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com

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Generallnformation
1-2
Chassis
andPaintCodes.......................
1-10
NumberLocations.........
ldentification
Warning/Caution
LabelLocations.......1-11
Under-hoodEmissionsControl
. . . . . . . . . . . . . .1
. .-.1. .5. .
L a b e l. . . . . . . . . .
Lift and SupportPoints
1-19
LiftandSafetyStands.......................
FloorJack
.......................
1-20
.........1-21
Towing
ServicePrecautions
1-22
PaftsMarkingLocations..,.................
for Real-time4WD
Precautions
(Four-wheel
Drivel.........
.................
1-23

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Chassisand PaintCodes
U.S. 1997Model
VehicleldentificationNumber
JHLRD184*VC000001

JHL: HONDAMOTORCO.,LTD
HONDA,Multipurpose
Passenger
Vehicle(MPV)
line, Body and Engine Type
RDl: CR V/82084
Body Type and TransmissionType
8: 5-door/4-soeed
Automatic
Vehicle Grade (Series)
4: LX
5: LX (with ABS)
CheckDigit
Model Year
Vt 1997
C: SaitamaFactoryin Japan(Sayama)

B-84P
NH-552M
NH-592P
R-94

Vehicleldentification Number
and FederalMotor Vehicle

SupermarineBlue Pearl
CypressGreenPearl
SebringSilverMetallic
FlamencoBlackPearl
San MarinoRed

(o

COLORLABEL

INT.COLOR

WPEF

EXT.COLOR

B-84P

KA S2BA1 C

to
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1-2

U.S.1998Model

JHLRD174*WC000001

B20B4t2.01 DOHCSequentialMultiport
Fuel-injected
engine

JHL: HONDAMOTORCO.,LTD
HONDA.Multipurpose
Passenger
Vehicle(MPV)
Line, Body and EngineType
RD1:CR-V/82084
RD2:CR'V/82084
Body Type and TransmissionType
7: 5-door/s-soeed
Manual
8; 5-door/4-soeed
Automatic

MDLA: 4-speedAutomatic
M4TA: 4-speedAutomatic
S B X M : s - s p e eM
danual
MDLA,SBXM:1000001M4TA: 3000001C: SaitamaFactoryin Japan(Sayama)

B-84P
G-82P
NH-552M
NH-592P
R-94

VehicleldentificationNumber
and CanadianMotor Vehicle

SupermarineBlue Pearl
CypressGreen Pearl
SebringSilverMetallic
FlamencoBlackPearl
San MarinoRed

COLORLABEL

INT.COLOR

TYPEF

EXT.
COLOR

8.84P

KA S2BA1 C

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1-3

Chassisand PaintCodes
U.S. 1999Model
Vehicle ldentification Number
JHLRDIT4*XC000001

B2OZ2:2.0
| DOHCSequentialMultiport
Fuel-injected
engine

JHL: HONDAMOTORCO.,LTD
HONDA.Multipurpose

RDlt CR-vlB20Z2
RD2t CR-V1B2OZ2
Body Type and TransmissionType
7: 5-door/5-speed
Manual
8: 5-door/4-spsed
Automatic
MDLA: 4-speedAutomatic
MDMA:4-speedAutomatic
SBXM: s-speedManual

4: LX

6:Ex
Chock Digit
Model Year
X: 1999

MDLA:2000001MDMA:1000001SBXM:2000001-

C: SaitamaFactoryin Japan(Sayama)

B-84P
B-92P
G.95P
NH-578
NH-552M
R,81

Vehicle ldentification Number


and CanadianMotor Vehicle

SupermarineBlue Pearl
NighthawkBlackPearl
CloverGreenPearl
TaffetaWhite
SebringSilverMetallic
MilanoRed

COLORLABEL

INT.COLOR

TYPEF

EXT.
COLOR

B.84P

KA S2BA1 C

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1-4

Model
U.S.2000

J H L R D 1 7 4 *Y C 0 0 0 0 0 1

B20Z2t2.0I DOHCSeouentialMultiDort
Fuel-injected
engine

JHL: HONDAMOTORCO.,LTD
HONDA,Multipurpose
Vehicle(MPV)
Passenger
Line. Body and EngineType
RDlt CR-V/82022
RD2iCR-v/BzOz2
Body Type and TransmissionType
Manual
7: 5-door/s-speed
8: 5 door/4-soeed
Automatic

MDLA; 4-speedAutomatic
MDMA:4-speedAutomatic
SBXM: s-speedManual

MDLA:3000001MDHA:2000001SBXM:2000001CrSaitamaFactoryin Japan(Sayama)

B-92P
B-95P
G-95P
NH-578
NH-552M
R-81

NighthawkBlackPearl
ElectronBluePearl
CloverGreenPearl
Taffeta White
SebringSilverMetallic
M i l a n oR e d

COLORLABEL

Safety Standard Certification.


lrl ..V

INT.COLOR

TYPEF

EXT,
COLOR

8.92P

KA S2BA1 C

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1-5

Chassisand PaintCodes
Canada1997Model

J H L R D 1 8 5 *V C 8 0 0 0 0 1

B20g4t2.0| DOHCSeouentialMultiDort
Fuel-injected
engine

HONDAMOTORCO.,LTD
HONDA,Multipurpose
Passenger
Vehicle(MPV)
Line, Body and EngineType
RDl: CR-V/B2084
Body Typ and TransmissionTyp
8: s-door/4-soeedAutomatic

MDMA- 1000001

MDMA:4-speedAutomatic
SDMA: 4-speedAutomatic
C: SaitamaFactoryin Japan(Sayama)

B-84P
G-82P
NH-552M
NH-592P
R-94

Vehicle ldentification Number


and Canadian Motor Vehicle
Safety Standard Certification.

SupermarineBluePearl
CypressGreen Pearl
SebringSilverMetallic
FlamencoBlackPearl
San MarinoRed

COLORLABEL

INT.COLOR

TYPEF

EXT.COLOR

B-84P

KCS2BC2 C

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1-6

Canada1998Model

J H LR D 17 4 * W C 8 0 0 0 0 1

JHL:HONDAMOTORCO.,LTD
HONDA,Multipurpose
Vehicle(MPV)
Passenger
Lino, Body and EngineType
RD1:CR-V/82084
Body Type and TransmissionType
Manual
7: 5-door/s-speed
Automatic
8: 5-door/4-speed

8208 4:2.0| DOHCSequentialMultiport


engine
Fuel-injected

M4TA: 4-speedAutomatic
SBXM:5-speedManual
SBXM:1000001M4TA: 3000001*
C: SaitamaFactoryin Japan(Sayama)

B-84P
G-82P
NH-552M
NH-592P
R-94

SupermarineBIuePearl
CypressGreen Pearl
SebringSilverMetallic
FlamencoBlackPearl
San MarinoRed

COLORLABEL

INT.COLOR

TYPEF

EXT.COLOR

8.84P

KCS2BC2 C

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1-7

Chassisand PaintCodes
Canada1999Model
Vehicle ldentification Number
J H LR D l T 4 * X C 8 0 0 0 0 1

B20Z2i2.0I DOHCSequentialMultiport
Fuel-injected
engine

JHL:HONDAMOTORCO.,LTD
HONDA,Multipurpose
Passen0er
Vehicle{MPV)
Line, Body and Engin6Type
RD1:CB-Y/B2OZ2
Eody Typ6 and Transmi$ion Type
7: 5-door/5-speed
Manual
8: s-door/4-speedAutomatic
4: LX
5: EX
ChockDigit
Model Yeal
X: 1999

MDMA:4-speedAutomatic
SBXM: s-speedManual

C: SaitamaFactoryin Japan{Sayama)

B-84P
a-92P
G.95P
NH.552M
R-81

VehicloldentificationNumber
and CanadianMotor Vehicle
Safety Standard Certification.

SupermarineBluePearl
NighthawkBlackPearl
CloverGreenPearl
SebringSilverMetallic
MilanoRed

COLORLABEL

INT.COLOR

TYPEF

EXT.
COLOR

B-84P

KCS2BC2 C

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1-8

J H LR D l7 4 * Y C8 0 0 0 0 1
Manulacturer, Make and
Type of Vehicle
JHL:HONDAMOTORCO.,LTD
HONDA,Multipurpose
Passenger
Vehicle(MPV)
Line, Body and EngineType
RDlt CR-VlB2oZ2
Body Type and TransmissionType
Manual
7: 5-door/s-soeed
Automatic
8: 5-door/4-sDeed
Vehicle Grade (Seriesl
4: LX
5: EX

8 2022:2.0| DOHCSequentialMultiport
engine
Fuel-injected

MDMA:4-speedAutomatic
SBXM: s-speedManual

Check Digit
Model Year
Yr 2000
FactoryCode
C: SaitamaFactoryin Japan(Sayama)
Serial Number
B-96P
B-92P
G-95P
NH-552M
R-81
YR-524M

Vohicle ldentification Number


and Canadian Motor Vohicle

EternalBlue Pearl
NighthawkBlackPearl
CloverGreenPearl
SebringSilverMetallic
MilanoRed
NaplesGold lVetallic

OOLORLABEL

tNrcoL0R

TYPEF

COLOR
EXT.

B-92P

KCS2BC2 C

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1-9

ldentificationNumberLocations

Vehiclldentific.tion Number tvtNl

VehicleldentificationNumber lVlNl

TransmissionNumb6r lManudl)

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1-10

TransmissionNumbor {Aulomaticl

EngineNumbel

Warning/CautionLabelLocations

A: CABLEREELCAUTION

OF THE SRSCABLEREELIS CRITICAL


TNSTALLATION
TO THE PBOPEROPERATIONOF THE SRS SYSTEM.
REFERTO THE SERVICEMANUAL FOR DETAILED
INSTALLATIONINSTRUCTIONS.
B: DRIVERMODULEDANGER
A DANGER
EXPLOSIVE/FLAMMABLE
CONTACTWITH ACID, WATEROR HEAVY METALS
S U C H A S C O P P E R ,L E A D O R M E R C U R YM A Y
PRODUCEHARMFULAND IRRITATINGGASESOR
EXPLOSIVECOMPOUNDS.STOMGE TEMPERATURES
M U S T N O T E X C E E D2 O O " F{ 1 O O ' C }F. O R P R O P E R
HANDUNG,STORAGE,AND DISPOSALPROCEDURES.
REFERTO SERVICEMANUAI- SRSSUPPI.EMENT,
POTSON
C O N T A I N S P O I S O N O U SS O D I U M A Z I D E A N D
POTASSIUMNITRATE.
FIRSTAID
tF CONTENTS ARE SWALLOWED, INDUCE
VOMITING.FOR EYE CONTACT,FLUSH EYESWITH
WATERFOR 15 MINUTES.IF GASES IFROMACID
OR WATER CONTACTIARE INHALED,SEEK FRESH
A I R . I N E V E R YC A S E , G E T P R O M P T M E D I C A L
ATTENTION.
KEEPOUT OF REACHOF CHILDREN

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C: DRIVERMODULEWARNING
A WARNING
T H E A I R E A GI N F L A T O RI S E X P L O S I V EA N D , I F
ACCIDENTALLYDEPLOYED,CAN SERIOUSLYHURT
OR KILLYOU.
TEST EOUIPMENTOR
. DO NOT USE ELECTRICAL
PROBINGDEVICES.
THEYCAN CAUSEACCIDENTALDEPLOYMENT.
. N O S E R V T C E A B LP
EA R T S l N S l D E . D O N O T
DISASSEMBLE.
. PLACEAIRBAGUPRIGHTWHEN REMOVED
. F O L L O WS E R V I C EM A N U A L I N S T R U C T I O N S
CAREFULLY.

(cont'd)

1-11

Warning/CautionLabelLocations
(cont'dl

(U.S.A.modelonlyl
{U.S.A.modolonlyl

o: SRSWARNING{HOOD}
SUPPLEMENTAL
RESTRAINT
SYSTEM{SRSI
THIS VEHICLEIS EOUIPPEDWITH DRIVERAND FRONT
SEATPASSENGER
AIRBAGS,
ALL SRS ELECTRICAL
WIRINGAND CONNECTORS
ARE
COLOREDYELLOW.
T A M P E R I N G W I T H , D I S C O N N E C T I N GO R U S I N G
ELECTRICAL
TEST EOUIPMENTON THE SRS WIRINGCAN
MAKETHESYSTEMINOPERATIVE
OR CAUSEACCIDENTAL
FIRINGOF THEINFLATOR.
A WARNING
T H E A I R B A G I N F L A T O R I S E X P L O S I V EA N D . I F
ACCIDENTALLYDEPLOYED,CAN SEBIOUSLYHURT YOU.
FOLLOWSERVICEMANUAL INSTRUCTIONS
CAREFULLY.

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1-12

E: STEERINGCOLUMNNOTTCE
tHOODI
NOTICE
TO PREVENTSRS DAMAGE, REMOVESTEERINGWHEEL
BEFOREREMOVINGSTEERING
SHAFTCONNECTING
BOLT.
F: MONITORNOTICE
NOTICE
. NO SERVICEABLE
PARTStNStoE.
. REFER TO SERVICEMANUAL FoR DETAILED

rNsrRucTtoNs.

AIRBAGMODULEDANGEN
G: FRONTSEATPASSENGER
A DANGER
EXPLOSIVE/FLAMMABLE
CONTACTWITH ACID,WATER.OR I{EAVY METALSSUCH
HARMFUL
T.EAD.
OR MERCURYMAY PRODUCE
AS COPPER.
AND IRRITATINGGASESOR EXPLOSIVECOMPOUNDS.
MUST NOT EXCEED2OO"F
STORAGETEMPERATURES
I l O O ' C ) . F O R P R O P E RH A N D L I N G ,S T O R A G E ,A N D
REFERTO THESERVICEMANUAL,
DISPOSALPROCEDURES
SRSSUPPLEMENT.
POTSON
SODIUM AZIDEANO POTASSIUM
CONTAINSPOTSONOUS
NITRATE.
FIRSTAID
IF CONTENTSARE SWALLOWED,INDUCEVOMITING.FOR
E Y E C O N T A C T ,F L U S H E Y E S W I T H W A T E R F O R 1 5
MINUTES. IF GASES (FROM ACID OR WATEN CONTACT)
ARE INHALEO.SEEKFRESHAIR. IN EVERYCASE,GET
PROMPTMEDICALATTENTION.
KEEPOUTOF REACHOFCHILDREN.
A WARNING
T H E A I R B A G I N F L A T O R I S E X P L O S I V EA N D , I F
CAN SERIOUSLYHURT OR
DEPLOYED,
ACCIDENTALLY
KILLYOU.
L E S T E O U I P M E N TO R
. D O N O T U S E E L E C T R I C AT
PROBINGDEVICES,
DEPLOYMENT.
THEYCAN CAUSEACCIDENTAL
. NO SERVICEABI-E
PARTSlNSlDE.DO NOT DISASSEMBII.
. PLACEAIRBAGUPRIGHTWHENREMOVEO.
. FOLLOWSERVICMANUAL INSTRUCTIONSCAREFULLY
INFORMATIONlU S.A. modell
H: PASSENGER
{U.S.A.'97model}
AIEBAGSEEOTHERSIDE,

lU.S.A.'98- 00 models)
WARNING
DEATHOR SERIOUSINJURYCAN OCCUR'
. CHILDREN12 ANO UNDERCAN BE KILLEDBY THE
AIRBAG.
. THE BACKSEATlS THESAFESTPLACEFORCHILDREN.
C H I L DS E A T l N T H E
. N E V E RP U T A R E A R - F A C I N G
FRONT.
o SIT AS FARBACKAS POSSIBLEFROMTHEAIRBAG
. ALWAYSUSESEATBELTSAND CHll-DRESTRAINTS.
TEN YEAnS AFTERlT lS
. THE SRSMUST BE TNSPECTED
INSTALLED.
. T H E O A T EO F I N S T A L L A T I O Nl S S H O W N O N T H E
DRIVER'SDOORJAMB.
AIRBAGWARNING
J: FRONTPASSENGER
lU.S.A.'98- 00 models)
WARNING
C H I L D R E NC A N B E K I L L E D O R I N J U R E D 8 Y T H E
AIRBAG.
PASSENGER
THE BACKSEAT IS THE SAFESTPLACEFORCI{ILDREN12
AND UNDER.
MAKE SURE ALL CHILDRENUSE SEAT BELTSOR CHILD
SEATS.
WARNING
K: FRONTSEATBELTTENSIONER
WABNING
EXPLOSIVEMATERIALINSIDE
HURTOR BURNED,
YOU CAN BE SERIOUSLY
. DO NOT TAMPEROR DISASSEMBLE
PARTSINSIDE.
NO SERVICEABLE
. REFERTO SERVICEMANUAL FORCOMPLETE
INSTRUCTIONS.

