the special tools as shown. DRIVER 07749 0010000
ATTACHMENT, 72 x 75 mrn 07746- 0010600
ATTACHMENT. 62x68mm 07746- 0010500
14-267
RingGearBearing
Replacement
1. R e m o v et h e r i n g g e a r b e a r i n g .
ControlShaft Assembly
RemovaUlnstallation
1. Remove the bolt and lock washer.
CONTROL SHAFT ASSEMBLY
TRANSMISSION
RING
RINGGEAR
Installthe new ring gear bearinguntil il bottoms in the ring gear,usingthe special tools as snown.
6x1.0mm 14 N.m (1.4kgf.m, 10 tbf.ttl DRIVER 0?749- 0010000 CONTROL LEVER LOCKWASHER Replace.
Remove controlleverfrom the controlshaft. the 3. Remove controlshaftassembly. the Install controlshaftassembly the transmission the in nousrng. 5. 6. Install the controlleverto the controlshaft. Install and tightenthe bolt with a new lockwasher.
b
14-268
Transmission
Reassembly
CAUTION: Whilereassembling, sure not to allow dust and other foreignparticles enter into the transmission. be to NOTE: . Coatall partswith CVTFluid. . Replace followingparts: the - O-rings - S e a l i n gi n g s r - Sealing ashers w - Gaskets - Stan clutchassembly and Secondary drive gear assembly
8 x 1.25mm 37 N.m {3.8kgl.in, 27 lbt.ft) 6x1.0mm 12 N.m lI.2 kgf.m,8.7 lbnftl
SNAPRING MANUAL VALVE REVERSE ERAKE ENDPLATE
RIGHT SIDE COVER DOWEL PIN

O.RINGS RIGHT SIDECOVEBGASKET 6x1.0mm lbf.ftl 12 N m (1.2kgf.m.8.7 SNAP RING MANUAL VALVE BODY
olsc
PLATE DISCSPRING THRUST SHlM.25x 31 mm part Selective RINGGEAR THRUST WASHER THRUST NEEOLE BEABING THRUSTWASHER CARRIER ASSEMBLY THRUST WASHER THRUST NEEOLE BEARING SUN GEAR INPUTSHAFT SNAPRING FORWARD CLUTCH O.RINGS
8 x 1.25mm 29 N.m 13.0 ln.22lbtftl kgt INTERMEDIATE HOUSING ASSEMBLY
ROLLER
ATF FEEDPIPE TRANSMISSION HOUSING GASKET
CONTROL SHAFT ASSEMBLY
SNAP AING
SPRING RETAINER/ RETURN SPRING ASSEMBLY REVERSE BRAKEPISTON O.RINGS
DOWEL PIN
HOUSING SNAPRINGRETAINER ATF FEEDPIPES
14-270
housInstallthe ATF feed pipe in the transmission ATF feed pipeswith new ing, and installthe three i n O - r i n g sn t h e t r a n s m i s s i oh o u s i n g . hous2 . Install two dowelpinsand newtransmission the housing. ing gasketon the transmission ? toward the outside Pushthe controlshaft assembly of the transmissionhousing,then installthe inter(fourbolts). mediatehousingassembly lnstall the manual valve body separatorplate and the two dowel pins on the intermediatehousing. then installthe manual valve body with the detent spring (fivebolts). Put the controlshaft assemblyback,then installthe housing. rollerin the intermediate Installthe reversebrake piston in the intermediate housing. on spring assembly 7 . lnstallthe springretainer/retu.n brakePaston. the reverse
1.
the return springs.then installthe snap Compress housing above the spring ring in the intermediate retarner. 1 0 . Verifythat the snap ring end gap is correct
i 1 M i n i m u m 5m m ( 0 . 5 9n )
/
RING SNAP
,'t
/,.' ir ir /
,a7 "-,,,,. \.,

' ', /
. :''
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 3 f Fluidorminimum 0minutes brakepiston. Install the discspringon the reverse

t5.
on NOTE:Installthereturnsprings the springguides oJthe reversebrake piston securelY the returnsprlng tool to compress Install the special as shown. REVERSE BRAKE SPRING COMPRESSOE
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 brakeplatesand discs lnstallthe installthe reverse brakeend piate,and the snap ring reverse
betweenthe reversebrake 1 4 . Measurethe clearance Zero end plateand the top discwith a dial indicator. b w i t h a r e v e r s e r a k ee n d p l a t e the dial indicator lowered,and lift it up to the snap ring.The distance that the reversebrakeand plate moves is the clearance between the reverseend plate, and the top disc. in NOTE:Take measurements at leastthree places, as and usethe average the actualclearance 0.45 STANDARD: - 0.75mm (0.018 0.030in)
o?TAE- P4V0110
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.
TOOL SPECIAL BRAKE REVERSE
(cont'di
14-271
Transmission
(cont'd) Reassembly
lf the clearance not withinthe standard, is remove the reverse brakeend plateand measure thickness. its S e l e c ta n d i n s t a l la n e w r e v e r s e r a k ee n d p l a t e , b then recheck. 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, the clearance still over the standard, but is replace reverse the brakediscsand plates. REVERSE BRAKE ENDPLATE
22. Verily that the outside diameter of the snap ring is correct. Maximum4l 4 mm 11.63 in)
""^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 assembly.
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.
2 3 5 6 7 8
22551 - P4V 003 3 . 6m m ( 0 . 1 4 2n ) i - P4V 003 3 . 8m m ( 0 . 1 5 0n ) 22552 i 22553-P4V OO3 4 . 0 m m ( 0 . 1 5 7i n ) 22554- P4V 003 4 . 2m m 1 01 6 5i n ) . 2 2 5 5 5 - P 4 V - 0 0 3 4 . 4m m ( 0 . 1 7 3n ) i 2 2 5 5 6 - P 4 V - 0 0 34 . 6m m ( 0 . 1 8 1n ) i 22551-P4V -OO3 4 . 8m m ( 0 . 1 8 9n ) i 2 2 5 5 8 - P 4 V - 0 0 3 5 . 0m m ( 0 . 2 0 0n ) i
CARRIER ASSEMBLY
1 7 . After replacingthe reversebrake end plate, make s u r et h a tt h e c l e a r a n cie w i t h i nt h e s t a n d a r d . s 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 , plates, dascs, 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 shaft. 20. Wrap the drive pulleyshaftsplineswith tapeto prev e n t d a m a g et o t h e O - r i n g s , h e n i n s t a l ln e w O t flngs. Installtheforwardclutchassembly the drive pul on ley shaft,then installthe snap ring. SNAP BIT{G
THRUST
THBUST NEEDLE BEARING
O.RINGS SNAP RING RETAINER
25. Install carrierassembly the forwardclutch. the on
14-272
26. Installthe thrust washer,the thrust needlebearang, and the thrustwasheron the carrierassembly.
SNAPBING SHIM, THRUST 2 5 x 3 1m m pa Selective rt
removethe 25 x is 30. lf the clearance out of tolerance, its 31 mm thrustshim and measure thickness.
3'|. Selectand install a new 25 x 3'l mm thrust shim,

then recheck. THRUST SHIM.25 x 31 mm
No.
RINGGEAR
Part Number 90451 P4V- 000 90452 P4V- 000 90453 P4V- 000
Thickness in) 1.05mm (0.011 1 . 1 2 m ( 0 . 0 4 i4 ) m n m n 1 . 1 9 m ( 0 . 0 4 i7 )
THRUSTNEEDLE BEANING
WASHERS THRUST
c
D
inl 9 0 4 5 4 - P 4 V - 0 0 0 1.26mm (0.050 in) 9 0 4 5 5 - P 4 V - 0 0 0 1.33mm {0.052 in) 9 0 4 5 6 - P 4 V - 0 0 0 1.40mm (0.055 '1.47 in) mm (0.058 90457-P4V-000 in) 9 0 4 5 8 - P 4 V - 0 0 0 1.54mm (0.061 in) 9 0 4 5 9 - P 4 V - 0 0 0 1.61mm {0.063 in) 9 0 4 6 0 - P 4 V - 0 0 0 1.68mm (0.066 90461- P4V 000 90462 P4V- 000 in} 1.75rnm {0.069 1.82mm (0.072 in)
E
F
G H
the ring gearand the 25 x 31 mm thrustshim. 27. Install then installthe snap ring.
K
L M N
28. Verifythat the outsidediameterof the snap ring is

correct. M a x i m u 3 0 . 7 m( 12 1i n ) m m F 1
't'":' /l \
in) mm (0.0427 9 0 4 8 0 - P 4 V - 0 0 0 1.085 in) mm 10.0454 9 0 4 8 1 - P 4 V - 0 0 0 1.155 in) mm (0.0482 9 0 4 8 2 - P 4 V - 0 0 0 1.225 in) mm (0.0510 9 0 4 8 3 - P 4 V - 0 0 0 1.295 mm {0.0537 in) 9 0 4 8 4 - P 4 V - 0 0 0 1.365 in) mm (0.0565 90485 P4V- 000 1.435 in) mm (0.0593 9 0 4 8 6 - P 4 V - 0 0 0 1.505 in) mm (0.0620 9 0 4 8 7 - P 4 V - 0 0 0 1.575 in) mm (0.0648 9 0 4 8 8 - P 4 V - 0 0 0 1.645 in) mm (0.0675 9 0 4 8 9 - P 4 V - 0 0 0 1.715 '1.785 in) mm {0.0703 90490-P4V-000
o
P
o
R
/./
\\
rl
i\
, SruEP RING, /
l\ r
_
'
b 29. M e a s u r e h e c l e a r a n c e e t w e e nt h e 2 5 x 3 1 m m t thrustshim and the snap ring. STANDARD: 0.05- 0.11 mm 10.0020 0.00/B inl in NOTE:Takemeasurements at leastthree places, as and usethe average the actualclearance.
32. After replacingthe 25 x 31 mm thrust shim, make is sure that the clearance within toleranceand the snap ring outsidediameteris correct shown. Install discspringin the direction the
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
a i n s t a l lt h e r e v e r s eb r a k eD l a t e s n d d i s c s .l n s t a l l selectedreversebrake end plate. then install the
snapflng. BRAKE REVERSE END PLATE BRAKE REVERSE PLATES
Dtscs
OISCSPRING in lnstall this direction
,*"ua{t",",
'!
ttl.
RING GEAB
(cont'd)
14-273
Transmission
Reassembly(cont'dl
35. Verifythat the snap ring end gap is correct.
M i n i m u m 8m m ( 0 . 7 1n ) 1 i
--
39. Installthe parkingbrakepawl, spring,and shaft on t h the transmission ousing,hen movethe control leverto any gearotherthan E position.
SNAPRING THRUST SHIM, SECONDARY GEABSHAFT COTTER RETAINER COTTERS, 25.5mm pan Selective
.,..
1r ' t
I'J
t\
.\i
,
sruapntruc-/ \ . : : ,/
l 36. I n s t a l t 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-rings the manualvalvebody and the interon mediatehousing.
8 x 1.25mm 37 N.m (3.8kgI.m,27 lbt.ft) 6x1.0mm 12Nm(1.2kgf.m. 8.7 tbt.ftl t'tl\
BRAKE PABKING PAWLSHAFT
STARTCLUTCH ASSEMBLY SECONDARY DRIVEGEAR ASSEMBLY O-RINGS
f, E J \ " E P
9>E
PARKING BRAKE PAWLSPRING

PARKING
RIGHT SIDE COVER GASKET DOWEL PINS O.RINGS
ORIVEN PULLEY SHAFT
gear shaft with selected x 25 40. Installthe secondary p 3 5 m m t h r u s ts h i m( s e e a g e1 4 - 1 0 0 ) .

MANUAL VALVE BODYPIPEA 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
preventdamageto the O-rings, then installnew Onngs. in 42. Assemble secondary the drive gear assembly the startclutchassemblv. then install them 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 t o o l u p , t h e n i n s t a l l l the tip of it into the driven pulleyshaft hole,and set the soecial tool on the startclutchCAUTION:While installing the start clutch and the secondarydriv gear assemblyusing the special tool, be sure not to allow dust and other toreign particlesto enter into the transmission.
STARTCLUTCH INSTALLER 07TAE- P4V0130
ATF FEEO PIPES
MANUAL VALVE BODY 37. Installthe two dowel pins and new right side cover g a s k e to n t h e i n t e r m e d i a t e o u s i n g ,t h e n i n s t a l l h new O-ringson the ATFleed pipes.
t r , ,n u n a ' " .
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
tool, then tightenthe 44. Pushthe handleof the special nut to seat the secondarydrive gear assemblyon the drivenpulleyshaftsecurely.
S?ART CLUTCHINSTALLER
is 4't. It the clearance not within the standard.remove th the cottersand measure eir thickness. and installnew cotters, then recheck. 48. Select coTTERS, 25.5mm No.
Part Numbel Thickness
n 9 0 4 2 9 - P 4 V - 0 0 02 . 9m m { 0 . 1 1 i4 ) n 3 . 0m m ( 0 . 1 1i8 ) 90430-P4V-000 i 90431 P4V- 000 3 . 1m m { 0 . 1 2 2n ) i 9 0 4 3 2 - P 4 V - 0 0 03 . 2m m { 0 . 1 2 6n )
c
D
49. After replacing 25.5mm cotters,make surethal the is the the clearance the standard. r r 50. I n s t a ltlh e c o t t e r e t a i n ea n dt h e s n a pr i n g . Verifyrhat the outsidediameterof the snap ring is correcI.
Minimum33.9mm 11.33 in)
HANOLE
45. Pull the handleof the specialtool up, and remove the special toolbetween 46. Installthecotters, then measure clearance the the cottersand the slart clutchguide. STANDARD: - 0.13mm {0 - 0.005in) 0 an NOTE|Takemeasurements at leastthfee places, and usethe average the actualclearance. as
"no"*,/\--/
52. I n s t a l t 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 l sprocket hub and the 22 x 28 mm thrustshim on the input shaft,then installthe snap ring.
SNAPRING\ ATF PUMPDRIVE SPNOCXET HUA THRUSTSHIM,22 x 28 mm Selectiveoan
COTTERS, 25.5mm
THRUSTWASHENS
GAUGE
li
,l
l)
STARTCLUTCH GAUGE
lf
STARTCLUTCH
( c o n td )
14-275
Transmission
(cont'dl Reassembly
53. Verifythat the outsidediameterof the snap ring is correct.
M a x i m u m 6 . 3 m { 1 . 0 4n ) 2 m i
r5
5 1 . After replacingthe 22 x 28 mm thrust shim, make sure that the clearance within toleranceand the is snap ring outsidediameter correct is 58. Installthe pitot flange using its cutout as shown to clearthe pitot pipes.
INPUT SHAFT
54. Measurethe clearancebetween the 22 x 28 mm thrustshim and the snap ring. STANDARD; 0.37- 0.65 mm 10.015 0.026in) NOTE:Takemeasurements at leastthree places, in and usethe average the actualclearance. as
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),
PUMPORIVE CHAIN 'l.0mm 6x 12 N.m (1.2kgf.m,8.7 lbtft) ATF PUMP DRIVE SPROCKET PITOTFLANGE
THFUSTSHIM, 22x28 mm
lf the clearance out of tolerance, is removethe 22 x 28 mm thrustshim and measure thlckness. its 56. Selectand install a new 22 x 28 mm thrust shim, then recheck. THRUSTSHIM.22 x 28 mm No. Part Number Thickness
ATF PUMP
c
D
9 0 5 7 3 - P 4 V - 0 0 0 1 . ' 1 m m { 0 . 0 4 5n ) 5 i 9 0 5 7 4 - P 4 V - 0 0 0 1.40mm (0.055 in) 9 0 5 7 5 - P 4 V - 0 0 0 1.65mm (0.065 in)
E
F
9 0 s 7 6 - P 4 V - 0 0 0 . 9 0 m ( 0 . 0 7 5n ) 1 m i
9 0 5 7 7 - P 4 V - 0 0 0 2 . 1 5m m ( 0 . 0 8 5n ) i 9 0 5 7 8 - P 4 V - 0 0 0 2.40mm (0.095 in)
INPUTSHAFT
14-276
assembly. the differential 60. Install pipe assembly with new O-rings(one bolt). 61. Install ATF passage the housing 62. Install three dowel pins and new flywheelhousinggasketon the transmission the (twentybolts). bracket the 63. Install flywheelhousingand connector
(two bolts). pipe holderassembly 64. InstalltheATF passage

6x1.0mm 12 N.m {1.2kgf.m, 8.7 tbI.ft) 8 x 1.25 mm 29 N.m (3.0k91.m,22lbl'ftl
PIPE arF PAssAGE I ASSEMBLY HOLDER I \
E {u
FLYWHEEL HOUSING
\n
[tr1 o-RrNG-___\S/
f-{ \A
CONNECTOR ERACKET
PIPE ATF PASSAGE
DOWEI.PIN
6x1.0mm kgf.m, 12 N.m 11.2 8.7 tbtftl
DOWEL PIN
FLYWHEEL HOUSING GASKET
at":
DOWELPIN
ri-{e
,):/;[
TRANSMISSION HOUSING ( c on t ' d)
14-277
Transmission
(cont'dl Reassembly
65. Installthe solenoidharness connector with a new O-ring{one bolt},then installthe lower valve body assembly with threedowel pins (eightboltsl. 66. Install the ATFstrainer with a new O-ring(two bolts). 67. lf necessary, assemble ATF pan,ATFfilter,and the ATF coolerinlet pipe(seepage'14-235). the 68. Install ATF pan with the two dowel pins and a new ATF pan gasket(fourteen the bolts). 69. Install ATFcoolerinlet pipe bracket the bolt. 70. lnstalltheATFcooleroutletpipe with the joint bolt and new sealing washers.
6x1.0mm kgf 12 N.m 11.2 m, 8.7 tbt.ftl DOWELPINS ATF STRAINER O-RING
ATF COOLER OUTLET PIPE OOWEL PINS ATF PAN/ATFFILTER/ ATF COOLER INLET PIPE ASSEMEI-Y SEALING WASHERS
O-RING JOTNT BOLT 28 N.m {2.9ksf.m, 21 lbf.ft) HARNESS CONNECTOR 5x1.0mm 12 N.m {1.2kgt.m, 8.7 tbf.ftl LOWER VALVEBODY ASSEMBLY 6x1.0mm 12 N.m 11.2 m, kgt 8.7 tbf.ft) ATF COOLEF INLET PIPEERACKET BOLT 8 x 1.25mm 26 N.m (2.7kgf.m,20 lbf.ftl
6x1.0mm 12 N.m 11.2 kgf.m, 8.7 tbf.ttl
14-278
Plate Flywheel/Drive
DRIVE PLATE
WASHER Install this direction. in
6nKn,
wear. teethot the ring gearfor excessive
1 2x 1 , 0m m 74 N.m {7.5kgI.m, 54lbl.ftl pattern. Torque in 6 crisscross
14-279
Transmission
Installation
l
Flushthe ATF cooleras described pages'14-284 on a n d1 4 ' 2 8 5 . R e m o v e 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 t and flywheelsplines. Fillthe inside the flywheel of hub cap,andcoatthe fly wheelhub splines with SuperHighTempUreaGrease (P/N08798 9002)as shown.
6.
Placethe transmission a jack,and raise it to the on engine ssembllevel. a y Attach the transmission the engine,then install on h t h e t r a n s m i s s i o n o u s i n gm o u n t i n gb o l t a n d r e a r engine ounting olts. m b
2.
7.
3.
TRANSMISSION HOUSING MOUNTING BOLT 64 N.m (6.5kgt.m,

41
REARENGINEMOUNTING BOLT Replace. '12 1,25mm x 59 N.m (6.0 kgf.m, 43 lbtftl
SPLINES HIGHTEMP Apply SUPER UREAGREASE {P/N 08798- 90021
WASHER
SUPER HIGHTEMP
.:_11
UREA GNEASE
{P/N 08798- 90021 1.5- 2.5 g (0.05- 0.ogozl
8.
4.
) r Instala new sealing ing (rubberon the input l shaft,and installtwo 14 x 20 mm dowel pins in the llywheelhousing. on lnstallthe flywheelsecurely the input shaft,then installthestartermotor on the flywheelhousing.
44 N.m (4.5kgf.m.33 lbf.ft)
mount bracket Tightenthe lnstallthe transmission long bolt loosely,and tighten the nuts and bolt on t 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 d o r q u e .T h e n torque. tightenthe long bolt to the specified
1 2x 1 . 2 5 m m 64 N.m {6.5kgl.m, 47 lbl.ft)
INPUT SHAFT STARTER
rtl
14x20mm PIN DOWEI-
S E A L I N GR I N G {RUBBER)
MOUNT
12 x L25 mm 74 N.m {7.5kgl.m,54lbtft}
PIN 14 x 20 mm DOWEL FLYWHEEL
14-280
housingmount9. Installthe remainingtransmission ing bolts.

OXYGENSENSOR PRIMARY
(see pulleybolt, if necessary 13. Tightenthe crankshaft section 6). 1 4 . Connect ATF cooler hosesto the ATF cooler pipes the (seepage 14-2891. CAUTION: While connecting the ATF cooler hoses, be sure not to allow dust and other loreign particles to enter ioto the transmission. Install the rightfront mounvbracket.
10 x 1.25mm kgl 4{ N.m (,1.5 m, 33 lbf ftl RIGHTFRONT MOUNT/EFACKET
ATF COOI.IRPIPE
1 0 . Removethe transmissionjack and the hoist, then

from the engine. removethe hoist bracket 1 1 . Attach the flywheel to the drive plate with eight boltsand torqueas follows: pulleyas necessary tighten to Rotatethe crankshaft torque,then to the the bolts to half of the specified pattern. final torque,in a crisscross 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 rotates freely. crankshaft 1 2 . Install flywheelcoverand the enginestiffeners. the
6x1.0mm 12 N.m 10 x 'l .25 mm 11.2 kotm. ENGINE STIFFENER ,14N.m (4.5kgf.m, e.zruittt 33 tbt.ftl 8 x 1.25mm 24Nm (2.6 kgf.m, 17 tbf.ftl
'10 1.25mm x 54 N.m 15.5kgt m, {0 rbf.ft)
ATF COOI.ER HOSE 16. Install the exhaust pipe A. A EXHAUSTPIPE
DRIVE
TE
GASKET Replace.
oo"*ar-@
DRIVEPLATEBOLT 6x1.0x14mm 12 N.m {1.2kgt m, 8.7 tbl.ft| FLYWHEEL
ENGINE STIFFENER
Replace. 8 x 1.25mm 26 N.m kgl..n. 12.7 20 rbf.ft) 10 x 1.25mm 44 N.m (4.5kgf.m, 33 rbtft) SELF.LOCKING Beplace. 8 x 1.25mm 22 N m {2.2kgf.m,16lbtftl
8 x 1.25mm 24 N.m (2.4 kgf'm, 17 lbt ft)
NUT SELF.LOCKING Replace. 10x 1.25mm 54 N.m (5.5kgf m, 4r) tbt.ftt NUT SELF.LOCKING Replace. 8 r 1.25 mm kgf 16 N.m 11.6 m, 12 tbf.ft) (cont'd)
14-281
Transmission
1 7 . Installa new set ring on the end of eachdriveshaft.
\
20. Install splashshield. the
(seesection16). 1 8 . Installtheright and left driveshafts CAUTION:While installing the drivcshalts in the diflerential, be sure not to allow dust and other foreign particlesto enter into the transmission. NOTE: I Cleanthe areaswherethe driveshafts contact the ( ) t r a n s m i s s i o nd i f f e r e n t i atl h o r o u g h l y i t h s o l w v e n t o r c a r b u r e t oc l e a n e r , n d d r y w i t h c o m r a pressed arr. . Turn the right and left steeringknuckle fully outward, and slideeach driveshaft into the differential until you {eel its set ring clip engagethe side gear. 1 9 . Install the damperfork,then installthe right and left 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 and new cotterprns.
SPLASHSHIELD 6 x 'l.O mm 9.8 N.m {1.0kgf.m, 7 .2 tbl'ttl
10 x 1,25mm 43 N.m (4,4kgf.m,32 lbf.ftl
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 secondarygear shaftspeedsensor connector.
VEHICLE SPEEO SENSOR CONNECTOR
6x1.0mm '12N.m {1.2kgf.m, 8.7 lbl.ft}
DRIVEN PULLEY SPEEO SENSOR CONNECTOR
NUT SELF-LOCKING ./*:, ./ PtN cbr-rER Replace. NUT CASTLE Beplace. 12x 1.25nm 1 2x 1 . 2 5 m m 64 N.m ks{.m,47 lbf.ftl 4 9- 5 9 N m 1 5 . 0 - 6 . 0 k g f . m , {6.5 36 43 tbf.ftl
a'.
SECONDARY GEAR SHAFTSPEED SENSOR CONNECTOR
6x1.0mm 12 N.m 11.2 m, 8.7lbf.ftl kgl
14-282
22. Installthe shift cableend on the control lever,and installthe shift cableon the shift cablebracket. CAUTIONT Takecarenot to bendthe shift cable. 2 3 . I n s t a l l t h c l i pi n t h e d i r e c t i o s h o w n . e n
LOCKNUT 29 N.m (3.0 kgl.m, 22 lbfftl SHIFT CABLE BRACKET
25. Connect startermotor cableon the startermotor, the and installthe cableholder. make the NOTErWhen installing startermotor cable, 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 23). facingout (seesection
SHIFTCABLE
MOTOR STARTER
WASHER IPLASTIC}
STARTER
B TERMINAL MOUNTING NUT I N.m 10.9 kgt.m, 7 lbtft)
CONTBOL LEVER the drive 24. Connectthe solenoidharnessconnector, 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 , n d t h e g r o u n d a c a b l ee r m i n a l s . t

6x1.0mm 12 N.m {1.2kglm, 8.7 tbt.f0 CABLE GROUND 6x1.0mm TERMTNAL 12 N.m 11.2 kgl.m, 8.7 rbf.ftl
and clamps. 26. Installall removedconnectors 27. Inslallthe distributor. h 2 8 . I n s t a l t 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 r o u s i n g l 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 p H C G e n u i n e o n d a W F l u i d( s e e a g el 4 - 2 3 1 ) , 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. {-) the Check ignitiontiming (seesection231. a ) Startthe engine. Setthe parkingbrake, and shiftthe t r a n s m i s s i otn 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 h (seepage14-287). shift cableadjustment (seesection18). the 33. Check front wheelalignment ( 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 g e m p e r a t u r e t h e t n r a d i a t o f 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 oin E r then turn it of{ and checkfluid level. or E position, p o 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 n r o c e d u r e n page 14-225. on 36. Roadtest as described pages14 228 and 14-229.
DRIVEPULLEY SPEED SENSOR CONNECTOR
14-283
Transmission
CoolerFlushing
To prevent iniury to face and eyes, always !@ wear satety glassesor a face shield when using the transmissionflusher, NOTE:This procedure shouldbe performedbeforereinstallinqthe transmission.
1. 7. With the water and air valves off, attach the water and air suppliesto the flusher. (Hot water if available.)
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 cracks found, replace hoses are the be{oreusing. Usingthe measuring cup,fill the tankwith 21 ounces (approximately tulll ot biodegradable 213 flushing fluid (J35944 20).Do not substitute with 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 e n t h e f l u i d o container. 8. Turn on the flusher water valve so water will flow throughthe coolerfor 10 seconds. NOTE:lf water does not flow throughthe cooler,it plugged,cannotbe flushed,and must is completely be replaced. 9. Depress triggerto mix the flushingfluid into the the waterflow. Usethe wire clipto holdthe triggerdown. 10. While flushingwith the water and flushingfluid for two minutes,turn the air valve on for five seconds every '15 20 seconds createa surgingaction. to AIR PRESSURE: MAX 845 kpa(8.45kgtcm,, 120psi) 11. Turn the water valve off. Release the trigger,then reverse the hosesto the coolerso you can llush in the opposite direction. Repeat steps8 through 10. Release trigger,and rinsethe coolerwith water the 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
2.
3 . Secure flusherfiller cap,and pressurize tank the the

with compressed to between550- 829 kpa (5.6air 8.45kgf/cm,,80 120psi). NOTE:The air line shouldbe equipped with a water trap to ensurea dry air system. 4. 5. Hangthe tool underthe vehicle. Attach the tank's discharge hose to the return line of the transmission coolerusinga clamp. Connect drain hoseto the inlet line on the transthe missioncoolerusinga clamp. IMPORTANT: Securely clampthe oppositeend ol the drain hoseto a bucketor floor drain.
6.
for two full minutesor until no moistureis visible leaving the 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 t h e t r a n s m i s s i o n ,n d l e a v et h e d r a i n h o s e l a attached the coolerline. to
availablel {Commercially Kent-MooreJ384O5-A or equivalent
14-284
't1 Makesurethe transmission in the position. . is E

F i l l t h e t r a n s m i s s i o n i t h C V T F l u i d ,a n d r u n t h e w or 0.95/ enginefor 30 seconds until approximately ( 1 . 0U S q t . , 0 . 8 m p q t . )i s d i s c h a r g e d . l '18. R e m o v e 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 t (seepage l4 287). returnhoseto the transmission with CVT Fluidto the proper 1 9 . Refillthe transmission ( 2 l e v e l s e ep a g e ' 1 4 3 1 ) .
TOOL MAINTENANCE '1. Emptyand rinseaftereachuse.Fillthe canwith water line to the and pressurize can. Flushthe discharge e n s u r eh a tt h e u n i ti s c l e a n . t 2. lf discharge liquiddoes not foam,the orificemay be blocked. f T o c l e a n d i s c o n n e c h e p l u m b i n g r o m t h e t a n ka t tt , n thelarge oupling ut. c couPLlf{G NUT
3.
CAP FILLER
I -@q
I
\
ORIFICE
filterfrom the discharge side and Remove in-line the 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
Make sure lifts, iacks and salety stands ale !@ placed properly (seesection 1). 1. 2. Remove front console(seesection the 20). Shift to ffi position,then removethe lock pin from the adiuster. 3. Remove air cleanerhousingassembly. the Removethe clip from the control lever,and loosen the locknut. CLIP SHIFT CABLE LOCKNUT
29 N.m {3.0 ksf.m, 22 lbtft) WASHER
Tr (>
SHIFI CABLE BRACKET
CONTROL LEVER
\
Removethe shift cable from the control lever,the shift cablebracket, and the clamp. Remove the 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)
!
14-286
1. 8.
Install shiftcablein the reverse the orderof removal. (seepage 14-2871. Check cableadjustment the
Adjustment
Make sure lifts,lacks and safety stands are @ placed properly {seesestion 11, 1. 2. Remove front console(seesection20). the Shift to E position,then removethe lock pin from the adjuster. is aligned that the holein the adiuster perfectly 3. Check Therearetwo holesin with the holein the shiftcable. 90" They are positioned apartto allow the adjuster. in cableadiustment 1/4turn increments.
lf the hole is not perfectlyaligned,loosenthe lockand adjustas required. nut on the adjuster Tightenthe locknut 7 N.m {0.7kgf.m,5 lbnft}. to Installthe lock pin on the adjuster.lf you feel the lock pin binding as you reinstallit. the cable is still and must be readjusted. out of adjustment
SHIFTCABLE
10.7 kgf'm, 5 lbf'ftl
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 securely. and verifythat Movethe shift leverto eachposition, the shift position indicatorfollows the automatic gear positionswitch. transaxle
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. any gear does not work properly.reier If (seepage14-226 and l4-227J. to troubleshooting Insen the ignition key into the key cylinderon the panel,and verifythat the gear positionindicator A//T shift lockleveris released.
14-287
Shift Lever
PUSHKNOB
,l
PUSHKNOBSPRING
GREASE SILICONE LAMP SHIFTINOICATOR
-6r
LEVER COVER SHIFTLOCK SOLENOID BUSHING ..@] GREASE SILICONE SCREW 3 N.m {0.3 kgt m, 2 lbtft) EJ ASSEMBLY SHIFTLEVER
LEVER COVER
@'""'-rccretn
ADJUSTER 6xl.0mm 9.8N.m {1.0kgl m, 1.2 tbt.ltl
-6.,1
SILICONE GREASE
A/T GEARPOSITION PLATE 3 N.m {0.3kgf.m, 2 tbf.ftl
SWITCH A/T GEARPOSITION
BRACKET BASE SHIFTLEVER SHIFTLEVER BRACKET BASECOLLAR
6x1.0mm 9.8N.m (1.0kgf m,7 2lbtft)
14-288
Panel Shift Indicator

Adjustment
r 1 . C h e c k h a t t h e i n d e xm a r ko n t h e i n d i c a t o a l i g n s t with the E mark on the shift indicatorpanelwhen s t h et r a n s m i s s i oi n i n N E U T R A L .
ATFCooler/Hoses
lnstallation
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 and the ATFcoolerhoses.
6x1.0mm
PIPE ASSEMBLY ATF COOLER HOSE ATF COOLER RADtAfoR /,/' 6xl.0mm 9.8N.m (1.0tgl m,7.8 lbf ftl
MOUNTING SCREW 3 Nm {0.3kgt.rn.2lbtft}
TANEL
HOSES ATFCOOLER
lf not aligned, remove the front console (see section 20). Remove the shift indicator panel mounting screws and adjust by moving the panel. NOTE: Whenever the shift indicatorpanel is removed, reinstallthe panel as described above,
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 them with the clips linesand ATF cooler,and secure a ss h o w n .

RADIATOR
\-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
seetion ...................... 13 Transmission Manual section14 ................. Transmission Automatic
Driveshafts
Tools.......... Special Driveshafts Inspection Removal Disassembly Reassembly lnstallation """.."' 16-2 16-3 ..."...'.'..'....'... ....16-3 16-5 ..".'...."....." 16-7 ......."...'.".... 16-11 ..'........'..'.'..'.
SpecialTools
Ref. No.
Tool Number BallJoint Remover, mm 28
16-2
Driveshafts
Inspection
Drivoshafi Boot for cracks,damage, Checkthe boots on the driveshaft bands.lf any damageis leakinggreaseand loose boot the found,replace boot and boot bands Loose Splines by Turn the driveshaft hand and make sure the splines and ioint are not excessivelyloose lf any damage as the found.replace inboardjoint. Twisted or Cracked is Makesurethe driveshaft not twistedor cracked. ReDlace if necessary. it
Removal
the 1 . Loosen wheel nuts slightlY. Raisethe tront of the vehicle,and support it with (seesection1). safetystandsin the properlocations Remove wheel nuts and front wheels. the
fluid (seesection13 or 14). Drainthe transmission 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, nut Remove self-locking and flangebolts. the
FLANGE EOLT 10 x 1.25mm BOOT BANDS
mm 12 x 1.25 Replace.
7.
Remove the damper fork.
(cont'd)
16-7
Driveshafts
Removal {cont'd)
8. Remove the cotter pin from the lower arm ball joint castlenut, and removethe nut. 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 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 differential oil seal.
07MAC- St_00200
9 . I n s t a l l 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 a that the hex nut is flush with the ball joint pin end, or the threaded sectionof the ball joint pin might be damagedby the special tool. 1 0 . Usethe special tool as shown in section18,to separate the ball ioint and lower arm. Be carefulnot to damagethe ball joint boot, NOTE: lf nece'ssary, apply penetratingtype lubricantto loosenthe bsll joint. 1 1 . Pry the driveshaft assemblywith a screwdriver, as shown, to force the set ring at the driveshaftend pastthe groove.
SCREWDRIVER
13. Pullthe knuckle outward.and removethe driveshaft 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 olastichammer.
SCREWDRIVER 3.5mm
ORIVESHAFT
16-4
Disassembly
1.
Caretullyclamp the driveshaftin a vise with soft jaws, then remove the set ring from the inboard joint. To removethe boot band, pry up the lockingtabs with a screwdriverand raise the end of the band. Takecarenot to damagethe boot.
It the boot band is double loop type, raise the band bendas shown.
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.
SET RING Replace. lf the boot band is the welded type, cut it off as snown. BOOT BAND Replace.
JOINT INBOARD lor splines wear or damage Check Check insideborefor wear' Inspect{or cracks.
lf the boot band is the crimpingtype, pry up the end of the bandwith a screwdriver.
BOOTBAND Replace. Mark3
{cont'd)
16-5
Driveshafts
4. Mark the rollersand spiderto identifythe locations then removethe rollers. of rollerson the sDider, with vinyltapeto 9. Wrap the splineson the driveshaft preventdamageto the bootsand dynamicdamper. INBOARD BOOT for Inspect cracking, BOOT BAND splitting wear. R e p l a c e . and
DYNAMICOAMPER
BAND
Replace.
OYNAMICDAMPER for Check damage.
OUTBOARD BOOT Inspect cracking, for splitting and wear.
1 0 . Removethe boot band and inboardboot.Takecare

not to damage the boot. 1 1 . R e m o v e 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 t damper,if equipped.Takecare not to damagethe dynamicdamper. 12. Removethe boot bsnds and outboard boot, then removethe vinyltape.
1 3 . Inspect outboardjoint for faulty movementand the

Remove circlip. the to Mark the spider and driveshaft identitythe position of the spideron the shaft. 7. Remove spiderusinga bearingremover. the Japanproduced). Remove stop ring (except the play is felt, replace or wear. lf any roughness excess joint. the outboard
JOINT OUTBOARD
16-6
Reassembly
Notetheseitemsduring reassemblyl air. partswith solvent, and dry them throughlywith compressed Do not wash the rubberparts . Cleanthe disassembled with solvent. . -,.6l packthe inboardjoint and both joint bootswith the ioint greaseincludedin the new driveshaft : Thoroughly
Greasequantity: lnboardJoint Joint Outboard Japan Produced JapanProduced Except JapanProduced JapanProduced Except ' 1 1 0 1 2 0g { 3 . 9 4 . 2o z ) '120 130g {4.2- 4.6ozl 70 - 80 g (2.5- 2.8 oz) 1 1 5- 1 3 5g ( 4 . 0 4 . 8o z )
SCTRING Replace. \zn
INBOARD JOINT ROLLER
STOPRING{ExceptJapan producod}
Pack cavitywith grease.
--"
B(rcT INBOARD - - -
&l
Packcavity with groase.
DYNAMICDAMPER
BOOTBANDS Replace.
DRIVESHAFT BAND DAMPER OYNAMIC Replace.
BOOT OUTBOARD
Packcavity wrtn grease.
-611
(cont'd)
16-7
Driveshafts
Reassembly(cont'dl
1.
Wrap the splineswith vinyl tape to preventdamage to the bootsand dvnamicdamoer.
4.
V;
APE OUTBOAROBOOT
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 {exceptJapan produced),Always rotate the stop ring in its grooveto be sure it is fully seated. \zr|<-C|RCL|P
DYNAMIC DAMPER 2. INAOARD BOOT 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 vinyl tape.Take care not to damagethe boots and dynamicdamper. joint with the joint grease Pack outboard the included in the new driveshaftset, Greasequantity: Japan Producd: 7o- 80g (2.5 2.aozl ExceptJapan Produced:115- 1359 (i1.0 4.8ozl 7. Installthe spider on the driveshaftby aligningthe markson the spiderand end of the driveshaft. Fit the circlip into the driveshaftgroove. Always rotatethe circlip in its groove to be sure it is fully seated. Fit the rollersto the spiderwith their high shoulders facingoutward,and notetheseitems: . Reinstall rollersin their originalpositionson the the spiderby aligningthe marks. . H o l d t h e d r i v e s h a f t o i n t e du D t o prevent the p rollers from tallingoff.
16-8
8.
Packthe inboardioint with the joint greaseincluded set. in the new driveshaft quantity: Grease 110- 120g (3.9 4.2ozl Jaoan Produced: ExceptJapan Produced:120- 130g (4.2- 4.6 ozl
10. Adjust the length of the driveshaftsto the figure below, then adiust the boots to halfway between a f u l l c o m p r e s s i o n n d f u l l e x t e n s i o nT h e e n d s o f and joint. bootsseatin the grooveof the driveshaft Left driveshaft: 774- 779 mm 130.5 30.7in) Right driveshaft:501- 506 mm 119.7 19.9in)
the 1L Position dynamicdamperas shown below. Left: t Without "SRl" mark:94 :t 2 mm 13.7 0.1 in) i 75 t 2 mm 12.9 0.1 in) With "SR1" mark: t R i g h t 5 5 1 2 m m ( 2 . 2 0 . 1i n l :
and note Fit the inboardjoint onto the driveshaft, thesertems: by . Reinstall inboardjoint onto the driveshaft the j i n b o a r d o i n rw i t h t h e t a l i g n i n g h e m a r k so n t h e markson the rollers. . Holdthe driveshaft the inboardjoint pointsup so to preventit from fallingoff.
INBOARD JOINT
BAND DYNAMICDAMPER
{cont'd)
16-9
Driveshafts
(cont'd) Reassembly
12. Set the doubleloop band onto the boot and dynamic damperwith the band end toward to front of the vehicle. Threadthe free end of the band through the nose sectionoJ the boot band tool and into the slot on 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,
AOOT BAND TOOL (KD-3191equivalent) or
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 clip, the
cuP
HAiIMER
16-10
lnstallation
5 18, Unwindthe boot bandtool, and cut oft the excess - l0 mm 10.2 0.4 in) from the cliP. 1. groove. Installthe new set ring onto the driveshaft Always use a new set ring wheneverthe driveshaft is beinginstalled.
5-10mm (0.2- 0.4 in) JOINT INBOARD
SETRINGGROOVE
'19. Secure the end of the boot band by tappingit down with a hammer,
2.
joint into the knuckle. the outboard Install
KNUCKLE
Notetheseitemsafter reassembly: with . Make sure the band and clip does not interfere anythingand the band does not move. o ! R e m o v e n y g r e a s er e m a i n i n g n t h e s u r r o u n d i n g a surtaces.
JOINT OUTBOARD
(cont'd)
1 16-1
Driveshafts
Cleanthe areas where the driveshaftcontact the transmission(differential) thoroughlywith solvent or carburetor cleaner. and dry with compressed air. Insertthe inboardend of the driveshaft into the differentialuntil the set ring locksin the groove. INAOARD JOINT 5. Installthe damperfork over the driveshaft and onto 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 fork so the aligning ab is aligned ith the stotin t w the damoerfork. FLANGE BOLT 10x 1.25 mm (3 N.mla.akgf.m. lbf.trl 32
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 the castlenut to the lowertorquespecification. then tighten it only far enoughto align the slot with the pin hole.Do not alignthe nut by loosening.
SELF.LOCKING NUI 12 x 1.25mm fl N.m (6.5 kgf.m, it7 lbf'ltl Repiace.
6. Loosely install the flange bolts and the new selflocking nut.
7 . Apply oil to the seating surface of the new spindle

nur. FRONT WHEEL WHEEL NUT 12 x 1.5mm 108 N.m {11.0kgt m, 80lbt ftl
CASTLE 12 x 1.25 mm alt - 59 N.m 15.0- 6.0 kg{.m, 36 - ail lbl.ftl
COTTER PIN Replace. On reassembly, bend the cotter pin
SPINDLE NUT 22 x 1.5 mm 181N.m 118.5 kg{.m, 134lbf.tt) NOTE: After tightening,use a drift to
stake spindle shoulder the nut against driveshaft. the 8. Installa new spindlenut,then tightenthe nut. 9. Cleanthe mating surfaces the brakedisc and the of wheel, then installthe front wheel with the wheel nutS, 10. Tighten the flange bolts and the new setf-locking nut with the vehicle's weighton the damper. 11. Refillthe transmission with recommended fluid (see section13 or 14). '12. Check the front wh;eltlbnment and adjust if nec'il essarv(seesection18).
f,
16-1 2
Steering
Tools Speciaf .............17-2 Inspestion and Adiustment
17-30 Steering Operation.......................... Power Assist Check ManualSteering 17-30 With VehicleParked .................... ComponentLocations 17-31 SteeringLinkageand Gearbox ....... ....... 17'3 fndex ................ .............. 17-32 Pump Beft Inspection and Adiustment 17-33 RackGuideAdjustment ................... 17-4 Operation.......................... Steering 17-33 ........................... FluidRep|acement 17-5 RackGuideAdjustment................... 17-34 PumpPressure Check...................... 'Steering Wheel *SteeringWheel (Seepower steering sec'tion) *SteeringColumn 17-35 ................. Removal (Seepower steering sectionl ............. 17-35 lnstallation Steering Gearbox I 7-36 ............... Disassembly/Reassembly 'Steering Column 17-5 ................. Removal 17'7 ........... Disassembly 17-37 ....................... Removal/lnstallation ............ 17-9 Reassembly .............. 17.38 Inspection ............. 17-13 Power Steering Hoses,Lines lnstallation 17-39 Inspection................. Fluid Leakage PowerSteering 17-39 .......... Replacement Component Locations Power SteeringPump ....... 17-15 lndex ................ 17-tlo ....................... Removal/lnstallation System Description ........... 17-41 Disassembly 17-16 FluidFlow Diagram.......................... ..............17-42 fnspection -17 17 Pump .................................. Steering ............17-44 Reassembly 17-20 Gearbox............................. SteeringGearbox Steering Troubleshooting 17-47 ,,,,.,........... Removaf -22 17 Generaf Troubleshooting................ 17-lt!l ........... Disassembly 17-26 Noiseand Vibration......................... ............ 17-55 Reassembly .............17-28 lnstallation Ff uid Leaks ............. 17-65 17-68 Ball Joint Boot Replacement..........
Special Tools
\
Ref. No I Tool Number 07GAF PH70100 07GAG SD40l0Aor 07GAG SD40100 07GAG SD40204 or 07GAG SD40200 *07JGG 001010A 07MAC S100200 OTNAD SR3O2OA 07NAG- SR3090A or 07NAG- SR30900 07RAK 5040110 07RAK 5040121 or 07RAK 5040120 07406 0010004 or 07406 00'10001 07725- 0030000 07746 0010100 07746 0020'100 07746 0030300 07749 0010000 07916 SA50001 07965- SA50500 07974 SA5020A or 07974 SA50200 07974 SA50800 Description Pilot ollar C PistonSealRing PistonSealRingSizingTool BeltTensionGauge B a l lJ o i n tR e m o v e r , 2 m m S Cylinder End SealRemover Attachment PistonSealRingSizingTool P/SJoint Adaptor(Pump) P/SJoint Adaptor(Hose) P/SPressureGauge Universal Holder Attachment,32 35 mm x Driver, mm l.D. 22 Attachment, mm l.D. 30 Driver Locknut Wrench, mm 40 FrontHub Dis/Assembly Tool Sleeve SealRingSizingTool
1 'l I 1
Oty
a
aal
PageReferenco 11-54 17-59 17-59
o
@
ao'r
17-6,47 17-51 17-56 17-34 't]-34 17-34 -42,46 17 17-57,58 l 7 -1 0 't7-44 17-57 17-68 17-51 17-57, 68
o
@ @ @ @ @ @ @
@ EallJoint BootClip Guide * Included the BeltTensionGaugeSet,07TGG - 001OOOA. in
g/
@
o
(o)
=fu*
@
,g
l:1
@
(D
7-2
Locations Component
lndex
ManualSteering NOTE: or vehicleor has beenfound defective damageddur. lf an intactairbagassemblyhas been removedfrom a scrapped 24)' it ing transit,storageor service, shouldbe deployed{seesection wheel and steering removethe driver'sairbagassembly . Beforeremovingthe gearbox, gearbox, the wheelalignmentand adjustif necessary. check . After installing the in precautions, and procedures the SRS are locatedin this area.Reviewthe SRScomponentlocations, SRScomponents or section {24}beforeperformingrepairs service
WHEEL STEERING page Removal/lnstallaiion, 17-35 page Disassembly/Reassembly, 17'36 AIRBAGASSEMBLY DRIVER'S 24 see Bemoval/lnstallation, section
COLUMN STEEBING Removal/lnstallation, 17 37 Page page'17-38 Inspection, REEL CABLE 24 see Femoval/lnstallation, section SWITCH IGNITION 23 Seesection
GEARBOX STEERING Rack GuideAdjustment, Page17-5 R e m o v ap,a g e ' 1 7 - 5 l page17-7 Disassembly, page'17 9 Beassembly, page17 13 Installation,
ENOBALLJOINT TIE.ROD page17-68 BallJoint BootFeplacement,
17-3
Inspection and Adjustment

SteeringOperation
SteeringWheel Rotational Play Placethe front wheels in a straightahead positionand the steeringwheel can be turned measure the distance without movingthe front wheels. PLAY: - 10 mm (0 - 0.4 in) ROTATIONAL 0 the lf the play exceeds servicelimit, perform rackguide (seepage17'5). adjustment after rack guide adjustment, lf the play is still excessive inspectthe steeringlinkageand gearbox as described
BOTATIONAL PLAY
\
Steering Eftort Check Raise front wheelsoff the ground. the wheelwith a springscaleand checkits Turn the steering reao Ing. 15 Standard: N {1.5kgf,3.3 lbfl maximum t 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 ( s e e page 17-5).
\ -J
TJ
LOCKNUT TIE.ROD for Check 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
JOINTS STEERING for Check looseioint bolts.
COLUMN for InsPect loosecolumn mountingboltsand nuts
PINIONSHAFTGROMMET for damageand deterioration BALLJOINT BOOT for Inspect damageand deterioration. for Seepage17-68 replacement.
END BALLJOINT for Inspect 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
for Inspect loosemountingbolts.
17 -4
SteeringGearbox
RackGuide Adjustment
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 wheelsin the straightaheadposition. 1. Loosenthe rack guide screw locknutwith the specialtool, then loosenthe rackguidescrew.
Removal
NOTE:Using solventand a brush.to wash any oil and air. Blow dry with compressed dirt off the gearbox. 1. Raisethe front of vehicle,and support it on safety (seesection1). standsin the properlocations Remove front wheels. the wheel (seepage 17-35). Remove steering the Remove steering the ioint cover
2. 3. 4.
STEEBING JOINTCOVER
07916- SA5000l
the Tightenthe rackguidescrewuntil it compresses springand seatsagainstthe rackguide,then loosen it. Retighten rackguide screwto 4 N.m (0.4kgf'm, the angle. 2.9lbtft), then backit off to specified 5. SpecitiedReturn Angle: 30' 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 compieteturningtravel. Recheck effort (seepage 17-4). steering Removethe steeringjoint lower bolt, and disconnect the steeringjoint by moving the joint toward t h ec o l u m n .
STEERING JOINT
{cont'd)
SteeringGearbox
Removal (cont'dl
Remove the cotter pin from the castlenut ('96-'97 model)or nut ('98 model)and removethe nut. 13, Remove mountingbracket. the
PINS COTTER Replace.
7 . Install the 10 mm hex nut on the balljoint. Be surethat the 10 mm hex nut is flushwith the ball joint pin end,or the threaded section the ball joint of pin mightbe damaged the balljoint remover. by NOTE:Remove tool. the ball joint usingthe special 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 remover. Separate tie-rodball joint and knuckle the usingthe specialtool. CAUTION: Avoid damaging lhe ball ioint boot. Removethe left tie-rod end, then slide the rack all the way to the right, 1 0 . Separate exhaustpipeA or TWC (seesection the _9). 1 1 . Disconnect shift linkage(seesection13 or secthe tion14). plate, 12. Remove stiffener the
PINION SHAFT GROMMET
1 4 . Pull the steeringgearboxall the way down to clear the pinionshaftfrom the bulkhead, then removethe pinionshaftgrommet. Move the steeringgearboxto right so the left rack end clearsthe rearbeam,then tilt the lelt sidedown to removeit from the car.
STEERING GEARBOX
17-6
Disassembly
l.
Placethe gearbox in a vise with a soft jaws, then 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 noustng. CAUTION: Be carful not to distort the gear housing by clamping it too tight in the vise incorrectly.
5.
Pushthe right end of the rackbackinto the cylinder housing so the smooth surfacethat rides against the sealwon't be damaged. 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 screw.
Remove the disc washer, spring and rack guide
6.
2. 3.
Remove tie-rodend and locknut. the Removethe boot bands and tie rod clips. Pull the bootsawayfrom the ends of the gearbox.
7.
from the gear housing.
SPRING OISCWASHER
LOCKNUT E-ROD L I P C BOOT

Replace.
FACK GUIDE SCREW
8.
@
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 unscrew the rackend with anotherwrench. CAUTION:Be caretulnot to damagethe rack surface with the wrench.
STEENING RACKENO
I I
t R e m o v e 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 ring. Holdthe pinionshaftwith a visesecurely. R e m o v e 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 t flanged sectionof the gearboxwith a plasticham m er . CAUTION: Do not tap on the steering rack. NOTE:Do not reusethe removedpinaon.
PINIONOUSTSEAL Repl6ce. SNAPRING,35 mm STEERING PINION Feplace.
9.
17-7
SteeringGearbox
10. Slidethe steeringrackout of the cylinderhousing. CAUTION: Be caretul not to damagethe bushing in the cylinderhousing. 12. Replace gearbox the mountingcushionif necessary: To remove cushion, a sharpknifeand make the use a cut downthe length the cushion. careful of Be not to damage painton the outside the cylinder the of housing. Remove old cushion. the Apply weatherstrip adhesive the insideof the to new cushion. Install cushiononto the cylinder the housingand positionit 20- 22 mm (0.79 0.87in) from the end of the cylinder housing shown. as N O T E :A f t e r i n s t a l l i n g h e c u s h i o n , i p e o f f a n y t w e x c e s sa d h e s i v e h a t m a y h a v e d r i p p e d i n t o t h e t i n s i d e f t h ec y l i n d eh o u s i n g . o r
1 1 . R e m o v eh e r a c ke n d b u s h i n g . t
GEARBOX MOUNTING CUSHION 20 - 22 mm 10.79 0.87in)
RACKENOBUSHING Inspect innerwall for wear or damage
1 7 -A
Reassembly
NOTE: air. partswith solvent, and dry them with compressed Do not dip the rubberpartsin solvent. . Cleanthe disassembled partswith new ones beforeassembly. . Alwaysreplace non-reuseable the gearbox. to . Do not allow dust,dirt, or otherforeignmaterials enterthe steering
RACKENO BUSHING MOUNTINGCUSHIONS GEARBOX
-6r
PINIONDUSTSEAL Replace.
-R4
r@
t_
M."^pR,NG.3smm
-$d
\ \ DISCWASHER RACKGUIDE
RACKGUTDESCREW
(cont'd)
17-9
SteeringGearbox
(cont'd) Reassembly
't. Apply a thin coat of greaseto the insidesurfaceot the rackend bushing. quantity:1 - 3 g (0.04-0.1 oz) Grease CAUTION:Do not fill the slots with greas;they must remain open to serve as air passages. 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 g h e r o u n d t projection the bushingwith the hole in the cylinon d e rh o u s i n g
DRIVER, 22 .rlml.D. 071460020t00
5. Drivein the steeringpinion in the gear housingwith t h es p e c i a l t o o l s .

PINION DUST SEAL Replace. SNAPRING, mm 35 Vinyltape 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 y n t h e g e a r i groove. nousrng 1 . Apply vinyl tape to the pinion shaft,then coat the v i n y l t a p e i t hg r e a s e . w 8. Install the piniondust sealon the gear housinguntil it seatsproperly, then removethe tape. 3.
4.
Grease steeringrackteeth. the I n s t a l l h e s t e e r i n g a c k i n t o t h e c y l i n d e rh o u s i n g t r c a r e f u l lty a v o i dd a m a g i n gh e r a c ke n d b u s h i n g . o t 9 . G r e a s e 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 t i n s t a lilt o n t o t h e g e a rh o u s 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 facingn. i
DISCWASHER
SPRING
LOCKNUT CYLINDER HOUSING
RACKGUIDESCREW
'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 steeringrack. IJ. Install the steeringrackend into the rack.

LOCK WASHER
Repiace. TAB
16. Apply grease around the outside of the rack end houstng.
kgif RACKEND 54 N.m 15.5 m, 40 lbtftl

t;J"' " .=-!!!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 the rackend with another. CAUTION: Be carelul not to damage the rack surtace with the wrench. t 5 , After tightening the rack ends, stakethe four sections of the lock washer with a roll pin drift and a mallet. . Place wood blockon the presstable,then set the 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 sectionof the steeringrackend.
ROLLPIN ORIFT: (Commorcially availablel Snap-OnNo. PPR8or equivalent
grooveson the rackends, 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 clrps. NOTE: Install the boot band with the rack in the straight ahead position (right and left tie-rods are equaln length). i
off NOTE:Wipe grease the threadsection.
Press
NOTE:This dritt hasa flat punctunng tip, to prevent
nncxl srrenrruc
ELocK woooEN
CLIP TIE.ROD
(cont'd)
17-11
SteeringGearbox
Reassembly(cont'd)
1 9 . Installthe boot band so that the lockingtabs of the points)are in the rangeshown below. band (stake (Tabsshouldface up and slightlyforwaro.J 22. Slide the rack right and left to be certainthat the bootsare not deformedor twisted.
20. Bendboth setsof lockingtabs.

2 1 . Lightlytap on the doubled-over portionsto reduce t h e i rh e i g h t . CAUTION: Stakethe band lockingtabs firmly.
Stakepoints
Front
L6ft Boot Band (Viewedfrom the left side)
Right Boot Band (Viewed from the right sidei
17-12
lnstallation
1.
2
Slidethe rackall the way to the right. Installthe pinion shaftgrommet,and insertthe pinion shaftup throughthe bulkhead. NOTE:Align the notch in the pinion shaft grommet with the tab on the gear housing.
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 plateattaching bolts. mountingboltsand stiffener 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 them securelv.

PLATE STIFFENER
PINIONSHAFTGROMMET
GEARBOX STEERING
MOUNTING BOLTS GEARBOX 43 N.m(4.{kgf.m, lbf.ft) 32 5. 6. rackwithin its stroke, Center steering the joint onto the pinSlip the lower end of the steering ion shaft{line up the bolt hole with the groove aroundthe shaft),and tightenthe lower bolt. NOTE: . Connectthe steeringshaft and pinion with the steering wheel and steeringrackcentered. j B e s u r et h a t t h e l o w e r s t e e r i n go i n t b o l t i s securelyin the groove in the steeringgearbox prn on. r 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 joint. steering JOINT STEERING
3.
with the two gearbox Installthe mountingbrackets mountingboltson the cushion.
kgl.m,29lbtftl 14.0 NOTE:The arrowon the bracket pointtowardthe front. JOINT STEERING LOWER BOLT 22 N.m 12.2kgt m, 16 lbf.ftl
(cont'd)
17-13
Gearbox Steering
'1. Centerthe cable reel by first rotating it clockwise until it stops,Then rotate it counterclockwise (approximately two turns) until the arrow mark on the steering the label points straight up. Reinstall wheel (seepage 17-35). Installthe steeringioint cover with the clamps and clros. the 9. Reconnect tie-rodendsto the steeringknuckles, then tighten the castlenut ('96 -'97 model)or nut torque,and installnew {'98 model)to the specified cotter Dins. the NOTE:Betoreconnecting tie-rodends,wipe off f a n y g r e a s ec o n t a m i n a t i o n r o m t h e b a l l l o i n t taoeredsectionand threads. CAUTION:Torquethe csstle nut to the lower torque spocification,thn 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
'95 - '97 model:
PINS COTTER Replace. bend On reassembly, the cotterPlnas shown. 38 model:
!=-
,10- 48 N'm (ir.o- 4.8 kgt m. 29 - 35 rbl.ftl
NUT 4,1N.m (4.5 kgf'm, 33 lbf.frl
9)' pipeA or TWC(seesection Install exhaust the the shift linkage(seesection13 or section 1 1 . Connect 14). the 12. Install front wheels. performthe followingchecks' After installation, . . Adjustthe front toe (seesection18). Checkthe steeringwheel spokeangle'Adjust by it turningthe right and lefttie-rods, necessary'
NOTE:Turn the right and lefttie-rodsequally'
1 7 -1 4
ComponentLocations
lndex
Power Steering: NOTE: . lf an intactairbagassemblyhas been removedfrom a scrapped vehicleor has beenfound detective dsmagedduror 24). ing transit,storageor service, shouldbe deployed(seesection it wheel. a Betoreremovingthe gearbox, removethe driver'sairbagassembly and steering . After installing gearbox, checkthe wheelalignmentand adjustif necessary. the precautions, in and procedures the SRS SRScomponents are locatedin this area.Reviewthe SRScomponentlocations, or section(24)beforeperformingrepairs service.
WHEEL STEERING page Removal/lnstallation, 17-35 page Disassembly/Reassembly, 17 36 AIRBAGASSEMBLY DRIVER'S 24 see Removal/lnstallation, section
STEERING GEARBOX page17 33 Rack GuideAdjustment, page17-47 Removal, page17-49 Disassembly, page17-55 Reassembly, page17'65 Installation, VALVEBODYUNIT page17 52 Overhaul,
COLUMN page Removal/lnstallation, 17-37 page17-38 Inspection, CABLE REEL 24 Removal/lnstallation, section see IGNITION SWITCH 23 Seesection
POWER STEERING PUMP page17'32 PumpBeltInspection, page17-32 PumpBeltAdiustment, page17 34 PumpPressure Check, page Bemoval/lnstallation, 17-40 page Disassembly/Reassembly, 17 41
END BALLJOINT TIE.ROD page17-68 BallJointBootReplacement,
17-15
SystemDescription
FluidFlow Diagram
is The fluid pressure propower steering, to connected the steeringgearbox. The systemis a compactrotary-valve,type by is pump which is driven by the enginecrankpulley.The amountof fluid and pressure regulated vane-type vided by a to from the pump is delivered the valvebody unit aroundthe the flow controlvalvebuilt into the pump.The fluid pressure pressure the and changes direcgearbox. The valveinsidethe valvebody unit controlsthe hydraulic pinjonof the steering from the power Fluid returning power cylinder, is generated. where rackthrust tion of the flow. The fluid then flows to the to wherethe fluid is "filtered"and supplied the pump again' flows backto the reservoir, cylinder
RESERVOIB
VALVEBODYUNIT SUB.VALVE
VALVE FLOWCONTROL
GEANBOX STEERING
CYLINDER POWER
17-16
SteeringPump
Construction
reliefvalve)and is drivenby a POLY-V-belt The pump is a vane-type incorporating flow controlvalve(with an integrated a for operations every rotafrom the crank pulley,The pump features10 vanes.Eachvane performstwo intake/discharge pulsebecomes fluid pressure extremely smallduringdischarge. tion of the rotor.This meansthat the hydraulic
VALVE FLOWCONTROL
ROTOR
VANE
CAM RING
Operation
is pulley rotatesthe rotor through the drive shaft.As the rotor rotates, the hydraulicpressure appliedto The belt,driven of the vanechamberof the rotor and the vaneswill rotatewhile beingpushedonto the innercircumference the cam ring. The inner circumference the cam ring has an extendedportionwith respectto the centerof the shaft,so the vanes of the internalvolume of the As move downwardin the axialdirectionas the rotor rotates. a resultof this roller movement. n a v a n ec h a m b ew i l l c h a n g er,e s u l t i n ig f l u i di n t a k e n dd i s c h a r g e . r
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 of the innercircumference the c a mr i n g .
The volumeof the vanecham so ber increases that fluid is sucked in.
f T h e s u c k e d - i n l ui d m o v e s pon. towardthe dascharge
As the vanes return to the o t h e i ro r i g i n ap o s i t i o n n t h e l 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 f t h e f l u i d i s d i s c h a r g e dr o m port. the discharge
(cont'd)
17-17
SystemDescription
SteeringPump(cont'dl
The flow control valve and sub-valvein the pump performs the following stepsO through @ to control the flow of fluid, that is to increasethe dischargevolume when enginespeed is low. and to decrease when the it , 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 t h r u s t o f t h e e w 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 e i t h t h e changein the discharge volume.
FLOWCURVE
L
l"
I
t r r
-..}
PUMPR.P.M.
When the engine starts,fluid discharged from the port stans to flow through oil passage discharge A, the fixed orificeand the variableorificeto the steering gearbox,When the engine speed is extremely low, the return port is closed by the flow control valve. Fluid pressure discharged from the dischargeport is appliedto the top of the sub-valve, and the fluid pressure that passed throughoil passage is applied A to the bottom of the sub-valve. When this happens, the pressuredifferencebetweenthe ends of oil passage A, which is causedby the resistance passage oil A when the fluid flows throughthe passage,s i appliedto the sub-valve. However, pressure the differenceapplied 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 e o w n , i s t o o s m a l l t o d overcome springforce,and the variable the orificeis fully openwhen the enginespeedis e)dremely low, Because fluid volume flowing throughthe fixed the oriticeand variableorificeincreases, pressure a difference is createdbetweenthe ends of these orifices, and it increases proportionto the engine in speed.As the lluid pressure that passedthe fixed orificeand variableorificeis directedto the bottom of the flow control valve, a pressuredifferenceis createdbetweenthe top and bottom of the valve, 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 discharged from the dischargeport returnsto the pump suction port, keepingthe dischargevolume conslanl, In this condition, the sub-valve does not move, and the variableorificestaysfully open.
To STEERING GEARBOx
SUB-VALVE
=K.Aq
Bottom //l'.zRx
o'.io"l^LKq;OY 11\t/./
FLOWCONTROL VALVE To STEERING GEARBOX
SUB-VALVE
ORIFICE
1 ) l
vr-
VALVE FLOWCONTROL
17 -1 8
To STEERING GEARBOX
A The fluid volumethat flows thoroughoil passage appliedto the sub-valve difference and the pressure i i n c r e a s e 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 the spring force,and sub-valvelowers overcoming the it startsto closethe variableorificeto regulate the volume,Whenthis happens, fluid voldischarge as ume flowing to the steeringgearboxdecreases At the engine speed increases. the same time. the to flow controlvalvecontinues controlthe fluid volume to the returnDort.
+/A<Y?il
\ \
/z/ffi\\
o',-lorlo[5o zit)Y -et27
VALVE FLOWCONTROL
To STEERING GEARBOX
SUB.VALVE further,the pressure @ As the enginespeedincreases furtheras well. increases difference the sub-valve at then closesthe variableorificecomThe sub-valve p l e t e l y ,r e g u l a t i n g h e d i s c h a r g e o l u m e f u r t h e r . v t . W h e n t h i s h a p p e n st 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 a and maintained t a given leveluntilthe engine the high speed range.The flow conspeedreaches trol valve functions continuesto control the fluid volumeto the returnDort.
TI-p..\ LTJ6("4")il o"'ro"iio't?2ia)f

11"QJtYl
/X
VALVE FLOWCONTROL
PressureRelief
s P r e s s u r e t t h e d i s c h a r g e i d e o f t h e f i x e d o r i f i c ei s a directedto the bottom of the flow control valve.When builds up, the reliefvalve in the flow conthe pressure at the trol valveopensto release pressure 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 discharge pressure (relief pressure)from exceedingthe given level by controlling the volume of the fluid to the pump returnpon.
VALVE FLOWCONTBOL DAMPINGORIFICE (Decreases excessive vibration in the valve.l RELIEF VALVE (Openl
17-19
SystemDescription
SteeringGearbox
fluid with the pinionlo controlthe steering The rackand-pinion type steeringgearboxhas a valve body unit incorporated pump is regulated a rotaryvalve in the valve body unit and is sentthroughthe cylin pressure. by fluid from the Steering pressure applied. fluid in the other side of the power cylinis The steering where hydraulic der line to the power cylinder, der returnsthroughthe cylinderline and valvebody unit to the reservoir.
VALVEBODYUNIT LINE CYLINDER To RESERVOIR + From PUMP ri
CYLINDER POWER
Valve Body Unit

The fluid pressure. Insidethe valve body unit is the valve.which is coaxialwith the pinionshaft,and controlsthe steering pump, the returnline to the reservoir, and the two cylinderlines with the fluid line from the valve housingis connected to with the input shatt connected the pinion power cylinder. The pinion shaft is double- structured from the respective gear,both of which are interconnected the torsionbar. wlth this allowsthe pinion shaft to rotatetogetherwith the The pin insertedin the valveand the pinion shaft grooveengage; the input sh8ftand the directionbetween in the valve.Because this construction, difference anglein the circumferential of maximumtorsion However. to valvebecomeslargeraccording the torsionalstrengthof the pinionor steeringresistance. to section hold the torsionbar splinesof the shaftsat the pin engagement is regulated the engaged by betlveen shafts the within the setvalue. fluid is not pressurtype systemto functionas an ordinaryrack-and-pinion steeringif the steering This allowsthe steering izedbecause a faulty pump. of
VALVE Diflerencein angle between the input shaft and pinion shaft
PINION SHAFT
l -la
INPUTSHAFT B INPUTSHAFT
17-20
Pressure Control
Low assistat higherspeeds: or is When steeringresistance low, such as when driving at high speeds, when driving straightahead,the input shaft is N4ost the feed pressure of so nearor in the neutralposition, there is littleor no flow to any of the power cylinderorifices. pressure in both sidesof the power cylinstaysthe same Because this,the of to from the pump is bypassed the reservoir. in der, resulting low or no assist.
VALVE From PUMP RETURN PASSAGE lTo RESERVOIR)
VALVEBODY UNIT A.A SECTION . A J
POWER CYLINDER GEAREOX
High assistat lower speeds: When steering resistanceis high, such as when driving at low speeds,or when turning the wheel with the vehicle on in stopped, the difference anglecreatedbetweenthe input shaft and the valve opensthe fluid passage one side, and in increases the side of the power The fluid pressure closesthe fluid passage the other side. at each pair of orifices, on pressure pusheson the rackpiston,allowingthe steering wheelto This increased cylinderfed by the largerfluid passage. fluid to opensallowingthe steering the returnpassage be turnedwith light effort.On the otherside of the powercylinder, change in size, The fluid passages the power cylinderautomatically to returnthrough the input shaft to the reservoir. In becomelargerand power assistincreases increases. other words. the passages increasing the steeringresistance as (for example, parkingor making low speedturns),and the paswhen when the steeringeffort would normallybe high, when the steeringeffort would normallybe low, (for example,when sagesbecomesmallerand power assistdecreases or drivingat high speeds straightahead).
FLUIDPASSAGE TO POWEB CYLINDER From PUMP
---------\\ r
- /
A-A SECTION
(High lluid pressurl
17-21
Troubleshooting
Troubleshooting General
Check followingbeforeyou begin: the . Hasthe suspension beenmodifiedin a way that would affectsteering? . Are tire sizes, varietyand air pressure tire correct? . ls the steering wheel originalequipmentorequivalent? . ls the powersteeringpump belt properlyadjusted? . ls steering fluid reservoirfilled properlevel? to . ls the engineidle speedcorrectand steady?
HardSteering(Check powerassist, page'17-30. the see lflhe forceis over 29 N 13.0 kgf,6.6lbf),Precede with this troubleshooting.)
Checkthe pump fluid pressure (seepage17-34). Measuresteadystate fluid pres sure while idling with the both valves fully open. It shouldbe 1,500 (15kgvcm,, kPa 213psi)or below.
Abnormal Iluid pressure {fluidpressure is too high)
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 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 delormation.
N o r m a l l i n e n dh o s e a
Normal Faulty valvebody 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). M e a s u r ep u mp r e l i e f p r e s s u r e while idling with the pressure control valveIully closed. It should be 6,400 7,400kPa165 psi) 75 kgflcm',920- 1,070
Reliefpres-
Checkthe tlow control valve (seepage 17-42). . Check the valvefor smooth movementin the housing. ' Check reliefvalvefor leaks. the
Normalreliefpressure
Abnormal
Go to page17 23
Faultypump assembly
Faultyflow control valve (Replace pump as an the assembly)
1 7- 2 2
lo Checkthe lorce required turn the wheol(seepage17-30). the Startthe engineand measure 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). wheelfully to the Turn the steering right and left while idling wirh the pressurecontrol valvg Iully open, and measurethefruid pressure. -7,400 kPa(65lr shouldbe 6,400 psi). 75 kgflcm,,920- 1,070 Abnormal -
Check rack guide adjustmgnt (see page 17'33).
Adjustment OK
Faulty valvebody unit
gearbox Faulty
Check gearbox. the Removethe gearbox and measurethe piniontorque. Thetorqueshouldbe; * 0.7- 1.2N.m (7 - 12 kgf'cm, 6 10 lbl.in) with the steering rack in th6 straight drivingposition. 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.
Checkthe parts othor than the gearbox-relatedparts lor Drooerrotation. part(s) . lmproper column-relatsd rotation ofthe steedng . Faulty joint steering . Faulty rackend ie-rodend ballioints . Interference the steeringsystem in
Abnormal
Adjust the rack guide (see Page t 1 7 - 3 3 )a n d r e c h o c k h e p i n i o n , torque.
Normal -
rackguide lmproperly adiusted
Abnormal
Faultygearbox
(cont'd)
17 -23
Troubleshooting
GeneralTroubleshooting (cont'd)
Assist (excossively light steering)at highspeed. Checkthe rack guide for proper (seepage17-33). adiustment lf the problem is not correctedby adjustingthe rack guide, adjust the lront whel alignment (see soction18).
Shockor vibration when wheelis turnedto full lock.
Checkthe rack guide tor proper (seepage17-33). adjustment
Adjustthe rackguide. guideis adiusted properly. Rack lf the problom is not correctedby adiusting the rack guide,replace the gearbox.
Checkthe belt tor slippageand adjust as necessary(see page 17-321.
Steering wheelwill 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 soctionl8).
W h e e l a l ; g n m e n ti s a b n o r m a l , adjust as needed.
Wheelalignment normal. is R e m o v et h e g e a r b o xf r o m t h e frame and measurehe pinion t torqueon the gearbox.
' 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 ) r o below with the steeringrack in the straightaheaddrivingposition. . 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 measurements are out of s p e c i f i c a t i o n s ,d j u s t t h e r a c k a gurde.
f''
17-24
lf the problemis not corrected by adjlsting the rackguide,replace the gearbox.
I
or Uneven roughsteering, Mjust the rackguide(seepage17-33).
lf the problom is not coftected bY the rackguide,roplace adjusting the gearbox.
the Adiustthe belttension.Replace (see belt,if necessary page17-321.
ldle speed low or erratic.
lfthe enginestallswhen the wheel is turnd while car is stoppodor moving at low speed,adjustthe idle speed(seeseclion11).
or Air in resgrvoir, checkpowor fluid level. steering
Checkpower stoeringfluid level.lf low, chock the level is excessively tor leaks in the system.Add fluid level. to the spcified
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 inlt hose,and the P/S pump housing mating surfaces and the pump shaft oil seal for suction leaks. Replaceparts as
wheelkicksback Stoering duringwid turns.
P!mp belt slippingon pulley {pumpstopsmomentarily).
Adlustthe belt tension{seePage 17-32)orreplace beh.
Installthe power steeringpressure gauge.Closethe pressurocontrol the valvelully and measure pump (seepage 17-34). pressure
Checkit pump prssureis normal and the gaugeneedletravel is 500 7 k P a( 5 k g f l c m ' , 1 p s i ) o r l e s s . Checkthe flow controlvalve if the needle travel exceeds500 kPa 15 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.
j H u m mn g
Humming due to pulsationof fluid is normal, particularlywhen the wheel is turnedwith the vehicle stoooed.
lf equipped with automatic transr n i s s i o nt,h e h ! m c o u l d b e t h e torqueconverter pump noise. or
Confirm by temporarily removing the pump belt.
High-pressure line touching the frame.
Repositjon line. the
Rattle chattering or
Loosesteeringshaft connector, tie-rod, ballioint. or
C h e c ka n d t i g h t e n , o r r e p l a c e parts as necessary.
Columnshaftwobbling.
Replace columnassembly. the
Checkthe rack guide lor proper (seepage17-33). adjustment
Adjust,if necessary.
Rattling soundand feelingwhen turningthe steering wheelright and leftwith the engineOFFis a soundwhen the valvebody unit contacts stoo.This is normal. the
Pump noise,though not loud,from the valve body unit can be heardwhen turning the steering wheelright 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
Pumpnoise
noise Grating from pump
causedby air bubbles Cavitation in the fluid.
Checkthe fluid lev1. t lf low, fill the reservoiro the propor level,and chockfor leaks. Tighten or rplaceas necessary.
suctionhose for Check a crushed or a loose hose clamp allowing air inlo the suction side ol tho system. Tightgn or replace8s necessary.
Pumpgearnoise
NOTE: Pump noise uP to 2 - 3 m i n u t e sa f t e r s t a r t i n gi n c o l d weatheris normal. Comparepump noiso at operating vehicle. temperature simular to
loud, ll pump noiseis abnormally the removeand inspect pump tor wear and damage(see page 1741t.
,Ou"u,,nn
Rattle chattering or
Tighten or roplacethe pully. 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
. Oil Checkthe gearboxassemblyfor oil leakscarefully. can leak out of various points,dependingon locationof the from the frame. faultyoil seals/seal rings.Check followingbeforeremovinglhe gearbox the
Gearbox Steering
Leaking from the oil seal on the top of the valvehousing.
Replace the valve oil seal from the valvehousing.
Leakinglrom cylinder end into left tie rod boot.
Replaco the valve oil seal from the pinionshaft.
Replace cylinderend sealon the the garhousing side.
Leakingfrom cylinder end into right tie-rod boot.
Replace cylinderend sealon the the cylinderend side.
Leaking from the shaftupperend sectionor pin engagemenlsection of the pinionshaft.
Replace valve body unit. the
Leaking lrom cylinderline A or B (at connections flarenut).
Tighton th6 connector. lI it's still leaking, replace lino,cylinder th or valvehousing unit.
L e a k i n g a u s e db y a d a m a g e d c cylinder lineA or L
Replace cylinder lineA or B.
from feed line and return Leaking linejoint fittingon the valvebody unit (atflare nut).
Tightenthe connector. it's still lf leaking, replace the line,joint fitting or valvehousing.
17 -28
Replace housing the O-rings. lf the housingstill leaks,replace the pump.
Reservoiris ov6rfilled. Pull off the hose and drain the reservoirto the proper lev1.
Air leak in suctionside ot the sysinlet hose,{ront lem {resrvoir, pump seal).
Pumpoutletline (high-pressure)
Leakingat the lhreadedlitting.
Tighten the fining. It it's still leakin9, replaco O-ringor feed line. the
joint. Leaking the swsgged at
af
Pumpinletline (low-pressure) Leakingbecauseof damage.deterioration,or improperassombly. Replace ropairas necessary. or

Steering Operation
Placethe front wheels in the straight ahead position, w and measure he distancehe steering heelcan be t t turnedwithout movingthe front wheels. ROTATIONAL PLAY:0 - 10 mm l0 - 0.39 inl lf the play exceeds the servicelimit, perform rackguide (seepage 17-33). adjustment lf the play is still excessive after rack guide adjustment, inspectthe steering linkageand gearboxas described on the next page.
PowerAssistCheckwith Vehicle Parked

1. Checkthe power steeringfluid level (see page l733) and pump belttension(seepage 17-32). Startthe engine,allow it to idle, and turn the steering wheel from lock-to-lock severaltimes to warm up the fluid. Attacha springscaleto the steering wheel.With the engine idling and the vehicleon a clean,dry floor, Dull the scaleas shown and read it as soon as the tires beginto turn.
2.
3.
ROTATIONAL PLAY
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.ROD END BALLJOINT Insoect faultvmovement for and damage. BOOT Inspect
damage and deterioration.
JOINTS for Check loosejoint bolts. SHAFTGROMMET and deterioration. Inspect damage for TIE.ROD LOCKNUT for looselocknut.
STEERING GEARBOX for Inspect loosemountingbolts. MOUNTINGCUSHIONS GEABBOX tor lnsoect deterioration.
3ALL JOINT BOOT for Inspect damageand deterioration. See p49e 17-68for replacement.
17-31

PumpBelt
NOTE:When usinga new belt,first adjustthe deflection or tensionto the valuesfor the new belt, then readjust the deflection tensionto the valuesfor the used belt or a f t e rr u n n i n g n g i n e o r l i v em i n u t e s . e f
Adiustment
1. Loosen power steeringpump mountingbolts. the
PUMPMOUNTING BOLT 24 N m 12.4 m, 17 lbffrl kgt
Inspection
Attachthe specialtool to the belt and measure the 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 cracks any damageevidenton the belt, or replace with a new one. it . Followthe manufacturer's instructions the tension for g au g e . BELT TENSION GAUGE _ 07JGG 001010A
POWER PUMP
PUMPMOUNTINGBOLT 24 N.m {2.4kgf.m, 17 lbr.ft)
2. Adjust the belt tensionby moving the power steering pump with a 1/2" drivebreaker to obtainthe bar 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 n h e m o u n t i n g t bolts. 3. Inspect pump beltfor cracks any damage. the or Replace beltwith a new one if necessary. the Measurement without 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 n e t w e e n h e p o w e r s t e e r i n gp u m p a n d t h e b t c r a n k s h aptu l l e y s . f Detlection: UsedBelt: 10.5- 14.0mm (0.41 0.55in) New Belt: 7.5- 10.0mm (0.30 0.39inl Start the engine and turn the steeringwheel from lock-to-lock several times,then stop the engineand recheck deflection the belt. the of
17-32
RackGuideAdjustment
with the wheels NOTE:Performrack guide adjustment in the straightaheadposition. 1. '96 - 97 model: Loosenthe rack guide screw locknutwith the specialtool, then loosenthe rackguidascrew.
FluidReplacement
and add fluid as at Check the reservoir regularintervals, necessary. CAUTION: Always use Gonuin Honda Powsr Steering Fluid-V or S. Using any oth.r type ot pow 3toering fluid or sutomatic lrsnsmis3ion fluid can cause increasedwear and poor steoring in cold woather. SYSTEMCAPACITY: US. qt, 0.75 lmp.qtl 0.85 litor 10.90 at dkassembly RESERVOIR CAPACITY: 0.4 liter {0.42US. qt, 0.35 lmp.qt)
UPPER LEVELLINE
LOWERLEVELLINE
tl
'98 modol: Removethe old sealantoff of the threadedsection, then apply new sealantto the first three threads. installtherackguidescrew. Loosely Tightenthe rack guide screwto 25 N'm (2.5 kgf m, 18 lbf.ft), then loosenit. Retighten rackguidescrewto 3.9 N.m (0.4kgf'm, the 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 completeturningtravel. followinginspections: Perform . . (seepage17-30). operation Steering with vehicleparked. Powerassist
the then disconnect returnhose the 1 . Raise reservoir, Connecta hose of suitablediameterto the disconnectedreturn hose,and put the hose end in a suitablecontainer. CAUTION:Taks car. not to spill tho lluid on tho body and parts. Wipe off any spilled fluid at once.
HOSE
4.
7.
Startthe engine,let it run at idle,and turn the steerk i n g w h e e l f r o m l o c k - t o - l o cs e 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 the engine.Discard fluid. the Reinstall returnhoseon the reservoir. to Fillthe reservoir the uoDerlevelline. Startthe engineand run it at fast idle,then turn the times to bleed air several steeringfrom lock-to-lock from the system. Recheck fluid leveland add some if necessary. the CAUTION: Do not fill the reservoir beYond the upper lovel line.
17-33
and Adiustment Inspection

Check PumpPressure
a C h e c kt h e f l u i d p r e s s u r e s f o l l o w s t o d e t e r m i n e whetherthe troubleis in the pump or gearbox. NOTE: First check the power steering fluid level and pump belttension. CAUTION: Disconnectthe high pressurehose with care so as not to spill the power steering fluid on the ftame and other parts. Disconnect outlet line from the pump outlet fitthe ting, then jnstallthe P/Sjoint adaptor{pump)on the pump outlet. 2. Connectthe P/S joint adaptor(hose)to the power steering pressuregauge, then connectthe outlet hoseto the adaptor. gaugeto the P/S the power steeringpressure 3. Install joint adaptor{pump)as shown. 1.
6 x 1.0mm BOLT OUTLETHOSEFTTNNG P/S JOINTADAPTOR IHOSE) 07MK - 5040121
6. Startthe engineand let it idle. several 7. Turn the steeringwheel from lock-to-lock temperature. timesto warm the fluid to operating fluid pressure while idling. lf 8. Measuresteady-state 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 readlessthan 1500kPa(15 kgflcm' ,213psi). lf it readshigh, checkthe outlet line or valve body 17-22). Troubleshooting unit (seeGeneral c 9 . C l o s et h e p r e s s u r e o n t r o l v a l v e ,t h e n c l o s et h e shut-off valve gradually until the pressuregauge needleis stable.Readthe pressure. controlvalvefully. 10. lmmediately openthe pressure CAUTION: Do not kp the pressure conlrol valve closed more then 5 seconds or the pump could be damaged by over-heating. the gaugeshould lf the pump is in good condition, read at least 6.400- 7,400kPa(65 - 75 kgflcn',920 psi).A low readingmeanspump outputis too 1.070 or the Repair replace pump. low for full assist.
GAUGE P/S PRESSURE 07{06 - 00'llD0A
ot
07RAK S040r20 GAUGE P/SPRESSURE 07405 001 000A

ol 07,106- q)l0001
oa
lPart of tooll 1 1N . m (1.1 ksf.m, I lbt'ft) PRESSURE CONTROL VALVE

.OFF
VALVE PUMPOUTLET FITTING
6 x 1.0mm BOLT (Partot tooll 1 1N m (1.1ksf.m,8lbtft)
VALVE SHUT.OFF
5.
valvefully. Openthe shut-off controlvalvefully. Openthe pressure
17-34
SteeringWheel
Removal
a S R Sc o m p o n e n t s 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 precautions, and procedures SRScomponentlocations, in the SRSsection(24)beforeperformingrepairsor service. w 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 g h e e l ,a l i g n t h e front wheelsstraightahead. ' 1 . R e m o v e h e d r i v e r ' sa i r b a ga s s e m b l y r o m t h e f t wheel(seesection24). steering 2. th r D i s c o n n e c t e h o r n c o n n e c t o a n d c r u i s ec o n t r o l switches connector.
lnstallation
CAUTION: Do not tap on the steering wheel or steering the steeringwheel. columnshaft when installing w t N O T E :B e f o r ei n s t a l l i n gh e s t e e r i n g 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 until it stops.Then rotateit counterclockclockwise two turns. The arrow mark on wise approximately the cablereellabelshouldpointsstraightup.
CABLEREEL
I
Remove the steering wheel nut.
2.
lnstall the steeringwheel with the steeringwheel nut. w N O T E :B e s u r e t h e s t e e r i n g h e e l s h a f t e n g a g e s sleeve. the cablereel and canceling
3.
NUT WHEEL STEERING Replace.
3.
to Attachthe cruisecontrol switchesconnector the s t e e r i n w h e e lc l i P . g the Connect horn connector. , 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 24). propersystemoperation lsee section 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.
4. 5.
4. Remove the steering wheel by rocking it slightly from side to side as you pull steadilywith both hands.
6.
17-35
SteeringWheel
\
*@*&*W
-:<z<z %
17-36
Steering Column
a S R Sc o m p o n e n t s 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 precautions, and procedures SRScomponentlocations, in the SRSsection(24)beforeperformingrepairsor service. NOTE: Before removing the steeringcolumn for SRS, and cablereel (see removethe driver'sairbagassembly 24). section wheel (seepage17-35). 1. Remove steering the l 2 . R e m o v et h e d r i v e r ' sd a s h b o a r d o w e r c o v e r a n d driver'skneebolster(seesection20). from the switchassemblv the combination 3. Remove the steeringcolumn shaft by disconnecting connecrors. 4. Disconnect ignitionswitchconnectors. the joint cover 5. Remove steering the joint bolts. the 6. Remove steering 7 . D i s c o n n e ct th e s t e e r i n g o i n t b y m o v i n gt h e j o i n t i toward the column,and removeit from the column shaft. 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 nuts and bolt. attaching
UPPER
is of 9. Installation the reverse the removalprocedure. NOTE: joint is connected follows: . Makesurethe steering as a. Insertthe upper end of the steeringjoint onto the steering shaft (lineup the bolt holewith the flat on the shaft),and looselyinstallthe upperjoint bolt. b. Slip the lower end of the steeringjoint onto the pinion shaft (line up the bolt hole with the groove 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 joint bolt. Be sure that the lower joint bolt is securelyin the groovein the pinionshaft. j c . P u l l o n t h e s t e e r i n g o i n t t o m a k es u r e t h a t t h e joint is fully seated. Thentightenthe joint steering bolts. . Be sure the wires are not caught or pinchedby any partswhen installing column. the . Make sure the wire harnessis routed and fastened properly, . Makesurethe connectors properlyconnected. are
COLUMN STEERING SWITCH COMBINATION ASSEMBLY
COLLAR RETAINING NOTE:Takecarenot to letthe retaining collarfall out of position duringinstallation. JOINT BOLTS STEERING 22 N.m {2.2 kgt m, 16 lbl.ftl
BOLTS FLANGE kgl'rn, 22 N.m 12.2
15lbl tr)
JOINT BOLT UPPER Bolt must line up on shaft. COLUMNCOVER
Groove.
JOINTCOVER CLIP JOINT BOLT

Bolt must line up with g.oove around on shaft.
17-37
Column Steering
Inspection
NOTE:The tilt steeringcolumn type is shown; the conv e n t i o n as t e e r i n g 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 l c mechanism. Check the steering column ball bearingand the steering joint bearingsfor play and proper movement.lf play,replace there is noiseor if there is excessive the steering columnas an assembly. C h e c kt h e r e t a i n i n g o l l a rf o r d a m a g e . f i t i s d a m c l aged,replace retaining the collar. Checkthe absorbingplates,absorbingplate guides and slidingcapsules distonionor breakage. for Replace the steeringcolumn as an assemblyif they are distorted broken. or
COLUMN BALLBEARING
ABSORBING PLATES PLATEGUIDES ABSORBING

RETAINING COLLAR
BEARINGS
IGNITION 23. Seesection
SLIDING
This part is attached to the column bracket with the plastic injections.
'1. lMovethe tilt lever from the loose positionto lock position to 5 times;then measure he tilt lever t 3 p r e l o a d 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 . 1 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 t o u t o f t h e s p e c i f i c a t i o n , s p u t a d j u s t h e p r e l o a d s i n g h ef o l l o w i n g r o c e d u r e s . the tilt lever,and set the steeringcolumn a. Loosen in the neutralposition. b. Remove 6 mm lock bolt and removethe stop. the c. Adjustthe preloadby turningthe tilt lockbolt left or ngnr. position and d. Pullup the tilt leverto the uppermost a t i n s t a l t h e s t o p .C h e c k h e p r e l o a d g a i n .l f t h e l repeat is measurement still out of specitication, "c" to adiust. "a" the aboveprocedures through
CAUTION: Be calelul not to loosen the tilt level when installing the stop or tightening the 6 mm lock bolt.
TILT LOCKBOLT Tighten lockbolt the the tilt leverraised.
k 9 . 8N . m{ 1 . 0 g l m , 7 l b l f t )
17-38
Lines PowerSteeringHoses,
Inspection Fluid Leakage
HOSES and 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 e r o rwrsI|ng. . Inspect fluid linesfor damage, rustingand leakage. . Inspectfor leaksat hose and line joints and connec trons.
POWER STEERING PRESSURE SWITCH 12 N.m (1.2ksf.m,9 lbthl CYLINDER HOUSING-to-CYLINDER LINES 28 N.m {2.7kg{.m,20 lbf.ft) LINES VALVEBODYUNIT-Io-CYLINoER 12 tbf ft, 1 7N . m1 1 . 7 LINES vALVE BODYUNIT-to-FEED/RETURN Feedline: 14 x 1.5 mm flare nut kgf.m, 27 lbl.ft) 37 N.rn 13.8 Rdurn Line Joint: 16 x 1.5 mm flare nui 28 N.m (2.7kgt m, 20lbf.ftl
BOOT for Check leaks.

GEARBOX and VALVEBODYUNIT Check leaks the matingsurface for at and flare nut conneclions.
OUTLET HOSE 1 1N . m
(1.1kgf.m,8
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.
(Double RingType)
Replacement
NOTE: pipesecurely . Connect eachhoseto the corresponding the clamp until it contacts stop on the line. Install the distance from the or adjustable clamp at the specified hoseend as shown. . Add the power steering levelon fluid to the specified the reservoir and checkfor leaks. ADJUSTABLE HOSECLAMP: . P o s i t i o nt h e a d j u s t a b l e o s e c l a m p s a t t h e p o i n t s h (a) indicated in the drawingabove. . Slidethe hoseoverthe line until it contacts stop. the CAUTION: Check all clamps for deterioration or deformation; leplace with the clamps new ones it necessary.
HOSECLAMP: . P o s i t i o n t h h o s ec l a m p s t t h e p o i n t si n d i c a t e{ b ) i n a d e the drawingabove. . Slidethe hoseoverthe line until it contacts stop. the
tqtT-f*r--!-t__1
_tr
2.5- 5.5mm (0.01 0.22inl
@ - f f_lli
2 . 0 - 4 . 0m m inl 10.08 0.'16 2.5- 5.5mm {0.01 0.22in}
g-
/Z\\\
17-39
PowerSteering Pump
RemovaUlnstallation
NOTE:Beforedisconnecting hosesf.om the pump, the placea suitable container underthe car. 1. Removethe belt by loosening the pump mounting bolts.
11 N.m {1.1kgt.m, PUMPMOUNTINGBOLT 2{ N.m {2.4kgf.m, 17 lbf ft) 7.
Connect the inlet hose and the outlet line. Tighten the pump fittingssecurely. Looselyinstallthe pump in the pump bracketwith mountingbolts. Install the oump belt. CAUTION: . Mako suro that the power 3teering belt is properly 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 11-33t.
PUMP MOUNTING EOLT 1? 2il N.m{2.4kgf.m, lbt.ft)
with several compressor shop towels Coverthe A,/C fluid. to protectit from spilledpower steering Disconnect the 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. Remove the 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 disassembled partswith a solvent,and dry them with compressed Do not dip the rubberparts in a solair. vent. a Always replace O-ringsand rubbersealswith new ones beforeassembly, the . Apply recommended power steering procedures. fluid to the partsindicated the assembly in . Do not allow dust,dirt, or otherforeignmaterials enterthe powe. steering to system. (+) . Replace pump as an assembly the ifthe pans indicated with asterisk are worn or damaged.
FLANGEEOLTS 20 N.m (2.0 kgf.m. 14 tbtft) 4.5mm ROLLEB PUMPCOVER SEAL Replace.
*OUTER PLATE SIDE

PUMPCOVER
5 mm ROLLER
*PUMP FOTOR .SIDE PLATE SNAPRING 13 x 1.9mm O-RING Replace.
3 t
.PUMPHOUSING
,SUB-VALVE
51 x 2.{ mm O-RING Replace. 15.2 2.4mm O-RING x
Beplace.
PUMPSEAL Replace. PUMPSEALSPACER
INLETJOINT BALLBEARING Inspection Replacement, and seepage17-43 a0 mm CIRCLIP *FLOWCONTROL VALVE Insoection Overhaul. and
FLANGE BOLTS 11 N,m {1.1kgf.m, 8 rbf.ft)
seePaselT"
PULLEY
spnrruc/ d
fi
'-tlu"i:3;'n^ô'^''o
FLOWCONTROL VALVECAP 4It N.m {5.0 kgf.m, 36 tbtft)
PULLEY NUT 64N.m{6.5 kgt.m, 47lbt.ft)
(cont'd)
17-41
PowerSteeringPump
(cont'd) Disassembly
1 . Drainthe fluid from the pump.
Inspection
Flow Control Valve: 1. Checkthe flow control valve for wear, burrs, and other damage to the edges of the grooves in the valve.
FLOW CONTROL VALVE
Hold the steering pump in a vise with soft jaws, hold the pulley with the specialtool, and remove the pulleynut and pulley. CAUTION: Be carelul not to damage th6 pump housing with thc iaws ot the viso and extension bar.
UNIVERSAL HOLDER
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
Loosen flow controlvalvecap with a hex wrench the and removeit. Remove O-ring,flow controlvalveand spring. the Remove inletjoint and O-ring. the Remove pump coverand pump coverseal. the
7 . Removethe outer side plate,pump cam ring, pump
rotor,pump vanes,side plateand O-rings, Removethe snap ring, then removethe sub-valve from the pump housing. Removethe circlip, then remove the pump drive shaft by tappingthe shaftend with the plastichammer. 1 0 . Remove the pump sealspacer and pump seal. lf OK, go on step 4; if not, replacethe pump as an assembly,The flow control valve is not available separately. Attacha hoseto the end of the valveas shown. VALVE FLOW CONTFOL HOSE
17 -4 2
5.
Submergethe valve in a containerof power steering tluid or solvent.and blow in the hose.lf air bubb 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 psi),repairit as follows. {1.0kgflcm,,14.2
Ball Bearing: 1. Inspectthe ball bearingby rotatingthe outer race is slowly. lf any play or roughness felt, replacethe ball bearing.
BALLBEARING
<--
POWER STEERING FLUIDor SOLVENT
Hold the bottom end of the valve with a open end wrench.
7.
.{ D
Unscrewthe seat in the top end of the valve, and removeany shims.the reliefcheckball, reliefvalve and reliefvalvespring.
VALVE RELIEF
RELIEFCHECK BALL
2.
Removeand discardthe ball bearingusing a press as snown. Install the new ball bearingusinga pressas shown. Ball Bearing Replacement:
SEAT
9 N.m {0.9kgl.m.6.5lbtft)
C l a m p h i se n d i n t a openeno wtencn.
VALVE FLOWCONTROL
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 , r y t h e m o f f , t h e n d reassemble and retestthe valve.lf the flow control valve tests OK, reinstallit in the pump. lf the flow the pump as an control valve still leaksair, replace assembly.The flow control valve is not available separately. relief pressureis adjusted at NOTE: It necessary, the factory by adding shims under the check ball seat.lf you found shims in your valve,be sure you reinstall manv as vou took out. as
lnstallwith the red shieldedside facing down.
NOTE:Supponthe innerrace with the toolsecurely-
17-43
PowerSteeringPump
Reassembly
1.
Align the pin of the sub-valve with the oil passage in pump housing, and push down the sub-valve. Installthesnap ring properly.
OIL PASSAGE Align the pin of sub valve with the oil passage.
Coat the pump cover seal and the cover bushing with the power steeringfluid, then installthe pump coversealinto the groovein the pump cover. Install the outer side olateoverthe two rollers.
ROLLER SET HOLES
OUTER SIDEPLATE
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 f a c i n gi n . Position the pump drive shaft in the pump housing, then drive it in usinga special tool as shown. Installthe 40 mm circlipwith its radiusedside facIng out. 40mm CtRCLtp ATTACHMENT,30mm
PUMPCOVER
,rr","oE \
7 . Setthe pump cam ring over the two rollerswith the " " " mark on the cam ring upward.
PUMPCAM RING
ozzlsoososob
q:D
PUMPDRIVESHAFT ROLI.IR SET HO|'.CS
BALLEEARING
PUMPSEALSPACER
ROLIIRS
17-44
Assemblepump rotor to the pump cover with the " o " markson the rotorfacingdown. 9 . Setthe 10 vanesin the groovesin the rotor. NOTE:Be surethat the round ends of the vanesare in contactwith the slidingsurface the cam ring. of
PUi'P VANES (10 plrt .)
fluid, and posiCoatthe O-ringwith power steering tion it into the pump housing.
1 3 . Installthe pump cover assemblyin the pump housIng.

