INTRODUCTION - How to Use This Manual ‘The 94 ACCORD COUPE Shap Manual (Meintenance, Repair and Construction) is divided into 23 sections. The first page of each scc- tion is marked with a black tsb that lines up with its. corresponding thumb index tab on this page. You can quickly find the fiest page of each section without looking threugh a full table of contents. The symbols printed at the top corner of each page can also be used as fa quick reference system. Each section includes: 1. A table of contents, or an exploded view index showing: © Parts disassembly sequence © Bolt torques and thread sizes © Page references to descriptions in text. Disassembly/assembly procedures and tools, Inspection. Testing/tioubleshooting, Repair Adjustments, oosen Special Information REMMI indicates o strong possibility of sevore personal injury 9¢ loss of Ife i instructions are not followed. CAUTION: Incicates a possibility of personal injury or equipment damage if instructions are not followed. NOTE: Givos helpful information. CAUTION: Detailed descriptions of stendard workshop procedures. safety principles and service operations ars not inchided, Please note that this manual contains warnings and cautions against some specit- Ie service methads which could cause PERSONAL INJURY, damage ings: ‘cannot cover di conceivable ways in which service, whether or not recommended by HONDA might be done, or of the possible hazardous consequences of overy conceivable way, nor could HONDA investigate all such ways. Anyone using service procedures ‘or tools. whether or not recommended by HONDA, ‘must satisfy him- ‘soff thoroughly that neither personal safety nor vehicle safety will be jeopardized Allinformation contained in this manual is based on the latest product information available at the time of printing. We reserve the right ‘to make changes at any time without notice. No part of this sublica- tion may be reproduced, stored in retrieval system, or transmitted, in any. form by any means, electronic, mechanical, photocopying, ‘cording, ocatherwise, without the prior written permission of the + publisher. This includes text, figures and tabies. rst Edition 1/94 1500 pages HONDA MOTOR CO., LTD. W Rights Rosavod Service Publication Office Ae sections with * include SRS componente; Sheetal procautions are requited when servicing, General Info Special Tools Specifications Maintenance Engine Cooling Fuel and Emissions *Transaxle *Steering Suspension *Brakes (Including [ABS *Body *Heater and Air Conditioning * Electrical __ {Including [SRGeneral Information Chassis and Engine Numbers .. 1-2 Identification Number Locations ....... 1-3 Warning/Caution Label Locations ..... 1-4 Lift and Support Points Lift . 1-10 Floor Jack 11 Safety Stands 1-12 Towing . 1-13 Abbreviations .. ~ 1-14Chassis and Engine Numbers European Model ;— Vehicle Identification Number 1HGCD71300A000001 ie a Manufacturer, Make and | \ ‘Type of Vehicle | 1HG: HONDA OF AMERICA, | MFG., INC., U.S.A, } HONDA, Passenger car Line, Body and Engine Type —— | D7: ACCORD COUPE/F22B5 | CD9: ACCORD COUPE/F20B3 Body Type and Transmission Type —! | 1: 2-door Coupe/S-speed Manual 2: 2-door Coupe/4-speed Automatic Vehicle Grade (Series) ———————! 3: 2.218. 4: 2.0118 or 2.21ES with leather seats 5: 2.01ES. Fixed Code ——— ‘Auxiliary Number —————————— | Factory Code ——— A: Ohio Factory in U.S.A. (Marysvito) Mode! Year —— Except European Model [- Vehicle Identification Number ——___— 1HGCD722"RAOOOD1 Make and ‘Type of Vehicle HG: HONDA OF AMERICA MEG., INC., U.S.A, HONDA Passenger car Line, Body and Engine Type — (D7: ACCORD COUPE/E2281 ‘and F22B2 Body Type and Transmission Type 2: 2-door Coupe/4-speed Automatic Vehicle Grade (Series) —— 2: OX 3: LX 5: EX Check Digit ——— Model Year R: 1994 } Factory Code — ae ‘A: Ohio Factory in U.S.A. (Marysville) ‘Serial Number ——————_—~ — | = [- Engine Number r2ee-000001 ee aol F20B3: 2.0 ¢ SOHC Sequential , Multi-port Fuel-injected engine F2285: 2.2 ¢ SOHC Sequential Mult-port Fuelinjected engine Serial Number ———— Transmission Number ———_1_____ 241000001 Tranemesion Type ———————} race: Manual \ POR: Automatic Sait Nomber ca,” 3900001 — tiPom: 1000001 — [- Engine Number F2281-1400001 ay Engine Type ——— | F281: 2.2 ¢ SOHC VTEC Sequentiat Multi-port Fuel-injected engine 2282: 2.2 £ SOHC Sequential Muilti-port Fuel-injected engine | Number —— [- Transmission Number MPOA-1000001 Transmission Type ——— MPOA: Automatic Serial Number —————Identification Number Locations Vehicle Identification ‘Number {VIN}Warning/Caution Label Locations 8: DRIVER MODULE DANGER «Hy & DANGER EXPLOSIVE/FLAMMABLE ‘CONTACT WITH ACID, WATER OR HEAVY METALS SUCH ‘AS COPPER, LEAD OR MERCURY MAY PRODUCE HARM- FUL AND IRRITATING GASES OR EXPLOSIVE COM. POUNDS. STORAGE TEMPERATURES MUST NOT EXCEED 200°F (100°C). FOR PROPER HANDLING, STORAGE AND DISPOSAL PROCEDURES REFER TO SERVICE MANUAL, SRS SUPPLEMENT. POISON CONTAINS POISONOUS SODIUM AZIDE AND POTASSIUM NITRATE, FIRST AID. IF CONTENTS ARE SWALLOWED, INDUCE VOMITING. FOR EYE CONTACT. FLUSH EYES WITH WATER FOR 15 MINUTES. IF GASES [FROM ACID OR WATER CONTACT) ARE INHALED, SEEK FRESH AIR. IN EVERY CASE, GET PROMPT MEDICAL ATTENTION. KEEP OUT OF REACH OF CHILDREN. ‘A: CABLE REEL CAUTION A (Ka, Ke) TSS] DANGER easy REFER TO SERVICE (SHOP) MANUAL FOR DETAILED IN- ExPLOSIVE/FLAMMABLE STRUCTIONS. Porson REFER To SHOP MANUAL POUR LES INSTRUCTIONS DETAILLIEES, SE REPORTER AU Dancer MANUEL DE REPARATIONS EXPLOSIF EY INFLAMMABLE Poison AAUSFOHRLICHE ANWEISUNGEN SIND DEM WERKSTAT- SE REPORTER AU MANUEL O'ATELIER, THANBUCH ZU ENTNEMEN © cerann ExeLosivienTZUNDBAR RAADPLEEG HET WERKPLAATSHANDBOEK VOOR NA- cr Dene AANWLIZINGEN. WERKSTATTHANDBUGH LESEN. # cevAan FURS - RAV aT e SIMO ST. EXPLOSIEGEVAAR/BRANDBAAR carrie LEES HET WERKPLAATSHANDBOEK. : DRIVER MODULE WARNING (xt) WARNING ‘THE AIRBAG INFLATOR IS EXPLOSIVE AND. IF ACCIDEN- ‘TALLY DEPLOYED, CAN SERIOUSLY HURT OR KILL YOU. ‘© DO NOT USE ELECTRICAL TEST EQUIPMENT OR PROB- ING Devices. ‘THEY CAN CAUSE ACCIDENTAL DEPLOYMENT. (@ NO SERVICEALE PARTS INSIDE. DO NOT DISAS- ‘SEMBLE ‘© PLACE AIRBAG UPRIGHT WHEN REMOVED. (© FOLLOW SERVICE (SHOP) MANUAL INSTRUCTIONS (CAREFULLY. A ATTENTION LE GONFLEUR DE COUSSIN D’AIR EST EXPLOSIBLE ET S'LL SE DEPLOIE ACCIDENTELLEMENT, IL RISQUE DE PROVO: ‘QUER DES GLESSURES GRAVES OU DE TUER. ‘© NE PAS UTILISER DE MATERIEL D’ESSAI ELECTRIQUE NUDE SONDE. ILS POURRAIENT PROVOQUER UN DEPLOIMENT ACCIDENTEL DU COUSSIN D’AIR. © ILN'Y A PAS DE PIECES REPARABLES A L'INTERIEUR. Ne PAS DEMONTER. ‘© QUAND ON RETIRE LE COUSSIN D“AIR, LE TENIR A LA VERTICALE. © SUIVRE ATTENTIVEMENT LES INSTRUCTIONS DU MANUEL D’ENTRETIEN.(KG, KE) WARNING [SRS] © REFER TO THE SHOP MANUAL. SE REPORTER AU MANUEL D’ATELIER, (© WERKSTATTHANDBUGH LESEN. @ LES HET WERKPLAATSHANDBOEK. D: INFLATOR BAM LABEL (KE, KG only) ISI manufactured inflator: ‘AIRBAG GAS GENERATOR GG7-100 ist HERSTELLUNGSJAHR: 1993 EINFOHRER: HONDA DEUTSCHLAND GMBH/OFFENBACH BAM PT.0469, HALTESYSTEME MIT LUFTSACK IN KRAFTFAHRZEUGE MONTIERT WERDEN. DIE MONTAGE UND DEMONTAGE DES GASGENERATORS DARF NUR VON DAFOR GESCHULTEM PERSONAL VOR- GENOMMEN WERDEN. CAUTION. THE GAS GENERATOR SHOULD ONLY BE CONTAINS _ INSTALLED IN VEHICLES EQUIPPED WITH | FLAMMAGLE THE AIRBAG SYSTEM. THE GAS GENERA. | SOLIDS US TORIS TO BE INSTALLED AND/OR DIAS. DOT-£.9066 _ SEMBLED ONLY BY TRAINED PERSONNEL. CONTENT DE STALE QUE SUR DES VEHICULES EQUIPES SOLIDES _D'UN SYSTEME AIRBAG LE MONTAGE ET FLAMMAGLES LE DEMONTAGE DU GENERATEUR DE GAZ us. INE PEUT ETRE EFFECTUE QUE PAR UN PER- DOT-£.9066 _SONNEL QUALIFIE, MORTON International manufactured inflator: MORTON INTERNATIONAL INC OGDEN UT. USA HERSTELLUNGSJAHR: 1992 EINFOHRER: HONDA DEUTSCHLAND GMBH/OFFENBACH BAM Pro3ee ‘DER GASGENERATOR DARE NUR FOR INGASSENRUGK- HALTESYSTEME MIT LUFTSACK IN KRAFTFAHRZEUGE MONTIERT WERDEN, DIE MONTAGE UND GEMONTAGE DES GASGENERATORS DARF NUR VON DAFOR GESCHULTEM PERSONAL VOR- GENOMMEN WERDEN. ‘CAUTION THE GAS GENERATOR SHOULD ONLY BE CONTAINS INSTALLED IN VEHICLES EQUIPPED WITH | FLAMMABLE THE AIRBAG SYSTEM. THE GAS GENERA. SOLIDS US. TORIS TO BE INSTALLED ANDIOR DISAS. DOT-£-8214_ SEMBLED ONLY BY TRAINED PERSONNEL "ATTENTION LE GENERATEUR DE GAZ NE PELT ETREIN- CONTENT DE STALLE QUE SUR DES VEHICULES EQUIPES SOLIDES._D'UN SYSTEME AIRBAG LE MONTAGE ET FLAMMABLES LE DEMONTAGE DU GENERATEUR DE GAZ us [NE PEUT ETRE EFFECTUE QUE PAR UN PER- DOT-E-2214 SONNEL QUALIFIE ‘DER GASGENERATOR DART NUR FUR INSASSENRUGK. | ‘ATTENTION LE GENERATEUR DE GAZ NE PEUT ETRE: | | AIRBAG GAS GENERATOR UT11600 — ‘TW Safety Systems manufacture inflator: TRIRGAG GAS GENERATOR ‘TAW SAFETY SYSTEMS/MESA HERSTELLUNGSJAHR: EINFOHRER: HONDA DEUTSCHLAND GMBHIOFFENBACH BAM PT.-0538 ‘DER GASGENERATOR DARE NUA FOR INSASSENRUGK. HALTESYSTEME MIT LUFTSACK IN KRAFTFAHRZEUGE MONTIERT WERDEN, DIE MONTAGE UND DEMONTAGE DES GASGENERATORS DARF NUR VON DAFOR GESCHULTEM PERSONAL VOR- GENOMMEN WERDEN. GAUTION “THE GAS GENERATOR SHOULD ONLY BE CONTAINS INSTALLED IN VEHICLES EQUIPPED WITH FLAMMABLE THE AIRBAG SYSTEM. ‘SOLIDS US THE GAS GENERATORS TO BE INSTALLED, DOT-£8236 AND/OR DISASSEMBLED ONLY BY ‘TRAINED PERSONNEL. ‘ATTENTION "LE GENERATEUR DE GAZ NE PEUT ETRE IN. CONTENT DE. STALE QUE SUR DES VEHICULES FQUIPES SOLIDES _D'UNSYSTEME AIRBAG. LE MONTAGE ET FLAMMABLE LE DEMONTAGE DU GENERATEUR DE GAZ us INE PEUT ETRE EFFECTUE QUE PAR UN PER. DOT-£.8236 SONNEL QUALIFIE. : STEERING WHEEL WARNING. IKE, KG) wanna [SRS (© REFER TO THE SHOP MANUAL. ‘© SE REPORTER AU MANUEL D’ATELIER. WERKSTATTHANDBUCH LESSEN. (© LEES HET WERKPLAATSHANDBOEK. E: STEERING WHEEL NOTICE (KH NOTIcE IMPROPER STEERING WHEEL REMOVAL OR INSTALLATION, CAN DAMAGE SRS COMPONENTS. FOLLOW SERVICE MANUAL INSTRUCTIONS CAREFULLY. F: SRS WARNING (HOOD) xn ‘SUPPLEMENTAL RESTAAINT SYSTEM (SRS) ‘THIS VEHICLE IS EQUIPPED WITH DRIVER AND FRONT SEAT PASSENGER AIRBAGS. ALL SRS ELECTRICAL WIRING AND CONNECTORS ARE COLORED YELLOW. ‘TAMPERING WITH, DISCONNECTING OR USING ELECTRI- CAL TEST EQUIPMENT ON THE SRS WIRING CAN MAKE ‘THE SYSTEM INOPERATIVE OR CAUSE ACCIDENTAL FIR. ING OF THE INFLATOR, ‘WARNING THE AIRBAG INFLATOR IS EXPLOSIVE AND, IF ACCIDEN- TALLY DEPLOYED. CAN SERIOUSLY HURT YOU. FOLLOW SERVICE MANUAL INSTRUCTIONS CAREFULLY. (cont'd) 1-5arning/Caution Label Locations r~ (cont'd) Ww.G: STEERING COLUMN NOTICE (Ke, KH) novice ‘TO PREVENT DAMAGE, REMOVE STEERING WHEEL BE- FORE REMOVING STEERING SHAFT CONNECTING BOLT. | REMARQUE: POUR EVITER TOUT DOMMAGE DU SRS, RETIRER LE VOLANT AVANT DE RETIRER LE BOULON DE RECCORDE. MENT DE L’ARBRE DE DIRECTION. G: STEERING COLUMN CAUTION (KG ‘ACHTUNG [SRS] UNM BESCHADIGUNGEN DER S.R.S-KABELROLLE ODER | DES KABELS. WELCHE DAS 5.R.5.-SYSTEM AUBER FUNK- TION SETZEN WORDEN. 2U VERMEIREN, VOR ARBEITEN AN DER LENKSPINDEL DAS LENKRAD AUSBAUEN, WAARSCHUWING [SRS] OM TE VOORKOMEN DAT DE S.R.S.-KABEL OF- HASPEL BESCHADIGD WORDEN, HETGEEN ERTOE ZOU LEIDEN DAT HET SYSTEM UITVALT, DIENT U HET STUUR TE VER- WWDEREN VOORDAT U DE STUURSCHACHTCONNECTOR- BOUT VERWLIDERT. H: FRONT SEAT PASSENGER AIRBAG MODULE DANGER Hy Z DANGER EXPLOSIVE/FLAMMABLE CONTACT WITH ACID, WATER OR HEAVY METALS SUCH [AS COPPER, LEAD OR MERCURY MAY RPODUCE HARM. FUL AND IRRITATING GASES OR EXPLOSIVE COM. POUNDS. STORAGE TEMPERATURES MUST NOT EXCEED 20°F (100°C). FOR PROPER HANDLING, STORAGE AND DISPOSAL PROCEDURES REFER TO SERVICE MANUAL, SRS SUPPLEMENT. POISON CONTAINS POISONOUS SODIUM AZIDE AND POTASSIUM NITRATE, FIRST AID IE CONTENTS ARE SWALLOWED, INDUCE VOMITING. FOR EYE CONTACT, FLUSH EYES WITH WATER FOR 16 MINUTES. IF GASES (FROM ACID OR WATER CONTACT) [ARE INHALED, SEEK FRESH AIR. IN EVERY CASE, GET PROMPT MEDICAL ATTENTION. KEEP OUT OF REACH OF CHILDREN. 4 ‘& WARNING ‘THE AIRBAG INFLATOR IS EXPLOSIVE AND, IF ACCIDEN- TALLY DEPLOYED, CAN SERIOUSLY HURT OR KILL YOU. ‘© DO NOT USE ELECTRICAL TEST EQUIPMENT OR PROB. ING DEVIces. THEY CAN CAUSE ACCIDENTAL DEPLOYMENT. (© NO SERVICEABLE PARTS INSIDE. DO NOT DISAS- SEMBLE. ‘© PLACE AIRBAG UPRIGHT WHEN REMOVED. ® FOLLOW SERVICE MANUAL INSTRUCTIONS (CAREFULLY. (Ke [panceR EXPLOSIVE/FLAMMABLE POISON REFER TO THE SHOP MANUAL. ‘© DANGER, EXPLOSIF ET INFLAMMABLE POISON SE REPORTER AU MANUEL D’ATELIER, © GEFAHR EXPLOSIV/ENTZUNDBAR Git WERKSTATTHANDBUCH LESEN. © GEVAAR EXPLOSIEGEVAAR/BRANDBAAR GrTiG LES HET WERKPLAATSHANDBOEK. 1 LABEL [AIRBAG] J: INELATOR BAM LABEL (KE only) MORTON INTERNATIONAL manufactured inflator: ‘AIRBAG GAS GENERATOR UT11873 MORTON INTERNATIONAL, OGDEN, USA HERSTELLUNGS (JAHR) EINFURER: HONDA DEUTSCHLAND GMBH/OFFENBACH Bam PT.0437, DER GASGENERATOR DART NUR FOR INGASSENRUGK- HALTESYSTEME MIT LUFTSACK IN KRAFTFAHRZEUGE MONTIERT WERDEN DIE MONTAGE UND DEMONTAGE DES GASGENERATORS. DARF NUR VON DAFOR GESCHULTEM PERSONAL VOR: GENOMMEN WERDEN. CAUTION ‘THE GAS GENERATOR SHOULD ONLY BE CONTAINS INSTALLED IN VEHICLES EQUIPPED WITH. FLAMMABLE THE AIRBAG SYSTEM. THE GAS GENERA. SOLIDS TORIS TO BE INSTALLED ANO/ OR DISAS. SEMBLED ONLY BY TRAINED. "ATTENTION LE GENERATEUR DE GAZ NE PEUT ETRE IN CONTENT DE_ STALE QUE SUR DES VEHICULES EQUIPES, SOLIDES —_D'UN SYSTEME AIRBAG LE MONTAGE ET FLAMMABLES LE DEMONTAGE DU GENERATEUR DE GAZ INE PEUT ETRE EFFECTUE QUE PAR UN PER- SONNEL QUALIFIE, (cont’a} 1-7Warning/Caution Label Loca r— (cont'd) K: DRIVER INFORMATION [SRS] _ALWAYS WEAR YOUR SEAT BELT ‘© THis CAR 1S EQUIPPED WITH A DRIVER AIRBAG AND AFRONT SEAT PASSENGER AIRBAG AS A SUPPLEMEN: ‘TAL RESTRAINT SYSTEM (SRS). ¢¢ ITIS DESIGNED TO SUPPLEMENT THE SEAT BELT. (© BEFORE DRIVING READ LABEL INSIDE THE GLOVE BOX. 'SHS) ALWAYS WEAR YOUR SEAT BELT ‘© THIS CAA IS EQUIPPED WITH A DRIVER AIRBAG AND [A FRONT SEAT PASSENGER AIRBAG AS A SUPPLEMEN- TAL RESTRAINT SYSTEM (S5.F.S.). ‘© IT IS DESIGNED TO SUPPLEMENT THE SEAT BELT. © IF-YOUR SRS INDICATOR LIGHTS WHILE DRIVING SEE YOUR AUTHORIZED HONDA DEALER. [SRS] ATTACHEZ TOUJOURS VOTRE CEITURE ‘© CE VEHICULE EST EQUIPE D'UN COUSSIN D’AIR POUR LE PASSAGER AVANT, QUI CONSTITUENT UN SYS. ‘TEME DE RETENUE COMPLEMENTAIRE (S.F.S. ‘© CE COUSSIN D’AIR COMPLETE LA FONCTION DE LA CCEINTURE DE CECURITE. ‘© SILE TEMOIN SRS S’ALLUME PENDANT LA CONDUITE, ‘ADRESSEZ.VOUS A VOTRE CONSSIONNAIRE HONDA OFFICIEL. [SRS] SICHERMEITSUGRTE BE! JEDER FAHRT ANLEGEN ‘© DIESES FAHRZEUG BESITZT JE EINEN AIRBAG FUR FAHRER UND BEIFAHRER ALS ZUSATZLICHES ROCK- HAL TESYSTEM (S.F.5.) © DAS ROCKHALTESYSTEM IST EINE ERGANZUNG ZUM. ‘SICHERHEITSGURT. © SOLLTE WAHREND DER FAHRT DIE SRS KONTROLLEUCHTE AUFLEUCHTEN SUCHEN SIE BITTE UNGEHEND EINEN HONDA-HANDLER SUF. [SRS]_ORAAG ALTIUD UW VEILIGHEIDSGORDEL "© Dit VOERTUIG IS UITGERUST MET AIRBAG (SAS) AN BESTUURDERSZLDE EN PASSAGIERSZIJDE VOOR EX- ‘TRA VEILIGHEIO. (© ONTWORPEN ALS EXTRA BESCHERMING NAAST DE \VEILIGHEIDSGORDELS. © ALS HE SRS-WAARSCHUWINGSLAMPJE GAAT GRAN. DEN ONDER HET ALJDEN, NEEM DAN KONTAKT OP MET EEN HONDA DEALER, [GLOVE 6OX INFORMATION (KH) ‘AIRBAG INFORMATION SUPPLEMENTAL RESTRAINT SYSTEM (SRS) © THE SRS MUST BE INSPECTED TEN YEARS AFTER IT IS INSTALLED. THE DATE OF INSTALLATION IS SHOWN ‘ON THE CERTIFICATION PLATE, LOCATED ON THE DRIVER'S DOOR JAMB. © DIAGNOSTIC CHECKS AND REPLACEMENT OF SRS. ‘COMPONENTS MUST BE DONE BY AN AUTHORIZED DEALER. © SEE YOUR OWNER’S MANUAL FOR ADDITIONAL SAS. INFORMATION. M: MONITOR NOTICE NOTICE [SRS] '@ NO SERVICEASLE PARTS INSIDE. © REFER TO SERVICE MANUAL FOR DETAILED IN. STRUCTIONS. 1-81-9Lift and Support Points r Lift When heavy rear components such as suspension, fuel tank, spare tie and trunk ld are to be removed. Place eddiionel weight in the trunk before hosting. When substantial weight Is removed from the rear of the car the Center of gravity may change and can cause the ear to tip forward on the hoist NOTE: Since each tire/wheel assembly weighs approximately 30 Ibs (14 kg), placing the front wheels in the trunk can assist with weight distribution 1. Place the lift blocks as shown, 2. Raise the hoist few inches (centimeters) and rock the car to be sure itis firmly supported. 3. Raise the hoist to full height and inspect lift points for solid support. / FRONT SUPPORT POINT urt docks REAR SUPPORT POINT (cont’ah 1-10safety stands when working on or under any vehicle that is supported only by a jack When lifting the rear of the car, put the gearshift © Never attempt to use a bumper jack for lifting or sup- lever in reverse (Automatic transmission in [P) po- Porting the car. sition) r- Floor Jack 1. Set the parking brake and block the wheels that are not being lifted 3. Raise the car high enough to insert the safety stands. 4. Adjust and place the safety stands as shown on page: 1-15 s0 the car will be approximately level, then low er the car onto them, Front CENTER BEAM Center the jacking bracket in the middle of the jack hit platform, FT PLATFORM, Rear Contor the"jacking of the jack it platform, UPT PLATFORM 1-11Lift and Support Points [- Safety Stands RUBBER ATTACHMENTS FRONT SUPPORT POINT SAFETY STANDS REAR SUPPORT POINTTowing If the car needs to be towed, call a professional towing service. Never tow the car behind another car with just {9 rope or chain. It is very dangerous. Emergency Towing ‘There are three popular methods of towing a car: Flat-bed Equipment — The operator loads the car on the back of a truck. This is the best way of transporting the Wheel Lift Equipment — The tow truck uses two pivot- ing arms that go under the tires (front or rear) and lifts them off the ground. The other two wheels remain on the ground. Sling-type Equipment — The tow truck uses metal ca- bles with hooks on the ends, These hooks go around parts of the frame or suspension, and the cables lift that end of the car off the ground. The car's suspension and body can be seriously damaged if this method of towing is attempted the car cannot be transported by flat-bed, it should be towed with the front wheels off the ground. If due to damage, the car must be towed with the front wheels fon the ground, do the following: Manual Transmission ‘¢ Release the parking broke. © Shift the transmission to Neutra. Automatic Transmission '@ Release the parking broke # stort the engine 1 Shift to [Ds] position, then [N] position © Turn off the engine NOTICE: Improper towing preparation will damage the transmission. Follow the above procedure exactly. If you cannot shift the transmission or start the engine (auto: ‘matic transmission), your car must be transported on a flat-bed © lis best to tow the car no farther than 60 miles (BOkm), and keep the speed below 35 mph (55 km/h NOTICE: Trying to lift oF tow the car by the bumpers will cause serious damage. The bumpers are not designed to support the car's weight. ‘TIE DOWN HOOKS TOWING HOOK 1-13Abbreviations Alc AUT ABS ArT ATE AME AMP ANT AssY AUX APPROX ATDC AUTO ATT ACL API BARO BAT BToc Boc cK cyP CAT or CATA, co cy. crc CARB comp cpu cHG Oo Dic prc DIFF DoH opi EVAP EGR ECM ecr EX EL EFL EPS, Air Conditioning, Air Conditioner ‘Alternator Anti-lock Brake System ‘Automatic Transmission ‘Automatic Transmission Fluid Air Fuel Ratio ‘Ampere (s} Antenna Assembly Auxiliary Approximately ‘After Top Dead Center ‘Automatic Attachment Air Cleaner American Petroleum Institute Barometric Battery Before Top Dead Center Bottom Dead Center Crankshaft Position Cylinder Position | Cetelytic Converter Carbon Monoxide Cylinder Clutch Pressure Control Carburetor Complete Central Processing Unit Charge Distributor Ignition Data Link Connector Diagnostic Trouble Code Differential Double Overhead Camshatt ual Point Injection Evaporative Exhaust Gas Recirculation Engine Control Module Engine Coolant Temperature Exhaust Electrical Load Detector Electronic Fuel Injection Electrical Power Steering List of automotive abbreviations which may be used in shop manual F FP Fwo FR FL FSR FIA GAL GND HB Ho2s He tap lac lar Ic lay Ima IN IG or IGN ‘0 1D or LD, IN INT ks L uy LHD uc uso uF LR La Leo Front Fuel Pump Front Wheel Drive Front Right Front Left Fail Safe Relay Fuel Injection Air Gallon Ground Hatchback Heated Oxygen Sensor Hydrocarbons Intake Air Bypass Idle Air Control Intake Air Resonator Ignition Control Module Intake Air Temperature Idle Mixture Adjustment Intake Ignition Identification Inside Diameter Injection Intermittent Knock Sensor Lett Loft Handle Left Handle Drive Lock-up Clutch Limited Slip Differential Left Front Left Rear In-line Four Cylinder (engine) Light Emitting Diode 1-14ws MAP Mit wt Mick MAX. MN. MPI Nox 028 BD 0D oF 0.0. PAIR PsP. Pev PIS PGM-FI PGM-IG PRI PIN PL PMR Psw PSF ary aR RHD REF RL RON SAE soHC SOL. SPEC SiR SRS sTO sw Manual Steering Manifold Absolute Pressure Malfunction Indicator Light Manual Transmission Motor Check Maximum Miniraurm Multi Point Injection Neutral Nitrogen, Oxides of Oxygen Sensor On-board Diagnostic Outside Diameter Park Pulsed Secondary Air Injection Power Steering Pressure Positive Crankease Ventilation Proportioning Control Valve Power Steering Programmed-fuel Injection Programmed Ignition Primary Part Number Pilot Light Pump Motor Relay Prossure Switch Power Steering Fluid Quantity Right Rear Right Right Handle Drive Reference Rear Left Research Octane Number Society of Automotive Engineers Single Overhead Camshatt Solenoid Specification Sun Root Supplemental Restraint System Standard Switch ses SEC Tem Twe pe 8 ac Te Tie TIN Tes vss VTEC ve vIN wis wio wot 2wo awo 2ws. aws 4aT MT (P) Rl [zE 2392 qehig] 2283a-F8l Service Check Signal Second Secondary Torque ‘Transmission Control Module Three Way Catalytic Converter Top Dead Center Throttle Body Throttle Position Torque Converter Timing Belt Tool Number ‘Traction Control System Vehicle Speed Sensor Viriable Valve Timing & Vaive Lift Electronic Control Viscous Coupling Vehicle Identification Number Variable Volume latake System with Without Wide Open Throttle Two Wheel Drive Four Wheel Drive Two Wheel Steering Four Wheel Steering 4-speed Automatic Transmission S-speed Manual Transmission Park Reverse Neutral Drive (1st through 4th gear) Drive (1st through 3rd gear) Second First Low (gear) Second (gear) Third (gear Fourth (gear) Fifth gear) 1-15Special Tools Individual tool lists are located at the front of each section.Specifications Standards and Service Limits Design Specifications Body Specifications ... 3-2 3-13 3-17Standards and Service Limits [> Cylinder Head/ Valve Train — Seetiom § MEASUREMENT STANDARD INEW) | _SERVICE LMT Cambression | 200,epm min and wide open trowlo } KPa tstem ps Nomina 1.290 125, 178) Minimum $30 (98, 138) Maximum variation | 200 (20, 28) Cylinder heed | Warpage — 05 0.002) Height 39.95 100.05 3895-2920) _ Tamara End play 005 -0.15 (0.002 - 0006) a5 ioom, Cemshatttoholder oi clearance {050-1089 (0.0020 0.0035) | 0.180006) | Total runout 3 (0001) max. 008 10002) Cem lobe height 72281 engine IN Primary | 372775 (2.4872) a Mid” | 50:726 13640) = Secondary | 34481 (13578) = x 36.388 (15105) == F282 engine N 38520 15168) a x 36.78 15257) = £2285 engine iN | ss.t6s 15020) = ex 38386 (15004) = 2083 engine iN | e741 's2sa) = | ° ex | Sera ensaeay _ vate Valve searance (Cold iN} 024-028 2009-011) — | ex | 028-032(0011 0.013) Valve stern 0.0, In | s4a5-5.495 02159-02165) | 5455 (02148) ex | 5450-5460 02146-02150) | Saz0 (02100) Stamto-guide clearance 1 | 0.020~0.085 0.0008-0.0018) | 0.080.003) ex | o.085-0.080 0.0022-0.003 | 0.4210.008) Valve sat wath IN | 125-155 (0.049 - 0.061) 200109078) ex | 125-1185 0.049 0.060) 20010078) Stem insaled height £2261 engine In | de75-a7ss ener) ‘780 (1382) Ex | 46g8~ 47.48 (1.098 — 1809) 730137) Except F2261 engine IN | 48.06 ~ 40.80 (1.899 — 1928) 49.13 01.938) 50.15 50.95 (1.974 2.006) 512012010) Valve sing Froelongth 225% engine in] st08 201 — ex | 556 2.126) = Except F228, F285 engines IN | 83.422 103)" — 54.82 (2.158)"? = ex | 5466,2 182)" — | sez a2r6ie leaees | F228 engine iw | 53:16 2.0051 — 55.15 (2.0801 = | ex | 5820 2 197)" = 58.78 2.196) = | Vaive guide | 16. iW | s5i5- sss o2i-ozim | sas w2Im, ex | sis—sss0102171-02177) | 8810219) Inatalod height 2281 engine in. | 2120-2220 0835-0874 — Ex | 206321. 