{U.S.A.'98- 00 modelsl
AIRBAGWARNING
FLIPVISOROVER.
l: SRSINFORMATION

model
lU.s.A.'97
i
'97
lcanada - 00modlsI
CAUTION
TO AVOIDSERIOUSINJURY:
lN ALL TYPESOF
. FORMAXIMUM SAFEW PROTECTION
CRASHES,YOU MUST ALWAYS WEAR YOUR SAFETY
8ELT.
CHILOSEATSlN
o OO NOT INSTALLREARWARD-FACING
SEATPOSITION.
ANY FRONTPASSENGER
CLOSETO THE
. DO NOT SIT OR LEAN UNNECESSARILY
AIRBAG.
. DO NOT PLACE ANY OBJECTSOVERTHE AIRBAGOR
BETWEENTHEAIRBAGAND YOURSELF.
. SEE THE OWNER'S MANUAL FOR FURTHER
INFORMATIONAND EXPLANATIONS
TEN YEARSAFTERlT lS
. THE SRS MUST BE INSPECTED
INSTALLED.
. T H E D A T E O F I N S T A L L A T I O Nl S S H O W N O N T H E
DRIVER'SDOORJAMB.

(cont'd)

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1-13

Warning/CautionLabelLocations
(cont'd)

VACUUM HOSEROUTING
DIAGRAMlUndor-hood
EmissionsControl Lrb6ll
ENGINECOOLANT
INFORMATION

SERVICE
INFORMANON
{Under-hood
Emission3
Control l.rbell
STEERING
COLUMNNOTICE
(sepage 1-12)

(Canadamodel)

RAOIATORCAP
CAUTION

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1-14

AIR CONDITIONING
INFORMATION

Under-hoodEmissionsControlLabel
EmissionGroupldentification
(1997modell
Example:
VACUUMHOSEROUTINGDIAGRAM

INFORIMATION
VEHICLE
Ii/PORTANT
VHN2
OIJCrcK
ENGINE
FAMILY
OLITER
DISPIACEMENT'2
VNNl0778YMBP
VEf AM]LY
EVAPORAT

CATALYST

NFORMATON.
REfERTOSEBVICEMANUALfORAODITIONAL
I-]P
TUNT
CONDITIONS
TEMPERATURE,
ATNORI\,!AL
OPERATNG
ENGINE
FANOIF
OFFCOOLING
ESTL]RNED
ALLACCESSOR
NNEUTRAL
TRANSM1SSION
ADJUSTMENIS
NEEDED
NOOTHEB

ap'

| \6( Zror '.

ND\. 61FL r

TO U.S EPAREGUI.ATIONS
TNISVENICLE
CONFORMS
TO I99] MODET
YEARNWL GNI DUTYTRACKS
APPICASLE

E n g i n eF a m i l y :

Year
Model
v:1s97

l JGKE
vHN2.o

T_fT

I I
| L

Manufaqturer
H N :H o n d a
Displacement
Class
1: Light DutyVehicle
Fuol Systom ,nd Numbr of valves
J: ElectronicSequentialMultiport
Injection(threeor more valvesper
cylinder)
Fuel Type
G: Gasoline
Standard
F: 49 or 50 StatesTier 1
K: 49 or 50 StatesTier 1
1: CaliforniaTier 1
2: CaliforniaTLEV
3: CaliforniaLEV
4: CaliforniaULEV
Catalyst
E, F, G, H: ThreeWay Catalyst

i
I

OBD

K - T: OBDEquipped

ONCONTROL'EOLJIPPED
OSVEORTRACT
fOUBWHEEL
OFPERMANENT
LOADED
IM TEST]NG
ZED
ON A IOUR WHEELDRVE SPEEOSYNCHRON
VEHTCLES
MUST BE CONDUCTED
ANONLOADEDTESTPBO(EOUBEMUSIBEPERFORMEO

50ST (50 Statesl:


TO U.S.EPAAND STATEOF
CONFOBMS
THISVEHICLE
C A L I F O R N IR
A E G U L A T I O NASP P L I C A B LTEO 1 9 9 7
MODELYEARNEWLIGHTDUTYTRUCKS.
49ST{49 Statos/Federall:
TO U.S.EPA REGULATIONS
CONFORMS
THISVEHICLE
YEARNEW LIGHTDUTY
TO 1997IVIODEL
APPLICABLE
TRUCKS.
CAL (Calitornial:
TO U.S.EPAAND STATEOF
CONFORMS
THISVEHICLE
TO '1997
APPLICABLE
I
A
R
E
G
U
L
A
T
I
ONS
CALIFORN
M O D E LY E A R N E W T L E V L I G H T D U T Y T R U C K S
THAT THISVEHICLEIS ONLY INTRODUCED
PROVIDED
I N T O C O M M E R C EF O R S A L E I N T H E S T A T E O F
CALIFORNIA.

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Families
Engineand Evaporative

Evaporative Family:
"r0",

V
HNlOTTBYMBP
T|

"*,

V: 1997
Manufacturer
HN: Honda
Storago System
1: Canister
CanistorWorking Capacity (gramsl
CanisterConfigulation
A: PlasticHousing(ClosedBottom)
B: PlasticHousing(OPenBottom)
Fusl System
Y: FuelInjection
FuelTank
M: Metal
Standard
A: CurrentEvap
B: EnhancedEvap
Wild C.rd

1 - 15

Under-hoodEmissionsControlLabel
EmissionGroupldentification
(1998modell

Engineand EvaporativeFamilies
EngineFamily:

Example:
DwlF\AIo|NG
oBcha\GtftcI + cootr\r -smsoru1or or FoNoA-IEaoTTxD-ibl
a\D wATfB.
M w r or_ut-ir coolqNt,oR-l;ir,FEaFEf1'v!Lrff EzEcoo-aN'
ENGINE
MAY
BESEflIOUSLYSIONTENEO.
DSEPLACI
CoOTANT
AnEs85 itNlgsloF@ MILIS
l@0 rnl, wHrcHEvEs
coMEs

Modl Year
W: 1998
ManufacturerSubcods
HNX:HONDA

TNEREAFTR,
REPLACE
EvEny
fmAFSlm m
M[Esi@ kml,wHcHrvEB
coMEs
DCHEC(ONADOCOOLqNTATTHE
RSSEFVETANX.
NOTTHE
iAD]ATOR.
DFOR
FUFTNEfr
INFO8MATION
ONINCOOT]NC
SYSIEM
NEAD
THE
OWNEN'S
MANUAL,
. CHECK
W|TH
YOUR
NONDA
OEALEF.

FamilyTypo
V: LDV
T: LDT

IMPORTANT
VEHICLE
INFORMATION
THISVEHICLE
CONFOEMS
TOI], S.EPA
FEGIJLAIIONSAPPLICASLE
TO1993MOOEL
YAFNEWLIGHTDUIYTNUCXS.

CATALYST

rwqHozst2l/sFt/osD
l cERI|FtEO
vAlvttAsH lrr0.l010.02nm
icolo)
EX:01310.02mm
SPAS(
PIUGGAP I.O IINM
686,13G96
lDLlSPTED
750I 50rym
PROCEOURESI
2.0L
TlNt UPCoND/ToNS:
ENGINE
ATNOiM
IEMPETAIURT,ALLACCESSORIESTUNNI
fANOFf.TRAI1SMISSON
INNEUTMI
NOOIIIERAOJUSTI\TFIIS
IIEEOED.

GD

50ST {50 States}:


THISVEHICLE
CONFORMS
TO U.S.EPAAND STATEOF
C A L I F O R N I AR E G U L A T I O N S
APPLICABLE
TO 1998
MODELYEARNEWLIGHTDUTYTRUCKS,
/$ST (itg Statos/Fodsrsll:
THISVEHICLE
CONFORMS
TO U.S.EPA REGULATIONS
APPLICABLE
TO 1998MODELYEARNEW LIGHTDUTY
TRUCKS.
CAL {California}:
THISVEHICLE
CONFORMS
TO U.S.EPAAND STATEOF
C A L I F O R N I AR E G U L A T T O NASP P L I C A B L E
TO 1998
M O D E LY E A R N E W T L E V L I G H T D U T Y T R U C K S
PROVIDED
THATTHIS VEHICLEIS ONLY INTRODUCED
I N T O C O M M E R C EF O R S A L E I N T H E S T A T E O F
CALIFORNIA.

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1-16

W HNX T O2.OUF1

Displacomsnt
SoquncoCharaciors

Evaporative Fami
Family:
Model Yeat
W:1998
Manufastu16rSubcode
HNX:HONDA
Family Type
E: EVAP
R; EVAP/ORVR
CanisterWork Capacity
SgquoncoCharaqtsrs

W HNXEOOSOAAB

EmissionGroupldentification
(1999model)
Example:
U-ECo-q.NOEDI
USE
THE
COOLANT.
NGORCNANGINC
@SOLU I ONOfFONOA
'.WNEN
AOO
0FTNE
LIFE
THE
CooLANT,0RTHE
oILLJTE
mcrtniuvcoourr mo wlttt NEVEF

coMEs
lmo rhl,wNrcHEVEn
"Eifil:$o""niii?i,THffiffi'"R@ MLEs
os@

i'lrt^torrrr,^,r*a, rurr"*

coMEs
MLEs
1@ kmrwNICHEVER

TAN(NOTIHENADIATOS
ATTHERESER!'E
}CNECK
ORADDCOOLANT
MANUAL'
READ
THEOWNER'S
NCSYSTEM
ONTHECOOL
DFOfifWTHEFNFORMATION
' CHECK
HONOA
OEALER.
WIIHYOUS

INFORMATION
VEHICLE
IMPORTANT
S EPANLEV
CONFOAMSTOU.
THISVEHICLE
TO1999MODL
APPLICCBLI
FEGULANONS
YEA8NEWTIEVLIGHTDUTY]nUCKSAND
IO 19S9
APPLICASLE
REGULATIONS
CALIFORNIA
YEARNEWTLEVLIGHTDUTYIFIJCKS,
MOOEL

CATALYST
mm
IASN lN:010r0.02
VALVE
E X0 1 3 1 0 0m
2m
lCoLDj
PLUG
GAP 10- l l nm
SPA8K
rPm
130
t
5{
IDLE
SPEED

NOB
I]PCONDIIIONS
INGINEAT
TUNE
ESTLJRN
ATLACCESSOS
TEI\'PERATUR
NNEL]TML
FANOFf IRANSMSSION
NEEOEO.
ADJUSTMTNTS
NOOINER

EngineFamily:

,|
F

--'-

Ll:.-.-,1
I
rFrll
\=#_H*
JL

SPEED
MUsT
BE
coMoufitooNArounwNEElDslvE
Iooro nr tist rc orn svtncrE
MU
sT8EPfRrouRE
DrEsrPRoCE
iitriunor mo ovuvo uenn orr EnwsEaNoN.loaDE

X HNXT02,OUA2

Model Year
X:1999
Manutao{urerSubcode
HNX:HONDA

FamilyType
V: LDV
T: LDT
Displacoment
SaquenceCharactors

EvaporativeFamily:

OBDIICERT]ATD
201

Engineand EvaporativeFamilies

X HNXEOO8OAAB

Model Yoal
X:1999
ManutacturarSubcode

HNX:HONDA
Family Typo
E: EVAP
R: EVAP/ORVR
Canbter Work Capacity
SquonceChartsters

GD
50 state TLEV + NLEV {Unrestricted}
T H I S V E H I C L EC O N F O R M ST O U . S . E P A N L E V
E O 1 9 9 9 M O D E LY E A R
R E G U L A T I O NA
SP P L I C A B L T
T
R
U
C K SA N O C A L I F O R N I A
N E W T L E V L I G H TD U T Y
T
O 1 9 9 9 M O D E LY E A R
A
P
P
L
I
C
A
B
L
E
REGULATIONS
NEWLIGHTDUTYTRUCKS.

www.emanualpro.com

1-17

Under-hoodEmissionsControlLabel
EmissionGroupldentification
(2000model)

EngineFamily:

Example:
DWFEN
aDDr,tc0RChA\CtN!
rlt cooraN.ust MsoLU- oNor fioNpAq-af6MrNp-ol

\rvEn
u u'r+-E
coo|-d',r
os-Fiiiiifi-'
lfi ;!,."5:P!$t:1t9ffilf
1

DREpf
cEcoolaNrAFTEBt3tlomistoR@MtLEs
r@km),wH ctlEvrscoMEs
T|E8EAFTER,
BEprAcE
EVEny
ErdFstoB@ MttEs
lmr,t,
ffitcHEVER
coMEs
DCIIICXOF ADDCOOLA\I I'-FE

":3lliJ#fl

AISIRVI TAI{I\.NOI THEMDIAIOR

s,5TEM
8r!D
TrE
owrEp
sMA\u.r.
"lj,9lx6L;T&Iji(0or|]\G
IMPORTANT
VEHICLE
INFORMATION

IHIS\/IHICLECONFONMS
TOU.S.EPANLEV
SEGULATIONS
APPIJCq3LE
TO2OOO
IVOOEL
YEAFNEWT!!V LIGHTDUTYTBUCKS
AND
CALIFONNIA
SEGULATIONS
APPLICASLE
TO2OOO
MOOLYIAA NEWTLEVLIGHT.OUTY
TFIJCKS.

vALvtLA5h tN:0,10r0.02
mm
{C0t0l
E l : 0 . 1 3 ! 0 0m2h
S P A n ( P L U G G A1P. 0 - 1 1 m m O8OCENTFIED
l D l ES P E E o
734150lpm
?.0t
TUNIUPCoNDIToNS:
ENGINE
ATNORM
TTMPERAIURE
ATLACCESSORIES
fu BNI
TANOFFTiANSMISS
ONINNUTRAL
NOOTHER
AD.ILJSTMENIS
NEEDEO.

.l-L

gt couolorooN,{raua.wxEtt
|oAoEDr/MTESTNG
oFTHsvtHrctE
uLrst
onuspreo
syNoiRoN
zEoDvNAMoMETER.
olrEiwsE.ANoN.LoAoEo
rEsrpBocEounr
uust sr pair

50 State TLEV + NLEV (Unrestricied,


T H I S V E H I C L EC O N F O R M ST O U . S . E P A N L E V
R E G U L A T I O NA
SP P L I C A B L T
EO 2 O O O
M O D E LY E A R
N E W T L E V L I G H TD U T Y T R U C K SA N D C A L I F O R N I A
REGULATIONA
S P P L I C A B LT
EO 2 O O O
M O D E LY E A R
NEWLIGHTDUTYTRUCKS.

www.emanualpro.com

Y HNX TO2.OUA2

Model Yar
Y: 2000
ManufaqturerSubcodo
HNX:HONDA

FamilyType
V: LDV
T: LDT
Displacement
SaquencoCharasters

Evaporative Family:

CATALYST

1-18

Engineand EvaporativeFamilies

Modol Yea.
Y: 2000
ManufacturerSubcode
HNX:HONDA
Family Type
E: EVAP
R: EVAP/ORVR
CanisterWork Capacity
SoquencaCharactet3

Y HNXEOOSOAAB

Lift and SupportPoints


Lift and SafetyStands
place
ffi
When heaw rear components such as suspension,Iuel tank, spare tire and tailgate are to b lemoved,
vehicle,
the
!iiii-'rn"t r""igtrt in the trunk before hoisting. When substantial weight is removed flom the lear ot the
center of gravity may change and can causethe vehicle to tip fotward on the hoist'
NOTE:Sinceeachtire/wheelassemblyweighsapproximately30 lbs (14 kg),placingthe front wheelsin the cargoareacan
assistwith weight distribution.
1. Placethe lift blocksas shown.
and rockthe vehicleto be sure it is firmly supported.
2. Raisethe hoista few inches(centimeters),
3. Raisethe hoistto full height,and inspectthe lift pointsfor solidsupport'
NOTE:Usethe samesuppon pointsto supportthe vehicleon safetystands'

FRONTSUPPORTPOINT

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LIFTBLOCKS

REARSUPPORTPOIMT

1-19

Lift and SupportPoints


FloorJack
1 . Blockthe rear wheelswhen raisingthe front of the
vehicle;blockthe front wheelswhen raisingthe rear
of the vehicle.
Placethe blocksbehindand aheadof the wheels,
Raisethe vehicle high enough to insert the safety
stanos.

Always usg safety standg when working on or under


any vehicle that is supported by only a iack.
Nevor attempt to use a bumper jack for tifting or
supporting ths vehicl.

Adjust and place the safety stands so the vehicle


will be approximatelylevel,then lower the vehicle
onto them.

Front:

Center the jack

bracketin the middle


of the jack lift platform.