FLANGEBOLTS 20 N.m {2.0 kgl.m, r4 tbf.ftl
PUMP ROTOR
aE
nn
't4. Coat the flow control valve with power steering
D
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 installit into the groovesin the side plate. 1 l . Install the side plateon the cam ring by aligningthe rollerset holesin the side platewith the rollers.
I
fluid. 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 p u m ph o u s i n g . 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 installit on the flow controlvalvecap.
't] . Installthe flow cont.olvalvecap on the pump housing, and tighten it. r
SPRING
SIDE PLATE
15-2 | 2.1 mm O-RING Replace. ROU.R SET HOll SET HOIf
Mv (64
\tbry
\
15.2x 2.4rnm O-RING Replace.
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 installit into the groovesin the inletjoint
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
tool, and tightenthe 21. Holdthe pulleywith the special pulley ut. n
HOLDER UNIVERSAL NUT PULLEY 64 N.m {6.5 kgtm,
15.2x 2.4 Beplace. 11 N.m (1.1kgl.m, 8 tbtfr)
Checkthat the pump turns smoothlyby turnrngrne pulley y hand. b
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 p I n s t a l t h e p u l l e yn u t . H o l d t h e s t e e r i n g u m p i n a l visewith softjaws. CAUTION:Be carelul not to damagethe pump housing with the iaws of the vise.
17-46
SteeringGearbox
Removal
NOTE:Usingsolventand a brush,wash any oil and dirt off the valve body unit its lines,and the end if the gearair. box. Blow dry with compressed 1, fluid as described page on Drainthe power steering 17 33. Raisethe front of vehicle,and support it on satety (seesectionl). standsin the properlocations Remove front wheels. the and steering Removethe driver'sairbagassembly, wheel(seepage17-35). joint cover. Bemove steering the 7. Remove the cotterpin from the castlenut ('96-'97 model)or nut ('98 model)and removethe nut.
END TIE.ROD
Install the 10 mm hex nut on the balljoint. 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 special tool. NOTE:Remove the ball joint usingthe special tool. 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. the Separate tie-rodball joint and knuckleusingthe special tool. CAUTION: Avoid damaging tho ball ioint boot.
6.
Removethe steeringjoint lower bolt, and disconnect the steeringjoint by moving the joint toward t h ec o l u m n .
1 0 . Remove lefttie-rodend,then slidethe rackall the the

way to the right. 9). 1 1 . Separate exhaustpipeA or TWC (seesection the (seesection13or section Disconnectthe shiftlinkage 141.
(cont'd)
17-47
,l
SteeringGearbox
Removal(cont'dl
the Loosen the 14 mm flare nut and disconnect feed 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 between valvebody unit and cylinder. the
HOSE ADJUSTABI.E CLAMP
17. Remove the mountingbrackets.
1 8 . Pull the steeringgearboxall the way down to clear then removethe the pinion shaftfrom the bulkhead, 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 FLARE NUT
Remove stiffenerplate. the NOTE:Some stiffenerplateattaching bolts are also used as gearboxmounting bolts.The gearboxwill tilt to sidewhen theseboltsare removed.
CAUTION:Be careful not to bend or damage the leed line and cylinder linss whn rmoving th6 gearbox.
PLATE STIFFENER ATIACHING BOLTS
STEERING GEARBOX
17 -48
Disassembly
Steoring Rack Disassombly NOTE: . Beforedisassemble gearbox, wash it off with solthe vent and a brush. . Do not dip sealsand O-ringsin solvent. 1. 2. 3. gearbox(seepage l7-47). the Remove stering Remove tie-rodend and locknut. the Remove airtube and clips. 5. Holdthe steeringrackwith a wrench{'98 model:left end onlv), and unscrewthe rack end with another wrench. CAUTION: Bo caroful not to damage tho rack surfac with tho wrench. NOTE:'96 -'97 model is shown.
RACKEND STEERING
RACK STEERING
.l
Removethe boot bands and tie-rod clips, Pull bootsawayfrom the endsof the gearbox. 7. Loosen the locknut, then remove the rack guide screw('98 model)and O-ring{'96-'97 model only). Remove springand the rackguidefrom the gear the housrng.
RACKGUIDE
scREws
BOOT CLIP TIE-ROO
(cont'd)
17-49
Gearbox Steering
Disassembly(cont'dl
8. Remove cylinder lines A and B from the gearbox
h i 1 1 . D r i l la 3 m m { 0 . 1 2 n ) d i a m e t e r 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.
2.5 Deprhr - 3.0mm {0.10 0.12in)
LINEB CYLINDER
CYLINDERLINE A CYLINDER
9. Drain the fluid from the cylinder fittings by slowly 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.)
VALVE BODYUNIT
FLANGE BOLT
a 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 p s shown.
, I
'96 - '97 model: 32 mm SHIMS '98 modol: WAVE WASHER
and removethe cylinderend. 13. Loosen
17-50
14. Assemble '12 1.25mm flangenut onto a 12 x 175 a x mm grade 10flangebolt as shown. 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 the cylinder. vinyl tapeto protect
'18. Removethe l2 mm bolt and nut from the steering 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 rack. HOUSING CYLINDER
END CYLINDER SEAL Repiace,
l " \s-,' r
tP/N 90177- SLo- 0001
| t
I n s t a l t 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 l 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 / 4t u r n . H o l d t h e f l a n g eb o l t , a n d the rackby hand. tightenthe flangenut against on bearing separator the gearboxhousing Install the as shown.
'12x 1t5 mm BOLT FLANGE Press
I t
" . . ^
r-,,'
SEPARATOR BEARING o- 4112"I (commerciallvavailablel
and the spelong, 20. Inserta 24" lol 3/8" drive extension from the gearboxs r d e . the cialtool into th cylinder N O T E :M a k ) s e sure that the specialtool is securely positioned n t backupring edges. on the CAUTION: Be careful not damage to inner surtace of the cylinderhousingwith the specialtool. then pressout the cylin21. Set the gearboxin a press, der end sealand backupring from the gearbox. CAUTION: . Keepthe tool straightto avoid damagingthe cylin' der wall. Checkthe tool angle,and correctit if necwhen removingthe cylinderend seal. essary, . 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
Q)*
I o-tfl
RACK STEERING CYLINOER END SEAL
24 "LONG 3/8" DRIVEEXTENSIONI available) {Commercially
17. Setthe gearboxin a pressso the gear housingpoint upward, then pressthe cylinderend seal and steering rackout of the gearbox. NOTE:Holdthe steeringrackto keepit from falling when pressed clear. CAUTION: . Be carelul not damage to inner surtace of the cylinderhousingwith the tlangebolt. . Do not place your lingers under the steering rack.
RING BACKUP
ENOSEAL CYLINDER
CYLINDER ENOSEAL ATTACHMENT REMOVER 07NAO SB3020A
(cont'd)
17-51
SteeringGearbox
pry the pistonseal ring and O-ringoff the 22. Carctully prslonracK. CAUTION:Be carefulnot to damagethe inside ot seal ring groove and piston edgeswhen temoving the sealring. Valve Body Unit Disassembly 2 3 . B e f o r e e m o v i n g t h e a l v eh o u s i n ga p p l y v i n ytla p e r v , to splinesof the pinionshaft. 24. Separate the valve housingfrom the pinion shaft/ valveusrn9a press.
VALVEHOUSING
Vinyl tape
PINIONSHAFT
Replace.
l
2 5 Check the 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 e h e t 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 eh o u s i n g . e p l a c e R the valvehousingonly if the wall is stepped. When the valve housingis replaced, installnew shim(s)on the bearingsurfaceof the housingto adiustthe thickness.
Check insideof valvehousing the whether wall is stepped. the
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 edgesof the groovesin the sleeve. NOTE:The pinion shaft and sleeveare a precision 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 must be replaced,replaceboth parts as a set.
SEALRINGS SLEEVE Checklorpeeloffor
damage.
tool, cut and remove 28. Usinga cutteror an equivalent the four sealringsfrom the sleeve. CAUTIONTBe careful not to damage the edges of the sleeve groovos and out6r sufaca whon romoving the 3eal rings.
SLEEVE
3 f
27. Removethe circlipand pinion shaft sleevefrom the pinionshaft.
Using a cutter or an equivalenttool. cut the valve seal ring and O-ringat the groovethe pinion shaft. the Remove valvesealring and O-ring. CAUTION: Be caretul not to damage the odges of the pinion shaft groove and outor 3urfacwhen rmoving ths valve seal ring 8nd O-ring.
Cuftingslot Position.
VALVESEALRING Replace.
(cont'd)
17-5 3
)
SteeringGearbox
(cont'd) Disassembly
30, Remove valveoil sealand backupring ('96-'97 the model)or wave washer('98 model)from the pinion shaft. NOTE: Inspect ball bearingby rotating outer race the the slowly.lf there is any excessive play, replace the pinionshaftand sleeve an assembly. as 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 c r e s sa n d s p e c i a t o o l p 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 special tool.
'96 - '97 model: PILOTCOLLAR 07GAF- PH70100 VALVEOIL SEAIReplace. ROLLER BEARING Beplace.
PILOTCOLLAR 07GAF- PH701(x) VALVEOIL SEAL Replace. BUSHING Replace.
t,,
17-54
Reassembly
NOTE: partswith a solvent,and dry them with compressed Do not dip the rubberparts in a sol. Cleanthe disassembled air. vent. . Alwaysreplace O-ringsand rubbersealswith new ones beforeassembly, the procedures. power steering . Apply the recommended fluid to the pans.indicated the assembly in . Do not allow dust,dirt, or otherforeignmaterials enterthe power steering to system. . Usethe appropriate special tools where necessary.
CYLINDERLINE A
CYLINDERLINE B VALVEHOUSING VALVEOIL SEAL Replace.
FLARE NUTS kgt.m, 12 lbt.ft) 17 N m 11.7
Replace .-.--------..-SLEEVE SEALRINGS

VALVEOIL SEAL. CYLINOER ENDSEAL Replace. BACKUP Replace.
-S-.S
.o'S
--=-..--
BEARING ",r"a,,
RePIace
Replace.
\ - " - v >
$<-----sueve
-.$}-S:"_------;T;i,',Tl"t',
RING valvE ***t.----..--..- -;;oi;"*. SEAL p -_____ ----_ ll
wAvEwASHER itoilJoril."." HouslNG CYLINDER

GEARHOUSING
\ \ - - - - . - W - - - P t . t t o ' r s " n modolonly: n

S,----'96-'97 S-32 mm SHIMS
'96 - '97 '98 modol: END CYLINDER 63 N'm {7.0 kqf.m,51 lbftll mod6l only: O.RING Replace.
{cont'd)
17-55
SteeringGearbox
(cont'd) Reassembly
Valvs Body Unit Rsassembly 1. Apply vinyl tape to the steppedportion of the pinion shaft,and coat the surfaceof the vinvl taDewith the power steering fluid. 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 washer ('98 model)with its taperedside as shown 3. 4. 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 with powersteering fluid. Slidethe valve oil seal over the pinion shaft,being carefulnot to damagethe sealinglip.
Vinyl tape lStepped ponion) position. Tapered EACKUP RING Grooveside. surethe springis seated the oil seal. in
PINION SHAFT S6aling lip
'96 - '97 modal:
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 shaft. 9. Apply power steeringfluid to the insideof the special tool. Set th largerdiameterend of the special tool overthe valvesealring. 10. Move the special tool up and down several timesto makethe valvesealring fit in the pinionshaft. 11. Remove special the tool, 12. Turn the special tool over,and setthe smallerdiameter end of the special tool over the valveseal ring. Move the special tool up and down several times to 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 shaft.
PISTON SEALRING SIZINGTOOL OTNAG SR3G'OA or 07NAG- SR3o900
mvewAsHERt
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 powersteering fluid. Fit the new O-ringin the grooveof the pinion shaft. Then slide the new valve seal ring over the shaft and the groovein on the pinionshaft. Remove vinyltapefrom the pinionshaft. the
(w(ffi
Use the larger diameter end of the special tool first to make the valve seal ring fit in the pinion shaft.
7.
Makethe valvesealring fit snuglyin the pinion shaftusingthe otherend (smaller diameter end)of the specialtool.
VALVESEALRING Replace Do not over-expand.
17-56
fluid to the surfaceof the speApply power steering tool cialtool. Setthe new sealrings over the special 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 expandthe seal rings. Do two rings at a time from eachend of the sleeve. NOTE: . Do not over-expand sealring. Install the the resin seal rings with care so as not to damagethem. After installation.be sure to contract the seal tool). rings usingthe specialtool(sizing . There are two types of sleeve seal rings: black and brown. Do not mix the different types of sleevesealringsas they are not compatible. and 1 4 . Setthe special tool in the groovesin the sleeve, set each ring in eachgroovesecurely. NOTE: After installation,compressthe seal rings with your fingerstemporarily.
fluid to the surfaceof the pin18, Apply power steering the ion shaft.Assemble sleeveover the pinionshaft 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 sleevewith the cutout in the shaft.Then installthe in new circlipsecurely the pinionshaftgroove. NOTE: 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 the when inserting sleeve. .Install the circlipwith its radiused sidetowardthe sleeve.
fluid to the seal ring lip of the 1 9 . Apply power steering valveoil seal,then installthe seal in the valve housi 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 specialtool. 16. Insertthe sleeveinto the special tool 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.
ATTACHMENT, 32x35mm 07746 0010100
NOTE: surethat the seal rings are not turned Be
fr
up.
SLEEVE SEALRING 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 bushing('98 model) into the valve housingusing a pressand special hydraulic tool as shown. NOTE:Placethe roller bearing('96 -'97 model)or 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 Pres3 07749-0010000
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 e s i n g a h y d r a u l i c u pressas 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 eu r n s t smoothlyby turningthe pinionshaft,
ATTACHMENT. 32x35mm 077i16 0010100
'96 - '97 model: ROLLER BEARING Letterstampedface upward,
21. Apply vinyl tape to the pinion shaft,then coat the

vinyltapewith power steering fluid.
Sealing lip lace. VALVEOIL SEAL
VALVEHOUSING
PINION r
SLEEVE SEALRINGS 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. Remove vinyl tapefrom the pinionshaft. the
17-58
Steering RackRoassembly 25. Coatthe pistonseal ring guide with power steering fluid,then slideit onto the rack,big end first the 26. Position 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 dambe age them. After installation, sure to contract ( t 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 go o l ) piston'sO-ringand sealring as a set. . Replace the 27. Pull the O ring off into the piston groove,then pull the pistonsealring off into the pistongrooveon top of the O-ring.
PISTON
31. Wrap vinyl tape aroundthe rackteeth and rackend edges.then coat the surface of the tape with the powersteering 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 so carefullv that there is no steppedportion.
32. Coatthe insidesurfaceof the new cylinderend seal

fluid. with powersteering
33. Installthe cylinderend seal onto the steeringrack

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. PISTON SEAL RING GUIDE or 07GAG SD,OloA 07GAG SDIO100
CYLINDER END SEAL
I
O.RING Replace PISTON SEALRING Replace-
28. Coatthe piston seal ring and the insideof the spefluid cialtool with powersteering 29. Carefullyslide the tool onto the rack and over the pistonsealring.
30. Move the specialtool backand forth severaltimes

to makethe pistonsealring fit snuglyin the piston.
srde. Grooved
PISTON Replace. r
Makesurethe sPringis in the cylinder eno seal
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. then placethe cylinderend sealto piston.
BACKUP RING
Installthe flange bolt into the end of the steering 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 tightenthe flangenut against rackby hand. the Installthe cylinderend seal into the bottom of the c y l i n d e rb y p r e s s i n g n t h e b o l t w i t h a p r e s sa s o 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 steering rackinto the gear housing. CAUTION: Be careful not to damage to inner surfaco ot tho cylinder housing with tho rack edgB.
12 mm FLANGE NUT
CYLINDER HOUSING
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 carelully that there is no steppedportion. so
17-60
of 4 1 . Coatthe insidesurface the new cylinderend seal fluid. with power steering Installthe cylinderend seal onto the steeringrack with its grooved side toward the piston, end sealwith your finger. 43. Pushin the cvlinder CAUTION:Wh.n irstalling the cylindsr ond 3eal, b6 csreful not damage the sealing face ol th seal with the threads and burrs at the stakad position of the cylinder housing.
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 power steering fluid,then installthe cylinderend by screwingit into the cylinderhousing gearbox. from the steering 4 7 . Remove C-cl8mp the 48. After tighteningthe cylinderend, stakethe point of h t h e c y l i n d e r 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 go to step51. NOTE: Stakethe cylinder in the position opposite from where the stakewas removed during disassemblY. point. inl Deplh: mm 10.0{ 1.0 Stake
ENO CYLINOER SEAL Replace. Makesurethe spring end seal is in the cylinder
in} mm {0.16 CYLINDEE END
Staked
posr!on, side Grooved END CYLINOER SEAL 44. Remove the vinyl tapefrom the steeringrack. CYLINDEB END 69 N.m {7.0 kgt m, 5l lbf.ft)
Be careful not to damage the bushing when insening the cylinder end.
of any residue tape adhesive. NOTE:Remove gearbox as usinga C-clamp shown. 45. Holdthe steering
the 32 mm shim(s)('96-'97 model only). 49. Select 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 ) without when the steeringgearboxis reassembled replacing pinion shaft,valve housing,and gearthe 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 selectthe new shimls)as folhousingare replaced, lows. Shim selestion: a. Setthe four 32 mm shims on the bearingsurfaceof o T t h e g e a r b o xh o u s i n g . o t a l t h i c k n e s s f t h e t o u r shimsshouldequalno more than 0,70mm. 0,10 mm, Shim set: four 32 mm shims (Thickness: 0.15mm, 0,20mm, 0.25mm respectively) CAUTION; Tho four 32 mm shims do not havo thickness identification ma1k3.Measuro iho thicknass of each shim using a micromster,and mark the shim for identitication.
GEARBOX
(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 torque. tightenthe flangeboltsto the specified
VALVEBODYUNIT BOLT FLANGE 20 N.m {2.0kgtm, l4lbfft}
Example: in): is lvleasurement 0.28mm (0.011 i7 0 . 7 0- 0 . 2 8 = 0 . 4 2m m ( 0 . 0 2 8 - 0 . 0 1 1 = 0 . 0 1n ) i T h e s e l e c t e d h i m s s h o u l db e 0 . 2 5m m ( 0 . 0 1 0 n ) a n d s i 0 . 1 5m m { 0 . 0 0 6n } i n t h i c k n e s s . i l f t h e r e q u i r e ds h i m t h i c k n e s s s 0 . 1 0 m m o r l e s s ,n o snrmsare necessary. 32 50. Set the selected mm shims on the bearingsurfaceof the gearboxhousing.
VE EODYUNIT
O.RING Replace.
b M e a s u r e h e c l e a r a n c e e t w e e nt h e g e a r b o xa n d t valvebody unit usinga feelergaugeas shown. at NOTE: Measurethe clearance the point midway the between two mountingbolts.
-61
32 mm SHIMS
BEARING NEEDLE
--6'
fit and carefully it Coatthe new O-ringwith grease, on the valvehousing. Apply greaseto the needlebearingin the gearbox housrng. d. o D e t e r m i n e h e r e q u i r e dt h i c k n e s s f t h e 3 2 m m t i e h s h i m sb y s u b t r a c t i ntg e c l e a r a n co b t a i n e dn t h e of step "c" from the total thickness 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 ) td i c k n e so f t h e s h i m s h s Require NOTE:Selectthe shims so that the total thickness thickness. is closeto, but lessthan,the required Installthe valve body unit on the gearboxhousing the by engaging gears. NOTE: Note the valve body unit installationposiof tion (direction line connection). torque Tightenrhe flangeboltsto the specified
[ ,
17-62
55. InstallthecylinderlinesA and B. NOTE: . 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 thoroughly. The joints must be free of foreign material. . Instaltthe cvlinderlinesA and I by tightingthe flare nuts by hand first, then tighten the fla.e torque. nutsto the specified
17 N.m {1.7kgl.m,12lbtft)
i 6 0 . l n s t a l lt h e n e w l o c k w a s h e r n t h e g r o o v e i n t h e steeringrack. 61. Screweachrackendsinto the rack. 62. Holdthe steeringrackwith a wrench('98 model:left end only),and tightenthe rackends. CAUTION: Be careful not to damags tho rack surfacr whh the wrench, NOTE:'96 -'97 model is shown
LOCKWASHER RACKEND STEERING 5il N.m 15.5kgf.m, 40 lbf'ft)
28 N.m {2.?kgf.m, 20 lbl.ft}
CYLINOER LINEB
LINEA CYLINDER
RACK STEERING
56. Greasethe sliding surfaceof the rack guide, and installit onto the gear housing. '97 model: 57. '95 Apply a thin coat of greaseto the new O-ring,and installit on the rackguide screw. '98 model: Remove the old sealant off of the threaded section, to then apply new sealant the firct threethreads. Installthe spring,rack guide screw and locknuton the gear housing. 59. Adjustthe rackguide screw(seepage 17-33). NOTE:After adjusting,checkthat the rack moves smoothlyby slidingthe rackright and left.
63. After tighteningthe rack ends, stakethe four sections of lockwasherwith a drift and a mallet. Place wood blockon the presstable,then set the the lock washer section of the rack end on the wood blocksecurely. Be sure the tool is alignedwith the flat sections of the steering rack end before pressing. Stake the lock washer in the centet of the flat sectionof the steeringrackend.
..-6ll
O.RING Replace.
'96 - .97 model:
NOTE:Thisdrift hasa flat, puncturing to prevent
RACK STEERING RACKGUIDE LOCKNUTS
scREws
WOODENELOCK
{cont'd)
17-63
SteeringGearbox
(cont'd) Reassembly
ot 64. Apply greaseto the circumference the rack end housing. 67. Adjust the air hose fitting positionof the boots by turningit as shown below.
LEFTBOOT (Viewedfrom the leftside)
RIGHTBOOT from the {Viewed rightside)
:!4AEn SILICONE GREASE
=_.
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. NOTE:Installthe boots with the rack in the straight ahead position (right and left tie-rodsare equal in length).
RACKEND
68. Installnew boot bandson the boot, and bend both setsof lockingtabs. CAUTION: Stake the band locking tabs firmly.
.:!!!!t!H SILICONE GREASE
a-.
portionsto reduce 69. Lightlytap on the doubled-over 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 boot. 72. Install the clipspn the cylinderlines,then clampthe air tube with the clips. CAUTION: Be caletul not to bend or damag ths tood line and cylinder linos when insialling tha gearbox. 1. Beforeinstallingthe gearbox,slide the rack all the way to right. Installthe mounting cushion on the steeringgearoox. Install the pinionshaftgrommet,then insertthe pinion shaft up throughthe bulkhead. NOTE:Align the notch in the pinionshaft grommet with the tab on lhe valvehousing.
2.
CYLINDERLINE A
3.
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 then installtwogearboxmountingbolts. cushion,

MOUNTINGBRACKET
N O T E : I n s t a l lt h e b r a c k e t with the arrow pointing
{4.0 kgf.m, 29 lbl ft)
(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 mountingboltsand stiffener plateattaching bolts. CAUTION: Be sure the air tube is not caught ol pinched by stiftener plate. 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 them securely. 9 . Center steeringrackwithin its stroke. the 1 0 . Slip the lower end of the steering joint onto the pinion shaft(lineup the bolt hole with the groove aroundthe shaft), and tightenthe lower bolt. NOTE: . Connectthe steeringshaft and pinion with the cablereeland steeringrackcentered. joint bolt is securely Besurethatthe lowersteering in the groovein the steering gearbox pinion. 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 s t l o w e r e n d o f t h e a joint. steering
STIFFENER PLATE
STEERING JOINT ATTACHING EOLTS 38 N.m (3.9 kg,f.m.28lbl.ftl GEARBOX MOUNTINGBOLTS , N.m ({.4 ksl.m, 32 lbl.fr}
Install the returnhosejoint by tightening the l6 mm flare nut. 1. Connectthe return hose securely, and tighten the a d j u s t a b l e 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 h ment. Connectthe feed ljne and tighten the 14 mm flare nut. NOTE: Makesure that there is no interference betweenthe fluid lines,the rear beam or any other pans.
ADJUSTAELE HOSE CLAMP (seepage17-39i FETURN HOSE 15 mm FLARE NUT 28 N.m {2.7 kgf.m.20 lbtft)
8.
STEERING JOINT LOWER BOLT 22N.m(2.2 kgf.m, lbl.ft) 16
'I
1. Centerthe cable reel by first rotating it clockwise
until it stops.Then rotate it counterclockwise (approximately two turns) until the arrow mark on the label points straight up. Reinstall the steering wheel(seepage17-35).
1{ mm FLARE NUT 37 N.m (3.8kgtm,27 lbf.tt)
17-66
joint coverwith the clampsand a 12. Install the steering clip.
pipeA or TWC (seesection 9). 1 4 . Install the exhaust the shift linkage{seesectionl3 or section 1 5 . Connect 14). lnstallthe front wheels. 1 7 . Fill the systemwith power steeringfluid. and bleed air from the system(seepage 17-33). performthe followingchecks, 1 8 . After installation. . 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 times to steeringwheelfrom lock-tolockseveral warm up the tluid. Chckthe gearboxfor lesks (seepage17-39). . Adjustthe tront toe (seesection18), . Checkthe steeringwheel spokeangle.Adjust by if turningthe right and lefttie-rods, necessary. NOTE:Turn the right and lefttie-rodsequslly.
the Reconnect tie-rodendsto the steeringknuckles, tighten the castlenut ('96 -'97 model) or nut {'98 torque,and installnew cotter model)to the specified prns. NOTE: Before connectingthe tie-rod ends, wipe off from the balljoint tapered any grease contamination and threads. section CAUTION: Torquethe castlenut to the lower torque specification, thn tighten it only far enough to align the slot whh the pin hole. Do not align the nut by ,97 modd onlyl. looeening('96NE.RODENO
PINS COTTER Replace. bend On reassembly, the cotterpin as shown.
NUT CASTLE ,+0 ,18N'm 14.0 4.8kgt'm, 29- 35lbf.fr)
NUT
il,l N.m (4.5kgl'm,33 lbffrl
17-67
Balljoint BootReplacement
'96 - '97 modol: L Remove the boot set ring and the boot. GAUTION:Do not contaminatethe boot installation section with gtease. 2. 3. Pack the interiorof the boot and lip with grease. 2. Wipe the greaseoff the sliding surfaceof the ball pin,then packthe lower areawith freshgrease. CAUTION: . Keep grsase off th6 boot installation section and the tapered s6stion ot the ball pin. . Do nol allow dust. dirt, or othar foteign matorials to enter the boot. LIP
BALLPIN TAPERED SECTION Wipe off the grease.
'98 modol: CAUTION: Do not contaminatetho boot instsllation sec. tion with grease. 1. Remove the boot from the tie-rodend, and wioe the old greaseoff the ball pin, Pack lowerareaofthe ball pin with freshgrease. the Packthe interiorof the new boot and liD with fresh grease. GAUTION: . Kep grgaseofftha boot installation soction and lhe tapered soction if the batl pin. . Do not allow dust, dirt. or othor foroign materials to enter ths boot,
3.
SECTION Wipeoff the grease-
BOOTINSTALLATION SECTION Wipeoff the grease.
BOOT INSTALI."A sEcnoN

Wipe offthe grease.
4.
Install the boot in the grooveof the boot installation section securelv, then bleedthe air from the boot.
ADJUSTING BOLT Adjustthe depth by turningthe bolt.
Install the new boot usingthe special tool as shown oerow, NOTE: The boot must not be a gap at the boot instaf lation sections.
FRONTHUB DIS/ASSEMBLY IOOL 0796s - SA5o500
, . .^' ,'
. -,.-.:.SETRING
,;i
i r
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 posiIron. CAUTION: After installing tho boot, chock the batt pin taprod section tor gtsase contamination and wipo il if necess8ry. CAUTION: Aftr installing the boot, chock the ball pin taperod sgction for grase contamination, and wipo it il nocessary.
f'
17-68
Suspension
18-2 ............. Toof s Speciaf ComponentLocations ...... 18'3 lndex ................ Wheel Alignment 18'4 ...,,, Caster,.............. 18-4 .................. Camber Front Toe Inspection/ 18-5 ......'. Adiustment RearToe Inspection/ 18-5 ........ Adiustment 18-6 ...............' TurningAngleInspection Wheel/HubInspection 1a'7 End Play.........................."" Bearing .......18-7 Wheel Runout Front Suspension Arms Replacement.....18-8 Suspension 18-9 ..'.......'.' Replacement Knuckle/Hub Lower Ball Joint Replacement.......18-15 18-16 Ball Joint Boot Replacement.......... Front Damper 18-16 ................. Removal "..' ........'.... 1A-17 Disassembly/lnspection 18-18 ........... Reassembly 18-18 ............. Installation RearSuspension Arms Replacement.....18-20 Suspension ......18-21 Hub BearingUnit Replacement Upper Arm BushingReplacement. 18-22 RearDamper t8-23 ................. Removal y/lnspection .............. 18'24 ".' Disassembf 18'25 ........... Reassembly 18-26 ............. Installation
Tools Special
Ref. No.
Tool Number 07GAF SE00200 07GAF SE00401 07GAG SD40700 07JAF SH20110 OTJAF SH2O120 07JAF SH20200 0TiilAC- S100200 07746 0010500 07749 0010000 07947 6340201 07965 S800100 07965 S800200 07965 SD90100 07974- SA50700
Description Hub AssemblyGuideAttachment Hub Dis/Assembly Base B a l l J o i n t o o tC l i pG u i d e B Hub Dis/Assembly Pilot,38 mm Hub Dis/Assembly Shatr,22.4 x25.4 mm BallJoint Remover Base B a l lJ o i n tR e m o v e r , 8 m m 2 Attachment, x 68 mm 62 Driver DriverAttachment BallJoint Remover/lnstaller B a l lJ o i n tl n s t a l l eB a s e r SupportBase B a l lJ o i n tB o o tC l i pGu i d e
Oty
1 'I 1 I 1 1 1 1 I 1 1 1 1 1
PageReterence 18-14 18-13 18-16 ' 1 81 3 18-13 18-15 '1, 18- 1 2 1 18-13 18-13 18- 4 1 18-15 18-14 1e 1R 16
o
@ at\ @
!o,
o
@
6l
@ @ @
o.(}
@,@
8-2
ComponentLocations
Index
Wheel Alignment, page 18-4
Front SusDension:
FRONT DAMPER ' Removal, page18-16 . Disassembly/lnspection, page'18'17 . Reassembly, page18 18 . lnstallation, page18'18
ARM UPPER . Replacement, page18-8
KNUCKLE/HUB . Replacement, page18 9 . WheelBearing page18.13 Replacement,

. 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
STABILIZER BAR . Replacement, page18-8
ARM LOWER . Replacement, page18-8
RearSuspension:
REABDAMPER ' Removal, page18 23 . Disassembly/lnspection, 18-24 page . Reassembly, page18-25 . Installation, page18-26 UPPER ARM ' Replacement, page18-20
ARM LOWER . Replacement, page18-20
. Replacement, page18 20
TRAILING ARM . Replacement, page18-20
18-3
WheelAlignment
Caster
of NOTE| For proper inspection/adjustment the wheel alignmentcheckand adjustthe following beforechecking the alignment. . . . . is Check that the suspension not modified. the Check tire sizeand tire pressure. the Check runoutof the wheelsand tires. ball joints. (Holda wheel with Checkthe suspension your handsand move it up and down and right and leftto checkfor wobbling.)
Camber
Inspection
cl m o 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 oe p u t e r i z efd u r w 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 e h e e l a l i g n , F t m e n t ( c a s t e rc a m b e r , o e , a n d t u r n i n ga n g l e ) . o l l o w instructions. the equipmentmanufacturer's 1. Check camberangle. the Camb6rangle: Front: 0'00' I 1' R e a r- 1 " 1 1 ' : 2. lf out of specification, checkfor bent or damaged components. suspension
Inspection
o cl m 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 oe p u t e r i z efd u r w wheel alignment quipment o measure heelaligne , F t m e n t ( c a s t e rc a m b e r , o e , a n d t u r n i n ga n g l e ) . o l l o w instructions, the equipmentmanufacturer's 1. Check casterangle. the Casterangle:1"40't 1" 2. checkfor bent or damaged lf out of specification, componenrs. suspensron
D=r$*
18-4
FrontToe Inspection/Adjustment
cl m o 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 oe p u t e r i z e fd u r w 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 e h e e l a l i g n , F m e n t ( c a s t e rc a m b e r , o e , a n d t u r n i n ga n g l e ) . o l l o w t instructions. the equipmentmanufacturer's '1. Check tire pressure. the 2. 3, wheelspokes. Center steering 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 ahead. Fronttoe: lN 1 t 2 mm (lN 1/16l: 1/16in)
RearToe Inspection/Adjustment
cl m o 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 oe p u t e r i z efd u r w e wheelalignment quipment o measure heelalign, F m e n t ( c a s t e rc a m b e r , o e , a n d t u r n i n ga n g l e ) . o l l o w t instructions. the equipmentmanufacturer's 1. parkingbrake. Release NOTE: . M e a s u r e i f f e r e n c en t o e m e a s u r e m e n tw i t h i s d the wheelspointedstraightahead. you may get an . lf the parkingbrakeis engaged. reading. incorrect Reartoe-in:2 1i mm ttlte:ljl8 int
go lf adjustment required, on to step 4. is lf no adjustmentis required.remove alignment equipment. go lf adjustment required, to step2. is 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 straightaheadposition.
note the locationsof adjusting Beforeadjustment, arms. boltson the right and left compensator Loosenthe adjustingbolts. and slide the compensatorarm in or out, as shown,to adjustthe toe.
BOLT ADJUSTING 1 0x 1 . 2 5 m m 64 N.m {6.5kgt.m. 47 lbtftl
TIE.ROD LOCKNUT 1 4x 1 . 5m m {,1 N.m (,1.5 m, 33 lbtftl kgt
Turn both tie-rodsequally until the toe readingon the turning radiusgaugeis correct. After adjusting, tightenthe tie-rodlocknuts. NOTE:Reposition tie-rodboot if it is twisted or the displaced.
IN 4. .
ARM COMPENSATOR
Tightenthe adjusting bolts. 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 nt h e w h e e l i s 2 m m (0.08in) out of the specification. 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 positionrecorded beforethe adjustment. The distance the adjustingbolt is moved should be equalto the amountout-of-specification.
18-5
WheelAlignment
Turning AngleInspection
o 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 oe p u t e r i z efd u r cl m wheelalignment quipment o measure heel aligne w , F m e n t ( c a s t e rc a m b e r , o e , a n d t u r n i n ga n g l e ) . o l l o w t the eouiDment manufacturer'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 n o m p o c nenrs.
18-6
Inspection Wheel/Hub
Bearing EndPlay
1. Raise vehicleoff the ground.and supportit with the (seesection1). safetystandsin the properlocations then reinstall wheel nuts. the Remove wheels, the Aftachthe dial gaugeas shown. lMeasure bearingend play by movingthe disc in the or outward. Front/Rear: Standsrd:0- 0.05mm {0 - 0.002inl 3.
WheelRunout
1.
Raise vehicleoff the ground,and suppon it wjth the (seesection1). safetystandsin the properlocations wheels. Check bent or deformed for Attachthe dial gaugeas shown. Measure wheel runoutby turningthe wheel. the Front and Rarwheel Axial Runout: Stand8rd: 0 - 1.0 mm (0 - 0.0/tinl Steel Wheel: wheel: 0 - 0.7 mm {0 - 0.03in) Aluminum
Service Limit:
2. 3. 4.
2.0 mm 10.08 inl
Front and RearWheel RadialRunout' Standard: SteelWheel: 0 - 1.0mm (0 - 0.0/tinl AluminumWheel:0 - 0.7 mm (0 - 0.03in) Limit: Service 1.5mm (0.06inl
Measure end 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 t t h e s t a n d a r d ,r e p l a c e h e w h e e l b e a r i n g .
5.
lf the wheel runout is more than the servicelimit, replace wheel. the
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 threadsbeforetightening fasteners. the . The right and left damper forks are not interchangeable. left damper fork is markedwith "AL" while the right The dampertork is markedwith "AR . . The right and left upper arms are not interchangeable. left upperarm is markedwith "SO1-L"while the right arm The is marked ith"SO1-R". w . Beforetightening the upperand lower mountingnuts on the stabilizer link,adjustthe locationof the link with the susp e n s i o n n d e r e h i c l eo a d . u v l . When installing radiusarm washers, "FR" markfacesthe front of the vehicle. the the . After installing suspension (seepage 18 4). the arm, check front wheelalignment, the and adjustif necessary
FLANGE BOLTS 1 0x 1 . 2 5 m m 54 N.m {5.5 kgl.m, 40 tbf.ft) STABILIZER BAR Alignthe stabilizer mark with end of stabilizer bushi ARM UPPER the for and Check bushing deterioration damage. BALLJOINT BOOT
. 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 . . See page 18 16 for boot replacement.
STABILIZER BUSHING
STABILIZER END RUBBER BUSHING for Check deterioration ano oamage, FLANGEBOLT lil x'1.5 m m 103N.m 110.5 kgtm, \ 76lbfftl \ FLANGE BOLT 8 x 1.25mm 22 N.m 12.2 kgt.m, 16 tbf.ftl
STABILIZER BAR for Check bending and damage.
LOWER ARM RUBBER BUSHING . Check deterioration for ano oamage.
1 4x 1 . 5m m Replacekg{.m,61 lbtft} 83 N.m 18.5 1 4x 1 . 5m m 89 N.m (9.1kgf.m,66lbf ft)
SILICONE GREASE RUBBER BUSHINGS SELF-LOCKING 8 x 1.25mm NUT 22 N.m (2.2kgl.m, 16 lbf.ft) Replace.
FLANGE BOLT 10 x 1.25mm i|i} N'm 14.4kgl'm. 32 rbf ft) SELF-LOCKING NUT 12 x'1.25 mm Replace. 64 N.m (6.5kgf.m, {7 lbnft} RUBBER BUSHING . Check deterioration damage for and
SILICONE GREASE STABILIZER RUBBER END BUSHINGS Notethe direction ot the bushings.
18-8
Replacement Knuckle/Hub
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: wheel weightsmay corrodeand damage . Use only genuineHondawheel weightsfor aluminumwheels.Non-genuine wheels. t h ea l u m i n u m . On the aluminumwheels,removethe centercapfrom the insideof the wheelafter removingthewheel. of o Beforeinstalling brakedisc,cleanthe matingsurfaces the front hub and brakedisc. the of . Beforeinstalling wheel,cleanthe matingsurfaces the brakediscand wheel. the . Wipe off the greasebeforetightening the nut at the balljoint.
CALIPER MOUNTINGBOLT 12x 1.25mm 108N.m (11.0 m,80 lbnftl kgt CASTLE NUT 10 x 1.25mm 39 - 47 N.m 14.0 4.8 kgf.m, 29 - 35 lbtft) COTTER PIN Replace. WI{EELBEARING Replace. page18-13 Replacement, GUARO CIRCLIP LOWER BALL for Inspect faulty movement and wear. page18 15 Replacement, SET BALLJOINT BOOT Check deterioration for ano oamage. COTTER PIN Replace. SCREW 5x0.8mm 4.9N.m {0.5kgtm.3.6lb{.ftl
FRONTHU8 C h e c kf o r d a m a g e 6 n d Replacement, page l8-10
CASTLENUT 12 x 1.25mm 49 - 59 N m 15.0 6.0 kgf m, 36 - iB lbf.ft)
SPINDLE NUT 22 x 1.5mm 181N.m 118.5 kgt.m, 134lbf.tt) Replace. NOTE: . Betore installing spindlenut,apply the surface ofthe nut. engineoilto the seating . Aftertightening, a driftto stakethe use the spindlenut shoulder against 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 ksf.m,80lbf.ft) {11.0 6 mm BRAKEDISCRETAINING SCREW 9.8 N.m 11.0 m, 7 lbtft) ksf
{cont'd)
18-9
FrontSuspension
Knuckle/Hub Replacement {cont'd}
1.
Loosen wheel nuts slightly. the Raisethe front of vehicle, and support it with safety standsin the properlocations(seesection 1). Remove wheel nuts and wheel. the
WHEEL NUT 108N.m {11kgtm.80 lbf.ftl
7. Remove 6 mm brakedisc retaining the screws.
2.
3.
6 mm BRAKEDISC RETAINING SCREWS 9.8 N.m ll.0 kgl.m, 7 lbf.ft)
8 x 1.25 BOLTS mm 8. Screwtwo 8 x 1.25mm bolts into the discto push it awayfrom the hub.
SPINDI.fNUT 181N.m {r8.5kgf.m,134lbtft) Replace. NOTE:Beforeinstalling the spindlenut, apply engine to the seating oil surface the nut.Atter of tightening, use a dritt to stakethe spindlenut shoulder against driveshaft the Raisethe locking tab on the spindle nut, then remove the nut. Remove the brake hose mounting bolts. BMKE HOSEMOUNNNG BOLT 8 x 1.25mm 12 N.m 11.2ksI.m,8.7 lbtftl
NOTE:Turn eachbolt two turns at a time to prevent cocking discexcessively. the 9 . Remove the brakediscfrom the knuckle.
1 0 . Check front hub for damageand cracks. the

5. 't1. Remove (for cars the wheel sensorfrom the knuckle with ABS). NOTE:Do not disconnect wheel sensorconnecthe
ror.
CAI-IPER MOUNTINGBOLTS 12 x 1.25mm 108N.m (11.0 kgf.m,80lbl.ft)
9.8N.m {1.0kgf.m, 7 rbr.ft)
6.
R e m o v e 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 t caliperassemblv one side. to CAUTION;To prevent accidentaldamage to th caliper assemblyor brake hose, use a short piece ot wire to hang the caliper from the undercarriage.
MOUNTING BOLTS 9.8N.m kgf.m,7lbf.ftl 11.0
'+
18-10
NOTE: Use the specialtool to separatethe ball ioints from the suspension steering or arm CAUTION: Be careful not to damagethe ball ioint boot. 1 2 . Cleanany dirt or greaseoff the balljoint. 1 3 . Removethe cotter pin from the steeringarm and removethe nut.
1 4 . Apply grease the special to tool on the areasshown.
17. Oncethe specialtool is in place,turn the adjusting bolt as necessary make the jaws parallel.Then to h a n d - t i g h t e nh e p r e s s u r eb o l t , a n d r e c h e c k h e t t jaws to makesurethey are still parallel.
T h i s w i l l e a s ei n s t a l l a t i o n f t h e t o o l a n d p r e v e n t o damage the pressure threads. to bolt

BOLT ADJUSTING PRESSURE BOLT
NOTE:After making the adjustmentto the adjusting bolt, be sure the headof the adjustingbolt is in this position the allow the jaw to pivot. to 18. With a wrench,tighten the pressurebolt until the balljoint shaft pops loosefrom the steering arm. I n s t a l a 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 l that the hex nut is flush with the ball joint pin end to 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 Jornt. 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 makingsure you do not damagethe ball carefully, 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 pressure bolt. N O T E :l f n e c e s s a r y ,p p l y p e n e t r a t i n gy p e l u b r i a t cantto loosenthe ball joint.
COTTER.PIN Replace. On reassembly, bendthe cotterpin
wear eye protection. The ball ioint @ can break loose suddenly and scatter dirt or other deblis in your eyes, 19. Remove tool, then removethe nut {rom the end the of the balljoint and pull the balljoint out of the steering/suspension Inspect arm. the ball joint boot and replace if damaged. it
CASTLE NUT 10 x 1.25mm ';" 39 - 47 N.m (4.0- 4.8 kgf.m, CASTLE NUT
xei ruur
Replace.
BALLJOINT REMOVER, mm 28 07MAC- SL00200
{cont'd)
18-1 1
FrontSuspension
Replacement Knuckle/Hub {cont'dl
20. Remove the cotterpin from the lower arm ball joint castlenut, and removethe nut. 23. Remove the cotterpin from the upperball joint castle nut. and removethe nut.
COTTER.PIN Replace. On reassembly, bendthe cotterpin
CASTLE NUT m 1 2x 1 . 2 5 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. Install the 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. tool as shown on page 18-11 septo Usethe special aratethe ball joint and knuckle. NOTE: lf necessary. apply penetratingtype lubricantto loosenthe ball joint.
NUT CASTI-E 1 2x 1 . 8 m m 28 BALLJOINT REMOVER, mm 07MAC- 5100200
2 1 . I n s t a l l 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 a that the hex nut is flush with the ball joint pin end, or the threaded sectionof the ball joint pin might be damagedby the ball joint remover. 2 2 . Usethe special tool as shown on page 18- to sep11 aratethe balljoint and lowerarm. N O T E :l f n e c e s s a r y ,p p l y p e n e t r a t i n gy p e l u b r i a t c a n tt o l o o s e nh e b a l l j o i n t . t
26. Pullthe knuckle outwardand removethe driveshaft joint from the knuckle tappingthe driveby outboard shaft end with a plastichammer,then removethe knuckle. KNUCKLE for Check damage.
18-12
NOTE: Replace bearingwith a new one after removal. the usingthe special 27. Separate hub from the knuckle the press. tools and a hvdraulic CAUTION: . Take care not lo disto.t the splash guard. . Hold onto lhe hub to keep it from falling when preised clear. a To prevenl damage to the tool. make Sure ihe threads are fully engagedbefore pressing.
HUBDIS/ASSEMBLY PILOT,38 mm 07JAF SH20r 10
u 2 9 . P r e s s t h e w h e e le a r i n g u t o f t h e k n u c k l e s i n g t h e b o and a pressas shown. soecialtools DRIVER 07749 00'10000

Press
+
ATTACHMENT, 62x68mm 07746- 0010500
KNUCKLE
l
KNUCKLE
HUBDIS/ASSEMBLY BASE 07GAF SE0040r
WHEELBEARING 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 x SHAFT.22.4 25.4mm 07JAF SH20120 BEABING SEPARATOR 0 - 1112in. (Commercially available) Pres3
HUB DIS/ASSEMBLY PILOT, mm 38 07JAF SH20110
Removethe circlip and the splash guard from the knuckle.
Checkfor bending and damage.
HUBDIS/ASSEMBLY x SHAFT,22.4 25.4mm 07JAF- SH20120

j l l
(cont'd)
18-13
FrontSuspension
(cont'd) Replacement Knuckle/Hub
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 highflash point solventbeforereassembly. Pressa new wheel bearinginto the knuckleusing the special tools and a pressas shown. with NOTE:Placethe wheel bearingon the knuckle the Dackseal (metal color) toward the inside. Be carefulnot to damagethe sleeveof the packseal.
Press HANDLE o7749DRIVER ATTACHMENT 58x72mm 07947- 6340201 OOUBLE SEAL LIP IBLACKCOLOR)
the hub on the knuckle usingthe specialtools 34. Install as shownand a hvdraulic Dress shown. CAUTION:Takecare not to distort the splashguard.
HUB/ASSEMBLY GUIDE ATTACHMET'rT 07cAF SEqt200
FRONTHUB
WHEEL
BEARING .,
SPLASH GUARD
I I I KNUCKLE SUPPORT BASE 07965 SO90100 groove. in 32. Installthecirclipsecurely the knuckle
35. lnstallthe knucklein the reverseorder of removal,

33. Installthesplashguardand tightenthe screws. and pay particular attention the followingitems: to 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 when installing knuckle. the Torque all mounting hardwareto the specified t o r q u ev a l u e s . Torquethe castlenuts to the lower torque specifications.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. Beforeinstalling the brakedisc,cleanthe mating surfacesof the front hub and the inside of the brakedisc. Beforeinstalling wheel,cleanthe matingsurthe faceof the brakediscand the insideof the wheel. Checkthe lront wheqlialignment, and adjustit if necessary {seepage{S0.
scREws 4.9N.m(0.5 kgf.m, 4lbtft)
*_l
,:1S
18-14
LowerBallJoint Replacement
1.
(seepage18 10). Remove knuckle the Remove the boot by pryingthe set ring off. a 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 n d d a m a g e , if replace necessary. 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 the castlenut.
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.
3.
ADJUSTING BOLT Adj!st the depthby turningthe bolt.
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.
07965- 5800100
JOINT REMOVER/INSTALLER SALL
NUT CASTLE
( - BASE BALLJOINT REMOVER 07JAF- SH20200
6. 7.
Placethe ball joint in position by hand. Install the special tools over the ball joint as shown, t h e n p r e s st h e b a l l j o i n t i n . BALLJOINT INSTALLER BASE BALLJOINT REMOVER/ INSTALLER 07965- 5800100
9.
Installthe knucklein the reverseorder of removal, aftention the followingitems: to and pay particular . r . 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 ntg e k n u c k l e . h Torque all mounting hardwareto the specified torquevalues. Torquethe castlenuts to the lower torque specif 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. the brakedisc,cleanthe mating Beforeinstalling surfacesof the front hub and the inside of the brakedisc. surBeforeinstalling wheel,cleanthe matang the faceof the brakediscand the insideof the wheel. and adjustit if Checkthe front wheel alignment, (seepage 18-4). necessary
. . .
SURFACE BALLJOINT HOUSING
18-15
FrontSuspension
Ball Joint Boot Replacement
Remove set ring and the boot. the CAUTION:Do not contaminatethe boot installation section with grease. Pack interiorof the boot and lip with grease. the
LtP BALLPtN TAPRED SECTTON
FrontDamper
Removal
' 1 . Remove the front wheels(seepage 18-10). 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 damperfork,
OAMPER FORK DAMPER FORK BOLT
Wipe ofl the grease.
BOOTINSTALLANON SECTION Wipe otf the grease. DAMPER PINCH BOLT 1 0x 1 . 2 5 m m
3.
Wipe the greaseoff the sliding surfaceof the ball pin and packwith freshgrease. GAUTION: . Keep greaseoff the boot installation section and the taperd section of the ball pin. . Do not allow dust, dirt, or other loreign matcrials to enter the boot. lnstallthe boot in the grooveof the boot installation section securely, then bleedair.
SELF.LOCKING NUT 12x 1.25mm Replace.
Removethe damper fork bolt and self-locking nut from the bottom of the damper fork, then remove damperfork. Remove damperby removingthe two nuts. the
5.
lnstallthe upper and lower ball joint boot set rlngs usingthe special tools as follows:
OAMPER
L o w e r b a l l j o i n t : A d j u s tt h e s p e c i a t o o l w i t h t h e l 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 Adiust the depth by turningthe boh.
BALLJOINT
aooTcLrP
GUIOE UPPER BALL JOINT BOOT: 07GAG- SDr0700 LOWER BALL 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
Disassembly 1. Compress the damper spring with the spring comi p r e s s o r c c o r d i n g o t h e m a n u f a c t u r e r 'lsn s t r u c t a tions,then removethe self lockingnut. CAUTION: Do not compress the spring more than neceaaeryto remove the nut.
29 N m 13.0 kg{.m,22 lbtftl Replace.
""----------------g io'i'i'"?Tllo
DAMPER MOUNTINGWASHEB
10 mm SELFLOCKING NUT Replace.
BASE
DAMPER MOUNTING RUBBEB
C h e c kf o r d e t e r i o r a t i o n and oamage,
STRUTSPRING COMPRESSOR: lCommerciallyavailablel T/N 7200, ERANICKo T/N MST.58OA, or eouivalent
OAMPER SPBING for Check weakened compression ano oamage. MOUNTINGRUBBER SPRING for Check deterioration ano oamage, BUMPSTOP Check weakness for and
Release the pressurefrom the spring compressor, the then disassemble damperas shown in the next column. Inspection 1. Reassemble parts,exceptthe spring. all a y o 2 . P u s h n t h e d a m p e r s s e m b la ss h o w n .
damage. DUST COVER PLATE
BUMPSTOPPLATE
DUSTCOVER Check bending for and damage.
t f 3 . C h e c k o r s m o o t ho p e r a t i o nh r o u g ha
stroke,
DAMPEB UNIT
4.
and extension. both compression 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 the or does not (no compression no extension), gas s i s l e a k i n g , n dt h e d a m p e r h o u l db e r e p l a c e d . a d o l f , C h e c k o r o i l l e a k sa b n o r m an o i s e s r b i n d i n g u r ing thesetests.
18-17
FrontDamper
Reassembly
1 . lnstallthe damperunit on a springcompressor. 2. Assemblethe damper in reverseorder of removal exceptthe damper mountingwasherand self locki n gn u t . 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.
Installation
L
Loosely install the damper on the frame with t h e a l i g n i n g a b f a c i n gi n s i d e , h e n l o o s e l yi n s t a l lt h e t t two flangenuts. FLANGE NUTS 10x 1.25 mm 49 N.m(5.0kgf.m, lbf.ft) 36
DAMPER ASSEMBLY
STRUTSPRING COMPRESSOR: (Commarcially availablol BRANICKO MST.58OA, T/N T/N 7200, or equivalent
SPRING LOWER SEAT
Position the damper mountingbaseon the damper u n r ta s s n o w n . Compress damperspring. the 5. Install dampermountingrubber,dampermountthe ing washerand a new 10 mm self-locking nut. Hold the dampershaft and tighten the 10 mm selflockingnut. SELF.LOCKING NUT 10x 1.25 mm
29 N.m {3.0kgf.m, 22 lbf.ft) MOUNTINGWASHER
18-18
and onto 2. Installthe damperfork over the driveshaft 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 tork. slot in the damDer
DAMPER FORK BOLT
ALIGNING TAB
DAMPER PINCH BOLT 10 r 1.25mm N.m 14.4kgf m, 32 lbf.ft)
NUT SELF.LOCKING 1 2x 1 . 2 5 m 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 selflockingnut 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 rsuli.
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
Suspension Arms 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 forward. 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 adjusting boltson the compensator arm are installed the samedirection. in . " 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 d 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 o G , ,o r " t U PR K " " t 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 compensator arm are symmetrical. lnstallso the "l UP" markstampedsidefacesforward. . After installing suspension the arm,checktherearwheelalignment,and adjust if necessa (seepage .18-4). ry
FLANGE BOLT 10x 1.25mm 54 N.m kgt.m, 40 lbl.ft) 15.5 ADJUSTING EOLT (FLANGE BOLT) 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, SILICONE -.-
.d@l
cREAsE
DAMPER MOUNTINGBOLT BOLT) {FLANGE 10 x 1.25mm sil N.m {5.5 kgt m, 40 lbt.ft)
10 mm FLANGE BOLT N.m 14.0kgf.m,29 lbt.ft) UPPER ARM Check bending for
i
FLANGE BOL '10 1.25mm x 54 N.m I (5.5kgf m, 40 lbtft)
damage.
COMPENSATOR ARM Check bending for ano oamage.
TBAILINGARM FI-ANGE BOLT 10 x 1.25mm 54 N.m {5.5kgt m, 40 lbtftl
COMPENSATOR ARM INNER BUSHING S|L|CONE ,--
*@l
cnense
for Check deterioration a n dd a m a g e . FLANGE BOLT 10 x 1.25mm 64 N.m {6.5kgf.m. 47 tbf.ftl LOWER ARM Check cracks for ano oamage. LOWER ARM EUSHING SILICONE ...,4@] GREASE Check deterioration for ano oamage.
FLANGE BOLT 12x 1.25mm 64 N.m 16.5 m, kgl rl7 lbf.ft)
18-20
Unit Replacement HubBearing

NOTE: wheel weightsmay corrodeand damage . Use only genuineHondawheel weightsfor aluminumwheels.Non-genuine w t h ea l u m i n u m h e e l s . . Onthe aluminumwheels,removethe centercap f rom the insideofthewheel after removingthewheel. of . Beforeinstalling brakedrum,cleanthe matingsurfaces the rear hub and the brakedrum. the of . Beforeinstalling wheel,cleanthe matingsurfaces the brakedrum and wheel. the
TRAILING ARM for Check cracking ano oamage.
BNAKE SHOE
NUT SPINOLE 22 x 1.5 rnm kgf.m,134lbt.ft) 181N.m 118.5 Replace. use NOTE:Aftertightening, a drift punchto lockthe spindlenut shoulder intothe spindle.
WASHER SPINDLE
BACKING PLATE BOLT FLANGE 1 0x 1 . 2 5 m m 5,1N.m (5.5 kgtm,,l0 lbtft) REARWHEEL UNIT HUBBEABING tor Check cracking and oamage. BRAKEDRUM for Check wear ano oamage.
WHEEL NUT 1 2x 1 . 5m m kgf'm,80lbtft) 108N.m (11.0
(cont'dl
18-21
RearSuspension
Hub BearingUnit Replacement (cont'dl
1. 2. 3. Loosen wheel nuts slightly. the Raisethe rear of vehicle,and supportit with safety (seesection1). standsin the properlocations Remove wheel nuts and rearwneel. the
UpperArm BushingReplacement
1. R e m o v e h e u p p e ra r m b u s h i n g n d i n n e rb u s h i n g t a as shown.
UPPER ARMINNER BUSHING
SPINOLE NUT 22 x 1.5mm 181N.m {18.5 ksf.m,134lbth) Replace. NOTE:Aftertightening, a drift to use stake spindlenut shoulder the against the spindle.
REARUPPERARM
2.
N 4 a r a 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 k so that it is in line with the bolt mountinosurface. 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
3.
REARWHEEL HUBCAP Replace. NOTE:Takecarenot to damage the hub bearing unit on disassembly. WHEELNUT 1 2x 1 . 5m m
4. 5. 6. 7. 8.
g0 108N.mfi1.0 kgf.m, tM.ftl Pullthe parkingbrakeleverup. Remove the hub cap. Raise locking on the spindlenut,then remove the tab the nut. Release parkingbrakelever. the Remove the brakedrum, hub bearingunit and spin d l ew a s h e r .
BOLTMOUNTING SURFACE
Drivein the upperarm innerbushingwith the marks aligned. 5. D r i v e h e u p p e r r m b u s h i n gn t ot h e u p p e ra r m . t a i 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 BEARING UNIT

Checktor cracksand damage
BRAKEORUM
SPINDLE WASHER
9.
Installin the reverse orderof removal.
18-22
RearDamper
Removal
1. 2. Rem ove the rearwheels(seepage 18-22). (Hatchbackl. coverand speaker Remove speaker the the Sedanand Coupe:Remove trunk side panel(see 20). section Remove two flange nuts. the
NUTS FLANGE 10 x 1.25mm
6.
and Lowertherearsuspension, removethe damper.
OAMPER
3.
4.
Remove flangebolt from the damper. the
FLANGE BOLT 1 0x 1 . 2 5 m m BOLT FLANGE m 1 0x 1 . 2 5 m
the Remove the flangebolt that connects lower arm to the trailingarm.
18-23
RearDamper
Disassembly/l nspection
Disassembly
L Compress the damper spring with the spring comp r e s s o ra c c o r d i n g o t h e m a n u f a c t u r e r ' is s t r u c , t n tions,then removethe self-locking nut. CAUTION: Do not compress the spring more than necessary remove the selflocking nut. to
lnspection
1. 2. Reassemble parts,exceptthe spring. all Pushon the damperas shown.
WOODENBLOCK
STRUTSPRING COMPRESSOR: (Commercially availablel BRANICI(@ MST-580A, T/N T/N 7200,or equivatent
Checkfor smooth operationthrough a full stroke. both compression extension. and 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 compression no extension), gas or the asleaking, and the dampershouldbe replaced. Check oil leaks. for abnormal noises and bindingduring these tests.
Release the pressure from the spring compressor, then disassemble the damper as shown on page 18-
I
18-24
Reassembly
SELF-LOCKINGNUT--------------- gr 10 x 1.25mm Y 29 N.m (3.0kgt.m, 22 lbl.ft) DAMPER MOUNTING WASHER MOUNTING OAMPER RUBBER for Check deterioration ano oamage. MOUNTING DAMPER COLLAR DAMPER MOUNTINGBASE MOUNTING DAMPER RUBBER for Check deterioration DAMPER SPRING ano oamage, Check weakness, for compression damage. and SPRING RUBBER for Check deterioration ano oamage. BUMPSTOP Check weakness for a n oo a m a g e . PLATE DUSTCOVER DUSTCOVER for Check bending
1.
c I n s t a ltlh e d a m p e ru n i to n a s p r i n g o m p r e s s o r ' instructions. NOTE:Followthemanufacturer's
2.
orderof disas the Assemble reardamperin reverse 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 n s e l fl o c k i n g u t . 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 springlower seatas shown.
3.
the dampermounting base on the damper Position unit as shown.

COMPRESSOR: STRUTSPRING available) MOUNTING(Commercially DAMPER T/N 7200, T/N BRANICKO MST-580A. or equivalent
LOWER SEAT SPRING the damper spring with the spring comCompress pressor.
5.
I n s t a l t 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 l nut. installa new self-locking Holdthe dampershaftwith a hex wrench and tighten nut. the self-locking NUT SELF-LOCKING DAMPER
'10 1.25mm x 22lbfft} 29 N.m {3.0kgf.m,
Replace.
6.
DUSTCOVERBOOT for Check deterioration a n oo a m a g e ,
MOUNTING WASHER
DAMPER UNIT
18-25
RearDamper
Installation
L L o w e r t h e r e a r s u s p e n s i o n a n d p o s i t i o nt h e , damperwith the springstop pointedtoward the left sideof the vehicle. ,i :..
SPRING STOP
2.
Loosely installthetwo flangeNUIs.

FLANGE NUTS 10x 1.25mm 49 N.m {5 kgl.m, 35 lbf.ftl Tighten thesenuts in Step7.
Looselyinstallthe flangebolt. FLANGE BoLT 10x 1.25 mm

'
i ' a - -: a as'.( r'
54 N.m {5.5 kgl.m,40 lbf.ftl
FLANGE BOLT 10 x 1.25mm 54 N,m 15.5kgt.m, 40 rbf.ft)
Raisethe rearsuspension with 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 specified torque. 7. Check the rearwheel alignmentand adjustit necessary (seepage 18-41.
18-26
Brakes
19-1 ........ Brakes Conventional 19-31 Brake System(ABS)............. Anti-lock
GonventionalBrake
Special Tools ............. 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/Torque Specffications 19-28 ..... Parking Brake ........ 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 DiscThickness and Parallelism fnspection ..........19-12 Front BrakeCaliper Disassembly .......... 19-13 Reassembly ........... 19-16 MasterCylinder/Brake Booster Removal/lnstallation ....................... 19-21 PushrodClearance Adiustment ......19-22 BrakeBoosterInspection..............,, 19-23
Tools Special
Ret. No.
Tool Number 07JAG- SD40100
Description Pushrod Adjustment Gauge
Oty
'l
PagRetorencs
't9-22
9-2
Locations Component
lndex
BRAKE PEDAIInspection and page Adjustment, 19-5

BOOSTER MASTER CYLINDER/ARAKE page Removal/lnstallation, 19-21 page19_22 Adiustment, Pushrod Clearance page19'23 Brake Booster Inspection,
BRAKEHOSESLINES page 19-28 specifications, Inspection/Torque page'19-29 HoseReplacement,
BRAKE CABLE PARKING and Inspection RePlacement, page19-36 PARKING BRAKE page19 6 Adjustment, FRONT NOTE: There are two types of front brakecalipers: "5410" by typescan be identitied the The caliper "2056"stampd the caliper the body.Check on or type ol the brakecaliperbelore servicing Pads FrontBrake 5410Type:page19-8 2056Type:page19-10 FrontBrake Disc,page'19-12 FrontBrake Caliper 5410Type:page19'13 2056Type:page19-14 REARORUMERAKES page19-25 Inspection, Erake ShoeReplacement, Page19 26
19-3
and Inspection Adiustment

BrakeSystemRubberPartsand BrakeBooster
@ BrakeBoostel
the brakes. by Checkbrakeoperation applying lf the brakesdo not work properly,checkthe brake the booster.Replace brakeboosteras an assembly if it does not work properlyor if there are signs of leakage. Brake Hoses Visually checkfor damageor signsof fluid leakage. Replace brakehosewith a new one if it is damthe agedor leaking.
) Piston Cup and PressureCup Inspeqtion

. by Checkbrakeoperation applyingthe brakes. Visuallycheckfor damageor signs of fluid leakage. i R e p l a c eh e m a s t e rc y l i n d e ra s a n a s s e m b l y f t the pedal does not work properly or if there is damageor signsof fluid leakage. 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 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 . Replace the master cylinder if there is a differencein oedalstroke.
Caliper Piston Seal and Piston Boots the brakes, by Checkbrakeoperation applying Visually checkfor damageor signsof fluid leakage. lf the pedal does not operateproperly,the brakes drag. or there is damageor signs of fluid leakage, disassemble and inspectthe brakecaliper.Replsce the boots and sealswith new ones wheneverthe brakecaliperis disassembled,
@ Wheel Cylinder Piston Cup and Du3t Cover

. by the brakes. Checkbrakeoperation applying Visuallycheckfor damageor signsof fluid leakage. It the pedal does not operateproperly,the brakes drag, or there is damageor signs of fluid leakage, and inspectthe wheel cylinder.lf necdisassemble replace wheelcylinderas an assembly. the essary,
19-4
Brake Pedal
PedalHeight the brakeswitch connector,loosenthe L Disconnect brake switch locknut, and back off the brake switch until it is no longertouchingthe brakepedal. 2. the At the carpetcutout,measure pedalheightfrom the right sidecenterof the pedalpad. PUSHROD LOCKNUT
BRAKESWITCH
4.
Screw in the brake switch until its plunger is fully depressed(threadedend touching the pad on the oedal arm). Then back off the switch 1/4 turn to b m a k e 0 . 3 m m ( 0 . 0 1i n ) o f c l e a r a n c e e t w e e nt h e threadedend and pad. Tightenthe locknutfirmiy. Connect brakeswitchconnector. the CAUTION: Make sure that the brake lights go off when th pdal is relea3ed.
LOCKNUT
I
5.
MEASURING POINT{CUTOUT}
0.3 mm {0.0'lin)
below. Check brakepedalfree play as described the
PedalFreePlay 1. With the engine off, inspectthe play on the pedal pad by pushingthe pedalby hand. FreePlay:1 - 5 mm (l/16 - 3/16 in) 2. adjust lf the pedalfree play is out of specification, the brakeswitch. CAUTION: lf the pedal froe play i3 insufficient, it may result in brake drag.
Standsrd PedalHeight (with carpet removedl: M/T: 156.5 mm (5.15inl A/T, CW: 161mm 16 5/16 inl
I
3.
and screwthe pushrod Loosenthe pushrodlocknut, in or out with pliers until the standardpedal height After adjustment, tighten from the floor is reached. 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
LOCKNUT PUSHROD 15 N.m kg{.m.11 lbf.ftl 11.5
19-5
iInspection and Adjustment

Parking Brake
Inspection 1. Pullthe parkingbrakeleverwith 196N (20kgf.44 lbf) force to fully apply the parkingbrake.The parking brake lever should be locked within the sDecified notches. Levsr LockedNotches:6 - I Remove rearconsole the {seesection20), Pullthe parkingbrakeleverup one notch. Tightenthe adiustingnut until the rearwheelsdrag slightlywhen turned.
Pulled with 196 N (20kgf,44 lbf) up
AOJUSTING NUT
2.
are Adjustthe parkingbrakeif the lever notches out of specification. Release parkingbrakeleveriully, and checkthat the the rear wheelsdo not drag when turned.Readjust if necessary. Make sure that the parkingbrakesare fully applied when the parkingbrakeleveris pulledup fully. 7. Reinstall rearconsole. the
Adiustment loosenthe parkNOTE:After rear brakeshoe servicing, ing brake adjustingnut, $tart the engine, and depress the brake pedal severaltimes to set the self-adjusting brakebeforeadjusting parkingbrake. the 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: . Always use GonuinoHondaDOT3 BrakeFuid. Using a non-Honda brake tluid can cause corro3ion and dcr.ase th. liis ot tho 3wtam. . Mako suro no dirt or other foroign matter is allowd 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'on the 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 Add fluid as required. caliper. 1. Makesure the brakefluid levelin the reservoir at is the MAX (upperllevelline.
BLEED SCREW I N.m 10.9 m, 6.5 lbf.ftl kgl
FRONT:
MAX {UPPERI LEVEL LINE RESERVOIR CYLINDER MASTER
REAR:
Havesomeoneslowly pump the brakepedalseveral times,then applysteadypressure. Loosen the 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 scuretv.
4.
/ i
BLEED SCREW 7 N.m10.7 kgl.m,5 lbf.ftl
Repeatthe procedurefor each wheel in the sequence shown below until air bubblesno longer appearin the fluid. to Refillthe mastercvlinderreservoir the MAX (upoer)levelline.
BLEEDING SEOUENCE: O F ont Risht O RearRight
O Front Left
O Re.r Left
1 e t*
Front BrakePads
and Replacement Inspection
NOTE:Therearetwo tvpesof front brakecalipers: "5410"or b 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 d y t h e "2056" stamped on the caliperbody 8s shown below. the Check type of the brakecaliperbeforeservicing. 4. and pads. the pad shim. pad retainers Remove NOTE:When the caliperis equippedwith on outer pad shim, replacethe shim togetherwith the pads as a ser.
5410Typo: procedures, page see NOTE:For 2056type disassembly 19-10.
@ . Nver use an air ho3e or dry brush to clean brako

assemblies. Use 8n OSHA approved vacuum claner io avoid breathing brake dust.
1.
Loosenthe front wheel nuts slightly,then raisethe vehicle. and support it on safety stands. Remove the front wheels. from the knuckle. Remove brakehosebracket the Removethe caliper bolt, and pivot the caliper up out of the wav.
o t . U s i n g v e r n i e rc a l i p e r s m e a s u r e h e t h i c k n e s s f eachbrakepad lining. Brake PadThicknss: Standard: 9.5 - 10.5mm (0.37- 0.,t1 inl ServicoLimit: 1.6 mm (0.06in)
BOLT CALIPER
does not includepad backing NOTE:Measurement platethickness. is lf the brakepad thickness lessthan servicelimit, the replace front padsas a set.
f i
NOTE:Checkthe hosesand pin boots for damage and deterioration.
19-8
7 . Cleanthe caliperthoroughly;removeany rust.and checkfor groovesand cracks, o . Check the brakediscfor damageand cracks. Install the pad retainers.
12. Pushin the pistonso that the caliperwill fit overthe pads. Make sure that the piston boot is in position to prevent damaging it when pivoting the caliper down.
CALIPER BOLT N.m {3.3ksl.m, 24 lbnftl
rl ii 10. Apply greaseto the points indicatedby the arrows in the foilowingillustration: NOTE:Use the pad greaseincludedin the pad set or Molykote M77 grease,and apply a thin coat of points. grease evenlyto the designated . . . . . Pistonend and inner pad contactsurface contactsurface Padand caliperbracket Outerpad and caliperbody contactsurface OuterDadshim and outer oad contactsurface Outerpad shim and caliperbody contactsurface
t 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 , h e n i n s t a l l caliperbolt and tightenit. CAUTION: Be careful noi damage tho pin boot when pivoting tho caliper down. on 1 4 . Installthebrakehosebracket the knuckle.
WEARINDICAIOS
or NOTE: Inspectthe brake hose for interference twisting. OUTER PAO SHIM ] 1 5 . DeDress brakeDedal the several times to makesure work,then test-drive. the brakes N O T E : E n g a g e m e n o f t h e b r s k e m a y r e q u i r ea t greater pedal stroke immediately after the brake pads have been replaced a set. Severalapplicaas 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 pedalstroke. 1 5 . After installation, checkfor leaksat hose and line jointsor connections, retighten necessary, if and
INNER PAO OUTERPAD
5...1
ur
11. Install the brakepadsand pad shim correctly.
Whon reusing the pads, always reinstall the brake pads in thoir original positions to prevent loss of braking efficiency. Contaminatd brake disca or pads reduce stopping ability, Keopgreaseoff the discs snd pads. NOTE: lnstall the pad with the wear indicator on the inside.
(cont'd)
19-9
Pads FrontBrake
(cont'dl Inspection and Replacement
2056 Type: 5, Using vernier calipers, measure the thickness of eachbrakepad lining. Brake P8dThickness: 8.5 - 9.5 mm (0.33- 0.37 in) Standard: ServiceLimit: 1.6 mm (0.06in)
@ Nev6r usg an air ho3e or dry brush to cloan brakg

sssembligs. Usg an OSHA approved vacuum cleanor to avoid 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:Measurement does not includepad backing olatethickness. 6.

CALIPER
B BOLT NOTE;Checkthe hosesand pin boots for damage and deterioration. Remove pad shim, pad retainers and pads, the NOTE:When replacing the pads. replacethe shim togetherwith the as a set.
7. 8. 9.
is lf the brakepad thickness lessthan servicelimit. replacethe front pads as a set. Cleanthe caliperthoroughly;removeany rust, and checkfor grooves and crscks. Check brakediscfor damageand cracks. the lnstalltheoad retainers.
OUTER PAD SHIM Check wear. for

INNER PAD PAORETAINERS for Check weakness and damage. OUTERPAD
19-10
by 10. Apply greaseto the points indicated the arrows in the followingillustration: NOTE:Use the pad greaseincludedin the pad set or lvolykote M77 grease,and apply a thin coat of grease points. evenlyto the designated . . . . . Pistonend and inneroad contactsurface Padand caliperbracket contactsurface Outerpad and caliperbody contactsurface Outerpad shim and outer pad contactsurface Outerpad shim and caliperbody contactsurface
12. Pushin the pistonso that the caliperwill fit over the pads.Make sure that the piston boot is in position to preventdamaging it when pivoting the caliper oown.
PISTON
CALIPER BOLTB 26 N.m {2.7kgl.m, 20 tbt.ftt
WEARINDICATOR
OUTERPAD OUTER PADSHIM
t 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 , h e n i n s t a l l caliperbolt B and tightenit. on 1 4 . lnstallthe brakehosebracket the knuckle. and NOTE:lnspectthe brakehose for interference twistrng. times to makesure 1 5 . Depress brakepedalseveral the work,then road-test. the brakes t N O T E : E n g a g e m e n o f t h e b r a k e m a y r e q u i r ea greater pedal stroke immediately after the brake pads have been replaced a set. Severalapplicaas 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 pedalstroke. After installation, checkfor leaksat hose and line jointsand connections. retighten necessary. if and
11. Install the brake pads and pad shim correctly.
o When reusing the pads, always reinstall the brake pads in their original positions to prevent loss of braking efficiency. . Contaminatd brake discs or pads reduca stopping ability. Keepgrea3off the discs and pads. o N O T E :I n s t a l l h e p a d w i t h t h e w e a r i n d i c a t o r n t the inside,
19-1 1
FrontBrakeDisc
DiscRunoutInspection
t. Loosenthe front wheel nuts slightly,then raisethe vehicle, and support it on safety stands.Remove the front wheels. Remove the brakepads(seepage19-8). Remove brakepads(seepage 19-8). the 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 . Clean the discthoroughlyand removeall rust.
4,
DiscThickness Parallelism and

Inspection
1 . Loosenthe front wheel nuts slightly.then rsisethe vehicle. and support it on safety stands, Remove the front wheels.
Use wheel nuts and suitableplain washersto hold the disc securely againstthe 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: in) ServiceLimit 0.10 mm {0.00,1
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 (0.4in) in from the outer edgeof the disc.
W{EEL NUT AND PLAINWASHER 108 N.m (11kgf.m,80lbtft)
BrakeDisc Thicknsss: Standard:20.9- 21.8 mm {0.82- 0.86 in) Limil: 19.0mm (0.75in) Max. Refinishing NOTE:ReDlace brakedisc if the smallestmeathe limit. surementis lessthan the max. refinishing inl Erake Di3c Parallelism:0.015mm 10.0006 max.
lf the disc is beyond the servicelimit, refinishthe brake disc with an on-car brake lathe. The KwikLathe produced by Kwik-way manufacturingCo. and the "Front BrakeDisc Lathe" offeredby Snapfor on ToolsCo.are approved this operation. M8x. Retinish Limit 19.0mm (0.75inl if NOTE:A new disc shouldbe refinished its runout in) is greater than 0.10mm (0.004
NOTE: This is the maximum allowabledifference betweenthe thicknessmeasurements. limit for parallelism, lf the disc is beyondthe service refinishthe brake disc with an on-car brake lathe. The Kwik-Latheproduced by Kwik-WayManufac"Front ErakeDisc Lathe"offered turing Co. and the by Snap-onTools Co. are approvedfor this operatron. NOTE:Seesection18for brakedisc replacement.
19 -1 2
Front BrakeGaliper
Disassembly
NOTE:Therearetwo typesof front brakecalipers: "5410"or b 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 d y t h e "2056" stampedon the caliper body as shown below. the Check type of the brakecaliperbeforeservicing. 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 calioerbracket. PIN CALIPER B CALIPER BRACKET
5410Type: procedures, page see NOTE:For 2056type disassembly '19-13.

PIN CALIPER A
Nsvr use an air hose or dry brush to clean brake assemblics. Use an OSHA approved vacuum clganer to avoid breathing brake dust. CAUTION: . Do not spill brske tluid on the vehicle; il may damage 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 passages with compressedair. L Removethe banjo bolt, and disconnectthe brake hosefrom the caliper. CALIPER
EANJO SOLT
lf necessary, apply compressedair to the caliper fluid inlet to get the pistonout. Placea shop rag or wooden blockas shownto cushionthe pistonwhen air it is expelled. Use low pressure in shortspurts,
. .
Do not place your fingrs in froni ot tho piston. 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 approved 30 PSInozzle.
Removethe pistonfrom the caliper,and checkthe pistonfor scoring. Remove boot clip,pistonboot and pistonseal. the CAUTION:Take care not to damagethe cylinder bore.
SEAL PISTON Replace. SEALING Replace. BOLTS CALIPER
BOOTCLIP Beplace.
Removethe caliperbolts, then remove the caliper from the bracket.
\ \
,
BODY CALIPER for Check scoring PISTONBOOT Replace. {cont'd)
19-13
L
Front Brake Caliper

2056Type: 4.
@ use an air hose or dry brush to clean brake . Never

. assemblis. Use an OSHA approved vacuum cleaner to avoid breathing brak dust,
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. CALIPER SODY Check scoring for

on cytinder wall.
CAUTION: . Do not spill brake fluid on tha vohicle; it may dsmage the paint; if brake tluid dos contaqt the paint. wash it otf immdiately 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 pasragoswith compressedair. 1. Removethe banio bolt, and disconnectthe brake hosefrom the calioer.
WASHERS SEALING Replace.
/
SLEEVE I Replace.
st EEVE I
Check damage. lor 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 pressure in shortspurts. air
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.
for Check damage.
GUIDEPIN BOOT Replace.
Removethe pistonfrom the caliper,and checkthe piston for scoling.
CALIPER BRACKET Check cracks. Ior
19-1 4
7.
Remove boot clip, pistonboot and pistonseal. the CAUTION:Take care not to damage the cylinder bore.
800T cLtP Replace.
SEAL PISTONEOOT Replace.
Front BrakeGaliper
Reassembly
5,110 Type: procedures. page 19-18, NOTE;For 2056type reassembly see
o . . .
Never use an air hose or dry brush lo clan brske t$embliss. Use on OSHA approvsd vacuum cleanerto avoid breathing brako dust, Contaminatedbraks discs or pads reducestopping ability. when teusing the pads, always reinstall the brake pads in their original positions to prevent loss ot braking cfficiancy.
CAUTION: . Do not spill brak lluid on the vehicle; it may damage tho paint; if brrke lluid does contact the paint, wash it off immediately with water. . Cleanall parts in brake fluid 8nd air dry; blow out all pa$ages with compr63sedair. . Bofore rea$embling, checkthai all parts a.o froo of dust and other lorsign particlog. . Roplacepart3 with nw 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. . Replace rubberpartswith new oneswhenever all disassembled. #r-anrrsr-H: recommended Use rubbergreasein the cslipersealset. -61' Userecommended sealgreasein the calipersealset.
WEABINDICATOR R TO
t \ '
(ln |trf,
R
rMA
BEAKEPAOS
PIN BOOTS Replace.
CALIPER BRACKET MOUNTINGBOLT
_41
\ \J q l c A \\r li
BRACKET
oUTER PADSH|M
---+-s'
ta,
caupeaetNa/
PADRETAINERS .H!!q9ril PISTON SEAL PISTONBOOT Replace. Replace.
=..
-6r
/
BLEED SCREW 9 N m (0.9kgr.m,6.5 lbf.ft) CALIPEB BOOY
eoorcue
Replace.
A] wo
19-16
1 . Cleanthe piston and caliperbore with brakefluid, for and inspect wear and damage. Coat the new Diston seal with the recommended rubbergreasein the caliperseal set.and installthe sealin the cylindergroove, seal greasein the caliper Apply the recommended seal set to the sealinglips and insideof a new piston boot. and secureinstallit in the caliperwith the new boot clio. CAUTION: 8o carelul not to damage the caliper cylinder wall.
Apply the recommended seal greasein the caliper seal set to the sliding surfaceof the pins and the insideof the new Dinboots, Installthe pin boots into the groovesin the caliper properly. bracket
PIN BOOT\ Replace. - \
CALIPER
CALIPER BRACKET
.@] PIN CALIPER B
PIN BOOTS Replace. PISTON SEAL Replace.

,->---!!!!!Lil RUBBER GREASE
=^.
-6,l
CALIPEF PIN
PISTONBOOT Replace. .,'.{@l GREASE SILICONE
7. Insertpin A and pin B into the caliperbracket. 8. Installthe pin boots into the grooves in the pins properly. (see 9. Installthe brakepads in their originalpositions page 19-9). 10- Pushin the pistonso that the caliperwill fit overthe pads,and installthecaliper. 11. Tightenthe caliperbolts. 12. Connect brakehoseto the caliperwith new sealthe ing washers, and tightenthe banjobolt.
BANJO BOLT 34 N.m (3.5kgl.m.25lbf ft) SEALING WASHERS Replace.
a L u b r i c a t eh e c a l i D e r n d p i s t o nw i t h b r a k ef l u i d . t with the dished then installthe pistonin the cylinder end facingin.
BOLT CALIPER 32 N.m {3.3ksf.m,24lbf.ft}
1 3 . Fill the brakereservoirand bleedthe brakesvstem

{seepage 19-7). 1 4 . Perform followingchecks. the . Checktor leaksat hose and line joints and conif nections, and retighten necessary. . Checkfor brakehosesfor interference twisting. and (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. . Clanall 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. . Rplaceparts 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 Reolace rubberDarts with new oneswhenever all disassembled. c''-"{@: -Gr, Use recommended rubbergreasein the calipersealset. use recommendedseargreasein the caliper searset. BRAKE BNAKE PADS PADS N
WEARINDICATOR OUTERPAO
@f "\
ERACKET MoUNTTNG BoLT _.-cALrpER toe ru'- {tt.o kg{.m. rbtft) 80 \ A-t -.ALTPER BRA.KET
ir*l;r**t,;;ll;-fn
culoEP,NBoor \\
--\_^
'l M lll r)
/ H, I ll I
*6ry-l' I
'ADRETA,NER
Pl
6"1
\ l lt l d 6 % . -t'.---.-o . , " , ""'*nW **-y. . ( b u " * ""-,t"oo*tJ*,

\l
\
s N.m ksr.m,6.s tbr.ft) ro.s
BLEED SCREW
SLEEVE A
'-b#\S"^.(*r1
tr._ \
/\
I
^/-^^..
YffA"
mFZ\
,o,,,,"o,,"/ W 26N.m{2.7ksf.m.2orbftt}
l.'
Tffi
\Uf->" | l(// )A{
-,P,sroNBoor Reorace.
;if;rqq
80()TcLtP Replace.
19-18
'1.
Cleanthe piston and caliperbore with brakefluid, for and inspect wear and damage. rubCoata new pistonsealwith the recommended ber greasein the calipersealset,and installthe seal in the cylindergroove. seal greasein the caliper Apply the recommended seal set to the sealinglips and insideof a new piston boot, and secureinstallit in the caliperwith a new boot clip. CAUTION: Be caretul not to damage the calipel cylinder wall.
4.
Lubricatethe caliper and piston with brake fluid, 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.
BOOTCLIP Replace.
5.
seal greasein the caliper Apply the recommended seal set to the sliding surfaceof sleeveB and the insideof the new pin and sleeveboots. 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
6.
Replace.
-e1
SILICONE GREAS
Replace. re---. - :-!!!r!ail RUBBER GREASE
B SLEEVE
P IN BOOT Replace,
Y
(cont'd)
19-19
Front BrakeCaliper
(cont'd) Reassembly
7 . Apply the recommended seal greasein the caliper
seal set to the sliding surfaceof sleeveA and the insideof a new guide pin boot. 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 sleeve A. Make sure that the brake pad retainersand brake padsare in their originalpositions {seepage 19-10).
1 1 . Connectthe brake hose to the caliperwith n"w a6aling washers. and tightenthe banjobolt,
12. Tightenthe caliperbolt B.

BANJO BOLT 34 N.m{3.5kgf.m,25 lbt.ftl
26 N.m(2.7kgf.m, lbt.frl 20
1 3 . Fill the brakereservoir and bleedthe brakesystem (seepage19-7). 1 4 . Performthe followingchecks. o Checkfor leaksat hose and line joints and connections, and retighten necessary. if . Checkfor brake hoses for interferenceand twistIn g .
10. Installthe caliperonto sleeveA, and pivot it down into position. NOTE:Installthe guide pin boot into the groove in the caliperproperly.
SLEEVE A
_ 1
19-20
Booster MasterCylinder/Brake
RemovaUlnstallation
CAUTION: . 86 carefulnot to bend or damagethe brake lineswhen removingthe mastercylinder. . Do not spill brake fluid on tho vehicle; it maY damage the paint; if brake tluid doas contaqt the paint, wash it off immediately with water. . To prevent spill3, cover thg hose ioints whh rags or shop towels. the 1 . Disconnect brakefluid levelswitchconnectors. cap trom the mastercylinder. the 2 . Remove reservoir ? The brakefluid may be suckedout throughthe top with a syringe. of the mastercylinderreservoir the Disconnect brakelinesfrom the mastercylinder' 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. 6. Removethe mastercylinderfrom the brakebooster' the 7. Disconnect vacuum hosefrom the brakebooster' the 8. Remove cofterpin and clevispin from the clevis' CAUTION: Do noi disconnect the clovis by remov' ing it from ths operating rod of the brake booster' lf the clevis is loosenod, adiust the pushrod length before installingthe brake booster (seepage 19-221 the 9. Remove four boostermountingnuts 10. Pull the brake booster forward until the clevis is clearof the bulkhead. 11. Removethe brake booster from the engine companmenr. 12. lnstallthe brakeboosterand mastercylinderin the orderof removal. reverse CAUTION: . When connecting the brake lines, make sure that lhere is no intrterence between the brake lines and other Parts. . Be caretul not to bend or damagethe brake lines when installing the master cylinder. t N O T E : l f r e p l a c i n g h e m a s t e rc y l i n d e ro r b r a k e c b o o s t e r , 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 beforeinstallingthe mastercylinder(seepage 19-22\. , 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 n d b l e e d t h e brakesystem(seePage19-7). checkthe brakepedal height and 1 4 . After installation, pedal free play (see page 19-5)and adjust if brake necessary. BRAKE BOOSTER (With brake boosier) ABS: . S" tandem 7"
-6ll
CLEVIS PIN
BRAKEFLUIDLEVEL SWITCH CONNECTORS MASTEFCYLINDER VACUUM HOSE
WheelCylinders To Rear 13 N.m {1.3kst m,9 lbtft) To FrontCaliper (Without ABS)
.--VALVE CONTROL PROPORTIONING
15 N.m (1.5kgf.m, 11 tbt.ft)
15 N.m (1.5ksf'm,11lbfft) (WithABSTTo unit) modulator
19-21
MasterGylinder/Brake Booster
Pushrod Clearance Adjustment
NOTE: . Master pushrod-to cylinder piston clearance mustbe checked adjustments and made, necessary, if before
installing mastercylinder. ABStype is shown,conventional brake tvpe is similar.
l.
Setthe specialtool on the mastercylinderbody; push in the centershaft until the top of it contactsthe end pistonby turningthe adjusting of the secondary nut.
PUSHROD ADJUSTMENT GAUGE 07JAG- SD'(}l00 SECONDARY PISTON ADJUSTING NUT
N O T E :l f t h e c l e a r a n c e e t w e e nt h e g a u g e b o d y b 8nd adjustingnut is 0.4 mm 10.02 the pushrodin), to-pistonclearance 0 mm. However,if the clearis ance betweenthe gauge body and adjustingnut is 0 mm, the pushrod-to-piston clearanceis 0.4 mm (0.02in) or more.Therefore must be adjusted it and rechecked. 6. lf clearance incorrect, is loosenthe star locknutand turn the adiusterin or out to adjust. NOTE: Adjust the clearance while the specified vacuum is appliedto the booster. Holdthe cleviswhile adiusting. 7 . Tightenthe star locknut securely.
CENTER SHAFT
MASTER CYLINDER
8. Remove special the tool. - 0 . 4m m{ 0 - 0 . 0 2n l 0 i

STARLOCKNUT 22 N.m 12.2kgt m, 16 lbf.ft) CLEVIS
2.
Withoutdisturbing centershaft'sposition, the install the specialtool upsidedown on the booster. Installthe mastercylinder nuts and tighten to the sDecified toroue. Connect boosterinline with a vacuumgaugeOthe 101 kPa (0 - 760 mmHg, 30 in.Hg)to the booster's e n g a n e 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 v speedthat will deliver66 kPa(500mmHg,20 in.Hg) vacuum. With a feelergauge,measure clearance the between the gaugebody and the adjusting as shown. nut Clearance: - 0.4 mm (0 - 0.02 in) 0
VACUUM GAUGE {Commercially aveilable) 0 - 101kPe {0- 760mm Hg,30 in.Hgl
PUSHROD ADJUSTMENT GAUGE 07JAG- SD40100
9. Adjust the pushrodlength as ts removed.