1012-882) — ExcoptF2281 engine IN | 73.50 ~ 24.50 (0.925 0.965) = ‘480 15.00 (0.569 06221 — Fock arn ‘Rrmtoahal clearance P2761 engino 10.026 0.067 (00010 0.0026) | 0:08 1.008) 018-0056 0.0007 -o.o2» | o.08,0.003) Except F22B1 engine IN | ©017 -o0.080 0.0007 0.0020) | 0.08;0.003) ex | 0018005400007 00020) | 0.0810.003) Tr Except Associated Spring manufactured valve spring "2; Associated Spring manufactured valve spring +3: CHUO HATSUJO manufactured valve spring "4: NIHON HATSUJO manufactured valve spring 3-2Unit of fength: men in) (— Engine Block — Section 7 MEASUREMENT STANDARD (NEW) | SERVICE LIMIT. ylnder Bock | Warpaye of dock surface 3077008) me 270,@a08 Bore darter ort | sear0 18.000 2st50-a472) | Booroaaten | Gorn | eeoco-esoro\sanes sae) | asoroiaade) sor taper — Gos 000) Reborig ie dsioan Fiion Skit OD. ]atF mm (OB wom] Noleier | eave0-easoo Gae7 aan | @:970 38H Sotomorscn "| aur’ | searo—eeaeo ease aaesn) | axaeo ene) Crearanca it eyidor fo20~coao(ouane cere | Bs (000m Groove wists oyna) Top 20-1290 (o0to ows) | 25%0040) { Second 1.220 ~ 1.230 (0.0480 - 0.0484) 1.25 (0.049) on Zoos gaze (orros-oania) | 288012) recor ing wroow dears op —} tase oiseo ania —oo0an —| 0:13.00 - Soon | Goso—oossiooe—om2s) | 613.0008 Ting end gap Too 0.20 -0.35 0008-0014 2600026 Setond O40 08s t2ore 0.0201 870 0028) ou 0.20 -0.70 (0.008 0.028) 0.80 (0.030) 71,994 ~ 22.000 (08689-08661) | —— | Piston Pin ‘0.410 ~ 0.922 (0.0008 - 0.0008), (0.013 - 0.032 (0.0005 0.0013), Small end bore diameter 21,968 - 21.981 (0.8649 0.8654) | —— | Large ena bore diameter Nominal Except F2083 engine | s.ozon — F20B3 engine #80 (189) End play installed on crankshalt | 0.15 - 030 (0.006 0.012) 0.40 10.016) Grankshate ‘Main journal diameter ‘No, Yand é journals | «9.984 - 50,006 (19679 - 19688) | —— No.2 journal 49.976 50.000 (1.9676 19685) | —— No.3 journal 49.972 - «8.996 (19674 1.9683) | —— No. 5 journal 49,988 - 60.072 (19680 -1.9690) | —— Rod journal diameter | Except F2083 engine 47.976 ~ 48.000 (1.8888 - 1.8698), | —— | F20B3 engine 44976 45.000 (1.7707 1.7717) | ——— Teper | 0.005 (0.0002) max, (0.006 (0.0002), Outotround £0,006 (0.0002) max 1.008 0.00021 End play | 0,100.35 (0.004~ 0.014) 0.45 (0.018) uncut 10.03 (0.001) max. 0.04 0.002) Bearings F Main bearing to-journal el clearance No.1 and éjournals | 0.013 - 0.037 (0.0008-0.0078) | 0.05040.0020), No.2 journal 0.021 -0.085 (0.0008 0.0018) | 0.0500.0020) No. 3 journal (0.025 0.049 (0.0010 0.0039) | 0.085 0.0022) No. journal (0.009 - 0.033 (0.0008 - 0.0013) 0.040 0.0016) Rod bearing o-journal oil clearance | ‘Excopt F2083 engine 0.021 ~0.088 (0.0008-0.0018) | 0.0600.0024) F2083 engine (0.015 ~ 0,043 (0.0006 0.0017) __| 0.080 (0.0020) Balancer shat | Journal damat No, {front journal 42.722 42.734 (1.6820 1.6628) | 42.71 (7.881) No. 1 rear journat 20.938 - 20.950 (0.8243 - 0.8248) | 2092 10.824) No.2 front and rear journals | 38.712 ~ 38.724 1.8241 1.8266) | 38.70(1.528) No. 3 font and rear journals | 34.722 34.734 (13670- 1.3675) | 3471 (1367) Journal taper 0.005 0.0002) End play Front | 0:10-0:40 (0.004 - 0.016) — Rear | 0,04 -0.15 (0.002 - 0.008) = Tota runout 0.020.001) ©.03 0.001) ‘Shaftto-bearing oll elearance No.1 front, No.3 front and rear journals | 0.086~0088 (0.0026~0.0038) | 0.12 0.005), | No. 1 rear journal ‘0.080 - 0.075 (0.0020 - 0.0030) 0.08 (0.004) No.2 front and rear journals (0.076 ~0,108 (0.0030-0.0083) __| 0.13 (0.005)Standards and Service Limits [— Engine Block — Section 7 Balancer shat bearing MEASUREMENT ‘STANDARD (NEW) SERVICE LMT pi ‘No. front journal ‘2.800 «2800 1.6850 ~ 1.6056) | 42.89 17.686) No, 1 rear ournal 21.000- 21.013 10.9268 -08273) | 21.02 (0.828) { No. 2front and rear journals | 38.800 38.820 (1.5276. 15283] | 38:89 (1.529) Ll No. 3 front and rear journals | 34.800- 34620 1.9701 137081_| 34.83 (1.371) r- Engine Lubrication — Section 8 ‘at ile {3 3.000 rom (ri) Pa (ister, pai) (MEASUREMENT |___sranparo iwew. SERVICE LiMT Engine of Capacity ~~ FEET engine 56 (59, £9) for engine overhaul EUS at imp at) 43 (45,38) for ell change, including fier 4042.35) for oil change, without fitor Except F2281 engine | 4.9 (52. 31 for engine overhaul 3181400, 33} for oll change, including fitor = ___| 35187. 3.11 foroilchange, without fker Giipame Toner to outer rotor clearance ‘0.02 0.16 10.001 0.006) (0.200.008) Pump housing-to-outer rotor clearance 0.10 0:18 10.008 - 0.007), 0.21 10.008), ___| Pump nousing:te-rotor axial clearance | 0102“ c.07 0.001 — 0.003 0.120.005), Folie valve Pressure setting at engine oil tmp. B0"C (176°F) 168 (0.7, 10) min, 340 35, 50) min jection 10 MEASUREMENT ‘STANDARD (NEW) ‘Thermoswitch "OFF" temperature °C) Ean timor “ON" tomparature °C Fan timer "OFF" tomporature °C CF) Radiator Coolant capacity (US at, imp qi MT: 6917.4, 6.1) for overhaul Including engine, heater, | :5.187, 48) for coolant change cooling line and reserva ‘AT:6.817.3, 60) for overhaul voir capacity: 0.67 (0.63 US at, 053 Imp at) 5.3 (6.6, 4.7) or coolant change ea Radistoreap | Oponing pressure KPa (tien, psi) BB— 123 (095-125, 14-18) __ Thermostat ‘Startte open “CFF | 70=80 (169-176) | Fully oper =c(-F) 30,194) Vaive it at fully open 3.0(0:31) min. _ Cooling fa [Thormoswitch "ON" temperature OTF) 90-96 1194-208) Subtract 2—7 (4 13) from actual “ON" temperature 309 109 217 = 228) Subract 49 (7~ 16) from actual “ON” temperature— Fuel and E ns — Section 11 MEASUREMENT STANDARD (NEW) Unit of length: me tn Pressure regulator Pressure with regulator vacuum hose disconnected | kee aticm, ps 265-314 (27-33, 38-46) Fusitanie Cepacity {US gal, imo 6a) a5 11741, 182) Engine Tale speed with headlight and cooling fan off | rpm rnin F228), F2282 engines 700-= 50 (M/T: neutral) position) F 2083, F2285 engines 710 = 50 (M/F: neutral 770 60 (A: (Hor position) “Festi Tom Gr) 11400 = 200 (M/T: neutral | 4400 = 200 (AT: [8 or (i position! Tale CO % max. -— Clutch — Section 12 MEASUREMENT ‘STANDARD (NEW) SERVICE LIMIT ‘Clutch pedal Pedal height te floor BHD: 200 (82), LHD: 184 (72) Stroke 1425 1525 66-60) — Pedal play 9-15104-06) — Disengagement height tofloor HD: 99 (39) min, = LHD: 74 (28) min Fiywhoal {Clutch surface runout 10.05 (0.002) max. (0.1810-008) Clutch dee Fiver head depth 13-19 (005-007) 02 (000) Thickness. 4-90 (033-035), 6.01024) Pressure plate | Warpoge 0.03 (0.001) max. 10.16 10.0087 Diaphragm spring finger alignment 0.6 (0.02) mex 0.8 (0.03) -— Manual Transmission — Section 13 MEASUREMENT STANDARD (NEW) SERVICE UMT Transmission all | Capacity (10S at. Imp ad) 19120, 1.7) for al enonge -“ 2.02.1, 18) for overhaul Mainshaht End play (0.10 -0.16 0.008 0.008) ‘Adjust Diameter of ball bearing contect area 27.977 -27:990(1,1018- 1.1020) | 27,961.10) Diameter of needle bearing contact area 37.984 38,000 (14956-14961) | 37.93 (1493), Diameter of bal bearing contact area 27.987 28,000 (11016 1.1028) | 27°94 (1.100) _ Aunout 0.62 (0.001) max : 0.05 0.002), MainshaR ed and | 10. 143,008 - «3.025 (16839 - 16898) | «3.080 (7.6961), 4th gears End play 0.08 -0.21 0.002 - 0.008) 0.30 (0.012) Thickness ‘rd gear | 32.42 - 32.47 (1276-1278) 3231.27) ‘ath gear | 30.92 30.97 1.217 1219) s08(121 Mainehar th TD. 143,008 - «3.025 (7.6933 1.6939) | 43.080 (1.6961), gear End play (0.08 -0.21 (0.002 0.008) 030 (0.012) | Thickness 3092 - 30.97 (1217-1219) 3082) Countershatt Diameter of nasdie bearing contact area "38.000 - 39.016 (1.4961 - 1.4967) | 97.95 0.49%) Diameter of bal Bearing and needle bearing contact | 24.987 —26,000(0.9837 -0.9843) | 24.94 (0.982) Diameter of tet gear contact area 39,984 40.000 (1.5742- 15748) | 39.99.5721 Runost (0.02 10.001) max. 0.05 0.902) Gouniorshate iat [ 1.0. “46.009 46.025 (18114-18120) | 46.08 (1.814) gear End play (0.08 ~0.10 0.002 - 0.008), adjust Counterehaht 2nd) 10. 47-000 - 47.025 (18507-18518) | 47.08 (7854) ar End play 0.08 -0.10 0.002 - 0.008), Adjust [thine 28.92 ~ 26.97 (1.199 1.341) 2081.19) (conta) 3-5Standards and Service Limits [— Manual Transmission — Section 13 (cont'd) MEASUREMENT STANDARD INEW) | _SERVICE LT Spacer color | 10. a Countersna | OD. 4999-2000 (16591 1.8535) | 41.94 (1852) Gnd gear Length a | o2-zeoanvers- 1160) | 3 | door asco tiaas— 15a) | Spacer collar | 1, Top Pye | -34002=31.012 (7.2205- 1.2200 | 31.08 13.229) iMainsnaran | 0 E112 | Srses—aeo0o t'ess6— 14a | 379e (1490 anastn gears) | Length a Spo A | SeAs~sass 222-2220) 1 TT 7? 8 | secs 2608i1005-102n | 2s0n .020) Fevers idler gear | 10 20016-20043 (0.7880 0.7897) | 20.090 7805) ‘Gear toreverse gear shat clearance {1036-0084 0016-00035) | 0.180 .0006) Syroing ing to-goa clearance ring pushed against gearl | 0.85 1.10 033-0043) 0.400016) Doubie cone | Clearance (ring pushed against gear) syncivo Suter synchro ring toon 098-168 (0.037 0.066) 051002) Synchro conssogear ds 191002-008) | osean - ter synch ing to-synehro cone 05 1010.02-000 831000 Shino Finger mekness 62-64 024-025) — : Fortto-synero sleeve clearance 035-005 0014 0.026) 1.010.088) Reverse ah fork | Paw groove width 330-193 (051-052) = Forko-reverse idler goar clearance ds- 111002000) Teoon Groove with axa | 705-725 (0:278- 0.285) — ate | 74°77 0025-030 = Forkto-Shroverse shit shaft le ara’ | 005~0.5 12002-0014) 05,000) L at | 84” 08 002-000 01008) Shi arm 1 1.873 16.000 (0.6265 0.255) Shit arm-to-shat clearence 005-0088 0002 0.0023) | —— Shit fork carter at contact area 129-130 0.508052) = Shit-ormto-snf fork shaft clearance 02-05 10008-0018} a5 002 Select over Shaft outer diameter 16501-15905 (06776~0.5257) | —— Shit arm cover clearence aaa 102 00013 ~o.0040) | —— Shit lever oo. 15.941 - 15.968 (08276-08267) | — ‘Transmission housing learance oer 0139 00011-0088) | —— interock ore diametar 16.00 1605 (0690-0632) — Shit arm clearance 032-109 .o0t3--0.004) | —— FT Measuring points 72 Measuring ponte 3-6 A Si;— Automatic Transmission — Section 14 Unit of length eam tnd MEASUREMENT STANDARD INEW) SERVICE LIMIT Trenamission | Capacity P10 qt, Imp 3163, 520 for overhaul fie 2.425, 2.1) for fluid change Hydraulie Line pressure at 2,000 apm imine) 830 (85, 120) 780 (6, 170) prossure inti or postion throttle flly-closed throttle more than 2/8 Ke tkatlem pit | open #80190, 190) throttle more than 2 open “th latch pressure at 2,000 epm (min) 520 (53, 75) 460147, 67 throtle info postion throttle fullyclosed fuliyclosed 880.0, 130) 72018, 110) throttle more than 218 open throttle more than 218 _ : pen ‘3eq.and 2nd dutch pressure t 2,000 rpm (min) 480050, 77) 440 (45, 6a ind postion {throtefull-closed {hvote fully closed i 1880 (9.0, 130) 780.6.0,1101 throttle more then 218 open theottle more than 2/8 open | Prd catch pressure af 2000 pen (ier) SHO ES—30 TAT | OWED. in'2! postion et ond tst-nold clutch pressure 0 BHO BE, 120-130) | 7OOTES. TIO) 812,000 rpm In] position _ Throtte 8 pressure Thats fally dosed | 070.0) — Throttle fully open _| 830 - 880(8.5-9.0, 120-130) _ | 780(8.0, 110) ‘Stall sp¢0d rpm (min) (Check with car on level eround) F20B3 engine 2550 | 2.400-2.700 F22B1, £2202, £2285 engines | 250 2/500 2600 cach Gicte iit clearance schol (0.80 1.00 (0031 - 0.038) — st, 2nd | 0.65 ~0.85 10.026 - 0.033) — ard. 4th 04-06 (0018-0020) — Cuteh return spring free length st 2nd, 3rd, ath | 98.5 (1.32) aisa20 Gluten ise thickness 1188 ~ 2.00 0.074-0.079) Unt grooves worn out Gluteh plate thickness Ist, tsthold | 1.95=205(0077 0.980 Discoloration 2nd 2.85 -26510.100 0.108 Discoloration 31a, Ath 2.25 2.35 0.089 0.083) Discoloration Clutch en wate rick Mark | 208-210 0.081 - 0.083) Discoloration Mark | 2.15~22010085 0.087 + Man3 | 225-2.20(0089 0.09 Mark | 235-240 (0093-0098 Marks | 245-260.0006 0.098) Marks | 285-2.6010.100-0.1021 Mark? | 2.65-2.70(0.108 0.100) Marks | 275~280(0.108 0.110) ' Marks | 285~200(0.112-0.114) Discoloration Valve Body ‘Stator shaft noodle bearing contact 1D. “Torque converter side 27.000 - 27.021 (1.0820 1.1638) | Wear or damage Oi pump side 29.000 ~ 29.013 (1.1497 — 1.1422) it pump gear thrust clearance 0.03 0.05 0.007 0.002) 07 0.000) il pump goarto-body clearance rive | 0210-0268 0.0082 0.0108) Driven | 9.970 ~0.128 0.0028 - 0.0089) ‘i pump driven gear LO. 14016 14.034 (0.5518~-0.5525) | Wear or damage Oitpump shaft OD, 13.980 13.990 (0.5508 0.5608) _| Wear or damege Shing device, —| Reverse shift ork finger thickness 5.90 - 600 0232 - 0.736) 5.40 (0273) parking brake and | Parking brake pov — Wear or throttle contro!” | Parking brake ge = ‘other dofect system “Throtle cam stopper heighte To~171(0669-0.673) = (cont'd) 3-7Standards and Service Limits | Automatic Transmission — Section 14 (cont'd) MEASUREMENT ‘STANDARD (NEW) SERVICE LiNiT Servo body ‘Shift fork shat bore 10. Ta.000 - 14.005 (05512 - 08518) body 18.008 - 14010 (0.5514-0.5516) | —— s4ort- 14015 (05516-05518) | —— Shift fork shaft valve bore LO. 37.000 37.039 (1.4567 1.4562) | 37.045 (1.4585), Regulator valve | Sealing ring contact LD. 135,000 -35.025 (1.3760 1.3789) | 95.0511.3799) ‘Accumulator body ‘Sealing ing contect 1D. ‘32000 32.075 11.2508 12604) Te ‘Stator shaft Sealing ting contact. 29,000 29.013 (1.1617 1.1472) 291050 17.1497), Transmission Diameter of naedle bearing contact area ‘On mainshat of stator shaft On mainchaft of 3rd gear collar ‘On msinehaft of &th gear collar On countershaft of te gear collar (On countershatt of th gear (On countershaft of parking gear On eountorshatt of reverse gear (On secondary shatt of 1st gear (On secondary shaft of 2nd gear On reverse idler gear shalt Inside diameter ‘Mainshaft ard geor Mainshat &th gear Countershatt 1st gear Countershaft 4h gear Countershaft reverse gear Countershatt idler gear Secondary shaft 1st gear Secondary shaft 2nd gear Reverse idler gesr Reverse idler gear shaft holder 22.984 - 23.000 0.9049 - 0.9085) 45.984 ~ 46,000 (1.8104 1.8110) ‘31.988 — 32.000 (12592 1.2598), 40.984 ~ 41.000 (118198 ~ 1.6142) 31.975 ~31.991 (7.2588 - 12585), 39,984 40.000 (15742 1.5748) 35.979 - 36.000 (1.4165 - 1.8173) 31.975 ~31.991 (1.2589 - 1.2598) 31975 31.991 (1.2569 12595), 13.99. 14.00 (0.5808 - 0.5512) 52.000 - 52.019 12.0872 - 2.0480), 38,005 ~ 38.021 (1.4963 ~ 1.4868) 47.000 — 47.016 (1.8504 - 1.8510) 38.000 - 38.016 1.4961 - 14967), 42.000 - «2.016 (16535 - 116542), 48,000 48.016 (1.8898 1.8904) 36.000 - 36.016 (1.4173 - 1.4179) 37.000 37.016 (14567-14972), 20.007 - 20.020 (0.7877 - 0.7881), 44.800 14.826 (0.5827 — 0.5836) Wear or damage ' ‘Wear or damage ‘Mainshat 3rd gear collar length Mainshat 4th geor collar length Countarshatt 1st gear colle length Thrust washer thickness ‘Countershaft 1st gear Countershaft idler ear Countershatt parking gear length Secondary shaft 1st gear cistonce collar length Secondary shaft 2nd gear thrust washer thickness 19.50 10.55 (0.768 0.770) 47.50 47.55 (1.870 1.972) 27°50 - 27.55 (1083-1085) 1.48 ~ 1.50 (0.057 - 0.058) 3.45 3.55 (0.136 0.140) 25,030 - 25.048 (0.9854 0.9861) 4.95 -5.00 (0.195 -0.197), 4.35 — 4.45 (0.1719 - 0.1752) Weor or damoge Wear or damage Wear or damage Wear or damage ‘Weer or damage ‘Wear or damage Wear or damage Wear or damage ‘Secondary shat 2nd gear spline washer “4024.05 (0.168 - 0.159) ‘407 - 4.10 (0.160 0.1611 412~ 4.15 (0.162- 0.163) 417 -420(0.164- 0.168), 422-425 (0.166- 0.167) 427 4.30 (0.168 0.169) 432-435 (0.170- 0.7), 437 - 4.40 (0.172- 0.173), 442~ 4.45 (0.174-0.178) 3-8[— Automatic Transmission — Section 14 —— Unit of tength: mm fn) ‘STANDARD (NEW) MEASUREMENT - Wire Dia oD. Free Length | No.of Cols Spring Regulator vaive spring A 1810071 va7os7e | 886 3.486) 185 Regulator valve spring 8 131007) seca | 44011732) 127 Stator reaction spring 450.17) ssaiiave) | 303ti1s3) | 492 Torque converter check valve spring 1110043) 4033 | 38211508) 140 elie valve soring 1010038) e4acossn | 38:111539) 151 Cooter reli! vaive spring 1.110.043) e4tossy | 4681.43) 170 2nd orifice contro valve spring 05 (0.028) 8610260) | 6541261) 250 Orifice contol valve spring, 07 (0028) 8610260 | 52512067 18.4 Serve contol valve spring 1010039) sits) | S220 24 ‘Ath exhaust valve sping 08 0030 710200 | 4881132 72 “Thratle valve B adjusting soxing 08 003 Saiz) | anomie | ‘ao Throttle valve B spring 14 (0.055) ssioz) | a1siis00) 105 110.055) asia) | 41si16a4) m2 1410085) 85.0335 | 41611636) 14 1-2 shite valve spring 09 (0038) 86.0339) | oat. so0 45 2313-4 shit valve spring 9.910.038) 7.6 (0.298) 57.0224) | 268 ‘sthold accumulator spring 4910157) zoos) | 647254 73 Ist accumulator spring A 2310081) we3i082) | 0s 14319 200 1st accumulator spring B iaoor 6310248) | 70512776) 153 4th aeumulator spring 290018 z20(oa6s | 90.1 3se7 109 2nd accumulator spring 350013) | 22010860 | sos | ros, 3rd accumulator spring 230110 1751088) | s95;3820, 184 Lock-up shift valve spring 08 (0.038) 7s10220) | 73.7 (2.902) 320 {Lock-up timing valve spring 08 (0.031) ss10260 | s1.112012) 147 CPC valve spring 414 (0.055) s.4os7 | 33011.209) 105 Moaulstorvawve spring 1.4 (0.055) s4cos7 | 3301120 | 108 LLock-up control valve spring 07 10.028) 8610260 | 36311.429) 164 07 (0028) 8610260 | 38111500) ua Sd kick down valve spring 1.010.038) 7810299) | 48:311.902) 158 Main orifice control valve spring 43110063) zacoze | artis) | 227 (- Differential (Manual transmission) — Section 15, MEASUREMENT | STANDARD NEW) | ___SERVICE LiMT ‘iarantal Finjan shaft contact area ID. 8.000 18.018 (0.7087 - 07058) Carrierto-pinion clearence 0.017-0.047 (00007-00019). | 0.1 (0008 Driveshaft contact area 10 28.005 ~ 28.025 (1.1026 1.10331 Cartierto-driveshaf clearance } 02025-0086 0.0010-o.0028) | 0.12.0.008) | 0.055 0.091 (0.0022-0.0036 | 0.15 (0.006) Differential Backlash 0.05 -0.15 (2002 0.006) — Pinon gear 10. ‘jgoe2 18.066 (07103- 071131 | —— Pinion gearto-pnion shat clearance 0055-01095 (00022-00037) | a5 0.006) Differential taper roller Bearing preload | a= 25 (i426, 1225) ‘Adjust Starting torque Nm tkofem, ohn) | (- Differential (Automatic transmission) — Section 15 MEASUREMENT STANDARD (NEW) SERVICE LNT Differential inion shaft contact area. 78000 — 18.018 (0.7087 - 0.7098 carrier Carrierto-pinion clearence 0.013~ 0,047 (0.0008-0.0019) | 0.1 (0008 Driveshaft contact area LO. } 28.005 28.025 1.1026- 1.10331 | = Carriorto-driveshaf clearance 0.025 0.066 (0.0010 0.0026) _| 0.12(0.005) Differential Backlash 0.08 -0.15 (0.003 - 0.006) — Pinion gear 10. 18042 16.066,0.7103- 0.7113 | —— Pinion georto-pnion shat clearance 0.055 0,095 (0.0022-0.0037) | 0.12 (0.005) Differential taper roller bearing preload For new bearing | 2.78.9 (28-40, 24-26) ‘Adjust Starting torque _ Rem tkgfem, tin). For used bearing | 25-36 (2537, 22~ 32) Adjust 3-9Standards and Service Limits [— Steering — Section 17 MEASUREMENT ‘STANDARD (NEW) ‘Sigoring wheel | Rotational play at steering whee! circumference (07 1010-039) ‘Starting load at steering whee! circumference N tg tof Engine running | 29(3.0, 6.6) Geer box ‘Angle of reck-guide-screw loosened from locked posi- | 20° 5° Pump Pump pressure with shutoff valve closed —=~=~«Y:~&. 400 7,400 168 928-1,067) kPa kgllom*, psi Power steering | Recommended fluid Honda powor Hearing MuldV ‘uid } Fluid capacity Foroverhaut | 1.1 11.16, 097), £USat imp at For fivid change | 0.4 0.42, 0.35) belt™ Power stearing | Deflection with 98 N (10 kgf, 22160 between pulleys [ Belttonsion —Nikaf bf Measured with belt tension gauge 130-160 (051-063) with used bee 110 12.5 (043 ~ 0.49) with now belt "290-640 (40-55, 68-121) with used bow ————SSSSC«S& 740 £80 (75 90, 165 ~ 198) with now belt [— Suspension — Section 18 (MEASUREMENT i STANDARD (NEW) Whee! alignment Came Front eer Caster Front Total too Front Reor Front wheel turning angle award whee! Gutward whet ‘7007 028 £30 sore 04300502) IN22 2 (0.08 = 0.08) 39°00" 2 3000" (Reference) ‘rake booster ‘Whoo bearing | Endy Front 0-005 00.000) Foor 0-008 00.002) STANDARD (NEW) ‘SERVICE UNIT Whoa! Rim runout Aluminum whee! Axial 3-07 0-00m 20008 Fadil 0-077(0-0031 ison Steel west al 8-1010-008 281000 fad! 8-1010-00e 151000) — Brakes — Section 19 | MEASUREMENT | STANDARD (NEW) Farking brake | Playin avoke at 200 N 20 Kot 4 oh “Tobe locked when pulled Di 7=11 pathos fever fever foros Drum: 48 notches Foot brake pedal | Pedal height (With floor mat removed) ‘MIT | LHD: 192 (7.56), RHD: 767 (6.57) Af | Uno: 499760), AND: 168661) free play eu ial Gece ie _ MasierSyinder | Piston-o pushrod aarance Ta 0-008) ail STANDARD (NEW) | SERVIGE LT Disc brake Disc thicknoss Front 2a 72.1 (090-090 Hower oor a910. (030-060) sowsn Dise unout Front = 250 0.000 Foor — 6.100.008 Oise paar Front and rear | —— far c.0008 Pod tcinese Front i20-130(047-05 ‘e000 fear 2e-a910s9-0sn 1.000) Drom brake Drm 15. 7198-7200 18657 Bae) | 221 (6.700) Unig thickness a8 430045018) 201000 ‘Cheracterisies af 200 N20 taf, Ad Ib padal force ‘Minimum ine proteure KPa kaHem, pail Vacuum — seein [ Bagger mes power [9 menor cower wih 010.0) 970 (9.9, 140) 85087, 720) 40.0 (300, 17.8) 5,530 (56.4802) ———~«| «6,120 (62.4, 887) 66,71800. 