JACK LIFTPLATFORM

Rsar:

Centerthe iack
bracketin the middle
of the iack lift platform.
www.emanualpro.com

1-20

JACK LIFT PLATFORM

Towing

l f t h e v e h i c l en e e d st o b e t o w e d , c a l l a p r o f e s s i o n a l
towing service.Never tow the vehicle behind another
vehjclewith just a rope or chain.lt is very dangerous.
EmergencyTowing
Thereare three popularmethodsof towing a vehicle.
Flat-bedEquipment- The operator loads the vehicle on
the
the backof a truck.Thisis the bestway of transporting
vehicle.
Wheel Lift Equipment- The tow truck usestlvo pivoting
armsthat go underthe tires lfront or rear)and liftsthem
o f f t h e g r o u n d .T h e o t h e r t w o t i r e s r e m a i no n t h e
g r o u n d . T h e v e h i c l e ' ss u s p e n s i o na n d b o d y c a n b e
seriouslydamagedif this methodof towing is attempted.
Sling-typeEquipment- The tow truck usesmetalcables
with hookson the ends.Thesehooksgo aroundpartsof
the frame or suspensionand the cableslift that end of
the vehicleoff the ground.The vehicle'ssuspensionand
body can be seriouslydamagedif thjs methodof towing
i s a t t e m p t e d .T h i s m e t h e d o f t o w i n g t h e C R - Vi s
unaccePtable.
The onlv recommendedway of towing the CR-Vis on a
f l a t - b e dt r u c k . T w o w h e e l d r i v e C R - V ' sm a y a l s o b e
towed with all four wheelson the ground.

Front:

lOwlNG HOOKS.nd
TIE DOWN BRACKETS

Rear:

Towing the four-wheel dlive CR-v with only two


wheels on the ground will damage parts of the 4wD
system. It this vehicle is damaged, it should be towed
on a flat-bed truck ol trailel.
It the 2 wheel drive CR-v is towed wiih all tour wheels
on the ground, do the following:
Manual Transmission
. Release
the parkingbrake.
. Shiftthe transmissionin Neutral
Automatic Transmission
. Releasethe parkingbrake.
. Start the engine.
. Shiftto lD.lposition.then E position.
. Turn off the engine.
TIEDOWNBRACKET
lmproper towing preparation will damage the
transmission.Follow the above procedure exactly. lf
you cannot shift the transmission or start the engine,
the vehicle must be transported on a flat-bed truck.
lf the vchicle is towed with four wheels on the ground,
il is best to tow the vehicle no larther than 50 miles (80
km), and keep the speed below 35 mph {55 km/h).
Trying to lift or tow the vehicle by ihe bumpers will
cause serious damage. The bumpers ale not dosigned
to support the vehicle's weight.

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1-21

ServicePrecautions
PartsMarkingLocations
To deter vehicletheft, cenain major componentsare markedwith the vehicleidentificationnumber
{VlN).Originalparts
will have self-adhesivelabelsor labelsattachedwith a break-offbolt. Replacementbody parts will have self-adhesive
labels,and replacement
engineand transmissionpartswill be stampedwith a codetor spareparts.
NOTE:
. Be carefulnottodamagethe partsmarkinglabelsduringbody repairs.Maskthe labelsbeforerepainting.
' Labellocationletterswithout parenthesisindicateoriginalparts.Letterswith parenthesisindicate
replacement
pans.
A, (A): Engine
B, (B): Transmission
C, (C): FrontBumoer
D, (D); Hood
E, (E): Tailgate
F, (F): RearBumper
G, (G):FrontFenders(Lefrand Right)
H, {H): FrontDoors(Leftand Right}
l, (l): RearDoors(Leftand Right)
J, (J): OuterSide Panel(Leftand Right)

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1-22

for Real-time4WD(Four-wheelDrivel
Precautions
U n d e r n o r m a l c o n d i t i o n s t, h e v e h i c l ei s i n 2 W D ( f r o n t - w h e edl r i v e ) .H o w e v e r ,t h e s y s t e m w i l l i n s t a n t l yt r a n s m i t
appropriatedrivingforceto the rearwheels{dependingon the drivingforceof the front wheelsand the road conditons)
The Real-time4WD-DualPump Systemdoes not have a manual switch to disablethe 4WD system.Wheneverservice
work requiresspinningthe front or rearwheelswith the engine,alwayslift up and supportthe vehicleso all lour wheels
are off the ground (seepage1-19).

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1-23

Specifications
2-2
Standardsand ServiceLimits...............
..........
2-12
DesignSpecifications
..................
..........2-14
BodySpecifications

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Standardsand ServiceLimits
EngineElectrical- Section4
MEASUREMENT
lgnitioncoil

R a t e dv o l t a g e V
P r i m a r y w i n d i n g r e s i s t a n c e0 a t 6 8 ' F ( 2 0 ' C )

lgnition wire

Besistance
at 68"F(20 C) ktl
Firingorder

Sparkplug

STANDAFDINEWI

1 3

l g n i t i o nt i m i n g

Type
Gap
At idle

Alternator belt*r

D e f l e c t i o nw i t h 9 8 N { 1 0 k g f , 2 2 l b f )

Alternator

Belttension N {kgf,lbt)
Measuredwith bek tensiongauge
OutputA (at 13.5V, hot and 6,000alternatorrpm

4-2

See Section 4
1 . 0 - 1 . 1 ( 0 . 0 3 9- 0 . 0 4 3 )

BTDC

AII
M/I

Brushlength
Staningmotor

SERVICELIMIT

12
0.63 0.77
25 max.

A/f
Mfi

Output kW
Micadepth
Commutatorrunout
CommutatorO.D.
Brushlength
Brushspringtension N (kgf,lbf)

1 6 12 { R e d )
8 . 5 1 1 . 5 1 0 . 3 30 . 4 5 ) w i t h
u s e db e l t
5.5- 8.0 (0.22- 0.31)with new belt
340- 490{35- 50,77 110)with usedbelt
690 880(70 90, 150- 200iwith new belt
95
90
1 0 . 5( 0 . 4 1 )
1.5(0.06i
1.1
1.0
0.5- 0.8{0.02- 0.03)
0,0.02 (0 0.0008)
2 7 . 9 2 8 . 0( 1 . 0 9 8 41 . 1 0 2 4 )
14.0 14.5(0.55 0.57)
- 3.97)
13.7- 17.7(1.40- 1.80,3.09

0.2 (0.008)
0.0s(0.002)
2 7 . 0( 1 . 0 6 )
9.0 (0.35)

' 1 W h e n u s i n g a n e w b e l t , d d i u s t d e f l e c t i o nt o n e w v a l u e . R u n t h e e n g i n e f o r 5 m i n u t e s t h e n t u r n i t o f { . B e a d i u s t d e f l e c t i o nt o u s e d b e l t v a l u e .

CylinderHead/ValveTrain - Section6
MEASUREMENT
Compression

250rpm and
wide openthrottle
,
kPa(kgflcm' psi)

Cylinderhead

Warpage
Height
E n dp l a y

Camshaft

STANDARD{NEW}

Camshaft to hoider oil clearance

Totalrunout
Cam lobe height

'97,'98models
'99,'00models

(Cold)*
Valveclearance
ValvestemO.D.
Stem'to-guide
clearance
width
Steminstalledheight

lN
EX
lN
EX
lN
EX
lN
EX
lN
EX
tN
EX
lN
EX

Valve spring

Freelength

lN
EX

Valve guide

I,D,

IN
EX
tN
EX

Installedheight
*: Measuredbetweenthe camshaftand rockerarm,

www.emanualpro.com

2-2

SERVICELIMIT

Nominal
1,230i'12.5, 11Al
Minimum
930(9.s,135)
Maximumvariation 20012.0,2al
1 3 1 . 9-5 1 3 2 . 0{55 . 1 9 -5 5 . 1 9 9 )
0.05 0.1s(0.002 0.006)
- 0.0027)
0.030- 0.069(0.0012
0 . 0 3{ 0 . 0 0 1 ) m a x .
33.204\1.30721
33.528{1.3200)
33.116 \1.3214)
33.528{'1.3200)
0.08- 0.12(0.003 0.005)
0.16 0.20(0.006- 0.008)
6.580- 6.590(0.2591 0.2594)
6.550- 6.560(0.2579 0.2s83)
0.02- 0.05{0.00t 0.002)
0.05- 0.08(0.002 0.003)
1.25- 1.55(0.049- 0.061)
1 . 2 5 1 . 5 5( 0 . 0 4 -9 0 . 0 6 1 )
40.765- 41.235{1.6049 1.6234)
- 1.70221
42.765- 43.235i'1.6837
42.36(1.668i
44.32t1.1451
- 0.261)
6.61 6.6310.260
6.61 6.63{0.260- 0.261i
1 3 . 7 -5 1 4 . 2 5
1 0 . 5 4 10 . 5 6 1 i
15.75- 16.25{0.620 0.640i

0.05{0.002)
0.5(0.02)
0.15(0.006)
0.04(0.002)

u* to.rutt
6.52lO.257l
0.08{0.003i
0.'1t(0.004)
2.0 (0.08)
2.0 (0.08)
41.485{1.6333}
43.485{1.7120i

6.6510.2621
6.65(0.262i

STANDARD(NEWI

MEASUREMENT
Cylinder block

Piston

Pistonring

Warpageof deck surface


Borediameter
Boretaper
bottomof skart
SkirtO.D.*1trom
in cylinder
Clearance
Groovewidth {Forringi

clearance
Ring-to'groove
Ringend gap

PistonPin

0.07(0.003)max.
84.00- 84.02(3.307 3.308)

Top
Second
oil
ToP
Second
ToP
Second
oil

o.D.

Pin-to-piston
clearance
Pin-to-rodinterference
Smallend borediameter
Nominal
Largeend borediameter
Endplayinstalledon crankshaft
Mainjournaldiameter
Crankshaft
N o .1 , 2 , 4 a n d5 i o u r n a l s
No.3 journal
Rodiournaldiameter
Taper
Out ol round
Endplay
Bunout
Main bearing-to-iournal
oil clearance
Bearing
N o .1 ,2 , 4 a n d 5 i o u r n a l s
No.3 journal
oil clearance
Rodbearing-to-,ournal
*1: '97,'98models15 mm (0.6in)
'99,'00models20 mm (0.8ini
rod
Connecting

Unit of length: mm (in)

EngineBlock- Section7

83.98- 83.99(3.306- 3.307)


- 0.00161
0.01- 0.04(0.0004
- 0.0492)
1.240- 1.250{0.0488
- 0.0484)
1.220 1.230{0.0480
2 . 8 0 5 2 . 8 2 51 0 . 1 1 0- 40 . 1 1 1 2 )
0.055- 0.080(0.0022 0.0031)
- 0.0024)
0.035 0.060(0.0014
0.20 0.30(0.008- 0.012)
0.40- 0.55(0.016 0.022)
0.20- 0.50(0.008- 0.020)
- 0.8268i
20.996- 21.000(0.8266
- 0.0007)
0.010- 0.017(0.0004
- 0.0013)
0.015- 0.032(0.0006
-0.8260)
20.968-20.98110.8255
48.0(1.89)
0.15- 0.30{0.006- 0.012i

SERVICELIMIT
0.10(0.004)
84.07(3.310)
0.05(0.002)
83.97(3.306)
0.05{0.002)
1.26(0.0s0)
1.25(0.049)
2.44lo.112l
0.13(0.005)
0.13(0.005)
0.60(0.024)
0.70(0.028)
0.70(0.028)

oroto.oroi

- 2.1654)
54.976- 55.000(2.' l644
- 2.1651)
54.970 54.994(2.1642
- 1.71111
44.976- 45.000/.1.1707
0.005(0.0002)max.
max.
0.005(0.0002)
0.10- 0.35(0.004- 0.0r 4)
0.03(0.001)max.

0.010(0.00041
0.010(0.0004)
0.45(0.0r8)
0.04(0.002)

- 0.042
0.024
10.00090.0017)
- 0.048(0.0012
- 0.0019)
0.030
0.020- 0.038(0.0008 0.0015)

0.06(0.002)
0.06(0.002)
0.05(0.002)

o
www.emanualpro.com

2-3

StandardsandServiceLimits
EngineLubrication

Section8
MEASUREMENT

Engineoil

Capacity
f (US qt, lmp qt)

Oilpump

Inner-to-outer
rotorclearance
Pumphousing-to-outer
rotorclearance
Pumphousing-torotoraxialclearance
Pressure
settingat engineoil temp. 176'F(80'C)
kPa(kgt/cm,,psi)
At ldle
At 3,000rpm

R e l i e fv a l v e

Cooling

Radiatorcap
Thermostat

Coolingfan

70 (0.7,10)min.
3 4 0{ 3 . 5 , 5 0m
) in.

Section 10
MEASUREMENT

Radiator

STANDARO{NEWI
SERVICELIMIT
4.6(4.9,4.0)Iorengineoverhaul
3 . 8{ 4 . 0 , 3 . 3 ) f oori l c h a n g ei n
, c l u d i nfgi l t e r
3.5 (3.7,3.1)for oil change,withoutIilter
0.04- 0.16(0.002- 0.006)
0.20(0.008)
0 . 1 0- 0 . 1 9 ( 0 . 0 0-4 0 . 0 0 7 )
0.20(0.008)
0.02-0.07 (0.001- 0.003i
0.15(0.006)

Coolantcapacity , (USq1,lmp qt)


llncludingengine,heater,I
lineand reservoirl
Lcooling
Reservoir
capacity:
0 . 6 1 ( 0 . 6 3U S q t , 0 . 5 3 l m pq t )
psi)
Openingpressure kPa(kgf/cm?,
Startsto open 'F 1"C)
Fullyopen 'F ("C)
Valvelift at tully open
"ON" temperature "F
Thermoswitch
{'C)
"OFF"temperature 'F ('C)
Thermoswitch

Fueland Emissions

M/T

STANDAROINEW}
5.9{6.2,5.2}toroverhaul
3.9(4.1,3.4ifor coolantchange
6.0(6.3,5.3ifor overhaul
4.0(4.2,3.5)for coolantchange
9 3 - 1 2 3( 0 . 9 5- 1 . 2 5 1, 4 1 8 )
169- 176(76- 80)
194(90)
8 . 0( 0 . 3 1 i m i n .
196- 203 (91- 95)
Subtract5 - 14 (3 - 8) trom actual"ON" temperature

Section 11
MEASUREMENT

STANDARDINEW}

Pressureregulator Pressurewith regulatorvacuum hose disconnected


'97,'98models
,
kPa(kgflcm' psi)
'99, '00 rnodels
Fueltank
(US
gal,
Capacity /
lmp gal)
En g i n e
ldle speedwith headlights
and coolingfan off rpm
'97 model
'98 model
'99,'00 models
Fastidle rpm

ldle CO %

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2-4

'97 model
'98 model
'99,'00 models

260- 31012.7 3.2,38- 46)


270-32012.8 3.3,40- 471
5 8 ( 1 5 . 31, 2 . 8 )
MT

750r 50
7301 50
1,5001200
1,600r 200
0.1max.

AT {E or E position)

750t 50
750r 50
7 3 0 15 0
1 , 5 0 0 12 0 0
1 , 5 0 0 12 0 0
1,600r 200

Clutch

Unitof length:mm lin)

Section 12
MEASUREMENT

Clutchpedal

Pedalheight
Stroke
Freeplay
Pedalplay
Disengagement
height
Clutchsurfacerunout

to floor

to floor

Clutchdisc

Rivet head depth


Thickness

plate
Pressure

Warpage
Diaphragmspringfingeralignment

SERVICELIMIT

STANDARDINEWI
183(7.20)
1 3 5 - 1 4 5 1 5 . 3- 15 . 7 1 )
7 - 2210.24- 0.41J
1-9 (0.04-0.35)
7 2 1 2 . 8 3m) i n .

max.
0.05(0.002)

0.r5(0.006)

1 . 2- 1 . 7 1 0 . 0 50-. 0 7 )
8 . 4 9 . 1( 0 . 3 3 , 0 . 3 6 )
0 . 0 3( 0 . 0 0 1 ) m a x .
0.6 (0.02)max.

0.2(0.01)
6.0i0.24)
0.15(0.006)
0.8 (0.03)

ManualTransmission Section 13
Transmission
fluid
Mainshaft

STANDARDINEW}

MEASUREMNT
Capacity f (USqt, lmp qti

SERVICEI-IMIT

1 . 71 1 . 8 1
, . 4 ) f o ro i l c h a n g e
2 . 1 ( 2 . 2 ,1 . 8 ) { o r o v e r h a u l

0.'11- 0.18(0.004- 0.007)


- 1.1020)
27.977- 27.990(1.1015
37.984- 38.000(1.4954-1.4961)

Endplay
Diameterof ball bearingcontactarea(clutchside)
Diameterof needlebearingcontactarea
Diameterof ball bearingcontactarea
(transmission
housingside)
Runout

Adjust
2 7 . 9 4( 1 . 1 0 0 )
37.93(1.493)

- 1.1024)
27.987- 28.000(1.1018
0.02(0.0011max.
43.009- 43.02511.6933- 1.6939)
0.06- 0.21 (0.002- 0.008)
- 1.377)
34.92 34.9711.375
31.42- 31.4'711.237, 1.2391

Mainshaftsth
gear

LD.
Endplay
Thickness

Countershaft

Diameterol needlebearingcontactarea
DiameteroI ball bearingand needlebearingcontact

27.94(1.100)
0.05{0.002)
43.08011.6961)
0.3 (0.01)
34.811.37)
31.311.23)
- 43.02511.6933
1.6939) 43.08011.6961)
43.009
- 0.008)
0 . 3( 0 . 0 1 )
0.06- 0.21(0.002
- 1.219)
- 30.97
3 0 . 8( 1 . 2 1 )
30.92
{1.217
36.000 36.015{1.4173 1.4179) 3s.95(1.415)
(0.982)
24.94
24.987- 25.000(0.9837- 0.9843)

Diametero{ 1st gear contactarea


Runout

-1.4567)
36.984- 37.00011.4561
0.02(0.001)max.