'11610.mm 5 (4.5710.02 in)
AOJUSTING NUT HOSE Connect hoseof a suitable diameter.
CYLINDEB NUT FEELER GAUGE

1 5 N . m 1 1 . 5k g f . m , 1 1 l b f f i )
PUSHROD LOCKNUT 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 then several times to depletethe vacuum reservoir, lf the depress pedalhard and hold it for 15 seconds. 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 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 g o n t r o l valve.or caliper) leaking. is 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, vacuumboosteris operating the 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 t 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 e o h o l d b a c k c a u t o m a t i c r a n s m i s s i o n r e e p .l f t h e b r a k ep e d a l t 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 to changes vacuumavailable the booster.) the Leak Test the brake pedal with the engine running, 1. Depress then stop the engine. lf the pedal height does not for the vacuum varv while depressed 30 seconds, 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 h e n t h e pedal is first depressed, should be low. On conit the secutive applications, pedalheight shouldgradually rise.lf the pedalpositiondoes not vary, check the boostercheckvalve. Booster CheckValve Test 1. Disconnect the brake boostervacuum hose at the booster. 2. Startthe engineand let it idle.Thereshouldbe vacthe checkvalve is uum. lf no vacuum is available, not working properly. Replacethe brake booster vacuumhoseand checkvalve,and retest. BRAKE BOOSTER HOSE VACUUM
( C h e c kv a l v e built-in)
19-23
Rear DrumBrakes
Index/lnspection
a a a a
N6vr use an air hos or dry brush to clean brako assemblies. Use an OSHAapproved vacuum cleanerto avoid brealhing brake dust. Contaminatedbrake linings or drums reducesiopping ability. 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. Release parkingbrake, the and removethe rearbrakedrum.
I N.m {0.9 kgt m, 6.5 lbf.ftl
WHEEL CYLINOER Inspect leakage. for It necessary, replaceas an assembly.
u-cLtP
Replace.
@
PIVOTPIN TENSIONPIN
UPPER RETURN SPRING Check weakness for ano oamage.
10 mm BOLT 64 N.m {6.5 kgf.m,
/ {-l
cLEV'sB /
47rbf.ft)
^ "*'"i II
( r
SELF.ADJUSTER SPRING Check weakness for ano oamage,
/ |
/
/
,.to,n.*.r*,"n
, Install securely on tensionpin.
&d / / ts
AOJUSTER EOLT Checkratchetteeth {or wear and damage.
BRAKESHOE lnspection, page19 30 see lf brakeshoesare to be reused, markand reassemble in sameposition.
LOWERRETURN SPRING lor Check weakness and damage-
19-24
Inspection
1.
Jor the Check wheelcylinder leakage. glazing,wear Checkthe brake liningsfor cracking, and contamination,
6.
M e a s u r e 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 t usingthe insideverniercalipers, Drum lnside Diametr: 199.9- 200.0mm (7.870- 7.874in) Standard: in) ServicsLimh: 201.0mm (7.913
INSIDEVERNIER CALIPERS
2.
the 3. Measure brakeliningthickness. Brake Lining Thicknoss: /1.0mm (0.157in) Sisndard: 2.0 mm (0.08in) ServiceLimit:
WHEELCYLINDER
7.
lf the inside diameter of the brake drum is more the limit, replace brakedrum. than service 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 cracks.
8. does not include brakeshoe NOTE: Measurement \ thickness, r l f t h e b r a k el i n i n g t h i c k n e s s s l e s st h a n s e r v i c e the limit, replace brakeshoesas a set 5. in the bearings the hub unit for smoothoperCheck referto section18. ation.lf defective,
RearDrumBrake
Brake Shoe Disassembly
1. R e m o v e 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 t springsand turningthem. 6, Removethe wave washer,parkingbrakelever and pivot pin from the brakeshoe by.emoving the UcliD.
PARKINGERAKE LVER
WAVE WASHER
@G
u'cLrP
RETAINER SPRINGS Lower the brake shoe assembly,and remove the lower returnspring. NOTE:Be carefulnot to damagethe dust cover on the wheelcylinder. Remove the brakeshoe assembly. Disconnect parkingbrakecablefrom the parking the brakelever. Removethe upper returnspring,self-adjuster lever a n d s e l f - a d j u s t es p r i n g .a n d s e p a r a t e h e b r a k e r t shoes.
ADJUSTER BOLT Checkratchettoeth tor wear ano damage. UPPER RETURN SPRING Check weakness for ano oamage.
Replace.
BrakeShoeReassembly
1.
Apply brake cylinder grease (P/N:08733- 8020E)or equivalentrubber greaseto the sliding surfaceof the pivot pin, and insertthe pin into the brakeshoe. Installthe psrkingbrakelever and wave wasneron the pivot pin and secure with U-clip, NOTE: Pinchthe U-clip securelyto preventthe pivot pin from coming out ofthe brakeshoe.
r\ r
\'
I
io
.: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 brakelever. Apply grease eachslidingsurface. on contaminated brake linings reduce @ stopping ability. Keep greaseor oil off the brake lin' ings. Wipe any excessgraseoft the parts. . Apply brakecylindergrease(P/N:08733 8020E) or equivalentrubber greaseto the sliding surfacesas shown.
A the Clean threadedponionsof clevises and B. Coat the threads of the cleviseswith grease.To turn the adjusterbolt. shorten the clevises, spring to the self-adjuster 6. Hook the self-adjuster leverfirst,then to the brakeshoe. 1 . Installthe clevisesand upper return spring noting direction, the installation NOTE;Be carefulnot to damagethe wheel cylinder dust covers. 8. Installthelower returnsPring.
-|a
Slidingsurface
springs. the 9. Install tensionpins and retaining
SPRING RETURN UPPER
B CLEVIS
A CLEVIS
SELF-ADJUSTER SPRING . 44MAto the brakeshoeendsand Apply Molykote oppositeedgesof the shoesas shown.
+a -)o
Opposite edge of the shoe Brake shoe ends
1 0 . Installthebrakedrum.
1 1 . lf the wh6el cylinderhas been removed.bleedthe brakc system (see page l9-6), and checkfor leaksat if and brakeline connections, retighten necessary. 1 2 . Depressthe brake pedal severaltimes to set the self-adjustingbrake.
1 3 . Adjusttheparkingbrake(seepage l9-6).
19-27
Brake Hoses/Lines
Inspection/Torque Specif ications
1. Inspect brakehosesfor damage, the deterioration, leaks, interference twisting. and 2. Check brakelinesfor damage, the rustingand leakage. Also checkfor bent brakelines. 3. Check leaksat hoseand linejointsand connections, retighten necessary. for and if 4. Check mastercylinderand ABS modulatorunit for damageand leakage. the CAUTION: Replace the brake hose clip wheneverthc brake hose is serviced.
ABSMODULATOR UNIT-Io-BRAKE L|NE 19N.m11.9 m. 1albtftl kgt

PROPORTIONING CONTBOL VALVE. Io.BRAKELINE 15 N.m (1.5kgf.m, 11 lbf.ft) MASTER CYLINDER.TO.ARAKE LINE 15 N.m {1.5 ksf.m, 11 lbf.ft}
aRAKE LINE-Io-WHEEL CYLTNDER 15N.m11.5 kgf.m, lbtft) 11 BLEED SCREW 7 N.m{0.7 m, 5 lbl.frl kgt
SRAKELINE-Io-BMKEHOSE 15 N.m (1.5kgf.m, 1r lbnftl
BRAKELINE-IO.BRAKE HOSE 15 N'm {1.5kgf.m,11lbf ftl
BRAKE HOSE-io-CALIPEB BOLT} IBAIUJO 3l N.ln(3.5 ksf.m,25 lbf'ft}
19-28
HoseReplacement
CAUTION: o Before reas3embling,check that all parts are free ol dust and other toreign particles. . Replaceparts with new ones whenever spcified 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. cracked, ReDlace brakehoseif the hoseis twisted, the or if it leaks, the Disconnect brakehosefrom the brakeline using a 10 mm flare nut wrench. FLARE NUT
(Commercially available) BRAKE LINE
6, lnstall the brake hose bracketand brake hose on the knucklefirst, then connect the brake hose to the washers caliper with the baniobolt and new sealing
6 mm HOSEERACKET BOLTS 9.8 N.m {1.0 ksf.m, 7 lbf'ft)
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.
the Connect brakelineto the brakehose. the brakehose,bleedthe brakesys9 . After installing t e m ( s e ep a g e ' 1 9 - 7 ) . 4. Removethe banjo bolt, and disconnectthe brake hosefrom the caliper. from the knuckle. Remove brakehosebracket the the 1 0 . Perform followingchecks. and . Check the brakehose and line joint for leaks, tightenif necessary. . Check the brakehosesfor interferenceand twistIng.
5.
19-29
ParkingBrakeCable
Inspection and Replacement
CAUTION: The parking brake cables must not be bent or distortad. Thi3 will lad to stiff operation and premature cable failure.
PARKING BRAKECABLE Check faultymovement. for
PARKING BRAKESWITCH
Removethe parkingbrakecablefrom the backingplate usinga 12 mm offsetwrenchas shown,
BACKING PLATE
19-30
Anti-lockBrakeSystem(ABS)
19-32 ...'......... SpecialTools 19-33 ....."..............'... Locations Component (ABSI Anti-lock Brake System 19-34 .....'...'.......... Features/Construction 19-35 '.............. Operation 19-38 ......... GircuitDiagram ABS Control Unit Terminal ......... 19-40 Arrangement " " " 19-42 Precautions....,.. Troubfeshooting TroubleCode (DTG) Diagnostic .. Diaonostic Trouble Gode (DTCI 19-44 ........... a lnaication 19-45 ........... DTCErasure 19-46 Symptom-to SystemChart .....'....... 19-52 ........ Wheel Sensor 19-54 ................. Solenoid 19-56 ABS PumpMotor ............................. 19-59 ..........." Main Relay .... 19-60 lgnition Voltage 19-61 Unit (CPU)........ CentralProcessing Modulator Unit 19-62 ....................... Removal/lnstallation ABS Control Unit 19-6:l .....'... Replacement Pulsers/WheelSensors 19-63 ..........."' Inspection 19-64 .......'.... Wheel SensorReplacement
Troubleshooting ABS Indicator Light Does Not 19-48 ............ ComeOn ABS IndicatorLight DoesNot 19-50 Go Off ............................................
SpecialTools
Rsl. No.
Tool Number
Description connector SCSService
Oty 1
Page Retorence 19-44
07PAZ 0010100
19-32
Locations Component
CHECK CONNECTOE SERVICE I2PI MODULATOB UNIT ABS CONTROL UNIT
RIGHT-REAR WHEEL SENSOR CONNECTOR RIGHT.REAR WHEELSENSOR
ABS UNOER.HOOO BOX FUSE/RELAY
LEFT.REAR WHEEL SENSOFCONNECTOR FUSE/RELAY BOX UNOER.OASH WHEEL LEFT.FRONT SENSOR CONNECTOR LEFT-FRONT WHEELSENSOR
BOX FUSE/RELAY UNDER-HOOO
rcl (40 FUSE A'
nnn
-r n -fl LIJ'- rr rr fl n LJ LJ I]
f l ft l n t t
Q!!
I,
ABS INDICATOR LIGHT
(15 HORN/STOP A) FUSE
BOX FUSE/RELAY UNDER.DASH METER A} FUSE {7,5
BOX ABS FUSE/RELAY UNDER-HOOD ABS +B {20 A} FUSE PUMPMOTORI40 A) FUSE
u [0000 0 0 0 0 [ 0000 0000[[

PUMPMOTORBEI-AY RRDEFRLY{7.5A) FUSE MTRCHECK AI FUSE {7,5
0000 n
19-33
Features/Construction
when the brakepedalis depressed duringdriving,the wheelscan lock beforethe vehiclecomesto a stop. In sucha case. the maneuverability the vehicleis reduced the front wheelsare locked, of if and the stabilityof the vehicleis reduced the if rearwheelsare locked. creatingan extremelyunstable condition. The ABS precisely controlsthe slip rate ot the wheelsto ensurethe grip forceof the tires,and it therebyensures maneuverbility stabilitvof the vehicle. the and Judgingthe vehiclespeed, ABS calculates slip rate of the wheelsbasedon the vehiclespeedand the wheetspeed. the the then it controlsthe brakefluid pressure attainthe targetslip rate. to
Grip Force ol Tire and Road Surface COEFFICIENT OF FRICTION TARGET SLIPRATE
STOPPOINT
A: Distancewithout slio B: Slipped distance C: Actual distanceto stoo SLIPRATE
sr.re =f nnre
19-34
Operation
ABS Control Unit
Main Control then it calculates vehicle the the wheel speedbasedon the wheel sensorsignalit received, The ABS control unit detects basedon the wheel speed.The control unit detectsthe vehiclespeedduring deceleration speed basedon the detected rateof deceleration. u t h T h e A B S c o n t r o lu n i t c a l c u l a t ets 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 s 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 r n i t w s o l e n o i d a l v e h e nt h e s l i pr a t ei s h i g h . v pressure and pressure intensi reduction, retaining that is pressure reduction controlis a three modesystem, The pressure fvino modes.
ABS CONIFOLUN T
Function Sell-diagnosis checkeachother. with a main CPUand a sub CPU,and the CPUS The ABS controlunit is equipped circuitof the system. The CPUS checkthe "systemdown mode" or the "controlinhibitionmode". they shift to the Whenthe CPUsdetectfailure, MODE SYSTEM DOWN CONTROL INHIBITION R A B SI N D I C A T OL I G H T ON ON MAIN RELAY No operation SOLENOID VALVE
Drive inhibition
CPU
Operation'l
Restartcondition
DTC Memory
lMemory
lgnition OFF ON switch Automatic
Drive No operation inhibition
Operation
+ 1 : E x c e p tC P U f a i l u r e
into thesefour categories. can The self-diagnosis be classifield l O r I n i t i ad i a g n o s i s ABS control @: Except D ur i n gA B Sc o n t r o l O: ( D :D ur i n gw a r n i n g On-board DiagnosisFunstion (16P) to The ABS controlunit is connected the data linkconnector with the HondaPGMTester' The ABS systemcan be diagnosed
(cont'd)
19-35
Operation {cont'd)
ABS Modulator The ABS modulatorconsistsof the inlet solenoidvalve, outlet solenoidvalve, reservoir,pump, pump motor and the damping hamber. c The modulator reduces caliper fluid pressure the directly. and it is alsoreferred as a circulating to type because brake fluid the circulates throughthe caliper, reservoir the master and cylinder. pressure The hydraulic reduction, controlhasthreemodes:pressure retaining and pressure intensifying. The hydraulic four channel circuitis the independent type, one channel eachwheel. for
SOLENOID VALVE
PUMPMOTOR
RF
LF
( l N : I N L E T V A L V EN O F M A L L Y P E N ) O OUT: OUTLETVALVE (NOFl\,4ALLY CLoSED)
Pressure intensiiying model Inletvalveopen,outletvalveclosed lvlaster cylinder fluid is pumpedout to the caliper. Pressure retaining mode: Inletvalveclosed, outletvalveclosed Caliper fluid is retained the inletvalveand outletvalve. bv Pressure reduction mode: Inletvalveclosed, outletvalveopen fluid flows throughthe outletvalveto the reservoir. Caliper Motor operation mode: Whenstaningthe pressure reduction mode,the pump motor is ON. When stoppingABS operation, pump motor is OFF. the The reservoir fluid is pumpedout by the pump,throughthe dampingchamber, the master to cylinder.
19-36
Wheel Soeed and Modulator Control
S VEHICLE PEED VEHICLE SPEED REFERENCE
WHEEL SPEED
OUTLET VALVE ON OFF INLET VALVE ON OFF MOTOR ON OFF to the Whenthe wheelspeeddropssharplybelowlhe vehiclespeed, inletvalvecloses retainthe caliperfluid pressure. to When the wheel soeeddrops further,the outletvalve opens momentarily reducethe caliperfluid pressureThe pump motor startsat this time. the to the As the wheel speedis restored, inletvalveopensmomentarily increase caliperfluid pressure. Wheel Sensol type. contactless are The wheelsensors the magnetic changes The magnetic coil,AC currentis generated. AC frequency As the gear pulserteeth rotatepastthe wheel sensor's and therebydetects the The ABS control unit detects wheel sensors;gnalfrequency wheel speed. with the in accordance the wheelspeed. one for eachwheel. Thereare four wheelsensors, The gear pulserhas50 teeth.
GEAR PULSER
at LOW SPEED
19-37
CircuitDiagram
UNDEF.OASH
LEFI.FBONT N SOLE OIO
-Fm-Feiu
.-..@u*
F GHi.FRONTSOLENOID
YE!8IK-1
REDDTU YELTLU
-FO -YTL-
BtKa
ABS UNDER.HOOD FUSE/RELAY BOX (a) 3PCONNECTOR number) I 2 3 l
UNOEF DASH FUSE,/BELAY BOX 20P CONNECTOR(C number)

l
M O D U L A T OU N I T1 O P O N N E C T O R R C (C number)
2
ll 15
5 6 18 1920
t0 11
UNDER.HOOD FUSE/RELAY ABS BOX 2PCONNECTOR number) i! a 1 , f
UNDEB.DASH FUSE/RELAY BOX ( 1 8 PC O N N E C T O Rf n l m b e r ) 1 2 3 alr,:15 6 21314/ 1 6 t7 ,/ P U M PM O T O R P C O N N E C T O R 2 (fl n!mber) 9 t0 Il
GAUGE ASSEMBLYCONNECTOR 5P (O numbsr) l 1 l / 3
fl"
5 l
WIRE SIDE FEMALE OF TERMINALS
19-38
fi
I
E C MI P C M I S C S ) GF|//vvHI--GR^L&Hr
V
n-, '_ l n '
rB
rL
cor, coz rr6P) I? l3lcoNNEcroF
n IoaTALNK
8tK
la 3
A ^
t'-
cot, ctoz
BTK
wln/GFN---E
-"**d
RIDE!I] YtlrBlll B!!/YEt GNDl
Tep*'
;--l
*l:,1.J
ABS CONTROL UNIT26P CONNECTOR (C number)
cnoic.oz cnoicloz
SERVICE CHECK (2P) coNNECTOF
2 3
15 11
/ : a 9 10
t2 tl 25 2E DATALINK coNNECTOB (16P)
WHEEL ENSOR S 2P CONNECTOF] FRONT
t9
./ zt / 123
llllrh
REAR
CONNECTOR ABSCONTROL UNIT22P (l number)
4 /",/lt
12
/),
l0 tt 21 22 W I R ES I D EO F F E M A L E E R M I N A L S T
1 i / 1 9 /
lT,tTl l-rl
T E R M I N AS I O EO F L MALETERMINALS
19-39
ABSGontrolUnit Terminal Arrangement

ABSCONTROL UNIT26PCONNECTOR
I ;:,
7-rt-Il:
I .li
VB: BatteryVoltage
WIRESIDEOF FEMALE TERM
Terminal numbel
Wire color
Tormind sign ITermin.l namol
Voltago Description
tafininlb
Condition3 (lgnition Switch ON (lll)
Output voltagg
PCOt\4 GRN^r'VHI (Primary common) BLIqWHT (Secondary common) BLK/BLU

(lgnition2) RRO BLU//EL (Rear-right 0)
Power source the solenoid tor valveandpumpmotor.

Power sourcelor the solenoid
1-GND
2
3
scoM
2.GND
Detects ignition switch 2 signal.{Systemactivatesignal) Detects right-rear wheel sonsorsrgnal.
6 OFF OFF the service] lConnect SCS connector l \
ON
ON
OV AC:3-6 V Approx. V 3 VB
3-GND
GRY
8 I GRN
RLO (Rear-left 0)
FRO (Front-right 0)
Detects left-rear wheelsensor s r g nla .

Detects right-front wheel sensorsrgnal. Detects brake switch signal. unnecessaryABS {Prevents operation) Detects left-front wheel sensor signal.
GRNA/VHT
STOP (Stop)
53mVorabove on digitaltester {AC Whenthe wheelis (Referance) turnedat 1 turn/second. range) 150 mvtrporabove onoscilloscope 8-21 Stops ADprox.2.5V Erakepedal depressed. VB 9-GND Erakepedal released. OV Whenthe wheelis turnedat 1 turn/ secono. Stops 53mVorabove on digitsl tester {AC (ffeferance) rangel 150 mvpporabove onoscilloscope
Approx.2.5 V
'5
10
FLO BRN^/vHT(Front-left 0)
10-23
12
YEL
RL-OUT (Rear-left outlet)
Drivesleft-rear outlet solenoid 12-GND Drivesright-rearinlet solenoid

uJ
ON
ON
OV AC:3-6 V Approx.3 V
-9
14
RR-IN REO/vVHT (Rearright inlet) B1 (Battery 1) r'VHT/GRN (Battery 2) GND2 BLK (Ground 2) RR1 GRN/YEL(Rear-right 1) RLl LT BLU (Rear-left 'l )
FR1 GRN/BLK (Front-righr 1)
I3-GND Power source the solenoid for valveandpumpmotor.

Power sourcefor the solenoid valve and pump motor. Ground for the ABS control unit. Detects right-rear wheel sensorsignal. Detectsleft-rear wheel sensor signal. Detects right-front wheel sensorsignal. Detects left-front wheel sensor signal. 14-GND
OFF SCS lConnectthe service] connector I \
VB
15,GND 16.GND
16 17 19
)1
Below V 0.3
53 mV or above on digital tester (AC range) (Referance) 150 mVp-p or above on oscilloscope
19,6
21-A
When the wheel is turned at 'l turn/second.
23
FLI (Front-left 1)
23-10
Stops
'6
A p p r o x . 2 .V 5 ON
OFF
Drives left-rear inletsolenoid valve. RED RL-IN (Rear-left inlet) 25.GND
ON
OV
AC:3-6V
OFF the seNicel lconnect SCS

I Connector l
Approx. V 3 Below V 0.3
26
BLK
GND3 (Ground 3)
Ground for the ABS control unit.
26-GND
19-40
ABSCONTROL UNIT22PCONNECTOR
WIRESIDEOF FEMALE TERMINALS VB: BatteryVoltage

Voltage Tsiminal numb6r WiJe cotol Terminal sign lTo]minal nomsl
Doscription
tef|ninak Drivesright-frontinlet solenoidvalve.
Conditions (lgnition Switch ON lll)l

'6
Output voltago OV AC:3-6 V Approx.3 V OV Approx.5 V Approx.2 V VB
FR.IN RED/BLU (Front-right inlet)
ON 1-GND o
ON
OFF
OFF theSCS servicel lconnsct connedor I \
BRN
(Service check signal)
Detectsservicechecksignal (Diagnostic trouble code indicationl
4-GND
SCS service connector connecleo.
connector SCSservice disconn6cted, Indicator lightoN
BLU/RED (Warning ramp,
ABSlndicator Iight{The Drives indicator lightgoesoff when ABS controlunit outputsbattery voltage).
7-GND Indicatorlight OFF 1O-GND
10
FL-OUT Drives left-tront outlet YEUSLK (Front-left solenoidvalve. outlet)

FL-IN RED/BLK (Front-let inletl Drivesleft-frontinlet solenoid
ON ON
OFF
OV AC:3'6 V
11
11.GND
uJ
FR-OUT Drivesright-frontoutlet YEUBLU (Front-right solenoidvalve. outlet)

l4
12-GND
OFF the seruiceJ /Connect SCS conneclor I \
Approx. V 3
LT BLU
DLC (Data link connector)
with Honda Communicates PGM Tester.
14-GND
Approx.5 V ON OFF ON ON
OFF
17
pumpmotordrive Detects MCK L BRN/VE (llotorcheck) s r g n a l . pumpmotorrelay. Drives

PMR
Pump 1 7G N D motor relay
VB OV OV AC:3-6 V Approx,3 V OV AC:3-6 V

A p p r o x . 3V
19
YEVRED (Pump motor

retay,
I9-GND
OFF the servicq lconnect SCS connefior l \ Pump ON motor reray OFF OFF the seNicq lconnect SCS connedor I \ ON
BLU
RR-OUT {Rear-right outlet) GND2 (Ground 2)
right-rear Drives outlet valve. solenoid

21-GND
BLK
Ground for the ABS control unit.
22-GND
Below V 0.3
19-41
Troubleshooting Precautions
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. determinethe To actualcauseof problem,questionthe customerabout the problem,taking the following conditionsinto consideraI|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 go switchis turnedoff, or it can automatically off, depending the mode. on . Lightstaysonuntil the ignitionswitchisturned off: Whenthesystemis inthesystem down mode. . Lightautomatically goesoff: Whenthe systemis in the controlinhibitionmode. (refer to symptom-to-systemchart) 3. The ABS indicator light 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-drive car afterservicing wheelsensorsystem,and be surethat the ABS indicator the the light does not come on. 4. Whenthe ABS controlunit outputsbatteryvoltageto gaugeassembly. ABS indicator the light goesoff, DiagnosticTroublo Code (DTCI 1. The diagnostic troublecode (DTC) memorized is when a problemis detected and the ABS indicatorlight does not go off, or when the ABS indicator light comeson. The DTCis not memori?ed when the ABS indicatorlight comeson unless the CPUis activated. 2. The memorycan hold any numberof DTCs. However, when the same DTCis detected twice or more,the laterone is writtenover the old one. Therefore, when the sameproblemis detected repeatedly, is recorded one DTC. it as 3. The DTCS indicated the orderof ascending are in number,not in the orderthey occur. (non-volatile 4. The DTC$ memorized the EEPROM are in memory). Therefore, memorized the DTCS cannotbe canceled disconnecting battery. by procedures the Performthe specified to erase. Self-diagnosis 1. The self-diagnosis be classifield can into thesefour catego.ies. . Initialdiagnosis: Performed ht afterthe enginestarts and untilthe ABS indicatorlight goesofJ rig . Except ABS control:Performed when the ABS is not functioning. . DuringABS control:Performed when the ABS is functioning. . Duringwarning; Performed when the ABS indicator light is ON. 2. The systemperforms followingcontrols the when a problemis detected the self-diagnosis. by ! ABS indicator light ON . Memory of DTC . Modechange the "systemdown mode" or the "controlinhibitionmode". to
MODE
SYSTEM DOWN CONTROL INHIBITION
ABS INDICATOR LIGHT ON
MAIN RELAY No operatron No opera on
SOLENOID VALVE Drive inhibition Drive inhibition
CPU Operation*1 Operation
Restart condition lgnition swatch OFF* ON
DTC
Memory Memory
ON
Automatic
*1: Except CPUfailure
19-42
Kickbsck 1. The motor operates when the ABS is functioning, and the fluid in the reservoiris forcedout to the mastercylinder causingkickback the brakepedal. at 2. You may afterthe initialdiagnosis. The ABS controlunit operates solenoid the valvewhen the brakepedalis released hearthe faint solenoid valveoperation soundat this time, but it is normal.
Pump Motor 1. The pump motor operates when the ABS is functioning. 2. You during acceleration. may hearthe faint operationsound The ABS control unit checks the pump motor operation at this time, but it is normal.
Brake Fluid Replacment/AirBleeding are brakes. 1. Brake fluid replacement air bleedingprocedures sameas conventional and Troubleshooting on that the causeof the problemis still pre1. The troubleshooting flowchartsexplainthe procedures the assumption light is still on. sent and the ABS indicator followingthe flowchartwhen the ABS indicatorlight does not come on can resultin jncorNotethat troubleshooting rectjudgment. the when the problemoccurred, and try to reproduce same conditions Ouestion the customerabout the conditions for troubleshooting. exceptABS control,during ABS control,during is Self-diagnosis made at varioustimes such as the initialdiagnosis, the symptom cannot be checkedunlessthe check acceleration, during the specifiedvehiclespeed,etc. Therefore. conditions matchwith the problemconditions. is but When the ABS indicatorlight does not come on duringthe test-drive, the troubleshooting performedbasedon poor contactof the terminals, etc,beforetroubleshooting. the DTC,checkfor the looseconnectors, light does not come on. the Aftertroubleshooting, erasethe DTCand test-drive car. Be surethat the ABS indicator with a double with a singleoutlineand the male connectors The connector illustrations show the femaleconnectors ouI|tne. from femaleterminalsare alwaysnumberedby lookingat the connector The connector terminalcavitiescontaining from the containingmale terminalsare alwaysnumberedby lookingat the connector the wire side,and the cavities terminalside.
19-{f
Code{DTC} Trouble Diagnostic

Indication TroubleCode{DTG) Diagnostic
can also be carriedout with HondaPGMTester. NOTE:This operation 1. 2, side kickpanel insidethe passenger's checkconnector to connector the service Connect SCSservice the Turn the ignitionswitchON (ll),but do not startthe engine the NOTE:Do not depress brakepedalwhen turningthe ignitionswitch. the indicates DTc. light.The blinkingfrequency of the Record blinkingfrequency the ABs indicator connector. Turn the ignitionswitchOFF,and removethe SCSservice NOTE;The MalfunctionIndicatorLamp (MlL)will stay on after the engine is startedif the SCSserviceconnectoris connected. the DTC. Erase
3. 4.
5.
condiiions for DTCindication . The car is stoDDed. beforethe ignitionswitchis turned ON (ll). . The SCSservice is connector connected . The brakepedalis released. duringthis procedure . The SCSservice remainsconnected connector 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. normalsignal(whichisfortheABS controlunit)from a HondaPGMTester. . TheABScontrolunitreceivesthe duringthis procedure. is . The SCSservice connector disconnected
u.s.A.
@
CANADA
LIGHT ABS INDICATOR
o r c| 1 2
LIGHT A8S INDICATOR
. 3sec.
8ff'?,1i'*"n
x : Eulbchckmc'd
0. 3sc.
Sscond
the bulb. Do not count it as a DTC. light comeson to check . When ignitionswitchis turnedON (ll),the ABS indicator any numberof DTCs. . The ABS controlunit can memorize the when the ABS controlunit has alreadymemorized same DTC. . The new DTCis not memorized .lftheDTCisnotmemorized,theABSindicatorlightstaysONafteritgoesoftfor36seconds'
19-44
DTCErasure
1. 2. 3. side kickpanel. insidethe passenger's to checkconnector the connector the service Connect SCSservice Depress brakepedal. the Turn the ignitionswitch ON (ll) while holdingthe brakepedsl, but do not start the engine.The ABS indicatorlight goes off after two seconds. light comeson afterfour seconds. The indicator light goesoft, rolease brakepedal. the Afterthe indicator After the indicatorlight comes on. depressthe brakepedal again.The indicatorlight goes off again after four seconds.(the brakepedalis still depressed.) light goesoff, release brakepedalagain, the Afterthe indicator light blinkstwice for 0.3secondand the DTCis erased. Afterfour seconds, indicator the and Confirmthe DTCindication, checkthat the DTCwas erased.
4. 5.
6.
,t
7. 8.
NOTE; Always maintain these steps. lf you disconnectthe SCS service connector and/or fail to operate the brake pedal the to light indication, DTCwill not be erased. according the indicator Conditions tor DTCorasuro . The car is stopped. o The SCSservice is beforethe ignitionswitchis turnedON (ll). connector connected . Thebrakepedal depressed is beforethe ignitionswitchis turnedON {ll). . The SCSservice remainsconnected duringthis procedure. connector The DTCerasurs stops and ABS control unit xacutostho software tunction if 8t least ons of the following conditions is satislid. . The car is not stopped. . The SCSservice is duringthis service, connector disconnected . The ABS controlunit receives normalsignal(whichisfortheABS controlunit)from a HondaPGMTester. the . The brakepedalis not operated to according the indicatorlight indication, . The DTCerasure finished. is
0.3sec.
ABSINDICATOR LIGHT OFF DEPRESS BRAKE PEDAL RELEASE
oN ( )
lqnilion switch
19-45
)
Diagnostic Trouble Gode(DTCI

Chart Symptom-to-System
OETECIIONTIMING
orc
sxk = < Y
oTAGNOSTS/ SYMPTOM
Z E zz EXts 48" 16> xE P8 6az e
>7
PROBAELE CAUSE i:Y
Open in the power source circuitfo.the ABS indacatorlight Elown ABS indicator lightbulb Op6n in the ABS andicato.light drive circuit. Shorrio powo. in th6 WALP ci.cuit F6ultv ABS codtfol unit Opsn in th lG2 cncuit Opsn in lh +B circuit Opsn and/or shon to body srcund in rhe WALP circuit FaultYaBS controluoil Op6n, shonto body sround and/orshonto pow6r inrhe whel
Drc
ON 1l Whe6l s6nsor (op6r'/shon ABS indacatorlight doos not go ofi aftsrngine is
NO
ABS indicEto. lisht do6s nor come on whon ignirion swirch is turnod on (ll)
15 11 12
oNr
o
RL
Faulty aBS contrclunit Shon io who6l sonsor (0)circuit inth whol scnsor (1)circuit Faulty wheel sensor inst8ll6tion
oN'
16
(chipp6d pulssr ga/noise)
o
RL FR IN
Faulty AgS controlunit
1E 32 33
opn, shonto body ground and/or shonlo powr inthe Opsn in lhe COM circuit Faulty AaS contrclunit
F8.OUT
FLIN Sol6noid {op6 sho.tio ON
3,r
35 37
FL.OUT
FA IN
RR-OUT
RT-IN
3a
51 ON
RI.OUT
Op.n in th6 motor poworsourco ci.cuit Op6n in rh motor GNDcarcuit 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 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 Faulty pump motor rcl.y Faultv ABS cont.olunit Opon, shorito body sround dncyor blown fuss in the B1 or 82
52
ON
53
ON
54
ON
6'I
ON
lgoilion voltago ilow voh'
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 Conoction oltho 24v battery for engine start Faulrycharuinq sy8tem Opn in th6lG2 circuit FaultvABS controlunit Exteml feto sj can b lho c!u!(s) ol the preblem FaultyABS ontrolunit c
81
ON
CPU
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 CONDITIONFOR DETECTION
DURING A8S CONTROL
EXCEPT ASSCONTROL
FFER TO PAGE
19
19-50
Th ABS indicalor light comes on when vehicl is stopped and wheelsensora givn 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. fasrsi wheel reachesa . When the vl@ity ol the faste$ wheel reachesor erc@ds a givsn sp*d, and ifthere a.e som whels ol whos vlo.ity is slowerthan a ce.lain parcnlaqe the fastel wheelspd 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. . Whn 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.
19,52
1954
. Th pump motor is aclivated once or twice afterevery ignition switch ON (ll)operation while lhe vehicle accelerals,thon lhe moror drive vollag ischocked. Whan lhe voltags is abnormal,lhoABS indi@ror light comes on. .AfterABS conrrol comglerion, lhe motorswirchgd is ofiand the main CPU chects the motor drivo voltaqe. Whn 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. i r 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 S n d i c a r o l i g h t c o m e so n .
'19,56
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 rpeats ON/oFF switching atalltims- whon the main relay is oft, a shon test pulse 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 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 . Whnrh6re is discrepancyin the phase informarion thatcontinues for morethan a givon priod . 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 radins and wrilins procadu.e of FAM.
t9 59
l9-60
1 96 1
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 whn ignhion switch is turned ON llll.
check the MEIER (7.5A) luse in the under-dash fuse/relay box.
NOTE:All indicator lights exceptthe charging systemlight will not come on when the METER A) fuse is blown. 17.5
Boplacothe tu3e and recheck. YES NOTE: Reinstallthe fuse it it is OK. Chocklor .n open in tho lcl circuit: 1. Disconnect gauge assemthe bly 5P connector. 2. Turnthe ignition switch (ll). ON 3, Measurethe voltage between the gauge assembly5P connectortermin6l 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. GAUGEASSEMBLY CONNECTOR 5P
IG1IYEL)
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: Measure voltagebeNveen the the g a u g e a s s e m b l y5 P c o nn e c t o r terminalNo. 1 and body ground. Ropairshort to powo. in the wiro between the gaugo a33omblv and ABS comrol unit.
ls there batteryvohage?
(To page19-49|
19-48
(Frompage19-48)
Checktho gaugo .$smbly: 1. Turnthe ignitionswitchOFF. 2. Connct the gauge assembly 5Pconnector, 3. Connect terminalNo. 3 to the b o d y g r o u n dw i t h a j u m p e r 4. Turnthe ignition switch (ll). ON
GAUGEASSEMBLY CONNECTOF 5P
Doesthe ABS ind;cator lightcomeon?
Roplacethe ABS indic.tor light drive cilcuit in tha grugg a33emblv.
.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 srvice connector connocted (s6o pago 194,11, no DTCis indicrted.
check the RRDEFRLY(7.5A) luse in the under-dash fuse/relaybox.
Raolaco tho fuso and Jachock. YES NOTE:Reinstallthe fuse it it is OK.
Checkthe ABS +B (20 A) fuse in the under-hood fuse/relaybox.
Replace tho tuse and rech6ck. YES fuse if it is oK. NOTE: Roinstallthe ABS CONTROLUNIT 26P CONNECTOR IG2 {BLK/BLU} Checkfor an opcn in the lG2 circuh: 1. Turnthe ignition switch (ll). ON 2. Measurethe voltage between the ABS controlunit 26Pconn e c t o rt e r m i n a lN o . 3 a n d body ground. Ropairopon in tha wira bstwaan the RR DEF RLY 17.5Al tu30 rnd ABS contrcl unh,
WIRESID OF FEMAI-E TERMINALS
ls there battery voltage?
ABS CONTROL UNIT 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 No. bodygroundand terminals 14 and No. 15individually.
81 IWHT/GRNI
Reprir opon in the wir6 brtwaan the ABS +B 120Al furo snd ABS control unh.
TERMINALS WIR SIDEOF FEMALE
{To page19-51)
19-50
(Frompage19 50)
UNIT 22PCONNECTOR ABS CONTROL Checkfor a short to bodY ground in the WALPcircuit: 1. Turnthe ignitionswitchOFF. 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. 3. Checkfor continuitybetween the ABS controlunit 22Pconn 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. WALPIBLU/REOI
UNIT 22PCONNECTOB ABS CONTROL WALP (BLU/REO)
Check the ABS control unat: 1. Connect the ABS control unit 22Pconnector. s 2. Turn the ignitaon witch ON (ll) 3. Measure the voltage between the ABS control unit 22P con nector terminal No. 7 and body ground.
TERMINALS WIRESIOEOF FEMALE Checklor an open in th GND2 circuit: the ABS controlunit 1. Connect terminalNo 16 26Pconnector to body groundwith a jumper 2. Measure the voltagebetween the ABS controlunit 22Pcon n e c t o rt e r m i n a lN o 7 a n d body ground. UNIT 26PCONNECTOR ABS CONTROL t 2 3 4
6 ,/8
I r0
12113
1 4 t 5 1 61 7
/ ' , 1 s./ 21
26
JUMPERGND2(8LK) WIRE TERMINALS WIRESIOEOF FEMALE
ls there batteryvoltageT
. Repairopen in the wire between the ABS control unit and bodY ground. . Repair poor ground {Gilo1, G402).
Checkfor loose ABS control unit connectors, It necessary.substitute a known-good ABS control unit and recheck. Chckfor an open in the WALP circuit; the the Measure voltagebetween g au g e a s s e m b l y5 P c o n n e c t o r terminalNo. 1 and body ground. 5P GAUGEASSEMELY CONNECTOR
Repairopen in th wire betwoen the ABS control unit and gauge assemblv.
the ABS indicator light Replace driv6 ci.cuit in the gauge assem' blv.
19-51
Troubleshooting
Wheel Sensor
Diagnostic TroubleCode(DTCI11-18:WheelSensorDiagnosis NOTE:TheABS indicator lightcomeson when onlythe drivewheelsareturning. signaldisturbance detected. Therefore, is etc. 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.
ABS CONTROL UNIT 26PCONNECTOR With tho ignition switch ON llll, ABS indicltor lisht does not go off. After dliving, ABS indicator light comes on. With the SCS serviceconnector connocted ls page 1$501, DTCa 11-18ar indicated. RRO IELU/YELI Appropriate Terminal (O) (1)SIDE SIDE 1 1 ,l 2 ( R i g h r - l r o n t ) N o . 8 : F R o N o . 2 1 : R l F
DTC
Checkthe wh6ol sensorcircuit: l Disconnectthe ABS control unit 26Pconnector. 2. Measure the resistance betweenthe appropriate wheel sensor and (1)circuit 10) termi-
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 '17, 18 {Left-rear) N o . 6 : R L o N o . 1 9 :R L ' l
RRl {GRN/YELI RL1ILT 8LU)
FLl {GRN/ORNI FRl {GRN/BLKI
750- 1050 o/20.c,68"F\ /Front: 850- 1150 020'C,68"F/ lRear.
ls the resistance OK?
. Roplir opcn in the l0l or ('l) circuit wire, or ahort to tho (0, circuit wir. in thc (1) circuit wire betwoon tha ABS control unit and appropriatawheal son3or. ' Roplacetho approprirto wh.el 3an30r,
Checktor a shon to body ground in the wheel sensorcircuit: Check continuity for between the ABS control unit 26P connector appropriate wheel sensor(0) cir cuitterminal*and body ground. ' Rspair 3hort to body ground in the l0) or {11 circuit wire between the ABS control unit and appropriatowheel snsor, . Replacethe appropiiate wheel
ls therecontinuity?
Checktor a short to power in the wheel sensorcircuitl 1. Reconnect ABScontrolunit the 26Pconnector. 2. Startthe engine. 3. Measurethe voltage between the ABS controlunit 26Pconnectorappropriate wheelsen s o r ( 0 ) c i r c u i tt e r m i n a l a n d body ground.
NOTE:Judgement valuetor short to
ls there4 V or more?
Repair shon to powor in the (01 or {l) circuit wiro btween the ABS control unit and appropriate
NO NOTE . Normalvoltage: Approx.2 V . 0 V: Replace ABScontrolunit. the . 4 V or more indicates shortto power. a (To page 19-53)
19-52
(Frompage19-52)
gear. pulser for Check chipped
Ropl.ce the driverhrft or hub unit. (Chippedpulst goerl
DTC 11. 13. 15, 17: Roplscothe ABS control unit, DTC 12, 1ir, 16, 't8: The ABS control unit may have dotected sig' nil dbturbanco.
19-53
Troubleshooting
Solenoid
Diagnostic TroubleCode{DTC) 31-38:SolenoidDiagnosis
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 connector connoctod lsoepage1$50). DTCS -38 are indicated. 31 ABS CONTROL UNIT 22PCONNECTOR FL-OUT{YEL/BLK}
DTC 3 1 : F RN l
Terminal
32:FR-OUT
33rFLN l
Chocktor a short to powr in the solenoidcircuit: 1 . D i s c o n n e ctth e A B S c o n t r o l unit 22Pand 26Pconnectors. 2. Startthe engine. 3, Measurethe voltage between the ABScontrolunitconnector a p p r o p r i a t e o l e n o i dc i r c u i t s terminal* and bodyground.
34i FL-OUT 35:RR-lN 36: RR-OUT 37iRL'IN
22P 22P 22P 22P

26P
No.1 No. 12 N o .1 1 No.10 No. 13 No.21 No.25 No.12
WIRESIDEOF FEMALE TERMINALS ABS CONTROL UNIT26PCONNECTOR RL.OUT IYEL}
22P
26P 26P
38:RL-OUT
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 Check {or continuity betlveen the appropriate solenoid circuit termi nal* and body groLrnd.
wlRE SIDEOF FEMALE TERMINALS
. Repairshon to body ground in the appropriatosolenoid circuit wire between tho ABS control unit end modulator unit. . Replace the inodulator unit.
oTc
Checkthe ABS control unit: 1. Turnthe ignitionswitchOFF. 2. Connect the ABS controlunh 22Pand 26Pconnectors. 3. Connect SCSservice the connector, 4. Turnthe ignition switch (ll). ON 5. Measurethe voltage between the ABS controlunit 26Pconnector appropriate COMcircuit terminal** and bodyground.
3 1 :F R I N
Terminal No. 2: SCOM No.2:SCOM No. 1: PCO[, No. l: PCOM No. 1:PCOM No. 1: PCO[, No. 2: SCOM No. 2: SCOM
32:FR-OUT
33:FL-lN
RL.OUT {YELI
34:FL-OUT
3 5 iR Rl N
36:RR'OUT
3 7 : R LI N
38:RL-OUT
YES
(Topagel9-55)
Chocklor loose ABS control unit conneclors. lf oecessary,substitule a known-good ABS control unit and recheck. PCOM (GRN/WHTI
19-54
{Frompage19-54)
Appropnale Connector
UNIT 22PCONNECTOR ABS CONTROL Appropriate Terminal

No. l No. 12 No. 1'l No.10 No. 13 No.21 N o .2 5 No.12
FL.OUTIYEL/BLK)
DTC 3 l : F Rl N
32:FROUT
33: FL]N 34i FL-OUT 35: RR lN
Checkfor an open in th. solenoid circuit: Measurethe voltage betweenthe ABS control unit connedor aPPro_ priatesolenoidcircuitterminal* and bodyground.
36:RROUT
37:RLIN
38:RL.OUT
22P 22P 22P 22P 26P 22P 26P 26P
ls therespprox.3V?
. Repair open in the appropriate COM circuit wire betwen the ABS cortrol unit and modulator unit. . Repair open in the applopriate solenoidcircuil wite bstween the ABS control unit rnd modulator unit. . ReDlace modulato. unit. the
UNIT 26PCONNECTOR ABS CONTROL
(YEL) RL.OUT
Checkfor looso ABS control unit connostors, lf nocGaary, sub3ti' tute 6 known-good ABS control unit and recheck. TERMINALS WIRESIDEOF FEMALE
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 srvice conn.cpegg 19-50}, tor connoc{d 13 DTCa5l-53 .rc indlstod.
check MTR the cHEcK A)tuse. 0.5
Rcplacothe tus6 and r6ch6ck. yES NOTE:Reinstall the fuse it it is OK. 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 groundfor a moment,and recheck fuse. the lf the fuse is blown, checkfor a short to body groundin the MCKcircuit.
ABS CONTROL UNIT 22PCONNECTOR

l l4
,/117
1 8 / 1 0t l 1 9 1 , / 21
PMRIYEL/RED}JUMPER I I wrRE
WIRESIDEOF FEMALE TERMINALS Repl.co the fuso and .scheck. 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 recheck tuse. the lf the fuse is blown, checkfor a shon to body ground in the wire be&veen underhood the ABS tuse/relaybox and pump motor.
YES NOTE: Reinstall thefuseif it is OK.
Replacctho pump motor .alay.
Check th pump motor powet sourcecircuit: Turnthe ignitionswitchON (ll). Check tor a short to powoJ in tho pump motot powar sourcocirc{it: Removethe pump motor relay. Repair3hort to powar in tha wile botwoon the under-hood ABS tu3o/rolay box and ABS pump motot.
Doesthe pump motor operate?
Doesthe pump motor operate?
Chocktor loose ABS control unit connector!. lf nece$sry, subslitute a known-good A8S control unit and recheck.
(Topage19-57)
19-56
T
I
{Frompage19-56) ABS UNDER-HOOD BOX FUSE/RELAY WIRE JUMPER Checkthe pump motor circ!it: the 1. Remove pumpmotorrelay ON switch (ll) 2. Turnthe ignition motorrelay the 3. Connect PUmP connector+B and MOTORter_ minalswith a jumperwire for a momenl. Checkfor an open in the PumP motor +B circuit: switchOFF. 1. Turnthe iOnition th 2. Disconnect e pump motor 2P connector. ON switch (ll). 3. Turnthe ignition the 4. Connect pump motorrelay tet' +B connector and MOTOR minalswith a iumPerwire. the 5. Measure voltagebetween the pump motor 2P connector terminalNo. l and bodY ground.
TERMINAL
TERMINA.
Doesthe pump motoroperate?
PUMP MOTOR2P CONNECTOR +B MOTOR (WHTl,S
rv) Y
TERMINALS SIDE FEMALE OF WIRE

Repairopen in the wire betwoen the under-hoodABS fus/relav box and pump motor.
ls there baftery voltage?
Check the pump molor opera' tion: to the Connect battery(+)termanal the pump motor 2P connectorter m i n a N o . ' 1a n dt h e( ) t e r m i n a l t o l , No.2 for a moment. theterminal
+B MOTOR iRED)
MOTOR GNDIBLKI
Doesthe pump motor oPerate?
Beolacethe modulator unit. {Fallty pump motorl
Checkfor a short to body ground in the PMRcircuit: 1. Turnthe ignitionswitchOFF. 2 . D i s c o n n e ctth e A B S c o n t r o l unit 22Pconnector. 3. Checkfor continuitybetween t e r m i n a lN o . 1 9 a n d b o d y ground.
Repah open in the wita between the pump motor rnd bodYground, or poor ground (G/o31.
ls lhere continuity?
Repairshort to body ground in th6 wire betweenlhe undrh o o d A B S t u s e / r e l a yb o x a n d ABS control unit.
TEFMINALS WIRESIDEOF FEMALE
(cont'd)
(To page19-58)
19-57
Troubleshooting
ABSPumpMotor (cont'dl
(Frompage19-57)
Check loi .n open in the PCOM circuit: 1. Turnthe agnition switchOFF. 2 . R e c o n n e ctth e A B S c o n t r o l unit 22Pconnector. 3. Connect SCSserviceconthe nector, 4. Turnthe ignition switch (ll). ON 5. Measure vokagebetween the t h e p u m p m o t o r r e l a yc o n nectorPCO terminaland M body ground.
) t-1E
tr
r.l
ls thereapprox. V2 3
Bopair open in the wire betwoen tha under-hoodABS tuse/reley box and ABS cont.ol unit.
ABS CONTROIUNIT 22PCONNECTOR
Chocktor an open in ihe PMRcircuit: Measurethe voltage betweenthe ABS control unit 22P connector terminal No. 19and bodyground.
10 t l
21 22
12 /
14
11
PMR{YEL/RED)
ls thereapprox.3V?
Ropairopen in the wire betwaen the under-hoodABS fuse/relay box and ABS control unit.
WIRESIDEOF FEMALE IERMINALS
Check tor an open in the MCK circuit: 1. Turnthe ignitionswitchOFF. 2 . D i s c o n n e ctth e S C S s e r v i c e connector. 3. Turnthe ignition switch (ll). ON 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 connecting the pump motor relay connector and MOTOR +B ter minal with a jumper wire for moment.
ls there battery voltage?
Repairopen in the wire betwoen the under-hoodABS fuso/rl.y box and ABS control unit.
Checktor loose ABS control unit connectors, It necessary,substituto a known-good ABS control un;t and recheck.
Main Relay
DiagnosticTrouble Code (DTC)54: Main RlayDisgnosis
With tho ignition switch ON {ll}, ABs indicator light do.s not go off. With the SCS 3oruics connector conn.ctod h6e Psgc 19601, DTCg b indcst d. check the ABs +B (20A) fuse. Raplac!lha fuso snd lachock. ABS CONTROL UNIT 26PCONNECTOR
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 circuh: 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 terminal No. 14 unit 26Pconnector and No.15individually. ls there batteryvoltage?
B1 (WHT/GRNI
Ropairopen in th. wi.o bdtw.en tho ABS control unit and under' hood ABS tuse/rol.y box.
Checklor a ihon to body Itound in the PMRcitcuit: 1. Turnthe ignitionswitchOFF. 2, Removethepump motor relay. 3. Disconnectthe ABS control unit 22Pconnector. 4. Checkfor continuity between 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' hood ABS fu3e/.ehY box tnd ABS control unil.
ls therecontinuity?
Checkfor a short lo bodY ground in the PCOM,SCOMcilcuit: 1 . D i s c o n n e ctth e A B S c o n t r o l unit 26Pconnector. 2. Checkfor continuitybetween body ground and the ABS control unit 26PterminalsNo l andNo.2 individually. ls therecontinuity?
PCOM SCOM {GRN/WIIT) {BLK/WHTI
. Repairshort to bodY ground in the PCOM circuit wirs bctween tho ABS control unit and undor_ hood ABS t6o/r.lay box. . Rpair3hon lo bodY ground in 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
t6 17
(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. 2. Measurethe voltage between body groundand ABS control unit 26P connector terminals No. l and No.2 individualty. ls there8 V or more?
Turn the ignhion switch OFFand conn.ct thc SGS sorvics connoclo.. Then tuJn the ignition rwitch 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|control unit.
. Rcp.i. 3hort to powor in the PCOM circuh wirc bqtwaen tho ABS control unit and undoahood ABS fuso/relaybor. . RopaiJshorl to powor in th6 PCOM or SCOM circuit wir. botwoen tha ABS control unit and modulato. unit. . Repl.co the modulator unit. lshorl to powol inside tho unitl NOTE: 8 V or more indicatesa short to
19-60
lgnition Voltage
DiagnosticTrouble Code {DTC)61: lgnition Voltage Diagnosis
With the engine running, ABS indic.lor light is ON. With the SCS serviceconnoctor connected (saepage 19-501, OTC61 is indicded.
Problemve.ification: 1. Erase DTC. the 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.
UNIT 26PCONNECTOR ABS CONTROL Chcckthe lG2 circuit: the Me6sure voltagebetween the ABS control unit 26P connector terminalNo. 3 and body ground. IG2IBLK/BLU}
ls there18V or above?
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 rchck.
9-61
Troubleshooting
CentralProcessing Unit (CPU)
DiagnosticTroubl Code {DTC}81: CPU Diagnosis
With tho ignition switch ON (ll), ABS indicato. light doos not go off. Wrth the SCS srvice connector connoctod lsee page 19601, DTC81 i! indieted.
Ploblem v6dtication: 1. Erasethe DTC. 2. Test-drivetho vehicle. 3. M6ke sure that the ABS indicator light comes on and DTC 81 is indicated.
RopbcG tho 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 immediately 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. 2. and pump motor 2P connectors Disconnect modulatorunit 10P the the Disconnect brakelines,then removethe modulatorunit
lnstallation 1. 2. 3. 4. the Install the modulatorunit,then connect brakelines. the Connect modulatorunit Bleedthe brakesystem. light goesoff. Startthe engine,and checkthat the ABS indicator 'l0Pand pump motor 2P connectors
PUMPMOTOR 2P CONNECTOR
ffi t'
'%
TORUNIT
19-63
ABSControlUnit
Replacement
1. 2.
Pulsers/Wheel
Sensors
Inspection
1. Checkthe front and rear pulserfor chippedor damagedteeth. Measure the air gap betweenthe wheel sensorand pulserall the way aroundwhiie rotatingthe pulser. Standard:0.4 1.0mm (0.02 0,04inl 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 n r m w h i c h a shouldbe replaced.
Remove right side kickpanel. the Disconnect ABS controlunit connectors. the
2. 3.
4.
Remove ABS controlunit. the Installthe ABS control unit in the reverseorder of removal.
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: to . Be carefulwhen installing sensors avoidtwistingthe wires. the . The torquevalueof the bolts is at 9.8 N'm (1.0kgf m, 7 lbift) Front
WHEELSENSOR
1. 2.
Remove hub bearingunit (seesection18). the platebolts Remove four backing the the to pull the backing plateawayfrom the trailingarm, then removethe wheelsensor.lt is not necessary disconnect brakeine. l
''-----_l'19-65
Body ('96 model)

Doors FrontDoorIndex(4D) RearDoorIndex(4D) DoorfndexlzDl3Dl Emblems fnstallation Exterior .-'2O-2 ..'..20-8 ."""20'14 20'118
I . . G o m p o n e n L o c a t i o n n d e x ' . . . . . . . " . . 2.0 - 9 3 t
2O'12O *Frame Ghart ........,. Repair *lnterior 20-58 ".'.....'. Index.... Location Component Mirrors .... "...'. MirrorReplacement "...'. .". " "' 20-24 ""'.'.""..' 20-25 Replacement MirrorHofder "."""'."". 20-25 MirrorCoverReplacement '..-""" 20'25 MirrorReplacement Rearview Moonroof ..'......'.'.....'.'.20'50 l n d e x, . . . . . . . . . and OpenerCable/Opener Latch/ WiperandWasher ". Index..'.......'.20-1oj Location Component Seatsand SeatBelts "".20'73 Index..'..'.... Location Component ."' 20-119 Sub-frame Glass Windowand Ouarter Rear Windshield, 20'26 '..'.".'."""'.'.' fndex......'.'.
...""."20-123 Body ('97 modell .............

Body ('98 model) ......... .....'....20-131
Doors
FrontDoor Index
ilD:
SASHTRIM
WEATHERSTRIP
o obn
POWER WINDOW SWITCH
OETENT ROO
fu-P
[q-/
'aer7a
DOOR
Adjustment,page 20-23 DOOR PROTECTOR
c \f
R--2''
7t'<
DOOR GRIP COVER DOOR GRIP
"rrd*r,
COVER
-."v
r-\
ef'
DOOBPOCKET
20-2
GLASS Replacement, page 20'6 Adjustment, page 20-20
CENTER LOWER CHANNEL
LOCKROO PROTECTOR
CYLINOER PROTECTOR
REGULATOR Replacement, pa9e20-6 .^@ \lzl
dD
STRIKER Adjustment, page20-23
e'
R e p l a c e m e n t ,p a g e 2 0 - 5
ô
HANOLE
\ t l
\ ( /
\".ou.oro,
LOCK CYLINDEB RETAINER CLIP
INNER HANOLE ROD
A(* V*#a
LATCH PROTECTOR CYLINDER ROD LATCH Replacement, 20-6
POWER DOOR LOCKSWITCH (driver's only)
-w fi6*
$@
INNER HANDLE
20-3
Doors
Door PanelRePlacement
the NOTE:Takecarenot to scratch door paneland other pans. 1. Remove: . Innerhandle(seePage20-3) . Mirror mount coverpanel(seepage20'24l'
ll applicable, remove the regulator handle by pulling the clip out with a wire hook TORHANDLE WIREHOOK
4.
the Release clips that hold the door panel Remove the door panelby pullingit upward the NOTE:Remove door panelwith as littiebending it or to as possible avoidcreasing breaking
inl 95 mm 13.74 .L 12 mm {0.47in} T-
TRIM PAD REMOVER (Commercially available) Snap-on , L,-#4171,or 1mm equivalent in) 10.04 45 mm inl {1.77 >: Cliplocations,5
./zn
/t4|
nu"
3.
then cover, the Remove door grip coverand speaker removethe screws. 5 >: Sctewlocations,
WINDOW POWER
swlTcH
J [ i :lt{
cL,P l\
REMoVERi I
ltN i
i
i
-E/
D i s c o n n e c tt h e s p e a k e rc o n n e c l o r '
5.
of is Installation the reverse the removalprocedure'
20-4
OuterHandleReplacement
the NOTE:Raise glassfully. 1. Remove: a Door panel . Plasticcover {see page 20-21 Pullout the retainer clip.
PROTECTOR CYLINDER
4.
Pull out the outer handle.Pry the outer handle rod cutters. out of its joint usingdiagonal NOTE: . To easereassembly, note location ofthe outer @ it. handlerod on the joint beforedisconnecting . Takecarenot to bendthe outer handlerod. . Use a shop towel to protectthe opening in the door.
OUTERHANDLE ROD
l
2.
BUSHING Replace.
DIAGONAL CUTTERS
LOCKCYLINDER
,1rl'.
RETAINER CLIP Remove the bolts,then removethe cylinderprotector, lockcylinderand outer handle.
>: Bolt locations,2
r$\'* \Af@
6 x 1.0 mm g.aN.m tsr.m, tr.o

?.2 tbI.ft)
I
i I
)
-_-_--/
CYLINDER
SHOP TOWEL
5,
of lnstallation the reverse the removalprocedure, is NOTEj Makesurethe door locksand opensproperly.
LOCKCYLINDER ROD CYLINOER
20-5
Doors
LatchReplacement
NOTE:Raise glassfully. the
1.
Replacement Glass/Regulator
' t . Remove: . Door panel(seepage20-4) . Plastic cover(seepage20-2) Carefully move the glassuntil you can seethe bolts, p t h e n r e m o v et h e m . C a r e t u l l y u l l t h e g l a s so u t throughthe window slot. the NOTE:Takecarenot to dropthe glassinside door. >: Boltlocations. 2
Remove: . Door panel(seepage20-4) . Plastic cover(seepage20-21 . Outerhandle(seepage20-5) Removethe bolt, then move the center lower channel forward. Disconnect the connector,and detachthe harness t c l i p f r o m t h e d o o r . R e m o v e 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. >: Screw locations,3
2.
3.
GLASS
LOCKROD
REGULATOR
6x1.0mm I N.m {0.8kgf.m, 6 tbf.ft)
4.
of Installation the reverse the removalprocedure. is 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 properly. are connected . lvlake surethe door locksand opens properly.
20-6
3.
the connector,and detachthe harness Disconnect r e m o v e h e r e g u l a t otrh r o u g ht h e h o l e i n t c l i p ,t h e n t h ed o o r .
4.
where of all Grease the slidingsurfaces the regulator shown.
>: Bolt locations a>,4 6x1.0mm 8>,3 6x1.0mm
REGULATOR
REGULATOR 5.
MOTOR
of is Installation the reverse the removalprocedure NOTE:Rollthe glassup and down to see if it moves freelywithout binding.Also make sure that there is betweenthe glassand glassrun channo clearance nel when the glassis closed.Adjust the positionof (seepage20-20). the glassas necessary
I l i
a: Nut locations,3 AR 6x1.0mm 6rbf ft)
rgt e ru.- 1o.a -,
L-r
REGULATOR (Manualtype)
20-7
Doors
RearDoorIndex
4D:
OUTER WEATHERSTRIP
INNER WEATHERSTRIP
...-\\\
iD\\
\b\
\\
DOOR Adjustment, page20-23
fu4 R'r"'
S"'P
HINGE
Y-*^
oooR
PROTECTOR
20-8
n (2
REARCHANNEL\ \ \\ \4\ \ \
t\
lll
Qll
a@
"ro."*o""..*
coLLAB \
I jl
J I
*-@\l'
OUTERHANOLE page20-1 1 Replacement,
REGULATOR HANDLE \
>-9 \n'
WINDOW POWER MOTOR
LOCKROD PROTECTOR
Replacement, page20-12 DOOR POWER LOCKACTUATOR INNER HANDLE ROD
20-9
Doors
Door PanelReplacement
NOTEjTakecarenot to scratch door paneland other the parts. '1. Remove: . Innerhandle{seepage20-9) . Regulator handle(seepage20-4) 2. Removethe door grip cover,then removethe screws. 3. Release clips that hold the door panel.Remove the the door panelby pullingit upward, NOTE:Removethe door panel with as little bending as possible avoid creasing breaking to or it.
TRIM PAD REMOVER (Commercially available) Snap-on t ./t ' 44177, ol 1fim -i-,.--t 6quivalent I L , inl 10.04 45 mm inl {1.77
.L 1 2m m {0.47in) T-
/={ , cs"
I
>: Cliplocalions, 7
4.
Installation the reverse the removalorocedure. is of
\20-10
e--'
Replacement OuterHandle
NOTE:Raise glassfully. the '1. Remove: . Door panel . Plastic cover(seepage20-8) 2. Remove screws. the >r Screwlocations, 3
6x1.0mm 6 N.m (0.6kgt m, 4 rbf.ft)
4.
Pull out the outer handle.Pry the outer handlerod out of its joint usingdiagonalcutters. NOTE: . To easereassembly, note location of the outer @ it. handlerod on the joint beforedisconnecting . Takecarenot to bendthe outer handlerod. . Use a shop towel to protectthe opening in the ooor.
I
)
.41
BUSHING Replace.
ft_-..p
^\
,Yt: :'"*'
DIAGONAL \
4 t---\--pS\.. \]
r r---t--J-
\-V
OUTER HANDLE ROD
3.
Move the latch down, and remove the bolts. >: Bolt locations,2 |
6@.1 s't.o-----,!Sl/
I
i
SHOPTOWEL
g.a N.m ) kd 11.o m,7 .2 tbt'ft| /
5.
Installation the reverse the removalDrocedure. is of NOTE:Makesurethe door locksand opensproperly.
20-11
Doors
LatchReplacement
the NOTE:Raise glassfully. 1. Remove: r Door panel(seepage20-10) . Plastic cover{seePage20-8) . Outerhandle(seepage20-11) 2. Remove the iockcrankand cliP.
>: Screwlocation, 1 1 >:Clip location,
RePlacement Glass/Regulator
1 . Remove: . Door panel(seepage20-10) . Plastic cover{seepage20-8) 2. move the glassuntil you can seethe bolts, Carefully then removethem. the NOTE:Takecarenot to dropthe glassinside door. 2 >: Boltlocations,
fi s'r.o-@ -
9.8N m tl.o kgtm, J L2 tbl.tlt , ,,-----/,/
\
collar. the rearchannel Remove NOTE:Takecare not to bendthe lock rod and inner handlerod.
REARCI{ANNEL LATCH
3.
\i
l C a r e f u l l y 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 then removethe glass screwtrom the rearchannel, trom the rearchannel. the NOTE:Takecarenotto dropthe glassinside door. >: Bolt.screwlocations
A'1
t't i
_-,/./ _
@@!iT,--,,-, ,J @ 6w.ftt
6x1.0mm INm(0.8kgf.m, 6 tbf.ft)
4. 5. D i s c o n n e c tt h e connector.
I I
B, 1
,,<\ t"<1' Fllt--n]nTl
the latchthroughthe hole in the door. Remove of is Installation the reverse the removalprocedure. NOTE: Makesurethe door locksand opensproperly.
6r1.0mm kgt I N.m 10.8 m,6lbf ftl ' )
,/
20-12
4.
Caretully remove the glass from the window slot.
CLIP
all of where Grease the slidingsurtaces the regulator shown. NOTE: a lf necessary, remove the power window motor from the regulator. . Beforeremovingthe powerwindow motor,scribe gearand regulator. a line across sector the
SECTOR GEAR REGULATOF
REAR CHANNEL COLLAR
5.
B Removethe outer molding,then removethe quarter glass.

OUARTER
wtNDow
POWER >: Bolt locations.3
wtNDow
MOTOR 6x1.0mm 7 N.ml0.7kgf.m, 5 tbf.ft)
6.
Disconnect the connector,and detachthe h a r n e s s clip, then removethe regulator through the h o l e i n the door. >: Boli locations a>,2 6 x 'l.0mm
REGULATOR
8.
lnstallation the reverse the removalorocedure. is of NOTE:Rollthe glassup and down to see if it moves freely without binding.Also make sure that there is no clearance betweenthe glassand glassrun channel when the glassis closed.Adjustthe positionof (seepage20-20). the glassas necessary
I
|
B> . 2
6x1.0mm
El sN-{o.a*gr.m, o rrr.rt ff
8Nmlo.8ksfm, 6 tbtftt )
20-13
Doors
DoorIndex
2Dl3Dl
GLASSGUIDE CLIP
sAsH
S 61 \ \ 1 P
\
OUTER WEATHERSTRIP
\ T a_\ \
: \
\.l+--
h\>l\\ -,-'\
r\J
9,, i i
@
, \
",Ro,--"ou", PANEL
covER
<an
\i
INNER HANDLE
tRtM {withoutpower
[-\r
ffi*'"o'
INNERHANDLE TRIM (with powerdoor locks)
S
Cf-.
\
\
eowenooon
LOCKSWTTCH \ \
tuf -re ".o.*.r\

- |
I
{h
ft{351'"'
oooR
Adjustment,
ts1.,h.* -\Q'-Qh.\\-*<y
\J' ARMRE'T POCKET
ARMREST POCKET
tls!^ (t!5t
\R]
,.JL
20'23 Pase
\\
W
+..-ooon
PROTECTOR
1-O-14
GLASS Replacement, page20-19 Adiustment, page20-20 GLASSRUN CHANNEL
3ill,'î,i"**\N
\\
\
\ z
\\\\ REGULATOR pas20.19 \\\\ Reptacement,
trq\\\t v.
,6@ POWER MOTOR CYLINDER PROTECTOR
l\\\\
e'
\".or.oro*
HANDLE
RETAINER LOCK CLIP CYLINDER
page20-17 Replacement,
RODPROTECTOR HANDLEBOD
FRONT LOCK ROD REARLOCK ROD
LATCH PROTECTOR
20-15
Doors
DoorPanel Replacement
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 other parts. 1. Remove: ! Innerhandletrim (seepage20-14) . Mirror mount cover panel{seepage20-241 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.
HANDLE REGULATOR WIREHOOK
\
5. Release clips that hold the door panel.Remove the the the door panel by pulling it upward.Disconnect soeaker connector. NOTE:Remove door panelwith as littlebending the or it. as possible avoid creasing breaking to
inl 95 mm 13.74 -L 12 mm TRIM PAD in) 10.47 1REMOVER (Commercially available) Snap-on *4177,or 1mm L---'"t/lf' equivalnt inl to.o4 I :
45 mm
/t1-]
I
(1.77 in) >: Clip location3,
Remove the armrest pocket,then disconnectthe oower window switch connector.
JF
=l$
il_
INOS
-------l I cr_rp REMoVER F? rI
t\
PANEL DOOR
ARMREST POCKET
4.
Remove the soeaker cover.then removethe screws.

>i Screw localions,3 |
L"
6hD:"
.i
CONNECTOR
6.
COVER
Installation the reverse the removalDrocedure. is of
20-16
Outer HandleReplacement
NOTE:Raise glassfully. the l. Remove: . D o o rp a n e l . Plastic cover(seepage20-14) P u l lo u t t h e r e t a i n ec l i p . r
PROTECTOR CYLINDER
4.
Pull out the outer handle.Pry the outer handlerod out of its joint usingdiagonalcutters. NOTE: . To easereassembly, note location of the outer @ it. handlerod on the joint beforedisconnecting . Takecarenot to bendthe outer handlerod. . Use a shop towel to protectthe opening in the door.
2.
LOCKCYLINDER
BUSHING Replace. OIAGONAL CUTTERS
,w,
\
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.
LOCK CYLINDER CYLINDER ROD
20-17
Doors
Latch Replacement
NOTE:Raise glassfully. the
l.
3.
Remove boltsand movethe centerlowerchannel. the NOTE:Take care not to bend the inner handle rod and lockrods.
Remove: . Door panel(seepage20-16) . Plastic cover(seepage20-14) . Outerhandle(seepage20-17) Remove the rod protector.
2.
>: Screw locataons A>,3 8>,3
5x1.omm i [v) ) 4 p 6 N m { 0 . 6 k e f m , i 4 tbt.h) )
l
_)
LOWER CENTER 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. lnstallation the reverse the removalprocedure. is ol NOTE:Makesurethe door locksand opensproperly.
20-18
Replacement Glass/Regulator
1.
Remove: . Door panel(seepage20-16) . Plastic cover{seepage20-14) move the glassuntil you can seethe bolts, Caretully remove then loosenthem. Slidethe guide rearward. 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. the NOTE:Takecarenot to dropthe glassinside door.
3.
the connector,and detachthe harness Disconnect clip, then removethe regulatorthrough the hole in the door. NOTE:Scribea line aroundthe rearrollerguidebolt to show the originaladlustment >: Bolt locations A>,4
6x1.0mm
2.
B>,2
6x1.0mm
>: Bolt localions,2 6x1.0mm
ksl.m, I I N.m10.8 6|lofttt )
8 N m {0.8 kst.m, I 6 rbrft | LOOSen.
E ,*
l
9.8N.m11.0 kg{.m, I 7.2tbrft) |

Loosen. /
ROLLER
BEGULATOR
BOLTS GUIDE
(cont'd)
20-19
Doors
Glass/Regulator (cont'dl Replacement
Grease the slidingsurfaces the regulator all of where shown. NOTE: a lf necessary, remove the power window motor from the regulator. . Beforeremoving powerwindow motor,scribe the a line across sectorgearand regulator. the
SECTOR GEAR
GlassAdjustment
NOTE: . Place vehicleon a firm, levelsurface the when adjusting the glass. . Check weatherstrips glassrun channel damthe and for age or deterioration, and replace them if necessary. 1. Remove: . Door panel(seepages20-4,10,16) . Plastic cover(seepages20-2,8,14) Adjustthe glass. 4D:
a, o.
2.
REGULATOR
R a i s eh e g l a s s u l l y . t f L o o s e n 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 ) t and regulator mountingbolts.

Push the glass rearward (front door glass)or forward (rear door glass). Tighten the glass mounting bolts (front door) and regulator mounting bolts.
c.
>: Bolt locations, 3
d.
q(])
6xr.om;]
POWER WINDOW
A >: Glassmountingbolt locations. B >: Rgulato.mouting bolt locations. Front:
; l L // -> -^\
5. Installation the reverse is ofthe removalprocedure. NOTE:Rollthe glassup and down to seeif it moves freely without binding.Also make sure that there js no clearance betweenthe glassand glassrun chan nel when the glassis closed.Adjust the positionof the glassas necessary.
REGULATOR
20-20
Rear:
GLASS
REGULATOR
e.
Loosenthe front channelmounting bolts (tront 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). Lowerthe glass.
2DI3D:
and hold Raisethe glassas far up as possible, it againstthe glassrun channel. 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 glassso it is parallel with the glassrun channel.
RUN GLASS CHANNEL
f. 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 glass, then tightenthe mountingbolts.
>r Fiontandrear mounting channel bolt locations Front:
ROLLER GUIDEBOLTS
(cont'd)
20-21
Doors
GlassAdjustment(cont'dl
c. d. e. f. Tightenthe rollerguide bolts. Loosen front channelbolts. the Lowerthe glass. Push the front channelagainstthe glass,then tightenthe mountingbolts.
GLASS
6.
Check water leaks. for Spray water over the roof and on the sealingarea as shown. NOTE: . Adjustthe water pressure shown. as . Do not squeeze tip of the hose. the
12 mm {0.47 inl
hd
HOSE
300mm (11.8 in)
MOUNTING BOLT 3. 4. 5. Check that the glassmovessmoothly. Raise glassfully and checkfor gaps. the Check glassoperation, the NOTE:Checkthat the glasscontactsthe glass run c h a n n ee v e n l y . l 7. Attachthe plasticcover,then installthe door panel (seepages20-4,10, 16). lnstallthe regulatorhandleso it pointsforward and up at a 45 degreeanglewith the glassclosed.
WEATHERSTFIP
Forward
20-22
g
PositionAdjustment
NOTE: Placethe vehicleon a firm. level surtacewhen adjusting doors. the After installingthe door, checkfor a flush fit with the body.then checkfor equal gaps betweenthe front, rear, 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 Adjust at the hinges body edgesshouldalso be parallel. asshown. CAUTION:Placea shop towel on the lack to prevent the door and hinge damageto the door when loosening mounting bolts lor adiustment. BOLTS DOOR MOUNTING 5 8 x ' 1 . 2m m 21 28 N.m{2.9kgt.m, lbf.ftl
Loosen door mountingboltsslightly the to movethe door lN or OUT until it's flushwith the body.lf necessary, you can installashim behindone hingeto makethe door edges with PARALLEL the body. HINGEMOUNTINGBOLTS 8 x 1.25mm 28 N m {2.9 kgf.m,21 lbf.ft) Remove innerfender, the loosen the hingemounting bolts,and movethe door BACKWARD FORWARD, or UP or DOWNas necessary to equalize gaps. the Lowerthe glass.
StrikerAdiustment
without slamming. securely Makesurethe door latches lf it needsadjustment: 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 in) 1.5 adjusted mm (0.059 up or down,and 3 mm (0.1in) tn or out. 1. then inserta shoptowel between the Loosen screws, the body and striker.
1 . 5m m (0.059 in)
1 . 5m m in} {o.059
Inserta shop towel between the body and
PLASTIC HAMMER
8 x 1.25mm l8 N.m {1.8kgl m, r3 tbf ft)
TOWEL
2. 3.
Lightlytightenthe screws. 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 the body to be surethe strikerallowsa flush against fit.
shouldbe parallel. The door and body edges

4.
then properly, loosenthe screws, lf the door latches removea shop towel.Tightenthe screwsand recheck
,lJl:ril:x;T9#
NOTE:Check water leaks. for
20-23
Mirrors
Mirror Replacement
NOTE:Takecare not to scratchthe mirror, mirror base coverano ooor. I 2. L o w e r h e d o o rg l a s s . t Carefullypry out the mirror mount cover panel by nano. Power milror: a: Nut locations, 3 3. Remove the mirror mounting nuts while supporting the mrrror.
)coNNEcToR (Mirrorside) MIRROR
{Doorharness side)
CONNECTOR MIRROR MOUNT PANEL COVER Manualmirror: Removethe cap, screwand knob,then removethe mirror mount cover panel.
MIRROR MOUNT
Installation the reverse the removalprocedure. is ot propNOTE:Make sure the connectoris connected erly.
KNOB
20-24
Mirror Holder Replacement

CAUTION: Wear gloves to remove and install the mirror holder. ' 1 . C a r e f u l l y 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 p as screwdriver shown.
PIVOT
JOINT PIN
Mirror Replacement Rearview

l. 2.
the Remove rubberdamper. Pry the cover off using the end of a flat tip screwdnver. CAUTION: When prying with a flat tip screwdriver, wrap it wilh a shop towel to prevent damage.
-6r
3.
--Gl
Removethe screws,then removethe rearviewmirror. of is lnstallation the reverse the removalprocedure
SCREW 5x0.8mm 4 N,m {0.{ kgf.m, 3 tbf.ftt JOINT PIN
DAMPER RUBBER
-6,l
MIRROR HOLDER SHOPTOWEL
2.
of is lnstallation the reverse the removalprocedure NOTE: Apply greaseto the locationsindicatedby tne arrows.
MirrorCoverReplacement
>: Screw locations A>.3 d\.nri''i.'.'i.i-. ]
REARVIEW MIRROR
s>,2
':::_)
d\.,.,',r.,+.I \{ P#'/u2 I
)
To removethe screws, pullthe sealaway.
-ln=T-
VIf. U .ll) |
._.[__
SHOPTOWEL
BASE MIRROR
20-25
Windshield, RearWindow and OuarterGlass

Index
of NOTE:The numbersafterthe part namesshow the quantities the partsused. (2Dl3D/4D): Windshield
MOLDING
RUBEEF UPPER
RearWindow {2Dl4D}:
FASTENER, 4 (Selt-adhesive-type, side) glass / /
REARWINDOW Removal,page20-32 page20-33 Installation,
FASTENER,4 body {Self-adhesive.rype, side}
* . /
SPACER,
w
g
20-26
RearWindow {3D):
,T FASTENER, glass lSelf-adhesive-type, side) SPACER,
,o.r.".*, n
Iff'".*-.Y'e'bod'side)
DAM,2 RUBBER
Removal,page 20-36 page20-37 Installation,
tI
SEALA, 1 SEAL8 , 2
Ouarter Glassi
3D:
GLASS OUARTER Removal, Page20-40 lnstallation, Page20_41
CLIP UPPER (Self-adhesive-type)
2Di GLASS OUATER page20-45 Removal, page20 46 Insrallation,
rr-il
(--/ /:=
LOWER RUBBER DAM
h\f
OUARTER TRIM GLASS
(Selt adhesive-type, body side)
LOWER CLIP (Self-adhesive type)
n \il
FASTENER type, {Sell-adhesive glassside) LOWER CLIP (SelI-adhesive type)
20-27
Windshield
Removal
CAUTION: . Wearglovesto removeand installthe windshield. . Use seat coversto avoid damaging any surfaces, 1. To removethe windshield, first removethe: . Rearview mirror (seepage20 25) . Sunvisors and holders(seepage20 64) . F r o n tp i l l a r r i m ( s e e a g e s 0 - 5 9 , 6 0 , 6 1 ) p t 2 . Windshield wiper arms and cowl cover(seepage 20 113\ Peel oll the molding, and removethe glass brack ets. NOTE: When molding removal is difficult,cut the moldingwith a knife. 4. Apply protective tape along the edge of the dashb 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 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 e r o m f i n s i d e 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 t hole,and wrap eachend arounda pieceof wood.
PIANOWIRE UPPER I RUBBER DAM WINDSHIELD ADHESIVE PROTECTIVE
tit'
2.
MOLDING
wlNDSHIELD
PROTECTIVE TAPE DASHBOARD
aoxesrir lowEB BUBBER

OAM 5.
DEFOGGEB SEAL
W i t h a h e l p e ro n t h e o u t s i d e , u l l t h e p i a n ow i r e p backand forth in a sawingmotion,and carefully cut 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 e r o u n dt h e a entirewindshield. CAUTION: Hold the piano wire as closeto the windshield as possible to prevent damage to the body and dashboard,
3.
Pull down the front of the headliner{see page 2064). CAUTION: Take care not to bend the headliner excessively.
6. Carefully remove the windshield.
20-28
lnstallation
1.
smooth to a Using a knife,scrapethe old adhesive of thickness about2 mm (0.08in) on the bondingsur openingtlange Iacearoundthe entirewindshield NOTE: . Do not scrapedown to the paintedsurfaceof the body; damaged paint will interferewith proper bonding. from the . Remove the rubberdams and tasteners body. beforepainting. . Maskoff surrounding surfaces
4.
t 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 s o t h e i n s i d e faceof the windshieldas shown. where NOTE:Be carefulnot to touch the windshield will be applied. adhesive
2.
dampwith a sponge Clean body bondingsurface the in alcohol. ened 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 , from gettingon the surface.
\._- - !41Ks _
ALIGNMENT MARK
inl {0.53
ALIGNMENT
use 3 . lf the old windshieldis to be reinstalled, a putty then knife to scrapeoff all traces of old adhesive, 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 is new adhesive to be applied. NOTE: Make sure the bonding surlaceis kept free of water,oil and grease. CAUTION:Avoid setting the windshield on its edges; small chips may later developinto cracks. NOTE: . Cleanthe shadowedarea. o Cleanarea@ as shown.
5. WINDSHIELD Align and glue the molding to the edgeof the wind shield. NOTE: Be careful not to touch the windshield where
'13.s mm in) 10.53 LOWER RUBBER DAM
lnside
JL
WINDSHIELD
WINDSHIELD
to Apply primer(3M N 200,or equivalent) edge of the windshield.
(cont'd)
20-29
Windshield
Installation (cont'dl
Installtheglassbrackets and fasteners shown. as NOTE:The numbersafterthe part namesshow the quantities the partsused. ot 9. With a sponge,apply a light coat of glass primer aroundthe edge of the windshieldas shown, then lightlywipe it off with gauzeor cheesecloth. NOTE: . Do not apply body primerto the windshield, and do not get body and glassprimerspongesmixed up. . Nevertouchthe primedsurfaces with your hands. lf you do, the adhesive may not bond to the windshieldproperly, causing leakafterthe windshield a is installed. . Keep water, dust, and abrasivematerialsaway glass primer Apply from the primedsurface. /fu gt here. , appty .. primer
9.5mm in) {0.37
RUBBER DAM FASTENER WINDSHIELD MOLDING
GLASSBRACKETS, 2
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. NOTE:Be carefulnot to touch the windshield where adhesive will be applied.
WINDSHIELD 10. With a sponge,apply a light coat of body primer to t h e o r i g i n a la d h e s i v e e m a i n i n g r o u n dt h e w i n d r a shield openingflange. Let the body primer dry for at least10 minutes. NOTE: . Do not applyglassprimerto the body.and be careful notlo mix up glass and bodyprimersponges. . Never touchthe primedsurfaces with your hands. . Maskoff the dashboard beforepainting flange. the ).///// /////// : Applr bodv wime. here.
6mm (0.2{in) 16mm in} {0.63 5mm in) 10.2 16 mm
In)
BRACKETS NOTE:Adjustthe glassbracketsto center windshield the in the opening, then tightenthe
8.
SCREW R e m o v eh e w i n d s h i e l d . t
20-30
together and hardener mix the adhesive 1 1 . Thoroughly on a glassor metalplatewith a putty knife. NOTE: . Cleanthe platewith a spongeand alcoholbefore mrxrng. . Followthe instructions that come with the adhesive. cut 12. Beforelilling a cartridge, the end of the nozzle as shown.
14. Use suction cups to hold the windshield over the opening,align it with the alignmentmarks made in . step7, and set it down on the adhesiveLightly push on the windshielduntil its edge is fully seated all on the adhesive the waYaround.
NOTEI Do not openor closethe doorsuntil adhesive is dry. MARK ALIGNMENT
C u t n o z z l ee n d
in) 10 mm (0.39
inl 7 mm (0.27 off adhesive with a putty 1 5 . Scrapeor wipe the excess knifeor towel. or from a painted surface NOTE:To removeadhesive wipewith a softshoptoweldampened the windshield, with alcohol. dry 1 6 . Letthe adhesive for at leastone hour,then spray Mark and checkfor leaks. water over the windshield the leakingareas,let the windshielddry, then seal with sealant. NOTE: . Letthe car standfor at leastfour hoursafterwind lf shieldinstallation. the car hasto be usedwithin the firstfour hours.it must be drivenslowly. . Keepthe windshielddry for the first hour after installation. . Checkthat the ends of the side molding are set underthe air scoop. removedparts. 1 7 . Reinstall remaining all NOTE: . Installthe rearviewmirror rubber damper after hasdriedthoroughly. the adhesive . Advisethe customernot to do the following things for two to three days: - 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 ys u c ha s w h e n ( going in and out of drivewaysat an angle or drivingover rough,unevenroads).
without air pockets into the cartridge Packadhesive in Put delivery. the cartridge a to ensurecontinuous a g c a u l k i n g u n , a n d r u n a b e a do f a d h e s i v e r o u n d as the edgeof the windshield shown. within 30 minutesafter NOTE|Apply the adhesive applyingthe glassprimer. in) 12mm (0.47
1 -tl
i .,1 aouestvr
Make a slightly thicker bead at each corner.
,T"Irr,,,",
MOLDING
-_rr
/
5mm (0.2in)
-/lr:.-,j.'o'.uo \--..
\
WINDSHIELD LOWER RUBBER OAM
FASTENER LOWER RUBBER DAM
inl 10.04 WINDSHIELD
20-31
RearWindow
Removal
2DI1D: CAUTION: a Wgar gloves to remove and install the rear window. . Use seat coversto avoid damaging any surfacss. . Do not damage the rear window defogger grid lines, window antenna grid lines, and terminals. 1. To removethe rearwindow,first removethe: . Trunk lid . Rearseatcushion(seepages20-79.81) . Rearseatside bolsters(4D,seepage20-791 . Rearseat-back (2D,seepage20-81) . Rearshelf(seepages20-59,61) . Rearpillartrim (4D,seepage20-59) . Sidetrim panel(2D,seepage20-61) . Ouarter trjm 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. Peeloff the molding. NOTE:When molding removal is difficult.cut the moldingwith a knife. ADHESIVE
MOLOING PROTECTIVE TAPE
4.
Apply protective tape alongthe edge of the body as shown. Usingan awl, makea hole through the adhesivefrom insidethe car. Push the piano wire 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 pieceof wood.
PIANOWIRE ADHESIVE REAR WINDOW
PEOTECTIVE TAPE
PIANOWIRE
3.
il"*t,
^D.HE:tyE ._ --,///
REARWINOOW
With a helper on the outside, pull the piano wire backand forth in a sawing motion,and carefully cut t h r o u g ht h e a d h e s i v e r o u n dt h e e n t i r er e a r w i n a dow. CAUTION: Hold the pisno wire as close to the rear window as possibleto prevent damageto the body.
S
MOLOING
6.
Carefully removethe rearwindow.
20-32
lnstallation
1.
smooth to a Using a knife,scrapethe old adhesive o t h i c k n e s s f a b o u t2 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 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 flange. NOTE: of . Do not scrape down to the paintedsurface the body; damaged paint will interferewith proper b o nd i n g . Maskotf surrounding beforepainting. surfaces . 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 DOOy. 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 i d a m p e n e dn a l c o h o l . , 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 from gettingon the surface.
4.
tape (NITTO501, Apply the double faced adhesive to or equivalent) the edge of the rearwindow,then installthe moldingaroundthe edge of the rearwin dow 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 i l l b e a p p l i e d . e
ALIGNMENT MARK ADHESIVE TAPE in) 867mm {34.1 5mm (0.2inl ADHESIVE TAPE Thickness: inl mm {0.006 0.'16 MOLDING ALIGNMENT MARK
3.
use lf the old rearwindow is to be reinstalled, a putty and the knifeto scrapeoff all tracesof old adhesive with rubberdam,then cleanthe rearwindow surface is wherenew adhesive to be applied. alcohol NOTE:Make sure the bonding surfaceis kept free of water,oil and grease. CAUTION:Avoid setting the rear window on its edges;small chips may later develop into cracks. area. NOTE:Cleanthe shadowed 5.
MOLOING
WlNDOW
to and spacers the insideface of Gluethe fasteners 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 i l l b e a p p l i e d . e

MOLDING
>: Fastener, spacer loc6tions A >. 4 FASTENER
--=,
I ALI GNMENT \ M MARKS A
B> , 2 Outside
REAR WINDOW
(cont'dl
20-33
RearWindow
6. Gluethe fasteners the body as shown. to
Fastenerlocations,4 FASTENER
9 . W i t h a s p o n g e , 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 a aroundthe edgeof the rearwindow as shown,then lightlywipe it off with gauzeor cheesecloth. NOTE: . Do not apply body primer to the rear window, and do not get body and glass primer sponges mixed up. . Nevertouchthe primedsurfaces with your hands. lf you do, the adhesive may not bond to the rear window properly, causing a leak after the rear window is installed. . Keep water, dust, and abrasivematerialsaway from the primedsurface. , appty gtassprimerhera.
10 mm 10.39 in) GLASS All around.
4i< ) l Y l
F_L^NGE NycH,/,/ '//f
\ e l
MOLDING
1.
Set the rear window, then centerit in the opening. Make alignmentmarksacrossthe rear window and pencil the four pointsshown. bodywith a grease at
FASTENER REARWINDOW
ALIGNMENT MABK
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 window openingflange.Letthe body primerdry for at least10 minutes. NOTE: . Do not applyglassprimerto the body,and be careful notto mix up glass and bodyprimersponges. . Nevertouchthe primedsurfaces with your hands.
S
8. Remove the rearwindow.
''/fu7.
, oort, Aoa,orimer here.
1 6m m inl {0.63
16 mm
In,
7mm in) 10.28
20-34
together and hardener mix the adhesive 1' t. Thoroughly on a glassor metalplatewith a pufty knife NOTE: . Cleanthe platewith a spongeand alcoholbefore mrxrng. . Followthe instructions that came with the adhe sive. cut 1 2 . Beforefilling a cartridge, the end of the nozzle as snown.
'14. Use suctioncups to hold the rear window over the opening,align it with the alignmentmarksmade in . step7, and set it down on the adhesiveLightly p u s h o n t h e r e a r w i n d o w u n t i l i t s e d g e sa r e f u l l y all on seated the adhesive the way around NOTE:Do not openor closethe doorsuntilthe adhesiveis dry.
SUCTION CUPS ALIGNMENT MARK
10 mm 10.39 inl
7 mm {0.27 inl without air pockets into the cartridge 1 3 . Packadhesive continousdelivery.Put the canridgein a to ensure a g c a u l k i n g u n , a n d r u n a b e a do t a d h e s i v e r o u n d the edgeof the rearwindow as shown. NOTE:Apply the adhesivewithin 30 minutesafter applyingthe glassprimer.
inl 12 mm 10.47
Make a slightly thicker bead at each corner. GLASS
off 1 5 . Scrapeor wipe the excessadhesive with a putty knifeor towel. from a paintedsurface NOTE:To removeadhesive rear window, use a soft shop lowel dampor the enedwith alcohol. 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 leaks.Mark the leakingareas,let the rear window dry, then sealwith sealant. NOTE:Let the car sland for at leastfour hoursafter lf re4window installation. the car has to be used within the first four hours,it must be drivenslowly. all 1't Reinstall remainingremovedparts. . NOTE:Advisethe customernot to do the following thingsfor two to threedays: . . Slamthe doorswith all the windows rolledup. (suchas when going Twist the body excessively a i n a n d o u t o f d r i v e w a y s t a n a n g l eo r d r i v i n g over rough,unevenroads).
[/
-+-
oo"r'u.
in) 8 mm (0.31
20-35
RearWindow
Removal
3D: 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
Upperportion:
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) Rearwindow wiper arm {seepage20-1 15) Hatchspoiler(seepage20-101) 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.
TAPE Side portion: GLASS
3. Apply protective tape to the inner edge of the tail

gare.
4.
From insidethe hatch,usea knifeto cut throughthe rearwindow adhesive the way around. all NOTE: . lf the rear window is to be reinstalled, take care not to damagethe molding. . lf the molding is damaged, replace the rearwin dow and moldingas an assembly
Lower Dortion:
MOLDING
HATCH
G^Yb\
's>
ADHESIVE
Carefully removethe rearwindow. NOTE:Checkthe moldingfor damage,and replace the rearwindow if necessary.
BEAR WINDOW
20-36
lnstallation
'1.
smoothto a Using a knife,scrapethe old adhesive t h i c k n e s s 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 o 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 flange. NOTE: . Do not scrapedown to the paintedsurfaceof the body; damaged paint will interferewith proper bonding. and fasteners . Remove the rubberdams, spacers from the hatch. . Mask off surroundingsurfacesbefore applying primer.
4.
Glue the rubberdams to the insidetace of the rear window, as shown, to containthe adhesiveduring and seals spacer and installation, gluethe fasteners, as shown. NOTE: . Gluethe rubberdams usingthe printeddots as a g ul d e . . Be careful not to touch the rear window where a d h e s i vw i l l b e a p p l i e d . e >: Fastener, spacer seal 6nd
locations a >,4 FASTENER
B > ,1
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 i d a m p e n e dn a l c o h o l . 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 from gettingon the surface. , 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 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 is where new adhesive to be applied. is NOTE:Makesurethe bondingsurface keptfree of water,oil and grease. CAUTION:Avoid setting the rear window on its edges;the molding can be psrmanently deformed. area. NOTErClean the shadowed
D> , 2
Insid.
-d ' -f--At
FASTENER REARWINDOW
RUBBER
REARWINOOW
PRINTED DOTS
RUBBER DAM
MOLDING
(cont'd)
20-37
RearWindow
lnstallation {cont'd)
Install fasteners the hatchas shown. the to >: Fastener locations, 4 8. With a sponge, apply a light coat of glass primer around the edge of the rear window, then lightly 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 primedsurfaces with your hands. lf you do, the adhesive may not bond to the rear window properly, causing a leak after the rear window is installed. Keep water, dust. and abrasivematerialsaway from the primedsurface. V//////7, , eppv stass c,im6, h6r6.
Insido
N r t A I \\ N
* \
V, llsmm I W-- ]10.59 inl
cr-l'ss
SPACER REAR wlNOOW
Set the rearwindow uprighton the hatch,then center 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 be applied. will
7.
Remove the rearwindow.
20-38
9. With a sponge,apply a light coat of body primer to r t h e o r i g i n a la d h e s i v e e m a i n i n ga r o u n d t h e r e a r window openingflange.Letthe body primerdry for at least10 minutes. NOTE: . Do not applyglassprimerto the body,and be caretul not to mix up glassand bodyprimersponges. . Nevertouchthe primedsurfaces with your hands. ///////l ' aooV roay primerhere.
l6 mm in) {0.63
without air pockets into the cartridge 12. Packadhesive continuosdelivery.Put the canridgein a to ensure g a c a u l k i n g u n , a n d r u n a b e a do f a d h e s i v e r o u n d the edgeof the rearwindow as shown. within 30 minutesafter NOTE:Apply the adhesive applyingthe glassprimer.
i:EI^,T_/:aDHEs,vE
8mm { 0 . 3 1i n l
JI\ ,/N \ SPACER
--_Jr-DZT ro.ornr tEt

GLASS
REAR WINDOW
22 Jnm
together and hardener 1 0 . Thoroughly mix the adhesive on a glassor metalplatewith a putty knife. NOTE: . Cleanthe platewith a spongeand alcoholbefore mrxrng. . Followthe instructions that came with the adhesive, cut the end of the nozzle 11. Beforefilling a cartridge, as shown.
GLASS
Cut nozzle
MOLDING
-----ll
,,.17
\
'10mm in) {0.3S MOLDING,7 mm {0.27 in)
ffi-f
f\-L,--int to.oe
(cont'd)
20-39
Rear Window
13. Use suctioncups to hold the rear window over the 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 a r k sm a d ei n , t step6, and set it down on the adhesive. Lightlypush on the rear window until its edgesare fully seated o n t h e a d h e s i v a l l t h ew a y a r o u n d . e NOTE:Do not openor close the doorsuntilthe adhesiveis dry.
SUCTION
Ouarter Glass
Removal
3D: CAUTION: a Wear gloves to remove and install the quarter glass. a Use seat coversto avoid damaging any surfaces. 1. To removethe quarterglass, first removethe: . Rear seat-back and rear seat cushion (see page 20_80) . Rear center shelf and rear side shelf (see page 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) Upper anchorbolts from the front and rear seat belts{seepages20 86, 89) Ouanertrim panel(seepage20-60) From insidethe car, use a knifeto cut through the quarterglassadhesive the way around. all NOTE: . lf the clip on the rear edge is broken, the quarter glasscan be reinstalled usingbutyltape(seepage 20-421. . Apply protective tape alongthe edgeofthe entire quarterglassopeningflange.
cuPs
.J
1 4 . Scrapeor wipe the excess adhesive with a putty off
2.
knifeor towel. NOTE:To removeadhesive from a paintedsurface or the rear window, use a soft shop towel dampenedwith alcohol. L e t t h e a d h e s i v e r y f o r a t l e a s to n e h o u r , t h e n d 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 dry, then sealwith sealant. NOTE:Let the car standfor at leastfour hoursafter rear window installation. the car has to be used lf within the first four hours,it must be drivenslowly. 1 6 . Reinstall remainingremovedpans. all NOTE:Advisethe customernot to do the following thingsfor two to threedays: . . Slam the doorswith allthe windows rolledup. (suchas when going Twist the body excessively i n a n d o u t o t d r i v e w a y s t a n a n g l eo r d r i v i n g a over rough,unevenroads).
GLASS
20-40
Installation
Upper portion: smooth to a Using a knife,scrapethe old adhesive t h i c k n e s s 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 o 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 body; damaged paint will interferewith proper bonding. . Remove rubberdamsfrom the body. the . lf any of the clips are broken,removethem from the body. . Mask off surroundingsurfacesbefore applying pnmer. 2. Clean body bondingsurface the with a sponge dampenedin 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 . from gettingon the surface. 3.
ADHESIVE
RUABER DAM
ADHESIVE PROTECTIVE TAPE
Lower portion:
PROTECTIVE TAPE
lf the quaner glass is to be reinstalled, use a putty knife to scrapeoff all traces of old adhesive, then cleanthe quarterglass surfacewith alcoholwhere is adhesive to be applied. NOTE:Make sure the bonding surfaceis kept free of water,oil and grease.
Pillar portion: OUARTER GLASS TRIM
CAUTION:Avoid setting the quarter glass on its edges;small chips may later develop into cracks. NOTE:Clean the shadowedarea.
ADHESIVE
CLIP
3.
Carefully removethe 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, them if necessary. and replace
(cont'd)
20-41
OuarterGlass
Installation {cont'dl
Gluethe upperand lower rubberdams to the inside face of the quarterglass,as shown, to containthe adhesive during installation. 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 adhesive will be applied. >: Alignment mark 'o""tton" oao""
UPPER RUBBER DAM OUARTER GLASS
6.
(and the lf the old quarterglass is to be reinstalled 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 coat of primer (3M C-100, equivalent), or then apply butyl tape to the quarterglass.as shown. and seal the body holewith pieceof urethane tape. NOTE: o Be careful not to touch the quarter glasswhere will be applied. adhesive . Do not peelthe separator the butyl tape. off
r-'J--.i..
mml tT13.5 I
i l 0 . 1 i4 l n \ \ I RUBEER DAM
--f-_1_-
'//////7r,
: eug tape tocstions(3M8628, equivelent) or Thickn*s:3.2 10.13 mm inl 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 adhesive will be applied.
UPPER
OUARTER
GLASSTRIM
NOTE:Contact clipsagainst the the quarter9lasstrim at the areas indicated the arrows. by
20-42
7.
With a sponge,apply a light coat of glassprimerto the insideface of the quarterglass,as shown,then lightlywipe it off with gauzeor cheesecloth. NOTE: . Do not apply body primer to the quarter glass, and do not get body and glass primer sponges mixed up. . Nevertouchthe primedsurfaces with your hands. It you do, the adhesive may not bondto the quarter glassproperly,causinga leak afterthe quar ter glassis installed. . Keep water, dust, and abrasivematerialsaway from the primedsurface.
8. With a sponge,apply a light coat of body primerto remainingaroundthe quarter the originaladhesive glassopeningflange.Let the body primer dry for at least10 minutes. NOTE: . Do not apply glass primer to the body, and be 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 sponges. . Nevertouchthe primedsurfaces with your hands. . Maskoff the rearside trim panel beforepainting t h ef l a n g e . ////////7 : aootvbodv odmerhere.
1 6m m (0.63inl
////////
' eooV st.,. primerhere.

21 mm 15 mm lo.tB io) {0.59inl
OUARTER GLASSTRIM
mix the adhesive and hardener together Thoroughly on a glassor metalplatewith a putty knife. NOTE: . Cleanthe platewith a spongeand alcoholbefore mr x r n g . . Followthe instructions that came with the adhestve.
15 mm in) {0.59 30 mm lr.2 in)
cut the end of the nozzle 10. Beforefilling a cartridge. as shown.