19.7) | 8.580 (875, 1,240) 8.980 (91.8, 1,300, 3-10Unit of tangth: me tind [- Air Conditioning — Section 22 MEASUREMENT STANDARD (NEW) ‘irconditioning | Lubricant type: system NIPPONDENSO: ND-OIL8 (PIN 38899 -PR7-003) | HADSYS: Dn. S10X (PIN 38999 - POA 003), Lubricant capacity, Condenser | 2516/6, 09) rmé (faz, Imp oz) Evaporator | 4011 13, 1.4) Line or hose | 10119, 04) Recover | 1011/8, 04) Compressor Lubricant type: NO-OL8 (PN 38809 PRT — 003) (NIPPONDENSO) | Lubricant capacity mt (fz, imp oz] 160°F 5 119°¥.5.6°% Stator coll resistance at 20°C (68°F) 34-38 | Pulley-to-pressure plate clearance 052 0.15 (002+ 0.008) Compressor Lubricant type: Dn, S10X (PIN 38899 - POA = O03) thaosys) Lubricant espacity mt (loz, Imp os) 18075 13-7564) Field col resistance at 20°C (68°F) 2 285-3.15 Palley-to-pressure plate clearance 05 $10.02 284) Compressor belt™ | Deflection with 98 N (10 ket, 22 bf) ‘80 10.5 (0.31 0.41) with used bolt between pulleys 5.07.0 (0.20 -0.28| with new belt Beit tension _N tka, Th “440 690 (45 — 60, 99-132) with used bait | Measured with belt tension gouge 830 1,130 (95 ~ 115, 209-254) with new belt *SWhen using a new belt adjust deflection or tension fo new values, Run the engine for 5 minutes then turn it of Readjust deflection or tension to used belt values 3-11Standards and Service Limits -— Electrical — Section 23 MEASUREMENT STANDARD (NEW) Ignition col Rated voltage V Primary winding resistance at 20°C (68°F) ‘Secondary winding resistance at 20°C (68°F) 2 F281 ongine: 04-06 F282 engine: 06-08 Except F2281 and F2262 engines: 0.80.8 F228! engine: 22.4-336, F282 engine: 18.4 ~218 Except F22B1 and F262 engines: 13-19 Brae harm ios SEER BME MEE poem {E42craSaD(ar Bor postion Bete Sean omimao ae | atvenson G90 a1 G0 08 hoe STANDARO Wt SERVE UM Soest Raoctn xa 22 on-oa | sorags ison ‘ots Basso rion Nt | Bees aaa | “88 Samer WF | Ounhtnacrr “imipnonenso Seo sot sesaswosncousn 250000 coruta ocae | S2ase 6 Soon Sisto av | Outer 1a TSU Son rs Son bi Sasioats otto os 9008 Brush spring tension (now) _N Uk, Ibf 16-18.6- 18 35—40) ie 7: FUBT, F22B2 engines "2: F208, F285 engines "3: When using a new bet, adjust deflection or tension to new values. Run the engine for S minutes then turn it off Readjust deflection or tension to used belt values +4 F208, F282, F225 engin: +5: F22B1 engine +6: 72281 engine 3-12Design Specifications rem METRIC ENGUSH Notes ‘DIMENSIONS ‘Overall Length “4.675 mm Bat in Overall widen 1.780 mn 70.1 in Overall Height 11390 mm 547 in Wheelbase 2715 mm | 106.3 in Track Front Rear 11516/1,500 mm 59.6/59.1 in Ground Clearance "160 mm 83in | Seating Capacity Five. WEIGHT Curb Weight KE 201s MT Ta20K Bi0 Tbe with SRS: European Model AT 1345 4 2965 ios lsiroag systom (KE, KG) 2aies wT 1395 ko 2943 ios land teather AT 136049 2998 os Jewith ABs Ke:201Ls MT 1295 kg 2685 tbs [-with leather ar 1320 kg 2310 Ibs 2oes | MT 133049 2932 bs at 135549 2387 Ibs 22ies MT 1315/1330" 2899/2932 Ibs aT 1340/1355" 2954/2987 Ibs Except European Mode! OX ar 1280, 2322 ike re ar sato/i3es? 2888/2921" x ar 1360/1370 2999/3020" Weight Distributions (FronuRear) Wii SAS European Model KEZO0LS MT 00/520 kg yr94/1146 ibe fsirbag system (KE, KG} ar 830/515 kg 1220/1135 Ibs_[and leather 22ies MT 525/510 ks rerg/ri2¢ibs [With ABS ar 85/605 ko 3895/1113 fa¢ | >Wth eather KG:201L8 MT "790/505 ks 42/1973 ibs ar 320/500 kg 1808/1102 Ibs 20ES = MT 3151515 3 1797/1136 ibs aT 845510 kg 1869/1126 Ibs i 221ES MAT | 8101820"/505 (510%) kg | 1786,B081/1913 1124") oe ‘ArT | 810 85071800 (6067 ag) | 1852 1874/1102 1113" | Except European Model OX AT 800/480 kg "1784/1058 Ibe (cH) ir AT | 925(9407/485 kg | 1819 (1852/1069 Ibs x AAT_| 58 (860°/505 (510) ko | 1885 (1696111871124 bs ENGINE ve F281 engine Water cooled, 4 stroke SOHC T VTEC gasoline engine Except F281 engine Water-cooled, 4 stroke SOHC ‘aecline engine Cylinder Aerangement Intine cylinder, transverse Bore and Stroke 2083 engine 85.0x 8.0mm 3353.46 in F281, £2262, F2205 engines 85.0950 mm 335x374 in Displacement F20BS engine 1,987 em im?) sezeuin F22B1, F262, F2205 engines 2,158 er? rn) 132 eusin (cont'd) 3-13Design Specifications [- (cont'd) rem METRIC encush | _ NOTES ENGINE Compression Rao tcona) 2083 waging eo: F283, 2282 engines aa: £2285 engine } 98:1 Valve Train F2281 engine Bett riven, SOHC VTEC ‘valve por evinder } Except 2281 engine | Bok driven, SOHC valve per ylinder Lubrication System Forced and.wet ump ochold pump | Cit ump Ciaplacernent | 2318.000 engine rm (min) 7350077 US at S47 Imp qiinute Water Pump Displacoment 118.000 engine rpm (i) 160 ¢ (169 US at, 141 Imp atiminate Fuel Required F2201,F2202, engines UNLEADED gasoline with» Research Ociane Number (RON! of 31 or highat 2083, F228 engines Iromium UNLEADED gasoline witha Research ctane Number (RON! of 95 or higher | STARTER Ty Gear eduetion Normal Ouput MT 1a at tskw Normal votoge av Hour Rating 20 seconds Direction of Rotation Cleckwise a5 viewed from 9 Weight 37g | B2ibe _ cute Typ2 Wit | Single pate dry. clophroam spring AT ‘Torque converter BE Eee ER ERNE raring AraVR ERNE TPE TPE FORT ORPTREEIEA047|EREERE217 oro BED 336 sain TRANSWISSION | Type wir Synchronized Bapeed forward, 1 ro ar Electronically controled «speed automati, | reverse Primary Reduction Tyematio Oieat | Manual Transmission £2003) 72205 Gear Ratio ae 3.207 and 11809 ah 0833 sh 787 Reverse 3.000 Final Reduction Geer Ratio 4.265 voe Single heen geor zl 3-14rem merric ENGLISH NoTes TRANSMISSION | Automate Transmission #2083, Te (conta) oes Fez F282 } Gear Ratio ae 276 | SSC ana Ym | ara 028 1026 ay ort oor Reverse 2007 2007 Final Reduction Gear Ratio 4285 a pe Single holicl goar a ‘Cooling Capacity aiao Keim | _ 16.400 81m CONDITIONING Compressor “ypeifanafecturer ‘Swash-plteiNIPPONDENSO Except F281 No.of Cylinder i engine Capacity rromtiev |) 10.4.euntev | Max: Speed 7,800 rom in") Lobricant Copscty eome 8 vat ox Esimpor Lubricant Type NO.OIL8 (iN 36899 - PR? ~ 003) Compressor “Type/Manufectrer ‘Swosh-platsHADSYS | FRB eran No of Gyindor 7 Capacity momeiey | 10.4 eusinvrew Mav Speed 7800 rom iin) Lubricant Capacity 160 me 5s oz 56 impor Lubricant Type (Dn. S10x (PN 38809 - POA ~003) Condenser “Type Corrugated fin Evaporator Type Corrugated fn Blower Type Sirocco fan Motor input 200 wna ‘Spood Control ‘poe Max, Capacity s20mim "| 16900608 “Temperature Contra Rime yee ‘Compressor Clutch Type Day single Pate. poly. V belt drive Power Consumption OW maxl2V. 1 20° (68°) Refrigerant Type TC T3ea 1348) Quantity on Naatior | STEERING Type Power assisted, rack and pinion system Overall Ratio 163 ‘Turns, Lockto-Lock an | Steering Whoot Bi 80mm "| 18010 (ont) 3-15Design Specifications - (cont'd) METRIC ENGLISH Notes Front Independont double wishbone, Gauge Lights Ingieator Lights Mlurnination andl Pilot Lights | Heater llumination Lights 12V=14W.30W 12V-0.88 W, 1.12 W, 1.4 12-056 W, 084 W, 0.87 W, 1.12, 14W, LED| "av-14W SUSPENSION Type coll spring with stabilizer Rear Independent double wishbone, coll spring with stabilizer Shock Absorber Frontand Rear | Telescopic, hydraulic nivogen gas-filled WHEEL Camber Front O° ALIGNMENT Roar 0725 Castor Front 00" | Tota! Toe Front omm Bin Rear tn zemm te 0.08 in BRAKE SYSTEM | Type Front Power-ssslated seltadjusting Ventilated dise Rear | Power-aesisted self-adjusting solid disct* Power-assisted self-adjusting drum™® Pad Surface Area Front a9 em x2, Te sain x2 Rear 2.0m? x2 43cqinx2 — | Disk brake Lining Surface Aro oar Ta om? x2 11sqinx2 | Drum brake Parking Brake Type_| Mechanical actuating, rear two wheal brakes TRE ‘Size ond Pressure ‘Soe tire label (ee page 1-9) ELECTRICAL Battery 12-88 AHS HR Starter 12V-1.4KW/T8 KW Aternator 12V-80ArV90 A" Fuses in Underdash FuseRelay Box TSA 10A 18,308 In Under hood Fuse/Relay Box TBA, 10A, 16.8. 20.8, 30.4, 40.8 50/4, 80.4, 100.8 In Under-hood ABS Fuse/Relay Box WOA,18A 204, 408 Heeaights Inside wav-s5W | Gutsige rv 6085 W Front Turn Signe! Lights r2v-21W Front Side Marker Lights v-5w Front Position Lights 2V-sW Side Turn Signal Lights v-5w oar Turn Signal Lights rv-21W StopyTaillights| RVv-2158W Rear Side Marker Lights 12V-5W ] High Mount Brake Light rav-21w Back-up Lights wav-21W Intetior Lights (FronuRear i2v-5W | 12V-3.4Wi50W) 12V-34W Vanity Mirror Light w2V-18W $1522) FS IKE, KG), 201 ES IKE, KG) and EX models +2 Others 3-16Maintenance Lubrication Points .. Maintenance Schedule . 44Lubrication Points For the details of lubrication points and type of lubricants to be applied, refer to the illustrated index and various work Procedure (such as Assembly/Reassembly, Replacement, Overhaul, Installation, etc.) contained in each section, No. | LUBRICATION POINTS I LUBRIGANT ‘Always use a fuoteliion ole that says “API Ser view 86 or SH | SAE Viscosity: See chart below. 1 | Engine [Transmission Manual AP Senvce Grades: SF or 86 7 SAE Viscosity: 10 W.~30 or 10 W—40 Automatic | Honda Premium Formula or DEXAON™ Tl | _ Automatic tansmission fis _ 3 | Brake line tncudes Antilock brake line) Brake fuid DOTS or DOTA 4 | Clutch tine Brake fluid DOTS or DOTS 5 | Powor steering gvarbox Steering grease PIN 08733~B070E | 6 | Releose fork (Manual vransmission Urea Grease UM264 (PIN 41211 -PYS 205) Tivotle wite end (Dashboard lower parel hole) | Sileone grease Brake master cylinder pushrod Clutch master evinder pushrod Hood hinges and hood latch 42 | Battery terminals Multipurpose grease 13 | Fuel fi ha 14 | Trunk hinges 18 | Door hinges, upper and lower 16 | Door open detent 17 | Rear brake calipers Rust-preventive agent 7 8 | Throtle cable end Tote ok 3 | $ | wer steering fluid-V 1 | Power steering system ~~ Honda power stering fd 19 | air condoning compressor Compressor i NIPPORDENSO: NO-olL8 (Pm 28889—R7—000) ADSVS: Dn St0x (Pm $8599. POA 003) for Retigorant HPC*1340 (R340) CAUTION: Used engine oil may cause skin cancer if repeatedly left in contact with the skin for prolonged periods. Although this is unlikely unless you handle used oil on a daily basis, itis still advisable to thoroughly wash your hands with soap and water as soon as possible after handling used oil Soe ee Recommended engine oll Engine all viscosity for ambient temperature ranges 4-24-3‘Jowoisn oyi Aq Jenuew s,20uMmo a4) 01 BuIpi099e AjjeondeAd auop 9q pInoYs {\9Ae| 142/009 puE JLY ‘YO aujBua) 219 hep Or AEG + ‘voRruby pow ueadoung weys 10410 103) 1 1 t t (siepow Ueadosng uewA Ze\RO J04) 1010) pue ded soINGUISIO 1 (Slepow ueadoing Ueya Jeyi0 403) WAISAS jonUOD ui tery fete {eye o 09 1p! pue peeds epi 1 ‘A/eA UOREHTUEA aSEOqUEID OATISOg ‘suoRDauUOS pur & queULja 49088 ay (Slepow uesdoung vay 19430 103) Bu vORILB) |—je\—le S6njd 3Hedg qwejoos eulbuR = ~fajel—loj le -|e}a|-le|-l@ ‘SuORDBUUOD puB S9S0y WiBIsAs BUN]OOD t ‘duind wae, a ‘yaq yeougjeq Ounun pus Heq Buy, Uossaidwos 3/y ‘dund sig soreUrer|y) suORIpuGD pue vOrSUa) 18g t ‘Sjepow ueadoung vey 1840 103, ‘sjpoui ueedoing 104 our. «|—|-|-]e}—)—|e}e|—|e}—|«]-|-/-|-|- 1 1 t 1 1 t y y ‘sjapou uesdong ueyp oy}O 104 t 1 1 a @ ‘epou ueadoing 104 yo uorsswsuesy + ‘syRUOUT g 10 | = '000°9) 49 000'01 Aone aoeidoy sjopow ueadoang ueys 10410 105 ‘sypuoui Z1 10 — (000°) 45 000'O! Alana aoeiday ‘sjapou ueadoin3 104 294} HO pue Yo eUIBUZ ozt | aor | s6 | ve | ze | 09 | av | oe | ve syiuow ozt | sor | 96 | +8 | ze | 09 | av | oe | vz ‘sau 000'L x o0z | oat | o9t | ovt | ozt | oot | o8 | 09 | ov Uw09 L9AdYOIYM ‘syiLOW Jo JoquNU eYs Joye Wx OOO'L | 10 (Say 40} WA OQ'L Xx PaIsH LeALOIU! ay ye EoLKIOS, Maintenance Schedule ‘Avessoaau }! a9¢jda1 10 wedes ‘dn jy "Isnipe “ueaps “uoNDedsur Jay 1900s wodunu T tSIRBA Q] Waishs 19—dsuy waishs lujensey jewawaddng 318 seypuey 200p TSuoeiedo preoqysep “Am syom Apoq pur sabewep iuieg ) 4 OOO‘! Ai—ne x ‘weeq 14b)/peay pue uOReredo S1yBN, 7 w 000°! 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BULA sjeuaiew eniso: ‘suonjpuoo Arsnp ul Bung ‘Buinup e0uersip woys poyeaday ‘2pnjau) suonipuos Buinup av@na§ 2a66ue SienvoIu! eoueUsiUIEW ateudoidde ay 10} mojaq WeYO ALR O1 19)0% suonipuco Suiaup e10n9s sepun pasn AijewiOU sie9 UO Ajanda1) 20W P9DInIAS @q ISMIU SWAY BUIMOLIOY 34. suonipuog Bung ox000g 4-6Engine Construction and Function (F22B1 engine) ... Engine Removal/Iinstallation .. Cylinder Head/Valve Train . Engine Block Engine Lubrication .. Intake Manifold/Exhaust System Cooling ... .- 10-1Construction and Function (F22B1 engine) Outline Description .... VTEC Description Mechanism Control System . Explanation of Timing Mechanism Operation ... aeOutline [ Description ‘The new F22B1 engine is an in-line 4:cylinder SOHC design displacing 2,156 cm? (131.5 cu-in. It is water cooled and ‘equipped with a center plug type pent-roof combustion chamber. It is specified to use unleaded fuel and uses a PGM-FI (Sequential Multiport Fuel Injection) syste. This engine incorporates a mechanism called Honda Variable Valve ‘Timing and Valve Lift Electronic Control (VTEC) System. ‘The design of other engine models are basically the same as F2281 engine except the displacements and VTEC system, This system allows the timing and lift of the intake vaives to be changed simultaneously. F281 engine: 5-2Major Specifications Tyee Water cooled & stroke, Inline cylinder gasoline engine Displacement 2,186 em? (131.8 cu-in) Bare x Stroke 25.0 x 95.0 mm (3.95 x 3.74 in) Compression Ratio Bast ‘Cam, Valve Mechanism [Single over-head camshaft, VTEC Valve Train Belt Driven Fuel Supply System ‘Sequential Multiport Fuel Injection (SFI) Main Features: ‘© The cylinder head is made of aluminum alloy, a center plug type, pentroof-shaped combustion chamber is used, and the 4-valve system uses 2 intake valves and 2 exhaust valves. ‘© The camshaft and the valve train are driven by a timing belt, and the two balancer shafts are driven by a timing bal- ancer belt. '# The cylinder block is made of aluminum alloy using cast iron sleeves. © The crankshaft is made by forging, is supported at five points and has eight balancer weights. The balancer shafts employ a gear-type reverse mechanism to reduce secondary engine vibration. ‘© The intake manifold is made of aluminum alloy. ‘© The electronic fuel injection system is # sequential multiport type. It injects fuel into all four eylindars. The throttle body is @ one-barrel, side-draft type. '¢ The ignition system is a fully-transistorized, contactless type. The spark advance is electronic, ‘© The air cleaner is equipped with a resonator. The radiator is @ corrugated type, and the cooling fan is electrically powered 5-3VTEC [- Description chronizing piston back when hydraulic pressure is reduced. TIMING PLATE tm RocKeR ARM SECONDARY ROCKER ARM ‘SYNCHRONIZING PISTON. SYNCHRONIZING PISTON A, “TIMING PISTON INTAKE VALVE camsHaer PRIMARY ROCKER ARM ‘This engine has a normal 4 valves per cylinder arrangement. At low engine speed, the primary intake valve operates at normal lift while the secondary intake valve opens only slightly to prevent fuel accumulation in the intake port. At high ‘engine speed the primary and secondary intake rocker arms are connected to the mid intake rocker arm to allow high valve lift. A synchronizing piston eonnectsidisconnects the three intake rocker arms. Hydraulic pressure against a timing piston moves the synchronizing piston A and B one direction, while a stopper piston and return spring moves the syn: 5-4A variable valve timing and lift mechanism is used so the engine achieves both low fuel consumption and high output This system has achieved high combustion efficiency and low fuel consumption in the low engine speed range while maintaining high output equivalent to that of a conventional 4-valve engine in the high engine speed range. This was made possible by providing a great lft difference between the primary intake valve and secondary intake valve in the low engine speed range to create a swirling fuel/air flow. Tigh Power Engine VEC Engine avave Engine i { ' Valve Timing I \ | i (exhaust/intake) \ Gy ‘\ Valve Lift — | ZAWYA LV. Exhaust ate xno / ate Eehast nae aes Max, Power ° ° x - Cow rom Teraue 7 3 3 iling Stability 5 3 3 Fuel consumption x 3 I 3 “TDC~= Top Dead Center *BDG= Botiom Deed Center Oe Optima Cheractersc Worst Chorasterte Rocker arms with rllar bearings reduce friction losses. rae aa Tipe @ Primary Roller @ Secondary Slider OMe Foler exnaust ne Te @A Roller os fi 5-55-6 VTEC p Mechanism At Low Speed: ‘As shown, the primary and secondary racker arms are not connected to the mid rocker arm, but are driven separately by ‘cam lobes A and 8 at different timing and lif, The lft of the secondary cam lobe is small so that one intake valve slightly ‘opens one-vaive control). Although the mid rocker arm is following the center cam lobe with the lost motion assembly, it has no effect on the opening and closing of the valves in the low rpm range. PRIMARY ‘SECONDARY cam PRIMARY CAM, PRIMARY ) ‘SECONDARY ROCKER ARM ROCKER ARM Nee = nee \ “ ‘and B cam lobes rive the rocker arms SYNCHRONIZING separately PISTON 8 pe ‘SYNCHRONIZING PISTON. PISTON A At High Speed: When driving at high spet , the timing piston moves in the direction shown by the arrow in the figure below. As a result, the primary, secondary, and mid rocker arms are linked by 2 synchronizing pistons like @ skewer) and the 3 rocker arms move as a single unit. In this state, all the rocker arms are driven by cam lobe C, opening and closing the valves at the valve timing and valve lift set for high operation, mip cam mip ROCKER ARM. mip cam HYDRAULIC PRESSURE Connected by hydraulic piston and driven only by the mid cam.1, ‘The control system for this mechanism, as shown below, constantly monitors the changes in engine status such as load, rpm and vehicle speed. This information is tcansmitted to the Engine Control Module (ECM) [- Control System Valve Timing Change Conditions Engine Speed: 2,300 ~ 3,200 rpm (depending on manifold pressure) Vehicle Speed: 6.2 mph (10 km/h) or faster Engine Coolant Temperature: 50°F (10°C) or higher Engine Load: Judged by intake manifold negative pressure Control System VTEC PRESSURE SWITCH VTEC SOLENOID VALVE Engine speed ENGINE Engine load CONTROL ‘MODULE From (ecm) ol PUMP — Vehicle speed Engine cot temperature 5-7VTEC rocker arm, Hydraulic Pressure ON © Lite 0: Switeh-over ig impossible as the timing Pate i into the timing piston, é ® Lit process begins: The timing plate is esengaged, and the timing prston stats shit. ting. The synchronizing piston does not move because of tha lift te ® Litto: Since the timing pate is pulled out, the valve operating mode starts to change from ‘valve operation to 2valve operation athe moment the lft becomes zea, @ Lit 0: Switen-over ie complete, r- Explanation of Timing Mechanism Operation The variable valve timing and lift mechanism switches intake valve operation between single valve operation and two valve operation depending upon engine speed. To help achieve switch-over, a timing plate is installed on the primary Hydraulic prossure OFF [Lite o: Switeh-over is impossibie asthe timing is Inserted into the timing piston, (ica cs Lif process begins: The timing plate alone Starts shifting. The synchronizing piston does hot move because of the load imposed. [B) Litto: The synchronizing piston is pushed back by the return spring and the valve operation mode starts to change from 2-valve operation to valve operation from the moment when the Iit becames ter. 5-8SYNCHRONIZING PISTON A imine PISTON SYNCHRONIZING PISTON 8 ® a a Lit process uo Lino Hydraulic Hydraulic Switeh-over pressure ON pressure ON io Primany ROCKER ARM ROCKER ARM SECONDARY ROCKER ARM AE sh © way a itt process Hydraulic pressure OFF @ ® ite process Ut process: © Gro Lito Hydraulic Switch-over pressure OFF 5-9Engine Removal/Installation Special Tools .... Engine Removal/Installation Removal . Installation Engine Mount Control System (A/T) Component Location Index. Description Circuit Diagram Troubleshooting. Diaphragm Actuator Test. 5-13 5-23Special Tools rat.no. | Tootnumter —_| oaseietion |_| render @ O7KAK - $J40101 | Engine Tilt Hanger Set 1 8-20 tm [Mt ornanSerorcold eam usar aay [ss ee 5-12Engine Removal/Installation b=] r Removal ‘® Make sure jacks and safety stands are placed proper- ly and hoist brackets are attached to the correct po- sitions on the engine. '* Make sure the car will not roll off stands and fall while you are working under it. CAUTION: © Use fender covers to avoid damaging painted su faces. '* Unspecified items are common. ‘* Unplug the wiring connectors carefully while holding the connector portion to avoid damage. © Mark all wiring and hoses to avoid misconnection. Also, be sure that they do not contact other wiring (or hoses, or interfere with other parts. 1. Secure the hood as open as possible, 2. Disconnect the battery negative terminal first, then ‘the positive terminal 3. Remove the battery, battery base and engine ground cable. 8x1.25 mm 22Nm (2.2 kgm, 16 bt) 6x 1.0mm 32Nhm (12 kgm Ground’ CABLE 841.25 mm 22Nm (22 kgtm, 16 mE 4. Remove the throttle cable and cruise control cable by loosening the locknuts, then slip the cable end out of the throttle linkage. NoTE: Do not loosen the adjusting nut. Take care not to bend the cable when removing Tt. Always replace any kinked cable with a new ‘© Adjust the throttle cable and cruise contro! cable ‘when installing (see section 11 and 23). ADJUSTING THROTTLE = LOcKNUT ne cause CONTROL CABLE Lockdur aouusTING Nur (cont'd) 5-13Engine Removal/installation [- Removal (cont'd) 5. Remove the intake air duct B and intake air duct/air cleaner housing assembly. 12 Nim (12 kgm, 8.7 WH INTAKE AiR oUCT/ AIR CLEANER HOUSING ‘ASSEMBLY INTAKE AIR oucrs. 6. Disconnect the intake air resonator (IAR) control solenoid valve connector, then remove the vacuum hose and IAR (F22B1, F2285 engines) 6x 1.0mm JAR CONTROL SOLENOID. 12 Nim{t2 kofm, 8:7 bt) VALVE CONNECTOR ‘VACUUM Hose 7. Remove the battery cables from the under-hood fuselrelay box and under-hood ABS fuse/relay box. BATTERY CABLES LUNDER-HOOD ABS FUSE/ LUNDER-HOOD FUSE/ RELAY BOX RELAY BOX 8. Remove the engine wire harness connectors on the right side of the engine compartment, 6x1.0mm 2 Neem (12 kam, 8.7 WEA) ENGINE WiRE HARNESS: 5-148. Remove the brake booster vacuum hose and vacu: BRAKE BOOSTER VACUUM HOSE ‘um hoses. vacuum HOSES 10. Relieve fuel pressure by loosening the service bolt ‘on the fuel filter about one turn (see section 11) Do not smoke while working on fuel jstem. Keep open flame or spark away from work ‘area, Drain fuel only into an approved container. 11, Remove the fuel feed hose and fuel return hose. washer SE Nimit zat, 87 th) oe ie AIT Y Yee WASHERS BANJO NUT Replace. 22.Nm (2.2 kote, rere 12, Remove the engine wire harness connectors, termi nal and clamps on the left side of the engine com- partment, 1, Remove the injector resistor connector on the left side of the engine compartment. ENGINE WIRE HARNESS Invector RESISTOR CONNECTOR 14, Remove the vacuum hoses and power steering (PIS) hose clamp. VACUUM HOSES 6x 10mm TON (12 kote, 87 EAD (cont'd) 5-15Engine Removal/Installation -- Removal (cont'd) 15. Remove the mounting nuts and adjusting bolt, then remove the power steering (P/S) pump belt and pump. ‘© Do not disconnect the P/S hoses. MOUNTING NUT 8x 125 mm 220m 22 kotm. et ADJUSTING BOLT P/S PUMP BELT MountiNG NUT 8x 1.25 mm 22.Nm (2.2 kgtm, 16 bt) 16. Loosen the alternator mounting bolt, nut and ad- justing bolt, then remove the alternator belt, MoUNTING BOLT 10% 1.25 mm 44 Rem (45 kate, 33 Ibe) ALTERNATOR MOUNTING NUT 22.Nm (22 kote, 16 It) ‘AoJUSTING BOLT 17, (Manual transmission) Remove the shift cable and solect cable. NOTE: Take care not to bend the cable when re- moving it. Always replace any kinked cable with a ‘Bx 1.25 mm 22Nm 22 kfm, 16 DEA) COTTER PIN Replace Inspect for “damage, correr én Replace ~_ SELECT CABLE STEEL ‘PLasmic WASHER! WASHER Inspect for wear and damage. 18, Disconnect the back-up light switch connectors and starter motor cable (M/7), BACK.UP LIGHT SWITCH ‘CONNECTORS STARTER MOTOR CABLE 5-1619. Remove the clutch slave cylinder and pipe/hose assembly (MIT) Nore: '* Do not disconnect the pipe/hose assembly. © Do not operate the clutch pedal once the slave cylinder has been removed. © Take care not to bend the pipe. 81.25 mm 22Nm (22 kglm, 16 Wt) SLAVE CYLINDER, 6x 1.0'mm 10 Nien (10 kgf, 7 bE) wncand. 22m (22 koh, 16 tt) 20. Disconnect the vehicle speed sensor (VSS) connec- tor. 21. Remove the radiator cap. Use care when removing the rediator {ap t0 avoid scalding by hot coolant or steam 22. Raise the hoist to full height. 23, Remove the front tires/wheels and the splash shield, 6x 1.0mm S.8.Nen (1.0 kgtm, 72 1te) pana SHIELD 2A, 26. 26. 