(1.4s4)
36.93
0.0s(0.002)

LD.
Endplay
Thickness
t.D.
Endplay
Thickness

- 43.025
(1.69331.6939)
43.009
- 0.007i
0.06- 0.18(0.002
- 1.063)
(1.061
26.9s,27.00
- 47.025
- 1.8514)
(1.8507
47.009
,0.006)
0.07- 0.1410.003
2As2- 2a.97l 1.139-1.1411

43.08(1.696)
0.2310.009)

3 1 . 0 6( 1 . 2 2 3 )
37.94(1.494)

Mainshatt3rd and
4th gears

countershatt1st
gear
Countershaft2nd
gear

LD.
Endplay
Thickness

3rd gear
4th gear

47.08{1.854)
0.18(0.007)

Spacercollar
(Mainshaft
4th
and 5th gears)

t.D.
o.D.

Reverseidlergear

t.D.
gearshaftclearance
Gear-to-reverse

31.002- 31.O1211.2205, 1.2205)


37.989- 38.000(1.4956 1.4961)
56.45- 56.55Q.222- 2.2261
26.03,26.08(1.025- 1.027)
20.01
6 - 20.043(0.7880,0.7891)
- 0.0033)
0.036- 0.084(0.0014

R i n g - t o - g e a rc l e a r a n c e ( r i n g p u s h e d a g a i n s l g e a r )

0.85- r.10(0.0330.043)

0.4 (0.02)

(ringpushedagainstgear)
Clearance
Outersynchroring to synchrocone
Synchrocone-to-gear
Outersynchroring-to-gear
Fingerthickness
3rdl4thshiftlork
Exceptabove
Fork-to-synchrosleeveclearance

0.5 1.0(0.02 0.04)


- 0.04)
0.5- 1.0(0.02
- 0.066)
0.95- 1.68(0.037
- 0.30)
7.4- 7.6(0.29
6.2- 6.4(0.24-0.2s)
- 0.026)
0.35- 0.65(0.0't4

0.3(0.01)
0 . 3( 0 . 0 1 )
0.6(0.02)

Synchroring
Dualcone

Shift fork

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Length

l' les

26.01t1.0241

20.09(0.7909)
0.16010.0063)

't, torag)

Standardsand ServiceLimits
ManualTransmission{cont'd}- Section 13
MEASUREMENT
Raverseshift Iork

Pawl groove width


Fork-to-reverseidler gear clearance
Groovewidth*l

STANDAROINEW)
'13.0
- 13.3(0.5' -j 0.52)
0.5- 1.1(0.02- 0.04)
7.O5- 7.25 i.0.21
4 - 0.2451
7.4-7.7 t0.29 0.301

at A
atB

Fork-to-5th/reverse
shift shaft clearance*'

PinionshaftcontactareaLD.
Carrier-to-pinion
shaftclearance
Driveshaft,intermediateshatt contact area LD,
Carrier-to-driveshaft
clearance
Carrierto-interrnediateshaft clearance

Backlash
t.D.
Piniongearto-pinion
shaftclearance

- 0.006)
0.05-0.r5{0.002
- 18.066
- 0.7113)
(0.7103
18.042
- 0.0037)
0.059- 0.09510.0023

oru ro.ooor

1.4 2.5i'14 26,12-231

Adjust

33.984- 34.000(1.337- 1.339)


21.977- 27.99011.1011.1021
- 1.576)
40.002- 40.01811.575
- 1.379)
35.002- 35.01811.378
26.975,26.988(1.062 1.063)
0.06- 0.16{0.002 0.006)
2.64 3.41
\21.3,35.4,23.1 30.t|

33.93(1.336)
27.92 (1.O99)
39.95(1.573)
34.95(1.376)
26.92(1.060)
Adjust
Adjust

Shift arm A

Shift fork diameter at contact area


Shift arm A-to-shitt tork shaft clearance

Shiftarm C

Shiftarm C'to-shiftarm B clearance


Diameterof shift arm B contactarea
Selectarm'to-shift arm A clearance
Diameterof shiftarm A contactarea

Selectlever

o.D.
Transmission
housingclearance

Shift lever

o.D.
Shift arm cover clearance

Differential
carner

Differential
piniongear

Ditferential
taperedrollrbesringpreloac
Staningtorque N.m (kgf.cm,lbl.ini
Transter

11:fuleasuring
points

Diameterof rollerbearingcontactarea
Translershaft {driven gear side}
Translorshaft {middle of shaft)
Transterdrive gear
Translordrivengearshaft{drivengearside)
Transterdrivengearshaft(splinedside)
Trans{ergear backlash
TotalstartingtorqueN.m (kgicm,lbiin)

A
'Ay"

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2-6

18 (0.07)

0.05- 0.35(0.002- 0.014)


0.4,0.8 (0.02 0.03)
12.9- 13.0(0.508- 0.512)
0.2- 0.5 (0.008-0.020)
0.05 0.25(0.002 0.01)
r2.9- 13.0(0.508- 0.512)
0.05- 0.25(0.002 0.01)
7 . 9- 8 . 0( 0 . 3 1-1 0 . 3 1 s )
- 0.6287)
15.94r- 15.968(0.6276
- 0.0034)
0.032- 0.086(0.0013
- 0.6287)
r5.941- 15.968(0.6276
- 0.0050)
0.032- 0.127(0.0013
- 0.7098)
18.010 18.028(0.7091
- 0.0022)
0.027- 0.057(0.0011
28.005- 28.025(1.1026,1.1033)
0.025- 0.066(0.0010,0.0026)
- 0.0036)
0.055- 0.09110.0022

at B'

Selectarm

SERVICELIMIT

*2: Measuringpoints

0.5{0.02)
1.0(0.04)
0.6{0.024i

0.1 (0.004)
0 . 1 2{ 0 . 0 0 5 i
0 . 1 5( 0 . 0 0 6 i

A'

-l-...

_{-P)

U n i t o f l e n g t h :m m ( i n )

Automatic Transmission Section 14


STANDAROINEW}

MEASUREMENT
Transmission
fluid

Capacity I {US qt, lmp q0

4WD
2WD

Hydraulic
pressure
kPa
(kgflcm', psi)

Linepressureat 2,000rpm in LII or El position


1slclutchpressureat 2,000rpm in Da position
1st-holdclutchpressureat 2,000rpm In l position

2nd clutchpressureat 2,000rpm in El position


3rd clutchpressureat 2,000rpm in E position('97,
'98 models),or positionwith O/DOFFindicator
E
light ON ('99,'00models)
4th clutchpressureat 2,000rpm in gl position('97,
'98 models),or
E positionwith O/DOFFindicator
lightoFF ('99,'00models)
Stallspeedrpm (Checkwith vehicleon levelground)
1st
Clutchinitialclearance
2nd,3rd,4th
'lst-hold
Clutchreturnspringfree length
Clutchdiscthickness
Clutchplatethickness
Clutchend platethickness
(lsti

1st,2nd,3rd,4th
'1st-hold
2nd,3rd, 4th
1st,1st-hold
Mark1
Mark2
Mark3
Mark4
Mark5
Mark6
Mark7
Mark8
MarkI
Mark 10

Clutchend platethickness
{2nd,4th)

Mark6
Mark7
Mark8
Mark9
M a r k1 0
M a r k1 1
lvlark12
M a r k1 3
M a r k1 4
M a r k1 5
M a r k1 6
Mark17

Clutchend platethickness
{3rdi

Mark8
MarkI
M a r k1 0
M a r k1 1
M a r k1 2
M a r k1 3
M a r k1 4
M a r k1 5
M a r k1 6
M a r k1 7
Mark1
M a r k2
Mark3

Clutchend platethickness
( 1 s th o l d )

No mark
Mark6
Mark7

SERVICELIMIT

6.8(7.2,6.0)for overhaul
2.9(3.1,2.6)for fluid change
5.9{6.2,5.2)foroverhaul
2.7{2.9,2.4}forfluid change
830- 880(8.5- 9.0,120 130)

780(8.0,1' t0)

800- 850(8.2 4.7,120 1241

760t7.7,1101

2,550
0.65- 0.85(0.026-0.033)
0.40- 0.60(0.016- 0.024)
0.5- 0.8(0.020- 0.031)
31.1 11.22)
3 4 . 6( 1 . 3 6 )
1.88- 2.00(0.074- 0.079)
'r.95- 2.05
{0.077 0.081)
'1.55-1.65(0.061- 0.065)
2.05- 2.r0 (0.081- 0.083)
2.15 2.20(0.085- 0.0871
2.25 2.30(0.089,0.091)
2.35 2.40{0.093- 0.094}
2.45- 2.50{0.096-0.098}
2.55- 2.60(0.100- 0.102)
2.65- 2.70(0.104- 0.106)
2.75 2.80i0.108- 0.110)
2 . 8 5- 2 . 9 0 1 0 1. r2 0 . 1 1 4 )
2 . 9 5- 3 . 0 0 1 0 . 1 1 6
0.118)
- 0.102)
2.55 2.6010.100
2.65 2.70(0.104,0.106)
2.75- 2.80(0.108 0.110)
2 . 8 5- 2 . 9 0( 0 . 1 1-20 . r r 4 )
2 . 9 5 3 . 0 0( 0 . 1 1 6 - 0 . 1 1 8 )
3 . 0 5- 3 . 1 0( 0 . 1 2-0 0 . 1 2 2 )
3 . 1 5 3 . 2 0( 0 . 1 2 4 - 0 . 1 2 6 )
3.25- 3.30(0.128 0.130)
3.35- 3.40(0.r32- 0.134)
3.45- 3.50(0.136- 0.138)
3 . 5 5 3 . 6 0( 0 . 1 4 -0 0 . 1 4 2 )
3.65- 3.70(0.144- 0.146)
2 . 7 5- 2 . 8 0( 0 . 1 0 8 0 . 1 1 0 )
2 . 8 5 -2 . 9 0( 0 . 1 1-2 0 . 1 1 4 )
2 . 9 5- 3 . 0 0( 0 . 1 1 -6 0 . 1 ' j 8 )
3.05 3.10(0.120- 0.122)
3 . 1 5 - 3 . 2 0{ 0 . 1 2 4 0 . 1 2 6 )
3.25- 3.30(0.128- 0.r30)
3.35- 3.40(0.132- 0.r34i
3.45- 3.50(0.136- 0.138)
3.55- 3.60{0.140- 0.142)
3.65- 3.70{0.144- 0.r46)
2.05 2.10(0.081- 0.0831
2.r5 2.20(0.085- 0.087)
2.25- 2.30{0.089- 0.091}
- 0.094i
2.35- 2.4010.093
2.45- 2.50(0.096-0.098i
2.55- 2.60(0.r00- 0.102)
2.65- 2.70(0.r04- 0.106)

2,400,2,700

2 9 . 1( 1 . 1 5 )
32.6(r.28)
Untilgroovesworn out
Discoloration
Discoloration
Discoloration

Discoloration
Discoloration

Discoloration

Discoloration

Discoloration

(cont'd)

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2-7

Standardsand ServiceLimits
Automatic Transmission (cont'd)- Section 14
MEASUBEMENT
Transmission

Diameterof needlebearingcontactarea
On mainshaftstatorshaftbearing
On mainshaft2nd gear
On mainshaft4th gearcollar
On mainshaft1stgearcollar
(torqueconverterhousingside)
On countershatt
On countershaft
3rd gear
4th gear
On countershaft
On countershaft
reversegearcollar
1stgearcollar
On countershaft
housingsidei
On sub-shaft{transmission
On sub shaft4th gearcollar
On reverseidlergearshaft
Insidediameterof needlebearingcontactarea
On mainshaft1stgear
On mainshaft2nd gear
On mainshaft4th gear
1stgear
On countershaft
3rd gear
On countershaft
4th gear
On countershaft
reversegear
On countershaft
On sub-shaft4th gear
On reverseidlergear
fleverseidlergearshaftholderl.D.
Endplay
Mainshaft1stgear
Mainshaft2nd gear
Mainshaft4th gear
Countershaft
1stgear
Countershaft
3rd gear
Countershaft4th gear
Sub-shaft4th gear
Reverseidlergear
Countershaftreversegear
Selectorhub O.D.
Mainshaft4th gearcollarlength
Mainshaft4th gearcollarflangethickness
Mainshaft1stgearcollarlength
Countershaft
distancecollarlength

Countershaft
3rd gearcollarlength
reversegearcollarlength
Countershaft
Countershaft
reversegearcollarflange
thickness
1stgearcollarlength
Countershaft
lst gearcollarflangethickness
Countershaft
Sub-shaft4th gearcollarlength
Sub shatt4th gearcollarflangethickness

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2-8

STANDARD{NEW}

SERVICELIMIT

- 0.9446) Wearor damage


23.980-23.993(0.9441
35.975 35.99'!(1.4163 1.4169)
( 1 . 2 5 8 91 . 2 5 9 5 i
3 1 . 9 7 53 1 . 9 9 1
- 1.2201l'
30.975- 30.99111.2195
- 1.4180)
36.004- 36.017(1.4175
35.980 35.996(1.4165 1.4172)
( 1 . 1 0 1-61 . 1 0 2 1 i
2 7 . 9 8-0 2 7 . 9 9 3
( 1 . 2 5 8-9' j . 2 5 9 5 i
3 1 . 9 7 5 -3 1 . 9 9 1
( 1 . 2 5 8-91 . 2 5 9 5 )
3 1 . 9 7 53
- 1.991
- 1.0236)
25.991- 26.000(1.0233
- 23.006s(0.9053 0.9058)
22.9935
- 0.5512) Wearor damage
13.990- r4.000(0.5508
35.000 35.016(1.3780 1.3786)
4 1 . 0 0-0 4 1 . 0 1 (61 . 6 1 4-21 . 6 1 4 8 )
-' 1.4967)
38.000- 38.016(1.4961
- 1.4967)
38.000- 38.016(1.496'1
4 1 . 0 0 0 4 1 . 0 1 (61 . 6 1 4 21 . 6 1 4 8 )
33.000- 33.016(1.2992 1.2998)
- 1.4967)
38.000- 38.016(1.4961
- 1.2605)
32.000- 32.016(1.2598
- 0.7094)
18.007- 18.020(0.7089
14.416 14.434(0.5676 0.5683)
0.05- 0.16{0.002- 0.006)
0.05- 0.13(0.002- 0.005)
0.05,0.'16(0.002 0.006)
0.1 0.5(0.004 0.020)
0.05 0.17{0.002 0.007)
0.10 0.18(0.004 0.007)
0.0s 0.17(0.002- 0.007)
0.05- 0.18(0.002- 0.007)
0 . 1 0 , 0 . 2 5 ( 0 . 0 0 40 . 0 1 0 )
51.87- 51.90(2.042- 2.043)
- |.9508)
49.50- 49.55(1.9488
4 . 4 3 5 4 . 5 2 5( 0 . 1 7 4 6 - 0 . 1 7 8 1 )
2 7 . 0 0 , 2 7 . 0{51 . 0 6 3 ' 1 . 0 6 5 i
38.97- 39.00(1.534- 1.535)
39.02 39.05(1.536, 1.537)
39.07 39.10(1.538 1.539)
3 9 . 1 2- 3 9 . 1 5( 1 . 5 4-0 1 . 5 4 1 )
39.17- 39.20(1.542* 1.543)
- 1.545)
39.22- 39.2511.544
- 1.547i
39.27 39.301'1.546
38.87 38.90{1.530 1.531)
38.92 38.95(1.s32 1.533)
21.15- 21.20rc.4327- 0.4346)
14.5, 14.6(0.57't, 0.575)
2.4- 2.6(0.094- 0.102)
14.5- 14.6(0.571- 0.575)
2.4- 2.6(0.094- 0.102)
24.0 24.1(0.945 0.949)
2 . 9 5- 3 . 1 0( 0 . 1 1 -6 0 . 1 2 2 )

Wearor damage

Wearor damage

il*=lo'.d"'.n"n"
Wearor damage

Wearor damage
Wearor damage
Wearor damage

Unit of length:mm (in)

Automatic Transmission - Section 14


(NEWI
STANDARD

MEASUREMENT
Transmission

Mainshaft 2nd gear thrust washer thickness

Thrustwasherthickness
l'rainshaftballbearingleftside
Mainshaft1stgear
Countershaft
3rd gearsplinedwasher
Sub-shaft4th gear thrust washer

ATFpump

One-wayclutchcontactareaLD.
1stgear
Countershaft
Parkinggear
Mainshaftfeed pipeA, O.D.(at 15 mm trom end)
Mainshaftfeed pipe B, O.D.(at 30 mm from end)
teed pipeO.D.lat 15 mm from end)
Countershaft
Sub-shaft
feed pipeO.D.(at 15 mm from end)
Mainshattsealingring thickness
(29mm and 35 mm)
MainshaftbushingI.D.
Mainshaftbushingl.D.
Countershaft
bushingl.D.
Sub shattbushingLD.
Mainshaftsealingring groovewidth
ATFpump gearsideclearance
ATFpump gear'tobody clearance
Drive
Driven
ATFpump drivengearLD.
ATFpump drivengearshaftO.D.