C u t n o z z l ee n d
in) 10 mm 10.39
7 mm 10.27 in) (cont'd)
20-43
Ouarter Glass
Installation {cont'd)
11. Packadhesive into the cartridge without air pockets Put in to ensurecontinuous delivery. the cartridge a g c a u l k i n g u n , a n d r u n a b e a do f a d h e s i v e r o u n d a the edgeof the quarterglassas shown. NOTEI . lf the old quarterglass is to be reinstalled, peel the separator the butyl tape afterapplyingthe off adhesive. . Apply the adhesive within 30 minutesafterapplying the glassprimer. 12. Use suctioncups to hold the quarterglassover the opening. alignthe clips,and set it down on the adhe sive.Lightlypush on the quarterglassuntil its edges arefully seated the adhesive the way around. on all 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 is adhesive drv.
li.;l,l/:ADHE','E
8mm {0 3'l inl OUARTER GLASSTRIM 22.5nm in) {0.89
CLIP
UPPER RUBBER DAM BUTYL TAPE
Scrape wipe the excessadhesive with a putty or off knifeor towel. from a paintedsurface NOTE:To removeadhesive or the quarter glass,wipe with a soft shop towel with alcohol. dampened 1 4 . L e t t h e a d h e s i v e r y f o r a t l e a s to n e h o u r , t h e n d spray water over the quarter glass and checkfor leaks.Mark the leakingareas,let the quarter glass dry, then sealwith sealant.
LOWER RUBBER DAM
NOTE:Let the car standlor at leastfour hoursafter quarterglass installation. the car has to be used lf within the first four hours,it must be drivenslowly. 1 5 . Reinstall remainingremovedparts. all NOTE:Advisethe customernot to do the following thingsfor two to three days: . . Slam the doorswith all the windows rolledup. (suchas when going Twist the body excessively i n a n d o u t o f d r i v e w a y s t a n a n g l eo r d r i v i n g a over rough,unevenroads).
RUBBER DAM
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-back and rear seat cushion (see page 20-81) . Sidetrim panel(seepage20-61) . Rearshelf(seepage20-61) o Upper anchor bolt from the front seat belt (see page20 86) . Ouanertrim panel(seepage20-61) 2. Ftom insidethe car, use a knifeto cut through the quarterglassadhesive the way aroundall NOTE: . lf the quarterglassis to be reinstalled, take care not to damagethe molding. . Apply protective tape alongthe edgeofthe entire quarterglassopeningflange.
Rear edge portion:
ADHESIVE
PROTECTIVE TAPE
a
Pillar portion:
TAPE
GLASS
removethe quanerglass. Carefully NOTE:Checkthe moldingfor damag,and replace it if necessary.
20-45
OuarterGlass
Installation
' t . Using a knife,scrapethe old adhesive smooth to a o t h i c k n e s s 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 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: . Do not scrapedown to the paintedsurfaceof the body; damaged paint will interferewith proper bonding. . Remove fastener from the body. the . lf any ot the clips are broken,removethem from the body. o Mask off surroundingsurfacesbefore applying primer. with a spongedampClean body bondingsurface the enedin alcohol. NOTE: After cleaning,keep oil, greaseand water from gettingon the surface. lf the quaner glass is to be reinstalled, use a putty knife to scrapeoff all traces of old adhesive, then cleanthe quarterglass surfacewith alcoholwhere adhesive to be applied. is NOTE: Make sure the bonding surfaceis kept tree of water,oil and grease. CAUTION:Avoid setting the quarter glass on its edges;small chips may later develop into cracks. NOTE:Cleanthe shadowed area. 4. Installthe molding around the edge of the quarter glassas shown. NOTE: . It the old molding is to be reinstalled, scrapeoff t h e o l d a d h e s i v e a p e f r o m t h e m o l d i n g ,a n d t 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 new adhesivetape is to be applied.Apply the adhesive tape to the molding and double-faced quarterglassas shown. . Be carelul not to touch the quarter glasswhere will be aDDlied. adhesive Adhesivetape A {3M 4215,or equivalentl Thickness:0.4 mm (0.02inl in) Width: 5 mm 10.2 Length:440 mm (17.3in) Adhesivetape B (NITTO501, or equivalontl Thickness:0.16 mm (0.006inl Width: 8 mm 10.3 inl Length:'140 mm (17.3in) Adhesivetape C {3M '1213, equivalentl or mm (0.03inl Thickness:0.8 Width: 5 mm (0.2in) Length:30 mm (1.2in) ADHESIVE
20-46
5.
glue the lf the old quarterglass is to be reinstalled, as upperand lowerclipsand fastener 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 adhesive will be applied. loc.tions >: Clip,tastener a>,2
ALIGNMENT
7.
With a sponge,apply a light coat of glassprimerto the insideface of the quarterglass,as shown,then lightlywipe it off wjth gauzeor cheesecloth. NOTE: . Do not apply body primer to the quarter glass, and do not get body and glass primer sponges mixed up. . Nevertouchthe primedsurfaces with your hands. may not bondto the quarlf you do, the adhesive ter glass properly,causinga leak after the quarter glassis installed. . Keep water, dust, and abrasivematerialsaway from the primedsurface. t///////1 ' aooV wav orime,hero.
15.5mm 10 mm {0.61in) (0.39in)
B> , 1
2.5mm
MOLDING
6.
Gluethe fastener the body as shown. to >: Fastener locstion. 1

ALIGNMENT
(cont'd)
20-47
Ouarter Glass
With a sponge.apply a light coat ol body primer to the originaladhesive remainingaroundthe quarter glassopeningflange.Let the body primer dry for at least10 minutes. NOTE: . Do not apply glass primer to the body, and be 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 sponges. . Nevertouchthe primedsurfaces with your hands. . Maskoff the rear side trim panel beforepainting the flange. t///////7, , epptyroay erimerhere. 11. Packadhesive into the cartridge without air pockets to ensurecontinuousdelivery.Put the cartrigein a g c a u l k i n g u n , a n d r u n a b e a do f a d h e s i v e r o u n d a the edgeof the quarterglassas shown. NOTE: . lf the old quarterglass is to be reinstalled. peel the separator the butyltape afterapplying off the adhesive. . Peel the separator off the adhesivetape after applyingthe adhesive. . Apply the adhesive within 30 minutesafterapplying the glassprimer.
1 . 5m m
i;.Ii^,/:
ADHE'T'E
8mm (0.31 in)
CLIP
9. Thoroughlymix the adhesive and hardener togeth, er on a glassor metalplatewith a putty knife. NOTE: . Cleanthe platewith a spongeand alcoholbefore mixing. . Followthe instructions that came with the adhe sive. 10. Beforefilling a cartridge, cut the end of the nozzle as shown.
Cut nozzle end 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 Lightlypush on the quaner glassuntil its adhesive. all edges are fully seatedon the adhesive 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 is adhesive dry.
CLIP
off 1 3 . Scrape wipe the excessadhesive with a puny or knifeor towel. from a paintedsurface NOTE:To removeadhesive or the quarter glass,wipe with a soft shop towel with alcohol. dampened
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. the car has to be used lf within the firstfour hours,it must be drivenslowly. removedparts. Reinstall remaining all NOTE:Advisethe customernot to do the following thingsfor tlvo to three days: . . Slamthe doorswith all the windows rolledup. Twist the body excessively lsuch as when going a i n a n d o u t o f d r i v e w a y s t a n a n g l eo r d r i v i n g over rough,unevenroads).
20-49
Moonroof
lndex
PLATE SWTTCH page20-56 Adiustment,
=-.
CABLEASSEMBLY page20-55 Replacement,
SUNSHADE page20 52 Replacement,
INNERCABLE RAIL HOI-DERB SLIDER
RAIL HOLDERA
REAR DFAIN TUBE ,
?<^ / \
UBE
LfP
REARDRAIN VALVE
ll
ll
U 6
?'''
a"w
FRONT DRAIN TUBE
20- 5 0
Troubleshooting
Symptom Waterleaks '1. Clogged draintube. and roof panel 2. Gap betweenglassweatherstrip glassweatherstrip or 3. Defective improperlyinstalled sealand roof panel. 4. Gap betweendrain and roof panel. betweenglassweatherstrip clearance 1. Excessive 1. Loosemotor. 2. Worn gear or bearing. deformed. 3. Cableassembly '1. Clutchout of adjustment. 2. Foreignmatterstuckbetweenguide rail and slider. 3. Innercableloose. properly. not 4. Cableassembly attached 1. 2. 3. 4. 5. Blownfuse. Faultyswitch. Batteryrun down. Defective motor. Faultyrelay. ProbableCause
Wind noise Motor noise
Glassdoes not move.but motor turns
Glassdoes not move and motor does not turn (glasscan be movedwith moonroofwrench)
HeightAdjustment Glass
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:
rl.3 1.7 mm 13:3i {0.07 in)
1.
Remove the bracket cover. Loosenthe nuts, and installthe shims betweenthe glassframe and glassbracket shown. as Shim thickness:Frontmax.3 mm {0.12inl Rearmax. 2 mm (0.08inl Repeat opposite on side if necessary
6xl.0mm 9.8 N m (1.0kgl m, 7.2lbl.ltl
BRACKET COVER
6x1.0mm kgI.m. 9.8 N.m {'1.0 7.2lbtft)
20-51
Moonroof
Glass,GlassBracketand SunshadeReplacement
1 . C l o s e h eg l a s s u l l y . t I 2. 3. Slidethe sunshade the way back. all Removeboth bracket covers.
6. R e m o v et h e d r a i n c h a n n e l . DRAINCHANNEL
BRACKET COVER
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 kst 9.8N.m{1.0 m,7.2lbf ft)
Removethe glassby lifting up and pulling forward as shown. NOTE| Do not damagethe roof panel.
GLASS
RAILHOLDER B
Usingthe moonroofwrench,move the glassbracket to the positionwherethe moonroofnormallypivots down, and removethe screws.
scREws
20-52
the 9. Remove rail holderA.

NUT 6x1.0mm 9 N.m {0.9 kgf m,
forward,then removeit. 12. Slidethe sunshade
of is 1 3 . Installation the reverse the removalprocedure. the NOTE:Check glassheight(seepage20-51). for 1 4 . Check water leaks. water' NOTE:Do not use high-pressure
ROO CHANNEL STOP DRAIN rail. it to Rotate shown remove fromtheguide as 10, Removethe drain channelrod slider by moving the cablesliderforwardusingthe moonroofwrench. '11. Detachthe drain channelrod stop from the cutout of the guide rail as shown,
20-53
Moonroof
Motor, DrainTubeand FrameReplacement
GAUTION: . Wear gloves to remove and install the ftame. . Be careful not to damagethe seats, dashboardand other interior trim. 1. 2. Remove (seepage20-64). the headliner Disconnect motor connector the and glasspositionswilch connector. NOTE:when removingthe motor,detachthe connector from the frame,removethe bolts and nuts.then removetne motor. 3. 4. 5. Remove glass{seepage20-52). the Disconnect draintubes,and detachthe ceilinglight harness. the Remove frame mountingbolts. the NOTE: . An assistant helpfulwhen removingthe bolts. is . Remove front bolts last. the 6. Detach the rearhooksby movingthe frameforward,then removethe frame.
Remove last,
BOLT 6x1.0mm 9.8Nm(1.0kgl.m, 7.2 tbl.tll 6 x 1.0mni 9.8 N.m 11.0 kgf.m,7.2 tbtfo
20-54
AssemblY Guide Rails/Cable Replacement

7. Pullthe draintubesout the front and rearpillars NOTE:Beforepullingout the draintube,tie a string to the end ot it so it can be reinstalled. CAUTION: Wear gloves to remove and install the guide railsand cableassembly. 1. 2. 3. the Remove frame. the Remove motor and glassbracket(seepage20 52)' Removethe nuts, and liit off each guide rail, then with slidersattached' removethe cableassembly NOTE:Take care not to bend the cable tubes and g u i d er a i l s .
REARDBAIN VALVE
of is lnstallation the reverse the removalprocedure' NOTE: the frame,clearthe drain tubes . Beforeinstalling alr. and drainvalvesby usingcompressed . Check frame seal. the of . Cleanthe surface the frame. . When installingthe trame, first attach the rear hooksinto the body holes. the . When connecting draintube, slide it over the at frame nozzle least10 mm (0.39in) . I n s t a l l t h eu b ec l i Pa s s h o w n . t GROMMET 4. of is Installation the reverse the removalprocedure' NOTE: partsshouldbe replaced . Damaged . Grease slidingportionwith SuperHighTemp the P/N UreaGrease, 08758 9002. grommetwith sealant. . Fillthe groovein each
Upward
I
I
TUBECLIP
TUBE DRAIN
9.
for Check water leaks. water. NOTE:Do not use high-pressure
a lnstallthe frame sealsecurelY the motor, makesure both slida Beforeinstalling
ers are parallel. the motor, installthe trame and Beforeinstalling glass,then checkthe openingdrag (seepage2057).
I f
20-55
Moonroof
Switch PlateAdjustment(FullyClosedPositionl
1. 2.
Remove the headliner {seepage20-64). Usingthe moonroofwrench,closethe glassfully. NOTE:Check glassfit to the roof panel. the
3. 4. 5.
Usingan open-end wrench,loosenthe switchplatemountingbolts. Adjustpositionof the switchplate(switchcam) as shown. Checkthe operation the glass(fromtilt-up positionto fully closedposition, of from the fully open positionto the fully closedpositjon) operating moonroofswitch. by the NOTE:Check glassheight{seepage20-51}. the
SWITCHPLATE GUIOE PLATE
Vt, ,
I l
I
cnecl Check switchplatecontacts the rr the

ca re r cablebracket. o o
CABLEERACKET ,
SWITCH CAM
INNER CAELE END
While movingthe switchplate little by little,securethe switch plate at the positionwherethe switchcam contacts switch the A (a faintclickis heard).
Closethe glassfully, and checktor water leaks. NOTE: Do not use high-pressure water.
2 0- 5 6
DragCheck Opening (Motor Removed)

the effort required the motor, measure Beforeinstalling glassusinga springscaleas shown. to openthe CAUTION: When using a spring scale.plotest the lading dge of the glasswith a shop towel. lf load is over 40 N (4 kgf,9 lbf),checkthe side clearance ( h a n d g l a s s e i g h t s e ep a g e2 0 - 5 1 ) .
ClosingForceCheck (MotorInstalled)
a 1 . A f t e r i n s t a l l i n g l l r e m o v e dp a r t s ,h a v e a h e l p e r hold the switch to close the glasswhile you measure the force requiredto stop it. Attach a spring scaleas shown. Readthe force as soon as the glass the switch stops moving,then immediatelyrelease and springscale. CAUTION: When using a spring scale, protect the leading edge ol the glass with a shop towel. Closing Force:200 - 290 N (20 - 30 ksf, /14- 66 lbf)
SHOPTOWEL
SCALE
installa new lf the force in not within specification, the tensionby turningthe motor lockwasher,adjust 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 nur. the against motor clutchadjusting
LOCK WASHEB Replace.
aI
COUNTERcLocKwtsE
To decrease
20-57
lnterior
Component LocationIndex
SRScomponents locatedin the pans areasmarkedwith an asterisk Reviewthe SRScomponentlocauons, are (*). precautions,and procedures the SRSsection(24)beforepertormingrepairs service. in or 2D l3D llDl
CENTER PILLAR UPPER TRIM {seepage20 59) FRONT PILLAR TRIM (seepages 20'59, 61i 60,
CENTER PILLAR LOWER TRIM PANEL (seepage20 59) REARPILLAR TRIM (seepage 20-59) REAR (seepage20-59) TRUNK TRIM (seepage20-62)
SEAT SIDE TRIM
(seepage20-59)
Component Removal/lnstallation, page20-68 page20-70 Removal,

TCARPET
page20-66 Feplacement, PANEL page 20-67 Replacement.
3D:
OUARTER TRIM PANEL (seepage20 60) REARROOFTRIM (seepage20 65)
2Dl
OUARTER TRIM PANEL
HATCH UPPER TRIM (seepage20 63) REARCENTER SHELF (seepage 20-60)
REARROOF TRIM {seepage20,65}
REAR
PANEL
(seepage20-60)
SIDETRIM {seepage20-60}
REAB
PANEL (seepage20-62) REAF (seepage20-6'1)
TRIM PANEL (seepage 20'63)
SIDETRIM 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. the NOTE:Takecarenot to bend or scratch trim and panels 4D:
>: Clip locations
a>,2
CLIP
8>,6
c>,21
o>,2
E> , 2
retu n>(
\Zl\
^f
J
CLIP
REARSHELF
LOCKCYLINDERTRIM FRONTPILLAR TRIM
PILLAR CENTER TRIM LOWER PANEL
SEAT
BELTUPPER ANCHOR (seepage20 85)
the Disconnect high mount brake lightconnector.
RIGHT KICK PANEL T SIOETRIM and rear Remove rearseatcushion the (seepage20 79i. seatsidebolster
of is lnstallation the reverse the removalprocedure. NOTE: . lf necessary, any damagedclips. replace . Beforeinstalling front seatbelt upper anchor the and rear shelt, make sure there are no twists or kinksin the seatbelts. (cont,d)
20-59
Interior Trim
3D: >: Clip locations a>,2
CLIP
B>.3
c>,8
>: Screw, bolt locations D>,3 E> , 8
a>,3
B>,6
n l-, rr,\\F\
,\\ \ \ ul\ / l
_ _ F > ,1 {
##/ _ s __CLIP
A i f , n \ l e
7
qHP Y l*@ \ /
c > .1 ,r+n
D> , 2
/
G>,2
H>,2
'.,.
N i 4 )
|_) _t),t )_w/
i @ i
rcig
REARSEATBELT UPPER ANCHOR {seepage20-89)
l@@
\-REARSIDE SHELF
\ - -
FRONTSEAT EELTUPPER ANCHOR (seepage20-86)
SIDETRIM PANEL Remove rearseat-back the and (seepage20-80) rearseatcushion Disconnect rearspeaker the (bothsides, connector for somemodels). REARTRIM PANEL
SIDETRIM PANEL PROTECTOB
SIDETRIM
REAR CENTER SHELF

FRONT SEAT BELT LOWER ANCHOR (seepage 20 86) H
SPABETIRE LID
,
Installation the reverse the removalprocedure. is of NOTE: . lf necessary, replace any damaged clips. . Before installing anchorbolts,makesurethere the 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
N,tU ffi
FRONTPILLAR SIDETRIM PANEL and Remove rearseat-back the (seepage rearseatcushion 2 08 1 ) . LOCKCYLINDER TRIM
,.
r$H
FRONT SEAT EELTUPPER ANCHOR {seepage20-86) SIDETRIM PANEL the Disconnect high mount brakelight connector. SIDETRIM PIVOTBRACKET (seepage20-81)
w'
A
a rrcx ntoir
, \ . / " c
SEATBELT LOWER ANCHOR (seepage20-86)
is of Installation the reverse the removalprocedure.
LEFT KICK
PANEL
NOTE: . lf necessary. clips. replace any damaged . Beforeinstalling the anchorbolts and rear shelf, or makesurethereare no tvvists kinksin the seat 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 scratch trim and panels. the . When removingthe trunk sidetrim or trunktrim panel,fold the seat-back torward.
Japan-produced: 4D: RIGHT TRUNK SIDETRIM REARTRIM PANEL >: Clip locations a >,6 NOTE:Do not push the innerclip in too far. I
I l'3{aQ'F-
R-.--\ra
"
CLIP
s:'\
B>,6
I
, t -
\\-
|NNER
cll
\-/tt
!l
i J
i ) :Hook locations Ai-), t
TRUNK MAT
2D:
TRUNK TRIM
B t-'),2
Installation the reverse the removalprocedure. is of NOTE: . lf necessary, replace any damaged cl;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. the NOTE:Takecarenot to bend or scratch trim and panel.
>: Cliplocations
a >' 2
NOTE:Do not pushthe I innerclip in too far. I
B> , 7
c>,13
vr: 54@-,1 / g * - \ |
M cr-rp. I
Y , / :?INNER ]
rr -
-N-l
IS]
",/
ct!,/
'Pr-u
a
.rt-ATa-a-a c l
;--'"[1"
LEFTHATCH SIDETRIM HATCH TRIM UPPER 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. wlap it with protective tape to prevent damage. NOTE: . Takecarenot to bendand scratch headliner. the . Be careful not to damagethe dashboardand other interiortrim. '1. Remove: 4D: a Frontpillartrim (bothsides,see page20-59) a Center pillarlowertrim panel(bothsides, page see 20-59) Upper anchorbolt from the front seat belt (both sides, page20-85) see pillaroutertrim and centerpillaruppertrim Center (bothsides,seepage20-59) a Ceilinglight (seesection23) Rearview mirror (seepage20-25)
2. Remove the sunvisor and holder from each side.
3.
Remove grab handles the and coathanger.
ACCESS LID
3D:
Frontpillartrim (bothsides, see page20-60) Right rear seat-back and rear seat cushion (see page20-80) . Rearcentershelf(seepage20-60) 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 , seepage20 60) . Upper anchorbolts from the front and rear seat belts{right side,seepages20-86, 89) . Ouarter trim panel(rightside,see page20-50) . Ceilinglight (seesection 23) . Rearview mirror (seepage20-25) . . 2Dl . Frontpillartrim (bothsides,see page20-61) . Right rear seat-back and rear seat cushion (see page20-81) . Sidetrlm panel(rightside, seepage20-61) . Upper anchorbolt from the front seat belt (rlght side,see page20-86) . Ouarter trim panel(rightside,see page20 61) . Ceilinglight (seesection23) . Rearview mirror (seepage20-25)
ACCESS LID
scREws
COATHANGER BRACKET
20-64
4.
Remove the rear root trim and clips, and remove the roof trim and socket plug (moonroof model)
2Dl
>: Clip locations A> 20l40,7 B > With moonrool,1 3 3D,5 Withoutmoonrool,
)At % )
EE & )
2D l3D l4Dl
REARBOOF REAR PILLAR TRIM
HEAOLINEB
OUARTER TRIM PANEL
5.
4D: Lowerthe rearpillartrim on both sides. 3D: Removethe upper anchor bolts from the front then lower and rearseatbelts(seepages20-86.89i, the quanertrim panelon left side. t 2 D : R e m o v e 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 then lower the quarter seat belt (see page 20-86), trim panelon left side. Lower heheadliner. t throughthe passenremovethe headliner Carefully ger'sdoor opening(2Dl4D) hatchopening(3D) or oI is Installation the reverse the removalproceclure. NOTE: . W h e n i n s e r t i n gh e h e a d l i n etrh r o u g ht h e o p e n t not ing, be careful to fold or bendit. Also,be carethe tul not to scratch 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 attached the trim. to securely . W h e n i n s t a l l i n g h e r o o f t r i m , i n s t a l lt h e j o i n t t towardthe right side (moonroofmodel)
6.
7.
8.
3D:
20-65
Carpet
Replacement
SRScomponents located this area.Review SRS are in the precautions, procedures the componentlocations, and in (24)beforeperforming SRSsection repairs service. or 1. Remove: . Frontseat(seepage20-7 4l . Rearseatcushion(seepages20-79, 81) 80, Kickpanel(seepages20-59, 61) 60, pillarlowertrim panel(4D.seepage20,59) Center a Frontseat belt lower anchor(2Dl3D, seepage2086) a Sidetrim {seepages20-59, 61) 60, a Frontand rearconsoles a Console panel Remove SRSunit covers. the 4. Remove footrestand parkingbrakelevermountthe ing bolts,and detachthe clips,then removethe carpet.
>: Clip locations, >: Bolt locations A>,2 B>.2
rft
\ t l
9s l /
N.m ksrm, tf I e.s t1.o E / 7 2 tbrftl
6x'l.0mm
2Dl3Dl4D:
FOOTREST
3 . Cut areas@ and @ in the carpet, then pull it backas

snown. >: Clip locetions, 2
l@l -llp
--.ils I |
2D l3Dl
SIDETRIM
LEFTSRS UNIT COVER
5.
Installation the reverse the removalprocedure. is of NOTE: . Takecarenot to damage, wrinkleor twist the car pet. . Make surethe wire harnesses routed correctly. are . lf necessary, replace any damagedclips. . Slip the carpet under the seat side trim (4D) or sidetrim panel(2Dl3D) eachside properly. on . Reattach the cut areas@ and @ in the carpet with wire ties.
20- 6 6
Panel Consoles/Console
Replacement
front seatand relatedparts. the NOTE:Takecarenot to scratch front and rearconsoles, Disassemble numberedsequence. in
>: Screw locations A>,8 A>./t
>: Clip localions
A>,2
B>,2
0F*
: ) "
@@'
-f
D7777777v-r
i
(' FRONT CONSOLE
Remove the shif! lever knob {M,/T).
) _ : )
o REARCONSOLE
lwith armrest)
^\
procedure. of Installationthe reverse the removal is NOTE:

. . . any damagedclips. lf necessary, replace are Makesurethe wire harnesses not pinched. properly. is Makesurethe connector connected
20-67
Dashboard
Removal/lnstallation Component
CAUTION:when plying with a flat tip screwdriver,wrap it with protectivetape, and apply protectivetape around the related parts,to prevent damage. and the NOTE:Takecarenot to scratch dashboard related parts. Instrument panel removal:
1.
Driver'sdashboardlower cover and knee bolster removal: the in are SRScomponents located this area.Review SRS precautions, procedures the in and componentlocations, repairs service. or SRSsection {24}beforeperforming 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 l r e m o v e t h e d r i v e r ' sd a s h b o a r d o w e r c o v e r .l f disconwith power mirrorsand moonroof, equipped nectthe connectors.
column. Lowerthe steering the and detachthe clips,then careRemove screws, panel. fully removethe instrument
2.
>: Screw, bolt locations B>,2 a >,3 --'4.i ***\Y /D,- ox lomm ((n1lfl )e.8 N m (l.o kgtm, \)- 7.2tbf.ftl
>: Screw locations,2
>: Clip locations.2
"[]
l
p 1
J
>: Clip locations B>, 1 a>.2
F-,,
MIRROR POWER CONNECTOR SWITCH (for somemodels)
PANEL
3.
lnstallation the reverse the removalDrocedure. is of

MU(,NTIUUI-
swtTcH
CONNECTOR models)
DRIVER'S DASHBOARD LOWER COVER
2. 3.
Remove the bolts,then removethe kneebolster. Installation the reverse the removalprocedure. is of
Glove box removal: Remove the bolts,then removethe glove box. >: Boltlocations, 2
Center dashboardlower covsr:

'1. Remove: . Driver's dashboard lower cover . Glove box Remove the screws and bolt. then remove the cen ter dashboard lower cover. Disconnect the accessory socket connector.
5xo.8mm
I
2.
9 N m lO.9 ksf.m,I '::" )
>: 8olt, scrsw locations A>, I
B>,5
6:u;q9 Q,
lnstallation the reverse the removalorocedure. is ot
A ,ro.r--
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 lower dashboard Remove driver's the cover,or openthe glovebox, then pushthe clipstrom each openingby hand,and pullit the out. Disconnect connedors (driver's side).
CENTER DASHBOARO LOWER COVER

CLIP
HOOKS
3.
Instgllation is the reverse of the removal procedure
DASHLIGHTS BRIGHTNESS CONTROLLER
lCRUISE CONTROL MASTER SWITCH CONNECTOR (forsomemodels)
[3LT'-""'31r",.,
(cont'd)
20-69
Dashboard
ComponentRemoval/lnstallation (cont'd)
Center panel removal: '1. Remove: . Center lowercover(seepage20-69) dashboard 23) . Radio(seesection 2. Remove the rear window defoggerswitch and haz the then disconnect connectors. ard warningswitch, locations,5 >: Cliplocations >: Screw B> , 3 A>,4
Removal
a S R Sc o m p o n e n t s 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 precautions, and procedures SRS componentlocatlons, in the SRSsection(24)beforepreformingrepairsor servtce. NOTE: . An assistanl helpfulwhen removingand installing is t h ed a s h b o a r d . t , . T a k ec a r e n o t t o s c r a t c h h e d a s h b o a r db o d y a n d relatedparts. 1. Remove: (seepage20-67) . Frontand rearconsoles . Console panel(seepage20-67) . Driver'sdashboard lower cover and knee bolster (seepage20-68) . Glovebox {seepage20-69) . Center lowercover(seepage20-69) dashboard column(seesection17) Lowerthe steering To avoid accidentaldeployment and @@ possiblo iniury, always disconnsct the driver's airbag connector before lowering the steering column lsee section 2,1). NOTE:To preventdamageto the steeringcolumn, wrap it with a shoptowel. 3. connectors, wire harness Disconnect dashboard the fuse/ remove the nuts, then move the under-dash the relay box. Disconnect antennalead and moonroof relayconnectors.
6tr'
CENTER
@-Y-r
2.
i'Y
ew I
HAZARD WARNING
/w4,
swrTcH
w I
N<4
Mtx
CONTROL CABLE
REAR WINDOW
DEFOGGER SWITCH
CONTROL UNIT
oasHeolno MOONROOF FRAME RELAY CONNECTORS (for somemodels)
9LlPs
SRSMAIN HARNESS
the Disconnect air mix controlcable,and removethe then pull out the centerpanel. screws,
4.
from the heatercontrol Disconnect connectors the unrt. of is Installation the reverse the removalprocedure. NOTE: properly. a Makesurethe connectors connected are (seesection21). . Adjustthe air mix controlcable
ANTENNA LEAD UNDER.DASH FUSE/RELAY BOX
DASHBOARO OATA CONNECTOR WIREHARNESS CONNECTORS Detach.
6x1.0mm 9.8 N.m 11.0 kg{.m, 7.2 tbt.tll
20-70
4.
Remove following partslrom the dashboard. the . Driver'sdashboard sidecover . Passenger's lower cover dashboard . Dashboard centerlid the and air mix controlcable. Disconnect connectors 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 22 N-m 12.2kgl.m, ) 16 tbt ftl / >: Clip locations A>, 1 B>,1
5.
B>,1 ,,{\ I x 1.25mm
c>,1
D>,1 6x1.0mm I
8x1.25mm I
l[!,P
22N.m ksrm, I LBJIP e.6 rn11.s N 1s1m, {2.2 I
I l\-
:
c>,5
I vt)
,"-- _,J
_:_'_"o'nt
___ L
OASHBOARD
ft,ffitsM,i "ffi j /ffi)

PROTECTIVE
PLATE
,Jiill
.ll
' | . 1 , / - - t t / - - - J
M WT
DASHBOARD AIR MIX CONTROL
UNOER.OASH FUSE/BELAY BOX
Loosen bolt. the
r
I
PASSENGER'S DASHBOARD LOWER COVER
6.
Remove bolts,then lift and removethe dashboard. the CAUTION: Use protective platss on the bottom ol the front pillar trim. (cont'd)
20-71
Dashboard
Removal (cont'dl
7. framefrom the dashboard removethe dashboard lf necessary,
>: Screw locations
a: Nut locations,3
a>,21
INSTRUMENT PANEL
I. -Fu' ( -
lft))@ !v
B>,4 .4\
]r45 s'r.o-ksf.m, N.m_11.0 \Gt"/ s.8 r1,b,ft \>: Clio locations
DASHBOARD
DASHBOARD FRAME
DASHBOARD WIREHARNESS
STRIKEB
DASHBOABD SIDECOVER 8. BRACKET
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

ComponentLocationIndex
2Dl3Dl1D: ANCHOR SHOULDER ADJUSTER I4DI 20-85) lseepage REAnSEAT BELT 12Dl,lDl page Replacement, 20-88 page Inspection, 20-91
REARSEATBELTBUCKLE/ CENTER BELTTONGUE{2DI4DI (seepage20'90)
FRONT SEATBELT pages 85,86 20 Replacement, page20-91 Inspection,
FRONT SEATS page20'74 Removal, page20-75 Replacement, Wiringand Becline Harness page20 77 CableLocations, page20 77 SeatCoverFeplacement,
REABSEAT(2Dl4D) pages Removal, 20-79, 81 page 20 82 LatchReplacement, Seat-back page20-83 SeatCoverReplacement, BELTBUCKLES (seepage20-87)
3D: REARSEATBELTBUCKLE/ BELTTONGUE CENTER (seepage20 90)
REARSEATBELT page20-89 Replacement, 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 it with proteqtivetape to preventdamage. NOTE: Takecare not to scratchthe seatcoversand body. '1. Removethe seat track end cover,then removethe bolts. 2. the Lift the driver'sfront seat,then disconnect seat belt switch connector.
)
Remove headrest. the Carefullyremove the front seat through the door openrng.
FRONT SEAT
Installation the reverse the removalprocedure. is of propis NOTE:Make sure the connector connected 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 scratch seatcoversand body. the . Remove front seatthroughthe door openang. the Drivel's: wiring location. for NOTE:Refer page20-77 the seatbelt switchharness to HEADREST
SEAT.BACK
SEATCUSHION
PIVOTNUT 8 x 1.25mm 22 N.n i'2,2 16 lbf.ft)
CENTER
1 0x 1 . 2 5 m m ,17N.m {4.8 kgt m,
v I
10x 1.25mm 47 N.m (4.8kgt.m, 35 tbt.fr) RECLINE AOJUSTER
LOW CAP ER
1 0x 1 . 2 5 m m
&
t
RECLINE
WIRE CONNECTING To connect, twist 180'. OUTERSEAT TRACK
of is Installation the reverse the removalprocedure,
8 x 1.25mm 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 properly. installed t . 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 g h e s e a t back cover. make sure the materialis stretched evenlyoverthe pad. . Grease slidingportion. the
(cont'd)
20-75
FrontSeat
Replacement(cont'dl
Passenger's lwith recline cablel: NOTE:Refer page20-77 the recline to for cablelocation.
HEADREST SEAT.BACK
PIVOT NUT mm I x 1.25 22 N.m(2.2kgf.m, rbr.ftl

SEATCUSHION
PIVOT WASHER LOWER CAP 10 x 1.25mm 47 N.m {4.8 kgf.m, 35 tbf.ftl l0 x 1.25mm 47 N.m (4.8 kgf.m, 35 tbnfr) INNERSEAT
RECLINE
rowE CAP R
10x 1.25mm 47 N.m ({.7 kgf.m, 35 tbf.ft) OUTERSEAT TRACK
WIRE
T o c o n n e c t ,t w r s t 1 8 0 .
Installation the reverse the removalprocedure. is of

8 x 1.25mm 20 N.m (2.0kgf.m, 14 tbtft)
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 ra r e properly. installed . To prevent wrinkleswhen installing seat-back the cover,makesurethe materialis stretched evenly overthe pad. . Adjustthe recline cable. . Grease slidingportion. the
20-76
Harness Wiringand Recline Locations Cable

the seat cushion,make sure the NOTE:When installing and reclinecableare connector seatbelt switchharness, fastened correctly the seatcushionframe. on Driver's:
>: Clip locations
SeatCoverReplacement
CAUTION: Wear gloves to remove and install the seat
GOVetS.
NOTE:Take care not to tear the seamsor damagethe seatcovers. Seat-backcover removal: 1. cover. the Release hook.and fold backthe seat-back
HEADREST
2. (with reclinecablel: Passenger's 3.
Release inside springs,then foid back the seatall DacK cover. Remove the headrest. Removethe headrestguide,then removethe seatDacK cover.
TRACK
is of lnstallation the reverse the removalprocedure. NOTE:To preventwrinkleswhen installinga seatbackcover. makesure the mateial is stretchedevenly the insidespringsand over the pad beforesecuring hook. (cont'd)
20-77
FrontSeat
(cont'dl SeatCoverReplacement
Seat cushion cover removal: 1. 2. Remove seatcushion(seepages20-75,76). the Remove the clipsfrom underthe seatcushion, then loosenthe seatcushioncover.
>: Clip locations
\
4. Installation the reverse the removalprocedure. is of NOTE: . To preventwrinkleswhen installing seatcusha ion cover, make sure the material is stretched evenlyover the pad beforesecuring clips. the . Replace released the clipswith new ones.
NEWCLIP
SEATFFAME COVER
Pull backthe edge of the seatcushioncover all the way around,then release clips,and removethe the seatcushioncover. >: Cliplocations
20-78
RearSeat
Removal
the NOTE:Takecarenot to scratch seatcoversand body. 4D:
::-):Hooklocations,2
c>,1
D>,1
>: CliplocatioG,14
@ ---------8tr-Fq EU
-w
,/
V
CENTER PIVOT BRACKET
r>t
r--r
B
RIGHTSEAT-BACK
SEATCUSHION
SEAT.BACK Pivot bolt construction:
TOOTHED LOCK WASHER

BUSHING PIVOTBOLT ERACKET 8 x 1.25mm 22 N.m {2.2 kgtm, 15 lbf.ftl Apply liquidthreadlock.
NOTE:
a Beforeaftaching and seatcushion,make sure there are no twists or kinks in the rear seat belts and the seat-back centerbelt. throughthe slits in the seat cushion. . When installing seatcushion, slip the seatbelt buckles the . N4ake lockssecurely. surethe seat-back (cont'd) latch(seepage20-82) and seat-back. o lf necessary, adjustthe seat-back
20-79
RearSeat
(cont'd) Removal
3D:
>: Bolt locations A>,6 (:) : Hook locations,2 >: Clip locations,14
8 > ,1
c>,1
6x1.0mm 9.8 N.m (1.0kst m,l
':*2
ffi
It
6x1.0mm 22 N.m |.2.2kgl.m)
6x1.0mm
16tbt'-ft') - -J)
TRUNK
v@n FE E e
SEATCUSHION
E /
STRIKER Remove sidetrim the panel(seepage20 60). 6 x 1.0mrn 9.8Nm(1.0kgf.m, 1.2 tbt.ftl
STRIKER
T
STRIKER
A CENTER PIVOT
BRACKET
PIVOT BRACKET
LEFT SEAT.BACK
Pivot bolt construction:
SEATCUSHION
TOOTHED LOCK WASHER

BUSHING
PtvoTBoLT BRACKET 8 x 1.25 mm Installation the reverse the removalprocedure. is of

22 N.m {2.2kgf.m,16lbtft) Apply liquidthreadlock.
NOTE: . Beforeattaching the seat-back and seat cushion,make sure there are no twists or kinksin the rear seat belts and centerbelt. . When installing seatcushion, the slip the seatbelt buckles throughthe slits in the seatcushion. . Makesurethe seat-back lockssecurely. . lf necessary, adjustthe strikerand seat-back.
20- 8 0
2Di 2 i) : Hooklocations, B>,1 >: Cliplocations, lil
>: Bolt locations A>,6
c>,1
R 6x1.Omm 9.8Nm11.0ksf.m,;
':*' )
,r@?r,
6x1.omm I ,8,u",,0-kgtm,' \ff 22N m t2.2 S.e m tr.O -, N ksf
16tbfitt 7.2rbr.tt) ) E
SEATCUSHION
FF
MAT SEAT-8ACK
V
PIVOTBRACKET
vv --v-.
CENTER PIVOTBRACKET RIGHTSEAT-BACK
|\
Pivot bolt construction:
SEATCUSHION
'..'
PIVOTBOLT 8 x 1.25mm 22 N m (2.2kgI.m, 16 lbf.ft) Apply liquidthreadlock.
TOOTHD LOCK WASHER BUSI{ING PIVOT BRACKET
NOTE: . Beforeattaching the seat-back and seatcushion,make sure there are no twists or kinksin the rearseat belts and centerbelt. . When installing seatcushion, throughthe slits in the seatcushion. slip the seatbelt buckles the . Makesurethe seat backlockssecurely. . lf necessary, latch(seepage20-82) and seat-back. the adt'ust seat-back
20-81
RearSeat
Seat-back LatchReplacement
2Dl1.D: 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 shelf(seepages20-59, 61). NOTE:Takecarenot to bend eachlockrod.
>: Bolt. screw locations a>,2 >: Boh, scrow locrtions A>,4 B>,1
\
3D: (seepage20Pullthe trunk mat awayfrom the seat-back 80).
B> , 2
/-\
ffifu
Ei E c
g.sw m tt.otot.-. 7.2tbr.ft,

7
ort.o--
r g l
/
11'11 )
s.a tt.o N.. r,sf.-.
6x1.0mm
: l
SEAT-BACK
LOCKCYLINDER TRIM
nstallation the reverse the removalprocedure. is of

BACKLATCH
Installation the reverse the removalprocedure, is of NOTE: a Makesureeachlock rod is connected securely. . M a k e s u r e e a c h s e a t - b a c k o c k s s e c u r e l ya n d l opensproperly. . lf necessary. adjustthe seat-back latch.
NOTE: . Replace released the clipswith new ones. . Makesurethe seat-back lockssecurely and opens propeny.
20-82
Seat Gover Replacement

CAUTION: Wear glovs to remove and install the seat covels. NOTE; Takecare not to tear the seamsor damagethe seat covers. Soat-backcover removal: 2DI4D: L 2. (seepages20-79,81). Remove seat-back the L o o s e nt h e s e a t - b a c k o v e r b y r e l e a s i n g l l t h e c a clrps. >: Cliplocations 3D:
'1.
4.
Installation the reverse the removalprocedure. is ot NOTE: . To preventwrinkleswhen installinga seat cushion cover, make sure the material is stretched the evenlyover the pad beforesecuring clips. . Replace released the clipswith new ones.
(seepage20-80). Remove seat-back the Loosen seat-back the coverby releasing allthe clips. NOTE:Removethe lock knob, lock collar and latch cover. >: Cliplocations
2.
3.
LEFTSEAT.BACK RIGHTSEAT.BACK COVER COVER Pull back the edge of the seat-backcover all the way around. then releasethe clips. >: Clip locations
SEAT.BACK COVER
3.
Pull backthe edge of the seat-back coverall the way the around,then release clips. >: Cliplocations
SEAT.BACK COVER
RIGHT
4.
of Installation the reverse the removalprocedure. is NOTE: . To preventwrinkleswhen installinga seat-back evenly cover,makesurethe materialis stretched the overthe pad beforesecuring clips. . Replace released the clipswith new ones. (cont'd)
20-83
Rear Seat
(cont'dl SeatGoverReplacement
Seat side bolster cover rmoval l,lDl:
1.
2Dl3Dl
Remove seatside bolster(seepage20-79). the Loosenthe seat side bolstercover by releasingall the clips,then removeit.
>: Clip locations
2.
EF*aa-bF-E< V \ , f.I--l f r -r_I--t lm n

rt=r/ { lr (!, .t=!l
SEATSIDE BOLSTER COVER
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:
3.
Installation the reverse the removalprocedure. is of NOTE: a To preventwrinkleswhen installinga seat side bolstercover,makesurethe materialis stretched evenlyoverthe pad beforesecuring clips. the . Replace released the clipswith new ones.
20 l3Dl
Seat cushion cover removal: 1. 2. ( R e m o v eh e s e a tc u s h i o n s e ep a g e s 0 - 7 9 , 8 0 , 8 1 ) . t 2 Loosenthe seat cushioncover by releasing the all clrps. >: Cliplocations 4D: COVER 4. Installation the reverse the removalprocedure. is of NOTE: . To preventwrinkleswhen installing seatcusha 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 beforesecuring clips. the . Replace released the clipswith new ones.
_ - / -.lL J
v,la
/.)
lL--Jl '.n
UPHOLSTERY RINGPLIERS lCommerciallv available)
SEATFRAME
20-84
Front Seat Belt

Replacement
CAUTION: Check the tront seat belts for damage, and replacethen if nacessary.B9 careful not to damage then during removal and installation, Fronl seat belt removal {,[D): 1 . Slidethe front seatforwardfully. Remove centerpillaruppertrim (seepage20-59). the 6. Remove shoulderanchoradjuster. the
2.
Remove the centerpillar lowertrim panel(seepage 20-59). Removethe upper anchorcover and lower anchor cap.
ANCHORBOLT UPPER 7/16-20 UNF 32 N,m (3.3kgf.m, 24 rbf.ftl Apply liquidthreadlock. I x 1.25mm 23 N.m (2.3 kgf m, 17 tbf.ft)
ANCHOR ADJUSTER
7.
UPPER ANCHOR COVER FRONT SEA BELT RETRACTOR MOUNTINGBOLT 6x1.0mm 9.8 N.m (1.0 kgf.m, 7.2 tbf.ftl
of Installation the reverse the removalprocedure. is NOTE: func. Check lockingmechanism that the retractor on tions as described page20-91. . Makesureyou assemble washersand collars the on the uoDerand lower anchorbolts as shown. . Before installing anchorbolts,makesurethere the are no twists or kinksin the front seatbelt.
Upper anchorboh construqtion:

UPPER ANCHOR ANCHOR UPPER BOLT Apply liquidthread
RETRACTOR COLLAR
RETRACTOR BOLT 7/1&20UNF 32 N.m (3.3 kgt.m, 2a tbtft)
+ I
LOWEN ANCHORBOLT 7,/16-20 UNF 32 N.m (3.3 kgf.m, 24 lbf ftl
LOW ANCHOR ER CAP
I I I
BEARING
Removeall the anchorbolts and the retractorbolt, remove the retractormounting bolt. then remove the front seatbelt and retractor. (cont'd)
20-85
Front Seat Belt

Lower anchor bolt construction:
SPRING WASHEF
\
Front seat belt romoval (2Dl3D): 1. 2. Slidethe front seatforwardfully. Remove: . Rearseat-back and 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) (3D, page20-60) . Reartrim panel see . Sidetrim panel(see pages 20-60,61) Remove upperanchor the coverand loweranchor cap.
UPPER ANCHOR BOLT 7/r6-20UNF 32 N.m 13.3 kgt.m, 24 rbf.ft)
3.
COLLARS WASHERS LOWER ANCHOR BEARING
FRONT SEAT Rtractor bolt construction:
BELT
RETRACTOR BOLT
I llrrtnn-ffi\
RETRACTOR
\Y **rss,t
RETRACTOR MOUNTINGBOLT 6x1.0mm 9.8 N.m {'t.0kgt.m, 7.2 tbf.ftl LOWER ANCHOR CAP
o
RETRACTOR BOLT 7/16-20 UNF 32 N.m (3.3kgl.m, 24 tbI.ft) 4. LOWER ANCHORBOLT 7/16-20 UNF 32 N.m {3.3kgt m,24 lbf.ftl
I I
Removeall the anchor bolts and the retractorbolt, removethe retractor mountingbolt,then removethe front seat belt and retractor.
2 0- 8 6
procedure. is of 5. Installationthe reverse the removal NOTE: . Check the retractor mechanism functhat locking 20-91. tionsasdescribed page on
Makesure you assemble washersand collars the on the uoDerand lower anchorboltsas shown. Before installing anchorbolts,makesurethere the are no twists or kinksin the front seat beit. Upper anchor bolt construclion:
WASHERS
Seat beh buckle removal: 1 . R e m o v e 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 t (seepage20 74). 2. 76). Remove centercover(seepages20-75, the Removethe centeranchor bolt, then removethe seat beltbuckle.
SEATBELT BUCKLE
SPRING WASHER Lower anchor bolt construction: SPRING WASHER COLLARS
BEARING
ANCHORBOLT
CLIP 4.
kgf 32 N'm {3.3 m, 2't lbfft)
BEARING
Driver's:Detachthe seat belt switch connectorand harness clip from the seatcushion(seepage20-77). Removethe seat cushion mounting bolts from the and innerseattrack{seepage20-751, movethe inner out. then pull the seatbeltswitchharness seattrack, NOTE:Takecarenot to damagethe hingebracket.
Center anchor bolt construction:

CENTER ANCHOR BOLT
WASHERS LowER
LOCKWASHER TOOTHEO LOCKWASHER
LOWER ANCHOR ANCHOR BOLT
Retractorbolt construction:
RETBACTOR
b
RETRACTOB
SPRING WASHER
WASHER
5.
Installation the reverse the removalprocedure. is of NOTE: Make sure you assemblethe washers and bearingon the centeranchorbolt as shown.
20-87
RearSeat Belt
Replacement
GAUTION:Checkthe rear seat belts for damage,and replacethen if necessary,Be careful not to damage then during removal and installation. Rearseat belt removal l2DllDl:. 1. Remove: . Rearseatcushion(seepages20-79, 81) . Rearseat-back {2D,see page20-81) . Sidetrim panel(2D,seepage20 61) r Rearshelf(seepages20-59, 61) . Reartrim panel(seepage20-62) . Trunksidetrim, Japan-produced page20-62) (see . Trunktrim panel,USA-produced page20-62) (see Removeall the anchorbolts and retractor bolt, then removethe rearseat belt and retractor. 3. Installation the reverse the removalprocedure. is of NOTE: . Check that the retractor lockingmechanism functions as described page20-91. on . Make sure you assemble washersand collar the on the upperanchorbolt as shown. . Beforeinstalling anchorbolt, make surethere the are no twists or kinksin the rearseat belt. Upper anchorboh construction:
2.
UPPER ANCHOR BOLT 7/16-20 UNF
RETRACTOR BOLT 7/16-20 UNF 32 N.m {3.3kgf.m, 24 rbf.ft)
TOOTHED LOCKWASHER
Lower anchor bolt construction:

LOWER ANCI{OR BOLT
LOWER ANCHOR
7/1S20UNF 32 N.m 13.3kgI.m,24lbl.ftl
Retrastor bolt construqtion:
trv-*q
,/Rr /i\ ntz ll l \
/7-'\
177--7,
TOOTHED LOCKWASHER
\
RETRACTOR
\
RETRACTOR BOLT
20-88
Rearseat belt removal l3Dl: 1. Remove: . Rear seat-back and rear seat cushion (see page 20_80) . Rear center shelf and rear side shelt (see page 20-601 . Reartrim paneland sidetrim panel(seepage2060) Remove the upperanchorcover
4.
of is Installation the reverse the removalprocedure. NOTE: funclockingmechanism . Check that the retractor on as described Page20-91 tions the . Makesureyou assemble washersand collars on the upperanchorbolt as shown . Betoreinstalling anchorbolt, makesurethere the are no twistsor kinksin the rearseatbelt.
2.
Upper anchorboh construqtion:
SPRING
ANCHORBOLT UPPER 7/16-20 UNF 32 N.m {3.3kgl m.24lbf ftl
BOLT RETRACTOB UNF 7/16-20 32 N.m (3.3kgf.m,
ANCHOR UPPER BOLT
WASHER
TOOTHEO LOCK WASHER
Lower anchorbolt construction:
LOWEBANCHOB
7/15-20 UNF 32 N.m (3.3kg{.m,24lbfft)
TOOTHED LOCKWASHER
boh conslruction: Retraqtor
3.
bolt.then Removeall the anchorboltsand retractor removethe rearseat belt and retractor'
TOOTHED LOCKWASHER BOLT (cont'd)
20-89
RearSeat Belt
Soat belt buckle/Canterbelt tongue removal: 1. Removethe rear seat cushion(seepages20-79,80, 81). Removethe center anchor bolts, then remove the seatbelt buckles and centerbelttongue.
ANCHOR CENTER
\
Centel anchor bolt construction:
2.
2DI4'D: CENTER BELT BUCKLE

7/16-20 UNF TOOTHEO LOCKWASHER
Installation the reverse the removalDrocedure. is of NOTE: Beforeattachingthe seat-back and seat cushion, make sure there are no twists or kinks in the center belts.
CENTER BELTTONGUE
3D:
CENTER ANCHORBOLTS 7/16-20UNF 32 N.m {3.3 kgf.m, 24 tbtftt
CENTERBELT
20-90
Seat Belts
Inspection
Retractor Inspection
'1.
3D:
check that the seatbelt the Beforeinstalling retractor, can be pulledout freely. lvake sure that the seat belt does not lock when the slowlv up to 15'from the mounted retractor leaned is position. The seatbelt shouldlockwhen the retrador is leaned over40". the CAUTION:Do not attempt to disassemble retractor.
*: Mounted Posilion
RETRACTOR Forward
Front: 4D: 3. Replace seatbelt with a new one if there is any the abnormality.
On-the-CarSeat Belt Inspection 1. Checkthat the seat belt is not twisted or caughton anyrnrng, After installingthe anchors,checkfor free moveremovethe ment on the anchorbolts.lf necessary. anchorbolts and checkthat the washersand other partsare not damaged improperlyinstalled. or Check seatbeltsfor damageor discoloration. the 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 alcohol. enedin isopropyl
lnside
2.
Forward lnside
2DI3D:
3.
Rear: 2Dl lDl
Checkthat the seat belt does not lock when pulled out slowly. The seat belt is designedto lock only duringa suddenstop or impact. automatically Makesurethat the seatbeltwill retract when released. seat belt, make sure that the For each passenger's w i l o c k i n gm e c h a n i s m n t h e s e a t b e l t r e t r a c t o r i l l engagewhen the seatbelt is pulledall the way out.
7.
Replace seat belt with a new one if there is any the abnormality.
Forward
lnside
20-91
Seat Belts
GhildSeat Anchor Plate
pointsare providedfor a rear seat mounted Attachment childrestraint system which usesa top tether. The attachment points are locatedon the rear shelf or rear trim just behindthe rearseat-back. panel, When usinga child seatwith a top tether,installthe chjld seatanchorplates securely. 2Dl4Dl N O T E : R e m o v e 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 t pointsof the rearshelf.
PLUGCOVERS CHILDSEAT ANCHOR PLATE NOTE: WASHER 8 x 1.25mm 22 N.m (2.2kgf.m.16lbf.ftl
Do not removethe toothedwasherfrom the childseat anchorplate.Usethe child seatanchorplatewith the toothedwasherattached it. to . When installinga child seat on the rear seat,follow the instructions the manufacturer the childseat. of ot . 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 ateachattachment point, Cut the rea. trim panel along the perforations to makea hole.
REARTRIM PANEL
20-92
a
Exterior
LocationIndex Component
r ho l M , , r N O T E :R e f e t o t h e C i v i cB o d yR e p a i M a n u a l 1 9 9 6 o d e lS e r i e sP / N . 6 1 5 0 3 3 0 , f o r t h e o d , t r u n ki d a n d h a t c h e m o v a l r 2D t3DtlD:
ROOFMOLDING Replacement, page 20 1O2 HOOD Adjustment, Page20-96 HoodEdgeProtector page20-99 SIDEWINDOW MOLOINGS Replacement, page 20-102 PLATE LICENSE TRIM Replacement, page20 't00 TRUNKLID page20 97 Adjustment, TorsionBarRemoval, 20 99 LID TRUNK WEATHERSTRIP Replacement, page20-100 REARBUMPER Replacement, page20'95 REARAIR OUTLET Feplacement, page20-106 PIPE PROTECTOR Replacement, page20-106 TRIM FENDERWELL page20 106 Replacement, 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
GRILLE FRONT (seepage20 99)
INNER
Replacement, page 20-106
3D:
HATCH WEATHERSTRIP
HATCHSPOILER page20-101 Removal,
HATCH Adiustment, page20 98
PLATETRIM LICENSE page20 100 Replacement,
REARAIR OUTLET page20'106 Replacement,
20-93
FrontBumper
Replacement
CAUTION: Wsa.gloves remove to andinstallthe front bumper. NOTE: . An assistant helpful is whenremoving frontbumper. the . Take carenotto scratch frontbumper bodv. the and
>: 8olt, screw locations a >,2
B>,2
>: Clip locations,7
c>,4
D> , 4
6x1.0mm 9.8 N.m {'1.0 kgf.m, 7.2 tbf.ft)
FRONTBUMPER BEAM
\I/
t165 ldb !J,J:ff,ry-"_.

_r6rbrftl _g
ABSOREER
I
A
Installation the reverse the removalprocedure. is of NOTE: . Make sure the front bumper engagesthe front bumperside stiffener eachside securely. on . lf necessary, adjust the front bumper side stiffener to obtainthe propergap.
FRONT EUMPER SIOESTIFFENER
20-94
RearBumper
Replacement
CAUTION: Wear gloves to remove and install the rear bumpet. NOTE: when removing rearbumper' the . An assistant helpful is the . Takecarenot to scratch rearbumperand body. are . 2D and 4D shown here;3Dremovalprocedures the sameas 4D.
>: Screw, bolt locaiions B >, 4 A>,2 >: Clip locations,7
A i,,A \r9{
,9iiffiF=*-..f
REARBUMPER BEAM
BUMPER REAR is of Installation the reverse the removalprocedure. NOTE: . lf necessary, replace any damagedclips. the . Makesurethe rearbumperengages side clip on eachside securely.
20-95
Hood
Adjustment
NOTE:Beforeadjusting hood,looseneachbolt slightly. the 1. Adjustthe hood hingesright and lefr,as well as fore and aft, by usingthe elongated holes. 2. 3. 4. Turn the hood edgecushions, necessary, makethe hood fit flush with the body at front and sideedges. as to Adjustthe hood latchto obtainthe properheightat the forwardedge. 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 centered the hood latchasshown. in
6x1,0mm 9.8 N.m 11.0 kgf.m, 7.2 tblfrl
2 0- 9 6
TrunkLid
Adjustment
the NOTE:Beforeadjusting trunk lid, looseneachbolt slightly 1. 2. 3. 4. holes. Adjustthe trunk lid hingesrlght and left,as well as fore and aft, by usingthe elongated to as Turn the trunk lid edgecushions, necessary, makethe trunk lid fit flush with the body at the rearand side edges Adjustthe fit betweenthe trunk lid and the trunk lid openingby movingthe striker' After adjustment, tighteneachbolt securely.
LIDEDGE TRUNK CUSHION
( i r/-\\ \ V,,'' /
NOTE: Take care not to hit the rear window when loosen ng the bolts.
21"
rY
\-2/\
./
TBUNKLID
srrucrs
:>
---
-)
6x1.0mm kgl.m,7.2lbf.ftl 9.8 N.m 11.0
20-59,61). NOTE: Remove rearshelf the lseepases //

tn NOTE:Move the strikerright or left until it's centered the trunk lid latchas shown.
6x1.0mm 9.8 N.m (1.0kgf.m, STRIKEB
20-97
Hatch
Adjustment
NOTE: . Beforeadjusting hatch,looseneachbolt and nut slightly. the o The supportstrutsshouldbe removed. . To adjust,removeboth hatchsidetrim {seepage20-63) and the rearroof trim (seepage20-65). 1. 2. 3. 4. Adjustthe hatchhingesright and left,as well as fore and aft, by usingthe elongated holes. Turn the hatchedgecushions, necessary, makethe hatchfit flush with the body at eachside. as to Adjustthe hatchfit to the hatchopeningby movingthe striker. After adjustment, tighteneachbolt and nut securely.
6x1.0mm 9.8N.m (1.0kgt.m, HATCH EDGE CUSHION
HATCH HINGE Rearward
HA EDGE CUSHION
10 x 1.25 38 N.m {3.9kgl.m, 2.8 rbf.ft)
\ coVER
HATCH HINGE
STRIKER
HATCH EDGE CUSHION
NOTE:Move the strikerright or left until it's centered tn the hatchlatch,as shown.
6x1.0mm 9.8N.m {1.0kgf.m, 7.2 tbl.ttl
Edge FrontGrille/Hood Protector

Replacement
Fronl grille: NOTE:Takecarenot to scratch front bumper. the
TrunkLid Torsion Bars

Removal
CAUTION:Wear gloves to remove and installthe torsion bars. NOTE:Takecare not to damagethe body.
Remove the front bumper (seepage20-94). Remove the clips and screws.then slide the front grille forward by detaching hooks. the >: Screw locations,4
j
Removethe torsion bars with the torsion bar assembly t o o lw h i l eh o l d i n g h e t r u n kl i d a s s h o w n . t
:Y/
A l
CENTER CLIP
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 asshown. tool
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
Replacement
When installing the trunk lid/hatch weatherstrip, align it with the alignment markon the trunk lid/hatch opening. NOTE: . Makesurethereare no wrinklesin the weatherstrip. . Check water leaks. for 2D l4Dl
ALIGNMENT MARK
License PlateTrim
Replacement
CAUTION: Wear gloves to remove and install the license plate trim. NOTE:Takecarenot to scratch trunk lid/hatch. the 1. 2. 3. plate. Remove the ljcense 3D: Remove the hatchtrim panel(seepage20-63). Remove the nuts and clips,and detach the clip,then platetrim. removethe license NOTE:Takecarenot to drop the nuts inside trunk the lid/hatch.
a: Nut locations,2
>: Clip locations,3
ffisxo.amm
kstm.l \Y9l,/ N.m{0.18 - 1.8 13 tbtfr) ,/
nA IEL
@ta9@
I L
WEATHERSTRIP
ALIGNMENT MARK
4. STEEL CORE ALIGNMENT MARK (2Dl4D) BODY
Installation the reverse is ofthe removalprocedure. NOTE:lf necessary, replace any damagedclips.
20-100
HatchSpoiler
Removal
the NOTE:Takecarenot to scratch hatchand body. 1. 2. Remove the hatchuppertrim (seepage20-63). Removethe nuts, and detachthe clip, then Iift the hatchspoilerup. 4. removethe spoilertrim from the spoiler lf necessary, frame. NOTE:The hatchspoilertrim for Canadaproduced carscannotbe disassembled.
>: Clip locations
a: Nut localions,4
6x1.0mm l ksf.m. 9.8N m 11.0 I 7.2 \t.to - _J/

GROMMET HIGHMOUNT BRAKE LIGHTCONNECTOR
>: Screw locations,4 l 6 \ l "ig
SPOILER SIDETRI
SPOILER CENTER TRIM A
5.
ACCESS CAP
is of Installation the reverse the removalprocedure. NOTE: clips. . lf necessary, replace any damaged a M a k e s u r e t h e c o n n e c t o r n d w a s h e rt u b e a r e a properly. connected
3.
and Disconnect high mount brakelightconnector the 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
Replacement
CAUTION: Wear gloves to remove and install the side window moldings. NOTE: . Takecarenot to scratch body. the . Remove screw,and pull the side window molding the
by hand. >: Clip locetions A>, 13
RoofMolding
Replacement
CAUTION;Whsn prying with a flat tip sc.ewdriver,wrap it with protective tape to prevent damage,and use protective tape on the body. NOTE:Takecarenot to scratch bodv, the
K
Screw locations,
(Bodyside)
WINDSHIELO MOLDING
I
)
*@
I
)
ARACKET
Installation the reverse the removalprocedure. is of NOTEi . Takecarenot to damage windshield the molding. . Makesurethe roof moldingis installed securely.
MOLDING ROOF MOLDING
lnstallation the reverse the removalprocedure. is of NOTE:lf necessary, replace any damagedclips.
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. with a spongedampenedin alcohol. . Before.eassembling, cleanthe door bondingsurface . After cleaning, keepoil, greaseand water from gettingon the surface . lf necessary, replace any damagedclips. 4D:
2Dl3Dl
REARSIDE MOLDING >: Clip locations A >: ,lO,11 2013r),7 a: Plasticnut location, 1
B> , 3
c>.2
@)
_/
(cont'd)
20-103
Doorand SideMoldings
Replacement(cont'dl
Door moldingremoval: The following materials and tools are requiredto repair t h e d o o rm o l d i n g s . instructionsNOTE:Followthe manufacturer's Materials: {Reference} . Striperemover 3M 08907 . Stripeadhesive remover 3M 08908 . Adhesive tape Attachment Tape 3M SuperAutomotive Tools: . Protectivetape . Knifeor Cutter . Spongeor Shoptowel . Infrared dryer Door moldinginstallation: 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 shown.
N\\N\l : Adhesivetape locations inl 820mm 132.3 60 mm t2.1
Forward MOLDING
40 mm (1.6in)
CLIP HOLDER
. . .
Film Puttyknife Alcohol 2Dl3Dl
Forward
CAUTION: Wear gloves to remove and install the dool moldings. 1. R e m o v e 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 t cover. Apply protective tape on and aroundthe molding.
1,050 mm {41.31 inl
2.
5 mm {0.2in)
ADHESIVE TAPE Thickness:1.2 mm 10.05 inl
2. 3. Release clips from insideof the door. Carefully the cut the adhesivetape with a knife or cutter while pullingthe edgeof the moldingaway from the door as shown. NOTE:Take care not to scratchor bend the moldIng KNTFE 2
I n s t a ltlh e c l i p so n t h e m o l d i n g . 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 moldingwith an infrareddryer. Door: 104- 140'F(40- 60'C) Molding:68 - 86'F (20- 30'C) NOTE: Use care when heatingto preventdeformat 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 tape. edgeis fully seated the adhesive on NOTE: Do not spray water on the molding within the first 24 hoursafterinstallation.
OOOB MOLDING
Reassemble removedparts. all
20-104
SideSill Panel
Replacement
NOTEI . Takecarenot to scratch body. the . 4D shown here;2Dand 3D removalprocedure the sameas 4D. is
>: Clip locations A>,3
>: Screw locations,4
B>,7
I
)
NOTE:Loosen screw, the then removethe lowerclip usinga clip remover.
SIDE CLIP Remove sideclipsfrom the body the by turningthem 45'
NOTE:When removing side the sill panel, sideclipswill the stayin the body.
SIDE SILL PANEL Remove the lower clips, then remove the side sill panel by sliding it forward.
then installthe sidesill To installthe sidesill panel,removethe sideclipsfrom the body, installthem on the side sill panel, o a n e o n t h ec a r . l NOTE: . Takecarenot to twist the side sill panel. . lf necessary, replace any damagedside and lower clips.
20-105
Trim, FuelPipeProtectorand Rear Fenderwell InnerFender, Air Outlet

Replacement
replace any damaged clips. NOTE:lf necessary, lnner fender: >: Screwlocations, 4
6h*l
: , /
>: Clip locations, 7
CLIP
Fenderwelltrim/Fuel pipe protector/Rearair outlet: NOTE: . Takecare not to bendthe tenderwell trim. . Betoreinstalling the fenderwelltrim, cleanthe body with a spongedampened alcohol. in bondingsurface . After cleaning,keepoil, greaseor water from gettingon the surface. . To removethe fuel pipe protector,first removethe rear wheel(seesection 18). . To remove the rear air outlet, first remove the rear bumper(seepage20-95). STEEL FENDERWELL
>: Clip locations
a>,4
B>,4
'@
c>.2
20-106
and Washer and OpenerCable/Opener Latch/Wiper

zDl3Dl4Dt aRMs *TNDSHTELD wrPER page 13 Replacement, 20-1 page 17 Adiustment, 20-1
WINDSHIELD NOZZLES WASHER page20-117 Adjustment,
FUELLIDOPENER CABLE (seepage20-108)
TNUNK LID OPENER CABLE (seepage20 108) LID/FUEL LIDOPENER {seepage20-111) REI."EAS HANDLE (seep6ge20-110)
3D:
wlPER REAR WINDOW ARMrnd MOTOR page 15 Eeplacement, 20-'l page 17 Adjustment, 20-'l
REARWINDOW WASHER NOZZLE page20-1 17 Adiustment,
REAR WINDOW WASHER TUBE (see page 1161 20
HATCH/ FUEL OPENER LID page 20-111) {see
FUEL OPENER LID CABLE {sepage20-'110)
(seepage20 111)
HATCI{OPENER CABLE (seepage20-110)
20-107
Opener Cables
Replacement
NOTE: . When removingthe clips,usea clip remover. . Takecarenot to bendthe openercables. Hood openr cable: NOTE:Removethe front bumper (see page 20-94)and innerfender(seepage20-106).
>: Clip locations A>,5
\
Trunk lid/Fuellid openercable(2Dli[D): NOTE:Removethe following partsfrom the left side of the vehicle.then pull the carpetback,as necessary {see page20-66). Rearseatcushion(seepages20-79, 81) Rearseatside bolster(4D,seepage20-79) Rearseat-back {2D,see page20-81) pillarlowertrim panel(4D,seepage20-59) Center Lower anchor bolt from the front seat belt (2D, page20-86) . Sidetrim (seepages20-59, 61) o Seatsidetrim (4D.seepage20-59) . Sidetrim panel(2D.seepage20-61) . Trunk mat and sparetire lid . Reartrim panel(seepage20-62) (see . Trunksidetrim, Japan-produced page20-62) (seepage20-62) . Trunktrim panel, UsA-produced . . . . . >: CliD. cable cushion locations a>,4 I>,4D,r
BD,1
#l
HOODRELEASE HANDLE {seepage20-110)
c >, 1 {4D)
#) l _-__l B _L
D> , 3 E> , 4 D ,1 2D,2
Routethe opener cable through the hole in the body.
ffi
\
_,)
Installation the reverse the removalprocedure. is of NOTE: . Make sure the hood openercable is routed and properly. connected . Makesurethe hood opensproperly.
20-108
TRUNK LID LATCH (seepage20 112)
4D:
To trunklid latch,
LID/FUEL TRUNK LIOOPENER ( s e e a g e2 0 ' 1 1 1 ) p
To trunklid latch.
a
A \
TRUNKLID OPENER CABLE FUELLIO OPENER CABLE
LIO/FUEL TRUNK LID OPENER ( s e e a g e2 0 - 1 1 1 ) p
(cont'd)
20-109
OpenerCables
Hatch/Fuellid opener cable (3D): NOTE:Bemovethe following parts,then pull the carpet (seepage20-66). backas necessary . . . . . . . Rearseatcushionand rearseat-back {seepage20-80} Lower anchorbolt from the tront seat belt (seepage 20-86) Sidetrim (seepage20-60) Sparetire lid Rearcentershelfand rearsideshelf(seepage20-60) Reartrim panel(seepage20-60) Sidetrim panel(seepage20-60)
Openerand Latch
Replacement
NOTE:Takecarenot to bendthe openercables. Hood releasehandle: p 2 N O T E :R e m o v eh e k i c kp a n e l( s e e a g e s 0 - 5 9 . 6 0 , 6 1 ) . t
>: Boll locations,2 |
I
HOOOOPENER CABLE {seepage20-108)
6 x 1 . 0 m mi 9.8N.m I
>: Clip,c.ble cushion locations A>,9 c>,1 B>,1
D>,5
HOODRELEASE HANDLE
#)
STRIKER
*i
Hood latch:
Routethe opener cablethroughthe hole in the body.
NOTE:Remove front bumper(seepage20-94). the

FUELLID LATCH (seepage20-112)
doo
--\,"
FUEL LID OPENER CABLE
o/l
HATCH OPENER CABLE
HATCH/FUEL LID OPENER
Installation the reverse the removaiprocedure. is of Installation the reverse the removalprocedure. is of NOTE: . N4ake sure each openercable is routed and con nectedproperly, . Makesurethe hatchandfuel lid openproperly. NOTE: properly. . Makesurethe openercableis connected . 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: NOTE:Remove sidetrim (seepages20-59,60.61). the >: Boltlocrtions, 2
a@-\ 6x1.0mm 9.8N.m (1.0kgt.m, 7.2 tbl.ftt LOCK OPENER CYUNDER
Striker l3D): the NOTE: Remove reartrim panel(seepage20-601.
>: Bolt locations.2
la//tzDt4Dl L-.-^
6x1.0mm 9.8N.m (1.0kgf.m, I
':-!, J
HATCH CABLE OPENER (seepage20-110)
TRUNKLID,/HATCH OPENER CABLE 1 2 0 - 1 0 8 ,1 0 ) {see To trunklid latch or striker. To fuel lid latch.
lnstallation is the reverse of the removal procedure. FUELLID OPENER CABLE (seepages20-108, 110) NOTEi
prop' a Makesure each openercableis connected erlY. . M a k e s u r e the hatch opens properly and locks securely.
is of Installation the reverse the removalprocedure. NOTE: properly. . Makesurethe openercableis connected . Makesurethe trunk lid or hatchand fuel lid open properly.
(cont'd)
20-111
Openerand Latch
Fuel lid latch: NOTE:Remove followingparts. the 2Dl4Di . . Rearrimpanel seepage2062) t { Rear edge of the trunk side trim or trunk trim p a n e l (leftside,seepage20-62)
Trunk lid latch/Lock cylinder:
B > ,1
3D: . Accesspanelon the sidetrim panel
>: Bolt locations, 2
5 x 1.0mrn
,-*Y:EiI::Y
FUELLID LATCH
TRUNK LID LATCH

CYLINDER ROD LOCK CYLINDER
FUEL LID After installing check for a flushfit with the body. CONNECTOR Disconnect.
I
I
a-
LID FUEL OPENER CABLE (seepages20'108, 1'10i FUEI-LID LATCH Remove fuel lid latch the by turningit 90'
LOCK CYLINDER
is of Installation the reverse the removalprocedure. Installation the reverse the removalprocedure. is ot NOTE: prop. Make sure each openercableis connected erly. . Make sure the fuel lid opens properlyand locks secureiy. NOTE: . Grease trunk lid latch. the . Makesure the trunk lid opensproperlyand locks securely. . M a k e s u r e t h e c o n n e c t o r n d c y l i n d e rr o d a r e a
20-112
WindshieldWiper Arms
and Linkage
Replacement
Hatch latch/Lock cylinder: NOTE: Remove the hatch trim panel (see page 20-63).
CAUTION: Wear gloves to remove and inslall the windshieldwiper linkage. the NOTE:Takecarenot to scratch hood and body.
>: Bolt locations A>,3 6x1.0mm kgf.m, 9.8 N.m 11.0 7.2 tbt.ft)
8>, 1 6x1.0mm 9.8N m (1.0kgf.m, j 1.2tbttij /
w t R e m o v e h e w i n d s h i e l d i p e r a r m s ,t h e n r e m o v e the hood sealand cowl cover.

>: Clip locations a >,9 I >,9
I t L.-.-=1 0x ' 1 . 2 5 m m l8 N.m (1.8kgf.m.
HATCH LATCH
i? Latr (lb \--:.t)
COWLCOVER
Disconnect the connector,then remove the winda w i p e rl i n k a g e s s e m b l y . shield Japan/Canada-produced:
is of Installation the reverse the removalprocedure. NOTE: . Grease hatchlatch. the . 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. properly. . Makesurethe cylinderrod is connected
(cont'd)
20-113
Windshield WiperArms and Linkage

USA-produced:
>: Boll locations,3 WINDSHIELD WIPER LINKAGE ASSEMBLY
USA-produced: NOTE:Scribea line acrossthe link and windshield wiper motor to show the o.iginaladjustment.
>: Bolt locations,2 R 6x1.0mm NUT 10 x 1.25mm 18 N.m 11.8 kgf.m, 13 rbf.ft)
l@.',,.0-E \_q. 9.8N.mn.o ksf.m, 7 2 rbr'ftl
tf
I N.m kstm,I to.s
P,:!-Y
S e p a r a t eh e w i n d s h i e l d i p e r l i n k a g e n d w i n d t w a shieldwiper motor. Japan/Canada-produced: NOTE:Scribea line acrossthe link and windshield wiper linkage show the originaladjustment. to
WIPER MOTOR
WIPERMOTOR '10 1.25 x mm 18 N.m (1.8kgt.m,
rbrftl
SPRING WASHER
Installation the reverse the removalprocedure. is of NOTE: . Makesurethe connector connected properly. is . li necessary, replace any damagedclips. . Install he wjndshield iperarmsas described t w o n p a g e2 0 - 1 1 7 . . Check windshield the wiper motor operation. . Grease moving parts. the
WIPERMOTOR WIPERLINKAGE
20-114
RearWindow wiper
Arm and Motor

Replacement
1. 2, the hatchtrim panel(seepage20-63). Remove R e m o v e 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 t motor as shown.
WasherReservoir
Replacement
1.
Remove front bumper(seepage20 94). the and washertubes from the Disconnect connectors washermotors, the >: Boll locations, 3
Ql(S) s.eNmtt.orsr'm. \-/

7.2 tbf.f
/)^
Gxl.o mm
- -
'/
)
H*?H"[*
Routethe washer tubes
to the washerreservoir
5x1.0mm 9.8 N.m {1.0kgf.m, 7.2 tbf.ft)
WIPER MOTOR
3.
of is lnstallation the reverse the removalprocedure. NOTE: properly. is a Makesurethe connector connected on a Install rearwindow wiper arm as described the page20-117 . . Check the rearwindow wiper motor operation. . Grease moving parts. the
MOTOR
MOTOR WASHER (3D, some models) for
3.
Removethe bolts, then remove the washer reservoir. of is lnstallation the reverse the removalprocedure NOTE: a . Makesure the washermotor connectors nd properly. washertubesare connected . Check washermotor operataon. the
20-115
WasherTube
Replacement
NOTE: . To removethe windshieldwashertube, removethe left innerfender(seepage20-'106). . To removethe rearwindow washertube (3D).remove the followingpartsfrom the leftsideof the vehicle. ( I n n e r e n d e r s e e a g e2 0 - 1 0 6 ) p f Kickpaneland sidetrim (seepage20-60) Rearseat backand rearseatcushion(seepage20 80) Sparetire lid Rearcenlershelf and rearside shelf lsee page 2060) Reartrim panel and side trim panel (seepage 2060) Ouarter trim panel{seepage20 60) Rearrooftrim {seepage20-65) (seepage20 101) Hatch spoiler
>: Washer nozzle, clip and cushion locations
A>,2
B>,3
c>.1
wrsren lNozzLE CE
wtwospteloI =--S1
\D>,1
\f
-f7!
@
E>,1
]\N
\ \ \
A
|g" c
|
F>, 11
<:/1+-+3
-,J:n
WINDSHIELD TUBE REARWINDOW WASHER TUBE
Routethe washertubes to the washerreservoir
a I
(seepage20-101).
Route washer the tubes underthe wire harness.
REARWINDOW WASHER TUBE (forsome models)
Installation the reverse the removalprocedure. is of NOTE: . Takecarenot to pinchthe washer tubes. . lf necessary, replace damaged any clips. . After installing, adjustthe aim of the washernoz zles(seepage20-117).
20-116
Nozzles Wiper Arms/Washer

Adjustment
Windshield Wiper/washer: 1. Adjust the wiper arms so that their park positions matchthe illustration. Rear Window Wiper/Washer (3D): l. Adjust the rear window wiper arm so that its park positionmatches the illustration.
View from front to rear
View from rear to front
Centerline
REAR WINDOW WIPEFARM
BLACK CERAMIC EDGE
WINDSHIELD ARMS WIPER 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 , so adjustthe washer nozzles that they aim at posit 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 \ II n e Nozzle aim i 4 0 0m m ( 1 5 . 7n ) A a n dA ' B a n dB ' 11 5 m m ( 4 . 5i n )
from black 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 , adjustthe washer nozzleso that it aims at position C as shown in the illustration. NOTE:The fluid jet should hit within a 50 mm (2.0 p a i n ) r a d i u s r o u n d o i n tC .
2.
in) 255mm (10.0 inl 322 mm 112.1
20-117
Emblems
Installation
Apply the emblemswhereshown. NOTE: o Beforeapplying, cleanthe body surface with a spongedampened alcohol. in . After cleaning, keepoil, grease and water from gettingon the surface. Attachment Points {Relerencel: U n i t :m m ( i n )
CIVICemblem
TRUNK LID
VBion emblem
Version emblem
Version emblm
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 kgf.m; 38 N.m 13.9 28 tbf.ft)
66 rb{.ft)
Replace-
20-119
FrameRepairChart
Unit:mm (in) 6: Innerdiameter
oETATL AREA:ll
> =
POINTd3
o15{0.591 Transmisaion Mount Point
20-120
l:3D
AA SECTION
UpperArm o12 10.471

POINT
Upper a12lo.0l a25
-o20 o8(
otN'
LOCA
Hole
Tank Strap Point
{0r8) Locate Hole POINT w
LocateHole o20 10.8)
SECTION 8B
Damoer Lower Bush Center
20-121
Body {'97 model}

FrontSeat Belt Removal/lnstallation RearSeat Removal/lnstallation Tube Washer .................. Repfacement Windshield lndex .......... ....20-128 .".20-126 20-129 20'124
I
i
Outline of
'97 Model Changes
The moldingsidesealwas added. (2Dl3D) the The methodof installing rearseatcushionwas changed. (2Dl3D) was changed. the gussetwas addedand the methodof detaching seatbelt retractor A middlefloor positionof the washertube was changed. The installation
Windshield
Index
NOTE:The numbersafterthe part namesshow the quantities the pans used. of
WINDSHIELO MOLDING
RUEBER UPPER DAM
FASTENER, 2 (Selt-adhesive-type, side) glass
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
6x1.0mm 22N-m 12.2 gf -,] k 16 tbf.ft)
ps.a ru'-{r.o rgr.-,

E 7.2 tbf.ftt
tQ6't.o--
,/
STRIKER Bemove sidetrim the panel(seepage20 60). 6xl.0mm 9.8 N.m {1.0kgt m,i 1.2tbt-ltl !
,)
STRIKER
V v
V Yvt
PIVOT
BRACKET
RIGHT SEAT
PIVOT BRACKET
--\--------
>: Cliplocations. 14 SEATCUSHION HOOK

I
;
I I
lMwm
F F \_ !t E F
,-------\
Pivot bolt construclion:
WASHER
SEAT.BACK PIVOTBOLT BRACKET 8 x 1.25mm 22 N.m (2.2 kgf.m, 16 lbnftl Apply liquidthreadlock.
NOTE: . Beforeattaching the seat backand seat cushion,make sure there are no twists or kinks in the rear seat belts and centerbelt. . When installing seatcushion. the slipthe seatbelt buckles throughthe slits in the seat cushion. . Makesurethe seat-back lockssecurely. . lf necessary, adjustthe strikerand seat-back.
i
I! -
20-126
2D:
8(-). t
B>,1
c>,1
ksf.m,' 93;mr, v
i i
@
MIDDLEFLOOR
g 7.2tbrftt
CENTER GUSSET
>: Clip locations,14
I
SEAT-BACK MAT
@ni
------irl|H--|
E E )
qr ,/ PIVOTERACKET
RIGHTSEAT-8ACK
i i l
TOOTHED LOCK WASHER BUSHING SEATCUSHION PIVOTBOLT BRACKET 8 x 1.25mm 22 N.m (2.2kgtm. 16 lbf.ft) Apply liquidthreadlock.
of Installation the reverse the removalprocedure. is NOTE: . Beforeattaching and seat cushion,make surethere are no twists or kinksin the rear seatbelts and the seat-back centerbelt. throughthe slits in the seatcushion. . When installing seatcushion, slip the seatbelt buckles the . Makesurethe seat-back lockssecurely. . lf necessarV, latchand seat-back. adiustthe seat-back
20-127
FrontSeat Belt
RemovaUlnstallation
2D l3Dt 1. 2. Slidethe front seatforwardfully. Remove: . Rearseat-back and rear seat cushion(seepages 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) . Rear trim panel(3D,seepage20-60) . Sidetrim panel(seepages2G60,61) Pull backthe carpetas necessary, and removethe bolts.then removethe middlefloor gusset.
UPPER ANCHORBOLT 7/16-20 UNF 32 N.m {3.3 kgf..n, 24 tbtftl
4.
Removethe upper anchorcover and lower anchor cap.
@'a---
'PPERANcHoR
3.
RETRACTOB MOUNTINGAOLT 6x1.0mm 9.8 N.m (1.0kgt m, 7.2 tbl.ftl
>: Boh locations,8
l-owER
10 x 1.25mm 38 N.m (3.9kgf.m. 28 tbt f0 ANCHOR CAP
o
RETRACTOR BOLT 7/16-20 UNF 32 N.m (3.3kgf.m, 24 rbnft)
LOWER ANCHORBOLT 7/16-20 UNF 32 N.m 13.3 kgl.m, 24lbl.ftl
Removeall the anchorbolts and the retractor bolt, remove the retractormounting bolt, then removethe tront seat belt and retractor. Installation the reverse the removalorocedure. is of NOTE: . Check that the retractor lockingmechanism functions as described page20-91. on . Makesureyou assemble washersand collars the on the upperand lower anchorboltsas shown. . Before installing anchorbolts,makesurethere the are no twists or kinksin the front seat belt.
20-128
Tube Washer
Replacement
washertube, removethe left innerfender(seepage20 106). NOTE:To removethe windshield
locations >: Washer nozzle. clip and cushion F>,1 G>,1
a>,2
wtNDSHtELD .--7 l
B>,'l
Ct',1
D>,1
E>,1
ffi,"td-<g *.\ |
\3t / -----J
-r'v!
@t"(
\T \\\
_*)
_ WINDOW E -/ _'' _-/ REAR _J

WINDOW I wasHERTUBE REAB WASHER TUBE I \
i ',',,4 | '*V W,'i .<a>t, J l
,,
9)
behind the EcM/PcM bracket.
WINDSHIELD
TUBE
A
REARWINDOW TUBE WASHER
\;
Routeihe washertubes to the washerreservoar
procedure. of Installation the reverse the removal is NOTE: . Takecarenot to pinchthe washer tubes. . lf necessary, clips. replace damaged any (seepage20-117). . Afterinstalling, adjust aim of the washernozzles the (cont'd)
20-129
Washer Tube
NOTE:To removethe rearwindow washertube (3D),removethe followingpartsfrom the leftside of the vehicle. - Innerfender(seepage20-106) - Kickpaneland sidetrim (seepage20-60) - Rearseat-back rearseatcushion(seepage20-80) and - Sparetire lid - Rearcentershelfand rearsideshelf(seepage20-60) - Rear trim paneland sidetrim panel(seepage20-50) - Ouarter trim panel(seepage20-60) - Rearrooftrim (seepage20-65) - Hatch (seepage20-101) spoiler >: Washer nozzle, andcushion clip locations A > ,9 B>,2 c>,1
-?) K)
To rear window washernozzle (seepage20-101).
_____J
./'-:.1 a/j
Installation the reverseof the removalDrocedure. is NOTE: a Takecare not to Dinchthe washertubes. . lf necessary, replace anydamaged clips. . Afterinstalling. (seepage20-1j7). adjust aim of the washernozzles the
motor.
20-130
Body ('98 modell

Openerand Latch .................. Replacement 20'132
Outline of
. .
'98 Model Ghanges
The hood latch cover was added. The hatch handle was added. (3D)
Openerand Latch
Replacement
HOODLATCHCOVER NOTE:Takecarenot to the hood latchcoverand body.
Hatch Handle
1. 2. Remove the hatchtrim panel(seepage20 63). Remove the hatchhandlebolts. >: Bohlocations,2
HOODLATCHCOVER HOODLATCH
6x1.0mm 9.8 N.m {1.0kgf.m,I
"'o::___,/
HANDLEROD
20-132
Gylinder HatchLatch/Lock
4. Notethe positionof the joint on the handlerod (A). Pry the handlerod of the joint using diagonalcutt 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 hatchhandle. the hatchtrim panel(seepage20-53). 1 . Remove Remove the hatchlatchscrews.
>: 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,

LOCK ROO
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: properly. . Makesurethe handlerod is connected . Beforeinstalling the hatchtrim panel,makesure the hatchopensproperly.
LOCKCYLINDER
RoD
...Ly';
/)<
{'
/
CONNECTOR
{cont'd)
20-133
Openerand Latch
Pullthe lockrod out. LOCK
5.
removethe lockcylinder. It necessary, >: Bohlocation, 1

6x1.0mm I 9.8N.m 11.0 kgf.m,l
!!,b,!)__J
o l n s t a l li n t h e r e v e r s e r d e r o f r e m o v a l ,a n d n o t e thesertems: . . . Apply grease the hatchlatch. to properly. is Makesurethe connector connected Beforeinstalling the hatchtrim panel,make sure the hatchopensproperlyand lockssecurely.
20-134
Heaterand Air Conditioning

Heater A i r C o n d i t i o n i n g' . ' . . . . . . . . .
SYSTEM(SRS} RESTRAINT SUPPLEMENTAL
(exceptsome The civic sRS includesa driver'sairbag locatedin the steeringwheel hub. ln addition,all models abovethe glove box' airbaglocatedin the dashboard havea passenger's modelsfor Canada) (*) the to necessary safelyservice sRS is includedin this serviceManual.ttemsmarkedwith an asterisk lnformation these or disassembling replacing servicing, on the contentspage include,or are locatednear, SRS components. Hondadealer. be and itemswill requirespecialprecautions tools,and shouldtherefore done by an authorized
"""""'21-1 "' 22-1
@ -;;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 activation ol the airbags. injury causedby unintentional 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 elstricaltst equipment on these circuits.
t I
Heater
21-2 fffustrated lndex ................................... Temperature Control ............21-23 Adiustment ,,,,,....21-3 CircuitDiagram Mode Control Motol Troubleshooting .......21-24 21-4 Test ................. SymptomChan ............................... .........21-24 Repf acement HeaterControl PanelInput/Output 21-5 Signals..........................................Recirculation GontrolMotor Flowcharts .......21'25 Test ................. 21-6 BlowerMotor Speed ................... ,.,,,.,,.21-25 Repfacement 21-8 BlowerMotor ............................... Relay 21-11 ModeControlMotor .................... .......21-26 Test ................. 21-14 Heater Fan Switch Recirculation Control Motor ,,,.... Blower Unit .......21-26 Test ................. .........21-16 Mode Control Switch Replacement ................21-17 Test ................. Overhaul ..,.,..21-27 * HeaterUnit * Read SBS precautions before working in .........21-18 Replacement ................21-20 this area. Overhauf HeaterControl Panel .........21-21 Repfacement ................21-22 Overhauf
lllustratedIndex
SRScomponents are locatedin this area.Reviewthe SRScomponentlocations, precautions. and procedures the SRS in section{24)beforeperforming repairsor service.
BLOWER UNIT page21'16 Replacement, page21 17 Overhaul, HEATEB UNIT page21,18 Feplacement, page21-20 Overhaul,
BLOWER RESISTOR page 21-7 Test,
CONTROL MOTOR Test,page21-25 page21-25 Replacement, A/C SWTTCH {with A/c) HEATER VALVECABLE page21-23 Adjustment,
MODECONTROL MOTOR Test,page21-24

R e p l a c e m e n t ,p a g e 2 1 2 4
AIR MIX CONTROL CABLE page21'23 Adiustment, page21 22 Replacement, MODECONTROL
swrTcH
TER FAN
Test,page21-26
swtTcHEs
lest, page21-27
HEAIERCONTROL PANEL page21-21 Replacement, Ovethaul,page21-22
TEMPERATURE CONTROL LEVER page Adjustment, 2123
Defroster-aqtivatedA/C System Turningthe defrosteron activates A,/Cand sets the air flow mode to FRESH. is possibleto turn the Ay'C or to the It off change the air flow to RECIRCULATE pressing Ay'C by the buttonor the FRESH/RECTRCULATE button.
21-2
CircuitDiagram
BOX UNDEN'HOOD FUSE/RETAY
UNDEsOASH
FECIRCULATION
BLOWEF
17
I I
BLU/RED
eil+ji'^*'l-fl Lr_l ?r Lf:} i,fi*r.,{| Ieff{+jir*'It-} -tr'-?il:Y | ?r,l

HEATERCONTROL PANL
a
{
G401 G'102
DASH LIGHTS SRIGHTNESS CONTNOLLEF
21-3
Troubleshooting
SymptomGhart
NOTE: . Check enginecoolantlevel,and allowthe engineto warm up beforetroubleshooting. the . Any abnormality must be corrected beforecontinuing test. the . Because the precise of measurements needed, usea multimeter when testing. . Beforeperforming procedures any troubleshooting checkl *1No.47 \1.5 A), *1No.55 {40A}, *,No. 17 (7.5A) ._ Fuses - G r o u n d s o .G 4 0 1 c 4 0 2 N , - Cleanliness tightness all connectors and of *rr In the under-hood fuse/relay box *' : In the under-dash fuse/relay box Symptom
Hot air flow is low.
Remedy Perform procedures the flowchan(seepage21 6). the in Check the following: for . Cloggedheaterduct . Cloggedheateroutlet . lncorrect door position (seepage21-8). Perform procedures the flowchart the in for Check the following: . Clogged heaterduct . Clogged bloweroutlet . Cloggedheatervalve . F a u l t y i rm i x d o o r a . Heatervalve cable adjustment(see page 21-23l, ' Air mix controlcableadjustment (seepage21-23) . Faultycoolingsystemthermostat (seesection10) ' Clogged (with air conditioning) evaporator . Frozen (with air conditioning) evaporator (seepage21-l 1). Perform procedures the flowchart the in (seepage2'l-14). Perform procedures the flowchart the in
Blowermotor runs,but one or more speedsare inoperative. Blowerruns properly.
No hot air flow.
Blowermotor does not run at all. Blowermotor runs.
Mode controlmotor does not run, or one or more modes are inoperative. Recirculation controldoor does not chanqebetween FRESH and RECIRCULATE.
I I
r-
21-4
HeaterControlPanelInput/OutputSignals
PANEL14PCONNECTOR HEATER CONTNOL
Terminal No.
Wire color YEL BLVYEL

WHT/BLU
Signal HEAT/OEF INPUT INPUT INPUT INPUT
Terminal No. 8
Wire color YEURED

GRN/YEL
Signal
VENT
HEATA/ENT GROUND A.i THERMOSTAT C FRESH RECIRCULATE HEATER FAN SWITCH
INPUT INPUT OUTPUT INPUT INPUT INPUT OUTPUT
tG2
+B DEF
'10
BLK BLU/RED
YEUBLU RED
6 7
DASHLIGHTS OUTPUT BRIGHTNESS CONTROLLER LIGHT COMBINATION SWITCH HEAT INPUT INPUT
12
13
14
GRN/WHT GRN/RED GRN
RED/BLK BLU^r'r'HT
21-5
Troubleshooting
Blower Motor Speed
Blower motor runs. but one or more spedsare 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?
HEATER FAN SWITCII6P CONNECTOR Checkfor a shon in the wi.e{s}: '1. Turnthe ignitionswitchOFF. 2, Disconnect blower motor the 2P connector, 3. Remove centerdashboard the lower cover (see section20), and disconnect heaterfan the switch6P connector, 4. Disconnect the blower resis tor 4Pconnector, 5. Checkfor continuitybetween 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 connectoand body ground r individually.
Replace the heater f'n switch.
Repair short in the wirels) between the blower resbtor, the heater fan switch and the blower
6A
z t-r,
.
tl\
Frompage2'l-6
Checkth6 blower rsistor: '1. Turnthe ignitionswitchOFF the blower resis 2. Disconnect tor 4P connector, 3. Measure the resrstance betweenthe No. 2 and No. 4 terminalsof the blower resis' tor.
RESISTOR BLOWEB
ls thereapprox.2- 3 ohms?
Checktor an open in thg witelslr the 1. Reconnect blower.esistor 4Pconnector. 2. Remove centerdashboard the lower cover (see section20i, the and disconnect heaterfn switch 6P connector. ON switch (lli. 3. Turnthe ignition 4. Ground each of these termiin nals individually the following order;No.4, 2, 5 and 3.
FAN SWITCH CONNECTOR 6P HEATER
BLU/WHT
2 1
6
BLU/BLK
JUMPER WIRE
BLUI
IBLU/Y
TERMINALS WIRE SIDE FEMALE OF
Does the blower motor run at p r o g r e s s i v e l yh i g h e r s p e e d s ?
Beolaco the heator fan switch.
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 resistor and tho heaterlan switch.
21-7
Troubleshooting
Blower Motor
Blower motor does not run al ell.
Check No.55 {40A)tuse in the the undeFhoodfuse/relaybox, and t h e N o . 1 7 ( 7 . 5A ) f u s e i n t h e under-dash fuse/relay box.
Roplaco the lu3o(!1,rnd rochock. BLOWER MOTOR2P CONNECTOR Checktho blowcr motor: 1. Connect the No. 2 terminaloI the blower motor 2P connector to body ground with a 2. Turn the ignitionswitchON (ll).
l l l
ruueeif6rureu wrRE 1
To page21'9 WIRESIDEOF FEMA1T TERMINALS
l-,1
Doesthe blowermotor run?
Checktor an open in the wire: 1 . D i s c o n n e ctth e j u m p e r w i r e and the blowermotor 2P connector. 2. Measure the voltagebetween the No. l terminal and body ground,
L'--r'|--] L1J d)
glulwxr
Chackthe blower motor relay: 1. Turnthe ignitionswitchOFF. 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, th anddisconnect ejumPer the 2, Remove centerdashboard lower cover (seesection20), the and disconnect heaterfan switch6P connector. ON switch (ll) 3. Turnthe ignition the 4. Measure voltagebetween l t h e N o . 3 t e r m i n aa n d b o d y ground.
6P FAN SWITCH CONNECTOR HEATER

ls there battery voltage? Ropair open in the wire between the blower motor and the heatol lan switch.
Checkfor an open in the wire: 1. Turnthe ignitionswitchOFF. 2. Checkfor continuitybetween heater the No. l terminalofthe fan switch 6P connectorand bodyground.
the heaier fan switch. Replace
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 box: Measure the voltage beNveen the No. 3 terminal of the blower motor relay 4P socket and body ground.
BLOWER MOTORRELAY4P SOCKET
rD
{
Chockfor an open in the wi.e: '1. Turnthe ignition switch (ll). ON 2, Me6surethe voltage between t h e N o . 4t e r m i n a l o f t h b l o w e er motor relay 4P socketand body ground.
rl, l 2 1 1 l
r r -
l r l 3| IBLK/YEL
o)
Y
Repairopcn in the wire between the No. 17 luse and the blowe. motor reley. Checktor an opon in the wire: 1. Turnthe ignitionswitchOFF. 2. Check for continuity betlveen the No. 2 terminal of the blower 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.
ReDlace lus, and rechck. the
MOTOR7P CONNECTOR MODECONTROL
ChscktoJ an open in the wire: 1. Disconnect mode control the motor7P connector, 2. Turn the ignitionswitch ON (ll). 3. Measurethe voltage between the No. l terminal and body grouno. Repairopen in the wi.e between the No. 17 fuse and the mode control motor,
3 BLK/YEL
ls lhere battery voltage?
Checktor an open in the wite: 1. Turnthe ignitionswitchOFF. 2. Checktor continuitybetween ofthe mode the No.7 terminal control motor 7P connector 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).
6 BLK
{l
lsthe modecontrolmotor OK?
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 motor (seepage21 24). 2. Check mode controllinkage the and doors for smooth movement.
To page21-12
Do the mode control iinkage and doors move smoothly?
Roolace the mode control motor.
(cont'd)
21-11
Troubleshooting
Mode Control Motor (cont'd)
F r o mp a g e2 1 - 1 1 HEATER CONTROL PANEL1{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: Check samewiresfor voltaoe. the
ls thereany voltage?
Repairshort to power in the wir6 betweon the mode control motor 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
HEATER CONTROL PANEL14PCONNECTOR TERMINALS WIRESIOEOF FEMALE
Ch6ckfor an open in tho wirolsl: Checkfor continuity between the followingterminalsof the mode control motor 7P connectorand the heatercontrolpanel14Pcon' nector, 14P: 7P: No.2-No.4 N o . 3 - N o .1 N o . 4 - N o .7 No.5- No.I No.6- No.8
MOTOR7P CONNECTOR MODECONTROL TERMINALS WIRESIDEOF FEMALE
Ropeir lny opn in tha wilolsl biwe6n 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 connactions !.o good, rcplace tho hgelr control pancl.
21-13
Troubleshooting
Recirculation ControlMotor
Recirculation control door does not change btween FRESHand RECIRCULATE.
Checkthe No. 17 (7.5Al {use in the under-dashfuse/relaybox.
Roplace the lus6, aod rscheck. RECISCULATION CONTROL MOTOR 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 control motor 4P connector. 2. Turnthe ignitionswitchON (ll). 3. Messure the voltagebetween t h e N o . ' 1t e r m i n a a n d b o d y l ground.
BLK/YEL
Repairopen in tho wirc botweon the No. 17 tuse and lhe recirculation control motor.
Check the recirculationcontrol motor: 1. Turnthe ignitionswitchOFF. 2. Test the recirculation control motor (seepage2l 25). Check the rccirculation control linkagoand door: 1. Remove the recirculation control motor (seepage2l-25). 2. Checkthe recirculation control linkageand door for smooth
To page 21 'l5
Oothe recirculation controllinkageand door move smoothly?
Repairthe recirculation control linkage or door.
21-14
F r o mp a g e2 1 - 1 4
PANEL14PCONNECTOR HEATEF CONTROL
1 CheckIor a short in the wite(s): the 1. Remove centerdashboard lower cover (seesection20), and disconnedthe heatercon trol panel14Pconnector' 2. Checkfor conlinuitybetween the No. 12 and No 13 terminalsand body groundindivid 7
2 8 9
'olx
;-?
4 11 12
r3
|
14
GRN/wHr
oo
GRN/REO
R6air short in the wilo(a) bstween the rdrculaiion conttol motor rnd tfte heater control Panel.
1
2 8
t
1 0|
Checkfor a short io powar: Check samewiresfor voltage the
11 12 1 3 1 4 GRN/RED
GRN/WHT
v)(v
Repairshort to Powsr in the wir between the recirculstioncontrol motor and tho heator control penel. lThis short damagesthe h6ater control pan6l'l 1 Checklor an opon in tho wire{s}: Checkfor continuity between the tollowing terminalsof the recircu lation control motor 4P connector and the heatercontrolPanel14P 14P: 4P: N o . 2 - N o .l 2 N o . 4- N o .1 3 7 2 8 9
''l
I
1 5 6
10I
1 1 1 2 't3 1 1
GRN/W
GRN/WHT \ r Repair open in the wire(sl between the recitculationcomrol motor and lhe heeter conttol oanel.
oA I_
tI
-tl
GRN/RED
,lr\/
I
4
iD iRN/RT
MOTOR CONTROL RECTRCULATION 4P CONNECTOR TERMINALS WIRESIDEOF FEMALE
Check for loose wiles or Poor connectionsat the heater control oanel l,lP connector. ll tha connections are good, replace the heater control Panel.
21-15
BlowerUnit
Replacement
NOTE:The blower motor, recirculation control motor and blower resistorcan be replacedwithout removinq the blowerunit (seenext page).
1. Remove the glove box {see section 20). Remove the self-tapping screw and the passenger,s dashboard lower cover. Remove the bolt, the nut and the knee bolster, then remove the five bolts and the glove box frame.
With Air Conditioning 3-b. Remove evaporator (seepage22-25). the
2.
6x1.0mm 9.8 N.m 7.2 tbt tll
:r-
KNEE
iCIi1,
6x1.0mm 9,8N.m(1.0 kgf.m,7.2 tbtf
GLOVEBOX FRAME
Disconnect connectors the from the blower motor, blowerresistor and recirculation controlmotor. Remove the wire harness clip from the recirculation controlmotor,and release wire harness the from the clamp on the blower unit. Removethe two mounting bolts,the mountingnut and the blowerunit.
6x1.0mm 9.8 N.m {1.0 kgf m, 7.2 tbf.tr)
Without Air Conditioning 3-a. Remove the wire harness from the heaterduct,then removethe two self-tapping screwsand the heater quct.
tr tr
6xl.0mm
9.8N.m(1.0 kgf.m, 7.2tbl.ttl Installin the reverseorder of removal.Make sure that there is no air leakage.
HEATER DUCT
6a
za-tr,
t\
Overhaul
NOTE: controldoor and linkagemove smoothlywithout binding' . Beforereassembly, makesurethat the recirculation control door will not allow the recirculation control motor, make sure its positioning . when attaching the recirculation to be pulledtoo far. control motor, connectpower and ground,and watch the movementof the recircula. After attaching the recirculation tion controldoor.
21-17
HeaterUnit
Replacement
S R Sc o m p o n e n t s 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 a precautions, SRScomponentlocations. and procedures in the SRSsection124) beforeperformingrepairsor service, 1 . Disconnect negative the cablefrom the battery. 2. When the engine is cool, set the temperature control leverto MAX. HOT(openthe heatervalve),then drain the enginecoolantfrom the radiator{seesection10). Do not remove the radiator cap when !@ the engine is hot; the engins coolant is under pressure and could severelyscald you. 3. the heatervalve Open the clamp, then disconnect cablefrom the heatervalvearm NOTE| Enginecoolantwill run out when the hoses are disconnected; drain it into a cleandrip pan. 4. Disconnect heaterhosesfrom the heaterunit. the CAUTION:Enginecoolant will damage paint. Ouicklyrinse any spilled sngine coolantftom painted surtaces.
HEATER HOSE SIOEI {OUTLET
CLAMP
5.
Remove the 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 HEATER VALVECABLE
8 x 1.25mm 22 N.m (2.2kgl.m, 16lbf.ft)
21-14
(seesection 20). Remove dashboard the 7. or the heaterduct (seepage 21-16) evapoRemove rator(seepage22-251. the connectorfrom the mode control Disconnect clips and wire motor, and removethe wire harness the clip from harness Jromthe heaterunit. Remove the heater duct, then remove the two mounting nutsand the heaterunit.
8.
6x1.0mm kgf'm,7.2lblft) 9.8N m 11.0
TERDUCT
HEATER UN]T orderof removal.Makenote oi lnstallin the reverse the followingitems.