2. LOWER RADIATOR HOSE. 28, Drain the engine coolant (see page 10-5). © Loosen the drain plug in the radiator. Drain the transmission oil or fluid. Reinstall the drain plug using @ now washer (see section 13 or 14). Drain the engine oil. Reinstall the drain plug using a new washer (soe page 8-4), CAUTION: Do not overtighten the drain plug. Lowor the hoist, then remove the upper and lower radiator hoses and the heater hoses. HEATER HOSE vearennose — YERERRADIATON (Automatic transmission) Remove the ATF cooler hoses. ‘© Refer to section 14 when installing, ATF COOLER HOSE (cont'a 5-17Engine Removal/Installation - Removal (cont'd) 29, Remove the radiator assembly (see page 10-4) 30, Remove the air conditioning (A/C) compressor. # Do not disconnect A/C hoses. ‘AIC COMPRESSOR, 8x 125 mm 22Nm (22 kat, t61brH) 31. Raise the hoist to full height, then remove the cen- ter beam, 10125 mm 50m (5.1 kgm, 37 bee) CENTER BEAM © 101.25 mm 50m 5.1 kat, 37 Ibe) 32, Remove the exhaust pipe A. NOTE: Refer to pages 9-5 thru 9-7 before installing, 33, Disconnect the heated oxygen sensor (HO2S) con- hector (F22B1, F285, F20B3 engines) '# Refer to pages 9-5 thru 9.7 when installing, 8x125mm 22m (22 kate, O25 CONNECTOR reer SELF-LOCKING NUT 8x1.25 mm 18 Nem (1.8 kgtm, a3 ber Replace asker Replace asker Replace. exnaust SELF-LOCKING NUT Pees 10125 mm, 54m 5.5 kam, 40 Ibe) ‘SELF-LOCKING NUT 10x 1.25 mm. 33 Nem (3.4 kgm, 25 Ibe) GaskeT Replace. Replace, asker Replace. SELF-LOCKING NUT 8x 1.25 mm SELF-LOCKING NUT 18 Nm 118 kfm, 13 be) 101.25 mm Replace 54m (5. kgm, 40 bet) Replace EXHAUST PIPE A 5-1834, Remove the shift cable (AT). NoTE: © Take care not to bend the cable when removing it, Always replace any kinked cable with a new ‘® Adjust the shift cable when installing (see sec: tion 14), Lock wasHer AIT SHIFT CABLE Replace, AON (1.0 kate, 7b) eovenl 841.25 mm TWN AB kgtm, sabe) 35. Remove the damper fork (see section 18). 36. Disconnect the suspension lower arm ball joints with the special tool. Refer to section 18 for the proper procedure, NOTE: Adjust the tool so the jaws are parallel to each other. epogne XC Seetzs mm 19-59Nm (5.0-60kgtm, 36-43 ibe) COTTER Pin BALL JOINT REMOVER, 32mm ‘O7MAK ~ PY20100 37, Remove the driveshatts, caution: © Do not pull on the driveshaft, the CV joint may come apart. ‘© Use care when prying out the assembly. Pull it straight to avoid damaging the differential oit soa! or intermediate shaft dust seal. NOTE: Coat all precision-finished surfaces with clean engine oil. Tie plastic bags over the driveshaft ends. DrIVESHAFT PLASTIC BAG DRIVESHAFT SUSPENSION LOWER ARM. (cont'd 5-19Engine Removal/Installation r- Removal (cont'd) 38, Lower the hoist 29, Attach the chain hoist to the engine as shown ENGINE SUB HANGER STAY VA ENGINE TILT HANGER SET O7KAK- $340101 i 5-2040, Remove the rear mount bracket. 41, Remove the front mount bracket. FRONT MOUNT BRACKET 42, Remove the side engine mount SIDE ENGINE MOUNT (cont’a 5-21Engine Removal/Installation - Removal (cont'd) 43. Remove the transmission mount and bracket. wt: ‘TRANSMISSION }OUNT. ‘TRANSMISSION’ MOUNT BRACKET arr: ‘TRANSMISSION MOUNT/BRACKET 44, Check that the engine is completely free of vacuum hoses, fuel and engine coolant hoses, and electrical wiring 4 Slowly raise the engine approximately 150 mm (6 in). Check once again that all hoses and wires are disconnected from the engine 4 Raise the engine all the way and remove it from the 5-22Installation Bracket Bolts/Nuts Torque Specifications: 10x 125mm 491m (5.0 Kote, 36 tH) | pys pump BRACKET ‘si BR 101.25 mm 490m GO Kgtm, aeibre) IDE ENGINE MOUNT 1ACKET 841.25 mm 22 Nm 22 kgtm, selbst) 84125 mm . 22m 22 kghm, 16H) (cont'd) -23Engine Removal/Installation ( Installation (cont'd) Engine Instatation Install the engine in the reverse order of removal Reinstall the mount bolts/nuts In the following sequence, Foilure to follow these procedures may cause excessive noise and vibration, and reduce bushing lif. 1. Position the side engine mount, 2. Tighten the mount bolt, then remove the 6 x 100, mm bolt NOTE: Do not tighten the bolt/nut on the engine side, mount soLr 6 x 100 mm 12%1.25mm BOLT 641M (6.5 kof, 47 ott) 3, Position the transmission mount. 4. Tighten the mount bolt, then remove the 6 x 100 mm bolt. NOTE: Do not tighten the nuts on the transmission side. MOUNT BOLT 12% 1.25 mm 84 Rem (6.5 kom, 47 bt) 5. Install the rear mount bracket, then tighten the bolts in the numbered sequence as shown (® ~ @). ® 121.25 mm 64m (65 kgtm, 47 ior) Replace. 1D 1241.25 mm © 12125 mm! 5a Nm 5 kgm, 54 Rm (5.5 kam, 40 Ibe) ome) Replace. Replace. 5-24125 mm 38 Nem (3.3 kgf, 2aibie) 7. Tighten the boltinut on the side engine mount. 1241.25 mm 54m 15.5 kom, 47 EA)Engine Removal/Installation r Installation (cont! ay) AAA 9. Tighten the bolts on the front mount bracket. © Check that the spring clip on the end of each driveshaft clicks into place, CAUTION: Use new spring clips. © Bleed air from the cooling system at the bleed bolt with the heater vaive open (see page 10-5). ‘© Adjust the throttle cable (see section 11). Check the clutch pedal free play (see section 12) © Check that the transmission shifts into gear smoothly. '® Adjust the tension of the following drive belts Alternator belt (see section 23). PIS pump belt (see section 17) ‘NC compressor belt [see section 22). ‘© Clean battery posts and cable terminals with sandpaper, assemble, then apply grease to pre '* Inspect for fuel leakage (see section 11), + Alter assembling fuel line parts, turn on the ignition switch (do not operate the starter) so that the fuel pump operates for approximately two seconds and the fuel line pressurizes. Repeat this operation two or three times, and check for fuel leakage at any point in the fuel line. 10 1.25 mm 38 Nm 2.9 kgm, 20 Ib) 5-26‘Mount and Bracket Bolts/Nuts Torque Valve Specifications: | REAR MouNT: a mir: at TRANSMISSION MOUNT 5-27Engine Mount Control System (A/T) [- Component Location Indexb=] [- Description ‘As opposed to previous liquid engine mounts, this engine mount control system remarkably reduces vibration in the idling range without affecting vibration damping in rpm ranges above idling. The system is comprised of the ECM, the solenoid valve and the rear mount with built-in diaphragm actuator. The ECM receives the engine 1pm signals and sends a signal to the solenoid valve to open only at idling pm. When the solenoid valve opens, intake manifold vacuum is applied to the diaphragm actuator, and the rotor valve located in the reat ‘mount rotates 80 degrees. The mount has Chamber A on its upper part and Chamber B on the lower part. The rotor valve located betwen these two chambers controls quantity of liquid that flows between them. At idling rpm: INTAKE ‘MANIFOLD 7 UNDER-DASH FUSE/RELAY BOX (No. 4(7:5 A) Fuse) | Rem siGNaL ENGINE MOUNT CONTROL, ‘SOLENOID VALVE CHAMBER A ‘biaPHRacm ROTOR VALVE cannwen 6 ACTUATOR ‘At idling rpm, the rotor valve opens, and liquid flows through passages 1 and 2. The quantity of liquid increases, and vibration in the idling range is reduced. CHAMBER A. PASSAGE 1 ROTOR VALVE OPEN CHAMBER: (cont'd) PASSAGE 2 5-29Engine Mount Control System (A/T) 7 Description (cont'd) Above idling rpm: UNDER-DASH FUSE/RELAY 80x tno. 4175 Al Fuse) ecm [Rem signat ENGINE MOUNT CONTROL, SOLENOID VALVE CHAMBER A ROTOR VALVE Diapnacm chamaer @ ‘ACTUATOR Above idling rpm, passage 1 is closed, and liquid flows only through passage 2. The quantity of liquid decreases, and vibration in ranges above idling is reduced. ‘CHAMBER A ROTOR VALVE closed Si CHAMBER B Sy Yy pasdace1 PASSAGE2 5-30[ Circuit Diagram BATTERY* No. 4. BATTERY 2281 engine (100 A) Except F22B1 engine (80 A) ECU (CRUISE CONTROLI/EAT ECU (TCM) LUNDER-HOOD FUSE/RELAY BOX (FUSE LABEL) BATTERY* IGN. SW1(S0 AD [on po o-—__} wor Ban G3 BLKIYEL IGNITION ‘SWITCH UNDER-DASH FUSE/RELAY BOX No 7.5 Al] (FUSE LABEL) BLK/VEL ENGINE MOUNT CONTROL SOLENOID VALVE 5-31Engine Mount Control System (A/T) [- Troubleshooting NoTE: © Check the vacuum hoses and pipes for damage and proper connections. © Rofer to page 11-18 thrn 11-25 before troubleshooting. ‘VacuUM Hose vacuum PuMP/ GAUGE [Disconnect the vacuum hose Tending to De rear engine mount | rome fteoi ve and con rect 8 vacuum pumplaauge to the solenoid valve ENGINE MOUNT = we ___]_Contot SoLeNo1o VaLve Is there intake manifold vacuum NO ‘th tne engine ting (700 pr? ENGINE MOUNT a CONTROL SOLENOID ves [_Trntneigntion switen OFF | 2P CONNECTOR VALVE Disconnect the 2F sonnecor | from the solenoid valve oo Start the engine |_Senteneine, _] Check for voltage between the | Bteivet'ay ana GANrwHT 1 BLK/VEL (+) vateae the NO_[—Saccwe sound vane] engine idling? ieee coerce eeeee| ves [ hve for voto bern tho SUR/VEL (e) terminal and body ground (To poge 5:3) (o page 533) 5-32be] (From page 5:32) (From page 532) No Is there battory voltage? ves Turn the ignition switeh OFF, and reconnect the 2° connector tothe solenoid valve, [mete Connect the test harness be. tween the ECM and 2? connec: Start the engine 225 Chock for voltage between the (6) and A10 (terminals gin idling? Substitute a known-good ECM ‘and recheck. H symptomindica No goes away. replace the org battery voltage with the YES | Open in the GRN/WHT wire the 2P connecter and the ECM (A10}, ‘Open in the BLK/VEL wi the No. 4 (75 Al fuse and 2P conector. | 1. 25 (+) 3500000000006] 50000000 FRREESE] 50000000000 000900000000 | 00000000 f 588688] 00000000000, m0) ves Is there vacuum withthe engine 3t1,000 rpm? No WY (To page 34) “Turn the ignition switch OFF. v (To page 5-34) (con's) 5-33Engine Mount Control System (A/T) [- Troubleshooting (cont'd) (From page 534) Vv ‘The solenoid valve is OK; test the diaphragm sctuator (see page 5.35) (rom page 5:34) Disconnect the 2P connector from the solenoid valve Start the Is there vacuurn? No ‘Turn the ignition switeh OFF, and reconnect the 2P connector ta the solenoid valve, [creck for vonage between tert nat A10 and body ground <_tethere battery voltage? ves NO_|"” Short to the GRN/WHT wire the >| Be econnestor sna the EON At0) Substitute a known-good ECM | | and recheck. 'symptomindica ton goss away, replace the orial nal ECM, D55GSS000G55S 35000000 FEBSTEB] 000000000 00000000 | 6Bg#g8| 00000000000 t AOU! L 5-341 [- Diaphragm Actuator Test Disconnect the vacuum hose from the solenoid valve, and remove the rear mount (see page 5-27), Clean and oil the diaphragm actuator rod, rear mount rotor lever, and lever linkage, With a vacuum pumpigauge, apply vacuum of about 230 mmHg, and check if the rotor lever turns 80 degrees, — Replace the rear mount if the rotor lever dose not operate. REAR MOUNT. DIAPHRAGM ACTUATOR RorOR vacuuM PUMP/ LEVER GAUGE 5-35Cylinder Head/Valve Train Special Toots 62 Variable Valve Timing and Vaive Litt Electronic Control (VTEC): F22B1 Engine Troubleshooting Flowchart — VTEC Solenoid Valve oa — VTEC Pressure Switch 66 VTEC Solenoid Valve Inspection niu 69 Rocker Arms = Manual inspection 610 — Inspection Using Special Tools =... 6-10 Valve Clearance Adjustment sone AB Crankshaft Pulley and Pulley Bott Replacement 615 ‘Timing Belt and Balancer Belt Mustrated Index... 6-16 Timing Bett Inspection 617 ing Balancer Belt Inspection wvc.ce-non-- 6-17 Tension Adjustment ers Removal. 6-19 "621 6-24 628 Installation oa? Rocker Arm Assembty Removal a2 Rocker Arms Overhaul oo 633 Inspection 6.35 Lost Motion Assemblies Inspection .. 635 Rocker Arms and Shafts Clearance Inspection ..... 636 Camshatts Inspection 637 Valves, Valve Springs and Valve Seals Remove sn 639 Installation Sequence o44 Valve Installation ead Valve Seats Reconditioning =m ve 640 Valve Guides Valve Movement 6-42 Replacement 6-43 Reaming .. 6-43, Camshaft/Rocker Arms and Camshaft Seal/Pulley Installation 645Special Tools | Dese Tool Number ay | Page Reference O7HAH-PI70100 | Valve Guide Reamer, 5.525 mm + | eas O7JAA-0010200 | Socket Wrench, 19 mm 1 | 615 o7JaB-0010200 | Handle 1 | 6s O7LAG~PT20100 | Balancer Shaft Lock Pin 1 | 622 o7LA)-PR30101 | Valve inspection Set 1 | en o7taj—PA30201_ | Air Stopper 1 | e101 o7Mas-Py30100 | Pulley Holder Attachment, HEX 50 mm 1 | 615 O7NAJ-Po70100 | Oil Pressure Gauge Attachment 1 | 67.8 o7PAD- 0910000 | Stem Seal Driver 1 | 64s 07406 - 0070001 Low Pressure Gauge 1 | 67,8 077420010100 | Vaive Guide Driver, 55 mm + | eas @ 07787 -0010000__| Valve Spring Compressor 1 | 639 °Variable Valve Timing and Valve Lift Electronic Control (VTEC): F22B1 Engine [- Troubleshooting Flowchart — VTEC Solenoid Valve Refer to page 11-16 thru 11-23 before troubleshooting. Matfunetion Indicator Lamp (MIL) indicates Diagnostic Trouble Code (OTC) 21: A problem in the VTEC Solenoid Valve circuit. = MIL has been reported on. = With the SCS short connector connected, code 21 is indicat- o. Do the engine contro! module (ECM) Reset Procedure (eee page ia Start the engine. Warm up engine to normal oper ating temperature (the cooling *Road Test: ‘ on ma ‘Accelerate in 1st goar to an engine speed over 4,000 rpm. — Hold that engine speed for at least two seconds. ————_L If the MIL does not come on during the first road test Do the Road Test.* repeat this test two more times. MIL on and does it indicate code 21? ves “Ten the ignition switch OFF Disconnect the 1P connector fram the VTEC solenoid valve Check for continuity between | VIEC solencid vaive connector terminal and body ground, | No ls there 14-2007 NOY ves. (To page 6-5) 6-4(From page 6-4) (ame — [Cheek for continuity between VTEC solen terminal and Ad terminal 2 Cheek for continuity between | } VTEC solenoid valve connector terminal [hat round Is there co DSSTSSOTSHSOS] SO0SGO0S Bssoeseosed Sposvosoas00|sssccooe fo 20000000000 a tetestharness. | tt ‘id valve connector ress sik aera ves | Repos shor inthe GRN VEL < 1s there continuity? > CM (A4) and i LM known-good ECM W symptom/ingiea je away replace the origi- M. 6-5VTEC [- Troubleshooting Flowchart — VTEC Pressure Switch Refer to page 11-16 thru 11-23 before troubleshooting. ZAC] [ZTE Malfunction inciestor Lamp (Mt) indicates Diagnostic Trouble Code [OTC) 22: A problem inthe VTEC FO ee pressure site crea steal 20a = MIL has been reported on, ‘SCS short connector ‘code 22 Is indi | Dotne ccm Reset Procedure woe | pooe 1-18), | ——__-| Stantneengin. | a rae arma | pond Tex Reece eee ares Do the Road Test. * ] {| Interenitent failure, system is OK J agen |S ps \ (er eon oF] Disconnect the 2P connector fromthe VIEC pressure switch. | ‘Turn off the engine, VTEC SOLENOID VALVE Check for continuity between the 2 terminals on the VTEC prossure | en wma commany SD _NO_[Reptace the VTEC pressur | sn ECM (D6) and 2P con | ves L_seeen a | Check fr continuity between 08 | [SSSooddS00000 [50000000 SOSTBE] Odo0TTCSOSS terminal ond boty ground 2009000000000 | 00000000 90900000000 no [ Ropar hor in he BLU/AL wi os | 84125 mm ENGINE Wine HARNESS 22 Nim 22 kot, Leia 16 ttft) (cone) 6-29Cylinder Head - Removal (cont'd) 14, Remove the engine wire harness connectors and 17, Remove the water bypass hoses. wire harness clamps from the cylinder head and the intake manifold. Four injector connectors ‘© Intake air temperature (IAT) sensor connector Idle air control (IAC) valve connector ‘© Throttle position sensor connector © Manifold absolute pressure (MAP) sensor con- nector '* Heated oxygen sensor (HO2S) connector (F282 engine) ‘i Engine coolant temperature (ECT) sensor con- rector ‘© ECT switch connector # ECT gauge sending unit connector © VTEC solenoid valve connector (2281 engine) © VTEC pressure switch connector (F22B1 engine) ‘© Exhaust gas recirculation (EGR) valve connector ‘* TDCICKP/CYP sensor connector Ignition coil connector ‘© Fuel injection air (FIA) control solenoid valve connector {F22B1 engine) it sensor WATER BYPASS Hoses 18, Remove the side engine mount (see page 5-21), 16. Remove the spark plug caps and distributor from the cylinder head. Nore: ‘© Use the jack to support the engine before the 16, Remove the upper and lower radiator hoses and, side engine mount is removed. heater h '® Make sure to place a cushion between the oil pan and the jack. 19. Remove the cylinder head cover. CYLINDER HEAD WASHER LOWER RADIATOR HEATER HOSE HOSE UPPER RADIATOR Hose 6-3020. Remove the timing belt see page 6-19). 21, Remove the camshaft pulley and back cover. BACK COVER ‘CAMSHAFT PULLEY Giese, 22. Remove the splash shield (see page 5-17) 23. Remove the exhaust manifold. EXHAUST MANIFOLD ’ Asker ve Replace, BRACKET ‘seur-LOckine NUT 8x 1.25 mm 31 Nm, (3.2 kote, 23 Ib) Replace, 24. Remove the intake manifold, Gasket Replace. Replace INTAKE MANIFOLD 25, Remove the cylinder head bolts, then remove the cylinder head. CAUTION: To prevent warpage, unscrew the bolts in sequence 1/3 turn at a time: repeat the sequence until all botts are loosened. CYLINDER HEAD BOLT LOOSENING SEQUENCE 6-31Rocker Arm Assembly 1 r Removal Loosen the adjusting screws, then remove the bolts land the rocker arm assembly, Nore: ‘© Unscrew the camshaft holder bolts two turns at 3 time, in a crisscross pattern to prevent damaging the valves or rocker arm assembly. ‘¢ When removing the rocker arm assembly, do not remove the camshaft holder bolts. The bolts will koop the camshaft holders, the springs and the rocker arms on the shatts Except F22B1 engine: ‘ADJUSTING SCREW 2281 engine: [ADJUSTING SCREW dl ADJUSTING SCREW CAMSHAFT HOLDER BOLT LOOSENING SEQUENCE Except F22B1 engine: F22B1 engine: 6-32Rocker Arms he r Overhaul NoTE: Identify parts as they are removed to ensure reinstallation in original locations, Inspect rocker shafts and rocker arms (page 6-26). ‘© Rocker arms must be installed in the same position if reused. © When removing or installing rocker arm assembly, do not remove the camshaft holder bolts. The bolts will keep the holders, springs and rocker arms on the shaft. ‘* When reassembling, fit the projection on the int @ rocker shaft to the notch in the camshaft holder. 7} Prior to reassembling, clean all the parts in solvent, dry them and apply lubricant to any contact parts Except F22B1 engine: Lotter “Bis stamped Lotter "A" is stamped fon rocker ate ‘on rocker arm. BS OD) INTAKE ROCKER INTAKE ROCKER WTAKE ROCKER —_WTAKE ROCKER ‘SHAFT (A) ‘SHAFT (6) ARM B ARM A tenors apices) tong. 3 aoe) (epoces teacen No.6 wo 6 Wea tos wo.2 no. Caitsuarr | GRivsHarr Skiguarr Stitsuart Cainsuart | Skatguarr RetSEeT) Sousa sites fist woustk water wave wasnen ‘Soucect 8 oha . ‘SPRING b ‘SPRING a EXHAUST ROCKER ARM [ahor. 2 places) long, 3 places) (8 places} EXHAUST ROCKER SHAFT (conta 6-33Rocker Arms r- Overhaul (cont'd) NoTe: © Idemtity parts as they are removed to ensure reinstallation in original locations. Inspect rockar shafts and rocker arms (page 6-35 and 36), Rocker arms must be installed in the same position if reused, © When removing or installing rocker arm assembly, do not remove the camshaft holder bolts. The bolts will keep the holders, springs and rocker arms on the shaft. ‘® Bundle the rocker arms with a rubber band to keep them together as a set. 7B] Prior to roassembiing, cloan all the parts in solvent, dry them, and apply lubricant to any contact parts. F22B1 engine: Lotter “A” ie stamped Letter “B”is stamped fon rocker arm fn rocker arr EXHAUST ROCKER SHAFT EXHAUST ROCKER EXHAUST ROCKER ARM A ARM 8. SPRING Jot ty de ane No. LeAMSHAFT L L HOLDER i + = RUBBER BAND INTAKE ROCKER, ARM ASSEMBLY INTAKE ROCKER SHAFT 6-34- Inspection NOTE: When reassembling the primary rocker arm, carefully apply air pressure to the oil passage of the rocker atm. 1. Inspect the rocker arm piston. Push it manually, —Ifit does not move smoothly, replace the rocker arm assembly. SYNCHRONIZING PISTON B SYNCHRONIZING PISTON A, ei ) SECONDARY ROCKER ARM ‘MID ROCKER, ARM PRIMARY ROCKER NOTE! ‘© Apply oil tothe pistons when reassembling. # Bundle the rocker arms with a rubber band to keep them together as a set. NOTE: Set the timing plate and return spring as shown below. ‘Tamive PLATE RETURN SPRING CAMSHAFT HOLDER Lost Motion Assemblies ion b=] 1. Remove the lost motion assembly from the cylinder hhead and inspect it. Pushing it gently with the finger will cause it to sink slightly. Increasing the force on. it will cause it to sink deeper. — If the lost motion assembly does not move smoothly, replace it - Inspec Push 6-35Rocker Arms and Shafts r- Clearance Inspection Measure both the intake rocker shaft and exhaust rocker shaft 1. Measure diameter of shaft at first rocker location ‘MICROMETER 2. Zero gauge to shaft diameter. CYLINDER BORE MICROMETER: 3 Measure inside diameter of rocker arm, and check for out-of-round condition, Rocker Arm-to-Shaft Ci Standard (New): Except F22B1 engi Intake: 0.017 - 0.050 mm (0.0007 ~ 0.0020 in) 0.018 - 0.054 mm (0.0007 ~ 0.0021 in) F281 engine: Exhaust: Intake: 0.026 -0.067 mm (0.0010 - 0.0026 in) Exhaust: 0.018 -0.054mm (0.0007 - 0.0021 in) ‘Service Limit: 0.08 mm (0.003 in) Inapeet rocker arm face for wear. Repeat for all rockers. — If over limit, replace rocker shaft and all overtal france rocker arms. NOTE: If any rocker arm needs replacement, re: place all three rockor arms in that set (primary, mid, and secondary), 6-36Camshaft r- Inspection be] Nore: # Do not rotate the camshaft during inspection. '¢ Remove the rocker arms and rocker shafts. 1. Put the camshaft and the camshaft holders on the cylinder head, then tighten the bolts to the specified torque, Specified torque: 8mm bolts: 22 Nem (2.2 kgfm, 16 Ibtft) 6 mm bolts: 12 Nem (1.2 kgf'm, 8.7 IbFt) Except F22B1 engi Emm bolts: 9,@.@, @,@, @ F22B1 engine: 6mm bolts: f, 6 2. Seat the camshaft by pushing it toward distributor fend of cylinder head. Zero the dial indicator against the end of distributor drive, then push the camshaft back and forth and read the end play, Camshaft End Play: ‘Standard (New): 0.05 - 0.15 mm (0,002 - 0.006 in) Service Limit: 0.5mm (0.02 CAMSHAFT Remove the bolts, then remove the camshaft hold. fers from the cylinder head, — Lift camshaft out of cylinder head, wipe clean, then inspect lift ramps. Replace the camshaft if lobes are pitted, scored, or excessively worn, — Clean the camshaft bearing surfaces in the cylin der head, then set camshaft back in place. — Insert plastigage strip across each journal Install the camshaft holders, then tighten the bolts to the specified torque as shown in the left column. of this page. Remove the camshaft holders. Measure widest por- tion of plastigage on each journal. Camshaft-to-Holder Oil Clearance: ‘Standard (New): 0.050 ~ 0.089 mm (0.0020 - 0.0035 in) Service Limit: 0.15 mm (0.006 in) PLASTIGAGE STRIP (cont'd) 6-37Camshaft - Inspection (cont'd) AAA 7. If camshaft-to-holder oil clearance is out of toler- 8. Measure cam lobe height Cam Lobe Height Standard (New: — And the camshatt hes already been replaced, Unit men tind You must replace the cylinder head. INTAKE | _ EXHAUST =f camshaft has not been replaced, first chock FOES srg sicrat{iszean|| cunts (lesa total runout with the camshaft supported on V. gine _ = Gh) pees F285 engine 39.167 (1.5420) | 98.356 (1.5494) F282 engine 36.526 (1.5168) | 96.778 (1.5267) Pri _| 37.775 (1.4872) = MID _| 39.725 (1.5640) | 38.366 (1.5105) eC [34.481 17.3575) | Camshaft Total Runout: ‘Standard (New): 0.03 mm (0.001 in) max. F22B1 Service Limit: 0.04 mm {0.002 in} engine Rotate camshaft ‘while measuring Y 9 F22B1 engin — Ifthe total runout of the camshaft is within toler ance, replace the cylinder heed. — ifthe total runout is out of tolerance, replace the camshaft and recheck, I the oll clearance is stil out of tolerance, rapiace the eylinder head _ a Inepect this araa for wear, 6-38Valves, Valve Springs and Valve Seals Removal NOTE: Identify valves and valve springs as they are removed so that each item can be reinstalled in its origi rm nal position. -re i c 1. Using an appropriate-sized socket and plastic mal: | let. lightly tap the valve-retainer to loosen the valve keepers before installing the valve spring compres: PLASTIC MALLET Except F22B1 engine: Intake Valve Dimensions AA Standard (New): 31.90 - 32.10 mm (1.256 - 1.264 in} B Standard (New): 107.82 - 108.32 mm (4.245 ~ 4.268 in) Standard (New: 5.485 ~ 5.495 mm (0.2159 - 0.2163 in) C Service Limit: 5.455 mm (0.2148 in) D Standard (New): 0.85 ~ 1.15 mm (0.033 - 0.048 in} D Service Limit: 0.65 mm (0.026 in} Exhaust Valve Dimensions A Standard (New): 28.90~ 29.10 mm (1.138 - 1.148 in) B Standard (New!: 116.95 ~ 117.45 mm {4.604 - 4624 in) © Standard (New): 5.450 ~ 5.460 mm (0.2146 - 0.2150 in} Install the spring compressor. Compress the sprin CService Limit: 6.420 mm 10.2134 in} * naremovetnevsieteepe, "2 |p standard New) 108-35 mm (0.041 ~ 0.053 in} D Service Limit: 0.95 mm (0.037 in} VALVE SPRING COMPRESSOR 07787 -0010000 (cont'd) 6-39Valves, Valve Springs and Valve Seals t- Removal (cont'd) F22B1 engine: Intake Valve Dimensions A Standard (New): 33.90 - 34.10 mm (1.335 - 1.343 in} B Standard (New): 110.30 - 110.80 mm (4.343 - 4.362 in} € Standard (New): 5.485 - 5.495 mm (0.2159 - 0.2163 in) Service Limit: 5.445 mm (0.2148 in) D Standard (New!: 0.85 - 1.15 mm. (0.033 - 0.048 in} D Service Limit: 0.65 mm (0.026 in} Exhaust Valve Dimensions A Standard (New): 28.90 - 29.10 mm (1.138 ~ 1.146 in} B Standard (New): 108.30 - 108.80 mm (4.264 — 4.283 in} € Standard (New): 5.450 - 5.460 mm (0.2146 - 0.2150 in) Service Limit: 5.420 mm (0.2134 in) D Standard (New): 1.05 ~ 1.35 mm. (0.041 - 0.053 in) D Service Limit: 0.95 mm (0.037 in) Valve Seats 7 Reconditio: 1. Renew the valve seats in the cylinder head using a valve seat cutter. NOTE: If guides are worn (page 6-42), replace them (page 6-43) before cutting the valve seats. 