Regulator
valve body

Sealing ring contact area l.D,

Stator shaft

Insideof diameteroI bearingcontactarea


On torqueconvenerside
On ATFpump side
Reverseshittfork fingerthickness
Parkingbrakepawl
Parkinggear
Shiftfork shattborel.D.
Shiftfork shattvalvebore l.D.

Shiftingdeviceand
parkingbrakecon'
trol
Servo body
Differential
carrier

Differential
prnrongear

o
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- 0.157)
4.0010.156
4.05{0.158- 0.159)
4.1010.160 .161)
4 . 1 5( 0 . 1 6-2 0 . 1 6 3 )
4.20(0.164 0.165)
- 0.167)
4.2510.166
4.30(0.168- 0.169)
4 . 3 5( 0 . 1 7 0 - 0 . 1 7 1 )
4.40(0.172 0.173)
4.45(0.174- 0.r75)

2.95
2.434.9s2 . 9 3-

3 . 0 5( 0 . 1 1 6 0 . 1 2 0 )
2.50(0.096- 0.098)
5.00(0.195- 0.197)
3 . 0 0( 0 . 1 1 -5 0 . 1 1 8 1

Wearor damage

83.339 83.365(3.2810 3.2821)


- 2.6259)
66.685- 66.698(2.6254
8.97- 8.98 (0.353- 0.354)
5.97 5.98{0.2350- 0.2354)
- 0.3142)
7.97- 7.98(0.3138
- 0.3142)
7.97,7.98 (0.3138
1.87- 1.97(0.074-0.078)

Wearor damage
Wearor damage
8.95(0.352)
5.95(0.234)
7.95(0.313)
7.95{0.313)
1.42$.O72)

- 0.2374)
6.018- 6.030(0.2369
- 0.3549)
9.000- 9.015(0.3543
8.000- 8.022(0.3150-0.3158)
8.000- 8.022(0.3150 0.3158)
2.025- 2.075(0.0797 0.0811)
0.03- 0.05(0.001- 0.002)
0.1050 0.1325(0.004,0.005)
- 0.002)
0.0350- 0.062510.001
14.016*14.034(0.5518 0.5525)
13.980- 13.990{0.5504 0.5508)
- 1.3782)
35.000 35.025{1.3780

5.045(0.2380)
9.03(0.356)
8.03(0.316)
8.03(0.316)
2.095(0.082)

2't.o00 27.021I '1.063, 1.064)


2 9 . 0 0-0 2 9 . 0 1 3 1 1 . r 4 117. 1 4 2 2 )

Wearor damage
Wearor damage
5.40(0.213)

5.90- 6.00{0.232,0.236)

I
I

Wearor damage

I
Wearor damage

0.0710.003)
Wearor damage
Wearor damage
35.050(1.3799)

lWear

or otherdefect

Carrierto driveshaltclearance
Carrier-to-intermediate
shaftclearance

- 0.5516)
14.000- 14.010(0.55' l2
- 1.4582)
37.000- 37.039(1.4567
'18.010
- 18.02810.709
- 0.710)
0.023- 0.057{0.001- 0.002}
- 1.0254)
26.025- 26.045(1.0246
28.025- 28.045(1.103- 1.104)
0.045- 0.08610.0020.003)
0.075- 0.11110.003-0.004)

Backlash
t.D.
Piniongear'to-pinion
shaftclearance

- 0.006)
0.05- 0.15(0.002
- 18.066
- 0.7113)
(0.7103
18.062
- 0.0037)
otu to.oout
0.055- 0.09510.0022

PinionshaftcontactareaLD.
Carrierto-pinion
shaftclearance
Driveshafvintermediate
shaftcontactare l.D.

S e t r i n g - t o - b e a r i n go u t e r r a c e c l e a r a n c e

Transfer

SERVICELIMIT

3.974.024 . 0 74 . 1 24.17
4.224.274.32
4.374.42-

Diameterof rollerbearingcontactarea
Transfershaft(transfergearside)
Transfershaft(middleof shaft)
Transferdrive gear
Transferdrivengearshaft{drivengearside)
Transferdrivengearshaft{splinedside)
Transfergearbacklash
TotalstartingtorqueN.m (kgf.cm,lbf.in)

2WD
4WD

37.045(1.4585)
0.r {0.004)
0.12(0.005)
0.15(0.006)

0 0.15(0- 0.006)

Adjust

38.485 38.500(1.515- 1.516)


- 1.102)
27.917- 21.990 |.1.101
40.002- 40.018(1.575- 1.576)
35.002 35.018(1.378- 1.379)
26.975 26.988(1.062-' l.063)
0.060 0.160(0.002- 0.006)
2.64- 3.41
- 35.4,23.1 30.71
127.3

3 8 . 4 3( 1 . 5 1 3 )
27.92(1.099)
39.95(1.573)
34.95(1.376)
26.92(1.060)
Adiust
Adiust

(cont'd)

2-9

Standardsand ServiceLimits
Automatic Transmission(cont'dl - Section 14
STANDAROINEWI
MEASUREMENT
Wire Dia.
Springs

Regulator
valvespringA
Regulator
valvespringB
Statorreactionspring
Modulatorvalvespring
Torqueconvenercheckvalvespring
'97 model
'98 - 00 models
Coolerreliefvalvespring
Reliefvalvespring
2nd orilicecontrolvalvespring
1-2shittvalvespring
2 3 shiftvalvespring
3-4shiftvalvespring
1staccumulator
spring
4th accumulator
springB
4th accumulator
springA
2nd accumulator
springA
3rd accumulator
springA
2nd accumulator
springB
3rd accumulator
springI
3rd sub accumulator
spring
2nd accumulator
springC
Lock-upshiftvalvespring
Lock-uptiming valvespring
Lock'upcontrolvalvespring
3'4 orificecontrolvalvespring
Servocontrolvalvespring
CPBvalvespring
4th exhaustvalvespring

o.D.

Fiee Length

1 . 81 0 . 0 7 1 )
1 . 8i 0 . 0 7 1 )
4 . 5( 0 . 1 7 7 )
1.4{0.055)

14.7(0.579)
9.6 (0.378)
35.4{1.394}
9.4 (0.370)

87.8(3.457)
44.011.1321
30.31r.193)
35.0{1.378)

1.1(0.043)
1.2(0.047)
1.0(0.039)
1 . 1( 0 . 0 4 3 )
0.7 (0.028)
0.9 (0.035)
0.9 (0.035)
0.9 (0.03s1
2.1 (0.083)
2.3 (0.091)
2.6 (0.102)
2.410.094)
2 . 8( 0 . 1 1 0 )
1.6(0.063)
2.1(0.083)
2.7{0.r06)
2.2lO.OA7)
0.9 (0.035)
0.9 (0.035)
0.7 (0.028)
0.6 (0.024)
1.0(0.039)
0.9 (0.035)
0.9 (0.035)

8.4 (0.331)
8.4 (0.331)
8.4 (0.331)
8.6(0.3391
6.6(0.260i
7.6{0.299}
7.6{0.299)
7.6{0.299)
16.0(0.630)
10.2to.402l
17.0(0.669)
29.0\1.1421
'r7.510.689)
9.0 (0.354)
3 1 . 0( 1 . 2 2 0 )
17.0(0.669)
14.510.571)
7.610.299i
8 . 1{ 0 . 3 1 9 }
6.6(0.260)
6.6(0.260i
8.1(0.319)
8.1{0.319)
6.t (0.240)

36.4{1.433)
32.4tl.216J
3 3 . 8{ r . 3 3 1 )
3 7 . 1( 1 . 4 6 1 )
34.8(1.370)
41.3(1.626)
57.0 (2.2441
57.0 12.2441
89.1(3.508)
5 1 . 6( 2 . 0 3 1 )
88.4(3.480)
39.011.s35)
94.313.713)
20.710.8r5)
38.2(1.504)
39.0(1.535)
68.0(2.677)
73.7 12.902)
8 r . 4( 3 . 2 0 5 )
38.0fl.496)
37.9(1.492)
5 2 . 1( 2 . 0 5 1 )
41.2 t\ .A5Al
36.4(1.4331

Differential (4WDl * Section 15


MEASUREMENT

STANOABD{NEW'
1 . 2( 1 . 3 1, . 1 )a t o v e r h a u l
1 . 0( 1 . 10, . 9 1a t f l u i dc h a n g e

Capacity f (US qt, lmp ql)

Steering

Section 17
STANDARD
INEWI

MEASUREMENT
Steeringwheel

Gearbox

Pump

playat steeringwheelcircumference
Rotational
Staningloadat steeringwheelcircumference
N {kgf,lbl)
Enginerunning
Angleof rack$uide-screw
loosenedlrom lockedposition
'97, '98 models
'99, '00 models
Pumppressurewith shut off valveclosed
kPa (kgvcm,,psi)

Powersteering
fluid

Recommended
tluid
Fluidcapacity
I {USqt, lmp q0

Powersteering
belt*

Deflection
with 98 N {1Okgl,22lht)
betweenpulleys
Belttension N {kgt,lbf}
Measuredwith belttensiongauge

0 - 1 0( 0- 0 . 3 9 )
29 (3.0,6.6)
10"1 5"
20" MAX.
6,900- 7,800(70 80,995 1,138)

Hondapowersteeringfluid.
For overhaul 0.85(0.90,0.75)
For reservoir 0.4{0.42,0.35)
11.0 14.5(0.43 0.57)withusedbelt
7.5- 10.0(0.30 0.40)with new belt
390- 540(40- 55,88 - 121)with usedbelt
740-880 (75 90, 165 198)withnew belt

* When usinga new belt,adjustdeflectionor tensionto new values.Runthe enginefor 5 minutesthen turn it off.
Readjustdellectionor tensionto usedbeltvalues.

www.emanualpro.com

2-10

No. of Coils

r 1.0
1.9
10.9
12.O
12.7
8.2
13.4
22.0
26.4
26.8
13.8
14.2
2.9
15.9
2.6
6.3
32.0
47.A
20.8
'18.3
'19.5

Unit of length:mm {in)

Suspension Section18

STANDARD{NEW)

MEASUREMENT
Wheelalignment

Front
Rear
Front
Front
near
Inwardwheel
Outwardwheel

Camber
Caster
Totaltoe
Frontwheelturningangle

Wheelbearing

E n dp l a y

Rim runout

Front
Rear
Aluminumwheel

Axial
Badial
Axial
Radial

Steelwheel

0"00'1 1'
- 1"00'1 1'
2"10'! 1"
0J3(011/8)
r N2 r i ( 1 / 1 6 11 / r 6 )
37"00'! 2
31'30'(Referencei
0 - 0.05{0- 0.002}
0 - 0.05(0 0.002i
STANOARD(NEW)
0 - 0.7 (0
0 , 0 . 7 ( 00 1.0(0 0 - 1.0{0 -

0.03)
0.03)
0.04)
0.04)

SERVICELIMIT
2.0(0.08)
'r.5
{0.06)
2.0{0.08)
1.s(0.06)

Brakes Sec'tion 19
STANDARDINEWI

MEASUREMENT
Parkingbrake
lever
Footbrakepedal

To be lockedwhen Dulled:2 - 6 notches

Playin strokeat 196N (20kgf,44lbf)


leverforce
Pedalheight(withtloor mat removed)
NT
Freeplay

Mastercylinder
Discbrake

tl o

Piston-to-pushrod
clearance
Front

Discthickness

Front
Front
Front

Discrunout
Discparallelism
Padthickness
Rearbrakedrum

'97,'98 models
'99,'00 models

LD.
Liningthickness

Air Conditioning

155(6 1/8)
1 6 1( 6 5 / 1 6 )
1 5 (1/16- 3/16)
0 - 0.4(0- 0.02)
STANDARD{NEW'
22.9- 23.1(0.902- 0.909)
23.6 23.8(0.929- 0.937)
10.5- 11.5(0.4' t 0.45)
2r9.9 220.0(8.657- 8.661)
3 . 9- 4 . 5( 0 . 1 5- 0 . 1 8 )

Compressor
(KEIHIN)

Compressor
belt*

221.O8.7011
2.0(0.08)

Section 22
STANDARD
{NEWI

MEASUREMENT
Air conditioning

SERVICE LIMIT

21.0(0.83)
21.0(0.83)
0.10{0.004)
0.015(0.0006)
1.6(0.06)

Lubricanttype:
KEIHINSP 10 (P/N38897- Pl3 - A01AHor 38899P l 3- A 0 1 )
Condenser
Lubricantcapacity
Evaporator
mf {floz, lmp oz)
Lineor hose
Receiver

25 (5/6,0.9)
40 {1 1/3,1.4)
1 0{ 1 / 3 , 0 . 4 )
10(.]/3,0.4)

Lubricant
type:SP 10
Lubricantcapacity ml ({l 02,lmp oz}
Stator coil resistanceat 68'F (20"C)O
plate clearance
Pulley-to-pressuae
Deflection
with 98 N (10kgl,22lbli
betweenpulleys
Belttension N (kgf,lbf)
Measuredwith belttensiongauge

130'3'{41fi'3o,4.6;"}
3.05- 3.35
0.51 0.15(0.021 0.006)
7.5- 10.5{0.30- 0.41)with usedbelt
5.0- 7.0(0.20- 0.28)with new belt
3 9 0- 5 4 0( 4 0 5 5 , 8 8 - 1 2 0 ) w i t h u s e d b e l t
740- 880 {75 90, 170- 200)with new belt

* When usinga new belt,adjustdeflectionor tensionto new values.Runthe enginefor 5 minutesthen turn it off.
Readjustdeflectionor tensionto usedbeltvalues.

o
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2-11

DesignSpecifications
ITEM
DIMENSIONS

WEIGHT(USA)
WEIGHT(CANADA)
ENGINE

METRIC

Overalllength
Overallwidth
Overallheight
Wheelbase
Track

Front
Rear

Seatingcapacity
Grossvehicleweightrating(GVWR)
Grossvehicleweightrating(GVWR)
Type
Cylinderarrangement
Bore and stroke
Displacement
Compression
ratio

'97,'98mooers
'99,'00 models

Lubricationsystem
Oil pump displacement
at 6,000enginerpm
Waterpump displacement
at 7,600enginerpm
Fuelrequired
Type
Normaloutput
Nominalvohage
Hourrating
Directionof rotation
Weight
CLUTCH

Clutchtype

MIT

Clutchlacingarea
Transmission
type

MIT

TRANSMISSION

MIT

PrimaryredLrction
Type
1st
2nd
3rd
4th
5th
Reverse

Finalreduction

Geartype
Gearratao

Transfer
Type

Transfer

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2-12

3.500
1.956
1.344
1.071
0.812
3.000*,.3.461*'
Single helicalgear
4.562

0.434

Reardifferential

Finalreduction

4 , 1 6 5t b s
|
1,900kg
Water-cooled,4-strokeDOHC
gasolineengine
Inline4-cylinder,
transverse
84.0x 89.0mm
3.31x 3.50in
.1,973
cm3(m{)
1 2 0c u - i n
9.2
9.6
Beltdriven,DOHC
4 valvesper cylinder
Forcedandwet sump,trochoidpump
501 (53 US qt,44 lmp qt)/minute
1401(148US qt, 123lmp qt)/minute
gasoljnewith 86
UNLEADED
PumpOctaneNumberor Higher
gearreduction
Planetary
A/T:1.1kW
M/T: 1.0kW
12V
30 seconds
Clockwiseas viewedfrom gearend
3.7kg
8.2 lbs
Singleplatedry, diaphragmspring
Torqueconverter
203cm,
31.5sq-in
Synchronizeds-speedtorward, 1 reverse
Electronically
controlled
4-speedautomatic,1 reverse
Direct I : 1

Approx.