a Apply sealant the grommets. to the inlet and outlet heater a Do not interchange
9.
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. and makesurethey are propall Connect cables, (seepage21-23). erly adjusted Makesurethat there is no air leakage.
21-19
Heater Unit
Overhaul
1.
Removethe two self-tapping screwsand the heater corecover. Pullout the grommetfrom the heatercore pipes. Remove self-tapping the screwand the clamp.
Pullout the heatercorefrom the heaterunit. NOTE: Be careful not to bend the inlet and outlet pipesduring heatercore removal. Assemblein the reverse orderof disassembly.
HEATER CONE COVER
21-20
HeaterControlPanel
Replacement
'1. Remove the driver's dashboard lower cover, the glove box and the center dashboardlower cover (seesection20). Disconnect air mix controlcablefrom the heater the unit (seepage21-23). Removethe rearwindow defoggerswitch,the hazard 23). warningswitchandthe audiounit (seesection irom the heatercontrol Disconnect connectors the panel.Remove screwsand the the five self-tapping 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, PANEL HEATER CONTROI.
Adjustthe 8ir orderof removal. Installin the reverse mix control cable and the heatervalve cable (see page 21-231.
21-21
HeaterGontrolPanel
Overhaul
ffi
g
^Jj-
\n4.---
f f i \
^gvry
6:B
AIR MIX CONTROL CABLE page21'23 Adiustment,
HEATER FAN SWITCH Test,page21-27
Air Mix Control CableReplacement ofthe innercable. 1. Cut the innercableon the leverside ofthe cableholder,then removeboth pieces lhroughthe end of the cablehousingat the two locations. 2. Usinga sharpknife,cut completely 3. Slidethe largesectionofthecable housingoutofthecable holder,beingcarefulnot to damagethe cablestops. 4. Carefully removethe cut pieces the cablehousingwith a smallflat tip screwdriver. of control lever,then push the cable housinginto the 5. Hookthe tip of the new air mix control cableto the temperature cableholderuntil it locksinto place.
AIR MIX CONTROL CABLE CAALEHOLDER
TEMPERATURE LEVER CONTFOL from rightto left. NOTE:Afterassem check bly, that the temperatu controlleverslidessmoothly re throughthe full stroke
21-22
Control Temperature
Adjustment
1. the heater valve cable Under the hood, disconnect the heatervalve. from 6. Underthe hood, move the heatervalve arm to the 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
VALVEA8M HEATER VALVE CABLE HEATER VALVE CABLE HEATERVALVE ARM
2.
Under the dash, disconnect the air mix control cable 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 then installthe heatervalvecable take up any slack, c i h o u s i n gn t ot h e c a b l e l a m p .
3.
controlleverto MAX. COOL Setthe temperature 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 temperaturecontrolleverwill 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 cable lamp. c
21-23
ModeControlMotor
Test
trom the mode control the 1 . Disconnect 7P connector motor. 2. Connectbattery power to the No. 1 terminal, and g r o u n d h e N o ,7 t e r m i n a l . t CAUTION: Never connect the battery in the opposite direction. 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 to individually the No. 2, 3, 4, 5 and 6 terminalsin that order. Eachtime the connectionis made' the mode controlmotor shouldrun smoothlyand stop. NOTE:It the modecontrolmotor does not run when jumping the first terminal,jump that terminalagain The mode control afterjumpingthe otherterminals. motor is OK it it runs when jumping the first termin a la g a i n .
Replacement
1 . Disconnectthe 7P connector from the mode control motor. Removethe rod from the arm of the mode control motor. screwsand the mode Bemovethe two self-tapping controlmotor.
7P CONNECTOR
MOTOR MOOECONTROL
After installaorderof removal. Installin the reverse m o d e c o n t r o lm o t o r r u n s t i o n , m a k es u r e t h e smoothlv.
4.
lf the mode control motor does not run in step 3, removeit, then checkthe mode control linkageand lf doorsIor smoothmovement. they move smoothly, replace modecontrolmotor. the
21-24
I
ControlMotor Recirculation
Test
the 1 . Disconnect 4P connectorfrom the recirculation controlmotor. 2. Connectbattery power to the No. 1 terminal. and the recirculagroundthe No. 2 and No. 4 terminals; tion controlmotor shouldrun smoothly. CAUTION: Never connect the battety in the opposite direction. from ground; Disconnect No. 2 or No. 4 terminals the the recirculation controlmotor shouldstop at FRESH or RECIRCULATE. control motor NOTE: Don't cycle the recirculation for a long time.
Replacement
1.
the Disconnect 4P connectorfrom the recirculation c 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 s l i p from it. screwsand the recirRemovethe two self-tapping culationcontrolmotor.
MOTOR CONTROL RECIRCULATION
CONTFOL MOTOR After installaorder of removal. Installin the reverse control motor runs tion, make sure the recirculation smoothly.
4.
lf the recirculation controlmotor does not run in step controllink2. removeit, then checkthe recirculation age and door lor smooth movement.lf they move controlmotor. replace recirculation the smoothly,
21-25
Relay
Test
Thereshouldbe continuitybetweenthe No. I and No. 3 terminalswhen power and ground are connected the to No. 2 and No. 4 terminals, and there shouldbe no continuitywhen power is disconnected.
HeaterFanSwitch
Test
Checkfor continuitybtweenthe terminalsaccording to the table below. Terminal Position OFF ,1
o
o ooo-
o -o --o
r [ Fa H
' r t
ffi
IF.=qI
l l
"++
21-26
Mode ControlSwitch
Test
to for Check continuitybetweenthe terminalsaccording the table below. Terminal Position Heat HeaVDef Def Vent 10 7 1 8 I
Heawent
o- -o o ooo-
-c -o -o
-o
7 8
;l t
21-27
T
I
Air Conditioning
"'.......".22'2 SpeciafTools 22-3 lffustratedIndex .........................'---...". 22-4 Locations'.............' Wiring/Connector Evaporator .-."....22-25 Replacement ................22-26 Overhaul Gompressor Description -......-.22-27 Repfacement """' 22'5 outfine ............ 22-29 fffustratedfndex "........'.....'..."..'..".. ....'....22'6 Circuit Diagram --22'30 Clutch Inspection...............'.....'.'.' Tloubleshooting ... ".. Cfutch Overhaul'.....'..'........"....22-31 22'7 SymptomChart ...................."..'---..' Thermal Protector Replacement .... 22'33 " ". Fan ....."......'.".........., 22-8 Condenser 22'33 RefiefValve Replacement.....-......". ."'...-'.'22'11 Compressor ..---.."'.22-15 A/C GompressorBelt A/C System .-."'..--..22-34 Adiustment A/C Thermostat Condenser ..""'22'14 Test ............"'.. Repfacement Relay .......22-14 A/G System Service Test ...'............. Evacuation ....'.22-19 A/C ServiceTips and Precautions Charging A/C System Torque Specifications ...-22-2O LeakTest A/C System Service ...".'...-.""22'21 Recovery 22-22 Test .....................'..',,'. Performance ...."' Test Chart ..'......."".... 22'24 Pressure -......'.22-35 ........,....22'36 "'......".....22-37 ....'..........22-37
Tools Special
\
Ret. No. Tool Numbor *07JGG- 001010A 07sAz - 0010004 07947- 6340300 07965- 6920500 Description BeltTensionGauge Backprobe Set DriverAttachment Hub AssemblyGuideAttachment Oty 1 2 'I 't I PageReference
o o
Ar
22-34 22-12,14 22-3'l
* Included the BeltTensionGaugeSet,07TGG-001000A. in
,a
I
22-2
lllustratedIndex
EVAPORATOR page22-25 Replacement, page22-26 Overhaul,
A/C PRESSURE SWITCH pressure below200kPa(2.0kgtcm' , is Whenthe refrigerant 28 psi) due to refrigerantleakageor above 3200kPa 132kgflcm', 455 psi) due to refrigerantblockage,the A,/Cpressureswitch opensthe circuhto the A/Cswitchand stopsthe air conditioning to protectthe compressor.
VALVE SERVICE SIOE} ILOW.PRESSURE
Test,page22 18
CONDENSER page22-35 Replacement,
RECEIVER,/DRYER
page22'27 Replacement,
22-3
Locations Wiring/Connector
DIODE, FAN RELAY, CONOENSER RELAY COMPRESSOF CLUTCH in box} {Located the underhoodfuse/relav
FAN CONDENSER CONNECTOR
COMPARTMENT WIREHARNESS
CONNECTOR
22-4
Description
Outline
throughthe system refrigerant by compartment circulating systemremovesheatfrom the passenger The air conditioner as shownbelow. High-temperature/ e h i g h - p r e s sru g a s Suction and compression High-temperature/ i h i g h - p r e s s u rleq u i d
Radiationof heat
t r a p so e D f l s , ano removes motsture
High-temperature/ ie h i g h - p r e s s ulr q u i d
c o M p R E s s o RC o N D E N S E R Less moisturized low-pressure vapor Absorption of heat

E VAT\JhA I UN \
RECEIVER/DRYER
Moreliquidified vapor low-pressure
EVAPORATOR
LINE RECEIVER LINE DISCHARGE
LINE SUCTION RECEIVER/DRYER COMPRESSOR
Pay which does not containchlorofluorocarbons, attentionto the following refrigerant This car uses HFC-134a {R-'134a) rtems: servtce (R-134a) (R-12) They are not compatible. and HFC-134a a Do not mix refrigerants CFC-12 compressor. (PAG)refrigerantoil (SP-10) designedfor the R-134a Use only the recommendedpolyalkyleneglycol failure. oil oil Intermixing recommended the {PAG)refrigerant with any other refrigerant will resultin compressor valve. expans'on receiver/dryer, condenser, line,suctionline,evaporator, discharge All Ay'C systemparts(compressor, parts. with R-12 R-134a. not confuse Do for O-rings joints)haveto be properfor refrigerant R-134a. for designed refrigerant a Usea halogengas leakdetector System Use equipment not interchangeable, only a Recovery/Recycling/Charging are servicing refrigerant R-12 and R,134a systems. R-134a conditioning air to ot to is U.L.,listed is certified meetthe requirements SAEJ2210 service and that any Systembeforedisconnecting R-'134a with an approvedRecovery/Recycling/Charging Alwaysrecover the refrigerant A,/C fitting.
22-5
Diagram Circuit
FU AY U N D E R - H O O D S E / B E LB O X N 0 . 4 18 0 A ) i ( N0.4240A) UNDER DASH FUSE/RELAY 8OX ( No.177.541
No.56l20A)
I
j
4 COMPRESSOR CLUTCH RELAY
BLU/ryVHT
(,r ) PRESSURE \.:J./ SWITCH
iS. rc
CONDENSER FANMOTOR
COMPRESSOR cLUTcH REsrsToR
.N..i.._-)
I
22-6
BIK
Troubleshooting
SymptomGhart
NOTE: the . Any abnormality must be corrected beforecontinuing test. when testing. needed, usea multimeter . Because the precise measurements of procedures check; o Beforeperforming any troubleshooting * . _ F u s e s 1 N o 4 7 ( 7 . 5 ) , * 1 N o . 5 6 2 0A ) , * , N o .1 7 ( 7 . 5 l ( A A - GroundsNo. G401, G751 G402, - Cleanliness tightness all connectors ot and *r: In the under-hood fuse/relay box *2:In the under-dash fuse/relav box Symptom tan Condenser does not run at all. clutchdoes not engage Compressor and A,/C systemdoes not come on (compressor tan). Remedy in Perform procedures the flowchart(seepage22-8). the procedures the flowchart(seepage22-11) in Perform the in Perform procedures the flowchan(seepage22-15). the
I
I !
22-7
Troubleshooting
Condenser Fan
Condensa does noi run at ell. lan
Remove the condenser relay, fan and test it {seepage22-18).
Replace the condensertrn relay. CONDENSER FAN RELAY4P SOCKET Checkthe unde.-hoodIuse/rlsy box: Measurethe voltage betweenthe 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: Connect the No. 'l and No. 3 ter minafs of the condensetlan rclay 4P socketwith a jumper wire.
Doesthe condenser run? fan
To page22'9
To page22-10
22-8
Frompage22 8
FAN RELAY'P SOCKET CONDENSER
wHTa------l 1 l
Checkfor an open in the wire: 1. Disconnect iumperwire. the fan the 2. Disconnect condenser 2Pconnector. 3. Checkfor continuitybetween the No. 1 terminalol the conand denser relay4Psocket fan the No. 1 terminalof the confan denser 2Pconnector.
I
l f f i 6 \ \:/
r--------------1
I l n l ' l
I I
wHT t-----l-----J
L-r,T;l
r- r
Repairopn in the wire betwoen tho condenser fan relay and the condensertan.
FAN 2P CONNECTOR CONDENSER TERMINALS WIRESIDEOF FEMALE
Checkfor an op.n in the wire: Checkfor continuity beNveenthe No. 2 terminal ol the condenser fan 2P connector and body ground.
ls therecontinuity?
fan RsDlace condenser motor, the
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
Condenser (cont'dl Fan
Frompage22-8
Checkthe diode: 1. Disconnect jumperwire. the 2 . R e m o v e h e d i o d ef r o m t h e t under-hood fuse/relay box. 3. Check currentflow in both for directions betweenthe A and B terminals.
ls therecurrent flow in only one direction?
a o--J(-----o n
22-10
Compressor
Removethe compressorclutch relay,and test it (seepage 22-18)BELAY4P SOCKET COMPRESSOR CLUTCH
Checkthe under-hoodfuse/relay box: Measurethe voltage betweenthe No. 3 terminalof the compressor clutch relay 4P socketand body ground.
ls there battery voltage? JUMPER WIRE Checktho compr*sor clutchl Connect No. 1 and No. 3 termi' the nalsotthe compressor clutchrelay 4Psocketwith a iumoerwire.
clutchclick? Doesthe comoressor
fo page22-12
lor.n oponin the wir: Check 1. Disconnect jlmper wire. the 2 . D i s c o n n e ctth e c o m p r e s s o r clutch1Pconnector. 3. Checkfor continuity between the No. 1 terminalof the compressor clutch relay 4P socket and the terminal of the com pressor clutch1Pconnector,
ls therecontinuity?
Rapairopen in tho wite botwoen tha compa6sor clutch aelay ,nd tho compressorclutch. 1P COMPRESSOR CLUTCH CONNECTOR WIRESIDEOF FEMALE TERMINAL
Inspct tho compressor clutch (sepago 22-301.
(cont'd)
22-11
Troubleshooting
(cont'dl Compressor
t u o mp a g e 2 2 - 1 1 COMPRESSOR CLUICH RELAY SOCKET 4P
Checkfor an open in the wi.e: 1. Disconnect jumperwire, the 2. Turnthe ignition switch {ll). ON 3. Measurethe voltage between the No. 4 terminalof the com pressor clutch relay 4P socket and body ground.
Is there batteryvoltage?
ECM/PCMCONNECTOR (32PI A Chocktor an open in thg wira: 1. Turn the ignitionswitch OFF, then reinstall the compressor clutch relay. 2. Nlakesure the A/C and heater tan switchesare OFF, then turn the ignition switch lll). ON 3. Using a *Backprobe Set (T/N 07SAZ- 001000A), measure the voltagebetweonthe No. 17 terminal of the ECWPCMcon, nector A {32P) and body groundwith the ECM/PCM conn6ctors connected.
ls therebattery voltage?
Repairopen in the wiro between the compressor clutch .elay snd rhe ECM/PCM.
fo page22-13
*How to usethe backorobe sets Connect backprobe patchcords,and the adapters the stacking to connect the cordsto a multimetor, Usingthe wire insulation a as guldefor the contoured ot the backprobe gentlvslide tip adapter, the tip into the connector from the wire side untal comesin conit tactwith theterminalendofthe wire lseesection11).
22-12
Frcm page22-12 2P SWITCH CONNECTOR A/C PRESSURE Chocklor an opon in tha wira; 1. Turnthe ignitionswitchOFF. pressure 2. Disconnoct the Ay'C switch 2P conneclor. 3. Turn the ignitionswitchON (ll). 4. Measurethe voltage between 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 rwitch: Ch6ckthc A/C pressuJo 1. Turnthe ignitionswitchOFF. 2. Check for continuity betwesn th No. 1 and No.2 terminals switch. of th NC Dressure
To page 22-14
system pressure. Checktor Ay'C
Rop.ir the A/C pr.3suroploblem.
Replaccth. A/C pr4sute swhch.
(cont'd)
22-13
Troubleshooting
Compressor {cont'd)
Frcmpage22 13
Checkfor an op6n in the wire: 1. Reconnect the ,a/Cpressure swilch 2P connector,then turn the ignitionswitchON {ll). 2. Using a *Backprobe Set {T/N measure 07SAZ- 001000A), the voltage betweenthe No. 5 terminal ol the EcM,rrPcM connector C {31P) and body groundwith the ECM,PCM connectors connected.
ECM/PCMCONNECTOR 131P) C
Ropairopon in the wire between 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 It connectorsA {32P}and C 131Pl. the connec,tions good, substiare tute a known-good ECM/PCM, and recheck. lf the symptom/ indication goes away, replace the oriqinal ECM/PCM. *How to usethe backprobe sets patchcords,and Connect backprobe the adapters the st6cking to Usingthe wire insulation a as connect the cordsto a multimeter. guidetor the contoured of the backprobe gentlyslide tip adapter, from the wire side until itcomes in conthe tip into the connector 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.
Replace tuse(sl,and recheck. the 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. ON switch (ll). 2. Turnthe ignition 3. i/leasurethe voltage between the No. 4 terminalof the cond 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: Measurethe voltage betweenthe 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 A/C THERMOSTAT CONNECTOR ChecktoJ an opon in lhe wire: 1. Turn the ignitionswitch OFF, a n d r e i n s t a lt h e c o n d e n s e r l Ian relay. the 2. Disconnect NC thermostat 3P connector. 3. Turn the ignitionswitchON (ll) 4. Measurethe voltage betlveen the No. 3 terminal and body ground.
TEBMINALS WIRESIDEOF FEMALE
Repairopen in the wite betwen the No. l? fuse and tho A/C thetmostal.
(cont'd)
To page22 16
22-15
Troubleshooting
A/C System{cont'dl
Ftom page 22-15
Ch6ckfor an open in the wirsi Measurethe voltage betweenthe No. 1 terminalof the A"/C thermo, stat 3P connector and body grouno,
Repai. open in the wire botwaen the condonser fan rolay and th6 A/C thermGt.t.
Chcklhe A/C thermostat: 1. Turnthe ignitionswitchOFF. 2. Reconnect the Py'C thermostat 3P connector, 3. Connect the No. 2 terminalto groundwith a iumperwire. 4. Startthe engine.
JUMPERBLU/RED I wrRE l
. -tlu----r---u 3 l 1 l 2 l
Do both fansrun and doesthe compressor clutchengage? PANEL,I4P HEATER CONTROL CONNECTOR Checklor an open in the wire: r , r u r n r n e r g n r t r os w n c hu t - t - , n t h e n d i s c o n n e ctth e j u m p e r
1
2 8
3 9
''|
2. Flemove centerdashboard the lower cover (see section20), and disconnect heater the con trol panel14P connector. 3. Turnthe ignition switch (ll). ON 4, Measure the voltagebetween the No. l1 terminaland body ground.
a
It
lol
12 1 3 14
WIRE SIDE OF FEMAI,TTERMINAU; ls there batteryvoltage? Ropair open in tho wire bttt oon the A/C th.rmGt.t.nd th. hertor conlrol panol.
To page 22-17
22-16
Frompage22-16
PANEL1'P CONNECTOR HEATER CONTROL TERMINALS WIRESIDEOF FEMALE
Chocktor en opon in the wire: 1. Turnthe ignitionswitchOFF. 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. 3. Check for continuity beNveen the No. 14 terminal of the heatercontrolpanel 14Pconnectorand the No. 6 terminal ofthe heaterfan switch6P connector, Rpairopen in tho wire bstwoon tho hoater control panl and the hoater f.n switch.
2 8 9 10
;--?
X
2
11 1 2 1 3 1 4
GRN
GRN
6P FAN SW]TCH CONNECTOR HEATER TERMINALS WIRESIDEOF FEMALE
Chocklor an op6n in the wir6: Checkfor continuity between the 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
Test
Connect batterypower to the No. 3 terminal, groundthe No. 2 terminal, and connect test light between No. 1 a the and No. 3 terminals. NOTE:Usea 12V, 3 W - 18W test tight. Dip the !y'Cthermostatinto a cup filled with ice water, and checkthe test light. Serpentinetype evaporator The light shouldgo off at 36 - 39'F{2 - 4"C) less,and or shouldcome on at 39 - 41"F(4 - 5"C) more. or 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 , replace Ay'C the thermostat.
Relay
Test
Thereshouldbe continuitybetween the No. 1 and No.3 terminalswhen power and ground are connected the to No. 2 and No. 4 terminals, and there shouldbe no continuitywhen power is disconnected.
l .nI
,YI t
t>
lo
I
I
12v,3w-18W
1.,
I
\ 1 \
rE-],,' A
i|
.,,fl--$-....
Llt
Tips and Precautions A/C Service
EI
(PAG) oil*' which are not refrigerant (R-134a) and polyalkyleneglycol refrigerant systemusesHFC-134a The air conditioner and do or and mineraloil. Do not use R-12refrigerant mineraloil in this system, with 6p6-121n-tZ)refrigerant compatible will result. your servicing equipment systemor to damage the air conditioner equipment; servicing to not attempt useR-12 *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) of Use only serviceequipmentthat is U.L. listedand is certifiedto meet the requirements SAE J2210to removeR-134a system. from the air conditioner CAUTION:Exposureto air conditioner rftigerant and lublicant vapor or mist can irritatg eyes, nose and lhroat. Avoid breathing the air conditioner refrigerant and lubticant vapor or mist. work areabeforeresumingservice' ventilate occurs, systemdischarge lf accidental testedor Ieaktestedwith compressed shouldnot be pressure systems service equipmentor vehicleair conditioner R-134a air. Some mixtures ol air and R.i34a havs been shown to b9 combusiible at elevated pressuresand can resuh @ servica equipcausing iniury or property damage. Nevet use compresscd air to pressuretest R-13/+a iiTiiffiiplo"ion ment or vehicle air conditionor systems. manufacturers' and lubricant from the refrigerant may be obtained information Additionalhealthand safetY parts. air cablefrom the batterywheneverreplacing conditioning the t. Alwaysdisconnect negative don't any When disconnecting lines,plug or cap the fittings immediately; dust out of the system. 2. Keepmoistureand eachline. removethe capsor plugs untiljust beforeyou reconnect oilto the O-ring' any hoseor line,apply a few drops of refrigerant 3. Beforeconnecting fitting' secondwrenchto supportthe matching a or 4. Whentightening loosening titting,usea system; don't releaserefrigerRecovery/Recycling/charging refrigerant use a R-134a the 5. When discharging system, atmosphere ant into the the oil 6. Add refrigerant after replacing followingparts: NOTE: and nevermix it with other refrigeronce dispensed, do . To avoidcontamination, not returnthe oil to the container ant oils. and sealit to avoid moistureabsorption the . lmmediately afterusingthe oil, replace cap on the container, the oil paint;ifthe refrigerant contacts paint,wash it oil . Do not spillthe refrigerant on the vehicle; may damagethe it off immediatelY. m/ .......20 (2/3fl'oz' 0.7 lmp'ozl Condenser ils m I 11213tl'oz' 1.6lmp'ozl ........................................ Evaporator 10 ml (1/3fl'oz.0.4 lmp'oz) Lineor hose........... 10 ml (1/3 fl'oz, 0.4 lmp'oz) Receiver/Dryer 25 m/ (5/6 ll'o2, 0.9 lmp'ozl Leakagerepair .., For compressot teplacement, subtract the volume of oil drained {rom the compressor from 130 m/ (4 1/3 fl'oz, '1.6tmpoz), and drain the calculated rmovedcomDressor 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' don t draln more NOTE:Even if no oil is drainedfrom the removedcompressor, than 50 m/ \1 2/3tl'o2,1.8lmp'oz)from the new compressor. NEW REMOVED COMPRESSOR COMPRESSOR
6(Cf i re f f i f
w w
I I
l6_d omrr,rrruc r l uver-.ffir volunae 130 t41/3 16rmP rr'oz' ozr m{ h['-saue ]
22-19
A/C SystemTorqueSpecifications
hoseto the compressor x i.0 mm) ............... (6 O Discharge ........................ 9.SN.m 0.0 kgf.m,7.2 lbf.ft) (6 hoseto the condenser x 1.0mm)................... @ Dischargo ....................... 9.8 N.m 0.0 kgf.m,7.2 tbf.ft) pipe to the condenser x 1.0mm|................... @ Condenser {6 ......................N.m fl.0 ksf.m,7.2 lbf.ft) 9.8 pipeto tho receiver/dryer x i,0 mm)......... @ Condenser {6 .......................... 9,g N.m (1.0kgt.m,7.2 lbr.ft} pipe A to the roceiver/dryer x 1.0mm)...,..... (6 @ Receiver .....................,.... 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) pipe C to the evaporator x 1.0mm) ............... (6 @ Receiver ......................... 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 ........................... {3.2kgf.m,23 tbf.ftl 31 N.m @ Suctionhoseto tho sustionpipe A... ........................... {3.2kgt.m,23 lbf.ft) 3t N.m (6 @)Suctionhoseto the compressor x 1.0mm),..............,... ........,,.............. 9.8 N.m {i.0 kSf.m,7.2 lbf,ft} io @ Compressor the comp.essor bracket(8 x 1.25mm).., .......,..,.......-....,,..- {2.4kgl.m,17 lbf.ft} 24 N.m bracketto the cylindorblock {10x 1.25mm} ..................................................._......kgr.m,33 tbf.ft) @ Compressor /14N.m (4.S bracketio the left front enginemount {12x t.2S mm) ..........................................(6.0kgf.m,43 tbr.ft) @ Compressor 59 N.m
22-20
ru
A/C SystemService
Recovery
that is U.L-listedand is cerequipment Useonly service of to meetthe requirements SAEJ2210to remove tified (R-134a) system from the air conditioner HFC-134a CAUTION: Exposure to air conditioner rfrigersnt and lubricant vapol or mist c8n irritate syes, nose and ihroat. Avoid breathing the air conditioner lgfrigerant and lubricant vapol or mist. work ventilate occurs, systemdischarge lf accidental resumingservice. areabefore sysor equipment vehicleair conditioner R-134a service testedor leaktestedwith tems shouldnot be pressure atr. comDressed 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. Nver use compressedair to pressure test R'i34a srviceequipment ot vehicleair conditionsr systems. may be obtained healthand safetyinformation Additional iubricantmanuJacturers. from the refrigerantand 1 . Connecta R-134arefrigerantRecovery/Recycling/ as Systemto the vehicle, shown,following Charging instructions. manufacturer's the equipment from oil the Measure amountof refrigerant removed system after the recoveryprocessis comthe A,/C pleted. NOTE: Be sure to installthe same amount of new refrigerantoil backinto the ly'C system before chargIng.
g/Charging system Recovery/Recyclin
22-21
A/G System Service

Performance Test
The Derformance will helo determineif the air contest ditionersystemis operating within specifications. Useonly service equipment that is U.L.-listed is cerand tified to meet the requirements SAEJ2210to remove of (R-134a) HFC-134a from the air conditioner svstem. 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, R-134a serviceequipmentor vehicleair conditioner systems should not be pressure tested or leak testedwith compressed air. 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 sy3tems. Additional healthand safetyinformation may be obtained from the refrigerantand lubricantmanufacturers. 1 . C o n n e c ta R - 1 3 4 a e f r i g e r a n R e c o v e r / R e c y c l i n g / r t ChargingSystemto the vehicle.as shown, following the equipment manufacturer'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 temDerature. Testconditions: . Avoid directsunlight, o Openhood. . Openfront doors. . Setthe temperature controlleverto MAX. COOL, the mode control switch on VENTand the recirculationcontrolswitchon RECIRCULATE. . Turn the IVCswitchon, and the heater switch fan on MAX. . Runthe engineat 1,500 rpm. . No driveror passengers vehicle in After running the air conditioningfor 10 minutes under the above test conditions,read the delivery temperature from the thermometer the dashvent in and the high and low systempressure from the !y'C gauges. Recovory/Recycling/charging Systom
5.
the charts: To complete . Markthe delivery alongthe verticalline. temperature (ambientair temperature) alongthe bottom line. o Markthe intaketemperature to . Drawa line straightup from the air temperature the humidity . Mark a Dointone line aboveand one line belowthe humiditylevel(10%aboveand10%belowthe humiditylevel). the temperature. line across delivery . Fromeachpoint,draw a horizontal the . The delivervtemoerature shouldfall between two lines test in the sameway. . Complete low side pressure test and high side pressure the the . Anv measurements outsidethe line maYindicate needfor further inspection
kPa lkgf/cm'l lpsil
2900(30t t0t 2500t25) t3601 2000t20) 1280t 1500 t15t t2101

DELIVERY PRESSURE
80/o
307o
DELIVERY PRESSURE 80vo kPa "F {kgt/cmz) tpsil {"c} 400 85 l,ll {30t t57l
980 {10) 11lol
300t3)
li(}l
77
l25l
200 tzl
I2Al 100 {11 lt 4l -
68 (20t
lI
INTAKE PRESSURE
59
tlst
INTAKE PRESSURE
50 {10}
ll
l
ri
DELIVERY TEMPERATURE
DELIVERY TEMPERATURE
11 (5t
6 a l20l
n a (251
6 t30)
95 (35)
104 (,r01
"F fC)
INTAKETEMPERATUFE
22-23
A/C SystemService
Pressure TestChart
NOTE:Performance Test is on page22-22. Test results Relatedsymptoms Probablecause Air in system Remedy Recover, evacuate, and recharge with specified amount. Evacuation: page22-36 see Charging: seepage22-37 Clean. Check voltageand fan rpm. Check direction. fan Restricted lines Replace compressor. the
h D i s c h a r g(e i g h ) After stoppingcompressor, prespressure abnor, suredropsto about200kPa m a l l yh i g h {2.0kgflcm,,28psi)quickly. and t h e nf a l l sg r a d u a l l y .

Reduced r no air flow through o condenser
. Clogged condenser fins . Condenser not workfan ing properly
Restricted flow of refriger ant in system pres. Faultycompressor Discharge Highand low pressures bal are diss u r ea b n o r m a l l y ancedsoon afterstoppingcompreschargevalve sor.Lowsideis higherthan normal. . Faultycompressor seal . Faultyexpansion Outletof expansion valveis not valve . Moisturein system frosted,low pressure gaugeindicatesvacuum. Suction(low) pressure abnorm a l l yl o w Expansion valveis not frosted, and low pressure is not cold.Low line pressure gaugeindicates vacuum. Frozen expansion valve Faultyexpansion valve
Lineto condenser excessively is hot.
. Replace. . Recover, evacuate. and recharge with specified amount.

Replacethe expansion valve.
Discharge temperature low,and is Frozen evaporator the air flow from ventsis restricted. Expansion valveis frosted. Receiver/dryer outletis cool,and inletis warm (shouldbe warm SuctionpresLow pressure hoseand check s u r ea b n o r m a l l y joint are coolerthan the tempera high tu re aroundevaporator. Suctionpressure loweredwhen is condenser cooledby water. is Clogged expansion valve Cloggedreceiver/dryer
Runthe fan with compressor off, then checkA,/C thermostat. Cleanor replace.
Replace.
11lr9i!99!:!.
. Expansion valveopentoo l on g . Looseexpansion capillary tube
Repair replace. or
Excessive refrigerant sysin tem l-l,gh ""d l"* pr""sureare equal- . Faultygasket . Faultyhigh pressure izedas soon as the compressor is valve stopped, and both gaugesfluctu ] . Foreignparticle stuckin a t ew h i l er u n n i n g . high pressure valve S""tl""""d d'; l Reduced flow throughcon- I . Cloggedcondenser air fins cnargepres. Condenser not workdenser. fan sures abnormally ing properly nrgn Suctionand dischargepressure abnormally low Low pressure hoseand metalend areasare coolerthan evaporator. Temperature aroundexpansion valveis too low compared with that aroundreceiver/dryer. Compressor clutchis dirty. Compressor bolt{s)are dirty. gasketis wet with oil. Compressor Clogged kinkedlow presor sure hoseparts Cloggedhigh pressure line
Recover, evacuate, and recharge with specified amount. Replace compressor. the
Cleancondenser. Check voltageand fan rpm. Check direction. fan Repair replace. or Repair replace. or
Refrigerant leaks
Compressor shaftsealleaking Replace compressor. the Leaking aroundbolt(s) Gasket leaking Tightenbolt(s) replace or compressor. Replace compressor. the
22-24
Evaporator
Replacement
']
2. the battery. Remove with a Recovery/Recycling/ Recover the refrigerant System(seepage22 21). Charging the suctionand Removethe bolts,then disconnect receiver linesfrom the evaporator. NOTE:Plug or cap the lines immediatelyafter disconnectingthem to avoid moisture and dust contaminatron.
LINE SUCTION :1i 6x1.0mm 9.8N.m (1.0kgl.m,
6.
from the A,,/C thermostat, Disconnect connector the from the evaporator' and removethe wire harness the mounting screws, the four self-tapping Remove 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 boit and the hose.then removethe evaPorator.
3,
ORAINHOSE
7.2tbt.ftt
.,
i, I
THERMOSTAT CONNECTOR EVAPORATOR LINE RECEIVER 1 . 0m m N.m {1.0kgl.m.7.2lbtft}
Remove glove box (seesection20). the 7. screwand the passenger's Remove the self-tapping t l d a s h b o a r do w e r c o v e r .R e m o v e h e b o l t ,t h e n u t then removethe five boltsand and the kneebolster, the glove box frame.
.1...
order of removal.Make note of Installin the reverse the followingitems. add a lf you'reinstalling new evaporator, refriger(seepage22-191. ant oil (SP-10) with new onesat eachfitting, Replace O-rings the and apply a thin coat of refrigerantoil before installing them. NOTE: Be sureto use the right O-ringsfor HFCto 134a{R-134a) avoid leakage. a Apply sealant the grommets. to a Makesurethat there is no air leakage. and test its a Charge the system (see page 22-311, (seepage22-22J. performance
,;1 ,, -;1 i1:-..... t'i i', r'l--.;:,i,, ,. i
22-25
Evaporator
Overhaul
1.
Pull out the Ay'C thermostat sensorfrom the evaporatorfins. Removethe self-tapping screws and clamps from the housings. Carefullyseparatethe housings,then remove the evaporator. lf necessary, removethe expansion valve. NOTE:Whenloosening expansion valvenuts,use the a secondwrenchto hold the expansion valveor the pipe.Otherwise, evaporator they can be damaged.
5.
Assemble the reverse in orderof disassemblv. Make noteof followjngitems. Replace O-rings the with new onesat eachfitting, 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 no i l b e f o r e t installing them, NOTE:Be sure to use the right O-ringsfor HFC 134a(R-134a) avoid leakage. to Installthe expansion valve capillary tube so that it is in direct contactwith the suction line.Then wrap wrth tape. Reinstall Iy'Cthermostat the sensorto its original location.
2.
3.
6th fin trom inlet side
1 2 0 15 m m {4.710.2 in)
UPPER HOUSING
Serpentinetype:
TAPE Replace. Makesurethereis no foreignmatterstuckbetween the capillary tube and outletline.
a
Laminatetype:
6015mm 12.1! 0,2 inl EVAPOBATOR blow dirt out of tins with compressed air. N.m {0.8 kgl.m,
rbr.ftl
6th fin from outlet side
CAPILLARY TUBE EXPANSION VALVE
N.m {2.itkg{.m,
A/C THERMOSTAT Testpage22 18
HOUSING LOWER
22-26
Compressor
Replacement
'1.
o , I t t h e c o m p r e s s oirs m a r g i n a l l y 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 then shut the engineoff. work tor a few minutes, cablefrom the battery. Disconnect negative the with a Recovery/Recycling/ Recover the refrigerant Systemlsee page22-211. Charging the suctionand Removethe bolts,then disconnect linesfrom the compressor. discharge NOTE:Plug or cap the lines immediatelyafter disconnectingthem to avoid moisture and dust contamination.
7.
2.
L o o s e n 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 t belt compressor bolt,then removethe Ay'C adjusting from the pulleys,Removethe two mounting bolts from the left front engine mount, then removethe belt by passingit through the gap A,/C compressor the between body and the leftfront enginemount.
ADJUSTINGBOLT CENTERNUT
6x1.0mm
LINE DISCHARGE
LEFTFRONT
1.0x125mm a4 N.m {4.5kg{.m,33 lbtftl
8. SUCTION LINE
Remove the four mounting bolts and the compressor.
COMPRESSOR
I I
5.
(seepage22-35). Remove condenser the the dischargehose from NOTE:Do not disconnect lhe condenser-
6.
Removethe power steeringpump belt {seesection 171.
2il N m 12.4 kg[.m, 17 lbf.ftl
(cont'd)
22-27
Compressor
9. as lf necessary, removethe compressor bracket foltows. Remove nut and the washer. the NOTE:When tighteningthe nut of the left front enginemount,makesurethe washeris set properly on the leftfront enginemount as shown. Removethe four mounting bolts and the compressorbracket. 10. lnstallin the reverse orderof removal.Makenote of the followingitems. lf you're installinga new compressor, drain all the refrigerant from the removedcompressor, oil the volume of and measureits volume.Subtract drainedoil lrom 130mf 14 1B fl.oz,4.6 lmp.oz); the result is the amount of oil you should drain from the new compressor(throughthe suction fitting). Replace the O-ringswith new ones at each fitt 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 beforeinstalling them. NOTE:Be sure to use the right O-ringsfor HFC134a(R-134alto avoid leakage. oil R-134a Sandenand Use refrigerant (SP-10lfor Hadsys spiraltype compressors only. To avoid contamination, not returnthe oil to do the containeronce dispensed, and never mix it with other refrigerant oils. lmmediatelyafter using the oil, replacethe cap on the container.and seal it to avoid moisture absorption. Do not spill the refrigerant on the vehicle;it oil may damagethe paint;if the refrigerant conoil tactsthe paint,wash it off lmmediately. Adjust the Ay'C compressor belt (see page 22-341 and the power steeringpump belt {seesection17). Charge the system (see page 22-371, and test its (seepage22-22'). performance
12 r 1.25mm 59 N.m {6.0 kgl.m, 43 tbf.ftl
COMPRESSOR BRACKET
WASHER
LEFTFRONT 1.0x 1.25mm ENGINEMOUNT a{ N.m 14.5kgt m.33 tbf.ft)
22-28
lllustratedIndex
CENTER NUT
Replace.
ARMATURE PLATE page22-30 Inspection,
sHrM{s)
Replace.
Replace.
ROTOR PULLEY page22-30 Inspection,
SNAPRINGA Replace.
FIELD COIL page22-30 Inspection,
q\
a_-2
COMPRESSOR ----"-}l {Do not disassemble.)
q \
RELTEF vALvE page Replacement, 22-33
PROTECTOR THERMAL Replace. page22-30 Inspection, page22 33 Replacement,
a
22-29
Compressor
Clutch Inspection
Checkthe platedpartsof the armatureplatefor color 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 . f t h e r e i s d a m , l age,replace clutchset. the Check the rotor pulleybearingplay and drag by rotating the rotor pulley by hand. Replace the clutch set with a new one it it is noisyor hasexcessive play/drag. . Release field coil connector the from the holder,then disconnectit. Checkthe thermal protectorfor contin u i t y .l I t h e r e i s n o c o n t i n u i t yr e p l a c e h e t h e r m a l . t Drotector.
Checkresistance the field coil. of Measurethe clearance betweenthe rotor pulley and the armature plate all the way around. lf the clearance is not within specified limits,the armatureplate must be removed and shims added or removed as required, followingthe procedure page22-31. on Clearanca: t 0.15mm {0.02010.006in} 0.5 NOTE: The shims are availablein four thicknesses: 0 . 1m m , 0 . 2m m . 0 . 4m m a n d0 . 5m m FieldCoil Resistance:3.2 0.15ohms at 68"F{20"C1 t lf resistance not within specifications, is replacethe field coil.
22-30
II
Clutch Overhaul
1. Removethe centernut while holdinqthe armature olatewith the tool.
CENTER NUT 17.6N.m {1.8kg{.m, 13 lbf.ft}
A/C CI-UTCH HOLDER (Commercially available) Robinai.: P/N 10204 Kent-Moore: P/N J37872
3.
Remove snap ring B with snap ring pliers. NOTE: 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 compressor during removal/installation. . Once snap ring B is removed,replaceit with a new one,
o
-..::::.:...-
2.
Remove armatureplateby pullingit up by hand. the

4. Remove the rotor pulley from the shaft with a puller 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.
ARMATURE PLATE
/t,
.\\
.)'
.l
t
(cont'd)
22-31
Compressor
ClutchOverhaul(cont'd)
5. Removethe screwfrom the field coil groundterminal,then disconnecthe field coil connector. 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, NOTE: . Be carefulnot to damagethe field coil and compressorduring remove/installation. . Once snap ring A is removed,replaceit with a new one. . When installingthe field coil, align the boss on the field coil with the hole in the compressor.
SNAP RING A Replace.
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 . Make noteof the followingitems. . . . . . Install fieldcoilwith the wire sidefacingdown. the r 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 s l i d i n g solvent, with non-pet.oleum surfaces Make sure the snap rings are fully seatedin the groove. Make sure that the rotor pulley turns smoothly after it's reassembled. Routeand clamp the wires properlyor they can be damagedby the rotor pulley.
6.
Position the 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 t 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 l press on straight, remove it, and check the rotor pulleyand compressor bossfor burrsor damage. CAUTION: Maximum press load: 39,200 kPa (400kgt/cm', 5,690psil
Preit
HUB ASSEMBLY GUIDEATTACHMENT 07965 - 6920500 FOTOR PULLEY
22-32
-
Thermal Protector Replacement

1. Bemovethe bolt. the groundterminaland the holder. Disconnect field coil connector. the then remove the thermalprotector.
7.{ N.m {0.75kgl.m, 5,4lbf.ftl
ReliefValve Replacement
1.
Remove reliefvalveand the O-ring, the NOTE: . Do not let the compressor run out. oil . Make sure that no foreign matterentersthe system.
THERMAL
PROTECTOR
Qt) .Y,/ ,
RELIEF VALVE 9.8 N.m (1.0kgt m, 7.2 rbnft)
O.RING Replace. Cleanthe matingsurfaces. Replace O-ringwith a new one at the reliefvalve, the 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 installing it. NOTE: . To avoid contamination, not returnthe oil to do and never mix it the containeronce dispensed, with other refrigerant oils. . lmmediatelyafter using the oil, replacethe cap on the container,and seal it to avoid moisture absorption. . Do not spill the refrigerant on the vehicle;it oil may damagethe paint;if the refrigerant conoil tactsthe paint,wash it off immediately. Installand tightenthe reliefvalve.
SILICONESEALANT
Replace thermal protectorwith a new one, and the apply siliconesealant the top of the thermalproto tector.
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 Compressor Belt

Adjustment
Deflection Method 1. Apply a force of 98 N (10 kgf, 22 lbf), and measure the deflection betweenthe A,/C compressor and the pulley. crankshaft A/C CompressorBelt UsedBelt:7.5- 9.5 mm 10.30 0.37in) New Belt: 5.0- 6.5 mm (0.20 0.26in) NOTE: . lf there are cracksor any damageevidenton the belt,replace with a new one. it . "Used belt" means a belt which has been used for five minutesor more. . "New belt" means a belt which has been used for lessthan five minutes. 2. 3. 4. 5. Loosen center ofthe idlerpulley, nut the 2. Turn the adjusting bolt to get properbelttension. 3. Retighten center ofthe idlerpulley. the nut 4. Recheck deflection the Ay'C the of compressor belt. 5. Recheck tensionof the Ay'C the compressor belt. Retighten center ofthe idlerpulley. nut the Turn the adjustingbolt to get properbelttension, Loosen center ofthe idlerpulley. the nut Tension Gauge Method '1. Attach the special tool to the Ay'C compressor belt as shown below,and measure tensionof the belt. the A/C ComprossorBelt Used Belt: 340 - it90 N (35 - 50 ksf, 77 - 110 lbfl New Belt: 690 - 830 N (70 - 85 kgf, 150- 190 lbf) NOTE: o Follow the manufacturer'sinstructionstor the belttensiongauge. . lf there are cracksor any damageevidenton the belt,replaceit with a new one. . "Used belt" means a belt which has been used for iive minutesor more. . "New belt" means a belt which has been used for lessthan five minutes.
22-34
Condenser
Replacement
1.
with a Recovery/Recycling/ Recover the refrigerant Charging System(seepage22 21). Disconnect the condenserfan connectorfrom the wire harness then removethe Ay'C A/C wire harness, fan from the condenser shroud.
4.
and Remove the bolt from the suctionhose bracket, removethe two bolts and the upper mount bracket. by the assembly liftingit up Remove condenser fins NOTE:Be carefuinot to damagethe condenser assembly. when removingthe condenser MOUNT BRACKET UPPER
2.
CONDENSER FAN CONNECTOR
6x1.0mm ftl 9.8 N.m (1.0kgf.m.7.2lbf
6x1.0mm kgl.m,7.2lbI.ftl 9.8N.m 11.0
A/C WIREHARNESS
3.
R e m o v e 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 t linesfrom the condenser. and condenser 5. after disNOTE: Plug or cap the lines immediately connectingthem to avoid moisture and dust conramlnaton.
6x1.Omm DTSCHARGE |NE 9.8 N.m 11.0 L
order of removal.Make note of lnstallin the reverse the followingitems. . add refrigera lf you'reinstalling new condenser, (seePage22-19). ant oil (SP-10) . Replace the O-ringswith new ones at each fitt 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 them. beforeinstalling NOTE:Be sure to use the right O-ringsfor HFcto 1344(R-'134a) avoid leakage. f 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 r i n s assembly. the condenser when installing and test its . Chargethe system{seepage 22-37). performance {seePage22-221
CONDENSER
6x1.0 9.8 N.m {1.0kgf.m, 7.2 lbf ft)
22-35
A/C System Service

Evacuation
Use only service equipmentthat is U.L.-listed is cer and tified to meet the requirements SAEJ2210to remove of HFC-134a 134a) trom the air conditioner {R system. CAUTION: Exposure to air conditioner refrigerant and lubricant vapor or mist can irrilate eyes, nose and throat. Avoid breathing the air conditioner refrigerant and lubricant vapor or mist. lf accidentalsystem dischargeoccurs,ventilate work areabeforeresumingservice. R-134a serviceequipmentor vehicleair conditioner systems should not be Dressure tested or leaktested with compressed arr. some mixtures ot air and R-134ahave bn @ shown to be combustible at elevatd ptessuresand can result in tire or explosion causing iniury or property damage. Never use compressed air to pressure test R134a service equipment or vehicle air conditioner sysIems. Additional healthand safetyinformation may be obtained from the refrigerant lubricant and manufacturers. '1. When an Ay'C Systemhas beenopenedto the atmosphere,such as during installation repair,it must or be evacuated using a R-134arefrigerantRecovery/ Recycling/Charging System.(lf the systemhas been open for severaldays,the receiver/dryer should be replaced, and the system should be evacuated for several hours.) Connecta R-134arefrigerantRecove rylRecycling/ ChargingSystemto the vehicle,as shown, following the equipmentmanufacturer's instructions, NOTE:lf low pressure doesnot reachmorethan 93.3 k P a( 7 0 0m m H g , 2 7 . 6 n . H g ) n 1 5 m i n u t e st,h e r ei s i i probablya leak in the system.Partially chargethe (seeLeak system, and check leaks for Test).
g/Charging System Recovery/Recyclin
2.
22-36
Charging
and that is U.L.-listed is cerequipment Use only service of to titied to meet the reouirements SAEJ22,!0 remove (R-134a) system. from the air conditioner HFC-'134a to CAUTION:Exposure air conditionerrefrigerantand lubricant vapor or mist can irritate eyes, nose and thloat. Avoid breathingthe air conditionerretrigerant and lubricantvaooror mist. w o l f a c c i d e n t as y s t e md i s c h a r g e c c u r s ,v e n t i l a t e o r k l A a r e a b e f o r e r e s u m i n gs e r v i c e . d d i t i o n a lh e a l t h a n d safetyinformationmay be obtainedfrom the refrigerant manufacturers. and lubricant Refrigerantcapacity:550:go {22.9:q oz) s I the CAUnON: Do not overcharge system;the compressor will be damaged. refrigerant Recovery/Recycling/Charging a Connect R-134a the equjpment as to System the vehicle, shown,following instructions. manufacturer's
LeakTest
equipment that is U.L.listedand is cerUse only service of tified to meetthe requirements SAEJ2210to remove (R-134a) system. from the air conditioner HFC-'134a CAUTION:Exposureto air conditionerrefrigerantand lubricant vapor or mist can irritate eyes,nose and throat. Avoid breathing the air conditioner retrigerantand lubricant vapor or mist. w o v l f a c c i d e n t as y s t e md i s c h a r g e c c u r s , e n t i l a t e o r k l areabeforeresumingservice. sysor R l34a serviceequiDment vehicleair conditioner tested or leak testedwith tems should not be pressure air. compressed have some mixtures ot air and R-13,1a ![@ been shown to be combustibleat elevatedpressures and can result in fire or explosion causing iniury or property damage. Never use compressedail to pressure test R-134aservice equipment or vehicle air conditioner systems. may be obtained healthand safetyinformation Additional manufacturers. and from the refrigerant lubricant 1. lin rylRecyc g/ Connecta R-134arefrigerantRecove a C h a r g i n g y s t e mt o t h e v e h i c l e , s s h o w n i n t h e S previous columnfollowingthe equipmentmanufacturer'sinstructions. NOTErBe sure to installthe same amount of new systembeforechargrefrigerant backinto the A,/C oil In g . Open high pressurevalve to chargethe systemto capacity, then closethe supplyvalve, the specified and removethe chargingsystemcouplers. ozl Refrigerantcapacity:650130 122.9:1a O 3. refrigerCheckthe systemfor leaksusing a R-134a of ant leak detectorwith an accuracy l4 g (0.5 oz) per year or better. that require systemto be opened the lf you find leaks (to repairor replace the hoses, fittings, etc.),recover Procedure page on systemaccording the Recovery to 22-21. leaks, the systemmust After checking and repairing Evacuation page22 36) on be evacuated System lsee
System Recovery/Recycling/Charging
4.
LOW.PRESSURE SIDE
5.
22-37
Electrical
.......-.-..........23-75 ,fgnition Switch .." """""'23-2 SpeciafToofs 23-88 " lgnition System Troubleshooting *A/T GearPositionIndicator............ ........ "" 23-133 . Tios and Precautions..............'. " " "" 23-3 23-140 ilntegratedControlUnit ........,.........-.-...............,.. ........" """" """ 23-5 Troubleshooting Five-step """"""""' 23-124 fnterlock System "" 23-5 wire color codes - """ " 23-146 Lighting System SYmbols.........'.'......'. "" " 23-6 Schematic Lights, Exteriol Relayand Control Unit Locations """"23-151 Bsck-upLights . Compartment..'.............'. " """" 23-7 Engine " "" 23-158 "" Brake Lights " " 23-8 Dashboard DavtimeRunningLights(Canadal...'. " "' 23-150 """"' 23-12 Door ...................... 23-151 . .... FrontParkingLights ....... ............ "" ,Airbags ...,........,... ........ Sestion24 " SignalLights......'......... " 23-151 FrontTurn Section 2l ." Air Conditioning .. " "" " 23-151 .......,........,........,..23-98 Headlights Atternator "" 23-159 High Mount BrakeLight ... .........."" " Section 19 Anti-lock BrakeSvstem IABSI ... .." " " "" 23-156 LicensePlate Lights Sestion 14 Automatic TransmissionSystem .. . "" " "23-153 Taillights............... """""""23-77 B a t t e l y. . . . . . . . . . . . . . . . . . .... """"""23-162 fnteriorLights Section 21 Blower Controls 23-203 .................,........... Moonrool " """"""23'72 System Charging """"""'23-57 Powel Distribution Connestorldentification and Wire Harness """"""23-219 """"' 23-11 PowerDoor Locks R o u t i n g. . . . . . . . . . . . . . . . . """ " 23'180 "" " """""""'23-2oa PowerMirrors cruise contlof """""""23-72 "" 23'160 . " " PowerRetays......... Dash Lights BrightnessController " "" "'23-191 ....... """ " 23-111 PowerWindows FanControls """""23-176 RearWindowDetogger.....'..........'...... .........""" Section11 FuelPump " "' 23'97 ..... "" """"""23-52 SparkPlugs , Fuses.................... ..... "" " 23-79 Seqtion11 "" StartingSystem ControlSystem... ................. PGM-FI 23-167 *StereoSoundSystem ........,......,........................' *G.uges " "" "23-116 'supplemental RestraintSystom (SRSI .....Section 24 CircuitDi.gram " "' 23-154 "" " """"'23-126 Turn Signal/HazardFlasherSystem "" FuefGauge 23-71 Box ............................... " 23-114 +Under-dash " Fuse/Relay ........' Speedometer . ...........23-65 VehicleSpeedSensor(VSS) ...... " " """"23"124 cround Distribution 23-186 " "" rwipers/Washers """" section 21 Heatet controls *Horn ..................... .............-..23-173 to references autoNOTE:Unlessotherwisespecified. the (A,/T) this section include CVT' in matictransmission
Tools Special
\
Rel. No. {t* I Tool Number A973X 041_ XXXXX 07JGG 0010104 _ PT3O2OA OTLAJ 07NAC SR20100 07PM- 0010100 Description V a c u u m u m pG a u g e0 - 3 0 i n . H g . P , BeltTensionGauge TestHarness FuelSender Wrench SCSService Connector Oty i PageReterence 23-215 23-'t 10 23-124,125 23-126 23-9'l
o o o
*: Includedin Belt Tension GaugeSet 07TGG- 0010004
ri
an
I
23-2
Troubleshooting
Tips and Precautions
g BoforeTroubleshootin fuse/relay . Checkagplicable fuses in the appropriate oox. . Checkthe batteryfor damage,state of charge,and cleanand tight connections. . Check alternator belttension. the 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 . Makesurethe connectors cleanand haveno loose are wire terminals. with are . Makesure multiplecavityconnectors packed grease(except connectors). watertight type locks. release . All connectors have push-down make sure the termiBeforeconnectingconnectors, placeand not bent. nalsare in b t N e v e rt r y t o d i s c o n n e c c o n n e c t o r s y p u l l i n g o n halvesinstead. their wires;pull on the connector plasticcovers. Alwaysreinstall
LOCKING TAB
. Some connectorshave a clip on their side used to attach them to a mount bracketon the body or on This clip hasa pull type lock anothercomponent. Some mounted connectorscannot be disconnected the lock and removethe conunlessyou first release bracket. nectorfrom its mount
and rubberseals. Check looseretainer for
RETAINER
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 lf greaseAdd greaseit necessary. the greaseis conit. replace taminated,
LOCKING PAWL ON OTHER Pull to HALF OF drsengage CONNECTOR
BRACKET
(cont'd)
23-3
Troubleshooting
(cont'd) Tips and Precautions
Insertthe connectorall the way and make sure it is securely locked. Position wires so that the open end of the coverfaces down.
Fsce opon end . Seat grommets in their grooves properly.
NOT GOOO
A & - / -w--_w\\
ll I
Testing and Repairs . Do not usewires or harnesses with brokeninsulation. Replace them or repairthem by wrappingthe break with electricaltaDe. a A f t e r i n s t a l l i n g 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 p oinchedunderthem. . W h e n u s i n g e l e c t r i c a t e s t e q u i p m e n t ,f o l l o w t h e l manufacturer's instructionsand 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 (exceDt waterDroof connector).
Handling Wires and Harnesses . Securewires and wire harnesses the frame with to their respective wire ties at the designated locations. . Remove clipscarefully; don't damagetheir locks.
Slip pliers under the clip base and through the hole at an angle,then squeeze expansion the tabs to release the c l lP .
Usea probewith a taperedtip.
PLIERS SNAP.RING
After installlngharnessclips, make sure the harness with any moving parts. doesn'tinterfere Keep wire harnesses away from exhaust pipes and other hot parts. from sharp edges of bracketsand holes.and from exDosed screwsand bolts.
Refer the instructions the HondaTerminalKit for in to i d e n t i f i c a t i o a n d r e p l a c e m e no f c o n n e c t o t e r m i n t r nals.
23-4
Troubleshooting Five-step
1.
Wire Color Codes

The following abbreviationsare used to identify wire colorsin the circuitschematics: W H T . . . . . . . . . . . . . . . . . . . .W,h i t e. . .. .... ... ... Y E L. . . . . . . . . . . . . . . . . . . . . Y e.l.l.o w . . .. . B L K . . . . . . . . . . . . . . . . . . . . .B.l.a c.k . . BLU..............................81ue G R N . . . . . . . . . . . . . . . . . . . .G r . . e.n . ... e . . R E D. . . . . . . . . . . . . . . . . . . . .R.e .d . . . . . . . ... a . . e O R N . . . . . . . . . . . . , . , . . . . .O r . . n.g . . .. P N K. . . . . . . . . . . . . . . . . . . . .P.i.n k. . . . . . . . B R N. . . . . . . . . . . . . . . . . . . . .B.r.o .w.n . . . . G R Y. . . . . . . . . . . . . . . . . . . . .G.r. a.y . . . P U R. . . . . . . . . . . . . . . . . . . . .P.u . .p l. e. . .r . . L . , t. L T B L U . , . . . . . . . . . . . . . . . . . i.g.h .B l u e . ig . . L T G R N . . . . . . . . . . . . . . , . .L . . .h.tG r e e n 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.
VerifyThe Complaint in Turn on all the components the problemcircuitto verifythe customercomplaint.Note the symptoms or Do not begin disassembly testing until you have narroweddown the problemarea. The Schematic Analyze 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 . Determinehow the circuit is supposedto work by tracing the current pathsfrom the power feed to throughthe circuitcomponents ground.lf several circuitsfail at the sametime, the fuse or ground is a likelycause. of Basedon the symptomsand your understanding identifyone or more possible the circuitoperation, of causes the problem.
2.
J.
lsolate The ProblemBy TestingThe Circuit you made Makecircuitteststo checkthe diagnosis in mind that a logical,simple procein step 2. Keep Test for troubleshooting. dure is the key to efficient the most likely cause of failure first. Try to make testsat pointsthat are easilyaccessible. FixThe Problem Once the specificproblem is identified,make the repair.Be sure to use propertools and sale proceoures. MakeSureThe CircuitWorks circuitin all in Turn on all components the repaired modes to make sure you've fixed the entire problem. lf the problem was a blown fuse, be sure to test all of the circuitson the fuse.Makesure no new problems turn up and the originalproblemdoes not recur,
WHT/ALK
23-5
Troubleshooting
SchematicSymbols
EATTERY
GROUND ground Componenl Groundterminal
\
FUSE
COIL, SOLENOID LIGHTER CIGARETTE
l,r
t""l
ril
r
RESISTOR
_d_ .:
I I
_1
-
I I
<'r.-e
rh t la
Al lT
i7
HEATER
VARIABLERESISTOR
THERMISTOR
IGNITIONSWITCH
BULB
MOTOR
ilHq.r + + + + D Q c /c\ A+, Y I4 v Y T

I I
/+'
I
Jl-
Al t=
PUMP
gREAKER CIRCUIT
HORN
DIODE
BUZZER SPEAKER,
T I
ANTI:NNA
TRANSISTOR(Trl
Mast
SWITCH lln n o.mal politionl I Normally closed Normally open switch
l'0\
I
'*i'"n
LIGHT EMITTING DIODE {LED)
\h/
RELAY {ln normal positionl Normallyopen relay Normallyclosedrelay
CONDENSER
CONNIicTtoN lnput Output
CONNECTOR
REED SWITCH
fT't t i
t--.--'l
l
G- l t
t i l trf
l-*'+
l r l
J-
--+>-r-l-
It'rl
!
23-6
Relayand ControlUnit Locations

Engine Gompartment
ELDUNIT UNDER.HOOD BOX FUSE/RELAY
t:
-fr@ D T'lrrrl
n
tl
tr
r-- --1
BLOWER MOTOR RELAY
FAN CONDENSER RELAY ABS UNDER.HOOD BOX FUSE/RELAY RADIATOR A/C COMPRESSOR FAN RELAY RELAY CLUTCH
23-7

Dashboard: 97 models 96,
UNIT CRUISE CONTROL DAYTIME RUNNINGLIGHTS CONTROL UNIT (Canad.)
DASHLIGI{TSBRIGHTNESS CONTROLLER (Hasbuilt-in controlunit)
. MOONROOF OPENRELAY
GRN/ORw. CAru/Ae O,l [wire colors: YEL, BLK and [WHT, I . MOONROOF CLOSE RELAY
[Wi]e colors:GRN/ORN,GRN/YEL,l and IWHT,GRN/RED, BLK I
CUT STARTER RELAY BLK/wHf,au/wxf,l Iwir6 colo]s: and l I BLU/aLK, BLK/RED
23-8
UNDER.DASH BOX FUSE/RELAY
INTEGRATED UNIT CONTROL
il-trral a\{\
Fnnr-1nnnnn-r
fi |
WINDOWRELAY POWER
FrJrJrJuuLluLrLJU|lJ
F-nnrr'-1nn|-1nrl
p!rrrLrLrrruLr'.uLJ|P
u_:;_:_:_l:_:_l_;E::
TURNSIGNAL/ RELAY HAZARO
UNIT CONTROL INTERLOCK
lTcM tcw)
.: Coupe
23-9

Dashboard:98 model
CRUISE CONTROL UNIT DAYTIME RUNNINGLIGHTS CONTROL UNIT {Cenada}
DASHLIGHTSBRIGHTNESS CONTROLLER (Hasbuilt-in controlunit)
[Wi]e colols: BLK/WHT,etX/WXf,l and BLK/RED IBLU/BI-K, J
Wire colors:WHT/GRN,BLU/RED, GRYand WHT/GRN
MOONROOF CLOSE RELAY
cRN/ORru, Cnn/Yel,l lwilo colo]s: GRN/RED, BLK and IWHT, I
23-10
POWER WINDOWFELAY
I\JJJ'IJJJIJJJ LI
UNIT CONTROL INTERLOCK
.TCM(CvT)
': Coupc
23-11
Relay and ControlUnit Locations

Dashboard/Door
AUDIO UNIT (Hasbuilt in keyless receiver circuit) POWER OOORLOCK CONTROL UNIT PGM.FIMAIN RELAY
MASTERSWITCH (Hasbuilt-in controlunit) ABS CONTROL UNIT
23-12
Routing and Wire Harness ldentification Connector
How to ldentily Connectols: "C" for connectors' by The number is preceded the lefter to numbershave been assigned all connectors. ldentification " T " f o r n o ng r o u n d e r m i n a l s " G " f o r g r o u n d e r m i n a lo r t t s Location Harness cables Starter groundcable Battery g A E n g i n e r o u n dc a b l e g c E n g i n e r o u n d a b l eB box wire ABSfuse/relay Under-hood (with ABS) harness wire harness Engine EngineCompartment T 1 ,T 2 a n d@ G l a n dO Dashboard Others lFloor. Door, Trunk/Hatch, and Root)
T4 G3
t5 ano (?
t C 1 0 1h r u C 1 4 7 T 1 0 l a n dT 1 0 2 G'r01 C 2 0 lt h r u C 2 1 4 G201and G202 C 3 0 1h r u C 3 1 0 t thru C360 C351 thru C446 C401 G401and G402 C501 thru C520 thru C573{C574) C551 G551and G552 t C 6 0 1 h r uC 6 1 7 G601 C631thru C639 C651thru C656 C661thru C664 C671thru C674 C701thru C703 t C 7 1 1h r u C 7 1 8 C721thru C727 thru C743 C741 t C 7 5 1 h r uC 7 5 4 C76l thru C768 G761
wlre narness Enginecompartment Main wire harness wire harness Dashboard Floorwire harness Rearwire harness door wire harness Driver's door wire harness Passenger's (Sedan) Left reardoor wire harness (Sedan) Rightreardoor wire harness moonroof) Roofwire harness {Without (Withmoon' Moonroofwire harness roof) A sub-harness Heater B Heater sub-harness A,/C wire harness (Hatchback) Hatchwire harness Rearwindow defoggergroundwire heatedoxygensensorsubSecondary harness sub-harness sensor Fueltank pressure S R Sm a r nh a r n e s s O : 9 7 , 9 8m o d e l
c771 G77'l
a C 7 8 1 n dC 7 8 2 thru C793 C791 C801thru C807 G801
23-13
Connector ldentification and Wire Harness Routing
Starter Cables Connectoror Terminal Numberol Cavities Location Rightside of enginecompanment Rightside of enginecompartment Battery
Connectsto Under-hood fuse/relay box Startermotor positive Battery terminal
Notes
T,1 T2
o
Battery Ground Cable Connectoror Terminal Number of Cavities
Location
Right front shock tower
Connectsto Bodyground,via batteryground cable Battery negative terminal
Notes
o
EngineGroundCableA Connectoror Tgrminal Number of Cavities
Baftery
Location Leftside of engine Leftsideof enginecompartment
Connectsto Powersteeringpump bracket Bodyground,via engineground cableA
Notes
T3
EngineGroundCableB Connectorot Terminal Numberof Cavities Location Rightsideof enginecompartment Rightside of front frame Connectsto Transmission Bodyground,via engineground cable B Notes
T4
Under-hoodABS Fuse/RelayBox Wire Harness Connoctoror Terminal Number of Cavities Location Rightside of enginecompartment Battery Connaqtsto Under-hood fuse/relay box positive Battery terminal Notes
T5
@
A/C Wire Harness Connestoror Terminal Numberof Cavities Location Rightsideof enginecompartment
1 2
ConnecGto Enginecompartment wire harness (c209) Compressor clutch Condenser motor fan pressure Ay'C switch Bodyground,via Ay'C wire harness
Notes
c751
c754
G751
Rightside of enginecompartment Rightside of enginecompartment Rightside of enginecompartment Leftside of enginecompanment
23-14
BATTERY GROUND CABLE

UNDER-HOOD ABS FUSE/RELAY
BOXWIRE HABNESS
GROUNO CASLEB A/C WIRE HARNESS
23-15

(Dl6Y5,D16Yg enginesl EngineWire Harness
c 101 c102 c103 c104 c104 c105 c106 c 107 c 108 c109 c110 c11l cl12 c113 c114 c115 c116 cl17 c118 c119 c120 c121 c122 c123
10 3
1
3 2 2 2 2 3 3 3 2 2 2 14 14 3 2 2 10 1 2 8 2 2 2 2 2 1 20
22
Left side of enginecompartment Middle of engine ot Niliddle engine Left side of engine compartment Left side of enginecomPartment Middle of engine M i d d l eo f e n g i n e Middle of engine Middle of engine Middle of engine Irliddleof engine Middle of engine Middle oI engine Middle of engine M i d d l eo f e n g i n e Middle of engine Middle of engine Left side of engine comPartment Middle ot engine Middle ot engine Middle ol engine Middle of engine Middle ol engine Middle ol engine Middle ol engine Middle o'f engine Middle ot engine Middle of engine Middle of engine Middle ot engine Middle of engine Rightside ol enginecomPartment Eehind right kick Panel Under right side ot dash Under right side of dash Under right side of dash Under right side of dash Under right side of dash Under right side of dash Under right side of dash Under right side of dash
Main wire harness{C303) sensor speedfluctuation(CKF) Crankshaft switch Engineoil pressure Alternator Alternator No. l fuel injector No.2 tuel injector No. 3luel injector No. 4 fuel injector IAC valve Throttleposition(TP)sensor Manilold absolutepressure(MAP)sensor Intakeair temperature(lAT)sensor Power steering pressure(PSP)switch EVAPpurge control solenoidvalve Junctionconnector Junctionconnector Vehiclespeedsensor{VSSI sPeedsensor Countershaft Engine coolant temperature (ECT)switch A Distributor Engine coolant tefiperature (ECT)sending unii Engine coolanttemperature(ECT)sensor PrimaryHO2S{sensor1)
c123 c124 c124 c125 cl26 c127 c128 c129 c130

c] 31 cl32
(sensor 1) HO2S Primary light Back-up switch
32 25 14
Lock-up control solenoid valve Secondary HO2S (sensor 2) Mainshaftspeedsensor Linarsolenoidvalve Shift control solenoidvalve Startersolenoid Junction connector Main wire harness(C446) ECM/PCM PCM ECM/PCM ECM/PCM Main wire harness(C305) Main wire harness{c305) Main wire harness(C305) Knocksensor(KS) IAC valve VTECsolenoidvalve VTEC pressure switch EVAPcontrol canistervent shut valve EGRcontrol solenoidvalve Secondarygear shaft speedsensor EGRvalve EGRvalve Drive pulley speedsensor Solenoidconnector(CVT) Driven pulley speedsensor
-,(Arr)
Ay'T: 96 model '1 (Avn: 97.98 models AlT.. 97,98 models
c136
'14
c 137 c138 c139 c140 c141 c142 c143 c144 c144 c145 c146 c147
2 2
1
2 2 2 2 2 8 2
Middle of engine Middle of engine Middle of engine Middle of engine Middle of engine Middle of engine Left side of engine comPartment Middle of engine Middle of engine Right side ol engine compartment Rightsideof enginecomPartmenl side of engine comPaftment Left side oI engine comPartment
-,{A,/T)
-1(Arr) ., (A/r) * 1{r\,riT)

-'(A/T) *1 (CVT) .,(A/T)
ground,via enginewire harness
*1: D16Y5 engine '2: D16Y8 engine *3: D16Y5 (A,,/T), D16YA engines
23-16
c132am
12
crog c138 c110
c113
T101
c141 T102. c117c143 c't17 c144 c140 cl18 c139 c120 c129 c146 c145
WINE ENGINE HARNESS
cl'r5 c116 c137 c102
23-17

\
EngineWire Harness engine):96 {D16Y7 model Connectorot Terminal Location
Left side of engine compartment Middleof engine Middleof engine Left side of engine compartment Left side of engine compartment Middleof engine [/iddle of engine Middleof engine Middleof engine Middleof engine Middle of engine Middleof engine fvliddleof engine Middleof engine Middleof engine Middleof engine Middleof engine Left side of engine compartment Middle of engine Middleof engine Middle of engine Middleof engine Middle of engine Middleof engine Middleof engine Middle of engine Middleof engine Middleof engine Middleof engine Middleof engine Right side of engine compartment Behind right kick panel Under right side of dash U n d e rr i g h t s i d eo f d a s h Under right side of dash U n d e r r i g h ts i d eo f d a s h Under right side of dash Left side of engine compartmenl Right side of engine compartment Middleof engine
Cavities 10 3
Connectsto (C303) Main wire harness Crankshaft (CKF) speedfluctuation sensor Engineoil pressure switch Alternator Alternator No. I fuel injector No. 2 fuel injector No. 3 fuel injector No. 4 fuel injector IACvalve Throttleposition(TP)sensor (MAp)sensor Manifoldabsolute pressure (lAT)sensor lntakeair temperature (PSP) Powersteering pressure switcn EVAPpurgecontrolsolenoid valve Junctaon connector Junctron connector Vehicle speedsensor(VSS) Countershaft speedsensor Enginecoolanttemperature (ECT) switchA Distributor Enginecoolanttemperature (ECT) sending nit u Enginecoolanttemperature sensor {ECT) PrimaryHO2S(sensor 1) Back-up light switch Lockup controlsolenoid valve Secondary HO2S(sensor 2) Mainshaft speedsensor Linearsolenoid valve Shiftcontrolsolenoid valve Startersolenoid JunctionConnector (C446) NIain wire harness ECM/PCM PCM ECM/PCM ECM/PCM
c 10'1 c102 c103 c104 c104 c105 c106 c'107 c 108 c 109 c110 c111 cl12 13 C'1 c 11 4 cl15 cl16 c117 cl18 c119 cl20 c121
USA Canada
Engine ground,via engine wire harness
23-18
96 model:
WIREHARNESS ENGINE
c135 C134 c133 cl32 c130

T102
c1' r7 c119 c120 c118 c129
c106
cr07
c103
t't, c"'
c108
23-19

(D16Y7 EngineWire Harness engine):97 model Connectoror Terminal Numberof Cavities 10 Location Leftside of enginecompartment Middle f engine o N4iddle engine of Leftside of enginecompartment Leftside of enginecompartment lvliddle engine of Middle f engine o lvliddle engine of Middle f engine o Middleof engine Middle f engine o Middleof engine Middle f engine o M i d d l eo f e n g i n e M i d d l eo f e n g i n e Middle f engine o Middle f engine o Leftside of enginecompartment Middle f engine o Middle f engine o Middle f engine o Middle f engine o Middle f engine o Middleof engine Middle f engine o Middleof engine Middle f engine o M i d d l eo f e n g i n e Middle f engine o M i d d l eo f e n g i n e Rightsideof engine compartment Behindright kickpanel Underright side of dash Underright side of dash Underright side of dash Underright side of dash Underright sideof dash Leftside of enginecompartment Middle f engine o Conneqtsto (C303) Main wire harness (CKF) Crankshaft speedfluctuation sensor Engineoil pressure switch Alternator Alternator No. 1 fuel injector N o . 2 f u e li n j e c t o r No. 3 fuel injector N o . 4 f u e li n j e c t o r IACvalve Throttleposition(TP)sensor (MAP)sensor pressure Manifoldabsolute (lAT)sensor Intake temperature air (PSP) Powersteeringpressure switch EVAPpurgecontrolsolenoid valve Junctionconnector Junc on connector Vehicle speedsensor(VSS) Countershaft speedsensor (ECT) Enginecoolanttemperature switch A Distributor (ECT) Enginecoolanttemperature sendingunit (ECT) Enginecoolanttemperature sensor ( r P r i m a r y O 2 S s e n s o1 ) H Back-up light switch Lock-up controlsolenoid valve Secondary HO2S(sensor 2) Mainshaft speedsensor Linearsolenoid valve Shiftcontrolsolenoid valve Stanersolenoid Junctionconnector (C446) Main wire harness ECM/PCM PCM ECM/PCM ECM/PCM (C305) Main wire harness EVAP controlcanister vent shutvalve
Notes
c101 c102 cr03 c104 c104 c105 cr06 cl07 cl08 c109 c110 c111 cl12 c113 c114 c117 cl18 cl19 c120 c121 c122 c124 c124 c't21 cl2A c129 c130 c 13'r c't32 c133 c134 c136 c137 T101 r102 G101
1 4 3 2 2 2 2 3 3 2 ) 2 14 14 3 , 2 10 'l 2 2 2 2 2 2 1 20 22 25 16 8 2
USA Canada
USA
NT
NT Alr Alr A/r
Alr
Leftside o{ enginecompartment Alternator Rightsideof engine compartment Under-hood fuse/relay box Middleof engine ground, engine Engine via wire harness
23-20
97 model:
WIREHARNESS
ctto
"',' '
23-21
ldentification and Wire Harness Routing Connector
EngineCompartment Wire Harnesg Connectoror Te.minal Number ol Cavities 10 6 2 4 2 Location Connctsto Notes
c201 c202 c202 c203 c204 c205 c206 c207 c20a c209 c210 c210 c211 c212 c213 c214
G201 G202
2 1 2 3 8
(C308) Leftsideof enginecompartment Main wire harness (C309) Leftsideof enginecompartment Main wire harness Leftsideof enginecompartment Main wire harness {C309} Lelt sideof enginecompartment Cruise actuator Behindtront bumper Windshield washermotor Behindfront bumper Rearwindow washermotor Leftsideof enginecompartment Leftfront turn signaUparking light Behindtront bumper Frontfog light Leftsideof enginecompanment Leftheadlight (C751) Leftsideof enginecompartment A,/C wire harness Behindfront bumper Horn Behindfront bumper Rightsideof engine companment Rightsideof engine compartment Rightsideof engine compartment Rightsideof engine compartment Horn Radiator motor fan Rightheadlight Rightfront turn signal/parking light (C355) Main wire harness
Optional
models 98 model
Rightsideof engine compartment Bodyground.via enginecompartment wire harness Leftside of enginecompartment Bodyground.via enginecompartment wire harness
*'l: With cruisecontrol *2: Withoutcruisecontrol
| I
I
23-22
COMPABTMENT ENGINE WIREHARNESS
23-23

Main Wire HarnesslLeft side ol engine compartment branch) Connectoror Terminal Number of Cavities 5 10 14 8 I 1 10 2 Location Leftside of enginecompartment Leftside of enginecompartment Leftsideof enginecompartment Leftside of enginecompartment Leftside of enginecompanment Leftside of enginecompanment Leftsideof enginecompartment Leftside of enginecompanment Leftside of enginecompartment Leftside of enginecompartment Leftsideof enginecompartment Leftside of enginecompartment Connectsto Notes
c301 c302 c303 c304 c305 c305 c306 c307 c308 c309 c309 c310
Windshield wjper motor Testtachometer connector E n g i n e i r eh a r n e s( C 1 0 1 ) w s Daytimerunninglightsresistor Canada (C136) Enginewire harness (C136) Engine wire harness Brake fluid levelswitch(+) Brake fluid levelswitch(-) (C2011 Engine companment wire harness Engine (C202) compartment harness wire Enginecompartment (C202) wire harness Left front ABS wheel sensor A8S
*1:D16Y5 ngine e *2: D16YB engine *3: With cruisecontrol *4: Withoutcruisecontrol Main Wire Ha.ness(Right 3ide of engine compartment branch) Connqtoror Terminal Number of Cavities 1'l 9 5 I 3 2 2 10 Location Rightsideof engine compartment Rightsideof engine compartment Rightsideof engine compartment Rightsideof engine compartment Rightsideof engine companment Rightsideof engine compartment Rightsideof engine compartment Rightsideof engine compartment Rightsideof engine compartment Rightsideof engine compaTtment Connectsto Under-hood fuse/relay box (C9081 Under-hood fuse/relay box (C906) Under-hood fuse/relay box (C905) Under-hood fuse/relay box (C907) (C214) Engine compartment harness wire Under-hood ABS fuse/relay box {C927) Under-hood ABS fuse/relay box (C926) Rightfront ABS wheelsensor ABS solenoid ABS pump motor Notes
c351 c354 c355 c357 c358 c3s9 c360

G403
USA ABS ABS ABS ABS ABS
Rightsideof engine companment Body ground, via main wire harness
23-24
UNDER-HOOD BOX FUSE/RELAY
MAIN WIREHARNESS (leftbranch)
23-25
ldentification and Wire Harness Routing Connector
Main Wire Harness (Left side of dash and floor branchl
Connectorol Terminal
Nurnberof Cavities
14 4 4 14 4 8
Location Above underdashfuse/relay box Underleft sideof dash Underleft sideof dash Underleft sideof dash Underleft sideof dash Underleft sideof dash Underleft sideof dash Underleft sideof dash Underleft side of dash Behindunder-dash fuse/relay box Underleft side of dash Underleft side of dash Aboveunder-dash fuse/relay box Underleft side of dash Underleft sideof dash fuse/relay Aboveunder-dash box Underleft sideof dash Underleft sideof dash Underleft sideof dash Behindunder'dash fuse/relay box Behindunderdashfuse/relay box Behindunder-dash fuse/relay box Behindunder-dash fuse/relay box Behindunder-dash fuse/relay box Underleft sideof dash Underleft sideof dash ln the steering columncover In the steering columncover In the steering columncover In the steering columncover Underleft sideof dash Underleft sideof dash U n d e r i d d l eo f d a s h m U n d e rm i d d l e f d a s h o U n d e rm i d d l e f d a s h o U n d e rm l d d l e f d a s h o Underleft side of dash Underleft side of dash Behindunder-dash fuse/relay box
Connectsto (C555) Floorwire harness (C554) Floorwire harness Security system Cruise controlunit Daytimerunninglightscontrolunit Daytimerunninglightscontrolunit (C701) Roofwire harness (C7'1 Moonroofwire harness 1) Frontfog light connector lntegrated controlunit Dashboard wire harness {C504} Dashboard wire harness {C502) (C802) SRSmain harness Datalink connector Starter relay cut lgnitionswitch Security system Clutchswitch Clutchinterlock switch fuse/relay Under-dash box (C919) fuse/relay Under-dash box (C920) Underdashfuse/relay box {C922) Underdashfuse/relay box (C914) Under'dash fuse/relay box (C915) Horn relay Brakeswitch Windshield wiper/washer switch Rearwindow wiper/washer switch Turn signalswitch Combination lightûrnsignalswitch Cablereel Interlock controlunit heated Secondary oxygensensor sub(C781) harness A,/Tgear position switch Shift locksolenoid pin Parking switchand IVT gear positionconsolelight Transmission controlmodule(TCM) Transmission controlmodule(TCM) Under-dash fuse/relay box (C925) Bodyground,via main wire harness
Notes
c401 c402 c403 c404 c405 c406 c401 c407 c408 c409 c410 c411 c412 c413 c414 c415 c416 c417 c418 c419 c420 c421 c422 c423 c424 c425 c426 c421 c42A c429 c430 c431 c432 c433 c434 c435 c437 c438 c439
ABS Optional Canada Canada
2 2
1 10 24
?
Optional
Atr
l6 4 7 6 2 2 18 20 18 7 6
Mtr
Optional M/T
8 6 7 3 8
14 2
A/r
CVT
26 22 1
cw
Optional
G401 Left kick panel *2: Withoutmoonroof *4: With moonroof *5: M//T (with cruisecontrolor for Dl6Y5 engine) *6: With secondary heatedoxygensensor(H025)
23-26
C410
-n--r--nr-n-rnn
UUUUUUUUUUUUqIU
23-27
Routing and Wire Harness ldentification Gonnector

Main Wile Harness(Left side of dash and floor branchl: 98 model Connectoror Terminal Number of Cavities 14 Location tuse/relay box Aboveunder-dash Underleit sideof dash Underleft sideof dash Underleft sideof dash Underleft sideof dash Underleft sideof dash Underleft sideof dash Underleft sideof dash Underleft sideof dash fuse/relay box Behindunder-dash Underleft sideof dash Underleft sideof dash Above under-dash fuse/relay box Underleft side of dash relaybox Under-dash Aboveunder-dash fuse/relay box Underleft side of dash Underleft side of dash Underleft side of dash fuse/relay box Behindunder-dash fuse/relay box Behindunder-dash fuse/relay box Behindunder-dash fuse/relay Behindunder-dash box Behindunder-dash fuse/relay box Under-dash relaybox Underleft sideof dash columncover In the steering In the steering columncover columncover In the steering ln the steering columncover Underleft sideof dash Underleft sideof dash Undermiddleof dash Undermiddleof dash Undermiddleof dash Undermiddleof dash Underleft side of dash Underleft side of dash Conneqtsto (C555) Floorwire harness (C554) Floorwire harness Securitysystem Cruise controlunit Daytimerunninglightscontrolunit Daytimerunninglightscontrolunit (C701) Roofwire harness (C711) Moonroofwire harness Frontfog light connector Integrated controlunit (C504) wire harness Dashboard (C502) Dashboard wire harness (C802) SRSmain harness Datalink connector cut Starter relay lgnitionswitch system Security Clutchswitch Clutchinterlock switch Under-dash fuse/relay box (C919) Under-dash fuse/relay box (C920) fuse/relay box (C922) Under-dash Under-dash fuse/relay box (C914) fuse/relay box (C915) Under-dash Horn relay Brakeswitch Windshield wiper/washer switch Rearwindow wiper/washer switch Turn signalswitch Combination lightnurnsignalswitch Cablereel controlunit lnterlock heated oxygensensor subSecondary (C781) harness gear positionswitch Ay'T Shift locksolenoid gear pin Parking switchand A,/T positionconsolelight Transmission controlmodule(TCM) Transmission controlmodule(TCM)
Body ground, via main wire harness
Notes
c401 c402 c403 c404 c405 c406 c407 c407 c408 c409 c410 c41'1 c412 c413 c414 c415 c416 c417 c418 c419 c420 c42'l c422 c423 c424 c425 c426 c421 c428 c429 c430 c431 c432 c433 c434 c435 c431 c438
ABS Optional Canada Canada
14 8 2 2 1 10 24 3 16 7 6 2 18 20 18 7 6
Optional
Mfi Optional M/T
I 6 4 7 3 8
14 2
Atr CVr
CVT
Leftkickpanel G401 *2: Withoutmoonroof *4: With moonroof *5: M/T (with cruisecontrolor for D16Y5 engine) *6: With secondary heatedoxygensensor(H02S)
23-28
98 model:
"n , c/(}0 c42A I clzs
ctza c,81
MAIN WIRE HARNESS
c412 C411 C410
UNDEB.DASH BOX FUSE/RELAY
23-29
ldentification Connector and Wire Harness Routing
Main Wire Harnsss(Bight side of dash branchl Conneclor or Trminal Number of Cavities Location Undermiddleof dash Underright side of dash Underright side of dash Underright side of dash Underright side of dash Underright side of dash Underright side of dash Rightkickpanel Connectsto Heater A sub-harness (C721) Service checkconnector Junctionconnector PGM-Fl main relay ABS controlunit ABS controlunit E n g i n e i r eh a r n e s ( C 1 3 1 ) w s Bodyground.via main wire harness Notes
c440 c441 c442 c443 c444 c445 c446 G402
20 7 22 26
MAIN WIREHARNESS
23-30
DashboardWire Harness Connectoror Terminal Numberof Cavities 20 24 16 12 5 3 20 5 5 14 '10 5 16 Location lower panel Behinddashboard fuse/relay box Aboveunder-dash fuse/relay box Aboveunder-dash box fuse/relay Aboveunder-dash wheel Leftside of steering wheel Leftside of steering Belowgauges g Behind auges g Behind auges g Behind auges Behindgauges g Behind auges Rightside of gauges Rightside of gauges m o Behind iddle f dash m o Behlnd iddle f dash m o Behind iddle f dash m o Behind iddle f dash Behindmiddleof dash g Behind auges Connectsto box (C912) fuse/relay Under-dash ( 1 M a i nw i r e h a r n e s sc 4 1 ) (C553) Floorwire harness s M a i nw i r e h a r n e s ( C 4 1 0 ) Cruisemain switch controller Dashlightsbrightness Junctionconnector Gaugeassembly Gaugeassembly Gauge ssembly a a Gauge ssembly Gaugeassembly Hazard warningswitch switch Rearwindow defogger receiver circuit) Audio unit {Keyless controlunit Security A u d i ou n i t system Security lighter Cigarette Gauge ssembly a via wire Bodyground, dashboard harness Notes
c501 c502 c503 c504 c505 c506 c507 c508 c509 c510 c512
L5 t5
SRS
c5l4 c515 c517 c5't 8 c519 c520
Optional Optional ABS
5 2 5
o U n d e rm i d d l e f d a s h G501 *1: With shift-upindicator cruisecontrolsystem(96,97models) or With cruisecontrolsystem(98model) cs09c511 cs10 c515
13 I C517
c520
c501 c502 c504
23-31

Floor Wire Harnsss{Coupe/Hatchback)
'16 8
c553 c554
Lb55
4 25 2 25 2 1 2 1 2 2 2 2 1
c556 c556 cs57

LSCO
c559
L50 r
c563 c564 c565 c566 cs67 c568 c569
box fuse/relaY Behindunder-dash box fuse/relaY Behindunder-dash box fuse/relaY Aboveunder-dash Underleft sideof dash box Juse/relaY Aboveunder-dash Driver'sdoor Driver'sdoor door Passenger's door Passenger's Middleof floor Leftsideof floor Left B-piller lnsideof left rearwheel LeftC-Piller LeftC-piller Fueltank Fueltank lnsideof right rearwheel LeftB-Piller Fueltank
box Undetdashfuse/relaY {C923) box fuse/relaY (C921) Under-dash (C503) wire harness Dashboard (C402) Main wire harness (C401) Main wire harness (C631) harness door wire Driver's (C63'l) wire harness door Driver's (C651) door wire harness Passenger's {C651) door wire harness Passenger's brakeswitch Parking seatbelt switch Driver's door switch Passenger's LeftrearABS wheelsensor {C60'l) Rearwire harness (C602) Rearwire harness Fuelgaugesendingunit FuelPumP RightrearABS wheelsensor Driver'sdoor switch sensorsub-harness Fueltank pressure
10 Left kick Panel Leftsideof floor
{c791) switch mirror Power

Bodyground.via floor wire harness Bodyground,via floor wire harness
*1: With Powerwindows *2: WithoutPowerwindows ( '3: 97modelD16Y3 ngine Coupe) e : engine(Coupe/Hatchback' D16Y8 98 model:
23-32
FLOOR WIREHARNESS
c552
23-33
Routing ldentification and Wire Harness Connector
Floor Wire Harness{Sedanl:96 model Connectoror Terminal Numberol Cavities 8 Location fuse/relay box Behindunder-dash fuse/relay Behindunder-dash box Aboveunder-dash fuse/relay box Underleft sideof dash Aboveunder-dash fuse/relay box Driver'sdoor Driver'sdoor Passenger's door Passenger's door Middleof floor Leftside of floor R i g h tB p i l l e r lnsideof left rearwheel LeftC-piller LeftC-piller Fueltank Fueltank Insideof right rearwheel Left B-piller Leftside of steering wheel R i g h tB - p i l l e r Left B-piller Leftquarterpanel Rightquarterpanel Left kickpanel Leftside of floor Connectsto Notes
c55'l c553 c554

LCCC
c556
ucco
14 25 2 2 1 2 1 2 14 2 2 2 1 10 6 6 1 1
c557 c558 c559 c560 c561 c563 c564 c565 c567 c569 c570 c571 c572 c573
G551 G552
Under-dash fuse/relay box {C923) fuse/relay box (C921) Under-dash (C503) wire harness Dashboard (C402) Main wire harness ABS s M a i nw i r e h a r n e s ( C 4 0 1 ) Driver's door wire harness {C631) (C63'l) Driver's door wire harness (C651) passenger's wireharness Front door (C651) passenger's wireharness Front door Parking brakeswitch Driver's seatbelt switch Frontpassenger's door switch Left rearABS wheelsensor ABS (C601) Rearwire harness (C602) Rearwire harness Fuelgaugesendingunit F u e lp u m p ( F P ) RightrearABS wheelsensor ABS Driver's door switch Powermirror switch (C671) Rightreardoor wire harness (C661) Left reardoor wire harness Left rear door switch Rightreardoor switch Bodyground,via floor wire harness Bodyground.via floor wire harness
*1: With power windows *2: Without powerwindows
23-34
96 model:
c558
c573
c566
C564
WIREHARNESS FLOOR
c570 c560
23-35
ldentification Routing and Wire Harness Gonnector
Floor Wire Harness(Sedanl:97. 98 models Connectorol Terminal Number of Cavilies l6 8 16 14 Location Behindunder-dash fuse/relay box box Behindunderdashfuse/relay fuse/relay box Aboveunder-dash Underleft side of dash fuse/relay Aboveunder-dash box Driver's door Driver's door Passenger's door Passenger's door Middleof floor Left side ot floor RightB-piller lnsideof left rearwheel LeftC-piller LeftC-piller Fueltank Fuetank l Insideof right rearwheel Left B-piller wheel Leftsideof steering RightB-piller LeftB-piller Leftquarterpanel Rightquarterpanel Fueltank Leftkickpanel Left side of floor *1: With powerwindows *2: Withoutpowerwindows Connectsto Notes
c553 c554
L555 LC50 L55b
c557 c558 c560 c562 c564
1 2 1 2 16
t
2 2 'I l0 6
c57r c512 c573 c514
,l 1
fuse/relay box {C923) Under-dash Under-dash tuse/relay box (C921) (C503) Dashboard wire harness (C402) ABS Main wire harness (C401) Main wire harness (C631) Driver's door wire harness (C631) Driver's door wire harness (C651) Frontpassenger's wire harness door (C651) passenger's harness Front doorwire Parking brakeswitch Driver's seatbeltswitch Frontpassenger's door switch ABS LeftrearABS wheelsensor (C601) Rearwire harness (C602) Rearwire harness Fuelgaugesendingunit F u e lp u m p{ F P ) RightrearABS wheelsensor ABS Driver's door switch Powermirrorswitch (C671) Rightreardoor wire harness (C661) Left reardoor wire harness Left rear door switch Rightreardoor switch Fueltank pressure sensorsub-harness {c791) Bodyground,via floor wire harness Bodv ground,via floor wire harness
97.98 models:
HARNESS
23-37