2. Carefully cut a 45° seat, removing only enough ma: terial to ensure a smooth and concentric seat. 3. Bevel the upper edge of the seat with the 30° cutter and the lower edge of the seat with the 60° cutter. Check width of seat and adjust accordingly 4, Make one more very light pass with the 45° cutter to remove any possible burrs caused by the other cut ter. Valve Seat Width: ‘Standard (New): 1.25 ~ 1.55 mm (0.049 ~ 0.061 in) Service Limit: 2.00 mm (0.079 ia a ase SEAT wor (a 6-40be] After resurfacing the seat, inspect for even valve ‘seating: Apply Prussian Blue compound to the valve face, and insert valve in original location in the head, then lift it and snap it closed against the seat several times, ACTUAL SEATING SURFACE, vatve SEAT PRUSSIAN BLUE COMPOUND ‘The actual vaive seating surface, as shown by the blue compound, should be centered on the seat. © IF itis too high (closer to the valve stem), you must make @ second cut with the 60° cutter to move it down, then one more cut with the 45° cutter to restore seat width. © IF itis too low (closer to the valve edge), you must make 9 second cut with the 30° cutter to move it up, then one more cut with the 45° cutter to restore seat width NOTE: The final cut should always be made with the 48° cutter. Insert intake and exhaust valves in the head and measure valve stem installed height. Except F281 engine: Intake Valve Stem Installed Height: Standard (New): 48.08 - 48.88 mm (1.893 - 1.928) Service Limit: 49.13 mm (1.934 in} Exhaust Valve Stem Installed Height: Standard (New): 50.15 ~ 60.95 mm (1.974 - 2.006 in) 51.20 mm (2.016 in} F22B1 engine: Intake Valve Stem Installed Height: Standard (New): 46.75 ~ 47.55 mm (1.841 - 1.872 in} Service 47.80 mm (1.882 in} Exhaust Valve Stem Installed Height: Standard (New): 46.68 ~ 47.48 mm (1.838 ~ 1.869 in) Service Limit: 47.73 mm (1.873 in} ‘vaLve stem INSTALLED HEIGHT i If valve stem installed height is over the service limit, replace the vaive and recheck. I still over the service limit, replace the cylinder head; the valve seat in the head is too deep. 6-41Cylinder Head - Warpage NOTE: If camshaft-to-holder oil clearance (page 6-37) is not within specification, the cylinder head cannot be resurfaced. camshatt-to-holder oil clearances are within specifica tions, check the cylinder head for warpage. ‘© If warpage is less than 0.05 mm (0.002 in) cylinder head resurfacing is not required. ‘© Hwarpage is between 0.05 mm (0.002 in) and 0.2. mm, (0.008 in), resurface cylinder head. © Maximum resurface limit is 0.2 mm {0.008 in} based ‘on a height of 100 mm (3.94 in} PRECISION STRAIGHT EDGE Measure along edges, and three ways across center. Cylinder Head Height: ‘Standard (New): 99.95 - 100.05 mm (3.935 3.939 in} Valve Guides - Valve Movement ‘Measure the guide-to-stem clearance with a dial indica- tor while rocking the stem in the direction of normal thrust (wobble method) Intake Valve Stem-to-Guide Clearance: Standard (New): 0.04 ~ 0.09 mm (0.002 - 0.004 in) Service Limit: 0.16 mm (0.006 in) Exhaust Valve Stem-to-Guide Clearance: ‘Standard (New): 0.11 ~ 0.16 mm (0.004 - 0.006 in) Service Limit: 0.24 mm (0.009 in) Valve extended 10 mm out from seat © If measurement exceeds the service limit, recheck using new valve, ‘¢ If measurement is now within service limit, reassem- ble using a new valve. '* if measurement still exceeds limit, recheck using al ternate method below, then replace valve and guide, if necessary. NOTE: An alternate method of checking guide to stem clearance is to subtract the ©.D. of the valve stem, mea: sured with a micrometer, from the I.D. of the valve guide, measured with an inside micrometer or ball ‘gauge. Take the measurements in three places along the valve ‘stem and three places inside the valve guide. The difference between the largest guide measurement and the smallest stem measurement should not exceed the service limit. Intake Valve Stem-to-Guide Cl ‘Standard (New): 0.020 - 0.045 mm (0.0008 ~ 0.0018 in} 0.08 mm (0.003 in) Service Limi Exhaust Valve Stem-to-Guide Clearance: ‘Standard (New): 0.055 - 0.080 mm (0.0022 ~ 0.0031 in} ‘Service Limit: 0.12 mr (0.005 in) 6-42- Replacement NoTE: ‘© For best results, heat cylinder head to 150°C (30°F) before removing or installint guides. # Itmay be necessary to use an air hammer to remove some valve guides. CAUTION: To avoid burns, use heavy gloves when ha dling heated cylinder head, 1. Drive the valve guide out from the bottom of the cylinder head. VALVE GUIDE DRIVER, 5.5 mm (07742-0010100 2. ‘VALVE GUIDE DRIVER, 5.5 mm (077420010100 Valve Guide Installed Height: Except F281 engine: Intake: 23.80 - 24.50 mm (0.925 - 0.965 in) Exhaust: 14.80 - 18.80 mm (0.583 - 0.622 in) F22B1 engine: Intake: 21.20 - 22.20 mm (0.835 - 0.874 ia Exhaust: 20.63 - 21.63 mm (0.812 - 0.852 in) VALVE GUIDE — Measure here. be] r- Reaming NOTE: For new valve guides only. 1. Coat both reamer and valve guide with cutting oil 2. Rotate the reamer clockwise the full length of the valve guide bore, 3. Continue to rotate the reamer clockwise while removing it from the bore. 4. Thoroughly wash the guide in detergent and water to remove any cutting residue. 5. Check clearance with a valve (see page 6-13). — Verify that the valve slides in the intake and exhaust valve guides without exerting pressure VALVE GUIDE REAMER, 5.525 mm REAMER HANDLE O7HAH ~P470100 Turn reamer in clockwise direction only, 6-43Valves, Valve Springs and Valve Seals NOTE: Exhaust and intake valve seals are NOT interchangeable. NOTE: Place the end of vaive ‘VALVE KEEPERS pring with closely mound cols ‘toward the cylinder head vaLve neva INTAKE VALVE SEAL Aner (WHITE SPRING) es STEM SEAL DRIVER, ‘O7PAD - 0010000 NOTE: Use 5.5 mm side EXHAUST VALVE SEAL (BLACK SPRING) Replace. vawve Sea Replace, SPRING SEAT NOTE: Install the valve spring seats Detoreinstaling the valve seals [- Installation Sequence, J —_$$__________ - Valve Installation PLasTic When installing valves in cylinder head, coat valve MALLET stems with oil before inserting into valve guides, and make sure valves move up and down smoothly. When valves and springs are in place, lightly tap the end of each valve stem two or three times with a plastic mal let to ensure proper seating of valve and valve keepers. NOTE: Tap the valve stom only along its axis ¢o you do not bend the stem, 6-44Camshaft/Rocker Arms and Camshaft Seal/Pulley 7 Installation CAUTION: ‘© Make sure that all rocker valves when torquing rock Valve locknuts should b screws backed off before installation. To prevent rocker arm assembly from coming apart, leave camshaft holder bolts in the holes. alignment with bly bolts. and adjusting ‘After wiping down the camshaft, camshaft seal end journals in the cylinder head, lubricate both sur: faces and install the camshatt 2. Clean and install the oil control orifice with a new O-ring (F22B1 engine only) on conTROL O-RING suse on ‘cAMSHAFT Koyway up. 7B Lubricate cam lobes after reassombiy 3. Turn the camshaft until its keyway is facing up. (No. 1 piston TOC), Apply liquid gasket to the head mating surfaces of the No. 1 and No. § or No. 6 camshaft holders. — Apply liquid gaskot to the shaded areas. Except F22B1 engine: i 5 F22B1 engine: No.6 No.t _ Ta = Loy Ic Oj Set the rocker arm assembly in place and loosely install the bolts. — Make sure that the rocker arms are properly positioned on the valve stems. (conta) 6-45Camshaft/Rocker Arms and Camshaft Seals/Pulley r Installation (cont'd) 6. Tighten each bolt two turns at a time in the se: quence shown below to ensure that the rockers do not bind on the valves. ‘Specified torque: ‘8mm bolts: 22 Nem (2.2 kgm, 16 Ibft) 6 mm bolts: 12 Nem (1.2 kgfm, 8.7 Ibf-t) Except F281 en 6mm bolts; @), @ DOD O® OHGB F22B1 engine: 6mm bolts: 1,2, 8,3 @ o 1 8 Install the back cover. Install the key and the camshaft pulley onto the camshaft, then tighten the retaining bolt to the torque shown. BACK COVER ‘CAMSHAFT PULLEY Clean. ax12dmm 6x 1.0 mm 37 Nem (3.8 kgm, 8.8 Ne (1.0 kgtm, 27 were 72 Bt) 6x 1.0m Y2Nem (12 kgf, 8:7 lott) 6-46Cylinder Head r- Installation b=] Install the cylinder head in the reverse order of removal: Nore: © Always use @ new head gasket © Cylinder head and cylinder block surface must be clean. ‘¢ "UP" mark on camshaft pulley should be at the top. '¢ Turn the crankshaft so the No. 1 piston is at TDC (see page 6.22). Clean the oil control orifice before installing. Do not use the upper cover and lower cover for stor: ing items disassembled ‘* Clean the upper cover and lower cover before instal- lation, 1. Cylinder head dowel pins must be aligned. 2, Install the oil control orifice (Except F281 engine). CYLINDER HEAD GASKET Replace. OW. CONTROL ORIFICE (Except F228: engi Clean Replace wo 3. Position the camshaft correctly (see page 6-22), 4. Tighten the cylinder head bolts sequentially in three steps. Jst step torque: 39 Nem (4.0 kgfm, 29 IbFt) 2nd step torque: 69 Nem (7.0 kgfm, 51 Ib ft) 3rd step torque: 98.1 Nem (10.0 kgfm, 72.3 IbFt) NoTE: © We recommend using a beam-type torque wrench. When using a preset-type torque wrench, be sure to tighten slowly and not to overtighton. © If 2 bolt makes any noise while you are torquing it, loosen the bolt, and retighten it from the Tst step. CYLINDER HEAD BOLTS TORQUE SEQUENCE (cont'd) 6-47Cylinder Head - Installation (cont'd) 5, Install the intake manifold and tighten the nuts in @ crisscross pattern in 2 or 3 steps, beginning with the Always use new intake manifold gasket. GASKET 8x 125mm none Zam 22 kote, ‘reibite 841.25 mm os Sega 6. Install the exhaust manifold and tighten the nuts in 2 crisscross pattern in 2 or 3 steps, beginning with the inner nut ‘© Always use a new exhaust manifold gasket. 7. Install the exhaust manifold bracket, then install the exhaust pipe A and the bracket, and then install the exHausT MANIFOLD SELF-LOCKING NUT 8x 1.25 mm BINm(SZkgtm, —— 10x'1.25mm 2a bee) 44m 5 kat, Repiace 233 oth 8145 mm 22Nm (22 ktm, 16 WE) 6-48b=] 8. Install the timing belt (see page 6-21) 9. Adjust the valve clearance (see page 6-13) 10. Install the head cover gasket in the groove of the cylinder head cover. Seat the recesses for the cam- shaft first, then work it into the groove around the outside edges. ling the head cover gasket, thor- oughly clean the seal and the groove. ‘© When installing, make sure the head cover gas- ket is seated securely in the corners of the re- cesses with no gap. CORNERS OF THE RECESS. HEAD COVER GASKET Clean, ‘CORNERS OF ‘THE RECESS CYLINDER HEAD cover 11. Apply liquid gasket to the head cover gasket at the four corners of the recesses. NOTE: © Use liquid gasket, Part No. 0Y740 - 99986. ‘© Check that the mating surfaces are lean and dry before applying liquid gasket. ‘© Do not install the parts if minutes or more have elapsed since applying liquid gasket. Instead, reapply liquid gasket after removing old residue. After assembly, wait at least 20 minutes before filing the engine with oil Apply liquid gasket to the shaded ares. (conta 6-49r Installation (cont'd) Cylinder Head 12, When installing the cylinder head cover, hold the head cover gasket in the groove by placing your fin- {gers on the camshaft contacting surfaces (top of the semicircles) Set the spark plug seal on the spark plug pipe (F22B1 engine only) Once the oylinder head cover is on the cylinder head, slide the cover slightly back and forth to seat the head cover gasket. NoTE: * Bofore installing the cylinder head cover, clean the eylinder head contacting surfaces with a ‘shop towel. ‘© Do not touch the parts where liquid gasket was applied © Take care not to damage the spark plug seal when installing the cylinder head cover (F22B1 engine only). Visually check the spark plug seal for damage (F2281 engine only) ¢ Replace the washer when damaged or deterio: rated. 6x1.0mm 2 Neen (1.0 kgf, 7.2 Itt CYLINDER Heap SSN (7-0 kat " COVER Waser SPARK PLUG. SEAL 18. Tighten the nuts in 2 or 3 steps. In the final step, tighten all nuts, in sequence, to 9.8 Nem (1.0 kgtim, 72 bt NOTE: After assembly, wait at least 20 minutes before filling the engine with oil Excopt F22B1 engine: F22B1 engine: 14. After installation, check that all tubes, hoses and connectors are installed correctly. 6-50Engine Block Special Tools Mlustrated Index .. Flywheel and Drive Plate Replacement Connecting Rod and Crankshaft End Play TT Main Bearings Clearance 18 Selection ..... 79 Connecting Rod Bearings Clearance nnn 7-10 Selection a Crankshaft, Balancer Shafts and Pistons Removal 72 Crankshaft Inspection 715 Pistons Inspection 7.16 Installation . 724 Cylinder Block Inspection 7A7 Bore Honing 718 Piston Pins Removal f 7-18, Installation 7-19 Inspec .7-20 Connecting Rods Selection 7-19 Piston Rings End Gap Replacement . Ring-to-Groove Clearance Alignment Crankshaft Oil Seal Installation Crankshaft and Balancer Shafts Installation Balancer Shafts 7-21 7-22 7-22 7-23 7-24 7-25 Inspection 7-29 Balancer Shaft Bearings Replacement ... 7-32Special Tools Ref. No. @ © @4 ® Too! Number ‘o7LAB - Pvo0700 O7LAF - PT20100 O7LAG ~ PT20100 O7PAF - 0010000 O7PAF - 0070880, 07749 - 0910000 07948 - $B00101 Description Ring Gear Holder Bearing Replacement Tool Set Balancer shaft Lock Pin Piston Pin Assembly Too! Set Pilot Collar, 0.0. 22 mm Handle Driver Driver Attachment, 96 mm. Page Reference 77 732 792,27 718, 19 7-18, 19 | 7:24 728 7-2Illustrated Index 7B Lubricate all internal parts with engine oil during reassembly. NOTE: © Clean the oil pan gasket mating surfaces before installing it. ‘© Apply liquid gasket to the recesses of oil pan gaskat (see page 7-28) oe Saran 6x 1.0mm as et 12. N-m (1.2 kgtm, 8.7 Ibfft) | Roast 2 Nem (1.2 kgm, 8.7 It) Gasket Foplace [BAFFLE PLATE (F22B1 engine only) 1x18mm 74Nem 75 kote, 54 i) BEARING CAP Apnly engine ot the bot BRIDGE. L one ‘Aker torquing each cap, turn eranishatt to check for binding. DOWEL PIN ‘TORQUE CONVERTER (Check for cracks ‘cuuteH cover wm M3 sx1.0mm 32.12 kot m, x 8.7 wort FLYWHEEL MT) = 125 1.0mm 103 Nim (105 kgf, 76 oF) Torque sequence, page 77 leon’ay 7-3Illustrated Index (cont'd) 7 Lubricate at internat parts with engine oil during reassembly. NOTE: ‘© Apply liquid gasket to the mating surfaces of the right side cover and oil pump case before installing them, ‘© Use liquid gasket, part No. 0¥740 - 99986. MAIN BEARINGS Oil clearance, page 7-2 Selection, page 79 NOTE: Now main boarings must bbe selected by matching erank and block identification markings, BALANCER | Geamoase 85125 mm | nn | a ) - © oe — by grinding or shimming, (CRANKSHAFT OIL. SEAL Installation, page 8-10 Z Sy S ‘Overhaul. page 88 onan leva 251m 5 kof ‘Apoly liquid gas 18 Ibi) allen etal TIMING BALANCER BELT DRIVEN PULLEY 7-4 NOTE: Thrust washer thickness Is fixed and must not be changed ‘CRANKSHAFT End play. page 77 Runout, Taper and Out-ot-Round, paga 7-15 Instaliaion, page 7-25, ‘CRANKSHAFT OIL SEAL Instatiation, page 7-26 RIGHT SIDE COVER Apply liquid gasket to block mating surface. 6x1.0 mm TaN (12 kakm, a7 met) Apply liquid gasket ro the bolt threads.7-5Illustrated Index (cont'd) 7B] tuoricateatinternat parts with engine oil during reassembly. NOTE: New rod bearings must be selected by matching connecting rod and crankshaft identification markings. (see pages 7-10, 11) PISTON RINGS Replacement, page 7-22 Measurement, pages 7:21, 22 Alignmont, page 7-23 PISTON PIN Removal, page 7-18 instalation, page 7-19 Inspection, page 7-20, PIsTON Removal, page 7-12 Measurement, page 7-16 NOTE: To maintain proper clearance, ‘atch the letter an the piston top with the lator for each cylinder stamped on the block, On tha piston top PISTON INSTALLATION DIRECTION EXHAUST INTAKE a the block No letter = ————— Aor! o—— Bart CONNECTING ROD. End play, page 7-7 Selection, page 7-18 ‘Small end measurement, page 7-20 ‘CONNECTING ROD BEARINGS. CONNECTING ROD BEARING CAP Installation, page 7-25 NOTE: Install cap so the bearing recess is on the same side as the re085s In the ro. ‘CONNECTING ROD NUT 2083 engine: 8x075 mm 321Nm (3.3 kgtm, 28 bt) Except F20B3 engine: 90.75 mm 46 Nm (6.7 kghm, 38 bt) ‘tor torquing each bearing cap, fotate crankshaft to check for binding. No. 7-6 CYLINDER BLOCK Cylinder bore inspection Warpage inspection, pa {Cylinder pore honing, page 7-18 Inepect top of each cylinder bore for carbon buildup or ridge before Femoving piston, Remove ridge if necessary, page 7-14 CYLINDER BORE SIZES (orl, Borih NOTE! To maintain praper piston clearance, match these lettors sith the letters on the pistons. The letters fn the black read fram left to right No. Tthrouph No. 4 cylinders, “On the block Gn the piston top _A Aor! —_s' No totter orn eeFlywheel and Drive Plate r Replacement Manual Transmission: Remove the eight flywheel bolts, then separate the fly- wheel from the crankshaft flange. After installation, tighten the bolts in the sequence shown. RING GEAR HOLDER o71LAB — PVO0100 ENGINE ING GEAR HOLDER Lock O7LAB = PYOOTO0 2241.0 mm 103 Nim (105 kgm, 76 fF Inspect ring gear teeth for wear or damage. Automatic Transmission: Remove the eight drive plate bolts, then separate the drive plate from the crankshaft flange. After installation, tighten the bolts in the sequence shown. Qx1.0mm 74mm (75 kgf, Babee Connecting Rod and Crankshaft r- End Play Connecting Rod End Play: Standard (New): 0.15 - 0.30 mm (0.006 - 0.012 in} Service Limit: 0.40 mm (0.016 in) CONNECTING ROD * Ifoutoftolerance, install a new connecting rod © If still out-of tolerance, replace the crankshaft (see pages 7-12 and 7-25), Push the crankshatt firmly away from the dial indicator, and zero the dial against the end of the crankshaft. Then pull the erankshatt firmly back toward the indicator: dial reading should not exceed service limit ‘SCREWDRIVER Crankshaft End Play: Standard (New: 0.10 - 0.35 mm (0.004 - 0.014 in) Service Limit: 0.45 mm (0.018 in) ‘© fend play is excessive inspect the thrust washers {and thrust surface on the crankshaft. Replace parts as necessary. NOTE: Thrust washor thickness is fixed and must not be changed either by grinding or shimming, ‘Thrust washers are installed with grooved sides facing outward, 7-7Main Bearings r Ch 1 jlearance To check main bearing-to-journal oil clearance, remove the main caps and bearing helves. Clean each main journal and bearing half with a clean shop towel Place one strip of plastigage across each main jour- ral NOTE: Ifthe engine is still in the car when you bolt the main cap down to check clearance, the weight of the crankshaft and fiywhee! will flatten the plast gage further than just the torque an the cap bolt and give you an incorrect reading, For an accurate reading, support the crank with a jack under the counterwoights, and check only one bearing at a Reinstall the bearings and caps, then torque the bolts, 74 Nem (7.5 kgm, 54 IF) NOTE: Do not rotate the crankshaft during inspec- tion, Remove the cap and bearings again, and measure the widest part of the plastigage. Main Bearing-to-Journal Oil Clearance: Standard (New): No. 2 0.021 - 0.045 mm (0.0008 - 0.0018 in) ‘Service Limit; 0.050 mm (0.0020 in) No.3 0.025 - 0.049 mm (0.0010 - 0.0019 in) ‘Service Limit: 0.055 mm (0.0022 in) No. 1and.4 0.013 0.037 mm (0.0005 0.0015 in) ‘Service Limit: 0.050 mm (0.0020 in) No. 5 0.009 - 0.033 mm (0.0004 - 0.0013 in) ‘Service Limit: 0.040 mm (0.0016 in) PLASTIGAGE STRIP If the plastigage measures too wide or too narrow, (remove the engine if t's stil in the car), remove the crankshaft, and remove the upper half of the bear ing. install a new, complete bearing with the same color code (select the color as shown on the next page), and recheck the clearance. CAUTION: Do not file, shim, or scrape the be: or the caps to adjust clearance. If the plastigage shows the clearance is still incor- rect, ry the next larger or smaller bearing (the color listed above or below that one), and check again. NOTE: If the proper clearance cannot be obtained by using the appropriate larger or smalier bearings, replace the crankshaft and start over. 7-8ie Selection CAUTION: If the codes are indecipherable because of ‘an accumulation of dirt and dust, do not scrub them with a wire brush or seraper. Clean them only with sol- vent or detergent. Crankshaft Bore Code Location (Numbers, Letters or Bars) Numbers or Letters or Bars have been stamped on the tend of the block as a code for the size of each of the 5 ‘main journal bores. Use them, and the numbers stamped on the crankshaft, (codes for main journal size), to choose the correct bear ings. "No. 1 JOURNAL (PULLEY END) Bearing Design "No.'5 JOURNAL (FLYWHEEL END) PROJECTION Lower Bearing Identification p> Larger crank bore Color codeis onthe [ror] serBer]swcoru]terdorul edge of the bearing. > simatier bearing (Thicker) T = ‘youow | veto | crown | cree Sort teen | Green | Brown | Brown! rows | suc row Scr | Smaller Smaller NOTE: When using bearing halves of main bearing different colors it does not matt journal (Thicker) whieh color i used inthe top oF bottom. Main Journal Code Locations (Numbers or Bars) F20B3 engine: ‘Main Journal Code Locations (Numbers or Except F2083 engine ‘The Main Journal Codes are stamped in one of the fol- lowing locations. "Main Journal Code Locations (Numbers or ) ‘Main Journal Code Locations (Numbers or Bars) ‘No.6 JOURNAL (FLYWHEEL END) No. 1 JOURNAL (PULLEY END) No. 1 CRANK WEB 7-9Connecting Rod Bearings r Clearance 1. Remove the connecting rod cap and bearing halt 2. Clean the crankshaft rod journal and bearing half with @ clean shop towel. 