Manualtransmission

Gearratio

Gearratio

NOTES

1 7 7 . 6i n
68.9in
63.3in
1 0 3 . 2i n
60.4in
60.4in
5lf

Valvetrain

STARTER

ENGLISH

4 , 5 1 0m m
1,750mm
1,608mm
2,622mrn
1,533mm
1,534mm

1st
2nd
3rd
4th
Reverse
Geartype
Gearratio

2.533
Automatictransmission
2.722
1.079
0.711
1.955
Singlehelicalgear
4.357

0.393

*1: '97- 99 models


*2: '00 model

ITEM
AIR CONDITIONING

Compressor

-Condenser
Evaporator
Blower

METRIC

Cooling capacity

Type/manutacturer
No. of cylinder
CaPacity
Max.speed
Lubricantcapacity
Lubricanttype
Type
Type
Type
Motor input
Speedcontrol
Max.capacity

ENGLISH

NOTES

j
14,000BTU/h
3,520Kcal/h
Scroll/KElHlN
85.7mf/rev

| 5.23cu'in/rev
10,000rpm
algIloz
130mf
1
sP-10
fin
Corrugated
Corrugated
fin
Siroccofan

200w 112v
4-Speeo
15,500 cu fvh

440 m3/h

Temperature
control
Compressor
clutch
Befrigerant

Type
Powerconsumption
Type
Ouantity

STEERING
SYSTEM Type
Overallratio
Turns, lock to lock
Steeringwheeldiameter
SUSPENSION

Type

Front
Bear

Shockabsorber
WHEEL
ALIGNMENT Camber

Tvpe

Front
hear
Front
Front
Rear
Front

Pad surface area


Lining surfacearea
P a r k i n gb r a k e

Rear
Front
Rear
Tvpe

Caster
Totaltoe

BRAKESYSTEM

TIRE
ELECTRICAL

Frontand Rear

Sizeand pressure
Baftery
Starter
Alternator
In under-dash
fuse/relaybox
In under hood fuse/relaybox
In underhoodABSfuse/relay
box
Headlights
Frontturn signallights
Frontparkinglights
Frontsidemarkerlights
Rearsidemarkerlights
Rearturn signallights
Erake/parkinglights
Back-uplights
Ceilinglights{fronvrear)
Licenseplatelight
Spotlights
Highmountbrakelight
lgnitionkey light
Ashtraylight
Gaugelights
Indicatorlights
lllLrmination
and pilotIights
Heaterilluminationlights

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Dry,singleplate,poly-V-belt
drive
40 W max./12V
HFC-134a
1R-134a)
24j anoz
zoo o' g
Powerassisted,rackand pinion

At 68'F (20 C)

Independent
doublewishbone,coil spring
with stabilizer
Independent
doublewishbone,coil spring
with stabilizer
hydraulicnitrogengas tilled
Telescopic,

0'
- r"00'
2.10'
0mm
0in
l n 1 / 1 6i n
ln2mm
Power-assisted
selt-ad,usting
ventilateddisc
Power assistedself-adiustingdrum
49 cm, x 2
7.6sq-inx 2
7 3 c m ,x 2
1 1 . 3s q - i nx 2
reartwo wheelbrakes
Mechanical
actuating,
Seetire inlormationlabel.

Drum brake

12V, 36 AH/sHR
1 2 V 1 . 0 ,1 . 1k W
12V 100A
7.5A, 10A, 15A, 20 A
7.5A, 10A, 15A, 20 A, 30 A, 40 A
'100A
7 . 54 , 2 0 A . 4 0A
12V 60/55W
12V- 21 W ('97model),
1 2V - 2 7W ( ' 9 8 - 0 0m o d e l s )
12V 5 W {'97model),3CP('98- 00 models)
12V-8W
1 2V , 3 C P
12V-21W
12V 2115W
1 2 V 2 1C P( 1 8W )
12V-8W
12V-8W
12V-5W
1 2 V- 2 1 W
1 2V - 1 . 4W
1 2 V 1 . 4W
1 2V 1 . 4W , 3 W , 3 . 4W
1 2 V - 0 . 8 4 W ,1 . 1 2W , 1 . 4W , 3 W , L E D
12V - 0.84W, 1.4W, LED
1 2V , 1 . 4W

2-13

Body Specifications
U n i t :m m ( i n )

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2-14

Maintenance
............3-2
Points
Lubrication
MaintenanceSchedulefor 1997Model
(NormalConditions)
...".3-4
Schedulefor 1997Model
Maintenance
(SevereConditions)
."...3-6
Schedulefor 1998- 2000Models
Maintenance
(NormalConditionsl
..'."3-8
Schedulefor 1998- 2000Models
Maintenance
(severeConditionsl
'....'3-10

I
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LubricationPoints

Forthe detailsof lubricationpointsand type of lubricantsto be applied.referto the illustratedindexand variouswork procedures(suchas Assembly/Reassembly,
Replacement,
Overhaul,Installation,
etc.)containedin eachsection.
NO.

LUBRICATION
POINTS
Engine

Transmission

Manual

Automatic
Reardifferential
Brakeline(includesABS line)
ClutchLine

Shift lever pivots (Manual transmission)

Release
fork (Manualtransmission)

10
l1
12
14
16
17
18
19
20
21
22
23
24

GenuineHondaMTF*1
GenuineHondaPremiumFormulaAutomaticTransmission
Fluid
(ATF)*'
GenuineHondaCVTFluid

4
5

LUBRICANT
gradeoil.The oil
APIServiceGrade:UseSJ "EnergyConserving"
containermay alsodisplaythe APICertitication
sealshown
"For
below.Makesure it says
GasolineEngines."SAEvjscosity:
Seechartbelow.

Power steeringgearbox

GenuineHondaDOT3 BrakeFluid*3
Brakefluid DOT3 or DOT4*3
Greasewith molybdenumdisultide
- PYs- 305
LJrea
GreaseUM264P/N4'1211
SteeringgreaseP/N 08733- B070E

T h r o t t l e c a b l e e n d { D a s h b o a r dl o w e r p a n e l h o l e l

Siliconegrease

Throttlecableend (Throttlelink)
Brakemastercylinderpushrod
Pedallinkage
Batteryterminals
F u e l f i l ll i d
Clutchmastercylinderpushrod
Hoodhingesand hood lock
Tailgatehinges
Hatchglasshinges
Doorhinges,upperand lower
Dooropeningdetent
Caliper Pistonseal,Dustseal,
Caliperpin, Piston
Shiltcableand selectcable{Manualtransmission)
Brakeline ioints(Frontand rearwheelhouse)
Powersteeringsystem
Air conditioningcompressor

25

API SERVICELABEL

/,.*-G\

/.'z-\e\
t / 6 A

E \ l
l-;-1 5w-30/---l

SEAL
API CERTIFICATION

ffi

Multi purposegrease

HondaWhiteLithiumGrease

Silicone grease

Rustpreventives
GenuineHondaPowerSteeringFluid-.
Compressor
oil: SP 10 lP/N38897- P13- A0lAH or
38899-P13-A01)
For Refrigerant:
HFC134a(R,134a)

Recomm6ndedEngine Oil
Engine
oilviscosity
for ambient
temperature
ranges

-20

20

-30 -20 .10

100'F

10 20 30 40'c
0
r1: Always use GenuineHonda Manual TransmissionFluid {MTF).Using motor oil can causestiffer shifting becauseit
does not containthe orooeradditives.
*2: Always use GenuineHondaPremiumFormulaAutomaticTransmissionFluid(ATF).Usinga non-HondaATF can affect
shift qualitv.
+3rAlways use GenuineHondaDOT3 BrakeFluid.Using a non-Hondabrakefluid can causecorrosionand decreasethe
life of the system.
*4: Always use GenuineHondaPowerSteeringFluid.Usingany other type of power steeringfluid or automatictransmission fluid can causedincreasedwear and poor steeringin cold weather.

www.emanualpro.com

3-2

NOTE:Lubricateall hinges,latches,and locksoncea year.


In corrosiveareas,more frequentlubricationis necessary.
We recommendHondaWhite LithiumGrease.

www.emanualpro.com

3-3

Maintenance
Schedule(for 1997Model)
Normal Conditions
>
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www.emanualpro.com

3-4

'5

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www.emanualpro.com

E #

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3-5

Maintenance
Schedule(for 1997Modell

SevereConditions

z
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3-10

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3-11

EngineElectrical
4-2
ChargingSystem
.............
SpeciafTools
4-22
ComponentLocationIndex ............
Starting System
4-23
....................,...........
Diagram
4-3
Circuit
ComponentLocationIndex ............
4-24
Troubleshooting..............................
4-4
CircuitDiagram................................
4-30
..........,.......
AlternatorReplacement
...........
4-5
StarterTest
4-31
AlternatorOverhaul.......,,................
4'5
StarterSolenoidTest ......................
.........4-32
RectifierTest
4-7
StarterReplacement.......................
...........
4-32
Inspection
Alternator Brush
4-7
FieldWindingTest ...........................
4-33
4-8
RotorSlip RingTest ........................
StarterOverhaul............................,.
4-33
.............
Stator Test
4-9
BrushInspection...........................,.,
Alternator Belt Inspectionand
OverrunningGlutchInspection ......4-9
........4-34
Adiustment
Armaturelnspectionand Test ........4-10
GruiseControl
4-12
BrushHolderTest ............................
4-36
ComponentLocationIndex .,,,........
4-12
StarterReassemb|y.........................
4-37
CircuitDiagram................................
4-13
PerformanceTest .............................
4-38
ControlUnit InputTest ...................
lgnition System
Main Switch Test/Replacement.....4-40
4-14
ComponentLocationIndex ............
Set/ResumeSwitch Test/
4-15
CircuitDiagram................................
4'40
Replacement.......................,........
lgnition Timing Inspectionand
....,,.,
4-41
Actuator Test
4-16
Setting ..........................................
4-42
Actuator Replacement...............,....
4-17
........,........
DistributorReplacement
4-43
Actuator CableAdiustment ............
4-18
DistributorOverhaul.............,,.........
4-43
ClutchSwitchTest ..........................
lgnition Control Module (lCM)Input
4-44
..........
SwitchTest ..................
T e s t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . , .4.-. 1
. .9. . . . . . . . .Brake
..
...,.
4-44
Test
..............
Actuator Solenoid
4-2O
fgnitionCoilTest ..............................
4-45
ActuatorDisassembly.....................
lgnition Wire Inspectionand
4-20
Test ...............................................
4-21
SparkPlugInspection.....................

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ENGINE

SpecialTools

Ref. No.

Tool Number

o
-o
o

A973X- 041 XXXXX


0 7 J G G- 0 0 1 0 1 0 A
07PAZ- 0010100

Description

Oty

VacuumPump/Gauge,
0 30 in.Hg.
BeltTensionGauge
SCSServiceConnector
* Includedin the BeltTensionGaugeSet,T/N 07JGG- 0010004

PageReference
4-41
434
4-16

o
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4-2

StartingSystem
ComponentLocationIndex

CLUTCHINTERLOCK

swtTcH{M/T)
BATTERY
Test,section23

I
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Test,page 4-43
Switchpositionadiustment,
section12

A/T GEARPOSITIONSWITCH{A/T}
Test,section14
Reolacement.
section14

Test,page4 5
SolenoidTest,page4-6
Replacement,page 4-7
Overhaul,page4 8
page4-12
Reassembly,
PerformanceTest,Page4-13

4-3

StartingSystem
CircuitDiagram
IGNTION
SWITCH

UNDER.HOOD
FUSE/RELAY
8OX
N0.41(100A)

N0.42(40A)

-+o

/ BAI

\i7

cf-.|

BLKMHT

II
I

ELKMHT

BLK'WHT

IGNITIONCONTROL
MOoULE
( CM)

STARTEF
CUl RELAY

-.1

GRY

BLKRED

GRN

I
PosrroN!
I A/TGEAR
(A/T) |
i swrTcH
ll \/ o N E o r N \ |
!--

p . s i t o n/
:
-_
--___J

f';--"-l
I TNTERLooK I

fYl""yl, I

8LK

STARTEB
(Fieldwndnglype)

Gl0l

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4-4

StartingSystem
Starter Test
NOTE: The air temperaturemust be between 59 and
'100'F(15and 38"C)beforetesting.
RecommendedProcedure:
.
.
.

Usea stanersystemtester.
Conneca
t n d o p e r a t et h e e q u i p m e n ti n a c c o r d a n c e
instructions.
with the manufacturer's
Testand troubleshootas described.

4. Unplug the connector(BLK /VHTwire and solenoid


terminal)from the starter.
5 . Connecta jumper wire from the bafterypositive(+)
terminalto the solenoidterminal.
The startershouldcrankthe engine.

Alte.nate Procedure:
.

Checkthe battery, battery positivecable, ground.


stanercut relay,and the wire connectionsfor loosenessand corrosion.Testagain.
lf the staner still does not crank the engine,go to
step 4.

Usethe followingequipment:
- Ammeter,0 - 400A
- Voltmeter,0 - 20 V (accurate
within 0.1volt)
T a c h o m e t e r ,-01 , 2 0 0r p m
Hookup a voltmeterand ammeteras shown.

NEGATIVETERMINAL

NOTE: After this test, or any subsequentrepair. reset


the ECM/PCM
to clearany codes(seesection11).

.
.

l f t h e s t a r t e rs t i l l d o e s n o t c r a n k t h e e n g i n e ,
removeit, and diagnoseits internalproblem.
lf the startercranksthe engine,go to step6.

Checkthe Starter Engagement:


'1. Removethe No. 44 (15A) fuse from the under-hood
fuse/relaybox.
2.

Turn the ignitionswitchto START(lll)with the shift


lever in E or E position (A/T) or with the clutch
pedaldepressed{M/T).The startershouldcrankthe
e n gi n e .
.
.

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lf the starter does not crank the engine, go to


step3.
lf it cranksthe engineerraticallyor too slowly,go
t o " C h e c kf o r W e a r a n d D a m a g e "o n t h e n e x t
page.

6 . Checkthe ignitionswitch(seesection23).
7 . Checkthe startercut relay{seesection23}.
8. Checkthe IVT gear position switch (A/T)or the clutch
interlockswitch (M[).
Checkfor an open in the wire betweenthe ignition
switchand starter.

(cont'd)

4-5

StartingSystem
StarterTest (cont'dl

Starter Solenoid Test

Checklor Wear and D8mage


T h e s t a r t e rs h o u l dc r a n kt h e e n g i n es m o o t h l ya n d
s t e a d i l y l.f t h e s t a n e re n g a g e s b, u t c r a n k st h e e n g i n e
erratically,removeit, and inspectthe starterdrive gear
and torque converterring gear or flywheelring gear for
oamage.

1.

Checkthe drive gear overrunningclutchfor binding or


s l i p p i n gw h e n t h e a r m a t u r ei s r o t a t e dw i t h t h e d r i v e
gear held.lf damaged,replacethe gears.

Checkthe hold-incoil for continuitybetweenthe S


t e r m i n a la n d l h e a r m a t u r eh o u s i n g( g r o u n d )T. h e
coil is OK if thereis continuity.
STARTER

B TERMINAL
MOUNTINGNUT
9 N.m 10.9kgtm,
7 tbtftl

CheckCrankingVoltage and Current Draw


Crankingvoltageshouldbe no lessthan 8.7 volts on Ay'T
models,and 8.0volts on M/T moders.
Currentdraw should be no more than 230 ampereson
A,/Tmodels,and 200ampereson M/T models.
lf crankingvoltageis too low, or currentdraw too high,
checkfor:
. deador low battery.
a o p e n c i r c u i t i n s t a r t e ra r m a t u r ec o m m u t a t o rs e g ,
ments.
. starterarmaturedragging.
. shortedarmaturewinding.
. excessivedrag in engine.
CheckCrankingrpm
Enginespeedduringcrankingshouldbe above 100rpm.
lf speedis too low, checkfor:
a loosebafteryor starterterminals.
. excesslvely
worn stanerbrushes
. opencircuitin commutatorsegments.
. dirty or damagedhelicalsplinesor drivegear.
a defectivedrive gearoverrunningclutch.
CheckStarter Disengagement
With the shift lever in @ or @ position(A,iT)or with the
clutchpedaldepressed{M/T).turn the ignitionswitchto
START(lll).and releaseto ON (ll).
The starterdrive gear shoulddisengagefrom the torque
c o n v e r t e rr i n g g e a r o r f l y w h e e l r i n g g e a r w h e n y o u
releasethe key.
lf the drive gear hangs up on the torque converterring
gearor flywheelring gear,checkfor
. solenoidplungerand switchmalfunction.
. dirty drive gear assemblyor damaged overrunning
clutch.

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4-6

TERMINAL

ARMATURE
HOUSING
(GROUND}

BLK/WHT
WIRE
2.

Checkthe pull in coil for continuitybetweenthe S


and M terminals.The coil is OK if thereis continuity.

StarterReplacement

Field Winding Test

1 . Disconnectthe battery negativecable.

t.