RaarWire Harnoss{Hatchback) Conneclor or Tsrminal
Numberot Cavities
14 2 2
Location Leftquarterpanel Leftquarterpanel Leftquarterpanel Left side of cargo area Rightside of cargoarea Rightquarterpanel Rightquarterpanel Rightquarterpanel Middleof cargoarea
Connectsto (C562) Floorwire harness (C563) Floorwire harness Left rear speaker Leftoutertaillight Rightoutertaillight Rightrearspeaker (C761) Hatchwire harness (C762) Hatchwire harness Bodyground,via rearwire harness
Notos
c601 c602 c603 c604 c606 c607 c608

G601
Optional
Optional
REARwlRE HARNESS
Rearwire Harness(CouPe/Sedan) Connectoror Terminal Number of Cavities Location Leftquarterpanel Leftquarterpanel Leftquarterpanel Leftsideof trunk Rightside of trunk Rightquarterpanel Leftsideof rearwindow Middleof rearshelf Middleof rearshell Rightside of rearwindow Leftside of trunk o Middle f trunk o Middle f trunk of lMiddle trunk Rightside of trunk Middle f trunk o Connectsto (C562) Floorwire harness (C563) Floorwire harness Left rearspeaker Leftoutertaillight o R i g h t u t e rt a i l l i g h t Rightrearspeaker Rearwindow defogger(+) l H i g hm o u n tb r a k e i g h t T r u n kl i g h t Rearwindow defogger(-) Leftinnertaillight platelight Leftlicense Trunklatchswitch platelight Rightlicense inner aillight t Right Bodyground,via rearwire harness Notes
c601 c602 c603 c604 c605 c606 c609 0 c6'r c611 c612 c614 c615 c617
G601
16 2 2 2
1 2 2 1 2 2 2 4
REARWIREHARNESS
c617
c615
J--
23-39

Driver's Door Wire Harness(Couoe/Hatchbackl Connectorol Terminal Numberof Cavities 25 2 2 Location Driver's door Driver's door Driver'sdoor Driver's door Driver's door Driver's door Driver'sdoor Driver's door Insideof left power mirror Driver'sdoor Connectsto (C556) Floorwire harness (C556) Floorwire harness Leftfront door speaker Driver'spower window motor Driver'sdoor lockactuator Tweeter Powerwindow masterswitch Driver'sdoor lockswitch Leftpower mirror Powerdoor lockcontrolunit
Notes
c634 c63s c636 c638 c639 c640
2 12
5
8 12
*'l: With powerwindows *2: Withoutpowerwindows Passenger's Door Wire Harness(Coupe/Hatchback) Connectoror Terminal Numberof Cavilies 25 2 2 2 2 8 2 Location Passenger's door Passenger's door Passenger's door Passenger's door Passenger's door Passenger's door Insideof right power mirror Passenger's door Connectsto (C557) Floorwire harness (C557) Floorwire harness Rightfront door speaker Frontpassenger's powerwindow motor Frontpassenger's door lockactuato. Frontpassenger's powerwindow switch Rightpower mirror Tweeter
Coupe Coupe Coupe Coupe Coupe Coupe Coupe
Notes
c651 c653 c654 c655 c656
Coupe Coupe Coupe Coupe Coupe
*1: With powerwindows *2: Withoutpowerwindows
23-40
.
WIREHARNESS OOOR DRIVER'S
DOORWIREHARNESS PASSENGER'S
23-41

Driver's Door Wire Harness{Sedanl Connectoror Terminal Numberof Cavities 25 2 2 Location Driver'sdoor Driver'sdoor Driver's door Driver's door Driver'sdoor Driver's door Driver's door Driver's door Insideof left power mirror Driver's door Connectsto (C556) Floorwire harness (C556) Floorwire harness Leftfront door speaker Driver'spowerwindow motor Driver's door lockactuator Powerwindow masterswitch Powerwindow masterswitch Driver's door lockswitch Leftpower mirror Powerdoor lockcontrolunit Notes
c632 c633 c634 c636 c638 c639 c640
1 3 8
*1: With powerwindows *2: Withoutpowerwindows Front Passenger's Door Wire HarnesslSedanl Connectorol Terminal Number of Cavities 25 2 2 2 2 5 I Location Passenger's door Passenger's door Passenger's door Passenger's door Passenger's door Passenger's door Insideof right power mirror Connectsto (C557) Floorwire harness (C557) Floorwire harness Rightfront door speaker powerwindow motor Frontpassenger's Frontpassenger's door lockactuator Frontpassenger's powerwindow switch Rightpower mirror Notes
c65l c653 c654
*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 Terminal Number ol Cavities 6 2 location Left B piller Left rear door Left reardoor Left rear door
Connectsto (C571) Floorwire harness Left rear power window motor Left rear power window switch Left reardoor lockactuator
Notes
c662 c663 c664
Right Rear Door Wire Harness{Sedan} Conneclor or Terminal Number of Cavities 6 2 5 2 Location RightB-piller Rightreardoor Rightreardoor Rightreardoor
Connectsto (C570) Floorwire harness Rightrearpowerwindow motor Rightrearpowerwindow swltch Rightreardoor lockactuator
Notes
c671 c672 c673 c674

Left Rear Door:
LEFTREARDOOR WIREHARNESS
Fight RearDoor:
RIGHTREARDOOR WIREHARNESS
23-44
Heater Sub-harnessA Connectoror Terminal Number of Cavities Location Underleft side of dash Behindglove box Behindglovebox Behindglove box Behindglove box Behindglove box Behindglove box Connecisto (C437) Main wire harness Mode controlmotor B Heater sub-harness (C741) thermostat AVC Blowermotor Blowerresister controlmotor Recirculation Notes
c721 c722 c723 c724 c125 c726 c727

Heater Sub-halnessB Connectoror Terminal
r6
7 20 3 2 4
Number ol Cavities
Location Behindglove box Behindmiddleof dash Behindmiddleof dash
Connectsto A Heater sub-harness (C723) fan switch Heater controlPanel Heater
Notes
cl4'l c142 c743
20 6
14
B SUB.HARNESS HEATER
2345
Connector ldentification Wire Harness and Routing

Hatch Wire Harness(Hatchbackl Connestoror Terminal Number ol Cavities 6 2 2 1 2 2 2 G761 Location Rightquarterpanel Rightquaner panel Rearof roof Rightsideof tailgate Middleof tailgate Middleof tailgate Middleof tailgate Middleof tailgate
Middle of tailgate
Connectsto (C607) Rearwire harness (C608) Rearwire harness Highmount brakelight Rearwindow defogger(+) Rightlicense light Leftlicense light Rearwindow wiper motor Tailgate latchswitch Body ground,via tailgatewire harness
Notos
c761 c764 c766 c767
RearWindow DetoggerGround Wire lHatchback) Connectot or Terminal Number of Cavities 1 Location Leftsideof tailgate Leftside of tailgate Connectsto Rearwindow defogger(-)
Body ground. via rear window defogger ground wrre
Notes
c711
G771
23-46
96, 97 models:
REAFWINDOWDEFOGGEB WIRE GROUNO
TCHWIREHARNESS
c768 c766 c767
REARWINDOWOEFOGGER WIRE GROUND
TCHWIBEHARNESS
2347
Gonnector ldentification Wire Harness and Routing

Roof Wire Harness(Coupe/Hatchbackl Connestoror Terminal Number of Csvities 2 2 Location Underleft sideof dash Center roof of Connectsto (C407) Main wire harness C e i l i n gi g h t l
Notes
c701 c702
Root Wire Harness{Sedan} Connectoror Terminal Number ot Cavities 2

I
Location Underleft sideof dash Centerof roof Center roof of
Connectsto (C407) Main wire harness Ceilinglight (Power) C e i l i n gi g h t( G r o u n d ) l
Notes
c701 c702 c703
Moonroof Wire HarnesslCoupe/Sedanl Connectoror Terminal Number ot Cavities 2 3 6 6 3 2 1 Location Underleft sideof dash Behinddashboard lower panel Leftsideof dashboard bracket Leftside of dashboard bracket Leftside of steering wheel Center roof of Rearof roof Rearof roof Frontof roof Conneststo (C407) Main wire harness Under-dash fuse/relay box (C910) Moonroofopen relay Moonroofcloserelay Moonroofswitch C e i l i n gi g h t l Moonroofmotor Moonroofmotor (Tiltswitch) Spot light Notes
c711 c712 c 7t 3 c714 c715 c716 c't17 c718 c719
Optional
98 model
WIREHARNESS
23-49

RearHeatedOxygenSensorSub-harness Connectoror Terminal Number of Cavities 4 4 Location
Under middleof dash Undermiddleof dash
Connectsto (C432) Main wire harness Secondary heated oxygensensor (Secondary HO25)
Notes
c7al c7a2
FuelTank Pressure SensorSub-harness Connector or Terminal Numberol Cavities 6 3 2 Location

Middleof floor Left side of fuel tank Left side of fuel tank
Connects to (C568: Floorwire harness Coupe/ Hatchback, C574: Sedan) Fueltank pressure sensor EVAP two way valve
Notes
c79'1 c192 c793
FUELTANK PRESSURE SENSOR
23-5 0
a
SRSMain Harness Connectoror Terminal Numbcr ol Cavities 2 3 2 2 2 2 18 Location Conneststo Notes
c801 c802 c803 c804 c805 c806 c807

G801
box fuse/relaY (c911) Under-dash Underleft side of dash s M a i nw i r e h a r n e s ( C 4 1 2 ) A b o v e u n d e r - d a s hf u s e / r e l a Y

DOX
f R i g h ts i d e o f u n d e r - d a s hu s e / relaybox Under left side of dash Underrightsideot dash Middleof floor Middle of floor
Middle of floor
Memoryerasesignal(MES)connector Cablereel airbagassemblY Passenger's connector Dummy resistor SRSunit Body ground,via SRSmain harness
USA Canada
SRSMAIN HARNESS
23-51
Fuses
Under-hood Fuse/Relay Box
ALTERNATOR ITo engine wire harness(T101)l
BATTERY (Tlll cables lTo starter
tE r'1
r-'l
IJ
47
tr tr tr
c901
ITo condensertan relayl
r'1 51
LI
n6 5
IJ
LI
r'1
LI
c904 lTo blowermotorrelayl c903

ITo radiator tan relayl
*: Not used
NOTErView from the backside the under-hood of fuse/relay box.
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 41
Amps
80A 40A
Wire Colol
Component(s)or Circuit(s)Protectod Powerdistribution To ignitionswitch(BAT) trunk light Ceilinglight,data linkconnector, main relay PGM-Fl Not used Powerwindow motors(viapowerwindow relay) (VBU) ECM/PCM Audio unit,clock,TCM {CVT). light switch(headlight) No. 33 (7.5A) fuse,To combination Not used Rearwindow detogger(viarearwindow defoggerrelay) Powerdoor lockcontrolunit, moonroofmotor Horn svstem,brakelights,brakesignal relay warninglight,turn signal/hazard Hazard Option{+B) Blowermotor (via blowermotor relay) fan motor (via condenserfan relaYl Condenser clutchrelay) compressor clutch(viaA\/C A/Ccompressor fan relay) fan Radiator motor (viaradiator
WHT/BLK WHT/RED
WHT/BLK
43
44
7 . 5A 1 5A 40A 7 . 5A
45 46 47 48 49 50 5l 52 30A 204 1 5A 1 0A 40A 40A 20A WHT/GRN WHT/GRN WHT/GRN
WHT/BLU WHT/BLU WHT
30A
53
54
5C
WHT/BLK WHT/RED
BLU,4/VHT WHT RED BLIqRED
56 57
20A
,a
23-53
Fuses
Under-dash Fuse/Relay Box
c912 wir6 [Todashboard harness lC501ll c913 lTo ignitionswhchl
llo main wire h.rno.s lciP2)l
c915
lTo main wiro harn$3 1C423)l
r-t r-'l -
I-J LI tJ LI LI LJ LI L.J tJ TJ LI LI
17 19 21
23 2a aa 26 27 2A 29 30 31 32 33
T-l Ft n El rl Fl Tt r'l
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

LI IJ I.J LI LJ LI L-JIJ LI LI I.J I.J 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 22
lTo powar window relayj

1
TI IJ LJ LI TJ IJ LI LI IJ LI TJ LI
a: Canada r: Not used O: Cg26loption @: C!t2?Ioption G)r Gt28 loption @: Cg2gloption
l+Bll (drsh lightsll lACCll llc2ll
c!'17 lTo turn signal/he2ardrolayl dotoggerrelayl
NOTE:View from the backside the under-dash of fuse/relav box.
C925(96,97 modebl lTo msin wiro h.rncss (C/('g)l
lTo main wire harn*31C419)l
23-54
Fus6Numbel
Amps
Wire Color Not used Not used
Componsnt{s)or Circuit(s)Protscted
10A 1 0A 5 6 1 8 9 20A 204 1 5A 10A
GRN RED/BLU RED/GRN
Rearwindow wiper motor,rearwindow washermotor

Right headlight (high beam) Left headlight thigh beam), high beam indicator light
Not used
RED/WHT YEUBLK
RED GRN/BLK
Left rear power window motor Rightrearpowerwindow motor Not used(96,97 models) (ignitioncontrolmodule)(98model) Distributor powerwindow motor Frontpassenger's Driver'spowerwindow motor switch) relay(viaturn signal/hazard Turn signal/hazard main relay PGM-Fl
10
l'l
20A 204
BLU/BLK YEUBLK YEUGRN
12
13 14 15
to
1 5A
cRY or BLKI/EL SRSunit {VA) controlsystem.audio unit Cruise BLKI/EL 8LK/WHT BLI</8LU BLK/YEL YEUBLK YEURED
BLK/WHT valve, EVAPpurgecontrolsolenoid VSS.ELDunit {USA), Alternator, (CVT) oxygen sensors,TCM ABS pump motor,rearwindow defogger l'lc system,power mirror,option (lG2) Daytimerunninglightsrelay(Canada) lights Back-up Daytimerunninglightscontrolunit (Canada) (low beam) Rightheadlight Leftheadlight {low beam) SRSunit (VB) Moonroofrelays controlunit lights,interlock Gaugeand indicator washermotor. wiper motor,windshield Windshield unit {Canada) control inteqrated Accessorvsocket (ACC) Audio unit,option (ACC) Not used Dashlights,option (dashlights) controlunit main relay.integrated PGM-Fl ECM/PCM, platelights license Frontparkinglights,taillights, solenoid controlunit, key interlock Interlock
7 . 5A 7 . 5A 7 . 5A 7 . 5A 10A 1 0A
17 18 19
20 22
24
REO,4ryHT L RED|YE
GRYor PNK GRN/ORN
10A 1 0A 7 . 5A 7 . 5A 20A. 1 5A
YEL
GRN/BLK
YEUGRN YEURED
RED/BLK
28 29 30
10A,/15A' 7 . 5A 7 . 5A 7 . 5A
31
BLU/IVHT RED/BLK
WHT/GRN
*('98 ModelOnly)
23-55
Fuses
Under-hoodABS Fuse/RelayBox
lTo undor-hoodABS tuse/relav box wire harnssl
c926
lTo main wire harness lC357ll
c928 lTo ABSpumpmotorrelayl
cs27
lTo main wire ha.ness{C350ll
FuseNumber 61 40A 7 , 5A 20A
Wire Color WHT BRN//EL WHT/GRN
Component(s)or Circuitls) Proiected ABS pump motor (viaABS pump motor relay) ABS controlunit lmotor check) A B Sc o n t r o u n i t( + 8 1 ) l
63
23-5 6
PowerDistribution
Circuitldentification
ABS HOOD UNDER BOX FUSEi RELAY
CONTFOL
wHT GFN -]
lBs.onuo'rn,t
V
GRNiWHT BFN/YEL YEURED
WHT
molof ABSpump
ABS conlrol unrt
BLK-
s l a d em o l o r r
UNDER-HOOD BOX FUSE/FELAY wHTBLKALTERNATOR wan nglighl Hazard relav Turn sional,hazatd (vras ilch) Horn
V t#i',33),5i3i L
Horn ay re
ABS conlrolunrl PCM ECMi (CVr) TCM Cruise conlrolwil ights Brake
I-*^
G401 G402
G R N / R E-D
PCM ECMi cl'. t Ot'r -C- :.Sw
l--'NHr -2>.=""1i")iis ts-/ WHT/FED
Celinglighl Trunklighl lD-: link Dala conneclor InleEaled conlroluni: re PGM Lmain Lay F
WHI/BLK-
UNDER DASi: ' FL.JSEIRELAV page a' (To 2:
TCM(CW) ECM/PCM
23-57
PowerDistribution
(cont'd) Circuitldentification
UNDEFHOOD FUSE]RELAY BOX
UNDER.OASI,] FUSEiRELAY BOX (Topage 23-62) COMBINATION SWLTCH LIGHT (Io page 23.63. 64) IJNDER.DASH FUSE/FELAY BOX (Topage 23-64) F\ .> >/ , , . , ^ - ^DaSHF-Sl ql I AYBoX ^ UNo-EF " - , t apagF zrb \
t4,-TGF\ -.,i
V'/-- Gi\
Powe. lo(l (ortro u t r door Moonroolmolor
,"--...
) N o . 1 ( 7 . 5 4F U S E 7 page 59) (From 23 BLUMHT-
h\ 1,.'
EUsE -\DEqDASFE-A'Box llo oag"2j-6n
Bower molor
"*-]
oot G402 BLU/1flHT ELUA&HT

(Va ECMi PCM ArCpressure swilch) ,nClhermoslal lan Condenser moloa
llo compressor c ulch
BLK/REO
PCM ECMi
BLK/RED
Fadiatorlan motor
23-5 8
(40A) FUSE N0.42 (From page 23'57) BOX UNDEFDASHFUSAFELAY
IGNITION SWITCH
BLKELU
+-l',
unit ABsConlrol
F\ > qEAR I\DOW EFOGGERLAV FE D W (V,a srldo$, deloqger swilcF rear (Topage 23.51)
eN i,,
I -., ACC
I I l-
l,z
No17(7.5A)
(Fuse/relay socket) box
swilcll wrndow delogger Rear ighl indicalor (lG2) conneclor Oplonal
. BLOWER RELAY MOTOR .CONDENSER FELAY FAN ' ,vc coMPREssoR RELAY CLUTCH . RADIATON RELAY FAN 23 {Io page 58)
Healer conlrolpanel A/Cthermoslat molor Mode conlrol molor Fecirculalion conllol
.| lefl
YELBL( -l |'\ j> V'
m,r,or actualor mwe,

L DAvllMERLNN'NG GH_S UN (Caladd) CO\TFO_ page23-64) llo
. 8L(YEL+
lgnilon coil
GRN N 0 . 1 ( 7s A ) 2 GRN
molor wndow washer Rear motor Re windowwipel relaY Turn sional/hazard (Via switdr) PGM-F relay firain lnil SRS (VA)
YEUBLK
_ YEUGRN
N0.1(7.sA) 4
-lBLK/VEL ll-
CrJseco"lroturl rvrama,ns\rilch) I'gtl lrdrcalor C'LEemarrswilch ctcuil) Auoio t(ey'e9s'ece'ver J1,r
N0.1(7.5A) 5
vss
HO2S valve venl conlrol canisler shut EVAP
BL</w-+
-BLXMHT
:J"!i'.rT F-"t
fTcM(cvTj lighl syslem chaGing
BLKtr/HT
' (cont'd
23-59
PowerDistribution
Circuit ldentification (cont'd)
UNDER,DASH FUSE/RELAY BOX
Back-up lighls
GFYo'PN<i i
S F SL r i l ( v a )
GF\.CF\
Moonroor reay open .etay Moolrool ctose
POWEH WINOOW RELAY page (To 23-61) No25(7.5A)

(Fuserelay sockel) bor
nlegfalpdconlro Llnil
.;. -l-
S ' l | r t o o ( s o r e n o o( , , - . I n t e r l o c ^ c o n t o l L nltrly r l I y Gauge assenb SRSndlcalor lighl ABS indicalor light Mqear Dosronndcatof J ormmrng crrc!l Cruriendcator I
box {Fusgrelay socke0
Inlegraled conlrctunil
GRN/8LK tGNtTtoN TcH(ACC) sw page (From 23.59)
Windshleldwper molor
Inlegraled conlrol !nil (VEwindshield wlprswlch) W ndshield u/asher motor (Vasrvitch)
YEUGRN
power Accessory sockel (ACC)
Oplonalconneclor (ACC) Audio unil
(40A)FUSE N0.54 page (From 2358)
BOX FUSEIRELAY UNDER.DASH
WHT/RED (Fuse/f boxsockel) elay (+B) conneclor Oplional
ft I
No24(75A)FUSE page 60) (From 23
(40A)FUSE N0.46 page (From 23'57) f-;-7
tr*a
G401 G402 d-J ts-^ + l'oitFr wrnJo{n'o;le $ .1 Powef nOOw w COntO Lnrl (viapower wrndow master lcn) sw
\7 I
I
Wl.lTiELLJ
GRN/BL(G R N / B L- J K
Passengers Power ] Fronl wn00wm0l0r powerwrndow masler ch\ sw /via Power l landlronlPassengels I \wndow swilch wrdow -olor i Le'lrearoowe, '/Vla $r.oowmdsleswdch\ Powr w swilclr / \and ell rearPower ndow
'::
::-
:":"1 No 50 (30A)FUSE paqe (From 23'58)
i Riohrealoowewndow-olor '/v'a power mas wlndow el swllcl l l d \ a r o n g l t ' e d p o w e ' w o w s wl c l /
WHT]GRN (7.sA)FUSE No16 (Vaswilch) (From 23'59) paqe
v I
f,7
BLll/YEL
window delogqer Rear
"n-f,G40t G402
(cont'd)
23-61
PowerDistribution
(cont'dl Circuitldentification
(M T)
GN|T SWTCH{ST) 0N (From page 23.59)
BLKMHI
i"'
tl
I
-fff "n*n'
--TlBLK4THT
cu qELA"
,,,,,,* @**-f_
BLK/RED T
ELKi ED R
cLU swlrcH c-
_ BLK,vHT
srarrer sotenoid G401
L-
NUTRAL POSLT]ON SWITCH
(Flse/relay sockel) box In1egraled conlrolunt
BLUI/VHI _ BTUMHT
PGM-F|main retay ECi?VPCM

Inle ockconrrotun (Viaintedoct swrlch) Keyinleiock sotenord
i,YF",5 [l;'if'"od)
**
..............-WI-]T/GRN I r-
*-, '
[\ V
covB NATToN swtrci LicHI'o Page 63 6', 23
23-62
USA:
FUSE]RELAY BOX UNDER'DASH COMBNATION LIGHT SWITCH
REDiBLU
headlghl beam) Frghl lHrgh
No48(30A) FUSE \2358
N0.5110A)
REDTGRN REDTGRN REDIWHT R E O I Y E-L
i H g hb e a r nd c a l o!rg h l glr Lellheadlighl(H beam) R L g h t h e a d l{g o w e a m ) L b beam) LellheadghllLow
w
I
l nPASSTNG
I to
N o4 8 1 3 0 A ) FUSE p /From age \ \2362 /
(Fuse/reay soc(el) box
(Dashghls) Oplonalconneclor
(Fuseirelay boxsockel) nieoraled conlro !n
warnrn! tchlghl sw Hazard G a u gL g h t s e swtch$h] Feafwndowdeloggr ma Cfurse n sw(ch11 n c r L t s e dc a t o r ) c m mn qc , r , r r n A q e a p o s r 0 n oc d r o r r er bnglrlness conlro Dashighls
-t RED/BLK
poslonconsoie lghl A'Tgear panelghl Healer conlro
REDlBLK
l e f , | i , o n t o a 'n ol o h t t Hqntl
FEDIELK Hqnr inn"'lu'gltt r'trh1J ---: e l c e n s o a l el o h l s

H q N IJ
(cont'd)
23-63
PowerDistribution
UNDER.DASH FUSEiRELAY BOX
R E D / B LU
R g h t e a d i g hH i g b e a m ) h (t h
--< BEDiBtU
\23.59 /
(Canada) REs sToF

Nigh beam indiclor ighl Lenheadlghl (H,qh bearn)
\7 I WHT
No48(30A) FUSE p /From age\ \2362 l
l oPASS NG
I to
REDMHT
RED/GFN FEDTGRN T
<
BEOMHT
REs lcanada) sroR

(Low Fighlheadlighl beam) ght Lellheadl (Lowbeam)
RED/GBN
box {Flserelay sockel) (Fuse/reay sockel) bor
Oplional connector (Dashghls) I Inlegraled conlrclunrl
RED/BLK N ol 8 ( 75 A ) FUSE /Frompage\ \23.59 J (40A) N0.48 FUSE \23 58 J
Hazard warning lighl swilch GalgeI ghls Audio un1 Rear window delogger lchlghl sw Crlisenan swllch lght Cruise cator nd I dlmmtng posil indicalorJ lVTgear crc!i1 on Dashhtsbrlghhess ler conlro Mgear pos onconsote rght panetqhl Healer contro
YELIBLK
REDTBLK -
-t RED/BLK
F,i6,'.E" I Y I
.*o^, '| ITIIFLUD
I , JI L E V E L
l"'l'n'uon' 'nn' ) ou"'"n
l-.,-;
t+ wHr/RED........+? I f-llrr-t---D FED,BLU | --> REo/GFN
h,'fn,'''"n*' ) '-"
o''.' l"fn,] ''"'nn"
o'"'" lt'j") '*n." 'nn,,

RGHT HEADLGHT (Hshbeanr) LEFT HEADL (Hish cHT beam)
I'*'" lBLK REDIGRN
I A I Y
.
8LK
RES STOF
G401 G402
G40l G402
GroundDistribution
Circuitldentification
Ballery
o,
brackel ng Power sleer pump
i'
nous Transnissron ng
I
i
(M/T)I HO2S Primary ( v E G R a l v eM / T ) " | l O r s v Sn g , n . ) vave (AiT) l soenoid
BLK BLK BLK BLK

BRN/BLK
ECTswlch VSS PSP ch sw ( P G 1I) fEoMTPCM {PG2)l
BLK s,r. -lFIpLh
page 66) 23
I V
'
menleay PGMF
E1tt"'tu-'
swilcfl WEC pressure r ( D 1 6 Y 0 1 6 Y 8 n g n e 9 8m o d e 5 e )
ground e cab Ballery
E B
: Engineground B cable harness Engnlvire
t',la wreturness n
trl
ground A cable Engine
(cont'd)
23-65
GroundDistribution
page 65) 23
w
A
|l]
BRN/BLK LG1I l Ect,t PcM
roz J
f _{r
L ^ FS e n s o r 1 L -E={ll (K K n o cs e n s o r S ) + i : k
I enNierx
Erui RED FED/BLU
PrmaryH02S*' -
WHT
Manshallspeed sensor- Counlershall se.sor -1Fl speed
RED BtU
l,."
Dl6Ygengrne
[--;'*:+il;
y:1=.":*:-]
Dl6Y5, 016Y7 engine
BRN/BLK
B R N / B L_ K
--:'--l
I
.-!l puleyspeed Drive sensor

puleyspeed Driven sefsor =.j ----1Fl S e c o n d a r y gs h a ls p e e s e n s o r ear l d
RED/BLU
WHT WHTTRED
reo[[,]- f tcvrc*1
wrr --+
WHT/RED.+ J
: Enginewre harness : Manwre harness
Shlelding
23-66
* 1: D]6Y5, 016Y8 engine * 2: Excepl D16Y5 (M/T) engine *3:016Y5 ne(M/I) eng
r-
Fiqhl headliqhr
BL^-
l-
;gn'ru,. Pc,"''e'sn Riqhllronl lurn signalllghl
o L ^ - - - - - ! -
ll-
lighl LerllronlParking Leitlrontlun gqnalight
< 8L
? l-
malo' !',/ ndshield wasrrr molor Fearwndowwashef cruisocontroltclualor
, Engine hatn"ss cotpanmentwre
(conl'd
23-67
GroundDistribution
o_^ ---t_ Yllnosr,eE wtcErmoro, Bra{e llLto eve swilci
6_^ ----
g1' or rev sw,lcrL
t.. o-c, i oata co-.ecro,

W ndsh d wiper/washer e swilch
,r* -fi-f6
B,L,oc^ -
:-'"
l-
"ud^
s6's7m.dels |
Re wlfdow wiper/waslrer swilch oL^-le1och onrrJr ! c o ' oaaiT on swilc,r J i a / r , ctJlci irreroc\swrtcLt lM-l
8rK 8LK
Cru conlrolunil se
I_
(Canada) Daylime runnng conlrolunll ighls Clllch switch ([,]/T crrise wlh conlrolor D]6Y5 lor engine) Fear ndow w relay delogger
(Fuse/relay sockel) box (Fuse/relay sockl) box (Fuse/relay socket) box
Inlegraled conlrcllnil
(Fuse/relaysocket) bor
BLK
Torn signal/hazard relay 1roon.oor.wrcr voon.oot 'etay oper Mool,oolctose,etay lasr r'gnls qrrress or co'rorer Key/ess ock doo' corro, u'r Seculry conlto, Jflr
nrain Crulse swrlch lighl Cluseindicalor dimming circut Re windowdslogger lght swlch l/T gsalposton indicator ng dlmm cncuit
J
\u/
G402
;L^ -----la-1 ---.....tsL^--F l-
( To Faqe 23 69-
oit
BLK-+ BLK BLK BLK
power ACCeSSOTy sockel SRS indicalor circuil lighr Gauges indcaloas and ABSndcatorighlcircu[ Gauge lighls
companmenlwre harness @ : Englne wre @ Main haness
E E
: Dashboard haness wre : Moonroolwire harness
rwih., I ARsr
-< BLK
(Fom 2,.6s)caol ease l

(wrhA8s)
BLKBLK UNDER.HOOD FUSE/RELAY BOX
l/TiearPosition swlch
conneclor Servrce check
ABSplmp molor
oro,
Audio un1
G501
la
BLK + lrI tt4 l-
Po{e! doot\od\ !oi\o\ uh\ loch aclualof Drveisdoor Dfiver door s tock swilch
i Pow windowrraLnsw ci ) molor Dfper s powerwrndow
Fuelunl
BLK -
5ii.?i1!"f1,.,,'"n
ttt fit
Dashboard harness wre
tr : Driversdoorwireharness
A sub-harness L r - ! l Heater : Healer harness B sub
trn
23-69
GroundDistribution
(cont'd) Circuitldentification
l-L! I J--. -t:JEL^ l
l -
lr
-l"r.,ln"'nno
' 3-{ -1_t-L: l ;_K
-d
G601
I 1t l"$$,)',r"n,"ou'.,,n'''. I Hghmoonl lighl brake

Rear windowwiper motor
I
G76l (Halcnback 97models) r96
t l
t-.1-...--!"..
l
l l
l l
L.
-iJ-1: < a_K
l -
tt't,ignt' t-iin1J
Leil ) . rrcene rqn$ Prale RrghtJ High mounl brake lighl Rear window wiper motor Trunk lalch swilch
ts-h
G60l
L
c :
G761 (Halchback:98 m00u
_l
o*t""'u'nn" h"'$,)
G601
Lefil. Innel larl||gn$ Rrghl J L e t ll . lrcense Prae{ms R qhtJ Trunklalchswitch High mounl take lighl Rearwindow delogger (Coupe/Sedan) Condenser rnolor lan
oir,
Rear window (Nalchbach) delogger
G77l
],,,,.' out
B
rdl
window ground delogger wire U : Rear : sns main harness El Hatclr hamess wire
* GRY: 96 97 models : GRN 98 model
23-70
Box Fuse/Relay Under-dash

SRS componeols'rle located in this area Reviewthe precautions, and procedures SRScomponentlocations, in the SRSsection(24)beforeperformingrepairsor service. Removal: t. cable,then disconthe Disconnect batterynegative nectthe positivecable,and wait at leastthree minutes. {seesection24) the Disconnect airbagconnectors l R e m o v et h e d r i v e r ' sd a s h b o a r d o w e r c o v e r a n d kneebolster(seesection20). mountingnuts,and pull the underRemove t\rvo the box out from underthe dash. dashfuse/relay lnstallalion: 1. f t C o n n e c tt h e c o n n e c t o r s o t h e u n d e r - d a s hu s e / fuse/relay box relaybox, then installthe under-dash 24). orderof removal{seesection in the reverse lower cover (seeseclnstallthe driver'sdashboard tion 20). (seesection24). Connect airbagconnectors the then connectthe Connect the batterypositivecable, cable. negative work properly. Conlirmthat all systems
2.
3. 4.
2. 3.
5.
4.
UNOER.OASH BOX FUSE/RELAY
f D i s c o n n e ctth e c o n n e c t o r s r o m t h e u n d e r - d a s h fuse/relaybox, and take out the under-dashfuse/ 24). relaybox (seesection
2?-71
PowerRelays
Relay Test
NOTE:Seepage23-155 turn signal/hazard for relalinput
Le5t.
\
o Rearwindow defoggerrelay
Normally-opentype: '1. for Check continuitybetween terminals. the . Thereshouldbe continuity between No. 1 and the No. 3 terminals when power and groundare connected the No. 2 and No. 4 terminals. to . Thereshouldbe no continuitybetween the No. 1 and No.3 terminals when power is disconnected. Terminal
ao*o o,o.= *o.if'

Disconnected Connected
l(-lh-'I
ln
5 P
a Starter cut relay:96,97models
Blowermotor relay
Horn relay:96,97 models
ABS pump motor relay
Normally-opentype: 1. the between terminals tor Check continuity the between No. 1 and . Thereshouldbe continuity when power and groundare con No. 2 terminals to nected the No. 3 and No. 4 terminals the No. 1 . Thereshouldbe no continuitybetween when power is disconnected' and No. 2 terminals
\ | ermrnal (N0.3 No.4) Power Disconnected Connectd \
Five-lerminaltyPe: 1. the between terminals. for Check continuity the between No l and . Thereshouldbe continuity when power and groundare con No. 2 terminals t n e c t e do t h e N o .3 a n d N o . 5 t e r m i n a l s . the between No.2 and . Thereshouldbe continuity when power is disconnected No. 4 terminals \ Terminal
1
t"i* r*"-, - t". u\

Disconnected Connected
ooO
---o
-----o
( 9
r.l
{
2 Powerwindow relay a Radiator fan relay a Condenser relay fan clutchrelaY IVCcompressor model cut Starter relaY:98 a H o r nr e l a y : 9 8 o d e l m 96, Moonroofopen relaY; 97 models
a Moonroofcloserelay:96,97 models
23-73
PowerRelay
RelayTest
Five-terminaltype: l. Check continuitybetween terminals. for the . There should be continuity betweenthe No. 1 a n d N o . 2 t e r m i n a l s h e n p o w e ra n d g r o u n da r e w connected the No. 5 and No. 3 terminals. to There should be continuity between the No. .l and No. 4 terminals when power is disconnected. Terminal Power(No. 5 - No. 3) Disconnected Connected \ 1
oo-
----o --o
5 a Moonroofopen relay:98 model a Moonroofcloserelay:98 model
|
L
23-74
lgnition Switch
Test
SRS componentsare located in this area. Reviewthe precautlons, and proceoures SRScomponentlocations, or in the SRSsection{24)beforeperformingrepaars servtce. 1. 2. cable. the Disconnect batterynegative Remove the driver's dashboard lower cover and knee bolster (seesection 20). the 5P connectorfrom the under-dash Disconnect from the main box and the 7P connector fuse/relay wire harness. Checkfor continuitybetweenthe terminalsin each to switchpositionaccording the table. Terminal
E (3) 1 (ACC) {BAT) 0 G 1 )
ElectricalSwitch RePlacement
SRS componentsare locatd in this area Reviewthe precautions, and procedures SRScomponentlocations, section(24)beforeperformingrepairsor serin the SRS vice, 1. 2. cable. the Disconnect batterynegative Remove the driver's dashboard lower cover (see 20). section the 5P connectorfrom the under-dash Disconnect from the main box and the 7P connector fuse/relay (seeleft column). wire harness Removethe steering column covers (see section 171. Insenthe ignitionkey,and turn it to "0 (LOCK)".
3,
3.
4.
4.
,olirton-__\ o {LocK)
| (ACC)
Il\rZ,
(1) {ST)
5. 6.
Removethe two screws and the electricalswitch from the steeringlock.
o- ---o
lr(oN)
III (START) [ ] :7P connector
oo-
--o
---o
Wire side of lemale terminals
BLK/WHT(ST}
WHT(BAT}
7P CONNECTOR
WHT/8LK YEL{IG2) (IGlI BLK/YEL
7.
orderof removal lnstallin the reverse
lf the continuitychecksdo not agreewith the table, switch reolace electrical the
23-75
lgnition Switch
Steering Lock Replacement
SRS componentsare located in this area. Reviewthe precautions, SRScomponentlocations, and procedures in the SRSsection(24)beforeperformingrepairsor service. Remove: 1. 2. Disconnect batterynegative the cable. R e m o v et h e d r i v e r ' sd a s h b o a r d o w e r c o v e r a n d l kneebolster(seesection20). 4. 3. Disconnect the 5P connectorfrom the under-dash fuse/relay box and the 7P connector trom the main (seeprevious wire harness page). Removethe steeringcolumn covers,then remove the mounting bolts and nuts from the steeringcolumn (seesection17). Lowerthe steerlng columnassembly. Center-punch eachof the two shearbolts,then drill their headsoff with a 5 mm (3/16in) drill bit. CAUTION: Do not damagethe steering lock body. Insiallation: 1. Installthe new steeringlock assemblywithout the key inserted. Loosely tightenthe new shearbolts. lnsertthe ignition key, and checkfor properoperation of the steeringwheel lock and that the ignition keyturns freely. Tightenthe shearbolts until the hex headstwist off.
2. 3.
SHEARBOLT
4.
5. 6.
TWIST-OFF PORTION
5.
Installin the reverse orderof removal.
7.
Remove shearboltsand the steering the lock ory.
Battery
Test
@ sulfuric acid. lt may causesevele burns if it gets on your skin or in youl eyos weal a Battery fluid (electrolytel Gontatns
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|odandcou|dcrackthebatterycaseandsp|atter acid on you. Keepsparkg.flames, and cigarottesaway lrom ths battery' ths electrolyte,This may force electrolyte to spray out of the battery vents. . overcharging will raise the temperatur; Fol|owthechargelmanufactuler,sinstructions,andchalgethebatteryataploper]ate. procedures. you don't have one of thesecomputlf tester,and follow the manufacturer's Useeithera JCI or BearARBST test follow this conventional procedure: testers, erized Toqetaccurateresu|ts,thetemperatureofthee|ectroIytemustbebetweenTo.F(21.c)and100.F(38"c).
or lf the caseis cracked the postsare loose,replace the battery.
EYEColor CheckIndicator
lf the indicator shows low electrolyte, add distilled
(#1) TestLoadCapacity t . 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 s o r e m o v e charge. surface . Allow 15 seconds recovery Perloo. . Applytest load (seeTestLoadChart) . Record voltageat the end of 15 seconds.
Staysabove9.6 volts; batteryis OK.
{co'::
23-77
Battery
Test (cont'd)
Charge HighSening{40amps} on Chargeuntil EYEshows chargeis OK; plus an additional minutesto assure charge. 30 full NOTE: lf the battery charge is very low, it may be necessary bypassthe charger'spolarity to 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 seconds removesurface to charoe. Allow l5 seconds period. recovery Apply test load (seTest Load Chart,. Record voltageat 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
fr,
23-78
TESTLOADCHART Usethe test loador 1/2the cold cranking amps (CCA) printedon the labelon the top of the battery, neitheris indicated, the lf use information below:
BATTE RY CODE
*: 5sB24L - MF (S)
COLD CRANKING AMPS(CCA) 4 0 5( * 4 1 0 )
LOAD tamps, 200
StartingSystem
Locationlndex Component
CUT RELAY(M/T) STARTER les\, page za t z, t r SWITCH A/T GEARPOSITION Test,page 23-138 page23 139 Replacement, INTEBLOCK CLUTCH
swrTcH
BATTERY Test,page23-77
STARTER Test,page23-81 Test,Page23-82 Solenoid Replacement, Page23 86 Test, Page23-87 Performance
23-79
Starting System
UNDER.HOOD FUSETRELAY BOX No41(80A) No42 (40A) IGNITION S WT C H
WHT]BLK {-WHT
SLKA/VHT
I
t
A,TTGEAR POS ION WTCH T S ( C l o s e d : lp o s o n N o r E ) n
BLKWHT
BLKMHT
STARTER CUTRELAY
BLI]/8LK
I
BLK STARTEF (Permanenlmagnellype)
pedal) Closed :Clulclr lullydepressed /
CLUTCN swiTcll
G40l G4A2
23-80
StartingSystem
StarterTest (cont'd)
Checklor Wear and Damage 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 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 , erratically, removeit, and inspectthe starterdrive gear and torqueconverter flywheelring gearfor damage. or . Checkthe drive gear overrunningclutchfor binding 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 d r i v eg e a rh e l d . - lf damaged, replace gears. the
Starter Solenoid Test

1. Checkthe hold-incoil for continuitybetweenthe S . t e r m i n a la n d t h e a r m a t u r e o u s i n g( g r o u n d )T h e h coll is OK if there is contjnuity.
ARMATURE HOUSING (GROUND) S TERMINAL
CheckCranking Voltage and Current Draw C r a n k i n v o l t a g e h o u l db e n o l e s s h a n8 . 5v o l t s . g s t Current draw shouldbe no more than 350amperes. 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. . stanerarmature draggtng. . shonedarmature winding. o excessive drag in engine. CheckCranking rpm E n g i n e p e e d u r i n g r a n k i n g h o u l db e a b o v e1 0 0r p m . s d c s lf speedis too low, checkfor: a loosebaneryor starterterminals. a excessively worn starterbrushes. . open circuitin commutator segments. . d i n y o r d a m a g e d e l i c as p l i n e r d r i v eg e a r . h l o . defective drive gear overrunning clutch. CheckStarter Disengagement With the shift leverin S or E position(A,/T) with the or (Mff), rurn the ignitionswitchto clutchpedaldepressed ( , e S T A R Tl l l ) a n dr e l e a s t o O N ( l l ) . The starterdrive gear shoulddisengage from 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 eg e a r a s s e m b l y r d a m a g e d v e r r u n n i n g o o clutch.
M TERMINAL
B TERMINAL
STARTER CABLE
B TERMINAL MOUNTING NUT 9Nm(0.9kgtm, 7 tbtft)
2.
Checkthe pull-in coil tor continuitybetweenthe S and M terminals. The coil is OK if thereis continuitv.
23-82
and ArmatureInsPection Test

1.
for the Inspect armature wear or damagedue to conmagnetor fieldwinding. tactwith the permanent
VERNIER CALIPEB
replace armature. the a lf there is wear or damage, for Inspect damage.
2.
and diameter. commutatorsurface Check . with emery lf the surfaceis dirty or burnt, resurface lathe within the following specifications, cloth or a with #500or #600sandpaper. or recondition limit, is . lf commutator diameter belowthe service the replace armature 3. the Measure commutatorrunout. . lf the commutator runout is within the service limit. checkthe commutatorfor carbon dust or the segments. brasschipsbetween lf the commutatorrunout is not within the ser the vice limit, replace armature.
Commutator Diamate. (NEW) Standard - 28.1mm 28.0 ( 1 . 1 0-2 1 . 1 0 i6n ) Limit Service 27.5mm ( 1 . 0 8 3n ) i
Commutator Runout (NEW) Standard Limit Service 0.05mm (0.002 in)
mm 0 - 0.02 (0- 0.0008 in)
COMMUTATOR
(cont'd)
23-83
StartingSystem
and Test (cont'dl ArmatureInspection
4. undercutmica Checktor mica depth. lf necessary, properdepth.lf serwith a hacksaw bladeto achieve replace armature. the vicelimitcannotbe maintained, 6. Placethe armature on an armaturetester. Hold a core. hacksaw bladeon the armature ARMATURE TESTER
NOT GOOD
MICA DEPTH
Commulator Mica DeDth (NEW) Standard - 0 . 5m m 0.4 ( 0 . 0 1 6 0 . 0 2i n ) 5. Service Limit 0.15 m m ( 0 . 0 0 6n ) i . Checkfor continuitybetweenthe segmentsof the commutator,lf an open circuit exists betweenany replace armature. the segments, 7.
ARMATURE
lf the blade is attractedto the core or vibrates while the core is turned.the armatureis shorted. Replace armature. the
Checkwith an ohmmeterthat no continuityexists betweenthe commutator and armature coil core, and between the commutatorand armatureshaft.lf replace armature. the there is continuity,
corl coRE
COMMUTATOR
23-84
Brush Holder Test

't. the O and that there is no continuitybetween Check O brush holders. t , l f t h e r e i s c o n t i n u i t yr e p l a c eh e b r u s hh o l d e r assemDry.
O BRUSHHOLDER
BrushInspection
limit, the brush length.lf not within the service Measure the replace brush(or brushholderassembly) Brush Length (NEW) Standard - 15.2 m m 15.8 (0.62 0.64in) Limit Service 11.0 m m ( 0 . 4 3n ) i
O BRUSHHOLDER
O ERUSHHOLDER
them in their NOTE:To seatnew brushesafterinstalling with the slip a strip of #500or #600sandpaper, holders, grit side up. over the commutatorand smoothly rotate The contactsurfaceof the brusheswill be the armature. sandedto the same contour as the commutator.
2.
lnsenthe brushinto the brush holder,and bring the then attach brush into contactwith the commutator, the scaleto the spring.Measure sprlngtena spring sion at the momentthe springlifts off the brush.
ClutchInsPection Overrunning
clutchalongthe shaft.Doesit 1 . Slidethe overrunning it. lf move freely? not, rePlace 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 lf reverse? it dces not lock in either directionor it it. replace locksin both directions,
GEAR CLUTCH
SCALE SPRING
BRUSH
SpringTension 15.7 17.7 N (1.60 1.80kgf,3 5 - 4.0 lbf)
23-85
StartingSystem
StarterReassembly
't. Disconnect batterynegative the cable. Disconnect startercablefrom the B terminalon the 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 Tr e , wi from the S terminal.
MOUNTINGBOLT 44 N.m {4.5 kgf.m,32 lbf.ft)
StarterReassembly
1. Pry backeach brushspringwith a screwdriver, then positionthe brush about halfwayout of its holder, and release springto hold it there. the
S TERMINAL
2.
BLK/WHT WIRE STARTER CABLE MOUNTINGBOLT 44 N.m {4.5kgl.m, 32 lbtftl B TERMINAL B TERMINAL MOUNTINGNUT 9 N.m {0.9kgt m, 6.5 tbtfr)
Installthe armaturein the housing.Next. pry back each brush spring again,and push the brush down until it seatsagainstthe commutator,then release the springagainst end of the orusn. the
aw
Install end coveron the brushholder. the
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 reverse orderof removal. NOTE:When installing the stanercable.make sure thatthecrimped sideofthe ringterminal isfacingout.
Crimped sideol ring termtnal
TERMINAL
Connectthe batterypositivecableand negativecable to the battery.
23-86
Test Performance
disconnect NOTE:Betorestaningthe following checks, a 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 n s (preferbelowusingas heavya wire as possible described to ablyequivalent the wire usedfor the car). Pull-in Coil Test: Connect the batteryas shown. lf the starterpinion pops out, it is working properly. CAUTION: Do not leave the battery connectedfor more than 10 seconds. RelractingTest: Disconnect batteryalso from the body. It the pinion the it retracts immediately, 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 batteryfrom the M terminal.lf the pinion the does not retract, hold in coil is working properly. the CAUTION: Do not leave the batterv connectedfor more than l0 seconds,
F4 J L /
Y
"pcr"
/'4 N
,t-\
STARTER
BATTERY
l f t h e e l e c t r i c 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 c when the batteryvoltageis at 1 1.5V, specifications the starteris workingproPerly, Specifications: r c 8 0 A o r l e s s ( E l e c t r i c u r r e n t ) , 2 . 6 0 0p m o r m o r e {Motor-speed)
23-87
lgnition System
Component Location Index
IGNITION TIMINGCONTROL SYSTEM . Troubleshooting, section11 . ldle speedInspection/Adjustment, section11 . lnspection and Setting,page23-91
SERVICE CHECK CONNECTOR {2PI lwire colors:BRN and BLKI
TESTTACHOMETER CONNECTOR
IGNITION WIRES Inspection Test,page23-96 and
PLUGS page23-97 Inspection,
DISTRIBUTOR page23'92 Replacement, page23-93 Overhaul, page23-96 lgnitionCoilTest, lgnitionControl Module(lCM) InputTest,page23-95
23-88
lgnitionSystem
CircuitDiagram: 96,97 models
FUSE/FELAY BOX HOOD UNDEF
GNTION SWITCH D UNDER ASH FUSE/RELAY BOX
BLKYEL YELiGRN
BLI(YEL
BLK/YEL YEL/GRN GNT]ON colL
^l
i I
T D C : T od e a d e n l e r p c posilion CKP Crafkshalt : posilron CYP CyLnder TDC/CKPiCYP SENSOR
+i wlteLu
IGNTIONCONTROL C M O D U L(E M ) b / H a s ul l . n\ noEe I l
TDC
CKP
CYP
BLU'
BLU' BLU
++
* 1 HITACH] *2 TEC
.lJ l-
Ji[3î''l=
TACHOMETER TCt\4 {CWr
I A
23-89
lgnition System
C i r c u i tD i a g r a m 9 8 m o d e l :
UNDER HOOD FUSE]RELAY BOX
IGNITON SWITCH UNDER.OASH FUSE/RELAY BOX
I-*',il] u''"'.-* /-1\, BLx'EL-E_,}I, -un*'{_:z
EcMipcM
Y
1
YELiGRN
T D C r T od e a d e n l e r p c posilion CKP: Crankshalt C Y P T Cn d ep o s l i o n iy r TDC/CKPiCYP SOF SEN
"
+lBLU_
BLU'
liIl]'_r ++ | i+++
-MFCMI 23-9 0
I
t
BLUl
I TACHOMETER \__7 CONNECTOR TACHOMETER TCM(CW)
t l l n I TEST
B L UJ
X1 HITACHI +2 TEC
lgnition Timing Inspectionand Setting

(see 1 . Checkthe idle speed,and adjustit if necessary 1 section 1). 2. 2P connector (BRNand BLK check Pullout the service wires)from the connectorholder locatedunderthe side,then connectthe dash on the front passenger (T/N07PM - 0010100)to it connector SCSservice 6. as Adjust the ignition timing if necessary, follows. Loosenthe distributormountingbolts,and turn the to ignition{Dl)housingcounterclockwise distributor to advancethe timing, or clockwise retardthe timIn g .
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 the timing light to the No. ignitionwire, Connect pointeron the timing then point the light towardthe 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 : blower fan, rear window defogger,and headlights, are air conditioner not operatlng. lgnitionTiming: ( ) 1 2 ' t 2 " B T D C R E Dd u r i n gi d l i n gi n neutral ( ) i 1 2 "1 2 " B T D C R E Dd u r i n gi d l i n g n @ BOLTS MOUNTING kgt'm, lbfft) 13 18N'm11.8 7 . Tightenthe distributormountingbolts,and recheck t r h e i g n i t i o ni m i n g . from the ser the Disconnect SCSserviceconnector vice checkconnector.
POINTER
orE
RED MARK
23-91
lgnition System
DistributorReplacement
Removal: 1. Disconnect connector the from the distributor. HITACHI: 2 - D i s c o n n e c t 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 th ( i g n i t i o n D l )c a p . 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 , then remove distributor the from the cylinder head.
No. 1 CYLINDER
4.
Connect the ignitionwires to the distributorignition ( D l )c a pa s s h o w n .
MARK
DISTRIBUTOR END
CAMSHAFI END
TEC:
No. 1 CYLINOER
MOUNTING BOLT 18N.m{1.8 kgt.m, lbtft} 13 lnslallation: NOTE:Beforeyou installthe distributor, bring the No. 1 pistonto compression strokeTDC. 1. 2. Coata new O-ringwith engineoil, then installit. Slip the distributor into positiof NOTE;The Iug on the end of the distributorand its mating groovesin the camshaftend are both offset to eliminate the possibility installing of the distribu' tor 180"out of time. 3. l n s t a l l t h e o u n t i n g o l t s a n dt i g h t e n h e m l i g h t l y . m b , t 5. 6. 7.
No.2
No. il
Connect connector the distributor. the to page). Setthe ignitiontiming (seeprevious After settingthe ignitiontiming, tightenthe mounting bolts.
23-92
DistributorOverhaul
HITACHI:
DISTRIBUTOR IGNITION HOUSING {DO for Check cracks and damaqe.
IGNITION COIL Test,page 23-96
)
section11 Troubleshooting, Do not disassemble.
MODULE{ICMI IGNTTION CONTROL lnputTest,page23'95
CAPSEAL for Check damage.
(DII CAP IGNITION OISTBIBUTOR wear, for Check cracks, d a m a g ea n df o u l i n g . , or Clean replace.
(cont'd)
23-93
lgnition System
Distributor Overhaul (cont'd)
TEC:
LEAKCOVER DISTRIBUTOR IGNITION(DI)ROTOB
CAP SEAL C h e c kf o r d a m a g e
DISTRIBUTOR IGNITION{DIICAP Check cracks, for wear, damage, and fouling. Clean replace. or
WHT/BLU
IGNITION COIL Test, page23-96
O-RING Replace
A v
TDC/CKP/CYP SENSOR Troubleshooting, section11 Do not disassemble.
DISTBIBUTOR IGNITION HOUSING {DI}

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: . See section11 when the mallunctionindicatorlamp (MlL)turned on. . 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 systems. ignitionsystemand the fuel and emissions 1. Removethe distributorignition{Dl)cap,the distrib utor ignition(Dl)rotor and the leakcover(TECl. the Disconnect wires from the lCM. 3. Turn the ignition switch ON (ll). Checkfor voltage the BLK//ELwire and body ground. between Thereshouldbe batteryvoltage. . lf there is no batteryvoltage,checkthe BLK/YEL fuse/relay box and wire betweenthe under-dash t h eI C M . go . lI there is batteryvoltage, to step4.
2.
Turn the ignition switch ON (ll). Checktor voltage between wire*r and body ground. the Thereshouldbe batteryvoltage. . check: lf there is no batteryvoltage, - theignition oil. c - t h e * r w i r e b e t w e e n h e i g n i t i o nc o i l a n d t h e t tcM. go . lf there is batteryvoltage, to step5. * 1 : B L U 'w i r e ( H I T A C H I ) wire (TEc) WHT/BLU A Chec. connector 132P). the Disconnect ECM/PCM w f o r c o n t i n u i t yo n t h e Y E L / G R N i r e b e t w e e nt l " . and ECI\I/PCM the lCM. Thereshouldbe contanuity. 6. wire to boc, Checkfor continuityon the YEL/GRN ground. Thereshouldbe no continuity. t o f C h e c k o r c o n t i n u i t y n t h e B L U r w i r eb e t w e e nh e and the lcM. connector testtachometer Thereshouldbe continuity. on for Check continuity the BLU'wire to bodyground Thereshouldbe no continuity. 9. the lf all the testsare normal,replace lCM.
HITACHI:
BLK/YEL BLU'WIRE WIRE YEL/GRN 7.
TEC:
WIRE BLK/YEL
23-95
lgnition System
lgnition Coil Test
Using an ohmmeter, measure resistance between the terminals.lf the resistance not within soecifications, is replace ignitioncoil. the NOTE: Resistance will vary with the coil temperature; specifications at 68'F (20'C). are HITACHI: Primary Winding Resistance (Between A and B terminalsl: the 0.45- 0.550 SecondaryWinding Resistance (Eetweenthe A and secondarywinding terminalsl: 22.4- 33.6 k{r
TERMINALB {-I TERMINAL (+ A
lgnition Wire Inspectionand Test

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 pulling on the rubber boots. Do not bend the wires; you might break them inside. 1. Check the conditionof the ignitionwire terminals. lf anv terminalis corroded, cleanit. and if it is broken or distorted, replace ignitionwrre. the
Check broken, for corroded, and benl terminals.
IGNITION WIRE
2. TEC: Primary Winding Resistance {Betweenthe A and B terminalsl: 0.63- 0.770 SecondaryWinding Resistance (Betweenthe A and secondarywinding terminals): 12.8- 19.2kO
SECONDARY WINDING TERMINAL
Connect ohmmeterprobesand measureresistance. lgnition Wire Resistance: 25 kO max. at 68'F (20"C)
@
A TERMINAL {+
O
IGNITION WIRE 3. B TERMINAL (_) lf resistanceexceeds 25 kO, replace the ignition wire.
23 -9 6
lgnition System
lgnition Coil Test
Using an ohmmeter, measure resistance between the terminals.lf the resistance not within soecifications, is replace ignitioncoil. the NOTE: Resistance will vary with the coil temperature; specifications at 68'F (20'C). are HITACHI: Primary Winding Resistance (Between A and B terminalsl: the 0.45- 0.550 SecondaryWinding Resistance (Eetweenthe A and secondarywinding terminalsl: 22.4- 33.6 k{r
TERMINALB {-I TERMINAL (+ A
lgnition Wire Inspectionand Test

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 pulling on the rubber boots. Do not bend the wires; you might break them inside. 1. Check the conditionof the ignitionwire terminals. lf anv terminalis corroded, cleanit. and if it is broken or distorted, replace ignitionwrre. the
Check broken, for corroded, and benl terminals.
IGNITION WIRE
2. TEC: Primary Winding Resistance {Betweenthe A and B terminalsl: 0.63- 0.770 SecondaryWinding Resistance (Betweenthe A and secondarywinding terminals): 12.8- 19.2kO
SECONDARY WINDING TERMINAL
Connect ohmmeterprobesand measureresistance. lgnition Wire Resistance: 25 kO max. at 68'F (20"C)
@
A TERMINAL {+
O
IGNITION WIRE 3. B TERMINAL (_) lf resistanceexceeds 25 kO, replace the ignition wire.
23 -9 6
SparkPlugInspection
1. for: and ceramicinsulator Inspect electrodes the 2. gap. Check electrode the !
. lmproper gap . Oil-fouling . Carbon deposits . Cracked center insulator electrode
worn or deformod
gappingtool. Adjustthe gap with a suitable
ElectrodeGap Standard 8 I t.t 8 mm (0.043 oo,in)

'l.l mm (0.043 in)
Damaged gasket
is Replace plug if the centerelectrode rounded the as shownbelow:

ROUNDED ELECTRODE
Burned or worn electrodesmay be causedby: . Advanced ignitiontiming . Loosesparkplug . Plug heat rangetoo low . Insufficient cooling Fouledplugs may be causedby: . Retarded ignitiontiming . Oil in combustion chamber . lncorrect sparkplug gap . Plug heat rangetoo high . Excessive idling/lowspeedrunning . cloggedair cleanerelement . Deteriorated ignitioncoil or ignitionwires EngineTypes D16Y5 D16Y7, D16Y8 3.
ll
I r----a
Fq-
SparkPlugs
Z F R 4 F . 1 1N G K ) { ( KJl4CR-111DENSO)
(N ZFR5F-11 GK) (1 K J 1 6 C R - 1 1D E N S O )
compound to Apply a small quantity of anti-seize and screwthe plugs into the cylinthe plug threads, Then torque them to 18 N m der head finger-tight. (1.8kgf.m,13lbf.ft).
23-97
Gharging System
CHARGING SYSTEMLIGHT (ln the gaugeassembly)
UNDER.HOOD FUSE/RELAY BOX replaceable ELECTRICAL j LOAD i*Has (ELD) I DETECToR UNIT 1
BATTERY lest, page 23-77
E]
page23-100 Troubleshooting, page23-105 Replacement, page23-106 Rectifier Removal, Rectifier Test,page23-107 page RearBearing Beplacement, 23-109
ALTERNAIORBELT Inspection Adjustment, page23-110 and
trr
CircuitDiagram
BOX FUSEiRELAY HOOD UNDER
No41(8OA)
,.4\
No42(40A)
,/T\ I BAT \ tcl \3-l

I
I ON]TION ,t S W T C H
BLKiYEL
GRN]RED
UNDER,DASH FUSE/BELAY BOX
I
WHT/GFN BLK/YEL
WHT/BLU
1,,*' T"*
REGULATOR VOLTAGE
ALTERNATOR
23-99
Charging System
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: (seepage23 771 1. Battery 2. Chargjng systemlight 3. Voltage 4. Alternator controlsystem(USA) 5. Alternator/regulator ChargingSystem Light Test
Charging SystemLight Chck-1: Make sure the charging system lightcomeson.
Doesthe charging system lightcome on?
Ch.ck lor a blown No. 15 {7.5Al fuse and a blown chargingsystem light bulb. lf the fu3e and bulb are OK, ropair tho opon in the wHT/BLU wila.
Charging Systcm Light Ch6ck-2: Startthe enoine.
Does charging the system lightgo off?
ALTERNATOR CONNECTOR 4P
{usAt
.-l1l 2l
Vollage Chock: Measure voltageat the No. 1 the of lNo.2lterminal the 4PI3Plconnectorwith the ignition switch ON flr). IG {BLK/YEL)
I l-T;l
Wire sideof terminals female
(v)
t I
Ropair the opon in the BLK/YEL wire bstwogn tho dternrtor and under{a3h f uio/relay box.
3P ALTERNATOR CONNECTOR {Canadal
femaleterminals IG IBLK/YELI
(To next page)
[ ]: Canada
23-100
)
(Fromprevious Page) ALTERNATOR'PCONNEGTOR
{usAt
.-r l l l 2 l Wire sideof

Chgck for an open in the L circuit-1: 1. Turnthe ignitionswitchOFF. the 4P [3Pl con2. Disconnect nectorfrom the alternator. 3. Groundthe No. 3 terminslof the 4P[3Plconnector. 4. Turn the ignitionswitchON (ll).
-rL
t-T;t femaletermrnals
IWHT/BLUI
Doesthe charging system lightcome on?
Turn the ignition switch OFF,and repair tho opon in tho wHT/ gLU wile.
3P ALTERNATOR CONNECTOR {Crnadal Wire sideof temaleterminals

L
IWHT/BLU)
-+.t 2
1 1
l.T;l
l)
-rl
'w"l".ur
Chock for an op6n in the L cir' cuit.2: the Disconnect No. 3 terminalot r t h e 4 P t 3 P lc o n n e c t ot r o m t h e ground.
systgm Doesthe charging lightgo ofi?
(WHT/8LUI
Turn the ignition 3witch OFF,and rgpair tha 3hon to ground in the wiro. WHT,/BLU
[ ]: Canada
(conl'd)
23-10
Charging System
g Troubleshootin {cont'dl
Alte.nator Control System Tost IUSAI NOTE:Beforetesting, checkproperoperation the ELDby confirmingwith the MIL (seesection11). of BATTERY
Chockfor a short in tha circuit (Al-TClinel: 1, Reconnect the 4P connector to the alternator. 2. Startthe engine, and turn the (highbeam)ON. headlights 3. Measurevoltage between the 4P connectorterminal No. 2 and the positive terminal of the baftery. CAUTION: Be sure to use a voltmetr with its plus terminal connctedto bat, tery plus and i$ minus torminal to the 4P connectortemrinal No. 2.
c
{WHT/GRNI Wire sideof femaleterminals ALTERNATOR ilP CONNECTOR
ECM/PCMCONNECTOR I32PI A 1 ls there1 V or less? 2 3

1
9 , 1 0 11
1 2 1 3 1 4 1 5 1 6 1 7 1 8 1 9 20 21 22 23 2a 25 26 21 Check for an open in the wire IALTClinel: 1 . T u r n t h e h e a d l a g h tn d i g n i a taonswitchOFF. 2. Disconnect 32Pconnector the from the ECM/PCM. 3. Checkfor continuitybetween the ECM/PCM 32P connector terminalNo. 19and alternator 4Pconnector terminalNo, 2. Wire sideof temaleterminals
30
ATLC IWHT/GRN)
([,
1 Wire sideof femaleterminals 3
_f
IWHT/GRN)
2 ALTERNATOR .I'UUNNEUI(,K 4
ls therecontinuity?
Rep.i. open in tho wi.e bolwocn the.lternator.nd ECM/PCM.
ECM/PCMCONNECTOR {32P} A Checkfor short in the wire {ALTC line): 1 . T u r n t h e h e a d l i g ha n d i g n i t tion switchOFF. 2. Disconnect 32Pconnector the from the EClvl/PcM. 3. Checkfor continuitybetween the ECM/PCM 32P connector t e r m i n a lN o . 1 9 a n d b o d y grouno, 1 2 3
I
6 1 7
30 I I
10 11
12 13 lil
l 5 1 5 1 1 1 8 t 1 9 20' 21 22123 21
25 26 Wire side of femaleterminals
ATLC WXf/CnXl
[]
Substitute a known-good ECM/ PCM,and recheck. ll prescribdvoltage is now avail" able, replacethe original ECM/ PCM,
ls therecontinuity?
Repairshort in th wi.e betwen th alte.nator and ECM/PCM.
23-102
i-_*_lffi*
Alternator/BegulatorTest (seepa9e 23-77]charged NOTE:Makesurethe batteryis sufficiently

lest_'l : Alternator/Regulator 1 . C o n n e c ta S u n v A T - 4 0 ( o r equivalent tester), ano lurn the selectorswitch to Posilion 1(stanang). in 2. Shift to neutral(A,/T 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 t h e r a d i a t o rf a n c o m e s o n , then let it idle. 3 . R a i s et h e e n g i n es P e e dt o rpm,and hold it there. 2,000 LOADADJUSTER ICARBONPILE) FULLFIELO TESTER LEAD IBLU} VOLTMETER NEGATIVE
(BLK}
r[@*.:
lrffil @ .gdi
VOLTMETER POS|TIVE LEAD IREDI
ovor 15.1V? ls the voltage
FIELD SELECTOR
swtTcH
INDUCTIVE PICK-UP {GRN)
TESTER NEGATIVE CABLEIBLKI TESTEi POSITIVE CABLE(REDI
Ahernator/negulatorTesl-2i the 1. Felease accelerator Pedal, and let the engineidle. are 2. Makesure all accessories turned off. Turn the selector 2 to switch position (charging). the 3. Remove inductive 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 rpm,and hold it there 2,000
INDUCTIVE PICK.UP
TIVE TERMINAL
V? lessthan 13.5 ls the voltage
Test-3: Alternator/Regulator Apply a load with a VAT-40until the battery voltage droPs to '13.5 V. between12-
To next page
(cont'd)
23-103
Gharging System
(cont'dl Troubleshooting
page Fromprevious
ls the amperage A or more? 50
The chargingsystem is OK.
Alternator/Regulator Test-4: W i t h t h e e n g i n e s p e e ds t i l l a t 2,000 rom,full-field alternator. the
CAUTION:The voltago will rise quickly when the alteinato. is tull-fielded.Do not.llow the voltage to exceed18 V; it may damagethe electricalsystem. NOTE:Aftacha probeto a VAT 40 full fieldtest lead,and insertthe probeintothe fulj field access holeat the backof the alternator. posiSwitch Iieldselector the "A (Ground),. the to tion momentarily, check amperage and the reading.
23-104
AlternatorRePlacement
from belowthe vehicle the NOTE: Remove alternator 1. cable,then disconnect the batterynegative Remove cable. the Positive from the alterthe Disconnect 4P (or 3P) connector naI0r.
TERMINALNUT 7.85 N.m (0.8kgf m, 5 79 lbtft) UPPER MOUNT BRACKET EOLT 44 N.m {4.5kgl.m,33lblftl ALTERNATOR BOLT ADJUSTING 24 N.m {2.4 kgf'm, 17 lbf ft)
4.
b R e m o v et h e a d i u s t i n g o l t a n d t h r o u g h b o l t n u t , beltfrom the pulley' then removethe alternator
2.
)
| ): Canada
4P lor 3P) CONNECTOR 44 N.m (4.5ksf m.33 lbIftl MOUNT LOWER BOLTS BRACKET 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. removethe mount bracketbolts, and lf necessary, the upperand lower mount brackets Adjust the alternatorbelt tension after installation ( s e e a g e2 3 - 1 1 0 ) . p
b.
1.
23-105
Charging System
RectifierRemoval
1. Remove four throughbolts. the 3. Sepa.ate rear housingfrom the drive-end the housing by inserting flat tip screwdriver a into the openings and pryingthem a part. Be carefulnot to damagethe statorwith the tip of the scfewdriver,
REAR HOUSING
DRIVE-END HOUSING
S e p a r a t eh e r e a r h o u s i n ga n d d r i v e - e n d o u s i n g t h with the statorattached the rearhousinq. to Heatthe rear bearingseatwith a '1,000 hair drier W for aboutfive minutes(120- 140"F, - 60"C), 50
HAIR DRIER
REAREEARING SEAT
23-106
RectifierTest
5. the rear housing from the stator/rectifier Separate assemblyby removingthe four screwsand the terminal nut. to NOTE:The diodesare designed allow currentto pass in one directionwhile blockingit in the oppositedirection. Since the alternator rectifier is made up of nine diodes,each diode must be testedfor continuityin both w d i r e c t i o n s 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 a capability; total of 18 checks 1. between for Check continuityin eachdirection - the B and P terminals. - the B' and P terminals. - E (ground) and the P terminals. All diodesshould havecontinuityin only one direction.
from the statorleads the Unsolder recti{ier . To avoid damagingthe diodes with heat, pinch the stator leads between pliers to carry heat off, and applythe solderingiron only long enoughto the separate leadsfrom the rectiller. iron. . Use a 100W soldering assemthe lf anv of the diodesfails,replace rectifier (Diodes not available separately.l are bly.
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
Charging System
RotorSlip RingTest
1. Check resistance the between slip rings. the Thereshouldbe 1.8- 3.0ohms. . lf resistancemeetsthe specification, to step 2. go . lf resistance oes not meetthe sDecification. d replace alternator. the
AlternatorBrushInspection
1 . Separate drive-end the housingfrom the rear housing as described page23-106. on Separate the rear housingfrom the stator/rectifier assemblyby removingthe four scrswsand the terminal nut from the rearhousing(seepage23-,|06). 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: (NEW) O Standard 19.0mm (0.75in) Limit O Service 5.0 mm (0.20in)
FOTORSHAFT
Checkthat there is no continuitybetweenthe slip ringsand the rotoror rotor shaft. lf the rotor fails eithercontinuitycheck,replace the alternato r.
StatorTest
1. Checkthat there is continuitybetweeneach pair of leads.
lf the brushesare lessthan the servicelimit, replace them.
cotL CORE
Check that there is no continuitybetweeneach lead and the coil core. lf the coil fails either continuitycheck,replacethe alternator.
23-108
RePlacement RearBearing
1. Pulloff the rearbearing. . Makesure the tips ot the bearingpullerjaws are thin enough to fit betweenthe bearingand the slip rings. . Do not reusethe bearing.
AlternatorReassemblY
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) holdthem there to
SLIPRINGS
PULLER BEARING
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 After heating,continue describedon page 23-106. beforethe rear bearwith assembling immediately ing seatcoolscompletely. assemblyand drive-end Put the rear housing/stator housing/rotorassemblytogether,tighten the four throughboltsand pull out the Pin.
Apply Use a hand pressto installthe new bearing. pressure only on the inner raceto avoid damaging the bearing.
BRUSH ACCESS
BOI,T THROUGH
REARBEARING SLIPRING
*,
REAR STATOBASSMBLY
turn the pulley by the alternator, After assembling hand to make sure the rotor rotatessmoothly and without noise.
23-109
Charging System
AlternatorBelt Inspection and Adjustment
DetloctionM6thod: Apply a force of 98 N (10 kgt,22 lbf), and measurethe deflection between the alternator and the crankshaft oulDeflection mm {0.31 0.41in} | 8.0- 10.5 Belt Tension Gaug Method: Followingthe gauge manutacturer,s instructions. attach the special tool to the belt,and measure tension. the Tension I 340-490N(35-50kgf,77-j10tbf)
NOTE: On a brand-newbelt {onethat has beenrun for less than five minutes), deflection the shouldbe 6,0- 9.5 mm (0.26 0.33in) when first measured. the belt is worn or lf damaged. replace it,
Measure here. 24Nm12.4kgf.m,
NOTE: On a brand-new belt (onethat hasbeen run for less than five minutes),the tension should be S4O -740 N (55- 75 kgt 121- 165lbf) when firsrmeasured. the belt lf as worn or damaged, replace it.
CRANKSHAFT PULLEY
BELT TENSION GAUGE 07JGG 0010'l0A
lf adiustmentis ncessary: l.
2.
Loosen lower the mounting andtheupper nut mounting bolt. Movethe alternator obtainthe properbelttension, to then retighten uppermountingbolt andthe lower the mountingnut to the specified torques. Recheck deflection the belr. the of
lf adiuslment is ncossary: 'L Loosen lowermountingnut andthe uppermountthe ing bolt. Movethe alternator obtainthe properbelttension, to then retighten uppermountingbolt and the lower the mountingnut to the specified torques. Recheck tensionot the belt. the
2.
3.
3.
23-110
FanControls
. -ri -rT _tF-1tr'l
t I r-r T-t T-l
FAN RELAY RAOIATOR Test,page23 73
,-, LJ L_JL_J I___I tQ -l r _ -
U LJL-Jrr
FAN RELAY CONDENSER Test,page23 73
UNOER-HOOD
CONOENSER FAN MOTOR
FAN MOTOR
Removal,section 10
COOLANT ENGINE (ECTI TEMPERATURE
swlTcH
section10 Removal, Test, section10
23-111
FanControls
CircuitDiagram
UNDEF.HOOD RELAY FUSEi BOX No4r i80A) No42(40A)
UNDER.DASI-1 FUSEi RELAY BOX
IGNITION TCH SW
-YEL-.].--o.\-F-h
l-'"----E l
-l
yEL BrK -J
BLKi RED
l,^,^,", ,J" 1,,**, T*' twl.i-:;"
I I
I I I
-:
BLK
f
t
BLK
G20l
G101
23- 1 1 2
GaugeAssembly
Index Location Component
in precautions' and procedures the sRS are locatedin this area.Reviewthe sRS componentlocations, sRS components performingrepairs service. or section{24}before
6x1.0mm 9.8 N.m (1.0 kg{.m, 22 tbt.ftl
SENSOR SPEED IVSS) VEHICLE 23 Troubleshooting, Page 124 UNIT SENDING GAUGE FUEL Test,page23'126
GAUGEASSEMBLY Gauge/lndicator/Terminal 23_114 Index, Location Page page23-119 Removal, BulbLocation, Page23 120 page23-122 Disassembly,
BRAKESWITCH
FLUIDLEVELSWITCH
SWITCH ENGINEOIL PRESSURE
IECT)GAUGE TEMPERATURE ENGINECOOLANT SENDINGUNIT
23-113
GaugeAssembly
Gauge/lndicator/Terminal LocationIndex
With tachometer:
"A" CONNECTOR (A/T GEAR POSITION INDICATOR) A1- - --+A6 lrl..::.fi| "8" CONNECTOR {GAUGEand INDICATOR} B1----------{-Bt6 "C" CONNECTOR
c 1- - - - - - - - - > c 1 3
t.t_..-ts| ---47 - ->A14
Jililil{ililt1 JililtHililL
.' "3{\
o o
D1- --->D5
Fl- - --> F5
"O" CONNECTOR {ABSINDICATOB}
"E" CONNECTOR
or I sHrFr-up cRU|sE I lrNDrcAToR I
"F" CONNECTOR (SRSINDICATOB}
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 vehiclespeed sensor (VSS).
A/T GEARPOSITION INDICATOR Seepage23-133
oa/
\oo
TACHOMETER: Indicates rpm at 100 per minute 200pulses of the ignitioncontrol ( modulelCM).
FUEL GAUGE page23 126 Gauge/Sending LJnitTest,
2 3- 1 1 4
EI'
Without tachometer: "A" CONNECTOR INOICATOR} tA/T GEARPOSITION
"B" CONNECTOR and IcAUGE lNDlcAToRl

8 1 . - - - - - - -- - - . - - - - - - + 8 1 6
"C" CONNECTOR INDICATORI IcAUGE and C1-----.---.--->C13
---->414
lilillllllL Innrruttttttl
\J
, 6
(Ju gr A: a-) s
Dl--->05 "D" CONNECTOR IABS INDICATOR) SPEEDOMETER: lndicates km/hat 637rpm or 60 rpm of the 60 mph at 1,025 (VSS). vehicle speedsensor
Fl--) F5
oo/
\oo
(ECT) GAUGE TEMPERATURE COOLANT ENGINE 5 Seesection
FUELGAUGE Unit Gauge/Sending Test,page23 126
23-115
GaugeAssembly
CircuitDiagram
U N D E R . H OF U S E i F E LB O X OD AY UNDER ASH D FUSEi RELAY BOX
N 0 . 3 ( 75 A ) 0 FUSE
V I
RED/BLK RED/BLK
CHAFGING SYSTEM LIGHT
GAUGE LIGHTS l3wx4 |
WHTIBLU
l"'
FED
I I
I
BLK I I
I l"
l
RED/GRN
T lt " t
t l i I l v
I I
' UNIT
TEFNATOF
+
DASH LIGHTS ERiGHTNESS CONTFOLLEF
L'*'(Wilh shillup ndicalor tighl) G401
t+
WHT/RED
*i"' I
t l
cRUlsE CONTROL
i I
i
BLK BLU
l"l'
olsyslem)
1",,-' I I
G401 G402
IJ
23- 1 1 6
ECM/PCM + BLKAVHT
l_"'f"'
(With lachomele0
TUFNS]GNAL' H A Z A RW A R N I N G D SWITCH LEFT F]GHT
: rc-,w'oi-_l CoNTROL
I I |
No.5ll0A)
V I
r-7 t t
f-7 l
t v I
MODULE (cM)
I I i
l GRN/RED CRN/YEL
i , l" ,i l l l
ENGINE COOLANT TEMPERATUFE {ECT) GAUGE
GAUGASSEMBLY E
RIGHT TURN SIGNAL INDICATOR L GHT
To NEXT PAGE
LOW FIJEL INDCATOF LIGHT
(3w)
8LK BtUtRED
BLK
ABS CONTROL IJNlT
ENGINE COOLANT TEMPERATURE (ECT) SEND I]N T NG
BLK
G401 G402
o,1o,
G4A2
G552
I
{cont'd)
23-117
GaugeAssembly
(cont'dl CircuitDiagram
GAUGE ASSEMBLY PREVOUS PAGE
ERAKE SYSTEM LGHT (1.4w)
SEAT BELT REMINDER LIGHT (1.4W)
) ./
C 't
\ './
TRUNK INDICATOS LIGHT 0.4w)
LOW OtL MALFUNCTION PRESSURE INDICATOS INOICATOR LiGHT (MrL) (1.4W) 0.4w)
B6
83
_i
PARKING BFAKE SW TCH up ) fclosedLever (Opn Leverdown J BLK
v l ,.y." I
|
| ,"",.
YEUFED GRN/ORN
swiTcH : down lolosedFloal

(Open FloalLrp
ERAKE FLUIO TEVEL
rRUNK :Unbuckled folosed l lopen :Euckled .l
,,,,,,,**, *.","n, i'iiifl rp rlt*i'!l*,
I
23-118
T
G552
BLK
c401 G402
t
:
Removal
1. 2.
panel. the Remove two screwsfrom the instrument Remove the instrument Panel. CAUTION: Carelully remove the instrument panel without damaging the clips'
3.
lever. wheeldown with the tilt adjustment Tilt the steering column cloth overthe steering Spreada protective
5. 6. 7.
Remove four mountingscrewsfrom the gaugeassembly. the from it' all out, and disconnect connectors Prythe gaugeassembly Takeout the gaugeassembly.
GAUGEASSEMBLY
INSTBUMENT PANEL
23-119
GaugeAssembly
(With Tachometerl Bulb Locations
\
TRUNKINDICATOR (1.4 LTGHT W) GAUGE LIGHT {1.4wl
CHARGING SYSTEMLIGHTI1.4 WI (1.4 LTGHT W) LOW ENGINE OIL PRESSURE INOICATOR LIGHT{1,4WI MALFUNCTION INDICATOR LAMP IMIL}
SEATBELT REMINOER LIGHT {1.4W} LOW FUELINOICATOR LIGHT 13W}
BRAKESYSTEM {1.4Wl HIGHBEAM INDICATOR LIGHT W {1.4 )
W t1.4 l
RIGHT TURN SIGNAL INDICATOR LIGHTI1.4WI LEFTTURN SIGNAL INDICATOR LIGHT{T.4WI
A/T GEARPOSITION INDICATOR x 11.12 6l {Onthe printed circuitboard)
GAUGELIGHTS{3 WI GAUGE LIGHT I3.4W}
(1.4 SRSINDICATOR wl {Onthe printed circuitboard) CRUISE SHIFT-UP (1.12Wl or INOICATOR {Onthe printedcircuitboard)
aBs tNDtcAToR Wt t1.4 the {On printed circuit board)
23-120
E'|
(WithoutTachometerl Bulb Locations
TRUNKINOICATOR SYSTEMLIGHT(1.4WI CHARGING LTGHT W) tl.4 GAUGE LIGHT {1.,1W) LIGHT GAUGE I1.{ W) BRAKE SYSTEM (1.{ W) LIGHT LOW ENGINEOIL PRESSURE SEATBELT TORLIGHT I1.4W) REMINDER LIGHT I1.4WI MALFUNCTION LOW FUELINOICATOR INOICATOR LIGHT(3 W) LAMP {MILI BULB(1.4W} TURN SIGNAL RIGHT LIGHT INDICATOR {1.4W} LEFTTURNSIGNAL INDICATOR LIGHT{1.,rwl
o /
A/T GEARPOSITION x INDICATOR {1,12 6) {Onthe printed circLrit board)
GAUGELIGHTS13W)
sRs tNDtcAToR W) t1.4

{Onthe printedcircuitboard) GAUGELIGHT Wt 13.4
ABStND|CATOR Wt t1.4 circuit board) {OntheDrinted
J
23-121
Assembly Gauge
Disassembly{With Tachometer)
NOTE: Handle the terminals and printed circuit boards c a r e f u l l y o a v o i d d a m a g i n gt h e m . t
e F - -.g
-^^ e\J
!=r c) ./
i'\ \\
.,:
o @', I o 1
\sê'-----"' \\.Q , ' I u t/@@

;=1
o,,o.
".,,Yu
@ /+i
PRINTED CIRCUIT
d,@
,-@ ob,
.,- Il $
| ""il\r
CRUISE SHIFT-UP or INDICATOR PRINTEO CIRCUIT BOARD TACHOMETER page23-1 Specification, 14 ABS INDICATOR BOARD PRINTED CIRCUIT
ts*u"El
A/T GEARPOSITION INDICA PRINTEO CIRCUIT BOARD
FUELand ENGINE COOLANT TEMPERATURE {ECTI GAUGE AUGE
@ * lI
\ \,/
METERPANEL
l6$-
23-122
(WithoutTachometer) Disassembly
NOTE:Handlethe terminalsand printed circuit boards to carefully avoiddamagingthem.
ID
i ; , i ,,,Y
'.oo..-----..\ '.o.,' \( o\
+ o l 6,,
\ [ J e
oOOo -z\\
FUELGAUGE {x MOUNTINGSCREWS 3}
TEMPEMTURE ENGINECOOLANT lx GAUGEMOUNTINGSCREWS 3l
' o @
,"o "
rmhiffi
.w-r?ft
A V
@
ôo
rugF5w
\\''$f ,a._d\
\
\
ABS INDICATOR BOARD PRINTED CIRCUTT
PoslrloN lNolcara A/T GEAR BOARO PRINTED CIRCUIT
.nd SPEEDoMETER METER ODO/TRIP page Specification, 23'115
ri\\,.j 4 \.{
D,l
GAUGE FUEL Tost, page 23-126
METERPANEL
J
23-123
VehicleSpeedSensor(VSSI
Troubleshooting
Before testing,inspect the No. l5 (7.5A) fuse in the under-dash fuse/relay box.
Test ths 8LK wire: 1. Disconnect the 3P connector trom the vehicle speedsensor
(vss).
2. Connect the test harness only to the 107LAJ PT30200) wire harness. engine 3. Connect REDtest harness the clip to the positive probe of a ohmmeter. 4. Check for continuity between the REDtest harness clip and body ground.
Repairopen in th. BLK wire botwoen the VSS and G101.
vss
Tesi tho BLK/YELWir: 1. Connectthe WHT test harness clip to the positive probe of a voltmeter, and connect RED the test harness to the negative clip probe. 2. Turnthe ignitionswitchON (ll).
Repairopen in the BLISYELwire betwoon tho VSS and tho underdash tuso/.slay box.
(Tonextpage)
23-124
-
(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 c l i p t o t h e p o s i t i v eP r o b e o f a voltmeter,and connectthe RED clip to the ngative test harness probe.
TESTHARNESS O7LAJ. PT3O2OA
REDTESTHASNSS
CLIP
ls thereabout5 V or more?
Repairopen in ihe BLUMHT wire bctween lh6 VSS and ECM/FCM, TCM {CWl, snd ctui3 control unit
PROTECTIVE TAPE
T6st the vSS: 1. Turnthe ignitionswitchOFF. 2. Connect the other test harto nessconnector the VSS the front of the vehicle, 3. Raise and support it with satety stands, with 4. Putthe vehiclein neutral the ignitionswitchON (ll) 5. Slowly rotateone wheel with the otherwheelblocked
CLIP GRNTESI HARNESS
Doesvoltage pulse from 0 to approx,5V or more? "8" 16P GAUGE ASSEMBLY CONNECTOR SpeodometelTost: the 1. Disconnect 16Pconnector " B " f r o m t h e g a u g ea s s e m _ 2. Toucha probeto the BLU,ryVHT wire, and connect it to body groundthrougha voltmeter. 3. Slowly rotate one wheel with the otherwheelblocked. femaleterminals
pulsthe meterindicate Dos ing voltage?
Ropairopsn in th BLU/WHTwire between tho VSS and the spo.d' meter.
23-125
FuelGauge
Gauge/Sending Unit Test
!@s@ Do nor smoKewnre worxrngon tne ruet
7. system, Keepopen flame away from yout work area. NOTE:Referto page 23-117 the fuel gauge system for crrcutl. 1. Check No. 25 (7.5A) fuse in the under-dash the fuse/ relaybox beforetesting. Remove access panelfrom the floor. the
ACCESS PANEL
Check that the pointerof the fuel gaugestartsmoving toward the "F" mark. CAUTION: Turn the ignition switch OFF betore the "F" on pointerreaches the gaugedial. Failure do to so may damagethe tuel gauge. NOTE|The fuel gauge is a bobbin (cross-coil) type, hencethe fuel level is continuouslyindicated even 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 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 t h e g a u g e . e lf the gauge is OK, inspectthe fuel gaugesend ingunit.
2.
8.
Remove fuel gaugesendingunit as shown. the Japan-produced
FUEL GAUGE SENDING UNIT
femaleterminals
D i s c o n n e ct th e 3 P c o n n e c t o f r o m t h e f u e l g a u g e r sending nit. u
4.
IJSA. Canada-Droduced
Connectthe voltmeter positiveprobe to the No. 2 terminaland the negativeprobeto the No. 1 termin a l ,t h e nt u r n t h e i g n i t i o n w i t c h N ( l l ) . s O Thereshouldbe between and 8 V. 5 . . lf the voltageis as specified, to step 5. go lf the voltageis not as specified, check for: - an open in the YEL/BLK BLKwire. or - p o o rg r o u n d( G 5 5 2 ) .
FUELGAUGE SENDINGUNIT
5. 6.
Turn the ignitionswitchOFF. Attach a jumper wire betweenthe No. 1 and No. 2 t e r m i n a l s h e nt u r nt h e i g n i t i o n w i t c h N ( l l ) . t, s O
23-126
E1
9. the No 1 and No. 2 between Measure resistance the 1 t e r m i n a l sa t E ( E M P T Y ) , / 2 ( H A L FF U L L )a n d F (FULL) movingthe float. by (Ceramic boardtypel: USA,Canada-produced
FIoat Position
(O) Resistance
105 108
1/2 29.5- 35.5
3.5-5
Japan-Produced {Wire-woundtype)' FloatPosition (O) Resistance
E
105 110 25.5 39.5
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 )
readings are beyondthe range,replace lf the resistance u s t h e f u e lg a u g e e n d l n g n i t .
23-127
4 __r.*_
InterlockSystem
INTERLOCK UNIT InputTest,page23 130
KEYINTERLOCK SOLENOID SWITCH and KEYINTERLOCK (ln the steering lockassembly) Test,page23 131
6'm
, \-/ \-!J
PARKING SWITCH PIN Test,page23-132 SHIFTLOCKSOLENOID Test,page23-131
23-128
BOX FUSE]RELAY UNDER.HOOD
(40A) No41(80A) N0.42
GRN]WHT YEL
nro feurrrn 0 l sleer

[o* -]
ftoL{Eu'flil' +
GRN/WHT
I
l
GRN'1flHT
J
INTERIOCK C RCUIT KEY
tfl
YELTBLK 3 r'lTGEAR POS TION INDICATOR
. BRAKE LIGHTS 'CRUISE CONTROT UNIT . ABS CONTROL UN]T . TCi,4 (CW)
UN1T NTERLOCK CONTFOL
17
WHT/BLK
I Yr
I
BLK G401 G402
BLK/BLU
BLK/BLU
N PARK G PLN TCH SW
J
G401
I
G401
BLK
l'
A,TT GEAR POSITLON SWITCH n ( Co s e d I np o s r l oE )
23-129
lnterlockSystem
ControlUnit InputTest
Disconnect 8P connector from the interlock conthe 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 r n d s o c k e tt e r m i n a l s o b e a t surethey are all makinggood contact. . lf the terminals bent,looseor corroded, are repair them as necessary, recheck system. and the . l f t h e t e r m i n a l s o o k O K , m a k et h e f o l l o w i n g l input testsat the connector. lf a test indicates problem,find and correct a the cause, then recheck system. the - l f a l l t h e i n p u t t e s t sp r o v eO K , s u b s t i t u t e a known-good controlunit, and recheck systhe tem. lf the checkis OK, the control unit must be faulty;replace it. 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 ignitionswitchis turned ON (ll) and you step on the brakepedal(with the shift leverin E), the shift lock s y s t e mi s e l e c t r o n i c a l ln o r m a l ;i f t h e s h i f t l e v e r y gear position cannotbe shiftedfrom E, test the A//T switch.parkingpin switch,and seesection14. t. Key Interlock System: Cavity
1
WHT/BLU
1 INTERI-OCK CONTROL UNIT

4
wHT sLr/glu wHrlneo

Wire sideof female terminals Possible cause if result is not obtained BlownNo. 48 (30A) fuse in the underhoodfuse/relay box BlownNo.33 (7.5Aifuse in the under dashfuse/relay box Faulty steering lockassembly (keyinterlock solenoid) An openin the wire . Poorground(G401, G402) . An openin the wire Poorground{G401, G402) Faulty switch M gearposition An openin the wire
Wire
Test condition
lgnitionswitchturnedto
Test: Desiredresult
C h e c kf o r v o l t a g e t o g r o u n d l There should be batteryvoltage.
WHT/BLU A C C( l l a n dk e yp u s h e d ; n
5
4
BLK BLI(BLU
U n d e ra l l c o n d i t i o n s
Shiftleverin E
Check continuity ground: for to Theresho(,ld continuaty. be lor to Check continuity ground: Thereshouldbe continuity.
the to controlunit. Reconnect 8P connector the interlock Shift Lock System: Cavity
2
Wire YEL
Testcondition
lgnitionswitchON (ll)
Test: Desiredresult
for Check voltage ground: to voltage. Thereshouldbe battery
Checkfor voltage to ground: There should be battery voltage.
Possiblecause if result is not obtained

' BlownNo. 25 (7.5A) fusein the under dashfuse/relay box . An openin the wire
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 dash fuse/relay box Faultyshift lock solenoid A n o p e n a nt h e w i r e
lgnition switch ON (ll)
YEUBLK ShiftleverIn E
BLK/8LU
lgnitionswitchON (ll) pedaldepressed Brake
Checkfor voltage to ground: There should be 1 V or less. C h e c kf o r v o l t a g e t o g r o u n d : There should be 1 V or less. C h e c kf o r v o l t a g e t o g r o u n d : There should be batteryvoltage.
WHT/RED B r a k e p e d a l a n d
accelerator depressed at the same trme
Poorground(G401, G402) gearposition Faulty A,/T switch An openin the wire BlownNo. 52 (15Alfuse in the under hoodfuserelaybox Faulty PCM Faulty 11) brakeswitch(seesection Faulty throttleposition {TP}sensor {seesectionl1) An open in the wire
23-130
KeyInterlockSolenoidTest
' 1 . R e m o v et h e d r i v e r ' sd a s h b o a r d o w e r c o v e r a n d l kneebolster{seesection20). f 2. D i s c o n n e ctth e 7 P c o n n e c t o r r o m t h e m a i n w i r e harness.
Shift Lock Solenoid Test