3. Place plastigage across the rod journal 4. Reinstall the bearing half and cap, and torque the nuts to: F20B3 engine: 32 Nem (3.3 kgtim, 24 IbFft) Except F2083 engine: 46 Nem (4.7 kgm, 34 bff) NOTE: Do not rotate the crankshaft during inspee- tion. 5, Remove the rod cap and bearing half and measure the widest part of the plastigage. Connecting Rod Bearing-to-Journal Oil Clearance: F20B3 engine: ‘Standard (New): 0.015 ~ 0.043 mm (0.0006 - 0.0017 Service Limit: 0.050 mm (0.0021 Except F20B3 engine: ‘Standard (New): 0.021 ~ 0.049 mm, (0.0008 - 0.0019 in) Service Limit: 0.06 mm (0.002 in) PLASTIGAGE STRIP If the plastigage measures too wide or too narrow, remove the upper half of the bearing, install a new, complete bearing with the same color code (select, the color as shown on the next pagel, and recheck the clearance. CAUTION: Do not file, shim, or scrape the bearings (or the cops to adjust clearance. If the plastigage shows the clearance is still incor- rect, try the next larger or smaller bearing (the color listed above or below that one}, and check clear- ance again. NOTE: If the proper clearance cannot be obtained by using the appropriate larger or smaller bearings, replace the crankshaft and start over. 7-10Selection CAUTION: If the codes are indecipherable because of fan accumulation of dirt and dust, do not scrub them with a wire brush or scraper. Clean them only with sol- vent or detergent. Connecting Rod Journal Code Locations (Numbers or Bars) Numbers or Bars have been stamped on the side of ‘each connecting rod as a code for the size of the big tend. Use it, and the letters or bars stamped on the crank {codes for rod journal size), to choose the correct bear- ings. Half of number or bar is stamped on bearing cap tnd the other half Stamped on rod PROJECTION COLOR Boating Identification p> Larger big ond bore Catrtaue in omine fe Serene [ser | aoe | corm | coc ee ai [= [= [om fom | \ le Black mater Smale ood Bernat Feces Connecting Rod Journal Code Locations (Letters or Bars) F20B3 engine: Code Locations (Letters or Bars) Connecting Rod Jour Except F20B3 engine: The Connecting Rod Journal Codes are stamped in one of the following locations. Connecting Rod Journal Code Locations (Letters or Bars) ‘No.1 JOURNAL (PULLEY END} No.4 JOURNAL (FLYWHEEL END) 7-11Crankshaft, Balancer Shafts and Pistons 7 Removal 1, Remove the right side cover. Dowel PIN RIGHT SIDE COVER. 2, Remove the balancer gear case. 8x 125mm 25.N'm (25 kof, 18 lf) Replace. 4 “BALANCER DOWEL PIN GEAR CASE 3, Remove the front balancer driven pulley as shown, BALANCER DRIVEN PULLEY MAINTENANCE HOLE 4. Align the bolt hole and the balancer shaft hole, then insert @ special too! to hold the rear balancer shaft. 5. Remove the bolt and the balancer driven gear. REAR BALANCER, SHAFT BALANCER SHAFT LOCK PIN O7LAG — PT20100 WwasHeR BALANCER Replace. DRIVEN GEAR,Remove the oil screen and the oil pump. 8. Remove the bolts and the bearing cap bridge, then remove the bearing caps. Remove the baffle plate (F281 engine ony). CAUTION: To prevent warpage, unscrew the bolts in sequence 1/3 turn at a time; repeat the sequence until all bolts are loosened. OWL ScREEN BAFFLE PLATE MAIN BEARING CAP BOLTS LOOSENING SEQUENCE (2281 engine only) asker Roplace. B sS power PIN, on sump {cont'd 7-13Crankshaft, Balancer Shafts and Pistons j- Removal (cont'd) 8. Turn the crankshaft so No. 2 and 3 crankpins are at the top. 10. Remove the rod caps/bearings and main caps/bear- ings. Keep all caps/bearings in order. 11, Lift the erankshatt out of the engine, being careful not to damage journals. ‘CRANKSHAFT. 12. Remove the bolts and the retainer, then romove the front balancer shaft and the rear balancer shaft REAR BALANCER SHAFT FRONT BALANCER SHAFT RETAINER 13. Remove the upper bearing halves from the connect- ing rods and set them aside with their respective caps. 14. Reinstall the main caps and bearings on the engine in proper order. 15. If you can feel a ridge of metal or hard carbon around the top of each cylinder, remove it with a ridge reamer. Follow the reamer manufacturer's instructions CAUTION: If the ridge is not removed, it may dam- age the pistons as they are pushed out. RIDGE REAMER 16. Use the wooden handle of a hammer to drive the pistons out. 17, Reinstall the connecting rod bearings and caps after removing each piston/connecting rod assembly. 18. Mark each piston/connecting rod assembly with its cylinder number to avoid mixup on reassembly. NOTE: The existing number on the connecting rod does not indicate its position in the engine, it indi ‘cates the rod bore size, 7-14Crankshaft - Inspection ‘* Clean the crankshaft oil passages with pipe cleaners or a suitable brush, ‘© Check the keyway and threads. Alignment ‘© Measure runout on all main journals to make sure the crank is not bent. ‘© The difference between measurements on each journal must not be more than the service limit. Crankshaft Total Indicated Runout: ‘Standard (New): 0.03 mm (0.001 in) max. Service Limit: 0.04 mm (0.002 in} DIAL INDICATOR Rotate erankshatt twa complete revolutions. Support with lathe: {ype too! of V-blocke, Out-of-Round and Taper * Measure out-of-round at the middle of each rod {and main journal in two places. ‘© The difference between measurements on each Journal must not be more than the service limit. Journal Out-of-Round: ‘Standard (New: 0,005 mm (0.0002 in) max. Service Limit: 0.006 mm (0.0002 in) Measure in two places at mice Measure taper rear edges ‘© Measure taper at the edge of each rod and main journal, © The difference between measurements on each journal must not be more than the service limit. Journal Taper: ‘Standard (New): 0.005 mm (0.0002 in) max. Service Limit: 0.006 mm (0.0002 in) 7-15Pistons - Inspection 1. Check the piston for distortion or cracks. NOTE: If the cylinder is bored, an oversized piston must be used, 2, Measure the piston diameter at a point 21 mm from, the bottom of the skirt NOTE: There are two standard-size pistons (No Letter (A) oF 8). The letter is starnped on the top of the piston, Letters are also stamped on the block as cylinder bore sizes. Piston Diameter: ‘Standard (New) [No Letter (A): 84.980 ~ 84.990 mm (3.3457 ~ 3.3461 in) B: 84.970 - 84.980 mm (3.3453 ~ 3.3457 in) Service Limit: No Letter (A): 84.970 mm (3.3453 in} 8: 84.960 mm (3.3449 in) skint 21 mm (0.8 in) DIAMETER, Calculate the difference between cylinder bore diameter (see page 7-17) and piston diameter. Piston-to-Cylinder Clearance: Standard (New): 0.020 ~ 0.040 mm (0.0008 - 0.0016 in) Service Limit: 0.05 mrn (0.002 in) ~ PISTON-TO-CVLINDER CLEARANCE If the clearance is near or exceeds the service limit, inspect the piston and cylinder block for excessive Oversize Piston Diameter: 0.25: 85.230 ~ 85.240 mm (3.9555 - 3.9559 (0.50: 85.480 - 85.490 mm (3.3653 - 3.3657 in) 7-16Cylinder Block - Inspection 1, Measure wear and taper in direction X and Y at three levels in each cylinder as shown. {6m (0.2 in} {6 mm (0.2 in} Not No.4 CYLINDER BORE SIZES (Worl, Bors) Fad the loters from let to-ight for No. 1 through No. 4 cylinders. CYLINDER BORE GAUGE Cylinder Bore Size: Standard (New): 35.010 ~ 85.020 mm (3.3468 ~ 3.3472 in) 35.000 — 85.010 mm (3.3465 — 3.3468 in) Service Limit: 85.070 mm (3.3492 in} Oversize: 0.25: 85.250 ~ 85.260 mm (3.3563 ~ 3.3567 in) 0.50: 85,500 ~ 85.510 mm (3.3661 ~ 3.3665 in) (Difference between first and third messure- ment) 0.05 mm (0.002 in} © If measurements in any cylinder are beyond Oversize Bore Service Limit, replace the block. «Ifthe block is to be rebored, refer to Piston Clear- ance Inspection (see page 7-16} after reboring NOTE: Scored or scratched cylinder bores must be honed, Reboring Limit: 0.50 mm (0.020 in) max 2. Check the top of the block for warpage. Measure along the edges and across the center as shown, ‘SURFACES TO BE MEASURED Z & y | Engine Block Warpage: Standard (New): below 0.07 mm (0.003 in) max. Service Limit: 0.10 mm (0.004 in) PRECISION STRAIGHT EDGE 7-17Cylinder Block Piston Pins - Removal [- Bore Honing 1. Measure cylinder bores as shown on page 7-16. If the block is to be reused, hone the cylinders and remeasure the bores. 2. Hone cylinder bores with honing oil and a fine (400 grit) stone in a 60 degree cross-hatch pattern, NOTE: © Use only a rigid hone with 400 grit or finer stone such as Sunnen, Ammco, or equivalent. # Do not use stones that are worn or broken, 3. When honing is compiete, thoroughly clean the engine block of all metal particles. Wash the cylin der bores with hot soapy water, then dry and oil immediately to prevent rusting. NOTE: Never use solvent, it will only redistribute the grit on the cylinder walls, 4. If scoring or scratches are still present in cylinder bores after honing to the service limit, rebore the cylinder block. NOTE: Some light vertical scoring and scratching is acceptable if itis not deep enough to catch your fin: ‘gernail and does not run the full length of the bore. ‘CYLINDER BLOCK (CYLINDER HONE NOTE: ¢ After honing, clean the cylinder thoroughly with soapy water. © Only a scored or scratched cylinder bore must be honed. NoTe: '* Use the piston pin aesembly tool set (No. O7PAF ~ (0010000) for removal of piston pins. © Be sure to use the pilot collar of correct No. as desig nated, 1, Set the special tools as shown. "LOT COLLAR, 0.0. 22 mm: o7PaF -0010680 2. Place the piston on the special tools and press the pin out using a hydraulic press. Embossed mark facing up. PILOT COLLAR, 0.0. 22mm O7PAF- 0010660 LI Lt NOTE: Use 2 hydraulic press. When pressing pin in ar out, ‘make sure thatthe racessed portion ofthe piston aligns ‘withthe lips on the collar, 7-18Connecting Rods - Selection Each rod falls into one of four tolerance ranges (from 0 to 0.024 mm (0.0009 in}, in 0,008 mm (0.0002 in) incre- ments) depending on the size of its big end bore. It's then stamped with a number or bar (1, 2,3, oF 4/1 i, ‘or mil) indicating the range. ‘You may find any combination of 1, 2, 3, oF 4 sl, l, or ulin any engine. Normal Bore Size: F20B3 engine: Except F20B3 engine: 48.0 (1.89 51.0 (2.01 NOTE: '* Reference numbers or bars are for big end bore size and do not indicate the position of the rod in the engine. ‘© Inspect connecting rod for cracks and heat damage. ‘CONNECTING ROD BORE REFERENCE NUMBER or BAR. Half of number i stamped on ‘beating cap, the other half on connecting rd. Inspect boks and nuts for stress cracks b=] Piston Pins [- Installation NOTE: ‘© Use the piston pin assembly tool set (No. O7PAF ~ (0010000) with a hydraulic press. © Be sure to use the pilot coller of correct No. as desig: nated, The arrow must face the timing belt side of the engine “The mark must f the timing belt side of the engine. 1. Install the piston pin as shown. wor coun, raise SPE oan — facing up. rd i - | DM | ill ji | ) WII | re | rron \ A NOTE: Install the assembled piston and rod with the oil hole facing the intake manifold 7-19Piston Pins [ Inspection 1, Measure the diameter of the piston pin, Piston Pin Diameter: Standard (New); 21.994 - 22.000 mm (0.9659 - 0.8661 in) Oversize: 21.997 - 22.003 mm {0.8660 - 0.8663 in) NOTE: All replacement piston pins are oversize, 2. Zero the dial indicator to the piston pin diameter. Measure the piston pin-to-piston clearance. NOTE: Check the piston for distortion or cracks. Ifthe piston pin clearance is greater than 0.024 mm (0.0009 in}, remeasure using an oversized piston pin. iston Clearance: Piston Pin-to- ‘Standard (New): 0.010 - 0.022 (0.0004 - 0.0009 in) Check the difference between piston pin diameter and connecting rod small end diameter. Piston pin-to Connecting Rod Interference: Standard (New): 0.013 - 0.032 mm. (0.0005 - 0.0013 in) 7-20Piston Rings [- End Gap Using a piston, push a new ring into the cylinder bore 15 ~ 20 mm (0.6 - 0.8 in) from the bottom. 2. Measure the piston ring end-gap with a feeler gauge: ‘© If the gap is too small, check to see if you have the proper rings for your engine. ‘© If the gap is too large, recheck the oylinder bore diameter against the wear limits on page 7-17 If the bore is over the service limit, the cylinder block must be rebored Piston Ring End-Gap: Top Ring Standard (New): 0.20-0.35 mm. (0.008 - 0.014 in} Service Limit: 0.60 mm (0.024 in) ‘Second Ring ‘Standard (New): 0.40 - 0.55 mm (0.016 - 0.022 Service Limit: 0.70 mm (0.02 Oil Ring ‘Standard (New): 0.20 - 0.70 mm (0.008 ~ 0.028 in} Service Limit: 0.80 mm (0.031 in} END GAP 7-21Piston Rings - Replacement 1. Using a ring expander, remove the old piston rings. 2. Clean all ring grooves throughly. NoTE: © Use a squared-off broken ring or ring groove cleaner with blade to fit piston grooves. © Top and 2nd ring grooves are 1.2 mm (0.08 in} wide, and the oil ring groove are 2.8 mm (0.11 in) wide. ‘© File down blade if necessary. CAUTION: Do not use a wire brush to clean the ring grooves, or cut ring grooves deeper with cleaning tools. NOTE: If the piston is to be separated from the con- necting rod, do not install new rings vet. 3. Install new rings in the proper sequence and posi tion (see page 7-23). NOTE: Do not use old piston rings. PISTON RING RING EXPANDER Ring-to-Groove Clearance ‘After installing a new set of rings, measure the ring-to- groove clearances: Top Ring Clearance ‘Standard (New): 0.036 - 0.060 mm (0.0014 ~ 0.0024 in) Service Limit: 0.13 mm (0.005 in) Second Ring Clearance ‘Standard (New): 0.030 ~ 0.055 mm (0.0012 ~ 0.0022 in) 0.13 mm (0.005 in) Service Limit: 7-22be] r Alignment 1. _ Install the rings as shown Identify top and second rings by the chamfer on the ‘edge. Make sure they are in their proper grooves on the piston NOTE: The manufacturing marks must be facing upward, TOP RING 2 3 DO NOT position any ring 9 SECONDRING GAP piston thrust surfaces, \ Approx. 90° onrne Approx: 1p CAP ey 18° 5 TOP RING GaP ee 10 NOT position any ring gap in ting withthe piston pinhole, ONL RING GAP 7-23Crankshaft Oil Seal r- Installation ‘The seal surface on the block should be dry. Apply a light coat of oll to the crankshaft and to the lip of the seal 1. Drive in erankshaft oll sal against right side cover. NOTE: Drive the crankshaft oil seal in squarely. HANDLE DRIVER ‘07749 - 9010000 Install geal withthe pan number side DRIVER ATTACHMENT, 96 men 07948 SB00101 2. Confirm that the clearance is equal all the way around with a feeler gauge. cn ance: 0.5 ~ 0.8 mm (0.02 - 0.03 in) RIGHT SIDE ‘COVER (0.02 — 0.03 im) cnfGoe | cower | | (CRANKSHAFT On seaL NOTE: Refer to page 8-11 for installation of the oil ump side crankshaft oil seal Pistons - Installation engine ail to the ring grooves and cylinder bores, na Before installing the piston, apply a coat of 1, Ifthe crankshaft is already installed: ‘* Set the crankshaft to BDC for each cylinder. ‘¢ Remove the connecting rod caps, and slip short sections of rubber hose over the threaded ends of the connecting red bolts. ‘© Install the ring compressor, check that the bear- ing Ts securely in place, then position the piston in the cylinder, and tap it in using the wooden handle of a hammer. © Stop after the ring compressor pops free, and ‘check the connecting rod-to-crank journal align: ment before pushing piston into place. ‘© Install the rod caps with bearings, and torque the ruts to: F20B3 engine: 32 Nem (3.3 kgfrm, 24 Ib) Except F2083 engine: 46 Nem (4.7 kgm, 34 IDF) 2. Ifthe crankshat is not installed: * Remove the rod caps and bearings, install the ring compressor, then position the piston in the cylinder, and tap it in using the wooden handle of a hammer. ‘* Position all pistons at top dead center. ‘The arrow must face the timing batt side of the fengine ‘The mark must foc ‘the timing belt side ofthe engine NOTE: Maintain downward foree on the ring com: pressor to prevent rings from expanding before entering the cylinder bore, Use the wooden handle, RING of a hammer to push or COMPRESSOR tap the piston into th cylinder bore hi 7-24Crankshaft and Balancer Shafts b=] Installation 1. Install the thrust washers in the No. 4 journal of the cylinder block ‘THRUST WASHERS Grooved side facing outward 2. Insert bearing halves in the cylinder block and con necting rods. 3. Hold the crankshaft so rod journals for cylinders No. 2and No. 8 are straight up. 4. Lower the crankshaft into the block, seating the rod journals into connecting rods No. 1 and No. 4 Install the rod caps and nuts finger tight. ‘CONNECTING. ‘CONNECTING ROD No.1 ROD No. 3 ‘SONNECTING WASHERS ROD No. 4 connedtine Tuaust ROD No. 2 5. Rotate the crankshaft clockwise, seat journals into ‘connecting rods No. 2 and No. 3, and install the rod ‘caps and nuts finger tight NOTE: Install caps so the bearing recess is on the same side as the recess in the rod, 6. Check rod bearing clearance with plastigage (see page 7-10), then torque the capnuts. 2083 engine: 32 Nem (3.3 kgtm, 24 IDF) Except F20B3 engine: 46 Nim (4.7 kgf, 34 Ibe) NOTE: Reference numbers on connecting rod are for big-end bore tolerance and do not indicate the position of piston in the engine. 7. Install the main bearing caps and bearing cap bridge. 8. Check clearance with plastigage (see page 7-8), then tighten the bearing cap bolts in 2 steps. In the first step tighten, all bolts in sequence, to about 29 Nim (3.0 kgm, 22 Ibf‘tl; in the final step, tighten in same sequence, to 74 Nem (7.5 kgtm, 54 oF NOTE: Coat the.bolt threads with engine oil CAUTION: Whenever any crankshaft be: connecting rod be: after r ing or ing is replaced, it is necessary sssembly to run the engine at idling speed reaches normal operating temperature, then continue to run it for approximately 15 minutes. (econt’a 7-25Crankshaft and Balancer Shafts r Installation (cont'd) NoTE: 10. Insert the balancer shafts into the block, then install Use liquid gasket, part No. 0740 - 999886. the retainer to the front balancer shaft and block. © Check that the mating surfaces are clean and dry before applying liquid gasket, ‘# Apply liquid gasket evenly, being careful to cover all the mating surface. © To prevent leakage of oil, apply liquid gasket to the inner threads of the bolt holes. ¢ Do not instal the parts if 5 minutes or more have elapsed since applying the liquid gasket. REAR BALANCER Instead reapply liquid gasket after removing the ur old residue. © After assembly, wait at least 20 minutes before filing the engine with oil 9. Apply liquid gasket to the block mating surtace of the right side cover, then install it on the cylinder block FRONT BALANCER RIGHT SIDE COVER: ace RETAINER, 6x 10mm T2Ne (12 hgh, 87 te) 11. Apply liquid gasket to the oil pump mating surface of the block, then install the oil pump on the cylin: der block, ‘© Apply grease to the lips of the oil seals Then, install the oil pump while aligning the inner rotor with the crankshaft. When the pump is in place, clean any excess grease off the crank- shaft and the balancer shaft, then check that the oil seal lips are not distorted Apply liquid gasket slong the Broken line, DOWEL PINS, ol PUMP: ‘Apply liquid gasket to block mating surface, 641.0 mm 12 Neem (12 kafen. 8.7 Ibe) Apply lauid gasket {othe bolt throads, 7-266x1.0mm ZN (1.2 kgf, 8:7 bef) > A 1 WN LZ 8 Apply engine ol Replace. asker, Replace, ‘DOWEL PIN ‘on. PUMP ‘Apply tiquid gasket to 6x1.0%0m block mating surface 12Nm (12 kot, a7 wre Apply liquid gasket tothe bolt threads, Apply grease tothe sea lips. 12, Install the baffle plate, then install the oil screen, 18. Hold the front balancer shaft with a screwdriver, then instal the timing balancer belt driven pulley. FRONT BALANCER SHAFT: ‘TIMING BALANCER BELT DRIVEN PULLEY ‘SCREWDRIVER MAINTENANCE HOLE 8x 129mm 25.Nm (3.0 kgtm, z21wtn) 14. Before installing the balancer driven gear and the balancer gear case, apply molybdenum disulfide to the thrust surfaces of the balancer gears as shown, Apply molybdenum aisullice BALANCER SHAFT DRIVEN GEAR. Apply molybdenum ‘isultige, BALANCER BELT BALANCER DI DRIVEN PULLEY |ALANCER DRIVE GEAR BAYANCER GEAR CASE 18. Hold the rear balancer shaft with the special tool, then install the balancer driven gear. REAR BALANCER SHAFT: REAR BALANCER SHAFT BALANCER SHAFT Lock IN 071AG - PT20100 MAINTENANCE HOLE REAR BALANCER HOLE wasueR Replace. \o7.aG~PT20100 8x 1.25 mm 28 Nm25 kofm, 12mm SEALING BOLT (cont'd) tit 291m (3.0 kgf, 22 bt) 7-27Crankshaft and Balancer Shafts [- Installation (cont’d) 18, Install the oil pan. 16, Install the balancer gear case to the oll pump. NOTE: Align the groove on the pulley edge to the JOTE: Clean the oll pan gasket mating surface. pointer on the gear case while holding the rear bal- OL PAN GASKET Apply liquid Replace ‘gaeket to here. ancer with the special tool, then install the gear DOWEL PIN 8x 125mm 25Nm 25 kgtm, F yeibee O-RING Apply engine ol BALANCER DOWEL PIN GEAR CASE waster 6x10. mm 16Nem (14 kgtm, Replace. POINTER Align the groove ro1bth) to pointer DRAWN BOLT: 4aNen (45 kat, 33 th) Do not ovenishten. 49. Tighten the bolts and nuts as shown below. Torque: 14 Nem (1.4 kgm, 10 IbF#t) Rove 17, Check alignment of pointers after installing the gear FPOWTERON THE PULLEY _O POINTER ON. ie eae) NOTE: Tighten the bolts and nuts in three steps ‘and torque them in a criss-cross pattern. 7-28Balancer Shafts 1 [ Inspection b=] NOTE: Inspect the balancer shaft before removing the right side cover and the balancer gear case (see page 7 12) Push the balancer shaft firmly away from the dial Indicator, and zero the dial against the front end of the balancer shaft, then pull the balancer shaft fim: ly back toward the indicator. Front Balancer Shaft End Play Standard (New): 0.10 - 0.40 mm (0.004 - 0.016 in) © If end play is excessive, inspect the retainer and thrust surfaces on the balancer shatt. Rear Balancer Shaft End Play Standard (New:0.08 - 0.15 mm (0.002 - 0.006 ‘© If end play is excessive, inspect the thrust wash. fer and thrust surfaces on the driven gear and oil Pump body. NOTE: The thickness of the retainer (front) and thrust washer (rear) are fixed and must not be changed either by grinding or shimming, Remove the balancer shafts (see page 7-12), NOTE: Clean the balancer shafts Inspect the surface of the balancer shaft journal and balancer bearing, Replace the bearing or balancer shaft if there is wear, damage or discoloration on the surface of the bearing or the balancer shaft journal. When replac ing the rear No. 1 bearing be sure to replace the cit pump housing with a new one. NOTE: A mirrorlike surface is normal Measure taper at the edges of each journal. © The difference betwoon measurements on each journal must not exceed the standard. Journal Teper ‘Standard (New): 0.005 mm (0.0002 in) (cont'a 7-29Balancer Shafts [- Inspection (cont'd) 6. Measure runout on the No. 2 journal of each bal: ‘ancer shaft to make gure the balancer shafts are not bent Balancer Shaft Total Indicated Runout. ‘Standard (New): 0.02 mm (0.001 in) Service Limit: 0.03 mm (0.001 in) DIAL INDICATOR Rotate two complete revolutions. ‘Suppor with tathe type tool or Vblocks. 