Disconnectthe startercablefrom the B terminalon


the solenoid. then disconnectthe BLK/WHTwire
from the S terminal.
B TERMINAL
MOUNNNG NUT
I N.m (0.9kgl.m,

Checkfor continuitybetweenthe brushes.lf there's


no continuity,replacethe armaturehousing,
Checkfor continuity between each brush and the
a r m a t u r eh o u s i n g{ g r o u n d ) l. f t h e r e i s c o n t i n u i t y .
replacethe armaturehousing.

STARTER
ERUSHES

7 rbtftl

RE

l0 x 1.25mm
4,1N.m {4.5 kgf.m,
33 tbt.ftl
5.

R e m o v et h e t w o b o l t s h o l d i n g t h e s t a r t e r .t h e n
remove the starter.

4.

I n s t a l l i n t h e r e v e r s eo r d e r o f r e m o v a l . W h e n
i n s t a l l i n gt h e s t a r t e r c a b l e , m a k e s u r e t h a t t h e
crimpedside ofthe ring terminal is facing out,
Crimpedside of ring
terminal

TERMINAL

o
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Connectthe batterypositivecableand negativecable


to the batterv.

4-7

Starting System
Starter Overhaul
STARTERSOLENOID

STARTER
SOLENOID
Test,page4 6
OVEBRUNNING
CLUTCH

w
ARUSH

-6^l
MOLYBDENUM
DISULFIDE

SPRINGCLIP
Replace.
BBUSHHOLDER
Test,page4-12
GEARHOUSING
ARMATURE
HOUSING

ARMATURE
Inspection
and Test.page4-10
ENDCOVER

BAUSH
InsPeclon,page4-9

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4-A

..'...:|@{
MOLYBDENUM
DISULFIDE

BrushInspection

ClutchInspection
Overrunning

Measurethe brush length.lf it is not within the service


limit, replacethe brush(or brushholderassembly).

1.

2.
Brush Lsngth
Standard{Newl:14.0- I'1.5mm (0.55- 0.57inl
ServicoLimit: 9.0 mm (0.35in)

Slidethe overrunningclutchalongthe shaft.Doesit


move freely?lf not, replaceit.
Rotatethe overrunningclutch both ways. Does it
l o c k i n o n e d i r e c t i o na n d r o t a t e s m o o t h l y i n
reverse?lf it does not lock in either directionor it
locksin both directions,reDlaceit.

BRUSH

NOTE:To seat new brushesafterinstallingthem in their


holders.slip a strip of #500or #600sandpaper,with the
grit side up, over the commutatorand smoothly rotate
the armature.The contactsurfaceof the brusheswill be
sandedto the samecontouras the commutator.

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3.

lf the starterdrive gear is worn or damaged,replace


t h e o v e r r u n n i n gc l u t c ha s s e m b l yt;h e g e a r i s n o t
availableseparately.
Checkthe conditionof the torqueconverterring gear
or the flywheel ring gear if the starter drive gear
teethare damaged.

4-9

StartingSystem
ArmatureInspectionand Test
1.

I n s p e c t h e a r m a t u r ef o r w e a r o r d a m a g ed u e t o
contact with the field winding. lf there is wear or
damage.replacethe armature.

3.

C h e c kt h e c o m m u t a t o rd i a m e t e r .l f c o m m u t a t o r
d i a m e t e r i s b e l o w t h e s e r v i c el i m i t , r e o l a c et h e
armalure.
Commutator Diameter
Standard(Newl:27.9- 28.0mm (1.09- 1.10in)
ServiceLimilr 27.0mm (1.06inl

lnspectfor damage.

Checkthe commutatorsurface.lf the surfaceis dirty


or burnt,resurfacewith emery cloth or a lathewithor reconditionwith
in the tollowing specifications,
#500or #600sandDaoer.

4.

Measurethe commutatorrunout.
l f t h e c o m m u t a t o r u n o u ti s w i t h i n t h e s e r v i c e
limit, checkthe commutatorfor carbon dust or
brasschipsbetweenthe segments.
lf the commutator runout is not within the service limit, replacethe armature.
CommutatorRunout
Standard(Newl:0 - 0.02mm (0 - 0.0008in)
ServiceLimit: 0.05mm {0,002inl

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4-10

5.

Checkthe mica depth. lf necessary,undercutthe


mica with a hacksawbladeto achieveproperdepth.
l f t h e s e r v i c el i m i t c a n n o tb e m a i n t a i n e dr,e D l a c e
the armature.

7.

Placethe armature on an armaturetester. Hold a


hacksawbladeon the armaturecore.

NOT GOOD

MICA DEPTI{

Commutator Mica Depth


Standard (Nsw): 0.5 - 0.8 mm 10.02- 0.03 inl
ServicoLimit: 0.2 mm (0.008in)
6.

Checkfor continuitybetweenthe segmentsof the


commutator.lf an open circuit exists betweenany
segments.replacethe armature.

lf the bladeis attractedto the core or vibrateswhile


the core is turned.the armatureis shorted.Replace
the armature.
8.

COMMUTATOR

With an ohmmeter,checkthat no continuityexists


betweenthe commutator and armature coil core,
and betweenthe commutatorand armatureshaft.lf
there is continuity.replacethe armature,

cotLcoRE

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4-11

StartingSystem
Starter Reassembly

Brush Holder Test


1.

Checkthat there is no continuitybetweenthe O and


O brush holders.lf there is continuitv,replacethe
brushholderassembly.

O BRUSHHOLDER

NOTE:Use the illustrationon page 4I as referencefor


reassemDty.
1.

Pry backeachbrushspringwith a screwdriver,


then
positionthe brush about halfwayout ol its holder,
and releasethe springto hold it there.

2.

Installthe armaturein the housing.Next, pry back


each brush spring again,and push the brush down
until it seatsagainstthe commutator,then release
the springagainstthe end of the brush.

@ BRUSHHOLDER

Insertthe brushinto the brushholder,and bring the


brush into contactwith the commutator,then attach
a springscaleto the spring.Measurethe springtension at the momentthe spring liftsoff the brush.

E ^

F*4#-@
6t ta

al

la

tl l l
ft

SPRINGSCALE

3.

SpringTension:13.7- 17.7N
(1.40- 1.80kgf, 3.09- 4.00lbf)

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4-12

I n s t a ltlh e e n dcovero n t h e b r u s hh o l d e r .

,r

Test
Performance
1.

Disconnect
the wire from terminalN4.

5.

Disconnectthe battery also from the body. lf the


pinion retractsimmediately,it is working properly,
To avoiddamagingthe starter,do not leavethe batterv connectedfor more than 10 seconds.

6.

Clampthe starterfirmly in a vise.

7.

Connectthe starter to the battery as describedin


t h e d i a g r a m b e l o w ,a n d c o n f i r mt h a t t h e m o t o r
starts and keepsrotating.

8,

lf the electric current and motor soeed meet the


when the batteryvoltageis at 11.5V,
specifications
the starteris workingproperly.

M a k e a c o n n e c t i o na s d e s c r i b e db e l o w u s i n g a s
heavy a wire as possible(preferablyequivalentto
the wire usedfor the vehicle).
3.

Connectthe batteryas shown. lf the starterpinion


pops out. it is working properly.To avoid damaging
the starter,do not leavethe batteryconnectedfor
more than 10 seconds.

12V
BATTERY

ie

Disconnectthe batteryfrom the M terminal. lf the


pinion does not retract,the hold-in coil is working
p r o p e r l y .T o a v o i d d a m a g i n gt h e s t a r t e r ,d o n o t
leavethe batteryconnectedfor more than 10 sec
onds.

Specifications:
Maker
DENSO

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Electriccurrent
90 A or less

Motor speed
3,000rpm or
more

4-13

lgnition System
ComponentLocationIndex
IGNITIONTIMINGCONTROLSYSTEM
. ldle speedInspection/Adjustment,
section11
. Inspectionand Sening.page4-16

SERVICECHECKCONNECTOR(2P)
lwi.c colo6: BRNrnd BLKI

TESTTACHOMETER

SPARKPLUGS
page4-21
Inspection,
DISTRIBUTOR
page4-17
Replacement,
Overhaul,page4-18
lgnitionCoilTest,page4,20
lgnitionControlModule CM)
InputTest,page4,19

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4-14

WIRES
Inspection
and Test,page4-20

CircuitDiagram
IGNITON
SWTCH

UNDEF.HOOD
FUSE/RELAY
8OX

UNDEF,DASH
FUSEiRELAYBOX

6\
l;;l
i{Hr6-(-\9-'-'*'.--EII

Eci,.pcM

' i Vl

BLK/YEL

l^

IGNITION
cotL

IGN]TION
CONTROL
MODULE
(CM)
/ Hasbuil-if\
I no|se
l

TDCTopdeadcenler
poslion
CKP Cran[shan
C Y PC y l n d epro s r l o n
TDC/CKP/CYP
SENSOR

l-- r

IGNTION
W]BES

i l ' i - - ,l
l
i f r
BLU

IJltfi
--cMFcr,r

SPARK
PLUGS

BLU BLU

l l / ' i
|

|
I

I I

resr

TACHOMETER

tott"to*

LTTCHoMEIEB
'97-'98 models

I
I l:
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'99- 00models

Gt01

4-15

lgnition System
lgnition Timing Inspectionand Setting
1.

Checkthe idle speed,and adjustit if necessary(see


section11).

2.

Pull out the servicecheckconnector2P (BRN and


BLKwires)from the connectorholderlocatedunder
the dash on the front passengerside,then connect
to
the scs serviceconnector(P/N07PAz- 0010100)
it.

6.

lf necessary,adjust the ignition timing as follows.


Loosenthe distributormountingbolts,and turn the
to
distributorignition(Dl)housingcounterclockwise
advancethe timing or clockwiseto retardthe timtn o ,
To RETARD

Startthe engine.Holdthe engineat 3,000rpm with


no load (A/T in N or E, Mff in neutral)until the
radiatorfan comeson, then let it idle.
Connectthe timing light to the No. I ignitionwire,
then point the light towardthe pointeron the timing
belt cover.
5.

C h e c kt h e i g n i t i o nt i m i n g i n n o l o a d c o n d i t i o n s :
headlights,blower fan, rear window defogger,and
air conditionerare not operating.
lgnitionTiming:
M/T: 16"12" BTDC(RED)idling in neutral
AlTt'16"!2" BTDC(RED)idling in E or E

MOUNTING
BOLTS
24 N.m{2.4kgfm, 17lbtft}
7 . Tightenthe distributormountingbolts,and recheck
t h e i g n i t i o nt i m i n g .
8.

CRANKSHAFT
PULLEY

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4-16

Disconnectthe SCSserviceconnectorfrom the servicecheckconnector.

DistributorReplacement
Removal:
e
o

5.

1.

Disconnect
the connectorfrom the distributor.

2.

Disconnectthe ignition wires from the distributor


i g n i t i o n( D l )c a p .

3.

R e m o v et h e m o u n t i n gb o l t s f r o m t h e d i s t r i b u t o r ,
then removethe distributorfrom the cylinderhead.

Connectthe ignitionwires to the distributorignition


(Dl)cap as shown,

I'

CAMSHAFT
END

No. 1
CYLINDER
MARK

6.

Connectthe connectorto the distributor.

7.

Setthe ignitiontiming (seepreviouspage).

8.

After settingthe ignitiontiming, tightenthe mounting bolts.

BOLTS
MOUNTING
8 x 1.25mm
17lbfftl
2,1N.m{2.,1kgrf.m,

lnstallation:
1.

Bringthe No. 1 pistonto compressionstrokeTDC.

2.

Coata new O-ringwith engineoil, then installit.

3.

Align the lug on the end of the distributorand its


mating grooves in the camshaftend, then slip the
distributorinto position.
NOTE:The lug on the end of the distributorand its
mating groovesin the camshaftend are both offset
to eliminatethe possibilityof installingthe distributor 180oout of time.

4.

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Installthemountingbolts,and tightenthem lightly.

4-17

lgnition System
Distributor Overhaul
LEAK COVEN

CAPSEAL
Checkfor damage.

DISTRIBUTOR
IGNITIONIDII ROTOR
IGNITION{DII CAP
OISTRIBUTOR
Checkfor cracks,wear,
damage,and to!ling.
Cleanor replace.

IGI{ITIONIDOHOUSING
OISTBIBUTOR
forcracks
anddamage.
Check

O.RING
Replace.

IGNITIONCOIL
Test, page 4 20

@_
IGNITIONCONTROL
MODULE{ICMI
InputTest,page4-19

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4-18.

lgnitionControlModule(lCMlInputTest
NOTE:
. See section11 when the malfunctionindicatorlamp
( M l L )c o m e so n .
. Performan input test for the ignitioncontrol module
( l C M )a f t e r f i n i s h i n gt h e f u n d a m e n t atl e s t sf o r t h e
ignitionsystemand the fuel and emissionssystems.
. '97 -'98 models:The tachometershouldoperatenorm a l l yi f t h e I C Mi s O K .

Turn the ignition switch ON {ll). Checkfor voltage


betweenthe BLK,^/EL
wire and body ground.There
shouldbe batteryvoltage.
.
.

lf there is no batteryvoltage,checkthe BLK/rEL


wire betlveenthe ignitionswitchand the lclvl.
lf there is bafteryvoltage, go to step 4.

Removethe distributorignition(Dl)cap,the distributor ignition(Dl)rotor,and the leakcover.

T u r n t h e i g n i t i o ns w i t c hO N ( l l ) .C h e c kf o r v o l t a g e
betweenthe WHT/BLUwire and body ground.There
shouldbe batteryvoltage.

2.

Disconnect
the wiresfrom the lCM.

8LU WIRE
'98 models}
{'97 -

lf thereis no batteryvoltage,check:
- ignitioncoil.
- WHT/BLUwire betweenthe ICM and ignition
corl.
. lf thereis batteryvoltage,go to step5,
'97 model: Disconnectthe ECM/PCM
connectorA
(32P)C
. h e c kf o r c o n t i n u i t yo n t h e Y E L / G R Nw i r e
betweenthe ICM and ECM/PCM.There should be
continuity.
'98 - 00 models: Disconnectthe ECM,PCM
connector
B (25P).Checkfor continuityon the YEUGRNwire
betweenthe ICM and ECM/PCM.There should be
continuity.
Checkfor continuityon the YEUGRNwire to body
ground.Thereshouldbe no continuity.
7 . Reconnect
the ECM/PClvl
connector.
'97 -'98 models:
Checkfor continuityon the BLU
wire betweenthe test tachometerconnectorand the
lCM.Thereshouldbe continuity.
9 . ' 9 7 - ' 9 8 m o d e l s :C h e c kf o r c o n t i n u i t yo n t h e B L U
wire to body ground.Thereshouldbe no continuity.
'10. lf all the

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testsare normal,replacethe lCM.

4-19

lgnition System
lgnitionCoilTest

lgnition Wire Inspectionand Test

Using an ohmmeter, measureresistancebetweenthe


terminals.lf the resistanceis not within sDecifications,
replacethe ignitioncoil.

1 . C a r e f u l l yr e m o v et h e i g n i t i o nw i r e s b y p u l l i n go n
the rubber boots.Do not bendthe wires;you might
breakthem inside.

NOTE: Resistancewill vary with the coil temperature;


specifications
are at 68"F(20'C).

Checkthe conditionof the ignitionwire terminals.lf


any terminalis corroded,cleanit, and if it is broken
or distorted,replacethe ignitionwire.

Plimary Winding Resistance


{Betweenthe A and B terminals):
0.6it- 0.77 0
SecondaryWinding Resistance
{Betweenthe A and secondarywinding terminals):
12.8- 19.2kO

IGNITIONWIRE

Connectthe ohmmeter probesand measureresistance.

lgnition Wire Resistance:


25 kO max. at 68'F 120'Cl

TERMINALA {+l

IGNITIONWIRE
4.

4-20

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lf the resistance exceeds 25 kO, replace the ignition


wire.

SparkPlugInspection
Inspectthe electrodesand ceramicinsulatorfor:

2.

Checkthe electrodegaP.
.

Adjustthe gap with a suitablegappingtool.

ElectrodeGap

.
.
.
.

lmpropergap
Oil-fouling
Carbondeposits
Crackedcenter
electrodeinsulator

in)
1.1 3 ' mm (0.043Loo.

Standard

the plug if the centerelectrodeis rounded


Replace
as shownbelow:
ROUNDEO
ELECTRODE

,--,
(--/
Burned or worn electrodesmay be causedby:
. Advancedignitiontiming
. Loosesparkplug
. Plugheat rangetoo hot
. Insufficientcooling
Fouledplug may be causedby:
. Retardedignitiontiming
. O i l i n c o m b u s t i o cnh a m b e r
. Incorrectsparkplug gap
. Plug heatrangetoo cold
. Excessive
idling/lowspeedrunnang
. C l o g g e da i r c l e a n eer l e m e n t
. Deteriorated
ignitionwires

| |

/
r--'--'--r

-.-l-:=---:1
:
Spark Plugs
'97 - '98 modsls:

Z F R 5 F - 1(1N G K )
(D
KJ16CR-11
1E N S O )
'99 - 00 models;
NGK)
Z F R 6 F - 1( 1
(DENSO)
KJ2OCR-111
Apply a small quantity of anti-seizecompound to
the plug threads,and screwthe plugs into the cylinder head finger-tight.Then torque them to 18 N'm
(1.8kgf.m.13lbf.ft).