1.
201. the Remove tront console(seesection Disconnect shift locksolenoid2P connector. the Connect battery power to the No. 1 terminal and momengroundto the No. 2 terminalof the solenoid rarIy, NOTE: Do not connectpowerto the No. 2 (-) termipolarity)or you will damagethe diode nal (reverse insidethe solenoid.
3.
Checkfor continuitybetweenthe terminalsin each to key positionaccording the table.
;il;
lgnition switch ACC{r)
--
Terminal
--\
Key pushedin Key released
o-oo
--'o
when the release Checkthat the shift lock releases lever is pushed.and check that it locks when the leveris released. release the lf the solenoiddoes not work, replace solenoid
4.
Checkthat the key cannot be removedwith power to and ground connected the No. 7 and No. 5 termi n al s . . . lf the key cannot be removed,the key interlock solenoidis OK. lf the key can be removed,replacethe steering (the interlock solenoidis not availlockassembly able separately).
I
23-131
Interlock System
ParkingPin Switch Test
1.
Remove front console(seesection20). the Disconnect the 4P connectorfrom the parking pin switch. Checkfor continuitybetweenthe No. 3 and No. 4 terminals with: - 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 button released. Thereshould be no continuity.It necessary, replace parkingpin switch. the
2.
NOTE: Parkingpin switch 4P connectorNo. 1 and No, 2 terminals are for A,/Tgear position console light,referto the circuitdiagramon page23-134.
23-132
Indicator A/T GearPosition
in precautions, and procedures the sRs are locatedin this area.Reviewthe sRs componentlocations, sRs components (24)beforeperformingrepairs service or section
INDICATOR A/T GEARPOSITION InputTest,Page23-136
E N E E E
E N E E B
(cvr)
SWITCH A/T GEARPOSITION Test,page23-138 Replacement, Page23-139
23-133
A/T GearPositionIndicator
CircuitDiagram
CW:
FUSE/RELAY BOX UNDER.HOOD
IGNITION SWTCH
\
UNDER-DASH FUSEi FELAY 8OX
t'*','uorl f..*fl I t l
. ECM . TCM YEL
N0.30 {7.54) FUSE
\-/
RED/BLK
(n A,4GEAR PoSlTloN NDICATORthegauge assenrbly)
LTGRN
NDICATOR DIMMING CIFCUIT A"/T GEARPOSITION
V Y Vl Yt t t
No30(7 5A)
NED/8LK
V I
t,
t'
l l
T/TGEAR POSTTl0N SWTCH
g'qen | ,,-k I
llqlcoNsoLEl I Y./ LGHT I
| | "'*'I
t
RED
OASH IGHTS L BRIGHTNESS CONTROLLER
I I
BLK
G401 G402
23-134
CircuitDiagram
Except CVT:
L R Y . \ O E P H O O D U S E E L AB O X UNDEF-OASH BOX FUSE/RELAY
RED/BLK (h T POS ONINDICATOR thegalgeassemby) l./TGEAR
PCM
A2
V
GRN]BL(
D]MI!,IING CIRCU]T ON A,TGEARPOSIT NDICATOR
YEL
I
No300.54)
RED
YYYY
I I
I
LIGHTS DASH B RG H T N E S S CONTNOLLER
REDi BLK
V I
t,
t l
\ \ l t / /
|{ ,L oe;"'lgn I l dlc NsotEl l Y i t e i l|

t
,t^jI
BLK
t' I I I
FED DASH LIGHTS BR]GHTNESS CONTROLLEF
A"|tGEAR T POS ON SWITCH
I-:
I I
G401 G402
(COnt d
23-135
A/T GearPositionIndicator
Indicator InputTest
1.
(seepage23-1'19), disconnect t4p connector Remove gaugeassembly the from the dashboard and the from rne gauge assembly. Inspect connector the and socket terminals be surethey are all makinggood contact. to . . lf the terminals are bent,looseor corroded,repa lhem as necessary,nd recheck system. ir a the lf the terminalslook OK,makethe followinginputtestsat the 14pconnector. - lf a test indicates problem, a find and correct cause, the then recheck system. the - lf all the inputtestsproveOK, but the indicator faulty,replace printedcircuitboard. is the
"A" 14PCONNECTOR
YEL
RED/BLK RED
BLU
BRN(*1I
A1
A2 A8
A3 A9 A10
A6
A 1 1 412 4 1 3 4 1 4
BLK
WHT
LT
GAUGEASSEMBLY
*1i Not used '2: ExceprCVT *3: CvT
23-136
Cavity A'I
Wire
Test condition lgnitionswitchON {ll)
Test: Desiled result for Check voltageto ground: Thereshouldbe batteryvoltage. for Check voltagebetween terminals: and RED/BLK RED Thereshouldbe batteryvoltage
Possiblecauseil result is not obtained . Blown No.25 (7.5A) fusein the box fuse/relaY under-dash . An open in the wire A B l o w nN o . 3 0( 7 . 5 ) f u s ei n t h e box fuse/relaY under-dash light switch Faultycombination dash lightsbrightness Faulty controller An open in the wire . Faulty switch gearposition A//T . An open in the wire
YEL
C o m b i n a t i o nl i g h t
A2
RED/BLK switch ON and dash

lights brightness control dial on full bright
A3
A4 410 A.12 413
RED BLU
GRN RED WHT
Shift leverin E or E Shift leverin [q] or E Shift leverin E Shift leverin @ Shift leverin E
to Ior Check continuity groundl Thereshouldbe continuity NOTE:Thereshouldbe no continuityin anYother Position
BLVBLU NOTE:Don't depress

the brakepedal. lgnitionswitchON (ll) and shift leverin anY positionexceptEl lgnitionswitchON (ll) GRN/BLK*' and shift leverin any positonexcept@
YEL*1
A9
for Check voltageto ground: voltagefor Thereshouldbe battery afterthe ignition tlvo seconds switchis turnedON (ll),and then lessthan 1 V. to for Check continuity ground: Thereshouldbe continuitY. for Check voltageto ground: . Thereshouldbe battery voltage*' . Thereshouldbe about5 V*r
TCM*' Faulty FaultyPCM*' An openin the wire
A8
BLK
a U n d e r l lc o n d i t i o n s
. Poorground(G401, G402) . An openin the wire TCM*' Faulty PCM*i Faulty An open in the wire
A14
LT GRN
*1: Except CVT *2: CVT
23-137
A/T GearPosition Indicator

A/T GearPositionSwitch Test
1. 2. 3. Remove front console the 20). lseesection Disconnect 14Pconnector gear position the from the Ay'T switch. Check continuity for between terminals eachswitchpositionaccording the table. the in to . . 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 described the next on page.
Terminal side o{ male terminals
A/T Gear Position Switch

\ Terminal
Back- up Light Switch 5 6 7

*1 I
1'
Neutral Position Switch l0

11
t**"\
(Not used)
l3
14
GCF
--o -_o --o -o --o -_o --o o- --o o- --o

CF
a tr
E E E E
N N
tr tr E tr 23-138
ooooo-
--o
* 1 : Withcruise controlsystem
A/T Gear Position Switch Replacement

1.
A/T GearPositionSwitch
Adjustment
1. 2. and loosenthe nuts' Shiftto the E position, Slidethe switchin the directionof El or E position in.)lso that there is continu'ty Iwithin 2.0 mm (0.079 betweenthe No. 1 and No.7 terminalsin the range of free play of the shift lever' for Recheck continuitybetweeneach of the terminals. NOTE: checkfor damage . It adjustmentis not possible, 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 switch' the replace console there is no damage, slart when the shilt lever is in . The engineshould position in the rangeof free play S
the 14P then disconnect Removethe lront console, A'/Tgear positionswitch from the connector nuts the Remove two mountang swrTcH SLIDER
3.
6 xl.0 mm 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 t P o s i t i o n h e s w i t c h s l i d e rt o above. 4. Movethe shiftleverto into posation. "Neutral", then slipthe switch
o{ Direction IDI or E Position in)l Iwithin 2.0mm (0.079
Fre play
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.
and clamp the harness, the 14Pconnector, Connect installthe front console.
LOCKPIN
23-139
Integrated ControlUnit
CircuitDiagram
UNDER,HOOD FUSE/RELAY BOX +WH'I WHT/8LK
WHT/RED
W NDSHIELD WIPERi WASHER 9WTTCH . OFF/INT INT
f7
t t
t
f7
l
8LU/BLK YEL/BLU
INTERMITTENT WPER BELAY CIRCUIT
* COMBINED WIPER WASHEH CIRCUIT
--1-lun^r,r-r
l$'lli3fl*"'I
ELU,JWHT
I
I I
i *'f--JI v
|
|
i
I
wHnBLK
BLK
r7
WINDSH ELD WIPER MOTOR
| ,,^v.,,
WASHER
"oto*
__
* With combrned washer on wiper opeGl
G40l G402
(ffr)
A/TGEAR POSITION SWITCH ( C l o s e d : p o s | o nl g o r [ N ] ) n
BLKI\lvHl
10\--l11
gr_r<rqrl
STARTER CUI FELAY
BLU,BLK+[:'##" I
COMBINATION LIGHTSW]TCH
f7
REDiGRN
BOX DASHFUSE/BELAY UNDER
YEL
RED GRNi
I
BELT SEAT NDER FEII,I LIGHT
UNIT CONTROL INTEGRATED
BLUi
''o |RED [t
9]
GRN
l u '
A Y ')lf#,]"J
BLU/BED
I ttu,.'
I
L
LI
I
, l =
T
c552
-
BLK
T
G401 G402
_
BLK
l(3ix';
I,if;',"",",.. ,
, Doorcrosed foeen -:
23-141
Input Test
SRScomponents are locatedin this area.Reviewthe SRScomponentlocations, precautions, and procedures the SRS an section(24)beforeperformingrepairs service. or 1. 2. 3. 4. Remove driver'sdashboard the lower coverand kneebolster(seesection20). Disconnect 10Pconnector the from the integrated controlunit. Remove integrated the controlunit from the under-dash fuse/relav box. Inspect connector the and socket terminals be surethey are all makinggood contact. to . lf the terminals are bent,looseor corroded, repairthem as necessary, recheck system. and the .lftheterminalslookoK,makethefollowinginputtestsattheconnectorandthefuse/relayboxsocket. - lf any test indicates problem,find and correctthe cause, a then recheck system. the - lf all the input testsproveOK,the controlunit must be faulty;replace it.
INTEGRATEO CONTROL UNIT
1OP CONNECTOR
Wiresideof femaleterminals
23-142
All Systems: Cavity A14 Wire BLK Test condition Underall conditions Underall conditions A9 lgnitionswitchON (ll) Test: Desiredresult to for Check continuity ground: Thereshouldbe continuity
Check for voltage to ground: There should be battery voltage
Possiblecauseif result is not obtained . Poorground(G401, G402) . An open in the wire Blown No. 43 (7.5A) fuse in the box fuse/relaY under-hood An open in the wire . Blown No. 25 (7.5A) fuse in the box fuse/relay under-dash . An open in the wire
A6
for Check voltageto ground: voltage. Thereshouldbe batterY
Intermittent Wiper SYstem: Cavity Wire Test condition Test: Desiredrssult the between for Check continuitY terminals: and BLU/WHT BLU/BLK Thereshouldbe continuitY. Possiblecause if result is not obtained B l o w nN o . 2 6( 2 0A ) f u s ei n t h e box underdashfuse/relay wiPerswitch windshield Faulty wiPermotor windshield Faulty An open in the wire B l o w nN o . 2 6( 2 0A ) f u s ei n t h e box fuse/relay under-dash wiPerswitch windshield Faulty An open in the wire B l o w nN o . 2 6( 2 0A ) f u s ei n t h e box fuse/relaY under-dash An open in the wire
. Faulty windshield washer switch . An open in the wire
B1 82
lgnitionswitchON (ll), wiPer BLU/BLK and windshield switchat OFFor INT and
BLU,AiVHT
B3
lgnitionswitchON (ll), wiPer and windshield YEUBLU at INT switch lgnitionswitchON (ll)
for Check voltageto ground: voltage. Thereshouldbe batterY
*A5 lgnitionswitchON (ll), washer WHT/BLK and windshield switchON
for Check voltageto ground: Thereshouldbe batteryvoltage for Check voltageto ground: voltage. Thereshouldbe batterY
*84
*: With combined operation wiper-washer
(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

C o m b i n a t i o nl i g h t switch ON
Test: Desiredresult
Check for voltage to groundl There should be battery voltage.
Possiblecause it result is not obtaineo

B l o w n N o . 3 0 ( 7 . 5A l f u s e i n t h e under-dash fuse/relay box Faulty combination light switch An open in the wire
A8
lgnition witch N(ll), s O 81
RED/BLU and driver'sseatbelt

switchunbuckled GRN Driver'sdoor open lgnitionkey inserted into the ignitionkey swrtcn
Check voltageto ground: for There hould e 1 V or less. s b Check voltageto ground: for Thereshouldbe i V or less. Check voltageto ground: for There hould e'l V or less. s b
P o o rg r o u n d( c 5 5 2 ) Faultyseatbelt switch An open in the wire . Faultydriver'sdoor switch ' An open in the wire , P o o rg r o u n d( G 4 0 1c 4 0 2 ) Faultyignitionkeyswitch An open in the wire
B9
8 1 0 BLU/RE D
Bulb CheckSystem (BrakeSystem Light): Cavity Wire Test condition Test: Desiredresult Connect ground:Brake to system l i g h ts h o u l d o m eo n . c Possiblecauseil result is not obtained Blown No. 25 (7.5A) fuse in the under dashfuse/relay box Blown brakesystemlight bulb An open in the wire Blown No. 31 (7.5A) fuse in the under-dash fuse/relay box Faultystartercut relay A n o p e ni n t h e w i r e
A4
lgnition witch N ( ), s o brakefluid reservoir GRN/RED f u l l ,a n d p a r k i n g r a k e b leverdown
lgnitionswitchat START ) 0 A 1 3 BtU/^/VHT
Check voltageto ground: for Thereshouldbe batteryvoltage.
23-144
l.r ^
LightingSystem
DAYTIMERUNNINGLIGHTS (canadal RESISTOR Test,page23-151
.HEADLIGHT '152 Adjustment, Page23 page23 151 Replacement,
DAYNME RUNNINGLIGHTS UNIT (Canadal CONTROL InputTest,page23-150
SIGNALLIGHT Replacement, Page23-151
HIGHMOUNT BRAKELIGHT page23 159 Replacement,
PLATE LICENSE page23-156 Replacement,
INNERTAILLIGHT page23-153 Replacement, TAILLIGHT OUTER RePlacement, 23 153 Page
*: Headlight and front parking/front turn signal light cannot be separated
(cont'd)
23-145
LightingSystem
ComponentLocationIndex (cont'dl
HIGHBEAM INDICATOR LIGHT DASHLIGHTSBRIGHTNESS CONTROLLER Controller lnputTest, page23-161 TURNSIGNAL INDICATOR LIGHT COMBINATION LIGHTSWITCH Test,page23 149
q L__.r L__Jt --:fft,1al flfl

O
_
r-
rll
l......--,.'...-1F''------4
'
nnnnnnnnnn;n
11 f-
---l
LJ
| l -;---- \
) L_J {_
|
Lr u r,J rJ rJ [J LJ LJ rJ LJ LJ rJ
I-nnnnrr-nnrrnn
IJ I-] IJ LI tJ IJ LJ t,J U T-J U LI utJlJ|'JLl|JLJLILI|.JLj|'JtJLl
r__rfl | !J
O a-
r'r n rr n it rr r't rl - n r.t 11it r'l
TURN SIGNAL/HAZARD RELAY InputTest,page23-155
23-146
trtt
(USA) CircuitDiagram
BOX FUSEi RELAY UNDEB,HOOD
-T\-" T,g,?..
.\--
---
--
--'r\-
To
---
'
FUSE/FELAY BOX I,JNDER.DASH
J No.5
00A) ? I
N0.22 (104)
Zltl ( I I
N0.4 00A)
No30 (7.5A)
i u',';
I
RED/BLK
REDiGRN
FEDi BLK
I
BLK
I I
I
I I
I
BEAM H]GI-] NDICATOR LIGHT (1.4w)
Y'
LIGHTS DASH LIGHTS DASH BRIGHTNESS CONTROLLER
r?
PARKING LIGHTS TA]tL]GHTS LIGHTS PLATE LICENSE
G401 G402
BLK
BLK
I oio,
G201
23-147
LightingSystem
CircuitDiagram(Canadal
U N D E F O O D U S E / R E L8 O X H F AY
REDI H T W
RED
L
I
RED/GNN
]T
:L
FLD GF\
FED'GRN
( e) i
I t&Jdt&JsJ
Y*,0 t N c
ILG
8LK
I
I
""t*
I | | r*.",-lT1F*,,._ 3t:'r{"is-t}6}"
OAYTIME FUNNNGLIGHTS CONTROL IT UN
| | | | ,^,f,-,,,^,."f:", t t l Eiffifg.'':trio.'''0-',
vF. cLD RFo WFFD 8LU qro e.,( neoa_x
'BLK ftHT YEL EBAKESYSTEM L GHT INTEGFATED CONTBOL UNIT
qbi L_l
| |
UNDER.DASH FUSE/FELAY BOX
No.4 (10A)
)No 30 L {7.sA)
)to.:z 'r t75A)
N0.20 , N 0 . 1 8 (r0A) (7.54) )
\-7
I RED/GRN
l)tJ-;-,
REDi RN 3
l(ra
ru$i'%H I I
G2A2
liE;;-""' lt*.'
T
:
REDiGFN
Al | )
. Floar Icosd downl I BLK
F I B R A K EL I J I D L I L E V ES WT C H
PARKING BRAKE
swrTcH
BLK
Lever)l upl lclosed
I
G401 G402
BL(
G2A1
BLK
n :
G40l G402
-L
-
G401 G402
23-14A
Combination Light Switch Test

columncovers(seesection20). lower coverand steering the 1 . Remove driver,sdashboard from the switch. the Disconnect 4P and 7P connectors Insoecttheconnectorandsocketterminalstobesuretheyarea||makinggoodcontact' . . the and are bent,loose.orcorroded,repairthemas necessary, recheck system' ll the terminals to them in eachswitchpositionaccording the tables lf there lf the terminalslook OK,checkfor continuitybetween switchharness any of them,checkfor continuityin the is no continuitybetween light switch' the - lf there is continuityin the switchharness' replace combination lt' replace - lf thereis no continuityin the switchharness,
rffi]
ttAltA2!l -l: fl-
l a rm J l
LIGHTSWITCH COMBINATION
7P CONNECTOB
Switch : Headlight/Dimmel/Passing \ Position

OFF Headlight switch
Tetminal \
B1
82
B3
*84
B5
B6
:m:
=D
OFF LOW HIGH
o-- - o cF- --o o- ----o
o-
oO-
--o ----o
---{
switch Passing
* : Canada
ON
Turn SignalSwitch : Terminal Position RIGHT NEUTRAL LEFT A1 A2 A4
oo 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 d o w e r c o v e r a n d l kneebolster(seesection20). D i s c o n n e ct th e c o n n e c t o r sr o m t h e d a y t i m er u n f n i n gl i g h t s o n t r o u n i t . c l I n s p e c t h e c o n n e c t o r n d s o c k e tt e r m i n a l s o b e a t surethey are all makinggood contact. lf the terminals bent.looseor corroded, are repair them as necessary, recheck system. and the 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 indicates problem, a find and correct the cause, then recheck system. the - l{ all the input tests proveOK, the controlunit must be faulty;replace it.
2.
3.
Cavity B1
Wire BLK
Test condition
Underallconditions
Test: Desiredrgsult
C h e c kf o r c o n t i n u i t yt o g r o u n d : T h e r es h o u l db e c o n t i n u i t y .
U n d e r l lc o n d i t i o n s a A2 BLK /VHT IgnitionswitchON (ll) 82
Check voltageto groundl for Thereshouldbe batteryvoltage. Check voltageto ground: for Thereshouldbe batteryvoltage.
YEUBLK
C o m b i n a t i o nl i g h t "=d' position switch in
Possiblecause il result is not obtained . Poorground (G401. G402) . An open in the wire . Elown No. 20 (10A) fuse in the under-dashfuse/relaybox . An open in the wire Blown No. '18(7.5A) fuse in the under-dash fuse/relay box Faultyignitionswitch An open in the wire Blown No. 48 (30Al fuse in the under-hood fuse/relay box Faultycombination light switch An open in the wire , P o o rg r o u n d( G 2 0 1G 2 0 2 G 4 0 1 , . G402) Blown bulbs Faultydaytimerunninglights resistor An open in the wire Blown No. 25 {7.5A) fuse in the under-dash fuse/relay box Blown brakesystemlight An open in the wire . Faultyparkingbrakeswitch . An open in the wire
RED
Check voltageto ground: for Thereshouldbe batteryvoltage.
A1
C o m b i n a t i olng h t i switchOFF;connect a jumperwire between WHT/RED t h e Y E U B L K n d a WHT/RED terminals, t h e nt u r n t h e i g n i t i o n switch N(ll) O

l g n i t i o ns w i t c h O N ( l l ) , brake fluid reservoir GRN/RED full, and parking brake lever down
( H e a d l i g h t s h i g hb e a m )s h o u l d come on, (andhigh beam i n d i c a t o rs h o u l d c o m e o n ) .
B3
Connect ground:The brake to systemlight shouldcome on.
B6
RED/GRN
Parking brakeleverup
Check continuity ground: for to Thereshouldbe continuity.
23-150
Turn Headlights/Front Lights Signal/Parking

Test (Canada)
LightsResistor Running Daytime

CAUTION: The davtime running lights resistor becomes very hot when the daytime running lights are on; do not touch it or the attaching hardware immediatelyaftel the lights have been turned oft. 1. from the resistor' the Disconnect 3P connector
Replacement
CAUTION: Halogen headlights become very hot in uss; do not touch them 01 the attaching hardware immediatelv after they have been turned oft. 1. 2. 3. Remove the lront bumper (see section 20). Remove the mounting bolts Disconnect each connector, then remove the head light/front turn signal/parking light assembly. MOUNTING BOLT
RUNNING DAYTIME
I
TURN HEADLIGHT,/FRONT SIGNAL/ ASSEMBLY LIGHT PARKING 60/55W HEADLIGHT: W 2115 LIGHT: TURNSIGNAL/PARKING FRONT side Terminal of male terminals
betweenthe resistortermi_ Measurethe resistance 'l nals(No. and No. 2) and the powerterminalNo 3 1,6 Resistance: o i 0 08 o the resistorwith a new one it any of the Replace are resistances beyondspecilication.
23-15'
. ^
Headlights
Adjustment
Beforeadjusting headlights: the . . . . . Parkthe vehicleon levelground. lvlake surethe fueltank is full. The driver or someonewho weighsthe same should sit in the driver'sseat. Loadthe trunk with the itemsyou usuallycarry. Pushdown on the front and rearbumoeGseveral times to makesurethe car is sittingnormally. Adjustthe headlights localrequirements turn, to by ing the adjusters. After headlightreplacement, may be necessary it to readjust horizontal gear. the indicator Firstinstalltheheadlight, and adjustits horizontal a n d v e r t i c a a i m i n g sa c c o r d i n go l o c a lr e q u i r e l t menIs. . Then checkthat the arrow on the horizontal indicator gear is alignedwith the mark on the horizontalindicator. - lf they are not aligned, remove screw, the adjust the indicatorgear,and retighten screw. the NOTE:As the outer lensesa.e made of an acrylicoated,polycarbonated material,do not cover the headlightswhen they are turned on. .
CAUTION: Halogen headlights become very hot in use; do not touch them or the attaching hardware immediately after they have been turned off, 1 . O p e nt h e h o o d . 2. Check horizontal the adjustment indicator. The "0" markon the horizontal gearshould indicator be aligned with the markon the horizontal indicator.
HORIZONTAL INDICATOR
HORIZONTAL INDICATOR
3.
l f t h e i n d i c a t o i s n o t a l i g n e d i t h i t s " 0 " m a r ka s r w described above, adjustment be madeby using an can a PhilliDs screwdriver.
23-152
Taillights
Replacement
NOTE: replaceit if it is distortedor stays . tnspect the gaskeU compressed. . After jnstalling the taillights,run water over them to makesurethey do not leak OuterTaillights: 1 . O p e nt h e t r u n kl i d / h a t c h . 2. the 4P or 6P connectorfrom the outer Disconnect taillight. R e m o v e 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 t o u t e rt a i l l i g h t .
,lP or 6P CONNECTOR
InnerTaillights(Coupe/Sedan): t s 1 . O p e nt h e t r u n kl i d ,t h e nr e m o v e h e a c c e s p a n e l 2. 3. from the innertaillight the Disconnect 4Pconnector t R e m o v e 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 . I l: Sedan Coupe:

INNER TAILLIGHT
3.
Sedan: INNERTAILLIGHT
Hatchback: BRAKE/TAILLIGHT:2115W 21 TURNSIGNALLIGHT: W BACK-UPLIGHT: 21W Coupe/Sedan: BRAKE/TAILLIGHT:2115w 21 LIGHT: W TURNSIGNAL
4P CONNECTOR
BRAKE/TAILLIGHT:2115W 21W LIGHT: BACK-UP
23-153
Turn SignaUHazard Flasher System

CircuitDiagram
UNOER HOODFUSEi RELAY BOX G NT ] O N W I C H S
UNDER.OASH FIJSEiRELAY BOX

N0.1(7.5A) 2
No30 (7.541
"l
V
RED/BLK
GRN/YEL TUFNS GNALSWITCH 2 (Nolused)
GRNMHT
t l r l
I
DASH LIGHTS BRIGHTNESS CONTROLLER
RIGHT TURNSIGNAL LIGHTS
(2rw)
BL(
FRONT
NDCATOR (1.4W)
INDlCATOR
BLK
BLK
G601. G76t Hatchback G601 CouperSedan
G2A2
G201 CoOt, GZOttlrt.nlr.t G40l G601 :Coupe/Sedan G4A2
23-154
trI\
.t
RelayInput Test Turn Signal/Hazard
SRS componentsare located in this area. Reviewthe precautions, and procedures SRScomponentlocations, in the SRSsection(24)betoreperformingrepairsor servrce. 1. relayfrom the underthe Remove turn signal/hazard box. fuse/relay dash terminals box socket the Inspect relayand fuse/relay 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 , the and recheck system. repairthem as necessary, 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 indicates problem'find and cora rect the cause,then recheckthe system. - lf all the input tests prove OK,the turn signal/ it hazardrelavmust be faulty;replace
{ {
2.
r=\-:=
t -
iln nE,\l ' ..ll L l l l

........r------
J
Cavity Tesi condition warningswitch Hazard the No. 1 ON;connect terminalto the No. 3 terminal. lgnitionswitchON (ll) and turn signalswitchin right the No. 1 or left;connect terminalto the No, 3 te.minal. Underall conditions lgnitionswitchON (lll Ted: Desiredresults lightsshouldcome on. Hazard
BOX FUSE/RELAY SOCKET
Possible caus if lesult is not obtained
, , P o o rg r o u n d( G 2 0 1G 2 0 2 G 4 0 1 , G76' 1) G552, G60' 1, G551. G402, warningswitch Faultyhazard An open in the wire . Faulty turn signalswitch
'l
Rightor leftturn signallightsshould c o m eo n ,
to for Check continuity ground: Thereshouldbe continuity. for Connect voltageto ground: voltage. Thereshouldbe batterY
' Poorground(G401, G402) . An open in the wire A B l o w nN o . 1 2 ( 7 . 5 ) f u s ei n t h e box fuse/relay under-dash warningswitch Faultyhazard An open in the wire Blown No. 53 (10A) fuse in the underbox hood fuse/relay warningswitch Faultyhazard An open in the wire
warningswitchON Hazard
for Connect voltageto ground: Thereshouldbe batteryvoltage
23-155
Turn SignalI HazardFlasher
System
License PlateLights
Replacement
Sedan/Coupe: 1. Remove two screwsfrom the licenseplatelight. the and pull the light out part of the way. Disconnect 2Pconnector the from the light. Takethe lensoff, then replace bulb. the
Hazard Warning SwitchTest

CAUTION: Be careful not to damage the hazard warning switch or the center outlet panel when prying the switch out. 1. Pry the hazard warningswitchout of the centerout let oanel. Disconnect 10Pconnector the from the hazard warning switch. Checkfor continuitybetweenthe terminalsin each switchpositionaccording the table. to
2. 3.
2.
3.
2P CONNECTOR
lOPCONNECTOR
Halchback: 1. Carefully the licence pry platelight out ofthe license platetrim. Disconnect 2P connector the from the Iight.
2.
2P CONNECTOR
Terminal \ .-\ _rostlton

\ .OFF
10
o o o ooo o o
(9
o
@
o o o
LENS
ON
Terminal No.4is not used
23-156
I
Lights Back-up
CircuitDiagram
IGN]TION BOX FI.JSE/RELAY UNDER.HOOD
wnreLx..*wHr6-I
-l ""'--""\9rf[,,*.iliuit*t**
eLx/YeL
swtTcH
YELiRED
r Vt[{,[H.,.
neosrrcn Ell lcLored ) I
GFN/BLK
lr /K
A TG E A R PosrTloN
I
23-15i
BrakeLights
CircuitDiagram
\
'61
\,
UNDER.HOOD FUSE/RELAY BOX
*l F!_*,. |
wjcPN_l
I
fi-GRNA'VHT
V H.BNSYSTEM
Pedardeoressedl
I,t'"t
..,F.,,*,,r
. ABS CONTROL UNIT ' ECi,I/PC[I 'TCM (CW) .]NTEHLOCK coNTRotUNT 'CRUISE CONTNOL UNIT GRN,ryVHT
I P } BRAKE
,l. ffi,!,.,
BLK
I
I
ffi; I
Yr,:"'
It*i i i r
Li;
* 2lW Coupe/Sedan 18W Hatchback contro [ ] Wilhc.uise
G601, G761 Halchback G601 :Coupe/Sedan
23-158
High Mount BrakeLight Replacement

Hatchback: t 1 . L o o s e nt h e t w o s c r e w s , h e n r e m o v et h e h i g h 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. from the light. Remove the bulb socket Coupe/Sedan: 1. 2 20) Remove the rearshelf{seesection 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.
)
BULBSOCKET
TWO SCREWS
23-15
DashLightsBrightness Controller
CircuitDiagram
\,
FUSE/RELAY UNDER.HOOD BOX
G401 c402
23-160
Input test Controller

NOTE:The controlunit is built intothe dash lightsbrightnesscontroller. 1. 2. 3. out pry Carefully the controller of the dashboard from the controller' the Disconnect 3P connector terminalsto be sure they are the connector Inspect all makinggood contact. . repair or are lf the terminals bent,loose, corroded, the and lhem as necessary, recheck system look OK,makethe lollowinginput . lf the terminals testsal the connector. - lf any test indicates problem,find and cor a the then recheck system' rectthe cause, - If all the input tests prove OK, the controller ii. must be faultyjreplace
Cavity
Test condition i C o m b i n a t i olng h t switchON
Test: Desiredlesults for Check voltageto ground: voltage. Thereshouldbe batterY
Possiblecauseif result is not obtained A B l o w nN o . 3 0( 7 . 5 ) f u s ei n t h e box f under-dashuse/relaY light swatch Faultycombination A n o p e ni n t h e w i r e . P o o rg r o u n d( G 4 0 1G 4 0 2 ) , . A n o p e ni n t h e w a r e ' A n o p e ni n t h e w i r e
RED/BLK
BLK
Underall conditions
Check for continuity to ground: T h e r es h o u l db e c o n t i n u i t y
RED
i C o m b i n a t i olng h t ON switch
to Connect groundl c s D a s hl i g h t s h o u l d o m eo n f u l l bright.
23-161
InteriorLights
Component Location Index
\
CEILING LIGHT Test,page 23-165 SPOTLIGHTS Test,page23-166 FRONT PASSENGER'S
oooRswtTcH
RIGHTREARDOORSWITCH
TRUNKLIGHT{Coup6/Sodan) Test. page 23-166
LEFTREARDOORSwlTCH IRUNK LATCHSWITCH
23-162
CircuitDiagram(Without Spotlights)
BOX FUSE/FELAY UNDER-HOOD
W].]T/RED
CEILING LIGHT ON \ OFF
BLU/BLK
I I
! I
I I &i*J,"' I V | ,,J,,, rf--l

6NN
T GRN/RED
| *tecroreo lcoNTBotUNLT
I T-'.- )
LTG FRONT PASSENGERS DOOR
BLK BLUi
A A \( Tn':ii ) ftm' Tt*:r.:,
I
. *1
8LK
l[3'&'i'
swtrcH open I 'l I TcosedDoo' open closed fcbsed Door Door -] | [OPen (Open :0oor closed J
I
:
LEFT REAR DOOR SWITCH :Door open I folosed (Open Doorclosed J
R]GHT REAR DOOR
swtTcH
fcbsed iDooropen ) (open :Doorclosed ,
G60l G761:Halchbac( : G601 Coupe/Sedai
a 3 4w:llsA,CanadProduceo 5WlJapan'Produced * 2 8 Wr W l hm o o n r o o l moonroo{ 5W :Wilhoul
23-163
lnterior Lights
CircuitDiagram(With Spotlights|
UNDER-HOOD BELAY FUSEi BOX
t"
WHT/REO
rhr I I.l'-,-1 T !
BLU/BLK
I I I
|
t
**,,",
]NTEGRATEO CONTFOL UNIT
I'V
BLU/BLK
A
I
BtK
| .,J,,-
t;:ff [niH,,,,,,*,,ItfuTi::.Ll li*r*.r

l3$?rt" IPASSENGEFS I DOOF
A Yoo* A Y*,urr"
I:
GRN
LTGRN/REO
A Y""
I REAR
ll3;:1"' ao
lDoorcrosed.J I(ooo :
CeOt CZOI ga"f,O""k G601:Coupe/Sedan
xI
3.4W :USA, Canada-pfoduced prodlced 5W:Japan *2 8W Wlhmoonrool 5W Wlhoul moonrool
23-164
L
Ceiling Light Test

1. Turn the light switchOFF. 2. 3. Pry off the lens. Remove the two mountingnuts (or a bolt) from the then removethe housing housing, from the housing. the Disconnect connector(s) Checkfor continuitybetweenthe terminalsin each to switchpositionaccording the table. Without moonrool: Coupe/Hatchback:
4. 5.
rermrnar \
Position OFF MIDDLE ON
2 or 2'
/a\
o-
oG_
\:/ /:\ \:./

/A
--o
--o -_o
BULB {5 WI
3 ot 3'
\./
With moonroof:
3P CONNECTOR
1 4 2'
l'
23-165
InteriorLights
SpotlightsTest
1. Turn the spotlight switchOFF. 2. 3. 4. 5. Pryoff the lens. Remove two screwsand the housing. the Disconnect 1Pconnector the from the housing. Checkfor continuitybetweenthe terminalsin each switchpositionaccording the table. to
Trunk Light Test

1. 2. 3. 4. Openthe trunk light coverfrom the housing. Pryout the light assembly. Disconnect 2P connector the from the housing. Make sure that the bulb is OK. Checkfor continuity between the No. 1 (+)and No.2 (-lterminats.
BULBITT
\ *"t*
Terminal _\
o-t (9
/a\
\-.7
--o --o --o --o

rl 3.4 W: USA, Canad!-producod 5 W: Japan-produced
ON
o- oJ
(9 /^ \,/
23-166
\.
StereoSoundSystem t
in precautions, and procedures the sRS are locatedin this area.Reviewthe sRS componentlocations, sRS components or (24)beforeperformingrepairs service. section
AUDIOUNIT (SfEREORADIOTUNER) Replacement, Page23 169 page23 170 Terminals, ANTENNAMAST Replacement, LEF1TWEETER page23-171 Replacement, RIGHTTWEETER page23 171 Replacement, SPEAKER RIGHTFRONT page23-171 Replacement,
it
SPEAKER LEFTFRONT page23_171 Replacement,
suB
LEAD
PLAYER CASSETTE Replacement, Page23-169 REARSPEAKERS page23-171 Replacement,
23-167
StereoSoundSystem
CircuitDiagram
U N D E R , H O F U S E / F E LB O X OD AY
GNITON SWTCH
UNDEF DASH FUSEi RELAY SOX
t'*'fdl -t-'---ll
I I I
ANTENNA LEAD
(7.5A) No.30
I
I
WHT/BLU
YEURED FED/BLK
I
I
REDTEr
,,I;J,
LEFT FRONI DOOR SPEAKER
RED
I I
H
LEFTREAR SPEAKER R l G HN E A R T SPEAKER
DASH LIGHTS BRIGHTNESS CONTROLLER
23-16 8
Removal
Stereo RadioTuner: 1. lower cover (seesecthe centerdashboard Remove tion 20). the Remove two mountingbolts,and pullthe stereo r a d i ot u n e ro u t l , th D i s c o n n e c t e 1 6 Pc o n n e c t o r ss u b a n t e n n a e a d (with cassetteplayer)'then remove and DIN cord the stereoradiotuner. CassettePlayel: L 2. 3. the Remove front consolepanel(seesection20). the Remove DIN cord from the stereoradiotuner' Removethe lour mounting bolts,then removethe cassette Player'
2.
3.
16PCONNECTORS
MOUNTINGBOLTS
RADIOTUNER STEREO
{t 23-169
StereoSoundSystem
Stereo Radio TunerTerminals
F o r k e v l e s se n t r v
MastAntenna Replacement
1. Disconnect connector the betweenthe antennalead a n ds u b a n t e n n ae a d . l Remove the two mountingscrews, then removethe mast antenna.
To OIN CORD
2.
MOUNTINGSCREWS
To DIN CORD
(forsecurity system) Cavity A1 Wire
MAST ANTENNA
RED/GRN BLU
Rightfront door speaker @, righttweeterO Leftfront door speaker O, left tweeter @ Lights-on signal power (tuning Constant memory) ACC(mainstereopower supply) Left reardoor speaker @ Rightreardoor speaker O Rightfront door speaker O, righttweeterO Leftfront door speaker O, left tweeter O Dashlightsbrightness controller ( Ground G50'1)
A2
A3
A4
RE LK D/B
WHT/BLU YEURED
A7
BLUI/EL REDI/EL
BRN/BLK GRY/BLK
A8 A9
410
412 414
415 416
RED BLK
GRYA/r'HT Leftreardoor speaker O

BRN,^/VHT Rightreardoor speaker O
T e r m i n a l A 6 ,4 1 1 s
Replacement Speaker
Front speaker: 1. 2. 3. cover' the Remove speaker the Remove threescrewsfrom the speaker' and removethe door the Disconnect 2P connector, speaker. Rgarspaker: 1. the rearsideshelf or rearshelf(seesection Remove 20). from the speaker. the Disconnect 2Pconnector then removethe speaker. the Remove four screws,
2. 3.
Hatchback:
g
Tweeter: 1. 2. 3, 4.
SPEAKER FRONT
2P CONNECTOR
Remove door panel{seesection20) the from the tweeter' the Disconnect 2P connector the mirrorgarnish. Remove then removethe tweeter' the Remove two screws, Coupe/Sedan:
REAR
|'
TWEETER
2P CONNECTOR
23-171
Horn
SRScomponents are locatedin this area.Reviewthe SRScomponentlocations. precautions. and procedures the SRS in (24)beforeperformingrepairs service. section or
HORNASSEMBLY Test,page 23-173
a\
\ rap
\ \-'/"''\
HORN RELAY: modot 98 WHT/GRN, cRy.l lWirecolors: BLU/RED IWHT/GRN, I Test,page23-73
L-l
/ -l i
hJrrfl
a\ a\
fl f-
---t i Ll
L--l
| | | | LJJ
nFFrnn-r-rFrl'1llrLrurrLr!Lrrrr.rLrUrrrr r ' rF r n n r ' rF r - n F r F r r r r l
J:::::::::tJ:-t l
HORNRELAY: 97 modots 96, lWiro color3:WHT/GRN,GRy,l lwHT/cRN, BLU/RED I Test,psge 23-72
UNDER.DASH FUSE/BELAY BOX
23-172
h-
96,97models CircuitDiagram:
BATTERY
HornTest:96,97models
'L 2. 20). the Remove tront bumper(seesection from the horn' the Disconnect 2Pconnector
HORN RELAY
LOW HORN
rt
the horn. Remove Test the horn by connectingbattery power to one terminaland groundingthe other.lf the horn failsto it. sound,replace
BLU/RED
Y-G401 G4o2
I I
B LK
23-173
Horn
CircuitDiagram: model 98
BATTERY
HornTest 98 model
1 . Remove front bumper(seesection20). the Oisconnect 1Pconnector the from the horn.
BRAKE SWITCH
TERMINAL Wlhl,eyessenry ";, svsm
\
Test the horn by connectingbattery power to the t t e r m i n a la n d g r o u n d i n g h e m o u n t i n gb o l t l f t h e it. horn failsto sound,replace
ir-?
lJ
t v i
!--oA"
3.
WHT/GRN
4,",,
It
':
23-174
Switch Test
1. thendisconnect cable, negative the Disconnect battery threeminutes' andwaitat least cable, the positive the driver's airbag connector(see secDisconnect tion 24). l t R e m o v e h e d r i v e r ' sd a s h b o a r d o w e r c o v e r { s e e 20). section 3P the Disconnect cablereel sub-harness connector from the main wire harness. ( t R e m o v e 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 r 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 f r o m t h e wheel. steering
7 . Checkfor continuitybetweenthe No 2 terminalof
2.
3.
3P the cable reel sub-harness connectorand horn p o s i t i v ee r m i n a l . t
4.
TERMINAL HORNPOSITIVE
REEL
MAIN WIRE HARNESS 3P CONNECTOR SUB.HARNESS 3P CONNECTOR CABLEREEL
HORN CONNECTOR
. .
of Terminalside maleterminals
t , l f 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 e h e c a b l er e e l (seesection 24). lf there is continuity,repairor replacethe horn switch.
5.
Checkfor continuitybetweenthe No. 2 terminalof s t h e c a b l er e e l s u b - h a r n e sa n d b o d y g r o u n dw i t h horn switchPressed. the
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 the assembly(seesection24), and reconnect cable connector' reelsub harness the 9 . Reconnect driver's airbagconnector,and relnwheel. panelon the steering stallthe access the 1 0 . Reconnect batterypositivecable,then the negative terminal. confirm proper the 1 1 . After installing airbagassembly, systemoPeratlon: Turn the ignition switch ON (ll);the SRS indicator light should come on for about six seconds and then go off. Makesureboth horn buttonswork.
sideol Terminal maleterminals
the horn switchis OK. a lf there is continuity, go a lf there is no continuity, to step6.
23-175
RearWindowDefogger
UNDER-DASH FUSE/RELAY BOX
o _
:uuu -n--nhnn-n;n
uu!uu!uu!u!u
t -
t t l :--=-=-=;----------.l
! !
.-1 fl | | l
/ ----t
uuuuuu!uluuu
REAR WINDOWDEFOGGEF SWITCH InputTest,page23-179
REAR WINOOWDEFOGGER FLrnction Test,page 23-178 DefoggerWjre Repair,page 23-1j8
23-176
U
trt\
-
CircuitDiagram
BOX HOODFUSE/FELAY UNDER No41 (80A) No42(404)
**"-*9
IGNITION SWTCH
BOX FUSE/RELAY DASH UNDER
(7 N0.30 sA) FUSE
BLK]BLU
\t
+
I| -r]] I ;BLK
t I
RED/BLK
T I
I I
I
--
I REAR | wrNDow I DEFOGGER
BLK
I I
LIGHTS DASH ERIGHTNESS CONTROLLER
rt
G6ol :Coupe/Sedan G771 HalchbacK
G40l G402
G401 G402
ZLITT
RearWindow Defogger
Function Test
CAUTION:Be carefulnot to scratchor damagethe detogger wires with the tester probe. 1. Check voltagebetween for the positive terminaland body ground with the ignitionswitch and defogger switchON. There hould ebanery ollage. s b v . lf there is no voltage, checkfor: - faulty defoggerrelay. - faulty defogger switch. - a n o p e ni n t h e E L I V B L U r r e . w lf there is batteryvoltage, to step2. go
DefoggerWire Repair
NOTE: To make an effective repair, the broken section 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. Lightly rub the area around the broken section with fine steel wool, then clean it with alcohol. Carclully mask above and below the broken portion of the defogger wire with cellophane tape. OPEN
2.
NEGATIVE TERMINAL
POSITIVE TERMINAL 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 negative terminal 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 , defogger roundwire. g Touch the voltmeterpositiveprobe to the halfway point of eachdefogger wire, and the negative probe t o t h e n e g a t i vt e r m i n a l . e Thereshouldbe approximately V with the ignition 6 switch and the deiogger switch ON. lJthe voltageis as specified, defogger the wire 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. 5.
Check continuityin the repaired for wire. Apply a secondcoat of paint in the sameway. Let it dry three hoursbeforeremovingthe tape.
23-178
Switch Input Test

CAUTION: Be careful not to damage the rear window defoggerswitch or the center panel when plying the switch out, c N O T E :B e f o r et e s t i n g , h e c kf o r b l o w n N o 1 6 ( 7 5 A ) box underdashfuse/relay fuse in the 1. 2. 3. 20)' panel(seesection Prythe switchout of the center from the switch. the Disconnect 5Pconnector the switchON {ll),and check voltage Turnthe ignition the between BLVBLU(+)andthe BLK{-) terminals voltage. Thereshouldbe batterY . . ll there is no voltage,checkfor an open in the BLVBLUwire go lf there is batteryvoltage, to step 4.
RED
terminals of Wireside famale
4.
and Connecta jumper wire betweenthe BLK/BLU terminals. the BLU/YEL Turn the ignitionswitch ON (ll). and checkthat the rear window defoggerworks; if it does, replacethe switch. defogger
rt
23-179
PowerMirrors
PowerMirror Function Test,page23-182 PowerMirrorTest,page23-183 Replacement, section20 ActuatorReplacement, page23-184
POWER MIRROR SWITCH Test,page23,183
23-180
hr-
CircuitDiagram
BOX FUSE/RELAY UNDER.HOOD
swrTcH
GNTION
YEL
I lu";I
BLK/YEL
UNDER.OASH FUSE/RELAY BOX
lt
* f#'-_'":1:
3 5 BLUi BLK GRN/WHT
G551
23-181
-...
PowerMirrors
Function Test
CAUTION: Be caretul not to damage the mirror switch or the dashboard driver's lower cover when prying the switch out. 1. 2. Pry the switch out of the driver,sdashboardlower cover. Disconnect 10Pconnector the from the switch. Left mirror inoperative: Connect the No. 2 (BLK/YEL) terminalof the 1Op connector to the No. 3 (YEURED) terminatand the No. 5 (or No. 6) terminalto body ground with jumper wires. The left mirror shouldtilt down (or swing left)when the ignition 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 YEVRED wire. lf the mirroroperates properly, check mirrorswitch. the Right mirror inoperative: Connect No. 2 (BLVYEL) the te.minalof the 1Op connector to the No. 3 (YEURED) terminatand the No. 9 (or No. 8) terminal body groundwith jumperwires.The rightmirto 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 switchis turnedON {ll).
POWRMIRROR
lOP CONNECTOR
BLK/YEL 2 6 BLU/WHT
YEL/REO BLK
4
swtTcH
/ 1 8
YEL/BLK
Mirror Test
Both inoperative:
lf the mirror does not tilt down (or does not swino left), removethe right door panel,and checkfor ai open in the GRN,Ar'/HT YEUBLK) (or wire between the right power mi.ror and the switch. - lf the wire is OK,check the right power mirror actuator. lf the mif ror neithertilts down nor swings left. repair the YEVRED wire. 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.
Checkfor voltagebetweenthe No. 2 (BLK,/YEL) terminal 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/relay box. - an open in the BLVYEL wire. . lf there is batteryvoltage, goto step 2. 2. Checkfor continuitybetweenthe No. 4 (BLK) termin a la n d b o d yg r o u n d . Thereshouldbe continuity. . 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 ) .
'1.
23-182
!.\-
Switch Test
1. Removethe switch as describedin FunctionTest (seepage23-182). Checkfor continuitybetweenthe terminalsin each to switchpositionaccording the table.
PowerMirror Test
1. Prv out the coverpanei{seesection20}
2.
covR
Mirror Switch:
\ Position rermrnal \
UP
DOWN
L
LEFT RIGHT
UP
DOWN LEFT RIGHT
o- o- -o -o o- -o o- -o -o G -o G -o o- G -o -o o- o- _o _o o- _o oo- -o o-o o- o- -o
from the powermitrrt the Disconnect 8P connector power-l Checkactuatoroperationby connecting groundaccording the tables. to \ P*t,i""-TILTUP
MIRROR POWER
Terminal -_\
o
o o
@ @
TILTDOWN SWINGLEFT R SWING IGHT
swlTcH
rt
23-183
PowerMirrors
(Donnelly Mirror ActuatorReplacement Typel
1. Removethe power mirror from the door (see sect,on 20),and disconnect 8P connector, the 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 housing.
MIRROR HOUSING
6.
Removethe two screws,cut the wire harness, and removethe actuator.

ACTUATOR
2.
BRACKET
MIRROR HOLDER 7. Remove the mirror holderfrom the mirror housing. Gentlypull it out by hand. Remove the three screwsfrom the actuator and the 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. 8. Record terminallocations the and wire colors. Routethe wire harness the new actuator of through t h e h o l e i n t h e b r a c k e t . e s u r et o p a s st h e w i r e B underthe bracketclip.
BRACKET
5.
Remove bracket the from the housino.
9.
Pass connector the boot overthe wire harness.
23-184
\r-
a
10. lnsertthe terminalsinto the connectorin the origii t n a l a r r a n g e m e n( r e c o r d e dn s t e p 7 ) , a s s h o w n Delow.
Left:
Right:
PNK
PNK
' ].
of Apply tape to sealthe intersection the connector boot and the wire harness. Be order of disassembly. in Reassemble the reverse it carefulnot to breakthe mirror when reinstalling to the actuator.
rt
to the 1 3 . Reinstall mirror assembly the door. the power mirror to checkthat the actuator 1 4 . Operate workssmoothly.
rt
23-185
Wipers/Washers
SRScomponents are locatedin this area.Reviewthe SRScomponentlocations, precautions, and procedures the SRS in (24)beforeperformingrepairs service. section or
WIPER/WASHER SWITCH Test,page23-189 WINDSHIELO WIPER ARMS/BLAOES
REARWINDOWWIPER MOTORlHatchbackl Test,page 23,190
WINDSHIELD WIPER MOTOR Test, page 23-189
WINOSHIELD WASHER MOTOR Test,page23'190
FLUID RESERVOIR
nf-___] l.,...--.--_
{ - J l l l
Ilfr
REARWINDOW WASHER MOTOR{Hatchb.ck) Tesl, page 23-190
[ ]_ll-l
23-186
\
CircuitDiagram(Windshield)
FELAYBOX FUSEi UNDEF.HOOD
UNDR-DASH 8OX FUSE/REtAY
]NTEGRATED CONTROL UNT / HasbuiLl'in \ I intem lenl I I wperreray I
rt
WHTiBLK
\t
Y I
BLK
WINDSHIELD WASHER MOTOR
BLK
BLK
G2A2
G401 G402
G401 G402
,I :W]lhCOMBINED WIPERMASHER OPERATION
23-187
Wipers/Washers
CircuitDiagram(RearWindow)
UNDER.HOOD FUSE/RELAY 8OX
REAR WINDOW WIPER MOTOR
REAF WINDOW W]PERA/VASHER SWITCH
,'/-\\:----
----l
BLK
BLK
8LK
G401
23-188
\ _
n\
tY Wiper/Washer Switch Test
Remove the driver's dashboard lower cover (see 20). section columncovers. the 2. Remove steering 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 switch.
'1.
WiperMotor Test Windshield

1.
Openthe hood, and removethe cap nuts.Carefully remove the wiper arms so that they do not touch the hood. Remove the cowl cover by prying out the trim clips (seesection 20). the 5P connectorfrom the windshield Disconnect wiper motor.
SWITCH WIPER/WASHER Terminalside of 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
4.
\t
\
Checkfor continuitybetweenthe terminalsin each to switchpositionaccording the table.
Windshield Wiper/Wssher Swiich:

| ermrnsl \ 1
rostr|on
OFF INT LO
HI
o o oo o o o o o o o
.o o
Test the motor by connectingbattery power a n o groundaccording the table. to \ Terminal
l\4ist switch"0N" "0N " Washer switch
;;ilLOWSPEED
HIGH PEED S
-\
o o
o
@
RearWindow Wiper/WasherSwitch:
\ Terminal
6 5.
lf the motor does not run or fails to run smoothly. replace it. an Connect analogvoltmeterbetweenthe No. 5 (+) and run the motor at low or and No. 3 (-) terminals, high speed. The voltmetershould indicate0 V and 4 V or less alternately.
t*t*---__\
"0N" switch Washer "0FF"} switch {Wiper
OFF
rt
ON " Washer switch0N' "0N") (Wiper switch
o- -o o- -o o- -o o- -o o- -o G -o
23-189
Wipers/Washers
RearWiper Motor Test (Hatchbackl
t. 2. Remove hatchlowertrim panel(seesection the 20). Disconnect 4P connectorfrom the wiper motor the assemDty.
WasherMotor Test
1 . Remove front bumper{seesection the 20). 2. Disconnect 2P connectors the from the washer.
Test the motor by connecting battery power to the No. 1 terminaland groundto the No.3 terminal. 3. lf the motor does not run or fails to run smoothly, replace[. Reconnect 4Pconnectorto the wiper motor. the Connect analogvoltmeterbetweenthe No. 4 (+) an a n dN o . 2 ( - ) t e r m i n a l s . Runthe motor by turningthe wiperswitchON. The voltmetershould indicate0 V and 4 V or less alternately. Testthe washermotor by connecting batterypower and ground according the table. to Terminal Battery Disconnected
Connected @
. .
lfthe motor failsto run smoothly,replace it. lf the motor runssmoothly, littleor no washer but 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 d r o blocked washerhose,or a cloggedpump outletin the motor.
23-190
\
PowerWindows
ComponentLocationlndex
WINDOWRELAY POWER Test,page23 73
P - ( ) ( ) ( )
( )
WINDOWSWITCH PASSENGEB'S FRONT Test,page23-200 BOX FUSE/RELAY POWER WNDOW MASTER SWITCH (Hasbuilt-in controlunit) InputTest,page23-196 Test,page23-194 WINDOWMOTOR PASSENGER'S FRONT Test,page 23_202 (SEdAN) WINDOWSWITCH RIGHTREAR Test,page23-200 RIGHTREARWINDOWMOTOB {Sedanl Test, page 23'202
\t
WINOOW DRtVER'S Test, page23-201 WINDOWSWITCH lS.LEFTREAR Test,page 23-200
LEFTREARWINOOWMOTOR(Sedanl Iest. page 23-202
\t
23-191
PowerWindows
CircuitDiagram(Coupe/Hatchback)
UNDER.HOOD FUSEi FELAYBOX UNDER.DASH FUSE/BELAY BOX
BLK
PASSENGERS WiNDOW I'IOTOR
G55l
G551
BLK
G401 G402
23-192
\
EfI
J
CircuitDiagram(Sedan)
FUSEi FELAY8OX UNDER.HOOD GNT]ONSWITCH AY U N D E R , D AF U S E / R E L8 O X SH
MASTER SWTCH
PASSENGER'S
lt
c 11 8 4
BLUIYEL BLU]oRN 8LK
B5
RED/YEL
3 I LEFT EAF R WINDOW SWITCH
REDYEL RED]BLU
RED/YEL
\I'
WINDOW LEFTREAR MOTOR
rffi-r
lul
FIGHTFEARW NDOW MOTOR FRONT PASSENGER S WINDOW MOTOR
^| ':i"'
3 I FIGHT EAR R W NDOW SWTCH
4I
TCH 8ru;FED I SW
3IFRONT PASSENGERS WINDOW M D R I V ES W N D O W O T O R I 4 F
BLK
BLK
G551
G551
G40l G402
2s-193
PowerWindows
MasterSwitch Test (Coupe/Hatchback)
1.
Removethe master switch from the driver's door panel(seepage23-196). \ 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.

MAIN
Passenger's Switch: Terminal
P",ir"'-T-mil\A2
ON
OFF OFF
A5
A6
A7
swtTcH UP
ON OFF ON OFF
ooo- --o
GG_ G_
--o --o o- --o o- -o *-o --o --o
DOWN
AI
A2 A8
A3
A4 A5 412
A6 A 7
Terminal ol male side terminals
3.
Checkfor continuitybetweenthe terminalsin each 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. the tests are normal. lf the driver'sswitchmust be faulty.
MasterSwitch Test (Sedanl

1. Removethe armrest from the driver's door panel (seepage23-198). f 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 s r o m t h e masterswitch. Switch: F ont Passenger's \
2.
t".-*Tm;\
ON
OFF OFF
Terminal
B1
82
Bl1
cl
oCF
--o
--.o
MAIN SWITCH WINDOW POWER MASTERSWITCH
UP
ON
OFF
o- --o
GG-
SWITCH oRtvER'S
ON DOWN
OFF FRONT PASSENGB'S
--o o- --o
o- --o --o
o- --o
815 Bl6
swlTcH
Left Rear Switch: \
r".-*-f-m}
ON
OFF OFF
Terminal
814
G CF
-_o --o
CF
J=\
H
B7
ON
o- --o
UP
OFF
--o
sideof Terminal maleterminals
00wN
ON OFF
o- --o c)--o oo- --o
B1
B3
B4 B5
Right RearSwhch: \ B8 P."-b"Tmm\ ON OFF

OFF
B8 B9 8 1 0 B r 1
,/1,/
8 1 48 1 5
Terminal
B9
810
c1
Check for continuitv between the terminals in each switch position according to the tables.
UP
ON OFF ON
Driver's Switch: The driver'sswitch is combinedwith the control unit so run the you cannot isolatethe switchto test it. Instead, at masterswitchinput test procedures terminals83, 84' 85, 86 and 87 on page 23-198 |f the tests are normal, the driver'sswitchmust be faulty DOWN
OFF
o -o o- --o o- -_o o- --o G- --o --o o--o o-o oG_
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. 2. Remove driver'sdoor panel,a nd disconnect I2p connectorfrom the masterswitch. the the lnspect connector the and socket terminals be surethey are all makinggood contact. to a lf the terminals are bent,looseor corroded, repairthem as necessary, recheck svstem. and the . lf the terminalslook OK, makethe {ollowinginputtestsal the connector. - lf a test indicates problem,find and correctthe cause, a then recheck system. the - lf all the input testsproveOK,the powerwindow masterswjtchmust be faulty;replace it.
Wire side of femalet6rminals
23-196
L-
!-t\
I '
l-l
v
Csvrty A5 Wire Ta3t condition Underall conditions To3t Desirodresult to for Check continuity ground: Thereshouldbe continuity. Possiblecause if result is not obttined . Poorground (G551) . An open in the wire
BLK
A8 A1 A6 BLU/BLK GRN/BLK the Check driver'swindow motor: connectthe BLU/BLK terminalto the RED/YEL It shouldrun (thewindow moves D/BLU RE terminal.and the RED/ down). BLUterminalto the then turn BLKterminal, RED/YEL the ignitionswitchON lgnitionswitchON (ll) for Check voltageto ground: There should be battery voltage. Blown No. 10 or 11 (20A) fuse in fuse/relaY box the under-dash Faulty power window relaY An open in the wire . Faultydriver'swindow motor . An open in the wire
A4
A3
flr).
A7 window the the Connect GRN/BLK Check passenger's ro the BLUI/EL motor: lt shouldrun (thewindow BLUI/EL terminal terminal,and the BLU/ movesdownl. ORNterminalto the BLKterminal,then turn BLU/ORN the ignitionswitchON window motor Faultypassenger's window switch Faultypassenger's An open in the wire
flr).
A't2
BLU
A8
BLK
the Connect BLU/BLK terminal to the RED//EL terminal,and the BLK terminalto the RED/ then BLUterminal, turn the ignitionswitch
Checkfor voltage betweenthe 6 BLUand BLKterminals:APProx. as be indicated the drivV should er'swindow motor runs.
pulser Faulty motor window Faulty driver's An openin thewire
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 2. Remove driver'sarmrest, the and disconnect 16Pand 1p connectors the from the masterswitch. Inspect connector the and socket terminals be surethey are all makinggood contact. to . . lf the terminalsare bent,looseorcorroded,repairthem as necessary, recheck system. and the lf the terminalslook OK,makethe followinginput testsat the connecror. - lf a test indicates problem, a find and correct the cause, then recheck system. the - lf all the input testsproveOK,the powerwindow maserswitchmust be faulty;replace it.
POWER WTNOOW
swtTcH
ABMREST
Wire sideot femaleterminals
23-198
L.
ry
Cavity Wire Test condition Underall conditions BLK Test: Desiredresult to for Check continuity ground: Thereshouldbe continuity. Possiblecausc il resuh is not obtained . P o o rg r o u n d( G 5 5 1 ) . An open in the wire
B4
c1
B3 BLU/BLK GRN/BLK
for Check voltageto ground: voltage Thereshouldbe batterY
82 B8
B l o w nN o .7 , 8 , 1 0o r 1 1 ( 2 0A ) fuse/relaY fuse in the under-dash box Faultypowerwindow relaY An open in the wire
YEUBLK
8 1 5 RDAr'VHT the Check driver'swindow motor: the Connecr BLU/BLK moves RED/BLU terminalto the RED/YEL It shouldrun {thewindow the RED/ down). terminal,and BLUterminalto the then turn BLKterminal. RED/YEL the ignitionswitchON Faultydriver'swindow motor An open in the wire
B7
B5
0r ) .
the Connect GRN/BLK to terminal the BLU/YEL B1 BLU//EL terminal,and the BLU/ ORNterminalto the then turn BLKterminal, 8 1 1 BLU/ORN the ignitionswitchON flr). connectthe YEUBLK to terminal the YELterYEL B9 a m i n a l , n dt h e Y E U GRNterminalto the then turn BLKterminal, 8 1 0 YEUGRN the ignitionswitchON flr).
Check front passenger's the window motor: It shouldrun (thewindow moves oown).
window front passenger's Faulty motor window front passenger's Faulty switch An open in the wire
the Check right rearmotor: It shouldrun (thewindow moves oown).
Faultyright rearwindow motor Faultyright window switch An open in the wire
the Connectthe REDny'VHT Check left rearmotor: It shouldrun {thewindow moves to terminal the GRN/ 8 1 4 GRNfYEL oown,. YELterminal,and the GRNterminalto the then turn BLKterminal, GRN 816 the ignitionswitchON 0l). the for Check voltagebetween the Connect BLU/BLK BLUand BLKterminals: to terminal the RED/ BLU as Approx,6 V shouldbe indicated YELterminal,and the the driver'swindow motor runs. BLKterminalto the B4 BLK terminal, RED/8LU then turn the ignition switchON (ll).
Faulty left rear window motor Faulty left rear window switch An open in the wire
Faultypulser Faultydriver'swindow motor An open in the wire
{Y
23-199
PowerWindows
Passenger's Window Switch Test
Coupe/Hatchback: 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
Switch side ot 5P terminal:
Checkfor continuitybetweenthe terminalsin each switchpositionaccording the table. to

Terminal
ilil----t
UP
o-
-o o- -o o- -o -o o- -o o- -o
OFF
5PCONNECTOR 2. Disconnect 5P connectorfrom the passenger's the window switch. DOWN
o-
Sedan: 1. Remove armrest(seesection20). the

5P CONNECTOR
ARMREST
wtNDow swtTcH
2. Disconnect 5Pconnector, remove mountthe then the

ing screw from the passenger's switch.
23-200
L{-
E\
v
Driver'sWindow Motor Test
Motol Test: 1. 20)' the Remove driver'sdoor panel(seesection PulserTest: 5. to the Connect test leadsof an analogohmmeter the No. 3 and No. 4 terminals. power and groundto Run the motor by connecting the No. 1 and No. 2 terminalsThe ohmmeterneedle shouldmove backand forth alternately. 6.
sideot maleterminals Terminal
2. 3.
the Disconnect 4Pconnectorfrom the motor' batTestthe motor in each directionby connecting to groundaccording the table. tery power and Terminal 2
\ ;;;;--_l\
UP
DOWN
o
@
CAUTION: When the motor stops running' disconnect one lead immedistelY. 4. lf the motor does not run or fails to run smoothly, it. replace
ly
23-201
PowerWindows
Passenger's Window Motor Test
Front: '1. R e m o v et h e p a s s e n g e r 'd o o r p a n e l ( s e es e c t i o n s 20t. D i s c o n n e ct th e 2 P c o n n e c t o f r o m t h e w i n d o w r motor. Rear: 1. R e m o v et h e p a s s e n g e r ' d o o r p a n e l ( s e es e c t i o n s 20). 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 molor. NOTE:The illustration showsthe right rearwindow motor;the left rearwindow motor is symmetrical.
2.
2.
2P CONNECTOB
2P CONNECTOR
Terminal sideof male terminals
Terminal sideof male terminals
3.
Check window motor operation connecting by power and groundaccording the table. to
Terminal
3.
il;;
UP
-_-l
Check window motor operation connecting by power and groundaccording the tabre. to Terminal
1
t
2
@
DOWN
o o
Direction
UP DOWN
o
@
CAUTION:When the motor stops running,disconnectone leadimmediately. 4. lf the motor does not run or fails to run smoothlv. replace it.
CAUTION: When the motor stops running, discon_ nect ons lead immediately. 4. lf the motor does not run or fails to run smoothlv. replace it.
23-202
f,.!*
I
Moonroof
Gomponent Location Index
SwrTCH MOONROOF Test,page23-206
. MOONROOF CLOSERELAY IWirr colo]s: w T, GRN/YEL, I IGRN/ORN,BLK,lNd GNN/REDJ Test, page 23-73,74 . MOONROOF OPENRELAY IWir. color.: WHT,GRN/REO,l BLK.nd YEL I LGRN/ORN, 3, Te6l. gage 23-7 74
MOTOR Test,page 23-206
\y
23-203
Moonroof
CircuitDiagram
U N D E q . - O O D S E E L AB O X FU R Y No4l (80A) N0.42 (40A) IGNITION SWITCH *1 :96,97 odels m x 2 : 9 8m o d e l
WHT/BLK +_
WHT
UNDER.DASH FUSURELAY 8OX
MOONFOOF OPEN BETAY
MOONROOF SWITCH
BLK
-1r
I
'
OPEN/CLOSESWITCH: . DLrrinq llinoooeraUon the (:lr[!-p Filticlosed) A andC lorminals @nnected. ate ' Durm theslidno ooeraton i (Fullyilosed Fullv opn) A andElermrna arecbnnecied s TILT/CLOSESWITCH: . Du nqthelillinO OOeratron (-Iill ui Fulticlosed) D andF terminalsare corinpded ' DufirE slidno lhe ooeratron -; Fltv oDen) (Fully closed D arldE lermrnals conhecied are
G401 G402
23-204
b.,1
nl
ry
Test Function
CAUTION:8e carsftilnot to damagethe moonroofswhch or the driver's dashboard lowet cover when prying the switch out. NOTE:Checkthe No. 51 {20 A) fuse in the under-hood box and No. 24 (7 5 A) fuse in the under-dash fuse/relay box, beforetestang fuse/relay 1. Pry the switch out of the driver'sdashboardlower cover. from the switch. the Disconnect 4P connector Connectthe No. 1 (YEL)terminal to body ground with a jumperwire,then turn the ignitionswitchON (ll),The moonroofshouldopen. . . lf the moonrooiopens,checkthe switch. lf the moonroofdoes not open,checkfor: - a n o p e ni n t h e Y E Lw i r e - faulty moonroofopen relay. - faulty moonroofcloserelaY. - p o o rg r o u n d( G 4 0 1G 4 0 2 ) . ,
2.
to terminal body ground the Connect No. 3 (YEURED) with a jumperwire,then turn the ignitionswitchON (ll).The moonroof shouldclose. checkthe switch . lf the moonroofcloses, a lf the moonroofdoes not close,checkfor: - an open in the YEURED GRN/RED wire. or - faulty moonroofcloserelaY. - faulty moonroofopen relay. - faultytilvcloseswitch. to terminal bodygroundwith the Connect No. 2 (BLU) a jumper wire, then turn the ignitionswitch ON (ll) The moonroofshouldtilt uP.
4P CONNECTOR
. .
lf the moonrooftilts up, checktheswitch. llthe moonroofdoes nottilt up, checkfor: - an open in the BLUwire. - faultytilvcloseswitch.
to terminal body ground the Connect No. 3 (YEURED) 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. Thereshouldbe continuity. . . checkthe switch lf there is continuity. for: check lf there is no continuity, - a n o p e ni n t h e B L Kw i r e - poor ground(G401, G402)
Wire sideoI femaleterminals
\y
23-205
Moonroof
Switch Test
1. Carefully removethe switchfrom the driver,sdash, boardlower cover(seepage23-205). 2. Checkfor continuitybetweenthe terminalsin each switchpositionaccording the table. to
Motor Test
1, 2. Remove headliner the {seesection20}. D i s c o n n e ctth e 2 P c o n n e c t o r r o m t h e m o o n r o o f f motor.
\ t*,*--_\
OFF
Terminal
l
OPEN
CLOSE
oo-
TILT
--o o- --o --o
Checkthe motor by connectingpower and ground according the table. to
\_ __lg.-rq
Position OPEN CLOSE 4.
o
@
lfthe motor does not run, replace (seesection2O). it NOTE: See Closing Force Checkin section 20 for motor clutchtest.
23-206
\
Switch Test Open/Glose-Tilt/Close

1. 2. (seesection20). the headliner Remove trom the moonthe Disconnect 2P and 4Pconnectors roo{ motor and the switch. betweenthe terminalsin each Checkfor continuitY to positionaccording the table switch Terminal Position CLoSE TltT
3.
o-- --o
G-
CLoSE
4.
oPEN
o- -_o -_o
the adjustor replace switch' ll thereis no continuity,
sideof maleterminals Terminal
\!y
23-207
Cruise Control
MAIN SWIICH TesVReplacement, page23 212
CABLEREEL Replacement, section 24
CRUISE CONTROL UNIT InputTest,page23-210
. Test,page23-214 . Pedal HightAdiustment, section19
swtTctltM/T)
A/T GEARPOSMON
. Test,page23 214 . clutch Pedal Adjustment, section12
swtTcH
. Test,page 23-138 . Replacement, page23 139
ACTUATOR CABLE page23-216 Adjustment,
VACUUM TANK
. . . .
TORASSEMBLY Test,page23-215 Replacement, page23-216 Sotenoid Test,page23_217 Disassembty, page23-218
23-20a
\ -.
CircuitDiagram
AY U N D E R . H O F U S E ] F E LB O X OD No41(80A) No42(40A) GN]TION SWTCH BOX FUSEi RELAY UNDER,DASH
No30{7.sA) FUSE
+WHT WHT/8LK
f7
REDJBLK
NDCATOF LGHT (084W)
WHTi GRN
GAUGE ASSEMBLY
CRNIWHT
5 9
2 1l
7 U C R U EC O N T F O LN I T S
10
l3 3
BRAKE TIGHTS
CRUISE PNK CONTROL ACTUATOR
ELL.JMHT
BLK
l'
:;i", I i"$L:H;JF Yr",) |

A
+ r--l
BLK BLK
\v
A
G202
I'
:
IoN:Pedareeasedl / T
l
G40l G402
G40l G402
23-209
'ry
Control Cruise
ControlUnit Input Test
precautions, in and procedu.es the SRS are locatedin this area.Reviewthe SRScomponentlocations, SRScomponents (24)beforeperformingrepairs service. or section 1. 2. 3. lowercoverand kneebolster(seesection20). Remove driver'sdashboard the Disconnect 14Pconnector the from the controlunit. terminals be surethey are all makinggood contact. to lnspect connector the and socket repairthem as necessary, recheck system. and the lf the terminalsare bent,loose,or corroded, lf the terminalslook OK, makethe followinginput testsat the connector. - lf any test indicates problem, find and correct the cause, then recheck system. the a - lf all the inputtestsproveOK,the controlunit must be faulty;replace it.
CONNECTOR
Wire sideol femaleterminals CRUISE CONTROL UNIT GRN/WHT LTGRN/RED LT GRN/BLK
;--?\
I
2
I
6 10
1l
7
l4
12
13
BRN/BLK
BLU/WHT
LT GRN
"-"0
v
Cavity 9
1 11
Wire BRN/VVHT
BRN BRN/BLK
Test condition Underall conditions Underall conditions Underall conditions lonitionswitchON (ll), riain switchoN and brakepedalpushed, then released
Under all condrtions
Test: Desiredtesult to for Check resistance ground: b s T h e r e h o u l d e 8 0 - 1 2 0O to for Check resistance ground: Thereshouldbe 40 - 60 O' to for Check resistance grouno: b T h e r e h o u l d e 7 0 - 1 1 0O ' s tor Check voltageto ground: Thereshouldbe 0 V with the pedal pushedand batteryvoltagewith the Pedalreleased.
ground: , Check for continuity to There should be continu'tY'
Possiblecau3eit result is not obtained solenoid Faultyactuator Poorground (G202) An open in the wire
. Faultybrakeswitch . An open in the wire
GRY
BLK
GRN/!VHT
BrakepedalPushed, then released
for Check voltageto ground: voltage Thereshouldbe batterY pedalpushed, and 0 V with the with the pedalreleased. for Check voltageto ground: voltage. Thereshouldbe batterY
. Poorground (G401, G402) . An open in the wire B l o w nN o . 5 2( 1 5A ) f u s ei n t h e box fuse/relaY under-hood Faultybrakeswitch An open in the wire Blown No. 52 (15A) tuse in the box fuse/relay under-hood Faultyhorn relaY switch Faultysevresume Faultycablereel An open in the wire B l o w nb u l b Blown No. 25 (7.5A) fuse in the box fuse/relay under-dash Faultydimmingcircuitin the gaugeassemDly An open in the w,re . Faulty vehiclespeedsensor(VSS) . An open in the wire
LT GRN/ RED 7 LT GRN/ BLK
Set button Pushed
buttonPUshed Resume
ly
10
RED/BLU
Attachto ground: light in the gauge Cruiseindicator shouldcome on. assembly
lgnitionswitchON {ll) and main switchON; 't2 BLU/VVHT raisethe front of the car,and rotateone wheelslowlywith the otherwheelblocked. lgnitionswitchON (ll) and main switchON 1 3 LT GRN
the for Check voltagebetween O and BLKO terminals: BLUMHT b s There hould e0- 5 V or more -0 - 5 V or more rePeatedly.
for Check voltageto ground: Thereshouldbe batteryvoltage
Blown No. 14 (7.5A) fuse in the box fuse/relaY under-dash Faultymain switch An open in the wire Faulty A,rr gear Positionswitch clutch Faultyor misadjusted switch(M/T) G402) Poorground(G401, An open in the wire
in A/f: Shiftlever E, b'l or [f

14
PNK
M/T: Clutch pedal released
to for Check continuity ground: Thereshouldbe continuity. NOTE:Thereshouldbe no continuitywhen the clutchPedalis or depressed when the shift lever is in other positions.
'\ty
23-211
CruiseControl
Main Switch Test/Replacement
Remove driver'sdashboard the lowercover(seesection 20). push out the swilch from behindthe dash_ Carefully ooarq.
3. Disconnectthe connector from the switch.
Set/ResumeSwitch Test/Replacement
l. Dlsconnect batterynegatjve the cable,then disconnectthe positivecable,and wait at leastthree min_
UIES.
Disconnect the driver's airbag connector(seesecrion 24). Remove dashboard the driver'slowercover(seesection 20).
4.
Disconnect cablereel sub-harness connector the 3p from the main wire harness.
MAIN SWITCH
BULBS W) {0.84
MAIN WIRE HARNESS 3P CONNECTOR
4.
Checkfor continuity betweenthe terminals of the cable reel sub-harness connectorin each switch 3p positionaccording the table. to
\ Terminal
\ t*t*-\
Terminal
3 /:\ \-/ /:\ \:,,
__\
t^,*
(ON} SET (ON} RESUME
OFF ON
oo
-o
G-
/5
\-/
/5
o o-
\:./
-o -o
o- -o o- ---o
a l f t h e r e i s c o n t i n u i t ya n d j t m a t c h e s h e t a b l e , , t
lf there is no continuity, reOlace switch. the
the switchis OK.

a lf there is no continuityin one or both positions,
go to step6.
23-212
llL *
6.
then removethe switch the Remove two screws,
the cable reel and lf all tests prove OK, reconnect the then reinstall connector. cable reel sub-harness columncovers. steering the 9 . Reconnect driver'sairbag connector,and reinwheel' panelon the steering stallthe access
SET/RESUME
then the negathe 1 0 . Reconnect batterypositivecable, tive cable. , t 1' ]. A f t e r c o n n e c t i n g h e a i r b a gc o n n e c t o r sc o n f i r m Turnthe ignitionswitchON propersystemoperation: (ll);the SRSindicator light shouldcome on for about go off six secondsand then
{y
7.
in the betlveen terminals switch for Check continuity to position according the table.
\ Position
lermlnal \
SET(ON) (ON} RESUME
oo-- -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
1. Disconnect 4P connector the from the switch.
GlutchSwitch Test (M/T)

1. Disconnect 2P connectorfrom the switch. the
1lx lffl
|
|,
l-N7-rl]]ll
2 |
. ll
I
4P CONNECTOR
CLUTCH SWITCH
BRAKE PEOAL Checkfor continuitybetweenthe terminalsaccording to the table. 2. \ tr**On----\ RELEASED DEPRESSED Terminal Checkfor continuitybetweenthe terminalsaccording to the table.
4 \ Terminal
o- --o
-\
o- --o
at**",
RELEASED DEPRESSED
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
\^
Actuator Test
1. cablefrom the actuatorrod the Disconnect actuator and the 4Pconnector' Connectbattery power to the No. 4 terminal and groundto the No. 1, No. 2 and No. 3 terminals a Connect vacuumpump to the vacuumhose Then applyvacuumto the actuator.
VACUUM PUMP GAUGE,0 30 in.Hq. (A973X- 041 -
5.
try With voltageand vacuumstill applied, to pull the rod out by hand.You shouldnot be ableto actuator pull it out. lf you can,it is defective.
2.
3.
xxxxxt
ACTUATOR
groundfrom the No.3 terminal The actuDisconnect ator rod should return. lf it does not return, but the vent hose and filter are not plugged.the solenoid valve assemblyis defective.
iy
.P CONNECTOR
7.
Repeatsteps 2 through 5, and disconnectground 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. be the lf vou reDlace solenoidvalve assembly, sure on to usenew O-rings eachsolenoid. power and ground from the 4P connector' Disconnect the Disconnect vent hose from the actuator.Connect vent hose pon, and a vacuumpump to the actuator rod shouldpull in comapplyvacuum.The actuator 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 . the Reolace aduator.
8.
4.
lfthe rod rod The actuator shouldpull in completely. part-wayor not at all, checkfor a leakpulls in only solenoid. ing vacuumline or defective
ROD ACTUATOR
23-215
Cruise Control
Actuator Replacement
t. Pullbackthe boot,and loosenthe locknut. Then disconnect cablefrom the bracket. the Disconnect cableend from the actuator the rod.
Actuator GableAdjustment
1 . Checkthat the actuator cable operatessmoothly with no bindingor sticking. Stan the engine.Hold the engineat 3,000rpm with no load (Aff in N or E . MfI in neutral)until the radiator comeson. then let it idle. fan 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 3 0 . 0 4i n ) . t
ACTUATOR ROD
2.
LOCKNUT
ACTUATOR CABLE
Disconnect 4Pconnector the from the actuator. Disconnect vacuumhosefrom the vacuumtank. the Pullout the vent hose. 5. Removethe three mounting bolts and the actuator with the bracket.
VACUUM HOSE
LOCKNUT FREE PLAY:11 t 1.0mm {0.43t 0.0i1in}
lf free play is not within specs,loosenthe locknut. and turn the adjusting nut as required. NOTE: lf necessary, check the throttle cable free play (seesection1I ), then recheck actuatorrod the free play.
5.
Retighten locknut, the and recheck free play. the
CABLE 6.
4PCONNECTOR
lf necessary, disconnect cableend from the linkthe age over the accelerator pedal,then turn the grommet 90' in the bulkhead, and removethe cable. Installin the reverseorder of removal,and adjust tree play at the actuator rod after connectingthe cable(seenextcolumn).
7.
rL-
23-216
trll
Test ActuatorSolenoid
1. from the actuator. the Disconnect 4Pconnector
ACTUATOR
2.
betweenthe terminalsaccordCheckfor resistance ing to the table. \ Terminal ;rb"*"Q)---\ VENT SOLENOID 40 - 60() SOLENOIO VACUUIVI 30- 50() SOLENOID SAFETY 40 - 60c) 1
{y
o-- --o oo-o --o
will varv slightly with temperaNOTE: Resistance is resistance at 70'F (20'C). ture;specified
VALVE SAFETY VACUUM VALVE
From VENT HOSE
To VACUUM TANK
{y
23-217
Cruise Control
ActuatorDisassembly
ACTUATOR CABLE
ACTUATOR BRACKET
CHECK VALVE
@,
SOI.ENOIDVALVES Tesr.page 23-217
WIRESUPPORT ERACKET
ACTUATOR page23-215 Test,
\9
o
elR
YAJ
e
FILTER COVER
23-218
E
PowerDoorLocks
Y
entry system): NOTE(With keYless but the LEDon the transmitterdoes not come on, the LED is faulty; . lf the doors unlockor lock with the transmitter. the replace transmatter. (However, comeson tor 30 seconds. the . when you unlockthedoorswith the transmitter, ceilinglight (middleposition) on l the if the audio unit is not installed, light does not come a lf any door is open,you cannotlockor unlockthe doorswith the transm'tter' does not activatethe horn repeatedly . The horn soundsonly the first time you press a transmitterbutton. (Pressing agatn.l the but do not open any of the doors within 30 seconds, doors relock the doors with the trsnsmitter, . lf vou unlocked automaticsllv. if . The doorsdo not lockor unlockwith the transmitter the ignitionkey is insertedin the ignitionswitch. and the transmitter the . lf you pressthe PANICbuttonfor more than two seconds, horn soundsfor about 30 seconds, is in the ignitionswitch.)The panic mode is if LEDcomes on. (The panic mode will not be activated the ignition key buttons. any of the transmitter by cancelled pressing the pressthe lockand unlockbuttonsfive or six timesto activate transmltter' the o After replacing t;nsmitter battery.
LEFTREAROOORLOCKACTUATOR Test, page 23-229 20 section Replacement,
RIGHTREARDOORLOCKACTUATOR Test, page 23-229 section20 Replacemnt,
DOORLOCKACTUATOR PASSENGER'S FRONT Test, page 23-229 section20 Replacemnt,
AUDIOUNIT RADIOTUNER) {STEREO keylossl /Hasbuih-in qrcu|l I \tecorvor page 23-169 Replacemont. Input Test,page 23-226 page23-228 Terminals,
LOCKACTUATOR Test, page 23 229 20 section Replacement,
t-.a
@ \ql
TRANSMITTER KEYLESS page23-231 Codes, oI Storing Transmitter TesvReplacement, 23 230 Page
DOORLOCKSWITCH DRIVER'S Test,page 23'228
POWEB OOORLOCK CONTROL UNTT lnputTest,page23-224
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F,,
23-219
PowerDoor Locks
CircuitDiagram(With Keyless EntrySystem)
UNDEFHOODFUSE/RELAY BOX No41(804) N0.42 (40A)
WHT/BLK WHT/RED WNT/BLU
POWER DOOR LOCK CONTHOL T UN
unLocx@ @ rocx
BLK
DOOF LOCK LOCK KNOB KNOB
GRN,4VHT GRN/ORN
n
]
I
xev
r--1--n1
WHT/FED
io'
LOCK
L FEAR llro* E N G E R ' S PASS

I
i-A-r I LIJ I
YEUFED
l , l
i-H__!J
lRsi^"s'
gLK
BLK
G551
G551
G551
23-220
I
]GNITION
swrTcl.l
BLK/YEL WHT/BLK
WHT/REC
|-+-_-+-l
YEUREDBLK/YEL
'J | r'ro.zg Norq I UNDEF-DASHY ) FUSE/RELA ( (roA)f, (7.5A) BOX HORN | |
RELAY
T
GFY T GRN/BED
T RUNK LIGHT
RECEIVER CIRCUlT KEYLESS (lnlheaudio un()
BLU/RED
l*recnereo
UN|T I coNTRoL
BLU/FED
ilt)
I I A A d\ v-, Y,,, f*,o" Il$'.i')""' I'r,t*rt* l::;=:-' l:xH i liff.ii ;

I REAR I DoOF
| :,.s!. | | loe. lccf opn loor c osed BLK
r
|
I Y
UN|T I CONTRoT t'---l-----"--------'7
| *rrurorro
,,u'rro
tr(
GRN
IL,.-)
LTG R N / F E D GRN/RED
LTGRN/RED
t_
v
oio,
G402 G401 G402
8silsr.:,to*" l I I lt3'tri'
FIGHT REAR DOOR SWITCH :uooropenI ubseo (Open :0oor closed ,l
I
-l
23-221
PowerDoor Locks
(WithoutKeyless CircuitDiagram EntrySystem)
UNDEF.HOOD FUSEi RELAY 8OX
DOOR LOCK KNOB t

I
DEIVER'S DOOH LOCK SWTCH
BLU/WI-17
WHT/FED
BLUi NED
POWER DOOR LOCK CONTROL UNIT
BLK
I
\
BLK
G551
G55l
23- 2 2 2
Troubleshooting
sequence NOTE:The numbersin the table show the troubleshooting Itemto be inspected
E
o _9
t 3
)
f
.z
-o o
3 :
{ p
; o
: ;
.g
9 - )
= E
o
F
9 c
Symptom Powerdoor locksystemdoes not work at all. Doorsdon't lockwith driver's door lockknob switch. Doorsdon't lockor unlock with driver'sdoor lockswitch. All doors O n eo r m o r e doors All doors 1
1 1
E5
2
(J
O Y o
3 n ' .z
< :
IL
2 3 1 2
G551
WHT/GRN
BLU,ryVHT
YEURED or WHT/RED
ry
GRN,ryVHT, GRN/ORN, YEURED or WHT/RED

YEURED or WHT/RED 1 2 G401 G402 or GRNAVHT GRN/ORN
O n eo r m o r e doors * The powerdoor locksystemworksproperlybut the keylessentry system doesn't. *: with keyless entrysystem
NOTE: . When the remotetransmitterbutton is pressedthe first time, only the driver'sdoor will unlock.When the button is time, all the doorswill unlock. the Dressed second ifa after30 seconds door is notopened,orthe key isout ofthe ignitionswitch . Thedoorswill relockautomatically . The keyless systemwill not lockor unlockthe doorswhen the key is in the ignitionswitch. entry
!y
PowerDoor Locks
ControlUnit InputTest
' t . Remove the driver'sdoor panel(seesection 20). 2. Disconnect 12Pconnector the from the controlunit. lnspect connector the and socket terminals be surethey are all makinggood contact. to a lf the terminals are bent,looseor corroded, repairthem as necessary, recheck system. and the . lf the terminalslook OK,makethe followinginputtestsat the connector. - lf any test indicates problem,find and correctthe cause, a then recheck system. the - lf all the inputtestsproveOK,the controlunit must be faulty;replace it.
12PCONNECTOR
YEL/RED GRN/WHT
2
1 I
5 12
BLU/WHT
Wiresideof female terminals *r With keylessentry system
t-
23-224
v
from the power door lockcontrolunit. Disconnect l2P connector the CAUTION: To prevent damage to the actuator, apply battery voltage only momentarily. Cavily Wire BLK Test condition
Under all conditions
Test: Degiredresult to for Check continuity ground: Thereshouldbe continuity. for Check voltageto ground: voltage. Thereshouldbe battery Checkdoor lockoperation: All passenger's doorsshould untocK.
Possiblecause if result is not obtained . P o o rg r o u n d( G 5 5 1 ) . An open in the wire . Blown No. 51 {20A) fuse in the box fuse/relay under-hood . An open in the wire Blown No. 51 (20A) fuse in the fuse/relay box under-hood Faultyactuator An open in the wire
't2 WHT/GRN
U n d e ra l l c o n d i t i o n s
the Connect YEURED to terminal the WHT/ and GRNterminal, the YEURED to WHT/REO terminal the BLKterminal momentarily. connectthe BLU/RED terminalto the WHT/ GRNterminal.and the BLU/RED WHT/RED terminalto the BLKterminal momentarily. the Connect WHT/RED terminalto the WHT/ G B Nt e r m i n a la n dt h e , WHT/RED terminalto YEURED the BLKterminal momenranry. Underall conditions.
Check door lockoperation: Driver'sdoor shouldunlock.
ry
5
door lockoperation: Check doorsshouldIock. All passenger
BLUI/EL
the for Check continuitybetween power door lockcontrolunit 12P No.6terminaland audio connector No.3terminal: unit 16Pconnector Thereshouldbe continuity.
. An open in the wire
*: With keylessentry system to Reconnect 12Pconnector the powerdoor lockcontrolunit. the Cavity Wire GRN/WHT
6
Test condition Driver's door lock switchin LOCK Driver's door lock switchin UNLOCK
Test: Desiredresult for Check voltageto ground: Thereshouldbe 1 V or less.
Possiblecause if result is not obtained Faultydriver'sdoor lockswitch r o o r g r o u n ot ( l 5 5r , An open in the wire Faultydriver'sdoor lockactuator P o o rg r o u n d{ G 5 5 1 ) An open in the wire
GRN/ORN
Driver'sdoor lockknob BLU,Mr'HT in LOCK
for Check voltageto ground: Thereshouldbe 1 V or less.
ty
23-225
PowerDoor Locks
Audio Unit (KeylessReceiverCircuitl Input Test (with keylessentry systeml
(seepage23-169). the Remove audio unit,then disconnect A and B connecto.s the terminals be surethey are all makinggood contact. to and socket Inspect connector the . . the repairthem as necessary, recheck system. and are bent.looseor corroded, lf the terminals lf the terminalslook OK, makethe followinginput testsat the connector' - lf anv test indicates problem, the find and correct the cause, then recheck system. a - lf all the input testsproveOK,the controlunit must be faulty;replace at.
A CONNECTOR
B CONNECTOR
AUDIOUNIT RECEIVER CIRCUIT) {KEYLESS
23-226
\.
v
from the audio unit the Disconnect A and B connectors Cavity A4 Wire WHTiBLU
lgnition switch ACC {l}
Test condition Underall conditions
Test: Desiredresult to for Check voltage ground: Thereshould be batteryvoltage. to for Check voltage ground: voltage. Thereshouldbe battery to for Check voltage ground: There should be batteryvoltage. to for Check continuity ground: There should be continuitv. for Check voltageto ground: Thereshouldbe 1 V or less. for Check voltageto ground: Thereshouldbe 4 V or more.
Possiblecauseif result is not obtaind . Blown No. 47 (7.5A) fuse in the box {use/relay under-hood . An open in the wire Blown No. 28 (10A) fuse in the box fuse/relay under-dash An open in the wire . Blown No. 14 (7.5A) fuse in the fuse/relay box under-dash . An open in the wire G402) Poorground(G401, An open in the wire G402) Poorground {G401. Faultyignitionkey switch An open in the wire Shortin the wire
YEURED
B6
BLfiEL
Underatl conditions BLK lgnitionkey inserted into the ignitionkeY switch lgnition key removed from the ignitionkey switch Under allconditions
BI
BLU/RED
B3
BLU//EL
Checktor continuity betweenthe No. 3 teraudio unit 16Pconnector minal and power door lockcontrol No. 6 terminal: unit 12Pconnector Thereshouldbe continuity. to Connect ground: The ceilinglight shouldcome on.
. An open in the wire
B8
LT GRN/ BLK
Ceiling light switch in "middle position"
Blown No. 43 (7.5A) fuse in the box tuse/relay under-hood Blown ceilinglight bulb Faultyceilinglight An open in the wire . Faulty door switch . An open in the wire Blown No.52 (15A) fuse in the box fuse/relay under-hood Faultyhorn Faultyhorn relay An open in the wire
814
LT GRN/ RED
Eachdoor open,one at a Irme Underall conditions
for Check voltageto ground: Thereshouldbe 1 V or less. to Connect ground: Horn shouldsound.
B16
GRY
only to the audio unit. the Reconnect B connector Cavity wire Tsst condition door lock Driver's switchin UNLOCK door lock Driver's switchin LOCK Driver'sdoor lock switchin UNLOCK Driver's door lock switchin LOCK Test: Desiredresult for Check voltageto ground: Thereshouldbe 1 V or less. for Check voltageto ground: Thereshouldbe 4 V or more. for Check voltageto ground: Thereshouldbe 4 V or more. fo. Check voltageto ground: Thereshouldbe 1 V or less. Possiblscause if r93ult is not obtaingd Poorground(G551) Faultydriver'sdoor lockswitch An open in the wire Shon in the wire Poorground (G551) Faultydriver'sdoor lockswitch An open in the wire Short in the wire
B9 GRN/ORN
8 1 0 GRN/WHT
23-227
PowerDoor Locks
Audio Unit (keylessreceiver circuitlTerminals
16PCONNECTOR
Driver's Door Lock Switch Test

1. 2. Remove the innerhandle(seesection20). D i s c o n n e ctth e 3 P c o n n e c t o r r o m t h e d o o r l o c k f
Cavity
Wire
Dsstination lgnitionkey switch Trunk latchswitch Valetswitch (lN) Security N o . 1 4( 7 . 5 ) f u s e A (D2) Security
\
B1 'B2 B3
B4 *85 *87 88 B9
BLU/RE D
LT GRN BLU LT BLU BLK/YE L ORN
BLU/YEL Unlock(Driver's door)

Terminal I
Position LOCK OFF UNLOCK
LTGRN/BLK C e i l i n gi g h t l
( G R N / O R N U n l o c k A l ld o o r )
----o o o
8 1 0 GRN^r'r'HTLock(Output) * B 1 1 BLU^ll/HT LED O *812 WHT/BLK Secufity(D0) *Bl3
YEUBLU
BLK GRY
(D1) Security , n G r o u d ( G 4 0 1G 4 0 2 )
HOrn
B l 4 LT GRN/RED Door switch 815

DRIVER'S DOOR LOCK
*i Forsecurity system(option)
swtTcH
Driver'sDoor LockActuatorTest
1. 2. the Remove driver'sdoor panel{seesection20). from the actuator. the Disconnect 4Pconnector
DoorLockActuatorTest Passenger's
'1.
door panel {see section Remove the passenger's 20t. from the actuator. the Disconnect 2Pconnector door lock actuatoris NOTE:The front passenger's shown;the left rear and right rear door lock actuators are similar.
v
Termin.l srdc ol mele l.rminals
3.
Checkfor continuity between the terminals in each ro knob switchpositionaccording the table Terminal 3.
sideoI maletorminals Terminal
Position
LOCK UNLOCK
4.
o--l
power and Checkactuatoroperationby connecting ground according the table. To preventdamage to apply batteryvoltageonly momento the actuator, tarily. Terminal
Checkactuator operation by con.!ct'ng power ano ground according the table.To p.went damage to to the actuator, apply battery voltage only momentarilv. Terminal
r-*r,r""----_\
LOCK UNLOCK 4.
o
@
;".ltfi
-\
1
@
it replace failsto work properly, lf the actuator
LOCK
UNLOCK
{y
5.
lf the actuatorfails to work properly, .eplace it.
23-229
PowerDoor Locks
Transmitter Inspection/Replacement
NOTE: . lf the doors unlockor lock with the transmitter, but the LEDon the transmitterdoes not come on, the LEDis faulty; replace transmitter. the . lf any door is open,you cannotlockor unlockthe doorswith the transmitter. . lf you unlocked with the transmitter, but do not open any of the doors within 30 seconds. the doors relockautomatically. . The doorsdo not lockor unlockwith the transmitter the ignitionkey is inserted the ignitionswitch. if in
Door3cannot bo locked o. unlockedwith the transmittor.
Pressthe lock or (rnlockbutton five or six times to r6sotthe transmtter.
CQ
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 transmitter cod, then try to lock/unlock the doors(seepage23-231).
\*
23-230
Storing of Transmitter Codes

NOTE: was can be stored in the control unit (lf a fifth code is stored'the code which . The codesof up to four transmitters storedtirst will be erased.l storedcodeswill be erased' mode,all previously . Whenthe systementersthe registration mode and returnsto the normalmode if you the . The systemleaves registration - turn the valetswitchOFF.or - turn the ignitionswitchOFF, or - do not Dress transmitter buttonfor more than 10 seconds' the Procedure:
1. lnsertthe ignitionkev into the ignitionswitch. 2. Turn the ignition switch ON flr). VALETSWITCH
go Within 1Oseconds, to step3.
ry
3. Pressand hold the valet switch lor at leastfive seconds. (Youwill hearthe soundof the t! actuators rningto UNLOCK.)
NOTE:lf the tuner is turned ON, it will go off and come on againwhen the regprocedure completed is istration
r-r . l-r l-l I t ' t t t l
go Within 10seconds, to steP4.
4. Pressone of the transmrtter buttons. (Youwill hearthe soundof the to turning UNLOCK.) actuators
NOTE: lf you want to registerthe codes of more than one transmitter,repeatstep with the ne)dtrans4 within 10 seconds mitter,
NOTE:Afterstoringits code,makesure the transmitter works properly oy pressingone of its buttons. repeatedly (The system starts to work when You pressany transmitter button six times )
TRANSMITTER
23-231
SupplementalRestraintSystem (SRSI
21'2 ..........' Tools... Speciaf Component/WiringLocations """21'3 fndex .'.............. 2/t-5 ................ Description ..'.,,,..2+6 GircuitDiagram Troubleshooting -....' ....... 24'13 Procedures Seff-diagnostic 24-13 the Reading DTC ........'.."...............'. ' Erasingthe DTGMemory ...."......" 24-15 Troubleshooting Intermittent .'--..........24-15 Faifures Precautions/Procedures 24-16 ...."..................21'7 SRSUnit ldentification....'..."...'..'... Precautions Generaf TroubleCode (DTCI Diagnostic Airbag Handlingand Storage ......".21-7 - '96 - 97 Mode|s............'... 24-17 Chart 2/t-8 SRSUnit Precautions....'................. (DTCI TroubleCode Diagnostic 24-8 lnspectionAfter Deployment '......'. '98 Model .....""""" """"" 24-19 chart 2tt-9 ".....",........"...... WiringPrecautions SRSIndicatorLight Wire Backprobing SPring-loadedLock ......24'25 Connections .-.,....2+S Connectors .............24-26 Flowcharts Lock Connector......'2+10 Spring-loaded Airbag Spring-loaded Lock Connector with ....",..24-67 acement Repf 2it-1 ShortContact'......'......... 0 Built-in .................24-70 Disposaf the Disconnecting Airbag ......21-11 CableReel Connector(s) 2+12 ..."....24'72 ..-..--... Precautions acement Repf Steering-related SRS Unit Repf acement .'.......24-76
'c \y
Tools Special
\
Ref.No. Tool Numbel 07HAZ 07PAZ 071AZ 07TAZ SG00400 0010100 5250200 0010204 Description Deployment Tool SCSService Connector SRSService Connector 0) {2 Backprobe Adapter,17 mm Oty 1 1 1 PageReferencs 24-70 24-' t4 24-42 24-30
o
6,
@-
*: Usewith the stacking patchcordsfrom T/N 07SAZ- 0010004, Backprobe Set.
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 { 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 , s e t h e S R S I n f l a t o r r , u Simulator,T/N 07SAZ- T8401'lA,and the SRS Simulator Lead C, T/N 07TAZ -525011A. When the SRS Service "2 Connector O),T/N 07TAZ 5250200, calledfor, connect is {2 the leadto one of the simulator's 0" iacks.
Locations Gomponent/Wiring
v Airbag lndex:With FrontPassenger's
LIGHT{ln the gauge assemblv) SRSINDICATOB Troubleshooting, Page24-13 23 section sssemblY, Gauge
To HORN CABLEREEL Replacement, page 24-72
AIRBAG To ORIVER'S ORIVER'SAIRBAG ASSEMBLY Replacement, page 24-67 Disposal,page 24-70
ry
DASHBOABDWIRE HARNESS UGHT in ro SRSINDICATOR GAUGEASSEMBLY 5P CONNECTOR
AIRBAG PASSENGER'S FRONT ASSEMBLY Replacement, Page24-67 Disposal,Page24-70
sRSMAINHARNESS ro CABII EEEL 2POONNECTOR
CHECK SERVICE {2Pl coNNECTOn BLKI IBRN,
SBS MAIN
to UNDER.DASH BOX FUSE/RELAY 2PCOT{NECTOR
SRS MAIN HABNESS to FRONTPASSENGER'S AIREAG 2P CONNECTOR
SRSMAINHARNESS to sRSUttlT 18P CONNECTOR MAIN