7. Measure the diameters of the balancer shaft jour- nals. MEASURING POINTS. No.3 JQURNAL No, 2 JOURNAL (No. 1 JOURNAL, FRONT BALANCER ae ‘No. 2 JOURNAL No. JOURNAL rean@avancen No. 1 JOURNAL, SHAFT Journal Diameter Standard (New): No. 1 journal Front: 42.722 -42.734mm. (1.6820 - 1.6824 in) Rear: 20.938 - 20.950 mm (0.8243 - 0.8248 in) No. 2 journals front and rear: 38.712 ~ 28.724 mm (1.5241 - 1.5248 in) No. 3 journals front and rear: 34.722 ~ 24.734 mm (1.3670 ~ 1.3675 in) Service Limit: No. 1 journal Front: 42.71 mm (1.681 in) Re 20.92 mm (0.824 in) No. 2 journals front and re: ‘38,70 mm (1.524 in) No. 3 journals front and rear: 34.71 mm (1.367 in) Remove the crankshaft, the pistons and the other parts from the block, then clean the balancer shaft journal bearings in the block and the oil pump housing with a clean shop towel. Cheek the surface of the bearings: if there is wear, damage or discoloration, replace the bearings or the oll pump housing, 7-3010. Measure the inner diameters of the balancer shaft journal bearings. MEASURE POINTS No. 2 BEARING ‘No. 1 BEARING (BLOCK) vo. a BEARING. (lock) (Block) . ae FRONT I REAR JT \. } ‘No, 9 BEARING (Block) ‘No.2 BEARING (elock) stock DIAL GAUGE DIAL GAUGE ‘No. 1 REAR BEARING (Ol PUMP HOUSING) n Bearing Inner Diameter Standard (New): No. 1 journals: Front: 42,800- 42.820 mm (1.6850 ~ 1.6858 in) Rear, 21.000-21.013 mm (0.8268 - 0.8273 in) No. 2 journals front and rear: 38,800 - 38.820 mm (1.5276 ~ 1.5283 in) No. 3 journals front and reat 34.800 - 34.820 mm. (1.3701 - 1.3709 in) ‘Service Limit: No. 1 journals: Front: 42.83 mm (1.686 Rear: 21.02 mm (0.828 in) No. 2 journals front and rear: 38.83 mm (1.529 in) No. 3 journals front and rear: 94.83 mm (1.371 in) Calculate the shaft-to-bearings oil clearances. BEARING LD. - JOURNAL 0.0. = OIL CLEARANCE Bearing-to-shaft Oil Clearance Standard (New): No. 1 front journal, No. 3 front and rear journals: 0.066 ~ 0.098 mm {0.0026 - 0.0039 in} No. 2 front and rear journals: 0.076 ~ 0.108 mm (0.0030 ~ 0.0043 in) NNo. 1 rear journal: 0.050 - 0.075 mm (0.0020 - 0.003 Service Limit: No. 1 front journal, No. 3 front and rear journals: (0.12 mm (0.005 in) No. 2 front and rear journals: 0.13 mm (0.008 in} No. 1 rear journal: 0.09 mm (0.004 in) 7-31Balancer Shaft Bearings r Replacement The procedure shown below is used when using the bearing replacement tool set (O7LAF — PT20100), CAUTION: ‘* Remove all attachment parts from the cylinder block and lay it with its oll pan side up. ‘© Remove or reinstall bearings one at a tim ‘© Remove bearings from the transmission side to the jiming belt side and reinstall them in reverse sequence. Removi NoTE: © By changing the size and attachment point of the attachment, all balancer bearings can be removed from the cylinder block in the same procedure. The illustration shows the attachment points of each special tool ‘* Whon removing bearings successively, put the cor ersponding attachment through the shatt without fix ing them in advance, SPECIAL TOOL SET LOCATION ATTACHMENT 8 ATTACHMENT A ATTACHMENT & ‘THRUST BEARING Guioe SHAFT pase | nut cum ATTACHMENT C ATTACHMENT & © Position of attachment fixing holes and guide marks fon the shaft, 1 STOPPER PIN 2 3 Put the ettachment with the side having larger diameter facing the bearing. Align the stopper pin holes of the attachment and the shaft Insert the stopper pin to fix the attachment. FRONT No. 1 BEARING: ATTACHMENT A No.2 BEARINGS: ATTACHMENT B No. 3 BEARINGS: ATTACHMENT C Align withthe guide mark, Hold the shaft end with a wrench and tuen the nut clockwise until the beating comes off ‘¢ Do not rotate the shaft When removing bearings in succession, loosen the nut, remove the stopper pin from the pin hole you have finished and repeat above step 1 and 2 on the next bearing. 7-32Installation: Front No. 1 be 9 NOTE: Always use new bearings. 1. Sot the resess of the bearing to the detent of the attachment FRONT No. 1 BEARING ATTACHMENT A Set here Attachment Front No. 1 bearing: Attachment A ‘© The illustration shows the attachment points of the special tools. cue SHAFT GUIDE ATTACHMENT A Nur |i 4 4 ‘twrusT BEARING 2. Install the shaft positioning pin, 3. Set the shaft s0 that the attachment pin is aligned ‘ith the positioning hole in the end dise. En o4sk POSITIONING PIN ATTACHMENT A BEARING PosmiONING HOLE SHAFT OETENT ENO DISK \\ (cont'd 7-33Balancer Shaft Bearings 4. Set the deten of the bearing to the groove of the cylinder block BEARING ATTACHEMENT A, POSITIONING PIN DETENT 5. Hold the end of the shaft with wrench and install the bearing by turning the nut clockwise. © Do not rotate the shaft [- Replacement (cont'd), AAA ind No. 3 Bearings 1, Sot the resess of the bearing to the detent of the attachment. No.2 BEARINGS: ATTACHMENT B No. 3 BEARINGS: ATTACHMENT C BEARING Set here, The illustration shows attachment points of each special tool When installing bearings successively, set the bearings to the attachment and put them thr ‘ough the shaft without fixing them in advance. ATTACHMENT 8 ATTACHMENT ‘THRUST BEARING Gung sHAFT ATTACHMENT ATTACHMENT. 7-342. Install the shaft positioning pin. Front side Rear side END Disk. POSMIONING PIN 3. Align the attachment with the guide mark. Applicable bearing No. is indicated at the guide mark. Align the pin holes of the attachment and the shaft. Insert the stopper pin to fix the attachment (for No. 2, and No. 3 bearings) SEARING STOPPER PIN ATTACHMENT 8 OR 4 Set the detent of the bearing to the groove of the cylinder block GROOVE — peTENT BEARING ATTACHMENT BORG Hold the end of the shaft with wrench and install the bearing by turning the nut clockwise. © Do not rotate the shaft, 7-35Engine Lubrication Special Tools Illustrated Index .. Engine Oil Inspection . Replacement Oil Filter Replacement Oil Pressure Testing ... Oil Pump Overhaul .. Removal/Inspec 8-9Special Tools RefNo. | Tool Number |_aty | Page Reference @ O7LAG - PT20100 Balancer Shaft Lock Pin + | en ® 07406 - 0030000 il Pressure Gauge Attachment 1 | 87 @ (07506 - 3000000 Oil Pressure Gauge 1 | 87 @ 07746 - 0010300 Driver Attachment, 42 x 47 mm 1 | 8-10 ® 07746 0010400 Driver Attachment, 52 x 5 mm + | a0 & | arr49-o010000 Handle Driver 1 | 810 @__| _orgr2-etr0001 Oil Fiter Wench 1 | 86lilustrated Index Note CAUTION: Do not overtighten the drain bolt. Use new O-rings when reassembling. ‘© Apply oil to O-rings before installation. '* Use liquid gasket, Part No. 0Y740 - 99986. ‘* Clean the oil control orifice before installing. ‘© Clean the oil pan gasket mating surfaces before in- stalling, ‘© Apply liquid gasket to the recesses of the oil pan gas- ket (see page 8-12) 841.25 mm 28Nm (25 kat, 18 tt) BALANCER DRIVEN OIL PUMP. GEAR Overnaul, poge 8.8 ‘THRUST Inspection, page 89 WASHER —APply uid oreo FRONT TIMING BALANCER BELT DRIVEN PULLEY 851.25 mm 28.Nim (3.0 ktm, 2a) oN o-nincs Replace O1L CONTROL ORIFICE {Except F22B1 engine) Clean. O-RING (Except F22B1 engine) Replace ENGINE OlL PRESSURE SWITCH 18 Nem (1.8 kgf, 13 lft) ‘ygin. BSPT (Brish standard pipe tape 2a threadsrinch. Use Proper liquid sealant BALANcEA GEAR CASE O-RING’ 8x 1.28 mm Replace. 25 Nm 25 kgtm, 18 ts) ou rureR cows Replacement, pegs 85 Pn 7 g vowed pin ZB | on screen GASKET: N Replace. Apply liguie asker here, 6x1.0mm. 12Nem (12 kgm, 87 Ibe) On PAN GASKET. Replace, onPan TaN m (14 kgf, 10 bt Replace RAIN BOLT” 14x15 mm 44 Nem 185 kat, 33 EH) Do not overtighten 8-3Engine Oil r- Inspection 1. Check engine oil with the engine off and the car parked on level ground, 2, Make certain that the oil level indicated on the dip stick is between the upper and lower marks. 3. Ifthe level has dropped close to the lower mark, ‘adc oll until it reaches the upper mark. CAUTION: Insert the dipstick carefully to avoid bending it. biestick upper Lower - Replacement CAUTION: Remove the drain bolt carefully while the engine is hot; the hot oll may cause scalding. 1, Warm up the engine. 2. Drain the engine ol. DRAIN BOLT 44. 145 kof, 33 eA) Do not evertighten WASHER Replace, 3. Reinstall the drain bolt with a new washer, and refill with the recommended oil. CAUTION: Do not overtighten the drain bolt. interval months "3: European models CapacitySelect the oil for the car ‘according to this cart: Ambient Temperature 4. Fill the engine with oil up to the specified level, run the engine for more than 3 minutes, then check for oil leakage Oil Filter r Replacement After 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 because the oil tem- porature is very high, 1, Remove the oil filter with the special oil filter wrench. 2. Inspect the threads and rubber seal on the new fil ter. Wipe off the seat on engine block, then apply a light coat of oil to the filter rubber seal NOTE: Use only filters with a built-in bypass sys- tom, ‘Apply ol to rubber seat before instaling, Inspect tends ang rubber teal surface FRANCE-MADE cil filter: Apply oll to rubber seat Detore installing, Inspect threads and ‘ubber seal surface (cont'd) 8-5Oil Filter -- Replacement (cont'd) 3, Install the oil filter by hand. 4, After the rubber seal seats, tighten the oil filter clockwise with the special tool. Tighten: 7/8 turn clockwise. Tightening torque: 22 Nem (2.2 kgm, 16 IbFt) FRANCE-MADE coil filter: Tighten: three quarter turn clockwise. Tightening torque: 22 Nem (2.2 kgm, 16 Ibtt) CAUTION: Installation using other than the above procedure could result in serious engine damage due to oil leakage. OO FILTER WRENCH. a7s12— 6110001 FRANCE-MADE oil filter: LABINAL-Purtlux 76 COMMERCIALLY AVAILABLE Eight numbers (1 to 8} are printed on the surface of the filter France-made oil iter: Four numbers (1 t0 4) are printed on the surface of the filter. ‘The following explains the procedure for tightening fil ters using these numbers, 1) Make @ mark on the cylinder block under the num- ber that shows at the bottom of the filter when the rubber seal is seated, 2). Tighten the filter by turning it clockwise seven num bers from the marked point. For example, if 2 mark is made under the number 2 when the rubber seal is seated, the filtor should be tightened until the umber 1 comes up to the marked point. France-made oil iter Tighten the filter by turning it clockwise three num- bers from the marked point. For example, if a mark is made under the number 2 when the rubber seal ig seated, the filter should be tightened until the umber 1 comes up to the marked point. ‘Number when cubirer Number efter tightening. seal ig seated. Number when rubber seal is seated “18/817 ]8 [2] Number aftertightoning [8 |} 1/2} 3| 4]8] 817 FRANCE-MADE oil fiter: Number when rubber sealis seated | 1 | 2/3| 4 Number after tightening afrf2ls 5, After installation, fill the engine with oll up to the specified level, run the engine for more than 3 min: utes, then check for oil leakage.Oil Pressure [- Testing Ifthe oil pressure warning light stays on with the engine running, check the engine oil level. If the oil level is cor rect: 1. Connect a tachometer, 2, Remove the engine oil pressure switch and install an oll pressure gauge. 3. Start the engine. Shut it off immediately if the ‘gauge registers no oil pressure. Repair the problem before continuing. 4. Allow the engine to reach operating temperature (fan comes on at least twice). The pressure should be: Engine Oil Temperature: 80°C (176°F) Engine Oil Pressure: Atidle: 69 kPa (0.7 kaf/em?, 10 psi) minimum ‘At 3,000 rpm (min): 340 kPa (3.5 kaf/om:, 50 pil © Ifoll pressure is within specifications, replace the oll pressure switch and recheck. * If oi! pressure is NOT within specifications, inspect the oil pump (page 8-10) ENGINE OIL PRESSURE SWITCH. MOUNTING HOLE ‘OIL PRESSURE GAUGE ATTACHMENT ‘07406 0030000 Olt PRessuRE GAUGE (07506 - 3000000Oil Pump p Overhaul Note: Use now O-rings when reassombling, Apply oil to O-rings before installation Use liquid gasket, Part No. OY740 ~ 99986. The rotors must be installed to the same direction in order. After raassembly, check that the rotors move without binding, - 6x 1.0mm 7 Nem (0.7 kgf, 6.1 Het of PUMP HOUSING outer ROTOR Inspection, page 8.9 Inspection, page &9 ‘Apply liguid gasket to mating surface of the cylinder block when installing, 6x 1.0mm 12 New (1.2 kat, 8:7 Ibe) Apply liquid gasket tothe bolt threads o-nINGs DOWEL PIN —Repiace PUMP COVER INNER ROTOR Inspection, page 89 on seas Installation, page 8-10 Foplace, RELIEF VALVE Valve must slice fray inhousing bore Replace it scored OSes 2aiwte) 8-8be - Removal/Inspection/Installation 1._Drain the engine oil 9, Remove the screws from the pump housing, then separate the housing and cover. 2. Turn the crankshaft so that the No. 1 piston is at top dead center (see page 6-22! 10. Check the inner-to-outer rotor radial clearance on the pump rotor. 3. Remove the timing belt and the timing balancer belt, (see page 6-18) Inner Rotor-to-Outer Rotor Radial Clearance ‘Standard (New): 0.02 ~ 0.16 mm (0.001 ~ 0.006 in} 4. Remove the timing belt tensioner and the timing Service Limit: 0.20 mm (0.008 in) balancer belt tensioner. 5. Remove the timing belt drive pulley and the timing balancer belt driven pulley (see page 6-16), IMMER ROTOR ‘OUTER ROTOR 6. Remove the balancer gear case and the balancer driven gear (see page 7-12). 7. Remove the oil pan and the ail sereen, 8. Remove the mounting bolts and the oil pump as- sembly. on PUMP If the inner-to-outer rotor clearance exceeds the service limit, replace the inner and outer rotors. o-ninas Ropiace 11. Check the housing-to-rotor axial clearance on the Pump rotor. Housing-to-Rotor Axial Clearance Standard (New: 0.02 ~ 0.07 mm (0.001 - 0.003 in} Service Limit: 0.12 mm (0.008 in} PUMP HOUSING OUTER ROTOR Gasket Feplace on screen —If the housing-to-rotor axial clearance exceeds the service limit, replace the set of inner and outer rotors andior the pump housing (cont'd) 8-9Oil Pump 42, Check the housing-to-outer rotor radial clearance. Housing-to-Outer Rotor Radial Clearance ‘Standard (New): 0.10 — 0.19 mm (0.004 — 0.007 in} Service Limit: 0.21 mm (0.008 in) PUMP HOUSING ‘OUTER ROTOR —If the housing-to-outer rotor radial clearance ‘exceeds the service limit, replace the set of inner and outer rotors and/or the pump housing 18. Inspect both rotors and the pump housing for seor* ing or other damage. Replace parts if necessary. 14, Remove the old oil seals fromthe oil pump. 15. Gently tap in the new oil seals until the special toot bottoms on the pump. NOTE: The oil seals alone can be replaced without removing the oil pump by using the special tool. HANDLE DRIVER (07749 - 0010000 DRIVER ATTACHMENT, 52 x 55 mm 07746 0010400 - Removal/Inspection/Installation (cont'd) 16 1. 18 19. HANOLE DRIVER ‘07749 - 0010000 DRIVER ATTACHMENT, 42x 47 mm (07746 0010300 Reassemble the oil pump, applying liquid thread Jock to the pump housing screws. ‘Check that the oil pump turns freely. Install @ dowel pin and the new O-ring on the pump, NoTE: '¢- Use liquid gasket, Part No. 0Y740 - 99986, © Check that the mating surfaces are clean and dry before applying liquid gasket. © Apply liquid gasket evenly, in a narrow bead cen- tered on the mating surface. # To prevent leakage of oil, apply liquid gasket to the inner threads of the bolt holes. © Do not install the parts if § minutes or more have elapsed since applying liquid gasket. Instead reapply liquid gasket after removing the old residue. © After assembly, wait at least 20 minutes before filling the engine with oil Apply liquid gasket to the oil pump and install it. ‘© Apply grease to the lips of the crankshaft oil seal and the balancer shaft seal. Then, install the oi ump inner rotor onto the crankshaft. When the ump is in place, clean any excess grease off the crankshaft and the balancer shaft, then check that the oil seal lips are not distorted, Apply liquid gasket falong the broken line. 8-10Apply grease tothe sea lip, 8x 1.0mm 12 Nem (1.2 kat, 8.7 tH Apply Tiquie gasket to the bolt threads, onpump: Apply lauid gasket te black mating surface, ‘o-nincs ‘npiyenaine i ple ge As GASKET Replace. 6x1.0mm 12Nim (12 kgtim, 87 Wee) on screen 20. Install the baffle plate (F281 engine only. 21. Install the oil screen, 22, Hold the front balancer shaft with @ screwdriver, then install the timing balancer belt driven pulley. FRONT BALANCER: ‘TWWING BALANCER BELT DRIVEN PULLEY MAINTENANCE HOLE. 291m (3.0 kgf, 22 tH) 23. Before installing the balancer driven gear and the balancer gear case, apply molybdenum disulfide to the thrust surfaces of the balancer gears, ae shown, BALANCER ORIVEN GEAR ‘Apply molvedenum disulfide N Apply molyodenum oieulfige, BALANCER DRIVE GEAR 24. Hold the rear balancer shaft with the special tool, then install the balancer driven gear. REAR BALANCER: REAR BALANCER, BALANCER SHAFT Lock. 071A - Pr20100 MAINTENANCE HOLE. ORIVEN GEAR BALANCER SHAFT Lock PIN O7AG ~PT20100 25Nm (25 kgtm, 12mm SEALING BOLT 18 Wott) 29m 8.0 kgtm, 22 ibe) (cont'd) 8-11Oil Pump -- Removal/Inspection/Installation (cont'd) 25. Install the balancer gear case on the oil pump. 27, Install the oil pan. NOTE: Align the groove on the pullay edge to the NOTE: Clean the oil pan gasket mating surface pointer on the gear case while holding the rear bal- before installing ancer with the special tool, then install the gear case on paN Gasker feet Navid ou pan asta noe Dower piv 8x 1.25 mm 25m (25 kot, ribet y@aLaNcER Dowel Pi Stam case on pés poinen wasn ‘ion he groove to 6x }.0mm aN 14 kgm, roibee) DRAIN BOLT ‘44 Nem (45 kgf, 33 bt) Bo not overtighten 28. Tighten the bolts and nuts as shown below. Torque: 14 Nim (1.4 kgfm, 10 Ibft) Groove 26, Check alignment of pointers atter installing the gear POINTER ON THE PULLEY POINTER ON. ‘THE OIL PUMP NOTE: Tighten the bolts and nuts in three steps land torque them in a crisscross pattern. 8-12Intake Manifold/Exhaust System Intake Manifold Replacement .... Exhaust Manifold Replacement ..... Exhaust Pipe and Muffler Replacement ....Intake Manifold - Replacement NOTE: Use new O-rings and gaskets when reassembling CAUTION: ‘© Check for folds or scratches on the surface of the gasket. ‘© Replace with a new gasket if damaged 84125 mm yet muecrion Snaceonmecoseary Banta kat, AFI CONTROL tPaastenge cn) ienen) 6x10mm (2281 engine only) T2Nm (12 kate, 6x 1.0mm a7 wre) INTAKE MANIFOLD 12Nm (12 kgf, (CHAMBER 87 Wee) Replace ifcracked or if mating surfaces are Boost CHAMBER asker Replace, O-RING Roplace. o-FING INTAKE AiR, Replace. TEMPERATURE WAT) SENSOR 18M (18 kate, aBibee) THROTTLE BODY 8x 1.25 mm 82125 mm 22m 2.2 kgtm, 22m 22 kat, aeibee) reibte BF rast nue HERMo VALVE ox 128 mm onne | a 22 Nim (22 kgm, \ tom, _ Se Sy iene IDLE AIR CONTROL a a parece eerie INTAKE MANIFOLD BRACKET iW mecossary (F2261 engine onty) 9-2Exhaust Manifold -- Replacement NOTE: Use new gaskets and self-locking nuts when reassembling CAUTION: '* Check for folds or scratches on the surface of the gasket. © Replace with a new gasket if damaged. F282 engine: ‘SELF-LOCKING NUT 8x 125 mm GasKeT 31 Nem (3.2 kgf, 23 bt) Replace, Replace. EXHAUST MANIFOLD HEATED OXYGEN ‘SENSOR (HO25) 44 Nn 8.5 kgf, 33 Itt) Be careful not to damsoe. ‘EXHAUST MANIFOLD pacer Sy—aastens 44 Neen (45 kgf, 93 It) woes SP Connector / S \ 101250 cover 81.25 mm 22Nmi22kgtm, 16 bE (conta) 9-3Exhaust Manifold y- Replacement (ont?) AAPA NOTE: Use new gaskets and self-locking nuts when reassembling. CAUTION: © Check for folds or scratches on the surface of the gasket. © Replace with a new gasket if damaged. Except F22B2 engine: GASKET Replace EXHAUST MANIFOLD EXHAUST MANIFOLD ‘SELF-LOCING NUT 8x 1.25 mm 311Nm 2 kote, 2a) Replace 81.25 mm 2ZNm (2.2 kgtim, 16 ft) 10 125 mm 44 Nem (85 kot, 33 EHD 9-4Exhaust Pipe and Muffler -- Replacement NOTE: Use now gaskets and self-locking nuts when reassembling, F22B2 engine: HEAT SHIELD ® MUFFLER EXHAUST PIPE TIP “I, 8 8 l- & _ eo & geal sevr.ocnne nur =D | Loom’ 33 New (3.4 kafm, 25 tt! Replace. 6x 1.0mm ‘9 Rem (0.9 kat, Stel GASKET Replace. 8x 125 mm 231m (23 kote, ‘ibe Replace. Tighten the flange nuts inteps, alternating side-to-side. weerzsnm [ txt2om aunt | Rac | Tighten tne ange nuts _in steps alternating Lid tsi, casket——__, Replace. as n 1 | A arseer wee Bete ate "0 siden BA Econvenren wer seursocandaut nan 2S ust sso Phen Suen, Resaes 125 mm 23.Nem (23 kgf, 17 be) ox tomm Nem (09 kgf, 6b) (cont’a) 9-5Exhaust Pipe and Muffler p Replacement (cont'd) NOTE: Use new gaskets and self-locking nuts when reassembling. F20B3, F285 engines: 6x 1.0mm ‘9am 10.9 Kafe, 6 IFA) HEAT sHiELD MUFFLER EXHAUST PIPE TIPS, Gasket Replace SELF-LOCKING NUT 33 Nem (8.3 kam, 25 tore) Replace. 81.25 mm, 23 Nem (2.3 kgf, 17 Ibe) Replace Tighten the flange nuts insteps, atermating side-o cide EXHAUST PIPE B 101.25 mm 38 Nem (3.9 kfm, Dome) onseets <2 Sep Replace, gaye GASKET Replace. we we EXHAUST y G Sox1.23mm petzemm ow ‘SELF-LOCKING NUT Yaw pig 23 Nem (2.3 kgm, 17 tht fe) fotsens % fepiace 125m Senimenatatn, 26 am samen epace Bain The. 97 Tighten the flange nuts in stops, alternating side-to-side 9-6F22B1 ongine: 6x10mm HEAT SHIELD 9mm (0.9 kgf, MUFFLER ZL EXHAUST PIPE TIPS. HEAT SHIELD 6x 1.0mm SELF-LOCKING NUT 9 Nim (0.9 kgf, 6 Ibe) 33 Nim (8.4 kgf, 25 bf} HEAT SHIELD Replace. Gasket Replace 81.25 mm 23.Nm (2.3 kom, 17 bt) Replace. Tighten the flange nuts in-stops, aternating side to-side HEATED ‘OXYGEN SENSOR (HO2S) 44 Nom (45 kgm, 33 bt) eee HEAT SHIELD 101.25 mm 38 Nem (3.9 kgf. zeit) caskets <= Se Reploce exnaust __> Pea | | GASKETS. Replace. wo “ Replace. SELF-LOCKING NUT 10% 1.25 mm 54m 65 kglm, . SELFLOCKING NUT HEAT SHIELD 8x}.25 mm 25.Nm (23 kgm, 17 EA) anim sree ® fest nine Staim 8x a8m wo he Een ET ktm, 04 Tighton the flange nuts in steps, alternating side to-sie. 9-7Cooling Radiator Illustrated Index .... Replacement ... Engine Coolant Refill and Bleeding 10-2 10-4 10-5 Cap Testing 10-6 Testing 10-6 Thermostat Replacement ... 10-7 Testing ... + 10-7 Water Pump Mlustrated Index 10-8 Inspection . 10-9 Replacement 10-9Radiator Mustrated Index System is under high pressure when engine is hot, To avoid danger of releasing scalding ‘coolant, remove cap only when engine is cool. Total Cooling System Capacity (Including heater and, reservoir) M/T: 6.9. (7.4 US gt. 6.1 Imp atl AIT: 6.8 ( (7.3 US gt, 6.0 Imp at) Reservoir capacity: 0.6¢ (0.6 US qt, 0.5 Imp at) AUTOMATIC TRANSMISSION upper FLUID (ATF) COOLER HOSE RADIATOR HOSE. Refer to section 14 when conpensor FAN SHROUD 6x 1.0mm 9.8.Nm (10 kot, 7 Nem (0.7 kat, sibtt FAN MOTOR RADIATOR FAN SHROUD 10-2 RADIATOR DRAIN PLUG FAN CAUTION: When pouring engine coolant, be sure to shut the relay box lid and not to spill coolant on the ‘electrical parts or the painted portion. If any coolant, spills, rinse it off immediately. NoTE: ‘© Check all cooling system hoses for damage, leaks or deterioration and replace if necessary. ‘© Check all hose clamps and retighton if necessary. ‘© Use new O-rings when reassembling. RADIATOR Engine coolant Refilling and bleeding, page 10:5 Leak test page 10-6 Ingpect soldered joints and seams for leaks Blow out cit fram between core fins with compressed ae WWinsects, ete, are clogging radiator, wash them off with low pressure water RADIATOR CAP. Pressure testing, page 10:6 Replace. sartooou cobtant RESERVOIR SELF.LOCKING NUT A:Aa Nem (0.45 kgtm, 330beR) 8:5.6 Nm (056 kgtm, Sorte) Replace. Lower RADIATOR HOSE ‘A: TOYO RADIATOR manutactured radiator. B: NIPPONDENSO manufactured radiator,Engine Hose Connections: IDLE AIR CONTROL FAST IDLE POSITIVE CRANKCASE (tac) VALVE. ‘THERMO VALVE VENTILATION (PCV) PIPE O-RING Replace. BYPASS HOSE ‘THERMOSTAT HOUSING HEATER INLET 841.25 mm 22.Nm (2.2 kgf, 16 bt) 8x 1.2mm 22Nm (22 kgkm, HEATER VALVE dere) HEATER INLET HOSE 10-3Radiator - Replacement 1. Drain engine coolant. 5. Remove the fan shroud assemblies and other parts from radiator. Remove the upper and lower radiator hoses, and Install the radiator in the reverse order of removat: 2, ATF cooler hoses, 3, Disconnect the fan motor connectors. Nore © Set the upper and lower cushions securely. 4. Remove the radiator upper brackets, then pull up «Fill the radiator with engine coolant and bleed the radiator. the air. 6x 1.0mm 9.8 Nem 1.0 kot, 7.2 1b64) UPPER RADIATOR, RESERVOIR HOSE 6x10mm HOSE UPPER BRACKET Teen (0.7 kgm, AND CUSHION Site RADIATOR pao ATF COOLER HOSE Refer to section 14 when installing cONDENSOR FAN SHROUD RADIATOR FAN SHROUD TM Nt, HN AN th COOLANT RESERVOIR RELAY BRACKET 6x 1.0mm 9.6.Nm (10 kgtm, 72 tot Replace etky CONNECTOR FAN MOTOR ~ CONNECTOR 6x 10mm 9.8.Nm (1.0 kgm, 72IbR) LOWER RADIATOR HOSE 6x 1.0mm 17 Ne (0.7 kgm, 5 Ib) 10-4Engine Coolant Refilling and Bleeding CAUTION: When pouring engine coolant, be sure to shut the relay box lid and not to let coolant spill on the electrical parts or the paint. if any coolant spills, rinse it 1. Set the heater temperature lever or control dial to maximum heat 2, When the radiator is cool, remove the radiator cap. Loosen the drain plug, and drain the coolant. 3, Remove the drain bolt from the rear side of the cylinder block to drain the block. 4. Apply liquid gasket to the drain bolt threads, then reinstall the bolt with a new washer and tighten it securely. 5. Tighten the radiator drain plug securely. 6. Remove, drain and reinstall the reservoir. Fill the tank halfway to the MAX mark with water, then up to the MAX mark with antifreeze. 7. Mix the recommended antifreeze with an equal amount of water in a clean container Noe: ‘© Use only genuine Honda antifreeze/coolant. ‘© For best corrosion protection, the coolant con: centration must be maintained year-round at 50% minimum. Coolant concentrations less than 50% may not provide sufficient protection against corrosion or freezing, '* Coolant concentrations greater than 60 % will impair cooling efficiency and are not recom. mended, cauTion © Do not mix different brands of antifreeze/ coolants. * Do not use additional rust inhibitors or anti-rust products; they may not be compatible with the genuine coolant. Engine Coolant Refill Capacity: including reservoir (0.6 ¢ (0.6 US at, 0.5 Imp qu. M/T: 5.40 (5.7 US qt, 4.8 Imp at AIT:5.30 (5.6 US at, 4.7 Imp qt) ria Loosen the air bleed bolt in the thermostat housing, then fil the radiator to the bottom of the filler neck with the coolant mixture. Tighten the bleed bolt as s00n a8 coolant starts to fun out in a steady stream without bubbles, BLEED BOLT 9.8 Nem (1.0 kgf, 7 IF) Replace DRAIN BOLT £3 Nem (85 kof, 61 It Apply liquid gasket to the bolt threads when installing, 8. 10. With the radiator cap off, start the engine and let it run until warmed up (radiator fan comes on at least twice). Then, if necessary, add more coolant mix to bring the level back up to the bottom of the filler neck. Put the radiator cap on tightly, then run the engine ‘again and check for leaks. 10-5Radiator [- Cap Testing 1. Remove the radiator cap, wat its seal with engine coolant, then instal it on the pressure tester, 2. Apply a pressure of 93 ~ 123 kPa (0.95 ~ 1.25 kof em?, 14~ 18 psi. 3. Check for a drop in pressure 4. Ifthe pressure drops, replace the cap. +1: TOYO RADIATOR "2: NIPPONDENSO manufactured radiator RADIATOR PRESSURE TESTER COMMERCIALLY AVAILABLE RADIATOR cap SMALL ADAPTOR ‘COMMERCIALLY AVAILABLE KE-20-5"" H-901122-09 + wanutactured radiator. - Testing 1, Wait until the engine is cool, then carefully remove the radiator cap and fill the radiator with engine coolant to the top of the filler neck. 2. Attach the pressure tester to the radiator and apply 2 pressure of $3 123 kPa (0.95 ~ 1.25 kaflem®, 14 18 psi. 3. Inspect for engine coolant leaks and a drop in pres: 4. Remove the teater and reinstall the radiator cap. NOTE: Check for engine oil in the coolant andior coolant in engine oll RADIATOR PRESSURE TesTeR ‘COMMERCIALLY AVAILABLE SMALL ADAPTOR COMMERCIALLY AVAILABLE KE-20-5"" H901%22-09 "1: TOYO RADIATOR manufactured radiator. “2: NIPPONDENSO manufactured radiator. 10-6Thermostat we - Replacement NOTE: Use new O-rings when reassembling pin THERMOSTAT 6x10 mm THeRmostar fm (1.2 kg, mouse a swenmoSrat nnn up useén seat ope Sdn tt bgt, sera -- Testing Replace the thermostat if it is open at room tempera. ture, To test a closed thermostat 1. Suspend the thermostat in a container of water as shown, 2, Heat the water and check the temperature with a thermometer. Check the temperature at which the thermostat first opens, and at which itis fully open. THERMOSTAT CAUTION: Do not let the thermometer touch the bottom of hot container. 3. Measure lift height of the thermostat when fully tit aa open. ‘STANDARD THERMOSTAT Lift height: above 8.0 mm (0.31 in.) Starts opening: 76 ~ 80°C (169 ~ 176°F) Fully open: 90°C (194°F) 10-7Water Pump Illustrated Index NOTE: Use new O-rings when reassembling, O-RING Replace. ging Replace 8x 1.25 mm 22Nem 2.2 kgf, 16 IDEA) ENGINE COOLANT TEMPERATURE (ECT) / SENSOR T8Nm (1.8 katm, 13 ee ECT GAUGE ‘SENDING UNIT 9m (09 kgf, ECT swircH A 7th) 27 Nien 2.8 kgtm, bt) O-RING Replace. Ecr switcH a WATER PUMP Inspection, page 109 Replacement, gy 84125 mm page 109 22Nm 22 kgtm, ‘reibHH ‘THERMOSTAT ics Replace. 8x1.25 mm 22Nm@2kgtm, re ibee) CONNECTING PIPE o-rines Replace 6x10 12 Nem (12 kgm, 827 Ibe) 10-81, Remove the timing belt (see page 6-18) 2. Check that the water pump pulley turns counter: clockwise, 3. Check for signs of seal leakage. NOTE: A small amount of “weeping” from the bleed hole is normal. BLEED HOLES BLEED HOLE RUBBER SEAL Apply liquid gasket tothe water pump ‘mating surface, -- Inspection —————________ 1 2 -- Replacement ——___— Remove the timing belt (see page 6-19) Remove the camshaft pulley and the back cover (see page 6-31). Remove the water pump by removing five bolts. NOTE: Inspect, repair and clean the O-ring groove ‘and mating surface with the cylinder block. WaTeR PUMP, ox tomm Y2Niem 11.2 kgm, 87 A Install the water pump in the reverse order of re: moval Note: ‘© Keep the O-ring in position when installing ‘© Ciean the spilled engine coolant. 10-9Fuel and Em Special Tools . Component Location Index System Description Vacuum Connections... Electrical Connections ‘Troubleshooting Troubleshooting Guide Self-diagnostic Procedur How to Read Flowcharts PGM-FI System ‘System Description Troubleshooting Flowcharts Control Module Heated Oxygen Sensor Heated Oxygen Sensor Heater Fuel Supply System ...... Manifold Absolute Pressure ‘Sensor «. i z ‘Top Dead Center/Crankshaft Position! Cylinder Position Sensor Engine Coolant Temperature Sensor ‘Throttle Position Sensor . Intake Air Temperature Sensor Ignition Output Signal ... Vehicle Speed Sensor ... Electrical Load Detector Barometric Pressure Sensor . AIT FI Signal A/B Idle Control System ‘System Troubleshooting Guide ‘System Description Troubleshooting Flowcharts Idle Air Control Valve Starter Switch Signal .. Air Conditioning Signal Alternator FR Signal ‘Automatic Transaxle (A/T) G Position Signal Brake Switch Signal Power Steering Pressure Switch ‘Signal . Fast Idle Thormo Valve Idle Speed Setting 2 V2 13 11-8 44 11416 11-18 11-23 211-24 11-26 11-30 11:34 11-37 11-39 11-42 11-44 11-46 111-48 211-50 11-52 14-54 211-56 11-87 11-88 11-59 11-61 11-63 11-64 11-66 11-68 11-70 14-71 214-72 11.73 Fuel Supply System ee Fuel Lines .. a 11-76 ‘System Description . 11-78 Fuel Pressure 11-78 Fuel Injectors . 211-80 Fue! Injection Air Control System 11-86 Injector Resistor fone 11-89 Fuel Pressure Regulator 11-90 Fuol Filter : 11-92 Fuel Pump. 11-93 PGN-FI Main Relay .. 11-95 Fuel Tank .... 11-98 Intake Air System ‘System Troubleshooting Guide 11-99 ‘System Description pcseenees 11-100 Ali Cleaner .. "14-101 Throttle Cable 11-102 Throttle Body 11-103 Intake Air Resonator Control System ...... 11-106 Intake Manifold ... 11-110 ion Control System ‘System Troubleshooting Guide wat System Descr W112 Tailpipe Emission — w12 ‘Three Way Catalytic Converter 1113 Exhaust Gas Recirculation System wa Posi inkcase Ventilation System =... 11-120 Evaporative Emission Controls W121Special Tools net. | Toot Nunbor | Deseiion enor @ ‘O7LAA—PT5O101 —_| Oxygen Sensor Socket Wrench | 1 ® | O7LAJ—PT30100 | Test Hamess 1 | | or o7tasPra0104 |: @ | O7PAZ—0010100 ‘SCS Short Connector 1 | @1 | orave-oosot00 | Pressure Gauge | a ® ® @ ® 2 np) oO @2 11-2rr Component Locations Index F22B1 engine: ‘MANIFOLD ABSOLUTE SURE (MAP) THROTTLE POSITION (TP) SENSOR SeNgon AP? IDLE AIR CONTROL (WAC) VALVE Troubleshooting, page 11-46 ‘Troubleshooting, Troubleshooting, page 11-61 page 11-39) INTAKE AIR TEMPERATURE (WAT) SENSOR. Troubleshooting, page 11-48 EVAPORATIVE EMISSION (EVAP) PURGE CONTROL SOLENOID VALVE ‘Troubleshooting, page 11-123 ELECTRICAL FUEL INJECTION AIR (FIA) Loap CONTROL SOLENOID VALVE DETECTOR Troubleshooting, page 11-87 (ELD) Troubleshooting, page 11-54 INJECTOR RESISTOR Testing. page 11-88 EXHAUST GAS RECIRCULATION (EGR) ‘VACUUM CONTROL ‘VALVE Troubleshooting, page 1-114 INTAKE AIR RESONATOR (WAR) CONTROL SOLENOID VALVE. Troubleshooting. page 11-107 ‘TOP DEAD CENTER/CRANKSHAFT POSITION/CYLINDER POSITION (TDC/CKP/CYP) SENSOR Troubleshooting, page 11-42 EXHAUST GAS RECIRCULATION (EGR) CONTROL SOLENOID VALVE Troubleshooting, page 11-118 IGNITION CONTROL MODULE (ICM) Troubleshooting, page 11-50 POWER STEERING PRESSURE (PSP) SWITCH Troubleshooting, page 11-71 ENGINE COOLANT TEMPERATURE (ECT) SENSOR Troubleshooting, page 11-44 HEATED OXYGEN SENSOR (H025) Troubleshooting, page 11-30 EXHAUST GAS RECIRCULATION (EGR) VALVE ‘and LIFT SENSOR Troubleshooting, page 11-114 11-3Component Locations Index F22B2, F22B5 engine: MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR Troubleshooting, page 11-29 EVAPORATIVE EMISSION (EVAP) PURGE CONTROL ‘SOLENOID VALVE [F22B5 engine} ‘Troubleshooting, page 11-125 EVAPORATIVE EMISSION (EVAP) PURGE CONTROL SOLENOID VALVE [F2282 enginel ‘Troubleshooting, page 11-123 IDLE AIR CONTROL (IAC) VALVE Troubleshooting, page 11-81 EXHAUST GAS RECIRCULATION (EGR) VALVE and LIFT SENSOR, Troubleshooting, page 11-114 INTAKE AIR TEMPERATURE (AT) SENSOR Troubleshooting, page 11-48 ELECTRICAL LOAD DETECTOR (e.0) [F262 engine) Troubleshooting, page 11-54. INJECTOR RESISTOR ‘Troubleshooting, page 11-89 ‘THROTTLE POSITION (TP) SENSOR ‘Troubleshooting, page 1 INTAKE AIR RESONATOR (IAR) CONTROL SOLENOID VALVE 1F22B5 engine) Troubleshooting, page 11-107 ‘TOP DEAD CENTERICRANKSHAFT POSITION/CYLINDER POSITION {TOCICKP/CYP) SENSOR ‘Troubleshooting, page 11-42 EXHAUST GAS RECIRCULATION (EGR) CONTROL SOLENOID VALVE Troubleshooting, page 11-114 POWER STEERING PRESSURE (esp) switcH Troubleshooting, page 11-71 IGNITION CONTROL MODULE (ICM) ‘Troubleshooting, page 11-50, ENGINE COOLANT TEMPERATURE (ECT) SENSOR ‘Troubleshooting, page 11-44 HEATED OXYGEN SENSOR (HO25) [F286 engine} Troubleshooting, page 11-31 HEATED OXYGEN SENSOR (HO2S) [F2282 engine} ‘Troubleshooting, page 11-30 11-4Ea F20B3 engine: THROTTLE POSITION (TP) SENSOR ‘Troubleshooting, page 11-46 EVAPORATIVE EMISSION (EVAP) PURGE CONTROL SOLENOID VALVE ‘Troubleshooting, page 11-125 TOP DEAD CENTER CRANKSHAFT POSITION’ GYLINDER POSITION (TOCICKPICYP) SENSOR Troubleshooting, page 11-42 IGNITION CONTROL MODULE (ICM) Troubleshooting, pege 11-50 ENGINE COOLANT TEMPERATURE (ECT) SENSOR Troubleshooting, page 11-44 EXHAUST GAS RECIRCULATION (EGR) VALVE and UFT SENSOR Troubleshooting, page 11-114 MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR Troubleshooting, page 11-39 IDLE AIR CONTROL (1AC) VALVE ‘Troubleshooting, page 11-61 INTAKE AIR TEMPERATURE (WAT) SENSOR ‘Troubleshooting, page 11-48 INJECTOR RESISTOR {rovbieshooting, page 11-89 \ \ exaust cas RECIRCULATION (EGR) VACUUM CONTROL \ Ac vatve \ Froubleshooting, page Viste EXHAUST GAS RECIRCULATION (EGR) CONTROL SOLENOID VALVE ‘Troubleshooting, page 11-114 POWER STEERING PRESSURE (PsP) swirch Troubleshooting, page 11-71 HEATED OXYGEN SENSOR (HO2S) Troubleshooting, page 11-31 11-5Component Locations Index LHD: ‘SERVICE CHECK CONNECTOR (2°) Sel-diagnostic Procedures, page 11-18 PoM-F ENGINE CONTROL MODULE (ECM) Sell-ciagnostic Procedures, page 11-18 ‘MAIN RELAY Troubleshooting, page 11-26 Relay Testing, page 11-95, Troubleshooting, page 11-96 SERVICE CHECK CONNECTOR (2°) Self-diagnostic Procedures, page 11-18 ENGINE CONTROL MODULE (ECM) Pon Sell-dlagnostic Procedures, page 11-18 MAIN RELAY Troubleshooting, page 11-26 Relay Testing, page 11-95 Troubleshooting, page 11:96A. FUEL TANK EVAPORATIVE FUEL GAUGE SENDING UNIT cele Sy EMISSION (EVAP) VALVE FUEL VAPOR PIPE EVAPORATIVE EMISSION (EVAP) TWO WAY VALVE FueL ur Testing, page 11-127 PRESSURE REGULATOR ‘Testing, page 11-90 Replacement, page 11-91 FUEL RETURN PIPE FUEL FILL CAP EVAPORATIVE EMISSION {EVAP) CONTROL CANISTER Troubleshooting, pages 11-123, 128 FUEL PUMP Testing, page 11-84 Replacement, page 11-94 FUEL TANK Replacoment, page 11-98, FUEL FEED PIPE Fuet muecrons FUEL RAIL FueL FILTER ‘Troubleshooting, page 11-4 Pviee itt eatin Replacement, page 11-92 Replacement, page 11-84 THROTTLE CABLE THROTTLE BODY (TB) Inspection/Adjustment, page 11-102 Inspection, page 11-103 Installation, page 11-102 Disassembly, page 11-104 ‘AIR CLEANER (ACL) Replacement, page 11-101 POSITIVE CRANKCASE FAST IDLE THERMO VALVE VENTILATION (PCV) VALVE Inspection, page 11-72 Inspection, page 11-120 RESONATOR 11-7System Description Vacuum Connections F2281 engine EVAPORATIVE EMISSION (EVAP) PURGE CONTROL SOLENOID. VALVE To EVAPORATIVE EMISSION (EVAP) TWO WAY VALVE EVAPORATIVE EMISSION (EVAP) CONTROL CANISTER To CRUISE CONTROL INTAKE AIR RESONATOR (WAR) CONTROL CHECK VALVE MANIFOLD ABSOLUTE PRESSURE (map) SENSOR EXHAUST GAS RECIRCULATION (EGR) VALVE LIFT SENSOR. FUEL PRESSURE REGULATOR EXHAUST GAS RECIRCULATION, (EGR) VALVE To ENGINE MOUNT CONTROL ‘SOLENOID VALVE am INTAKE AIR RESONATOR WAR) CONTROL SOLENOID. VALVE INTAKE AIR RESONATOR FUEL INJECTION AIR (FIA) WAR) CONTROL VACUUM CONTROL SOLENOID VALVE INTAKE AIR RESONATOR: AR) _ FRONT OF VEHICLE EXHAUST GAS RECIRCULATION (EGR) VACUUM CONTROL VALVE EXHAUST GAS RECIRCULATION (EGR) CONTROL SOLENOID VALVE 11-8(@ HEATED OXYGEN SENSOR (HO2S) @ MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR. G) ENGINE COOLANT TEMPERATURE (ECT) SENSOR @ INTAKE AIR TEMPERATURE (IAT) SENSOR @ IDLE AIR CONTROL (IAC) VALVE @ FAST IDLE THERMO VALVE © FUEL INJECTOR @ FUEL FILTER (© FUEL PRESSURE REGULATOR (@ FUEL PUMP (FP) © FUEL TANK @ FUEL TANK EVAPORATIVE EMISSION (EVAP) VALVE {© FUEL INJECTION AIR (FIA) CONTROL SOLENOID VALVE (@ AIR CLEANER, RESONATOR @ INTAKE AIR RESONATOR (IAR) CONTROL CHECK VALVE (@ INTAKE AIR RESONATOR (IAR) CONTROL VACUUM TANK @ INTAKE AIR RESONATOR (IAR) CONTROL SOLENOID VALVE @ INTAKE AIR RESONATOR (IAR) CONTROL DIAPHRAGM VALVE @® THREE WAY CATALYTIC CONVERTER (WC) @) EXHAUST GAS RECIRCULATION (EGR) VALVE @ EXHAUST GAS RECIRCULATION (EGR) VALVE LIFT SENSOR @ EXHAUST GAS RECIRCULATION (EGR) VACUUM CONTROL VALVE. © EXHAUST GAS RECIRCULATION (EGR) CONTROL SOLENOID VALVE ® POSITIVE CRANKCASE VENTILATION (PCV) VALVE. GD EVAPORATIVE EMISSION (EVAP) CONTROL CANISTER. @ EVAPORATIVE EMISSION (EVAP) PURGE CONTROL ‘SOLENOID VALVE @ EVAPORATIVE EMISSION (EVAP) TWO WAY VALVE @ ENGINE MOUNT CONTROL SOLENOID VALVE (cont’a 11-9System Description Vacuum Connections (cont'd) F222, F22B5 engine: EVAPORATIVE EMISSION (EVAP) PURGE CONTROL DIAPHRAGM VALVE. TF22B5 engine) ‘To EVAPORATIVE praronearie] EMISSION {EVAP) EMISSION (EVAP) EVAPORATIVE TWO WAY VALVE TSS ON EMISSION [EVAP) Sere ene ane! Gras (F285 engine) EVAPORATIVE 12285 engined EMISSION (EVAP) en PURGE CONTROL EVAPORATIVE SOLENOID VALVE EMISSION (EVAP) 1F2282 engine] CONTROL, CANISTER MANIFOLD ABSOLUTE PRESSURE [2262 engine) INTAKE AIR RESONATOR. (WAR) CONTROL CHECK VALVE (MAP) SENSOR EXHAUST GAS RECIRCULATION (EGR) VALVE LIFT SENSOR. To ENGINE MOUNT CONTROL SOLENOID VALVE IKE (A/T) modell aA To ENGINE MOUNT CONTROL SOLENOID VALVE IKG. KH ‘model (A/T) modell INTAKE AIR RESONATOR WAR} CONTROL SQLENOID VALVE [F22B5 engine} ‘To CRUISE CONTROL INTAKE AIR RESONATOR IKE modell (WAR) CONTROL VACUUM INTAKE {AIR RESONATOR (IAR) 1F2285 engine) EXHAUST GAS RECIRCULATION (EGR) VALVE FRONT OF VEHICLE EXHAUST GAS RECIRCULATION (EGR) VACUUM CONTROL VALVE EXHAUST GAS RECIRCULATION (EGR) CONTROL SOLENOID VALVE 11-10{F286 engine! 2282 @ HEATED OXYGEN SENSOR (HO2S) @ MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR ENGINE COOLANT TEMPERATURE (ECT) SENSOR @ INTAKE AIR TEMPERATURE (IAT) SENSOR, @ IDLE AIR CONTROL (IAC) VALVE @ FAST IDLE THERMO VALVE @ FUEL INJECTOR @ FUEL FILTER @ FUEL PRESSURE REGULATOR @ FUEL PUMP (FP) © FUEL TANK (@ FUEL TANK EVAPORATIVE EMISSION (EVAP) VALVE GO AIR CLEANER (@ RESONATOR @ INTAKE AIR RESONATOR (JAR) CONTROL CHECK VALVE @ INTAKE AIR RESONATOR (WAR) CONTROL VACUUM TANK @ INTAKE AIR RESONATOR (IAR) CONTROL SOLENOID VALVE @ INTAKE AIR RESONATOR (1AR} CONTROL DIAPHRAGM VALVE (F2285 engines @ THREE WAY CATALYTIC CONVERTER (TWC} @ EXHAUST GAS RECIRCULATION (EGR) VALVE 4) EXHAUST GAS RECIRCULATION (EGR) VALVE LIFT ‘SENSOR @® EXHAUST GAS RECIRCULATION (EGR) VACUUM CON- ‘TROL VALVE @ EXHAUST GAS RECIRCULATION (EGR) CONTROL SOLENOID VALVE POSITIVE CRANKCASE VENTILATION (PCV) VALVE © EVAPORATIVE EMISSION (EVAP) CONTROL CANISTER @® EVAPORATIVE EMISSION (EVAP) PURGE CONTROL DIAPHRAGM VALVE ® EVAPORATIVE EMISSION (EVAP) PURGE CONTROL SOLENOID VALVE ® EVAPORATIVE EMISSION (EVAP) TWO WAY VALVE ENGINE MOUNT CONTROL SOLENOID VALVE (cont'd) 11-11System Description Vacuum Connections (cont’d) F2083 engine: To EVAPORATIVE EVAPORATIVE EMISSION (EVAP) EMISSION (EVAP) TWO WAY VALVE EVAPORATIVE PURGE CONTROL EMISSION (EVAP) DIAPHRAGM VALVE PURGE CONTROL SOLENOID VALVE EVAPORATIVE 1, ENIISSION (EVAP) a CONTROL ——1S CANISTER T MANIFOLD ABSOLUTE PRESSURE (Map) SENSOR FUEL PRESSURE REGULATOR. tro ENGINE MOUNT CONTROL iSOLeNo} vate {ike (An) med 1 Bm« : EVAP PURGE CONTROL SOLENOID VALVE EVAP PURGE CONTROL SOLENOID VALVE AR CONTROL SOLENOID VALVE FIA CONTROL SOLENOID VALVE EGR CONTROL SOLENOID VALVE ENGINE MOUNT CONTROL SOLENOID VALVE ECM-B sono \ fo| 12a) 20,22) 11-15Troubleshooting Troubleshooting Guide NOTE: Across each row inthe cher, the systems that could be sources ofa symptom are ranked in the order they should be inspected starting with @. Find the symptom in the left column, read across to the mast likely source, then refer to the page listed at the top of that column. If inspection shows the system is OK, try the next most likely system @, ete. pace | system | Power Tor DEAD CENTEW | Exon excne | weareo | MANEOLD |"°CRanKsiarT | cooLanT | TaRorne | INTAXEAR leanoucrac| soni convo: | Gevgen | ABSOLUTE ‘TEMPERA. BAROMETRIC) IGNITION rosmon’™ | fewens | Pos essune | Qutrut freseune Tune Srovuce | Senson | PRE Grunoen | “une” | ‘Sexson | URE | "Sensor | Sigua le [88808 | posmonsenson | SENSOR 2 s sverom nas | 325 [ae v2 wae [sae | nas [ats | rre0 ‘tata tome on PSP Switch Signal EGR Control Solenoid Valve EGR Valve Lift Sensor Engine Mount Control Solenoid VTEC Prossure Switeh*? Valve (AT 1) £2281, F2282 engine 12: £2281 engine *3: F22B1, F22B5 engine PGM-FI System ‘The PGIM-FI system on this model is a sequential multiport fuel injection system. Fuel Injector Timing and Duration ‘The ECM contains memories for the basic discharge durations at various engine speeds and manifold pressures. The basic discharge duration, after being read out from the memory, is further modified by signals sent from various sensors to obtain the final discharge duration. Idle Air Control Idle Air Control Valve {IAC Valve} When the engine is cold, the A/C compressor is on, the transmission is in gear (A/T only), the brake pedal is depressed, ‘the P/S load is high, or the alternator is charging, the ECM controls current to the IAC Valve to maintain the correct idle speed. Ignition Timing Control ‘The ECM contains memories for basic ignition timing at various engine speeds and manifold pressures. Ignition timing is also adjusted for engine coolant temperature. Other Control Functions 1. Starting Control When the engine is started, the ECM provides a rich mixture by increasing fuel injector duration. 2. Fuel Pump Control © When the ignition switch is initially turned on, the ECM supplies ground to the PGM-Fl main relay that supplies current to the fuel pump for two seconds to pressurize the fuel system ‘© When the engine is running, the ECM supplies ground to the PGMLF main relay that supplies current to the fuel pump, © When the engine is not running and the ignition is on, the ECM cuts ground to the PGM-Fl main relay which cuts, ‘current to the fuel pump. 11-24Fuol Cut-off Control © During deceleration with the throttle valve closed, current to the fuel injectors is cut off to improve fuel economy ‘at speeds over 1,100 rpm (min~") [F2281, F282 engine], 1,200 rpm (min-) [F22B5, F20B3 engine]. ‘© Fuel cut-off action also takes place when engine speed exceeds, 6,500 rpm {min-") [F22B1 enginel, 6,600 rpm (min~") [Except F22B1 engine], regardless of the position of the throttle valve, to protect the engine from over- revving, 4. AIC Compressor Clutch Relay When the ECM receives a demand for cooling from the air conditioning system, it delays the compressor from being energized, and enriches the mixture to assure smooth transition to the A/C mode. 5. Evaporative Emission (EVAP) Purge Control Solenoid Valve When the engine coolant temperature is below 167°F (75°C), the ECM supplies a ground to the EVAP purge control solenoid valve which cuts vacuum to the EVAP purge control canister. 6. Intake Air Resonator (JAR) Control Solenoid Valve*? When the engine speed is below 2,900 rpm (min~') [F22B5 engine: 3,000 rpm (min-")], JAR control solenoid valve is deactivated by the ECM, and intake air does not flow from the IAR. At engine speeds between 2,900 rpm (min-") and 3,700 rpm (min-") {F22B5 engine: 3,000 rpm (min=) and 3,800 rpm (min~")} (mid-range), the solenoid valve is activated by a signal from the ECM, and intake air flows from the IAR. 7. Fuel Injection Air (FIA) Control Solenoid Valve*? When the engine speed is between 1,300 rpm (min-1) and 4,500 rpm (min~"), the ECM supplies ground to the FIA control solenoid valve, sending intake air to the fuel injectors. 8. Exhaust Gas Recirculation (EGR) Control Solenoid Valve When the EGR is required for control of oxides of nitrogen (NOx! emissions, the ECM supplies ground to the EGR control solenoid valve which supplies regulated vacuum to EGR valve, 9. Alternator Cantrol*! The system controls the voltage generated at the alternator in accordance with the electrical load and drive mode, which reduces the engine load to improve the fuel economy. ECM fail-safe/back-up Functions 1. Fall-safe Function When an abnormality occurs in a signal from a sensor, the ECM ignores that signal and assumes a pre-programmed value for that sensor that allows the engine to continue to run. 2. Back-up Function When an abnormality occurs in the ECM itself, the fuel injectors are controlled by a back-up circuit independent of the system in order to permit minimal driving, 3. Self-diagnosis Function [Malfunction Indicator Lamp (MILI] When an abnotmality occurs in a signal from a sensor, the ECM supplies ground for the MIL and stores the code in erasable memory. When the ignition is initially turned on, the ECM supplies ground for the MIL for two seconds to check the MIL bulb condition. 4, Two Trip Detection Method To prevent false indications, the Two Trip Detection Method is used for the HO2S, fuel metering-related and EGR self-diagnostic functions. When an abnormality occurs, the ECM stores it in its memory. When the same abnormality recurs after the ignition switch is turned OFF and ON again, the ECM informs the driver by lighting the MIL. However, to ease troubleshooting, this function is cancelled when you short the service check connector. The Ml. will then blink immediately when an abnormality occurs. 11-25