MEMORYEMSE SIGNAL EPI IMES)CONNECTOR IGRY,GRYIot [GRN,GRNI HARNESS
SRS MAIN I{ARNESS to MAIN WME HANNESS 3P OONNECTOR
HABNESS MAINWIRE HARNESS WIRE to DASHBOARD 24PCONNESTOR
SRS UNTT {lncludingsaling snsor and imPactsensor) Page24-76 Replacement,
24-3
Component/Wiring Locations
Index:Without FrontPassenger's Airbag(Partof CANADA Model)
\
SRSINDICATOR UGHT(ln the gaugeassembly) page24-13 Troubleshooting, Gauge assembly, section 23
swtTcH
CABLEREEL Replacement, page 24-72 To CRUISE CONTROL
sEt
swtTcH
DASHEOARD WIREHARNESS tO SRSINOICATOR LIGHTiN GAUGEASSEMBLY 5P CONNECTOR
DRIVER'S AIREAG ASSEMBLY Replacement. page2+67 Disposal,page 24-70
To DRIVER'S AIRBAG
SERVICE CHECK CONNECTOR {2PI IBRN,BLK] SRSMAIN HARNESS
SRSMAIN to UNOER-DASH FUSE/RELAY BOX 2P CONNECTOR SRSMAIN HARNESS to SRS UNIT 18PCONNECIOR
SRS UNIT {lncluding safingsensor and impactsensor) page 24-76 Replacement,
DUMMYRESISTOR
SRSMAIN HARNESS MEMORYERASE SIGNAL io MAIN {MESICONNECTOR I2PI WIRE IGRY,GRYIo. [GRN,GRNI HARNESS 3P CONNECTOR
24-4
Description
v
(and to with the seatbelt,is designed help protectthe driver The sRS is a saletydevicewhich,when used in conjunction lrontpassenger)inafronta|lmpactexceedingacertainset|imit'ThesystemconsistsofthesRSunit(inc|udingsafin (andlront passenger's airbag)' the sensorand impactsensor), cablereel,the driver'sairbag
AIBBAG ORIVER'S
CABLEREEL
Operation ThemaincircuitintheSRsunitsensesandjudgestheforceofimpactand,ifnecessary,ignitesthein'|atorcharge(s batteryvo|tageistooloworpowerisdisconnectedduetotheimpact,thevoltageregu|atorandtheback.uppowerci will respectively keepvoltageat a constantlevel'
Fol the SRSto operate: signalsto the microprocessor' and sendelectric {1) The impactsensormust activate, to and must sendsignals the airbaginflator(s)' the signals, mu$ compute (2) The microprocessor igniteand deploythe airbag(s)' must {3) The inflator(s)
*;_--l ff*:
+
i*wt t gsIF'-'"
I
Self-diagnosisSysiem turned oN (ll)' the sRS indicatorlight comes circuitis built into the sRs uniu when the ignitionswitch is A self-diagnosis normally if off on and goles afteraboutsix seconds the systemis operating an if it comeson while driving,it indicates abnormallf 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 to nected the DLC(16P).
24-5
CircuitDiagram
UNOER HOOD FUSE/NETAY 80X WHT/BIK +-WHT
IGNITION SWITCH
L
UNDEROASH FUSE/RELAY BOX
SRS INDICATOR CIBCUIT {lnthegauge assmblyl SRS INOICATOR t-tGHT t1.4W)

Bfake systm light
BLKffEL
PGM-FI
passenge/s airbag
p8ssnger's aib8g
! sytru%,Ii / I
BLK
[**-*i-l
DRIVER'S AIRBAG INFLATOR
I lfrsEsATGE*s I rNFr.AroR
- \ i I
GRY (GRN}
GRY IGRN}
10 16 17
14
1 15 GRY IGBN)
13
6 SRS UNIT 9 GRY IGRN) t8
TIVA) I
3{VB)
LT8LU I
t
l l
BRN
8RN
t t
G401 G402
G80t
DATA TINK ECM/PCM SERVICE CONNECTOR CHECK {DLC)(16P) CONNECTOR
f7
t " " t
MEMORY ERASE (MES) SIGNAL CONNECTOR I2PI
t.rTl
SRS UNITTERMINALS
24-6
ti
Teminalsideof lnaleierminals
res Precautions/Procedu
v
Precautions General
. Carefullyinspectany SRSpart before you install it Do not install any part that shows signs of being dropped or improperly handled,such as dents, cracksor deformaI|on: - Airbagassemblies - Cablereel - S R Su n i t
Airbag Handlingand Storage

the Do not try to disassemble airbagassemblylt has no parts. Once an airbag has been operated serviceable or (deployed), cannotbe repaired reused. it duringser of storage the airbagassembly Fortemporary the followingprecautions: observe vice,please . with the pad surStorethe removedairbagassembly airbag front passenger's) face up. The driver's {and has (have)a built-in short contact{see connector(s) page24-11J.
r the airbagis improprlYstored 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 to 1OmA (0.01A) or lesswhen switched the smallest value in the ohmmeterrange.A testerwith a higher output could damagethe airbagcrrcultor causeaccliniury. and possible dentaldeployment ) Do not install used SRS parts lrom anothervehicle useonly new pans' When makingSRSrepairs, e r E x c e p tw h e n p e r f o r m i n g l e c l r i c a il n s p e c t i o n s , both the negativecableand posialwaysdisconnect tive cable from the battery,and wait at least three work. minutesbeforebeginning . R e p l a c e m e no 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 / t 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 wheel: donewithout removingthe steering l F o r c o m b i n a t i o n i g h t a n d w i p e r w a s h e rs w i t c h 23 see replacement, section switch replacement, For cruisecontrolsevresume 23. seesection .
AIRBAGCONNECTORS {Withbuilt'inshortcontact)
Store the removedairbagassemblyon a secureflat surfaceawav from any high heat source(exceeding or detergent and 212'Ft1OO"CI free of any oil, grease, water,
Wheneverthe ignition switch is ON tllr, or has been turned OFFfor lessthan three minutes be carefulnot c t o b u m pt h e S R Su n i Ut h e a i r b a g ( s lo u l da c c i d e n t a l causedamageor injury' ly deployand
CAUTION: lmproper handling ot storage can internally damagethe airbag assembly,making it inoperative' lf you suspeqtthe airbag assembly has been damagGd, install a new unit, and refer to the Deployment/Disposal procedures disposingof the damaged airbag. for
{y
. Whenever the airbag(s)has(havelben activated, the reolace SRSunit.
24-7
Precautions/Procedu res
SRSUnit Precautions
Takeextracarewhen paintingor doing body work in the area belowthe dashboard. Avoid directexposure 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 spraying equipment. 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 ) (seepage24-11l,. nectingSRSharness connectors After any degreeof frontal body damage,or after a collisionwithout airbagdeployment, inspect the SRS unit for physicaldamage.lf it is dented,cracked, or deformed, reDlace it.
lnspection After Deployment

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 ) deployed, replace SRSunit,and inspect following: the the l. Inspectall the SRS wire harnesses. ReDlace, don't repair,any damagedharnesses. Inspect cablereelfor heatdamage. thereis any the lf damage, replace cablereel. the 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 y e p a i r e dt,u r n t h e r ignitionswitchon, lf the SRS indicatorlight comes on for aboutsix seconds and then goes off. the SRS systemis OK. lf the indicator light does not function properly, to SRSTroubleshooting. go
2.
3.
Be surethe SRSunit is installed securely. Do not disassemble SRSunit. the 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 installation replacement, carefulnot to or be bump (impactwrench,hammer,etc.)the areaaround the SRSunit. The airbag(s) could accidentally deploy and causedamageor injury.
24-8
\
I
v Wiring Precautions
. Neverattemptto modify,spliceor repairSRSwiring yellow by NOTE:SRSwiring can be identified special covering. outer Protective
Lock SPring-loaded Backprobing Connectors

. on voltageor resistance this type of When checking to the connector first time, it is necessary removethe probesfrom the wire side to retainer inserttester to NOTE: lt is not necessary reinstallthe removed the retainer; terminalswill stay lockedin the connec tor housang.
wiresso that they are not the Be sureto install harness with otherparts. or Dinched interfering
RETAINER * Discard afterremoval.
v
To removethe retainer,insert a flat tip screwdrtver and carefully betweenconnectorbody and retainer, pry out the retainer' NOTE;Takecarenot to breakthe connector'
RETAINER FLATTIP SCREWDRIVER
a 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 s r e c l e a na n d for fastened optimum metal-togroundsare securely Poor groundingcan causeintermittent metalcontact. that are difficultto diagnose. Droblems
RETAINER
24-9
Preca utions/Procedu res

Spring-loaded Lock Connector
SomeSRSsystemconnectors havea spring-loaded lock. Disconnecting To release lock,pull the spring-loaded the sleeve toward the stopwhile holdingthe opposite halfof the connector. Thenpull the connector halves apart. 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 connector half. SPRING.LOADED SLEEVE
Spring-loadedLock Connectorwith Built-in Short Contact

The driver's airbag (and front passenger.s) airbag has ( h a v e )a s p r i n g - l o a d e do c k c o n n e c t o r i t h a b u i l t - i n l w short contact. When this connectoris disconnected. the 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 connector automatically are shorted. Conneqtothalves disconnected:
GROUNO TERMINAL
D o n o t p u l l o nt h i s halfot the connector.
Connecting 1. Holdthe pawl-side connector half,and presson the backof the sleeve,side connector half in the direction shown. As the two connector halves are pressed together, sleeve pushedbackby the pawl. the is NOTE:Do not touch the sleeve.
SHORTCONTACT
CASLEREEL CONNECTOR
Connegtor halves connected: GROUNDTERMINAL
Whenthe connector halves completely are connected. the pawl is released, and the spring loadedsleeve
locks the connector. SPRING-LOAOED SLEVE
| 24-1O It
the Disconnecting AirbagGonnector(s)

disconnect the nogltiv! blttrty To provant accidenlal ai.bag dsploymsnl, turn the ignition switch oFF' !u@ ..lt-.. and wait th,ee minutes before disconnectingany sRs connostors' . . both airbaqs(C' D)' (A) the Beforedisconnecting SRSmain harness from the SRSunit' disconnect (C)' the nector(B),disconnect driver'sairbag2Pconnector the Beforedisconnecting cablereel2P con
1.
the negativebatterycable,and wait at Disconnect leastthrse minutes. the Disconnect airbagconnector(sl.
Sids: Front Passonger's . the the Remove glove box.then disconnect front passenger'sairbag2P connectorand SRSmain harness 2P connector.
2.
Driver's Side: . Removethe accesspanel from the steeringwheel, and the then disconnect driver'sairbag2P connector cablereel2Pconnector.
PANEL AOCESS
{y
Precautions/Procedu res
Steering-related Precautions
SteoringWheel and Cable ReolAlignment NOTE:To avoid misalignment the steeringwheel on of reassembly, make sure the wheels are turned straight aheadbeforeremovingthe steering wheel. SteeringColumn Romoval GAUTION: . Betoro rmoving the steering column. first disconnect tho connector between ihe cable 1a9l and tho SRSmain harness. . lf the steering column is going to be removed without dismounting the stering 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 airbagassembly and cablereel are disconnected.and the batteryis reconnected and the ignition 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 disconnecting the spring-loadedlock type connector, refer to page24-10.
Rotate cablereelclockwise the until it stops. (approximately Then rotateit counterclockwise two and a halfturns) until the arrow mark on the cablereel label pointsstraightup.
ARROWMARK
SRS MAINHARNESS 2PCONNECTOR Do not replace originalsteering the wheelwith any other d e s i g nb e c a u s e t w i l l m a k e i t i m p o s s i b l eo p r o p e r l y i t installthe airbag(only use genuineHonda replacement parts). After reassembly,confirm the wheels are still turned straightaheadand that the steeringwheel spokeangle is correct.lf minor spokeangleadjustment necessary, is do so only by adjustingthe tie-rods,not by removing and repositioning steering the whee..
24-12
\)
Troubleshooting
Y
Procedures Self-diagnostic
to storethis intormaot functionof the sRs systemallowsit to locatethe causes systemproblemsand The self-diagnostic via this troubleshooting, datacan be retrieved a data link circuit' For tion in mem-ory. easier
.whenyouturntheignit|onsw|tchoN(||},thesRsindicatorwi||comeon.|fitgoesoffattersixseconds,thesys normar. in memory.and turns the . lf there is an abnormality, systemlocatesand definesthe problem,storesthis information thesRsindicator|ighton.Thedatawi||remaininthememoryevenwhentheignitionswitchisturnedof'orif tery is disconnected. and turn the ignitionswitch oN (ll)' to connector the sewicecheckconnector(2P), the scs service . when you connect by troublecode (DTC) the numberol blinks' the light will indicate diagnostic the SR3 indicator for with the troubleshooting this code' the recording DTC,proceed . After readingand Precautions A) makesure its outputis 10 mA (0.01 to . Useon|y a digita|mu|t|meter checkthe system.|f it,s not a Hondamultimeter, could damagethe with a higher output or lesswhen switchedto the smallestvalue in the ohmmeterrange.A tester iniury' and possible airbagdeployment circuitor causeaccidental airbag be caretulnot to bump the r Whenever the ignitionswitchis oN (ll),or has beenturned oFF for lessthan three minutes, and causedamageor injuries' deploy could accidentally SRSunit;the airbags airbag the disconnect driver'sairbagconnector(and the front passenger's . Beforevou removethe sRS main harness, connector). valueswon't be charged(seesection23). lf the batteryis dead or low, measuring . Make surethe batteryis sufficiently . correct. and do not connectthe terminals connectors, Do not touch a testerprobeto the terminalsin the sRS unit or harness connector' set with a jumperwire. Useonly the backprobe and the SCSservice referto page24-9' lock spring-losded type connectors, For backprobing
the DTC Reading

light is on, readthe DTCusingone of thesemethods: Whenthe SRSindicator
(DLC), and follow the tester'sprompts' lf the tester the HondaPGM Testerto the 16PData Link Connector A. Connect indicatesnoDTc,doub|e-checkbyjumpingtheservicecheckconnectorandwatchingthesRsindicator next page).
HONDAPGMTESTER
{16P) DATA LINKCONNECTOR
2+1'
Troubleshooting
B . The SRSindicatorlight can also indicate DTCby the numberof blinkswhen the SCSservice the connector connectis
ed to the service checkconnector {2P}. 1 . Turn the ignitionswitchOFF,and wait for ten seconds. Then connectthe SCSservice connector the servicecheck to (2P). you do not wait ten seconds, SRSunit will not be completely connector lf the resetand will not output DTCS.
SERVICE CHECK (2PI CONNECTOR

IGRY,GRYIor [GRN,GRNI SCSSERVICE CONNECTOR 07PAZ- (x)101(xt
Turn the ignitionswitchON (ll).The SRSindicator light comeson for aboutsix seconds and goesoff. Then it will indicate the DTC: - The DTCconsists a main code and a sub-code. of - Including most recentproblem,up to three different the malfunctions be indicated. can - In caseof a continuous (seeexample1 below). failure. the DTCwill be indicated repeatedly - ln caseof an intermittent failure, SRSindicator the lightwill indicate DTCone time,then it will stayon (seeexarnthe ple 2 below). - lf both a continuous and an intermittent failureoccur,both DTCs will be indicated continuous as failures. * In casethe systemis normal{no DTC}, SRSindicatorlight will stay on (seeexample3}. the Readthe DTC. Turn the ignitionswitch OFF,and wait for ten seconds. Then disconnect SCSserviceconnector the from the service checkconnector {2P). Ex8molosof DTCIndications: 1. Continuous failure,SRSIndicator Light is:
[.- , s --]
- l1'"*0" f - . f DTC 2.1 Mosr rocntp.obt.m
- l F M.in.ods ll)
Sub,code l2l
-4
!._.--!-
t-
--t F
Sub.cod. (1)
Main cod. (l)
oTc r.2
DTC .1 r Thnd moll r66.t
Intermittent failure,SRSIndicator Lightis:
l-ight 3rry3 on in e$
ot
oTc5.1
3.
Normal(no failure), SRSIndicator Light is:
\"
the Erasing DTCMemorY

To erase the DTC(s)from the SRS unit, use a Honda 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 or SystemSupplement) the followingprocedure' 1. 2. Makesurethe ignitionswitchis OFF to connector the MES conthe Connect SCSservice Do nector(2P). not usea iumperwire
g Troubleshootin Intermittent Failures

but lf therewas a malfunction, it doesn'trecur,it will be failure.and the storedin the memory as an intermittent light comeson. SRSindicator After checkingthe DTC,troubleshoot as tollows: 1. 2. "Reading DTc") the Readthe DTC(see " E r a s i n gt h e D T C E r a s et h e D T C m e m o r y ( s e e Memory"). turn the ignitionswitch With the shift leverin neutral, (ll),and let the engineidle. ON The SRSindicatorlight comeson for about six seconds and goes off.
&
MEMORYEMSE {2PI SIGNAL{MESICONNECTOR IGRY,GRYIor [GRN,GRNI
I L
3.
4.
coruruscron ics senvtce

07PAZ- 0010100
I
ON
6.oc l<-
--
3.
Turnthe ignitionswitchON (ll). light comeson for aboutsix secThe SRSindicator onds and goes off. Removethe SCS serviceconnec{2P)within four seconds tor from the tat "onn"61or light went off. after the SRSindicator 5. The SRSindicatorlight comeson again Reconnect the SCS service connectorto the MES connector afterthe SRSindicator {2P)within the four seconds light comeson. The SRS indicatorlight goes off. Removethe SCS (2P) 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 ' within four seconds that the memoryls light indicates 7 . The SRSindicator two times. erasedbY blinking 8. Turn the ignition switch oFF, and wait for ten seconds.
-J
Shakethe wire harnessand the connector,take a test quick braking,cornering), drive (quickacceleration, wheel fully left and right,and and turn the steering hold it there for five to ten secondsto find the cause of the intermittentfailure l , 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 r i g h t w i l l stay on.
4 sec or less
::ff
--l ** F
Problemrecurs,light staYson'
SRS indic.tor figlrr
L .--
Blinkiog
lt|Il
CONNECTED
DISCONNECTED
MES connactoi to.minal!
the failure. sYsthe lf you can't duplicate intermittent tem is OK at thistime.
24-15
Troubleshooting
SRS Unit ldentification
*: On '98 models,the troubleshooting procedures different eachtype of SBS unit. ldentifythe SRSunit in the vehiare for cle usingthe chartbelow,then follow the properflowchartin the followingpages. '98 Model SRSunits PARTSNUMBER 77960-S04-A91 NEC 7 7 9 6 0 ,S 0 4- N 9 1 77960-S04-N91 77960-S02-A82 IDENTIFICATION MARK* [/41 M1 M2 M3
MAKER
Remark Driver'ssideSRSairbagonly Driver's Passenger's & side SRSairbag Driver's& Passenger's side SRSairbag Driver's& Passenger's side SRSairbag
KEIHIN SIEMENS '96 - 97 Models SRSunits MAKER

NEC
PARTSNUMBER 77960-S04-C81 77960-S04-N8l 77960-S04-N82 77960-S02-A81
Remark Driver's sideSRSairbagonly Driver's& Passenger's side SRSairbag Driver's& Passenger's side SRSairbag Driver's Passenger's & side SRSairbag,'97 Modelonty
TAKATA SIEMENS
24-16
Chart-'96 - 97 Models TroubleCode (DTC) Diagnostic
light circuit FaultySRSindicator

Faulty SRS indicator light circuit, internal failure of SRS unit.Iaulty SRS power supply
1-1
ODenin the driver'sairbaginflator in resistance the driver'sairbag lncreased inflator Shortto anotherwire in the driver'salrbag resistance inflatoror decreased Shortto Dowerin the driver'sairbaginflator Shortto groundin the driver'sairbaginflator airbag: With front passenger's airbaginflator Open in the passenger's airbag: Withoutfront Passenger's in the dummy reslstor Open airbag: With front passenger's airbag in resistance the passenger's lncreased inflator airbag: Withoutfront Passenger's in resistance the dummy reslstor lncreased airbag: With front passenger's wire in the passenger's Shortto another resistance airbaginflatoror decreased airbag: Withoutfront Passenger's Shortto anotherwire in the dummy reslstor resistance or decreased airbag: With front passenger's airbag Shortto power in the passenger's inflator airbag: Withoutfront Passenger's Shortto power in the dummy resistor airbag: With front Passenger's airbag Shortto ground in the passenger's inflator airbag: Withoutfront Passenger's Shon to ground in the dummy resistor
Troubleshooting
(cont'd)
24-17
Troubleshooting
Diagnostic TroubleCode (DTCIChart-'96 -'97 Models (cont'dl
SRSindicatorlight
DTC
5-1*'
Possiblecause
Correctiveaction
See page
Internal failure of the SRS unit
5 4 6-1
S R Su n i t repracement
2 41 6
6-2
6-4 7-2 comeson
lnternal failureof the SRSunit
SRSunit reptacemenl
24-16
Internal failureof the SRSunit
S R Su n i t replacement
24-76
8-1 8-2
8-3
8-4 8-5 8-6
8-6*3
SRSunit replacement
24-76
Internal failure the SRSunitor two failu.es a of at time Internal failure ofthe SRSunit Internal failureof the SRSunit FaultySRSpower supply(VBline)
Troubleshooting S R Su n i t replacement S R Su n i t repracement Troubleshooting S R Su n i t replacement
24-62 24-76 24-16 24-64 2476
10-1
SRSunit replacement code (SRSunit must not be usedany longer)
NOTE: *11In caseof an intermittent failureDTC9-1,it meanstherewas an internalfailureof the SRSunit or a faulty SRSindicator light circuit.Do the troubleshooting intermittent for failures(seepage24-15). *2: lt both DTC9-2 and DTC5-1 are indicated, the troubleshooting do for DTC9-2. *3: Apply to the '97 modelcoupeHX and DX. *4: DTCcannotbe readwith a HondaPGMTester; checkby jumpingthe SCSservice connector.
Ghart-'98 Model TroubleCode(DTC) Diagnostic

NECSRSUnh
light circuit FaultySRSindicator light circuit,internal none*. I FaultySRSindicator powersupply (doesn't I fallureolsRs unit.JaultvSRS
No DTC'r {li9ht comes on
Faulty SRS power supply (VA line)
Troubleshooting
Openin the driver'sairbaginflator in resistance the driver'sairbag lncreased inflator Shortto anotherwire in the driver'sairbag tesistance inflatoror decreased Shortto power in the driver'sairbaginflator Shortto ground in the driver'sairbaginflator airbag: With front passenger's airbaginflator Openin the passenger's airbag: Withoutfront Passenger's in the dummy resistor Open airbag: With front passenger's airbag in resistance the passonger's lncreased inflator airbag: Withoutfront Passenger's in resistanc the dummy resistor lncreased airbag: With front passenger's s Shon to anotherwire in the passenger resistance airbaginflatoror decreased airbag: Withoutfront passenger's Shortto anotherwire in the dummy reslslor resistance or decreased airbag: I With front Passenger's airbag St o.t to power in the passenger's I inflator airbag: Withoutfront passenger's Shortto power in the dummy resistor airbag: With front Passenger's airbag groundin the passenger's Shon to Inialor airbag: tvnhout front Passenger's Shortto ground in the dummy resistor
Troubleshooting
Troubleshooting
24-52 24-59
2-4
2-5
v
(cont'd)
24-19
Troubleshooting
Diagnostic TroubleCode(DTC) Chart-,9g Model (cont,dl
SRSindicator light
DTC
5-1 5-4 6-1
Possiblecause Internal failureof the SRSunit
Correctiveaction SRSunit repracement
Ses pago 24-16
o-J
S R Su n i t replacement
24-76
6-4
7-2
comeson 8-1
5l|5 Unrt
replacement SRSunit repracement Troubleshooting SRSunit reptacement SRS unit reptacement SRSunit reptacement
24-76
a-2
8-6
Internal failureof the SRSunit Internal failureof the SRSunit or two failures at a time Internal failureof the SRSunit
24-76 24-62 24-16 24-76 24-76
9-2*' *1
Internal failureof the SRSunir SRSairbagsdeployed(SRSunit must be replaced)
l0-1
NOTE: r1: In caseof an intermittent failureDTC9-1,it meanstherewas an internaltailureof the SRSunit or a faulty SRSindicator light circuit.Do the troubleshooting intermittent for failures(page24-15). +2:In caseof an iniermittent failu.e DTc 9-2, it meansthere was an internalfailureof the power supply(vB line).Do the troubleshooting intermittent for failures. *3: DTCcannotbe readwith a HondaPGMTester; checkby jumpingthe SCSservice connector,
KEIHINSRS Unit SRSindicator light doesn'tcome on
DTC
none (doesn't come on) none*3 (doesn't go off) 1-1
Possiblecause light circuit FaultySRSindicator light circuit,internal FaultvSRSindicator failureoJSRSunit,taultySRSpower supply (VB line) Open in the driver'sairbaginflator in resistance the driver'sairbag lncreased inflator
Short to another wire in the driver's airbag inflator or decreased resistance
Correctivesction Troubleshooting
Ses page 24-26
Troubleshooting
24-34 24-42 24-12
1-3
1-4
Troubleshooting
24-44 24-46 24-48 24-50 24-50 24-52 24-54 24-56
comeson
1,5
Shortto power in the driver'sairbaginflator Shortto ground in the driver'sairbaginflator airbaginflator Openin the passenger's airbag in resistance the passenger's lncreased inflator Shon to anotherwire in the passenger's resistance airbaginflatoror decreased airbag Shortto power in the passenger's inflator airbag Shortto groundin the passenger's inflator
2-3
Troubleshooting
ry
2-5
v
(cont'd)
24-21
'...-'--.
Troubleshooting
Diagnostic TroubleGode(DTG) Ghan-'98 Model {cont,d}
sRs indicaror tighr I DTc
5-1 5-3 5-4 6-2 6-3 6-4 comeson 1-3 8-'l Internal failureof the SRSunit SRSunit replacement lnternal failureof the SRSunit S R Su n i t replacement 24-76 Possiblocause Correstiveaction See page
SRSunit replacement
24-76
24-76
8-2
8-6
9 - 1 + 1* 3
SRSunit replacement
-rI5 untr replacement
24-76
Internal failureof the SRSunit Internal failureof the SRSunit SRSairbagsdeployed(SRSunit must be reolaced)
24-76 24-76 24-76
9-2*, *3 10-1
SRSunit replacement SRSunit replacement
NOTE: *l: In caseof an intermittent failureDTCg-1,it meansthere was an internalfailureof the SRSunit or a faulty SRSindicator light circuit.Do the troubleshooting intermittent for failures(page24_15). *2: In caseof an intermittent fairureDTc 9-2, it meanstherewas an internar fairureof the power suppry(vB rine).Do the troubleshooting intermittent for failures. *3; DTCcannotbe readwith a HondapGM Tester; checkby jumpingthe SCSservice connector.
24-22
-'-'.-
.J
SRSUnit SIEMENS SRSindicator light doesnt come on
DTC
none (doesn't c o m eo n )
Possiblecause light circuit FaultySRSindicator
Correctiveaction Troubleshooting
SeL page
24-26
none*, I FaultySRSindicatorlight circuit,internal (doesn't failureof SRSunit,faulty SRSpowersupply (VBline) go off) Openin the driver'sairbaginflator 1,1 Shortto anotherwire in the driver'sairbag resistance inflatoror decreased Shortto oower in the driver'sairbaginflator Shortto ground in the driver'sairbaginflator airbaginflator Openin the passenger's Shortto anotherwire in the passenger's resistance airbaginflatoror decreased airbag Shortto power in the passenger's
rnltaror
Troubleshooting
24-34 24 42 24-44
Troubleshooting 24 46 24-44
1-4 comeson 1'5 2-1 zr

t-4
24-50
24-52 Troubleshooting 24-54 24-56
2-5
alrbag Shortto ground in the passenger's inflator
l/
(cont'd)
24-23
Troubleshooting
Diagnostic TroubleCode {DTC) Chart-'98
SRSindicatorlight DTC 5-l 5-4 6-4
Model (cont'dl
Correstiveaqtion S R Su n i t replacement S R Su n i t replacement S R Su n i t replacement See pago 24-76 24-76
Possiblecause Internal failureof the SRSunit Internal failureof the SRSunir

7_?
24-76
comeson
8-1
a-2
g _ l* r * 3 9-2*2 *3 10-1
Internal failure of the SRS unit
SRSunit reptacement S R Su n i t reptacement
24-76
Internal failureof the SRSunit l n t e r n afla i l u r e f t h e S R Su n i t o SRSairbagsdeployed (SRSunit must be replaced)
24-76 24-76 24-76
SRS unir
replacement
SRSunit replacement
NOTE: "1: ln caseof an intermittent failureDTC9-1,it meansthere was an internalfailureof the SRSunit or a faulty SFS indicator light circuit.Do the troubleshooting intermittent for failures{page24-15). *2: In caseof an intermittent fairureDTc g-2,it meanstherewas an internar fairureof the power suppry(vB rine).Do the troubleshooting intermittent for failures. *3: DTCcannotbe readwith a HondapGN4 Tester; checkby jumpingthe SCSservice connector.
24-24
SRSIndicatorLightWire Connections
SRS Indicator Light Power Circuit
WIREHARNESS OASHBOARO
C508 -+ To UNOER-DASH BOX <_ FUSE/RELAY 2OPCONNECTOR
To GAUGEASSEMBLY
C411, C412 : Torminalside of mslo trminsls csor. csoz, csog. c801, c802, c8o7 : wire sidoot f.male to'minals
SRS Indicator Light Control Cilcuit To SRSUNIT
tI
a.j
SRS MAIN HARNESS
MAIN WIREHARNESS GRY IGRN) 8LU
c411
GRY |GRN)
_ _ - lI l +f;I? csol
t--qt I
To GAUGEASSEMBLY
I |
To UNDER-DASH BOX FUSE/RELAY 2P CONNECTOR 3P C8O2 : SRSMAIN HARNESS CONNECTOR 3P C412 : MAINWIREHARNESS CONNECTOR 24P CONNECTOR c411 : MAINWIREHARNESS 2rtP CONNECTOR wlRE HARNESS C5O2 : DASHBOARD
2OPCONNECTOR WIREHARNESS CsO1 : DASHAOARD 5P WIREHARNESS CONNECTOR CSO8 : DASHBOABD 2P CONNECTOR C8O'l : SRSMAIN HARNESS'l8P 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 check whetherthe other indicator lightscome on or not {brake system, etc.). Do the other indicator lights como on?
YES
NO
Checkihe fuse: Check No.25 (7.5Alfuse in the undeFdash the fuse/relav box. ls th6 fuse OK?
YES
NO
))
Checktho bulb: Replace the No. 25 (7.5 A) Iuse, and checkthat the SRSindicator lightcomeson. Doesthe SRSindicalor liqht come on?
I YES END
No
No. 25 (7.sAl FUSE
Checkthe wir harnessbetween fuse and gauge assemblyl Checkfor an open in the wire harnessbetween fuse No. 25 {7.5A) and the gaugeassembly, repair. and Check that the sRs indicator laght comeson. Doe3the SRSindicator liqhl come on?
I yEs I
END
Check SRSindicato.light th butb: 1. Turnthe ignitionswitchOFF. 2, Remove gaugeassembly, the 3. Check blownSRSindicator for liohtbutb. ls the SRSindicator light butb OK?
No
YES
NO
Checkthe SRSindicatorlight circuit: R e p l a c eh 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 t connectors. Thenturn the ignilionswitchON (tl). Doesthe SRSindicator light come on?
YES :ND
No
lAl ro page24-27
lBl10 page24-27
I $
24-26
T
J
Frompage24-26 (A) Frompage24-26 (B) WIBEHARNESS DASHBOARD Chockthe SRSindicator light circuit: the dashboardwire harness5P connoctor 1. Disconnect from the gaugeassembly 2. Connecta voltmeterbetweenthe No l terminal(+) of and ground the 5Pconnector 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$embly; rplace the SRS plinted circuit board in the 93uge
v
Chsckth. wir6 harnessot the SRSindicator light circuit ll l: 1. Turnthe ignitionswitchOFF. from the 2, Disconnect main wire harness24P connector wire harness the dashboard 3. Connecta voltmeterbetweenthe No 5 terminal {+) of and ground 24P the mainwire harness connector voltage 4. Turnthe ignitionON {ll),and measure V or less for six seconds after the ignition ls there 8.5 switch has beentumed oN llll? MAIN WIREHANNESS
Short to Dowor in the BLU wire ot the dashboard wire
WIRE DASHBOARD HARNESS2iIP CONNECTOR
To page 24-28
c411
(cont'd)
24-27
Troubleshooting
The SRS Indicator Light Doesn't Come On (cont'dl
Frcm page24-27
Checkth wire harnessotthe SRSindicator light circuit (2): 1. Turnthe ignitionswitchOFF. 2. Disconnect SRSmain harness connoctor the 3P frornthe main wire harness, 3. Connecta voltmeterbetweenthe No. 1 terminal(+) of the SRSmain harness connector 3P and ground. 4. Turnthe ignitionswitchON (ll),and measure voltage. ls there 8.5 V or less tor six seconds .tter the ignition switch has ben turnod ON llll?
Shori lo powq in the BLU wire of lhe main wirs hrnolis:
SRSMAIN HARNESS 3P CONNECTOR
c802
SRSUN]T
Checkthe wire harnossofthe SRSindicator circuit 13)i 'L Turn the ignitionswitchOFF. 2. Disconnectthe battery nagative cable, then the positive cable. and wait threeminutes. 3. Disconnect drivor's(andfront passenger'sl the airbagcon(s6e page2+11). necto(s) 4. Disconnect SRS main harness18p connector the from the SRSunit. 5. Connecta voltmeler betweenthe No. 6 terminal (+) ol the SRSmain harness connector 18P and ground. 6. Turn the ignitionswitchON (ll),and measu.evoltage. There shouldbe 0.5V or less.
SRSMAIN HARNESS 16PCONNECTOR
SRSunit; roplacotho unit (seepaq6 2+
Short to power in the BLU wire of the SRS main harne$:
24-28
The SRSIndicatorLight Doesn'tGo Off -'96
-'97 Models
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. Erase DTCmemory (seepage24'15) the 2. Turn the ignitionswitch OFF,and wait for ten seconds' 3. Turn th ianitionswitchON lll), and checkthat the SRSindicator 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: 1. Turnthe ignitionswitchOFF. i N 2 . C h e c k f o r t l o w n o . 1 3( 1 5A ) a n dN o . 2 3( 1 0A ) f u s e sn box. fusekelaY the under-dash
v'
the Replaca fuses, and erasethe memory the L Replace luses. to the SCSserviceconnector the MES con2. Connect nector, the 3. Erase DTCmemory(seepage24-15) the then disconnect SCS 4. Turn the ignitionswitchOFF, seryiceconnectorfrom the MES connector' 5. Turnthe ignitionswitchON lll) Doesth. SRSindicator light go ofl aftol six soconds? YES
No. 13 (15Al FUS
SBS UNIT SRSMAIN HARNESS
Confirm tho OTC,snd continuo Checklo. an open in the SRSmain harnoss{vA lino}: 1. Turn the ignitionswitchOFF the 2. Disconnect batterynegativecable,then disconnect and wait for threeminutes cable, the positive airbag the driver's (and Iront passenger's) 3. Disconnect (see connector(s) Page24_11). from the 4. Disconnect SRS main harness18Pconnector the sRs unit. the battery positive cable, then reconnectthe 5. Reconnect cable. negative a 6. Co-nnect voltmeterbetweenthe No 7 terminal (+) of and groLlno 18P the SRSmain harnoss connector 7. Turnthe ignitionswitchon
18PCONNECTOR SRSMAIN HARNESS
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
From page 24-29 (A) SRSMAIN HABNESS 18PCONNECTOR Checkthe SRSunit: 'l8Pconnector No. Connect SRSmain harness the terminals 6 and No.7 with a iumoerwire and
- 97 Models (cont'd)
SRSUNIT
Faulty SRSunit or pool contact at tho SRSmain harness 18Pconnector;chockthe connoctor. lfth connectoris OK, replacethe SRSunit.
07TAZ- @1020A WIRE JUMPER
terminals Wire ot fsmale side
WIRE HARNESS OASHBOARD Frompage24-30 {B)
Chockthe SRSindicator circuit: 1. Turnthe ignitionswitchOFF the 2. Remove gaugeassemblY 5P wire harness the NOTE:Do not disconnect dashboard connectorfrom the gauge assembly 3. Turnthe ignitionswitchON (ll). termi5P wire harness connector the 4. Connect dashboard nalsNo. 1 and No 5 with a jumperwire. Do.s the SRSindicator light go otff
y;T7f;V4csoe
Fsulty SRS indic.tor light circuit in the g.uge ts3embly; replace the SRS printed circuil board in the gauge Llr.-L_v)fr
BLU
IYEL
JUMPER WIRE WIREHARNESS DASHBOARD
of wire.side female termlnals
Check to. a short to ground in rhe SRS indicator light circuit: 1. Turnthe ignitionswitchOFF the dashboardwire harness5P connector 2. Disconnect from the gaugeassembly betweenthe No. 1 terminal ot the dash3. Checkresistance and ground.Thereshould 5P boardwire harness connector be 1 Mo or more.
7o page 24-32
Checkfor an oDenin th6 SRSindicttor light circuit: the No 6 terminalof the SRS between 1. Checkresistance and No 1 terminalof the main harness18Pconnector there should be wire harness5P connector; dashboard 0- 1.0 . 0
Wire side of female Iermtnats
SRSMAIN HARNESS ,I8PCONNECTOR
(D) 24-33 To page
(E) 24-33 To page

WIRE HARNESS DASHBOARD 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. Disconnect dashboard the wire harness24p connector from the main wire harness, 2. Checkresistance between the No. 5 terminalof the main wrre harness connector 24P and ground.Thereshouldbe 1 N40 more. or
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 harness connector 3p from the maan wire harness, 2. Checkresistance between the No. i terminalofthe SRS main harness Connector ground,Thereshouldbe 3P and 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.
\,1
From page 24-31 (D) WIREHARNESS DASHBOARD 5P CONNECTOR
Checkthe SRSindic.to. circuit input voltag: to the 1. Reconnect SRS main harness18Pconnector the SRSunit. 2. Connecta voltmeterbetweenthe No 1 lerminal l+) o{f and ground' 5P the dashboard connector
ol!!!!jl!lg!:ylly9!j399switch 3. rurn theisnition
ls thorc 8.5 V or more lix secondsafter the ignhion swhch has benlurned 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.esnt, tepltco the SRS m'in har' ncss. Frompage24-31 (E)
Checkfor an opsn in tha drshbo.rd wi.o harnos: wire harness24P connector the 1. Oisconnect dashboard lrom the mainwire harness 2. Checkresistancebetween the No O terminal of the SRS and No 5 terminal of the main harness18Pconnector ; 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
c807
c411
sideof maleterminals MAINWIREHARNESS Terminal 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: from the 3P the 1. Disconnect SRSmain harness connector main wire harness. 2. Checkresistancebetweenthe No. 6 terminal oI the SRS and No l terminalof the main harness18Pconnector there shouldbe 0 - 1 0 O SRSmain harn6ss3P connector;
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. Erase DTCmemory(seepage24-15). the 2. Turn the ignitionswitchON (ll),and checkthat the SRS indicator light comeson for aboutsix seconos ano ooes off. Doesthe SRSindicator lioht stav on?
Inte.mitlent failure, systom b OK at thi3 tim6. See TroubleIntrmittentFailur3 page2+lS. on
checkthe No. 23 {10Alfuse: 1. Turnthe ignitionswitchOFF. 2. Checktor blown No. 23 (10 A) tuse in the under-dash
Replace fuse, and erassthe memory the 1 . R e p l a cte e N o .2 3 ( 1 0A ) t u s e . h 2. Erase DTCmemory(seepage24,1S). the 3. Turnthe ignitionswitchON (ll). Doesth6 SRSindicstor light qo off after six seconds?
No. 23 {10A} FUSE FUSE/RELAY BOX
Check lor an oDen in the SRS main h.rn6ss [vB line): 1. Disconnect battervnegativecable,then disconnect the the positive cable, and wait for threeminutes. the driver's (and front passenger's) airbag 2. Disconnect (see connectorls) page24'11). lrom 3. Disconnect SRS main harness18Pconnector the the sRS unir. 4. Reconnect the batterv positive cable, then reconnectthe negative cable. 5. Connecta voltmeterbetweenthe No. 3 terminal (+) of '18P the SRSmain harness connector and oround. 6. Turnthe isnitionswitchON (il).
SRSMAIN HARNESS 18PCONNECTOF
18P CONNECTOR SRSMAIN HARNESS
Open in rhe SRS main harn63s (VB line); replace the
To page24-35
24-34
Frompage24_34 (A)
sBs UNIT
Checkthe SRSunit: No terminals 18Pconnector the Connect SRSmain harness adapt 6 and No.3 with a jumperwire and backprobe Doesthe SRSindicato.light go oll?
YES
NO
Faultv SRSunit or poor contact al the SRS main harnass 18Pconnector;checkthe connector. lf the connectoris OK, replacothe SRSunit
18PCONNECTOR SBS MAIN HARNESS Did fuse No. 23 (10A) blow?
YES
NO
WIRE JUMPER
( Il ) f o p a g e 2 4 ?6
Check for a short to ground in the SRS indicator light cir' cuit: 1. Turnthe ignitionswitchOFF. the dashboardwire harness5P connector 2. Disconnect from the gaugeassembly the between No 1terminalofthedash resistance 3. Check r 5 b o a r dw i r e h a r n e s s P c o n n e c t o a n d g r o u n d T h e r e shouldbe 1 MO or more. ls the resistanceas specitied? -
termanals ot Wire side lemale WIREHARNESS DASHBOARD 5P CONNECTOR
YES
NO
(c)
Io page 24'37 Short to ground in the gtuge assembly;replacethe gauge
WIRE HARNESS DASHBOARD 5P CONNECTOR
c50a
l of female
(cont'd)
24-35
Troubleshooting
The SRS Indicator Light Doesn't Go Off -'98
From page 24 35 (B)
Model (cont'dl
OASHEOARO W|REHARNESS 5P CONNECTOR
Checkthe SRSindicator circuit: 1. Turnthe ignitionswitchOFF. 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 3. Turnthe ignitionswitchON (ll). 4. Connect dashboard the wire harness connector 5P terminalsNo. 1 and No.5 with a iumDer wire. Do6sth6 SRSindicator liqht go oftT
YES
NO
Faultv SRS indicator light circuit in the gauge assembly; roplaca the SRS printed circuit board in the gauge assombly.
OASHBOARD WIREHARNESS 5P CONNECTOR
Checkfor an open in the SRSindicator light circuit: 1. Turnthe ignitionswitchOFF. 2. Disconnect the dashboardwire harness5P connector from the gaugeassembly. 3. Checkresistancebetween the No. 6 termanalof the SRS main harness18Pconnector and No. 1 terminalof the dashboard wire harness5P connectori there should be 0- 1.0 . 0 ls the resistancoas 3pecified? YES NO
\J# Bru I
l;rfr-zr-cuo"
IYEL
JUMPER WtRE Wire side of female tormanats
SRSMAI[{ HARNESS 18PCONNECTOR
Wire sideot temaleterminals
(D) To page24-38
(E) To page24-38
DASHBOARD WIRE HANNESS 5P CONNECTOR
, 24-36 [r.
From page24-35
(c)
Chockfor a short to ground in the main wiro harness: wire harness24P connector the 1. Disconnect dashboard from the main wire harness the beNveen No 5terminalofthedash_ resistance 2. Check bosrd wire harness24P connectorand ground There shouldbe 1 MO or more.
Short to glound in the dashboard wire hamoss; repail
WIRE DASHEOARD 24PCONNECTOR HARNESS
WIREHARNESS OASHBOARD BLU 24P CONNECTOR
Wire sideof female lermrnals
MAIN WIREHANNESS 3P CONNECTOR
Checkfor a short to ground in lhe SBS main hamess: from the 3P the 1. Disconnect SRSmain harness connector mainwire harness the No. I terminalof the SRS between 2. Checkresistance and ground Thereshouldbe 3P main harness connector 1 MO or more,
SRSMAIN HARNESS 3P CONNECTOR Short to ground in tho main wire herness;rspair ihe
Short to glound in the SRS main harness;repl.ce the SRS
c802
(cont'd)
24-37
Troubleshooting
The SRSIndicatorLight Doesn'tGo Off -'98
Frompage24-36 rD)
Model (cont,d)
DASHBOARD WIREHARNESS 5P CONNECTOR
Checkthe SRSindicato. circuit input voltago: '1. Reconnect the SRS main harness1gPconnector the to SRSunit. 2. Connecta voltmeterbetweenthe No. I terminal{+) of the dashboard connector 5P and 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 TroubleIntermittent Failuleson paqe 24DASHBOARD WtREHARNESS 5P CONNECTOR
Poor contact ai the SRSmain h.rness 18p connector;check the connoctor. . lf ihe connector is OK, subslituto a known-good SRS unit, and recheck. . It the problem is still presont, repbce the SRS main harness. Frompage24 36
c508
Check lor an open in th dashboa.d wire narness: 1, Disconnect the main wire harness 24P connector from 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 main harness 18P connector and No. 5 terminal ofthe main wire harness 24P connector; there should be 0 - 1.0 0.
SRSMAIN HARNESS lAP CONNECTOB
c807
ls the resistanceas sDecifiedT
YES
NO
c411
Open in the BLU wire of the dashboard wire harness; repairthe dashboardwire ha.noss. Terminal sideof maleterminals Checktor an open in the main wire harnsss: 1. Disconnect SRSmain harness connector the 3p from the mainwire harness, 2. Checkresistance between the No_6 term;nalof the SRS mainharness connector No. 1 terminal the SRS 18P and ot main harness connector;there 3P shouldbe 0 _ 1.0O.
ls the resistance as soecified?
YES
NO
Open in the BLU wire of the main wire harness;reDair the main wire harn6ss.
Open in the SRS main harnoss; replace the SRS main har-
c802
243A
\
No DTC-'98
Model
CAUTION:Wheneverthe ignition switch is ON (ll), or has been turned OFF for less than three minutes, be careful not to bump the SRS unit; the airbags could deployand causedamageor iniuries' accidentally
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 on IntermittentFailures Page2+15' seTroubleshooting
Check for short to ground between the undet-dash fuse/ relay box and the SRSunit. 1. Turnthe ignitionswitchOFF the 2. Disconnect batterynegativecable,then disconnect and wait for threeminutes cable, the positive airbag) the driver's (and front passenger's 3, Disconnect (seePage24'11) connecto(s) lrom the SRS main harness18Pconnector 4 . Disconnect the sRS unit. the No 7 terminalof the SRS between resistance 5 . Check and ground 18P main harness connector Thereshouldbe 1 MO or more ls the resistanceas specified?
sRs
18PCONNECTOR
FauftySRSunit; replacethe SRSunit {seepage21'761'
{B) To page24-40
(cont'd)
24-39
Troubleshooting
No DTC-'98 Model (cont'd)
trom page 24-39 1B) Chacktor short to ground in the SRSmain harness: 1. Disconnect SRSmain harness connector the 2P from the under-dashluse/relaybox. 2. Checkresistancebetween the No. 7 terminal of the SRS main harness18Pconnector and 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.
FUSE/RELAY BOX
c807
(A)Frompage24-39
Checklor an opgn in the SRSmain hrlness: 1. Turnthe ignitionswitchOFF. 2. Disconnect battorynegativecable,thn disconnect the the positive cable, and wait for threeminutes. 3. Disconnect th6 driver's land front passenger's) airbag (see conneclor(s) page24-11). 4. Disconnect SRS main harness18Pconnectorfrom the 5. Reconnect the battery positive cable, then reconnectthe negative cable. 6. Connect a voltmeter btween the No. 7 terminal oI the SRSmain harness connector 18P and oround. 7. Turnthe ignitionswitchON (ll),and measure
Poor conlact at ths SRS main harnoss 18P connoctor; checkthe connoctoa, . 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.
SRS MAIN HARNESS 18P CONNECTOR
caoT
To page24 41
24-40
From page24'40
Checkfor an oDenin the SRSmain ha.ness: 1. Turnthe ignitionswitchOFF. 2P from the 2, Disconnect SRSmain harness connector the fuse/relay box. undeFdash the No. 1 terminalof the SRS 3. Checkresistance between main harness2P connectorand No. 7 terminal of the SRSmain harness connector. 18P Thereshouldbe 0 0.5o.
Poor contact at the SRS main harness2P connector; checkthe connector. . lf the connector is OK, substitute a known-good under' dash fu3e/relaybox, and recheck. . It lhe problem is still present, replace the SnS main harness.
FUSE/RELAY BOX
caoT
Open in the SRS main harness;replacethe SRS main har' ness,
24-41
Troubleshooting
DTC1-1and DTC1-2
CAUTION:Wheneverthe ignition switch is ON (tt),or has besn tulned OFF lor less than three minuts, be carelul not to bump the SRS uniti the airbag(slcould accidentallydeploy and causedamage or iniuries.
Try to reproducethe SRSindicator lighti 1. Erase DTCmemory{seepage24,15i. the 2. Turnthe ignition switch {ll), ON andcheckthatthe SRSindicatorlight comeson for aboutsix seconds and goesoff. Doe3the SRSindicaror light stay on? YES NO CABLEREEL 2P CONNECTOR DRIVER'S AIRBAG 2P CONNECTOR DRIVER'S AIRBAG ASSEMBLY
Intrmittem tailure, svstem is OK ai thb time. S6eTroublr shooting Intermittent Failuroson page 2G15.
Chcktor an opon in the driver's airbag inflator 1. Turnthe ignition switchOFF. 2. Disconnect batterynegativecable,then disconnect the the positive cable, andwait for threeminutes. 3. Disconnect driver's the airbag connector 2P from the cable reel 2P connector, CAUTION:Do not disconnect the psssenger's airbagconnec{or, 4. Connect special the tool (2 O)to the cablereel2Pconnec tor. 5. Beconnect the battery positive cable,then reconnectthe negative cable. 6. Erase DTCmemory(seepage24-15). the 7. Readthe DTC(seepage24 13i. ls DTC1-1 or DTC1-2 indicatod? YES NO
07TAZ- SZ5011A and SRSINFLATOR SIMULATOR {2 0 JACK) 07sAz - TB401rA
SRSSERVICE
(2 CoNNECTOR0l 07TAZ 5250200
Opon or increasedaesidancein the driver's airbag inflator;.eplace th driver'sairbagessemblv(seepase 2+671.
SRSMAIN HARNESS 2P CONNECTOR CABLE REEL 2P CONNECTOR
Chocklor sn open in the cable reel: l- Disconnect batterynegativecable,then disconnect the the positive cable, and wait for threeminutes. 2. Disconnect special the tool (2 0) Irom the cable reel 2P connector. 3. Remove the dashboard lower cover,and disconnect the cablereel2P connector from the SBSmain harness. 4. Connect the special tool (2 0) to the SRS main harness 2P connector. {cont,d}
fo page 24'43
SRSSIMULATOR LEADC 07TAZ- SZ5011A and SRSINFLATOR SIMULATOR t2 0 JACK) 07sM - T84011A
SRSSERVICE CONNECTOR O' {2 07TAZ- 5250200
24-42
1
Frcm page 24-42 Checkfor an opon in the cable loel (cont'd) the batterv positive cable, then reconnectthe 5. Reconnect negativecable. the 6. Erase DTCmemorylseepage24-15). 7. Read DTC{seepage24-13). the 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: the 1. Disconnect batterynegativecable,then disconnect and wait for threeminutes. cable, the positive 2. Disconnoctthe front passenger'sairbag connectorftom (withfront passenger's airbag) the SRSmain harness from the 3. Disconnect SRS main harness18Pconnector the specialtool (2 O) the SRS unit. Do not disconnect 2P from the SRSmaln harness connector' No 1 and No 13 of terminals between 4. Checkresistance 18P the SRSmain harness connector. 2.0 Thereshouldbe approx. - 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 has been tu.ned OFF for less than three minutes, be caretul not to bump the SRS unit; the airbag{s)could accidentally deployand causedamageor iniuries.
Tryto rproducetha SRSindicator light: 1. Erase DTCmemory(seepage24-15). the 2. Turnthe ignition switch (ll), ON andcheckthatthe SRSindi catorlight comeson for aboutsix seconds and goesoff. Doesihe SRSindicator light stay on? DRIVER'S AIRBAG 2P CONNECTOR DRIVER'S AIRBAG ASSEMBLY
YES
NO
CABLE REEL 2PCONNECTOR
lr e.mittent failure,systomis OK at this limo. S6eTroubleshooting Intermittent Feilureson page 2il-15.
Checklor a short to another wire in the driver's airbao inflalor: 1. Turnthe ignitionswitchOFF. 2. Disconnect batterynegativecable,then disconnect the the positive cable, and wait for threeminutes. 3. Disconnect the driver's airbag 2P connectorlrom the cablereel2P connector, CAUTION:Do not disconnectthe passenger's airbag connector. 4. Connect special the tool (2 0) to the cablereel2Pconnector. 5. Reconnect baftervpositive the cable,then reconnect the negative cable. 6. Erase DTCmemory(seepage24 15). the 7. Beadthe DTClseepage24 13). ls DTC1.3 indicatod?
07TAZ- SZ5011A and SRSINFLATOR SIMULATOR 120 JACK) 07saz - T8401'tA
5(\
\ \ \,/'
sRssERvtcE coNNECToR ol 12
07TAZ - 5250200
YES
NO Short in the driver's airbag inflator; replacelhe driver's airbag assembly(seepaqe 24-67).
S8S MAIN HARNESS 2P CONNECTOR CABLE REEL 2P CONNECTOR
Checktor a short in the cable reel: 1. Disconnect batterynegative the cable,then disconnect the positive cable, and wait for threeminutes. 2. Disconnect special the tool (2 0) from the cable reel 2P the dashboard lower cover,and disconnect 3. Remove the cablereel2P connector from the SRSmain harness, 4. Connect the spacial tool (2 0i to the SRS main harness (cont'd) 2P connector, SRSSIMULATOR LEADC 07TAZ SZ5011A and SRSINFLATOR SIMULATOR 120 JACK) 07sAz - TB4011A or
To page24 45
,^F--.24-44
SRSSERVICE coNNECTOR{2 0) 07TAZ - 5250200
Frompage24-44
Checkfor a shon in the c.ble tool lcont'd): the battery positive cable, then reconnectthe 5. Reconnect cable. negative the 6. Erase 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: the 1. Disconnoct bafterynegativecable,then disconnect and wait for threeminutes cable, the Dositive from airbagconnector the 2. Disconnect front passenger's airbag) the SRSmain harness(with front passengor's from the 3. Disconnect SRS main harness18Pconnector the specialtool (2 0) the SRS unit. Do not disconnect 2P lrom the SRSmain harness connector' terminaisNo. 1 and No 13 of between 4. Checkresistance 18P the SRSmain harness connector. 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
CAUTION:Wheneverthe ignition switch is ON fll), or has been turned OFF for less than three minutes, be carefulnot to bump the SRS unit; the airbag{s) could accidentally deployand causedamageor iniuries.
Try to reproducethe SRSindicator light: 1. Erasethe DTCmemory(seepage24 15). 2. Turnthe ignition switch (ll), ON andcheckthatthe SRSindi catorlight comeson for aboutsix seconds and aoesoff, Doesthe SRSindicrtor liqht stav on? NO Intormittentfailure,sydem is OK atthis time. SeTroubleInlermittent Failureson page 24-15. CAELE REEL 2P CONNECTOR DRIVER'S AIRBAG ASSEMBLY
Checkfor a shon to power in the driver's airbag inflator: 1. Turnthe ignitionswitchOFF. 2. Disconnect batterynegatave the cable,then disconnect the positive cable, and wait lor threeminutes. 3. Disconnect the driver's airbag 2P connectorfrom the cablereel2P connector. CAUTION: Do not disconnect the passongr,s airbag connactor. 4. Connect SRSservice (2 the connector O)to the cablereel 2P connector. 5. Reconnect the battery posiitive cable,then reconnectthe negative cable. 6. Erase DTCmemory(seepage24-15). the 7. Readthe DTC(seepase24 t3).
SRSSIMULATOR LEADC 07TAZ- SZ5011A and SRSINFLATOR SIMULATOR {2 0 JACKI 07sAz - TB401lA
SRS SERVICE CoNNECTOR 0} {2 07TAZ S250200
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 rel: 1. Disconnect the battery negative cable, then disconnect the positivecable,and wait for three minutes. 2. Disconnectthe special tool (2 0) from the cable reel 2p 3. Remove the dashboard lower cover, and disconnect the cable reel 2P connector from the SRS main harness. 4. Connect the specjal tool (2 O) to the SRS main harness
2P connector,
(cont,
SRSSIMULATOR LEADC 07TAZ- SZ5011A and SRSINFLATOR SIMULATOR {2 0 JACK) 07sAz - TB4011A
fo page24-41
---
"*" ,a"u,"a
GoNNECTOR O) {2 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 )
the DTC(seePage24'13) 7. Read

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: the 1.Disconnect batterynegativecable,then disconnect and wait for threeminutes' cable, the positive from airbagconnector the 2. Disconnect front passenger's (withlront passenger's airbagi the SRSmain harness tool (2 0ifrom the SRSmain harness the 3. Remove special 2Pconnector. 'l8P connector lrom the 4. Disconnect SRS main harness the sRS unit. the positive cable,then reconnect the 5. Reconnect batterY negativecable. a 6. Co-nnect voltmeterbetweenthe No 1 (+) terminal of and bodv ground' 18Pconnector the SRSmain hatness 7.Turn the ignilion switch ON (llr, and measurevoltage' Thereshouldbe 0.5V or less L Turnthe ignitionswitchOFF. 9. connect; voltmeterbetweenthe No 13 (+) terminalof and bodyground 18P the SRSmain harness connector voltage lO.Turn the ignitionswitch ON (ll), and measure Thereshouldbe 0.5V or Iess
Short lo power in lhe SRS main harness;leplace the SRS
24-47
Troubleshooting
DTC1-5
CAUTION:Wheneverthe ignition switch is ON (lll, or 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. Erase DTCmemory(Seepage24 15). the 2. Turnthe ignition switch {ll), ON andcheck thatthe SRSindi,
cator light comes on for about six seconds and goes off.
DRIVER'S AIRAAG 2P CONNECTOR
DRIVER'S AIRBAG ASSEMBLY
Do6sthe SRSindicator liqht 3tev on?
lmehittent tailure, svstem is OK at tfiis timc. See lroubleIntermittent Failureson Daqe24-15.
Checkfor a short to ground in the driver's airbag intlator: 1. Turnthe ignitionswitchOFF. 2. Disconnect batterynegative the cable,then disconnect the positive cable, and wait for threeminutes. 3. Disconnect the driver's airbag 2P connectorfrom the cablereel2Pconnector. CAUTION:Do not disconnoclthe passangei'3airbag connoctot, 4. Connect special the tool (2 0) to the cablereel2P connec, tor. 5. Reconnect the battery positive cable, then reconnectthe negative cable. 6. Erase DTCmemory(seepage24-15). the 7. Read the DTC{seepage24,13).
%.. sRssERvrcE
\ \
\,/ CoNNECTOR0l t2 07TAZ 5250200
Short lo ground in the ddvo.'s airbag inflator; replacethe
SRSMAIN HARNESS 2P CONNECTOR CABLE REEL 2P CONNECTOR
Ch6ckfor a short to ground in the cable reet: L Disconnect batterynegativecable,then disconnect the the positive cable, and wait for threeminutes. 2. Disconnect specialtool (2 0) from the cablereel 2P the connector, 3. Bemovethe dashboard lower cover,and disconnect the cablereel2Pconnector from the SRSmain harness. 4. Connect the Special tool (2 O) to the SRSmain harness (cont'd). 2Pconnector
SRSSIMULATOR LEADC 07TAZ- SZ5011A and SRSINFLATOR SIMULATOR {2 0 JACK) 07sAz - TB4o11A
To page24-49
( -,
^P*---.- sERvrcE sRs
07TAZ - 5250200
coNNECTOR t20t
24-48
\__
From pag 24-48 Ch.ck for ! Bhortto gtound in tho clble rool (cont'dl: the battry positive cable, then reconnectthe 5. Reconnect negativecabl. the 6. Erase 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.
Chcckfor a lhort to ground in tho SRSmain hlrn.ss: cable,then disconnect the 1. Disconnect batterynegative the positivecable,and wait for three minutes' airbag 2P connector the 2. Disconnect lront passenger's 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). tool (2 0)Irom th6 SRSmain harness the 3 Removo special 2P connector. 4. Checkresistancebetweenthe No- 1 terminal of th SRS and ground,and between main harness18Pconnector 18P the No. 13terminalof the SRSmain harness connector and ground. Thereshouldbe 1 Mo or more. b th. r$bt.nc6 13 spocifiod?
SRSUNIT
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 careful not to bump the SRS unit; the airbags could accidentallydoploy and causedamage or iniuries.
Trv to reproducethe SRSindicstor light: 1. Erase DTCmemory(seepage24,15). the 2. Turnthe ignitionswitchON (ll),and checkrhattheSRSindicatorlight comeson for aboutsix seconds and goesoff. Doesthe SRSindicator light stay on?
YES
NO
Intermiftcm tailure, 3ystem is OK at thb lime. S6e Trouble shooting Intermittent Failureson pag6 2+15.
Checklor an open in the passenger's airbag inllator: 1. Turnthe ignitionswitchOFF. 2. Oisconnect batterynegative the cable,then disconnect the positive cable, and wait for threeminutes. 3. Disconnectthe front passenger'sairbag connector from (seepage24-11). the SRSmain harness 4. Connect the special tool (2 O) to the SRSmain harness 2P connector. CAUTION: Do not disconnocttho driver's airbag connector. 5. Reconnectthe battery positive cable, then reconnectthe negativecable. 6. Erase DTCmemory(seepage24-15). the 7. Read DTC(seepag24-13). the ls DTC2-1 or DTC2-2 indic.t6d?
YES
NO
Open or increasdresiitance in lhe prssenger's airbag intlator; replec6 the pa3sgnger'sairbag e3sombly lsee page 24-67).
SRS SERVICE CoNNECTOR 0l t2 07TAZ SZ5m00
To page24'51
24-50
\
E\
From page 24-50 Chackfor rn ooen in ths SRSmain hatnossi '1. Disconnect bafteryngativecable,then disconnect ths cable, and wait tor threeminutes. the positive the driver's airbag 2P connectorlrom the 2. Disconnect csblereel2Pconnector {seepage24-11). from the 3. Disconnect SRS main harness18Pconnector the specialtool {2 0) the SRS unit. Do not disconnect from the SRSmain harness2P connector' be8voenthe No. 10 terminal and No. 14 4. Check@sistance There 18Pconnector. terminalof the SRSmain harness -3.0 o. shouldbe aDorox.2.0 ls tho r4irtance a3 3pecifiad? SRSUNIT NO
YES
'l8P connector; Poor conlact at lhe SRS mtin ha]ngss ch.ck tho connctor. . lf the connoctol is OK, subitituta . known-good SRS unit, .nd rochcck. .ll lh. probl6m is still ptesont, replsce the SRS main hatnas!!.
SRSMAIN 18PCONNECTOR
Opcn or incrarsad re3ist!nc6 in tha SRS m.in harnoss; rcplac! tho harnots.
24-51
Troubleshooting
DTC2-3- With FrontPassenger's Airbag
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 roproductho SRSindic.to.light: 1. Erasethe DTCmemory (ssepage2+15). 2. Turn the ignitionswitchON { ), and checkthat the SRSindic6torlight comeson for aboutsix seconds ahd goes off. Oo.3 tho SRSindic.tor light ltrv on7
Into.mitt.nt tailurc, rwtam b OK st thb tim6, S.e TroubloIntermittont Friluraa on gaqe 24-15.
FRONT PASSENGER'S AIRBAG2P CONNECTOR
Chack to. . Bhon to another wir. or docroasod r$irtanca in tho pr3sgngor'r airbag intlator: 1. Turnthe ignitionswitchOFF. 2. Disconnect batterynegativecable.then disconnect the the positive cable.and wait for three minutes. 3. Disconnct the tront passenggr's airbag 2P connector trom the SRSmain harnss {seepage24-11). 4. Connect the special tool (2 0) to the SRS main harness 2P connector, CAUTION: Do not dbconnect tho driver'r airbag connoctor. 5. Reconnectthe battery positive cable, then reconnectthe negativecable. 6. Erase DTCmemory(seepase24-15). the 7. R6adthe DTC(see pag'e24-131.
Short to anothoi wi.e or docrgagod r63btancoin the parsangg/s airbf,g inflator; roplaco thg passongor,r ai.b6g
To page 24-53
SRSSERVICE CoNNECTOR 0) t2 07TAZ - 5250200
\ _
24-52
Frompage24-52
Chock for a lhort to anothor wiro or dacrcatad lotittancc in th. SRSfi.in hamo3s: cable,then disconnect th6 1. Disconnect batterynegative the positivecable.and wait for three minutas' the driver's airbag 2P connectorfrom the 2. Disconnect cablereel2P conngctor. 'l8P conngctorfrom the 3. Disconnect SRS main harn6ss the the SRSunit. Do not disconnect specialtool (2 O)from the SRSmain hsrness2P connedor' the between No. 10terminaland No 14 resistance 4. Check terminal of the SRS main harness 18Pconnector' Thsre shouldbg approx 2.0
b thc .eai3tlnca ss aPacifiad?
SRSMAIN HARNES9 18PCONNECTOR
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's Airbag
Whenevertho ignition switch is ON (ll), or CAUTION: has been turned OFF for less thar thrse minutes. be careful not to bump the SRS unit; the airbsgs could accidentallydeploy and causdamag or iniu.ies,
Try to reproducotho SRSindicator light: 1. Erasethe DTCmemory (sepage24-15). 2. Turn the ignitionswitchON (ll),and checkthatthe SRSindicatorlight comeson for aboutsix seconds and goesoff. Doesthe SRSindicator light stay on?
YES
NO
lrtermittont fsilure, 3ystom is O|( at this time. SeTroubleshooting Intormittent Failuroson pago 2{-15.
Ch6ckfor a shon to powsr in the psssengor'sairbag inflalor: 1. Turnthe ignitionswitchOFF. 2. Disconnoct bafterynegativecable,then disconnect the the positive cable,and wait tor three minutes. the tront passenger's 3. Disconnect airbag 2P connector from the SRSmain harness lseepage24'11)4. Connect the special tool (2 0) to the SRS main harness 2P connector. CAUIION: Oo not disconnestthe d.iver's airbag connoctor. the 5. Reconnect batterypositive cable,then reconnect the negative cable. 6. Erase DTCmemory(seepage24 15). the 7. Read the DTC(seepage24 13). ls DTC2-4 indicat.d?
FRONT PASSENGER'S AIRBAG2P CONNECTON
YES
NO
HARNESS 2P CONNECTOR
Short to pow.r in the p.$eng6r's airbag inflator; .cplace thg pa$enger's airbag a$ombly {s.e p.ge 24-67).
SBSSIMULATOR LEADC 07TAZ- SZ5011A .nd SRSINFLATOR SIMULATOR (2 0 JACK) 07sAz - TBa011A
To page 24-55
/,4\ ( - /,/
sRs SERV|CE GoNNECTOR0l t2 07TAZ SZso200
N-_
24-54
a
Frompage24 54 Chocklor a short to oower in tho SRSmain harnss: the 1. Disconnect batterynegativecable,then disconnect and wait lor threeminutes. the positive cable, 2. Disconnect the drivr's airbag 2P connectorfrom the cable reel 2P connector. from 3. Disconnect SRS main harness18Pconnector the the SRSunit. tool (2 O)from the SRSmain harness 4. Remove special the 2Pconnector, the battery oositive cable, then reconnectthe 5. Reconnect negative cable. 6. Connect voltmeterbetweenthe No. 10 (+) terminalol a 18P and ground. SRSmain harness connector 7. Turn the ignition switch ON (ll), and measurevoltage. Thereshouldbe 0.5V or less. L Connect voltmeterbetweenthe No. 14 (+) terminalof a and ground,and the SRS main harness18Pconnector vohage. Thereshouldbe 0.5V or less. measure SRS UNIT
SRSunit; rsDlacetho SRSunit (sopage 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 careful not to bump the SRS unit; the airbags could aqcidentallydeploy and causedamage or iniuries.
Try to roproducetho SRSindicator light: 1. Erase DTCmemory (seepage24-1S). the 2. Turn the ignitionswitchON 0t),and checkthat the SRSindi_ catorlight comeson for aboutsix seconds and 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: 1. Turnthe ignitionswitchOFF. 2. Disconnect batterynegative the cable.then disconnect the positive cablo, and wait for threeminutes. 3. Disconnect tront passengsr's the airbag 2p connoctor from the SRSmain harness (seepage24,11). 4. Connect the special tool (2 0) to the SRS main harnass 2P connector, CAUTTON: not disconnectthe drivor.sairbrg connecDo loa, 5. Reconnect the battery positive cable, then reconnectthe negative cable. 6. Erasethe DTCmemory {see page24,15). 7. Read the 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 (2 CoNNECTOR 0l 07TAZ - 5250200
To page24-57
24-56
N-
\ I
From page 24-56
\
SRSUNIT
Cha.t to. a ahon to ground in th. SRSmrin harnda: the 1. Oisconneci banery negativecable,then disconnect and wail tor threeminules. the positive cable, 2. Disconnect the driver's airbag 2P connectortrom the cable reel 2P connector. 3. Oisconnccl tha SRS main harnass 18P connector from a Rarnoyr thc sp6itl tool {2 O)from the SRSmain harness 2P @nnctor. oftheSRS the between No 10terminal 5 Checl resistance and ground,and between maanharness18Pconnector 18P rhe No. l4 terminalol the SRSmain harness connec'
lor and qround. There should be 1 MO or more. b tha l.aaat|nc! !3
!\. s s u^n
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. Erase DTCmemory{seepage2+15). the 2. Turn the agnition switchON 0), and checkthattheSRSindi_ catorlight comeson tor abootsix seconds and goesoff. Doesthe SRSindicator lisht stav on?
SRSUNIT
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 1. Turnthe ignitionswitchOFF. 2. Remove dummy resistor the trom the SRSmain harness 2P connector. 3. Checkthe resistance betweenthe A and g terminalsof the dummy resistor. Thereshouldbe 1.5 2.50. ls the rsistancas sDecifiod?
DUMMY REStSTOn
Checkfor an open or increasedrcsistancein the SRS main harness: 1- Disconnect batterynegative the cable,then disconnect the positive cable, and wait for threemtnutes. 2. Disconnect the driver,s airbag 2p connectorfrom the cablereel2P connector {seepage24-11). 3. Disconnect SRS main harness1gp connector the from the sRs unit. 4. Connect dummy resjstor the SRSmain harness the to 2p connector. 5. Check resistance between No. l0terminal andNo. 14 the terminalof the SFS main harness 1gp connector. There shouldbe approx.1.5- 2.50.
Poor contect at the SRS m.in hamess lBp connector; chckthe 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
Airbag DTC2-3- Without FrontPassenger's
CAUTION: whensver ths ignition switch is ON (ll), or has been turned OFF tor l3s than three minutes, be careful nol to bump th SRS unit; lhe airbag could accidntally daploy and causdamag or iniuries.
Try to rep.oduc. th. SRSindicatot ligM: 1. Eraseth DTCmemory {seepage24-15). 2. Turn the ignitionswitchON (ll),and checkthat the SRSindiand gogsoff com6son lor aboutsix seconds 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. from the SBSmain harness the 2. Remov6 dummy resistor 2P connsctor. 3. Checktho resistancebetween the A and B tsrminals of Thereshouldbe 1 5 - 2 5 0. the dummv resistor. rgsistancg as 3pocified? 13tho
DUMMY RESISTOR
Chacklor a ahort to rnothd wile or dccreasedrelbtance in the SRSmain harn6s: the 1. Disconnect batterynegativecable,then disconnect cable,and wait for threemanutes the Dositive the driver's airbsg 2P connectorfrom the 2. Disconnect (seepage24-111 cablereel2P connector from the 3. Disconnect SRS main harness18Pconnector the SRSunit. NOTE: Do not connoctthe dummy resistorto the SRS msin harness2P connector, betwonthe No. 10 terminal and No. 14 4. Checkresistance There 18Pconnector' terminalof the SRSmain harness shouldbe 1 M0 or more.
SRSUNIT
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 taplacoths SRSmain harness. mrin hsrnoaa;
24-59
t
Troubleshooting
DTC2-4- Without FrontPassenger,s Airbag
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 cau3damago or iniuries.
Try to rep.oducothe SRSindicator light: 1. Erae DTCmemory {s6epage24-15). the 2. Turnthe ignitionswitchON 0t),and checkthatthe SRSindi_ catorlight comeson for aboutsix seconds and goesoff. 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. Disconnect the driver.s airbag 2p connectorfrom the cable reel 2P connector(seepsge 2+1.1). 3. Disconnect SRS main harnesslgp connector thg from the SRSunit. 4. Feconnectthe battery positive cable, thn reconnectthe negativecable. 5. Connecta voltmeter between th No. 10 (+) terminal ot the SRSmain harness connector 18p ano grouno. 6. Turn the ignitionswitch ON ll, and moasurevoltage. There should be 0.5 V or less. 7. Connect voltmeterbetween a the No. 14 (+) terminalof the SRS main harness18p connector and ground,and measure voltage. Thereshouldb6 0.5V or less. Aro vohtgos as rpocili.d?
SBSMAIN HARNESS 18PCONNECTOR
YES
NO
F.uftySRS unit;replace SRS the unit l.oo p ago 2+761. I
Sho to power in tha SRS main harno!3 or tha dummy rsi3tor; chcck tor contact betwoen tho dummy rosistor and another wiro. It tharo is no contact. ,oplace tho SRS mrin natnoss.
24-60
\ -
Airbag DTC2-5- Without FrontPassenger's

CAUTION: whenver 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. Erase DTCmemorvtseepsge24_15). the
2. Turn the ignition switch ON (ll), and check thal lhe SRS indi-
and gosoff catorliqht comeson for aboutsix seconds Oo.3 tho SRSindicator light .t!Y on?
SRSUN]T Chockfor e short to ground in tho SBS main halne3si the 1. Disconnect batterynegativecable.then disconnect the Dositivecable, and wait for three minutes' 2. Dis;onnectthe driver's airbag 2P connectorfrom the (seepage24-11) cablereel2Pconnector lrom the 3. Disconnect SRS main harness18Pconnector the sRS unit. belween No lO terminal of the SFS 4. Checkresistance and ground,and belween main harness18Pconnector 18P the No. 14terminalof the SFS main harness connec_ 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 lss than thre minules, bs carsful nol to bump the SRS unit; the airbags could sccidentallydeploy and causodamage or iniulies. Besides indicating abnormalityin the SRS unit, DTC an 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, Proceed the ordershown below. in
Checkthe SRSmain harn$s: 1. Disconnect batterynegativecable,then disconnect the the positive cable, and wait for thrceminutes. 2. Disconnect the driver's airbag (and tront passenger,s airbag)connecto(s) (see page 24-111. 3. Disconnect SRS main harness18Pconnectorfrom the the SRSunit. 4. Reconnectthe battery positive cable, then reconnectthe negative cable. 5. Turnthe ignitionswitchON (ll). 6. Connect a voltmeter and measure voltage betlveen the No. 10 terminalof the SRSmain harness l8p connector and ground, and btween No. '14 the terminal and ground. Thereshould be approx.0 - 0.5 V. Aro voltag.3 as spocifi.d?
sRs
18PCONNECTOR
YES
NO
Short to powsr in tho SRS main h6rnoss; roplace the SRS msin hamesl.
Checkthe SRSmein hr]ne3s rnd the csble recli Connect a voltmoter and moasure voltage between the No. 1 terminalof the SRS main harness18p connector a n d g r o u n d , a n d b e t w e e nt h e N o . 1 3 t e r m i n a l a n d ground.Thereshouldbe aDprox.0-0.5V. Aro voltag$ a3 apecifiod?
YES
NO
FauftySRSunit; replacethe SRSunit {3cepage 2+761,
To page24-63(A)
24-62
\_
E1
Frompage24'62(Al Chocktho ceble ro.l: 1. Turnthe ignitionswitchOFF 2. Disconneitthe cable reel 2P conn6clot f'om the SRS matnharness. 3. Turnthe ignitionswitchON (ll) 4, Connect a voltmeter and measure vohaga btreen 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 .,o'n'd- Thereshouldbe aoprox. - 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 thre minutes, bo clrctul not to bump tho SRS unit; the airbag(sl could lccidontally deploy and cau3edemage or iniuries.
Checkth6 tu3ei 1. Turnthe ignitionswitchOFF. 2. Checkfor blown No. 23 (10 A) fuse in the underdash
(A) To page 24-65 Replace fuse.Turnthe ignitionswitchON (ll), and check the 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.23 110 FUSE A) FUSE/RELAY BOX
SRSUNIT
Chock tor 3hort to g.ound betwoan tho undgr-dashfus6/ reby box and tho SRSunii. 1. Turnthe ignitionswitchOFF. 2. Disconnect batterynegative the cable.then disconnect the positivocable, and wait lor three minutes. 3. Disconnect the driver,s(and tront passengsr,s) airbag (see connector{s) page2/t-1'l). 4. Disconnect SRS main harnesslgp connector the lrom the SRSunit. 5. Checkresistancebotweenthe No. 3 terminal of the SRS main harness connector 18P and Oround. Thereshouldbe 1 M0 or more.
SRSMAIIIIHARNESS,I8P CONNECTOB SRSunh; replacsth. SRSunir {3oopage 2+761.
To page 24-65
1B)
24-64
fl
(B)from page24-64 tor ChaFk lhort to ground in th. SRSm'in h'mo3t: {rom the 2P the 1. Disconnect SRSmain harness connector box. underdash fuse/rlaY 2. aheck resistancebetweenthe No 3 terminal ot the SRS and ground There should main harness18Pconnector be 1.0Mo or mor ls tho l.3itt nco .. 3P.cifi.4l-
YES
NO
0t'@r
BOX FUSE/RELAY
Short to gtound in tha undor'dtth fu3'/tolf,Y box; r.of.ca th. und.rdssh rusolrelaV box.
-sho.t
m groundin th. sRs m.in htrnes;;r'plrct th' sRs
fiain h!mo$.
(A) From page 24-64 Chackloa an opcn in lha SRSmain harne3s: 1. Turn the iqnitionswitchOFF 2. Disconne;tthe batterynegativecable,then disconnect cable,and wait tor threemrnutes' the positive airbag the driver's (and lront passenger's) 3. Disconnect (seePage24-11). connector from /t. Disconnect SRS main harnessl8P connector the the sRs unit. the battery positivo cabl,then reconnectthe 5. Reconnect cable. neoative a S. Co-nnect voltmeter betlveon the No 3 terminal of the ancl 18P SRSmain harness connctor grouno' 7. Turnth ionitionswitchON {ll},and measure
SRSMAIN HARI{ESS 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: 1. Turnthe ignition switchOFF. 2. oisconnectthe SRSmain harness 2pconnectorlromthe under-dash fuse/relaybox. 3. Checkresistancebotweenthe No. 2 terminal of the SRS main harness2P connectorand No. 3 terminal of the SRSmain harness connector. 18P 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/rlaybox, 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 harnosli,
CaOl
i\
24-66
"L
Airbag
Replacement
the After a coltisionin which the airbagswere deployed, the SRSunit must be replaced' and airbagassembliss sb'! r'..-eycd l*bag whh the oad sur' !@ r tm ri6r9 b improPorly storod lac down' iiFup. accidcnti d.plovnanl Gaald proprl lht unit with f{u.V. nough to.6 to Glr !-iqt CAUTION: . Always disconnoctthc airblg connoctol(s) when the harnessis disconnactad. . Oo not disa3sembloor ttmper with ths airbag' NOTE: . Do not installusedSRSp8rtsfrom anothervehicle' usa when repairing, onty new SRSparts' inspectthe airbag beforeyou installit Do . CareJully being not insiall 8n airbag that shows signs of such as dents'cracKs droooedor improperlyhandled, or deformation. 1. Disconnectthe battery negative cable' then disconat nect the positive cable from the battery' and wa't leastthtee minutes. the Disconnect airbagconnector(sl: 4. the Remove sirbag(s): F ont P[.Jrga/t . Sld.: Disconnectthe 2P connec'torbetween the tront p88aitbagand SRSmsin harnsss' sengr's NOTE: When disconnected,the airb8g connoctor ls shoned. FRONTPASEltlGER's automatically
AIRBAG 2P @NNECIOR
2.
Driver's Side: . wheel' Removethe accesspanel from the steering the 2P connectorbetweenthe drivdisconnect then er's airbagand cablereel' is the NOTE:When disconnected, airbag connector shorted automaticallY S DRIVER AIRBAG
Diivar's Side: then o Removethe two Torx bolts using a Torx T30 bit' removethe drivers airbag'
TORXBOI-TS U.. . Torr F0 bit.

AIRBAG DRIVER'S 2P CONNECTOR
(cont'd)
24-67
.
Airbag
Front Passenger's Side: . . Removethe three mounting nuts from the bracket, then removethe harness cliD. Liftthe front passenger's airbagout of the dashboard by coveringthe lid and dashboard /ith a cloth, and \ pryingcarefully with a flat-tipscrewdriver, 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 which attachit to the dashboard. CAUTION: B sure to instsl the SRSwiring so that it is not pinched or intertsring with othr parts. 4. Install the new airbag(s):
Driver'sSide: Placethe driver'sairbaginto the steering wheel.and secureit with new Torx botrs.
TORXBOLTS 9.8N.m ll.0 kgf.m,7.2lbtfrl Replace.
DRIVER'S AIRBAG
Front Passenge.'s Side: . . P l a c et h e f r o n t p a s s e n g e r , a i r b a g i n t o t h e d 6 s h _ s board. Tightenthe front passenger,s airbagmountingnuts.
AIRBAGMOUNTINGNUTS 9.8 N.m 11.0 kgf.m,7.2lbf.ft) Reolace.
2+68
5.
the Reconnect airbag connector(s).
Driver's Side: . to the driver'sairbag2P connector the cable Connect panelon the then installthe access reel2P connector, wheel. steering
Frod P.ss.nga/s Sidc: . Aftach ths ai.bag connector to the connector holder' then rinstallths glove box.
RT'T
?ASSE'{GER'S AIRBAG
)
AIRBAG DRIVEN'S 2PCONNECTOR
CONNECTOB KOTDR
the then connect the Connect batterypositivecable, cable. negative 1. After installingthe airbag,confirm proper system operatlon: . Turn the ignitionswitch ON (ll);the SRS indicator light should come on for about six seconds and then go off. . Makesure both horn buttonswork'
24-69
1T
Airbag
Disposal
Before scrapping any airbags(including those in a whole lf vehicle be scrapped), airbagsmust be deployed. to the the vehicleis still within the warrantyperiod,beforeyou deploythe ai.bags,the HondaDistrictServiceManager instructions, must giveapproval and/orspecial Onlyafter the airbagshavebeendeployed{as the resultof vehicle collision, example), they be scrapped. tor can lf the airbagsappear intact {not deployed), treat them with extreme caution. Followthis procedure: Deployingthe Airbags: In-vohicl NOTE:It an SRSvehicleis to be entirelyscrspped,its airbags shouldbe deployed while still in the vehicle. The pans airbagsshould not be considered salvageable as and shouldneverbe installed anothervehicle. in confirm that esch airbag assemblyis !@ 3.cursly mounted; otherwisg, soverg ptsonal iniury could result from doploymont. l. Disconnect bafterynegative the cable,then disconnectthe positive cable. 5. 2. Confirmthat the special tool is tunctioningproperly by following the checkprocedure the tool label on ot on page 24-7'l. MAINHARNESS SRS Cut off the airbag connector,strip the ends of the airbagwires,and connectthe deployment tool alligator clips to the airbag.Placethe deployment tool at leastthirty teet (10meters) awayfrom the airbag,
DRIVER'S AIRBAG FRONT PASSENGER'S AIRBAG
Front Passngsr's Airbag: 4, Remove the glove box, then disconnect 2P conthe nector between the front passenger's airbag and sRS main harness pAssENGER's FR.NT AIRBAG
Driver's Airbag: 3. Removethe accessDanel,then disconnect the 2P connecto. betweenthe driver's airbag and the cable reel. DRIVER'S AIRBAG
2P CONNECTOR
BATTERY
t'4-70
a Connect 12 volt batteryto the tool: . lf the green light on the tool comes on' the airand cannotdeplov bag ignitercircuitis defective 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 Procedure. lf the red light on the tool comeson, the airbagis to readY be dePloYed.
Deployingthe Airbag: Out-ot-vehicle 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 or scraooedvehicle,or has been found defective dami o r s e r v i c e , t s h o u l db e a g e d d u r i n g t r a n s i t ,s t o r a g e as deployed follows: Posilion the airbag face up, outdoors on tffi l"ast thirtv feet (10 ml trom anv obstacles iiffiat 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 with this procedure tool comeson, continue doesn't deploy,yet the green light . lf an airbag comes ON. its igniter is delective Go to Dam aged Airbag Specia\Procedure' ri.,-.d .l.nlovment the airbag assem=E u"co-. hot enough to burn you wait thirF".n the w'minut.s after deployment before touching assemulY.
1.
tool is functioningproperlY Confirmthat the special on procedure thrs pageor on by followingthe check the tool label. deploY Follow steps5, 6, 7, and 8 of the in-vehicle ment Procedure.
8.
part Disposeof the completeairbag assembly No Placeit in a sturdy plasticbag' of it can be reused and sealit securely, CAUTION: . wear a lace shigtd and gloves when handling a deploYedairbag. r Wash your handsand rinse them well with water after handling a deploYedailbag'
AIRBAG
2.
DamagedAitbag SpecialProcedure r an ailbag cannot be deployed' it should !!@ considnot be treatgd as normal scrap; rt should still be that can cause serlered a potentiallY explosive device ous iniury. 1. 2. 3. proce lf installedin a vehicle,follow the removal dure on Page24-67' makea shortcircuitby twistingtogether ln all cases. wlres the two airbaginflator
the airbag in exactlythe same packaging Package part that the new replacement cameIn "DAMAGEDAIRBAG 4. Mark the outside of the box with sQ NOT DEPLOYED" it does not get confused your Partsstock. for S y 5 . C o n t a c t o u r H o n d aD i s t r i c t e r v i c eM a n a g e r and whereto returnit for disposal how DeploymentTool: CheckProcedure 1. 2. 3. protector Connectthe yellow clips to both switch the tool to a battery' on handles the tool; connect switch:green meansthe tool is Pushthe operation OK; red meansthe tool is faultY the Disconnect batteryand the yellowclips'
24-71
T:
Gable Reel
Replacement
sto.e a remove airbag assembly with the @ pad surface up. lf the 8irbag is improperly stored face down, accidontaldeployment could propl the unit with enough torce to causeserious iniury, CAUTION: . Always dkconnest th6 airbag conneqtor(s)when the harnsssis disconnected. . Do not disassemble tampor with the airbag. or N O T E :C a r e f u l l y 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 i installing Do not installan airbagthat shows signsof it. b e i n g d r o p p e do r i m p r o p e r l y a n d l e d s u c h a s d e n t s , h , cracks deformation, or
1.
Makesurethe wheelsare alignedstraightahead.

4.
Remove driver'sdashboard the lowercover.

TORXBOLTS Use a Torx T30 bh.
Disconnect batterynegative the cabl,then disconnectthe positivecablefrom the battery, and wait at leastthreeminutes. Removethe accesspanel from the steeringwheel, then disconnect 2P connector the betweenthe driver's airbagand cablereel. NOTE:When disconnected, airbagconnecror the ts automatically shorted.
DRIVER'S AIRBAG DRIVER'S AIRBAG
DRIVER'S DASHBOARD LOWER COVER
5.
Remove two Torx boltsfrom the steering the wheel. and disconnectthe horn connector.Then remove the driver'sairbag.
DRIVER'S AIRBAG 2P CONNECTOR
-El
from 6. Disconnect connectors the hornandcruise the then remove steerthe switches, cont.olsevresume
ing wheel nut, WHEEL STEERING
8. Romove columnrdverq tho
CABLEREEL 2P CONNECTOR
1.
Removethe steeringwheel using a steering wheel puller.
between the main wire the 9 . Disconnect 3P connector and harness and cablereelsub-harness, the 2P conthe nectorbetlveen cablereeland SRSmain harness.
CABLEREEL
WHEELPULLER STEERING (Commercially-available) SUB CABLEREEL HARNESS 3P CONNECTOR
t 1 0 . R e m o v eh 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
Gable Reel
Replacement(cont'd)
NOTE: . B e f o r ei n s t a l l i n g h e s t e e r i n gw h e e l ,t h e f r o n t t wheelsshouldbe alignedstraightahead. . Be sure to lnstallthe harness wires so that they are not pinched interfering or with other parts. . After reassembly, confirm that the wheels are still turned straightaheadand that the steering wheel spokeangle is correct(roadtest).lf minor spokeangleadjustment necessary, so only is do by adjustingthe tie-rods,not by removing and repositioning steering the wheel. 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 s r e a alignedvenically.
r 3 , Installthe steering columncovers.

1 4 . lf necessary, centerthe cable reel. (New replacement
cablereelscome centered.) this by first rotatingthe Do cable reel clockwiseuntil it stops.Then rotate it coun(approximately terclockwise two and a half turns) until the arrow markon the cablereellabelpointsstraight uD.
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 t o t h e r cablereel sub-harness, connectthe 2p connecand tor to the SRSmain harness.
1 5 . I n s t a l lt h e s t e e r i n g h e e l ,t h e n c o n n e c t h e h o r n w connector and cruisecontrolsevresume switchcon_

neclor. STEERING WHEEL CRUISE CONTROL SET/RESUME
SRSMAIN HARNESS
o'1
: _ - - - - - - -
- - - - - - <
SRSUnit
Replacement
CAUNON: . Beforo disconnesting any part of the SRS wire harness,disconneetthe ailbag connector(s). . During installation or rsplacement, do not bump (impact wronch, hammor etc.) the aroa near tho SRS unit. NOTE: . Do not damagethe SRSunit terminals connectors. or . Do not disassemble SRS unit; it has no servicethe ableoarts. . Storethe SRSunit in a clean,dry area. . Do not useany SRSunit which has beensubjected to wateror showssignsof beingdroppedor improperly handled, suchas dents,cracks deformation. or l. Disconnect batterynegativecable,then disconthe nectthe positive cablefrom the battery,andwaitat leastthree minutes. Disconnect airbagconnector{s}: the NOTE:When disconnected, airbagconnectoris the automatically shorted. Driver's Side: o Removethe accesspanel from the steeringwheel. then disconnect the 2P connectorbetweenthe driver's airbagand cablereel(seepage24-11). Front Passenggr's Sidg: . Disconnect 2P connectorbetweenthe front pasthe senger's airbagand SRS main harness(seepage 2411). 3. Remove right sidecoverfrom the SRSunit. the
I
SRSUNlT
TORX BOL?S U3ar Torx T30 bit.
2.
RIGHTSIDE
COVER Removethe left side cover from the SRS unit. then 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 from the SRSunit,
SRS UNIT
l,---, $'
Remove the 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 connctor,than rernstallthe access panelon the steering r*reelthe front passenger's ai.bag conneclor 1 0 . Reconnect to the SRSmain harness. cable,thn lho n6gathe 1 1 . Reconnect batterypositive tive cable. the After installing SRSunit, confirmpropersystem Turn the ignitionswitchON (ll);the SRS operation: light shouldcomeon for aboutsix seconds indicator and then go off.
TORXBOLTS 9.8 N.m 11.0 kgf.m, 7.2 lbfft) Uso a Torx T30 bh. Replace.
TORXBOLTS
kgtm.7.2lbtftl 9.8N.m(1.0 Usoa TorxT30bit. Replace. 7. to 18Pconnector the the Connect SRSmain harness SRSunit;push it into positionuntil it clicks 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
8.

Honda Civic Service Manual 96-98

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Honda Civic Service Manual 96-98

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Information General

and PaintCodes Chassis

2HG: HONDA CANADA OF

D16Y7: 1600SOHC16-valves Sequential Multiport Fuel-injected Engine

A4RA:4-speed Automatic Transmission S40 : s-speed ManualTransmission

H: AllistonPlant, Ontario, Canada Destin.iions

GY-16P NH-503P NH.583M R-97

Midori GreenPearl Granada BlackPearl New VogueSilverMetallic RomaRed

Vehicle ldentification Number and FederalMotor Vehicle Safety Standard Certification

U.S. 1996Model {4-doorSedanl

Automatic Transmission A4RA:4-speed ManualTransmission S40 : s-speed ManualTransmission S4C : s-soeed

A4RA {U.S.A.) : 5000001(JAPAN): 1000001S40. SaC

B-73M G-82P NH-538 NH-503P NH-583M R-95P

BlueMetallic Cyclone CypressGreenPearl FrostWhite BlackPearl Granada New VogueSilverMetallic lslandCoralPearl

Vehicle ldentification Number and FederalMotor Vehicle Safety Standard Cortification

Chassis and PaintCodes

Vehicle ldentification Number and FederalMotor Vehicle Safety Standard Certification

1996 Modell2-door Hatchbackl CANADA a

A4RA:,t-speedAutomatic Transmission S40 :s-soeedManualTransmission

Vehicle ldentification Number and CanadianMotor Vehicle Safety Standard Certification

Chassis and PaintCodes

lHG EJ653*TL 800001

D16Y7: 1600SOHC16-valves Sequential Multiport Fuel-injected Engine

A4RA;4-speed Automatic Transmission ManualTransmission S40 : 5-soeed A4RA:5000001S40 :1000001-

Vehicleldentification Number MotorVehicle andCanadian Safety Standard Gertif ication

B-73M G-82P NH-503P NH-538 NH-583M

CANADA 1996Model (2-doorCoupel

1HG J6 2*TL 000001 E 1

Vehicle ldentif icationNumber MotorVehicle andCanadian SafetyStandardCertification

G-82P NH-503P NH-538 NH-583M R-81 R-95P

Chassis and PaintCodes

Vehicle ldentification Number and FederalMotor Vehicle Safety Standard Certification

U.S. 1997Model l4-door Sedanl

B.73M G-82P NH-538 NH-503P NH-583M R.96P

Vehicle ldentification Number and FederalMotol Vehicle Safety Standard Certification

Chassis and PaintCodes

Vehicle ldentification Number and FederalMotor Vehicle Safety Standard Certification

A4RA 6000001: B4RA 6000001: S40 :1000001M4VA: 2000001-

G-82P NH.5O3P NH-538 NH.583M R-81

CANADA 1997Model (2-door Hatchbackl

D16fr: 1600SOHC16-valves Multiport Sequential Fuel-injected Engine

A4RA:4-speed Automatic Transmission Automatic Transmission B4RA:4-sDeed S40 : s-sDeed MsnualTransmission

NH-503P NH.583M PB-74P R-97

G.anadaBlackPearl New VogueSilverMetallic DarkAmethyst Pearl RomaRed

and PaintGodes Chassis

D16\.t: 1600SOHC16-valves Sequential Multiport Fueliniected Engine

A4RA:4-speed Automatic Transmission 84RA:4-speed Automatic Transmission S40 : s-sDeed ManualTransmission

L: EastLibertv, Ohio Plant,U.S.A.

Vehicleldentification Number andCanadian MotorVehicle SafetyStandard Certif ication

B-73M G.82P NH-503P NH-538 NH-583M

CANADA 1997Model (2-doorCoupel

44RA: 4-speedAutomatic Transmission Transmission B4RA:4-speed Automatic S40 :s-speedManualTransmission

A4RA: 6000001B4RA: 6000001S40 :1000001-

L: East Liberty, Ohio Plant. U.S.A.

G-82P NH-503P NH-538 NH-583M R-81

Cypress GreenPearl BlackPoarl Granada FrostWhite New VogueSilverMetallic MilanoRed

Chassis and PaintCodes

2HGEJ632 *WH 1 00001

NH.592P NH-583M PB-74P R-97

Flamenco BlackPearl New VogueSilverMetallic DarkAmethystPearl RomaRed

Vehicle ldentification Number and FederalMotor Vehicle Safety Standard Certificataon

U.S. 1998Model (4-doorSedanl

8.73M NH-578 NH-592P NH.583M R.96P

VehicleldentificationNumbel and FederalMotor Vehicle Safety Standard Certification