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4-21

ChargingSystem
ComponentLocationIndex
CHARGINGSYSTEMLIGHT
(ln the gaugeassembly)
Test, page 4-24

BATTERY

Test,

ALTERNATOR
Troubleshooting,
page4-24
Replacement,
page4-30
Overhaul,page4-31
RectifjerTest,page 4,32

4-22

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ALTERNATOR
BELT
Inspection
and Adjustment,page4 34

CircuitDiagram
BOX
FUSUFtAY
UNDES.HOOD
BATTERY

(1Cr0A)
N0.41

,-a\

(40A)
N0.42
WHT/8tK

l.

( tot,o, )

IGNITON
SWITCH

8LI(YEL

GRN/RED

ECM/PCM

V
I

WHT/RED

ALTERNATOR

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4-23

GhargingSystem
Troubleshooting
lf the chargingsystemlight does not come on or does not go off, or the batteryis dead or low, test the followingitems in
the order listedbelow:
1. Battery(seesection23)
2. Chargingsystemlight
3. Voltage
4. Alternatorcontrolsystem(U.S.A.model)
5. Alternator/regulator
ChargingSystem Light Test
ChsrgingSystomLight Check:
Turn the ignition switch ON {ll),
and makesure the chargingsys
tem lightcomeson.

Doesthe chargingsystem
lightcome on?

Check for a blown No. 15 17.5Al


fuse and a blown charging system light bulb. lf the tusa .nd
bulb are OK, repair th open in
th WHT/BLUwire.

Charging System Light Check


{com'd}:
Startthe engine.

Doesthe chargingsystem
light go offf

Perform the Alte.nator/Regulator


Test lsee page +281.

ALTERNATOR
4P CONNECTOR
{U.S,A.modell

Voltage Check:
Measurethe voltageat the No. I
lNo.2iterminalof the 4P [3Plconnectorwith the ignitionswitch ON

(BLK/YEL)

Wiresadeof
femaleterminals

{ ).

ls there battery voltage?

Ropair the open in the BLK/YEL


wiae betwoen the altemator and
under-da3hluso/relay box.

ALTERNATOR
3P CONNECTOR
lCanedamodel'

Iemale terminals

(To next page)

[ ] : C a n a d am o d e l

4-24

www.emanualpro.com

(Frompreviouspage)

in

Ch6ckthe L circuil:
1. Turnthe ignitionswitchOFF.
2. Disconnectthe 4P [3P] connectorfrom the alternator.
3. Turnthe ignitionswitchON (ll).

Doesthe charging system


lightcomeon?

Repairthe short to ground in the


WHT/BLUwire.

[ ]: Canadamodel

www.emanualpro.com

(cont'd)

4-25

ChargingSystem
Troubleshooting(cont'dl
'97 modol:

Alternator Control System Test {U.S.A.model)

NOTE:Beforetesting,checkproperoperationofthe ELDby checkingfor a DTC(seesection.11).


BATTERY
Chockfor a short in the circuit
IALTCline):
1. Disconnectthe 4P connector
from the alternator.
2. Startthe engine,and turn the
headlights
thigh beamiON.
3. Me8surevoltage between the
4 P c o n n e c t o tre r m i n a lN o . 2
and the positiveterminal of
the battery.

CAUTION: Be sure to use a voltmeter


with ils positive terminal connectedto
battery positive and hs negative terminalto the 4P connectorterminal No. 2.

{WHT/GRNI
ALTEFNATOR
4P CONNECTOR

Wiresideof
femaleterminals

ECM/PCMCONNECTOR
A I32PI

,/1./

lstherelVorless?

1
t4

./ l./

26 27
Check for an open in the wire
(ALTClinel:
1 . T u r n t h e h e a d l i g hat n d i g n i tion switchOFF.
2. Disconnectthe 32P connector
from the ECN4/PCM.
3. Checktor continuitybetween
the EcM/PcM 32P connector
terminalNo.30 and alternator
4P connectorterminalNo.2-

ls therecontinuity?

Rprir short in the wire between


the altornator and the ECM/PCM.

4-26

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2A 29 30

Wire side of
femaleterminals

femaleterminals

21
32

] ALTC
I tWHT/cRNl

tl

WHT/GRN)

ALTERNATOR
irP CONNECTOR

Repairopen in the wi.e betwoen


the atternatorand ECM/PCM.

ls therecontinuity?

Check for a shorl in the wiro


IALTCline):
1 . T u r n t h e h e a d l i g hat n d i g n ; ,
I|on swrtcnUFF
2. Disconnect
the 32Pconnector
from the EcM/PcM.
3. Checktor continuitybetween
the ECM/PCN4
32P connector
t e r m i n a lN o . 3 0 a n d b o d y
ground.

10

1 6 1 7 1 8 t9 20 21

ECM/PCMCONNECTOR
A {32P}
4

,/ ,/

,/1,/

14

6
8
1 6 l 7 t 8 '19 20 21

10

27

:t2

2A 2S 30

Wire side of
femaleterminals
Subslitute a known-good ECM/
PCM,and recheck.
It prescribedvoha96 b now available, replacethe original ECM/
PCM.

23 21

I ALTC
{WHT/GRNI
f)

'98 -'9O modols: Alternator Contlol SYstemTe3t (U.S.A'model)


NOTE:Beforetesting,checkproperoperationof the ELDby checkingfor a DTC(seesection11)
EATTERY

'oR

Chock tor . short in tha circuit


IALTClino):
1. Disconnoctthe 4P connector
Irom the alternator.
2. Startthe engine,and turn the
headlights(highbeam)ON.
3. Measurevoltage between the
4P connectorterminal No. 2
and the positive terminal oI
the battsry.

CAUTION: Be surc to uso a voltmetor


with its oo3itive torminel connccted to
battery po3hivo tnd its negativo teami'
nal to the 4P connectortorminal No 2.

c
IWHT/GRN)
Wire sideol
femaleterminals

ALTERNATOR
4P CONNECTOR

l s t h e r e1 V o r l e s s ?

Check for an opon in the wire


IALTCline):
1 . T u r n t h e h e a d l i g hat n d i g n i tion switchOFF.
2. Disconnect
the 31Pconnector
from the ECM/PCM.
3. Checktor continuitybetween
th6 ECM/PCM31P connector
terminalNo. 2 and alternator
4PconnectorterminalNo. 2.

ECM,/PCM
CONNECTOR
c {31P)
Wire sideol
temaleterminals

Ropairopen in the wiro between


the ahornrtor and ECM/PCM.

C {31P}
ECM/PCMCONNECTOR
ALTC
IWHT/GBNI
Chack lor a rhort in tho wire
{ALTClincl:
' ! . T u r n t h e h e a d l i g hat n d i g n i '
tion switchOFF.
the 31Pconnector
2. Disconnect
Irom the ECM/PCM.
3. Ch6ckfor continuitybetween
the ECM/PCM31P connector
terminalNo. 2 and body
ground.

lu

Substituto . known-good ECM/


PCM,.nd rochock.
lf prdcdbd voltage b now av.ilable, repl.ce the original ECM/

rcM.
Rcpair rhort in thc wire b.twcon
th. ahGrn.tol.nd the EcM/PcM.

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(cont'd)

4-27

GhargingSystem

(cont'd)
Troubleshooting
Alternator/RegulatorTest
NOTE:Makesurethe batteryis sufficientlycharged(seesection23).
Alternator/RegulatorTest:
1 . C o n n e c ta S u n V A T - 4 0( o r
e q u r v a l e ntte s t e r ) ,a n d t u r n
the selectorswitchto position
1{sraning).
2. Shift to neutral(A/T in E or
, n d s t a r tt h e
N) positiona
e n g a n eH. o l d t h e e n g i n ea t
3,000rpm with no load until
t h e r a d i a t o rf a n c o m e s o n ,
then let it idle.
3 . R a i s et h e e n g i n es p e e dt o
2,000rpm, and hold it there.

l s t h e v o l t a g e o v e r 1 5 . 1V ?

(BED)

FIELD
SELECTOR
TEST

NEGATIVE
TESTER
CABI.E{BLKI

swtTcH
Ahernator/Regulator
Test (cont'd)l
I Releasethe accelerator
pedal,
and let the engineidle.
2 Makesure all accessories
are
turned off. Turn the selector
switchto posjtion2 (charging).
3 Removethe inductivepickup,
and zerothe ammeter.
{ P l a c et h e i n d u c t i v ep i c k - u p
over the batterygroundcable
so that the arrow pointsto the
bafterynegativeterminal.
5 . R a i s et h e e n g i n es p e e dt o
2 000rpm, and hold ir there.

VOLTMEIER
POSmVE

INDUCTIVE
PICK.UP
{GRN)

TESTER
CABLEIREDI

WHTWIRE

l s t h e v o l t a g e l e s st h a n 1 3 . 5V ?

Altarnator/Regulator Test (cont'd:


Apply a load with a VAT-40 until
the battery voltage drops to
b e t w e e n 1 2 - 1 3 . 5V .

To next page

www.emanualpro.com

4-28

Frompreviouspage

ls the amperage65 A or more?

Aharnator/Regulator Tesl (cont'd):


W i t h t h e e n g i n e s p e e ds t i l l a t
2.000rom,fulllield the alternator.

The charging sy3tem b OK.


CAUTION:The voh.ge will tise quickly whon th. ahornato. is tull-li.lded Do not allow
the voltage to exceod18 V; it mry damagothe .loctrictl 3yaiGm.
into the tull field
NOTE: Attach a probe to a VAT-40Iull tield test lead,and inseft the probe
"A
lGround)"posiaccessholeat the backof the altemator'Switchthe fieldselectorto the
and checkthe amperagereadrng.
tion momentarily.
REGULATOR
(Locatedinside
the ond coverl
FULLFIELD
ACCESSHOLE

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4-29

ChargingSystem
AlternatorReplacement

l
I

' t . Disconnect
the batterynegativeterminalfirst, then

the positiveterminal.

Removethe adjustingbolt and mounting nut, then


removethe alternatorbelt.

N
ir

Disconnectthe 4P (or 3P) connectorand WHT wire


from the alternator.

Pullout the throughbolt,then removethe alternator.

T
n

THROUGH
BOLT

WHT WIRE

MOUNTINGNUT
10x 1.25mm
44 N.m 14.5kgf.m.
33 tbtftt

LOCKNUT
8 x 1.25 mm
24 N.m (2.4kgt m, 17 lbl.ft,

Installthe alternatorin reverseorderof removal.


o.

4-30

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'll

Adjust the alternatorbelt tension after installation


(seepage4-34).

AlternatorOverhaul

PULLEY

NOTE:Do not removethe pulley unlessthe front bearing needsreplacement.


To loosenthe pulley locknut,use the tools as shown. lf
necessary,
usean impactwrench.

,T
PULLEYLOCKNUT
111N.m (11.3kgf.m,81.7lbf.ft)

BEARINGINSULATOR

FRONTBEARING

PULLEY

CAUTION: Do not get grease


or oil on the slip rings.

"'^.^t%
BRUSHHOLDER
INSULATOB

THROUGHBOLT

RECTIFIER
ASSY
Test.page4 32

PULLEYLOCKNUT
111N.m {11.3kgf.m,81.7lbf,ft)

REARHOUSING

COVER
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4-31

ChargingSystem
RectifierTest

AlternatorBrushInspection

NOTE:The diodesare designedto allow currentto pass


in one directionwhile blockingit in the oppositedirec
t i o n . S i n c et h e a l t e r n a t o r e c t i f i e ri s m a d e u p o f e i g h t
diodes(four pairs),each diode must be testedfor conti
nuity in both directionswith an ohmmeterthat hasdiode
checkingcapability;a total of 16 checks.

1.

Removethe end cover,thentakeout the brushholder


by removing its two screws.

2.

M e a s u r et h e l e n g t ho f t h e b r u s h e sw i t h a v e r n i e r
calrper.

'l.

Checkfor continuityin eachdirectionbetween


- t h e B a n dPt e r m i n a l s .
- E ( g r o u n da) n d P t e r m i n a l s .
A l l d i o d e ss h o u l dh a v ec o n t i n u i t iyn o n l y o n e d i r e c tion.

Alternator Brush Length:


Standard(Newl:10.5mm 10.41inl
ServiceLimit: 1.5mm {0.06in)

VERNIERCALIPER

2.

lf any of the diodesfails,replacethe rectifierassembly. (Diodesare not availableseparatelv.)

4-32

www.emanualpro.com

lf the brushesare lessthan the servicelimit, replace


the alternatorbrushassemblv.

Stator Test

RotorSlip RingTest
1.

betweenthe slip rings.


Checkthe resistance
Thereshouldbe 1.8- 3.0ohms.
go to step2
. lf resistance
meetsthe specification,
. l f r e s i s t a n c ed o e s n o t m e e t t h e s p e c i f i c a t i o n ,
replacethe alternator.

1.

Checkthat there is continuitybetweeneach pair of


leads.
LEADS

ROTORSHAFT

corLcoRE
SLIPRINGS

Checkthat there is no continuitybetweeneach lead


and the coil core.
It the coil fails either continuitycheck,replacethe
alternator.

Checkthat there is no continuity betweenthe slip


ringsand the rotoror rotor shaft.
lf the rotor fails eithercontinuitycheck,replacethe
alternator.

www.emanualpro.com

4-33

ChargingSystem
AlternatorBelt Inspectionand Adjustment
NOTE:When usinga new belt,first adjustthe deflection
or tensionto the valuesfor the new belt, then readjust
the deflectionor tensionto the valuesfor the used belt
afterrunningenginefor five minutes.
Deflection methodi
A p p l ya f o r c eo f 9 8 N ( 1 0 k g t , 2 2 l b l l , a n d m e a s u r et h e
deflectionbetweenthe alternatorand crankshaftpulley.
Detlection:
UsedBelt:8.5- 11.5mm (0.33- 0.45inl
New Beft: 5.5 - 8.0 mm 10.22- 0.31 inl
NOTErlf the belt is worn or damaged,replaceit.

Measurehere

4-34

www.emanualpro.com

Belt tension gauge m6thod:


Attachthe belttensiongaugeto the beltand measurethe
tension.Followthe gaugemanufacturer's
instructions.
Tension:
Used Belt:340 - /0 N (35 - 50 kgf, 77 - 1r0 tbf)
New Belt: 690 - 880 N (70 - 90 kgf, 150- 200 tbt)
NOTE:lfthe belt is worn or damaged,replaceit.

lf adjustment is necessary:
1.

Loosenthe mountingnut and the locknut.

2.

Move the alternatorto obtain the proper belt tension,then retightenthe nuts.

LOCKNUT
8 x 1 . 2 5m m
24 N.m (2.4kgtm,'17lbf ft)

NUT
MOUNTING
10x 1.25mm
14N.m{4.5kgl.m.33lbf.ft)

Recheckthe deflectionor tensionof the belt.


NOTE: For the power steeringpump belt and A,/C
referto section17 and
compressorbelt adjustments,
section22.

www.emanualpro.com

4-35

GruiseControl

ComponentLocationIndex
CRUISEINDICATORLIGHT
(Builtinto gaugeassembly)
BulbLocations.
section23

BA

SET/RESUMESWITCH
Test,page 4 40
Beplacement,
page4-40

CRUISECONTROLUNIT
Input Test,page 4 38

swtTcH
Test, page 4-44

CLUTCHINTERLOCK

swrTcH{M/T)

PedalHeightAdjustment,
section19.

Test,page 4-43
Switchposkionadjustment,
section12
ACTUATOfiASSEMBLY
and VACUUMTANK
Test,page4 41
SolenoidTest,page4 44

A/T GEABPOSITION
swlTcH (A/Tl
'14
Test,section
www.emanualpro.com

+36

ACTUATORCAELE
Adjustment,page4-43

GircuitDiagram
IGNITON
SWITCH

FUSEi
RELAY
BOX
UNDER.HOOD

FUSARELAYBOX
UNDER.OASH

COMEINATON
L GH'I SWITCH

No41(100A) No42(404)

f7
I

RED/BLK

INDICATOR
LIGHT
(0.84W)

lP

IOSET

BRAK
LGHTS

2
1

6
1

7
1
2
C R U I SCEO N T R OUTN L T
1
1

3
10

CRUISE
PNK
CONTROL
ACTUATOR

BLK

It

4F\ /lr,mcern

t'

BLK

*: '98 00 modelswith
AutomaticTransmission.

www.emanualpro.com

n:
G202

BLK

L_ll
I I

Y{"^i?tr'.flffi'JF
)l
t

rereasedl
/l
loN: Pedar

8LK

BLK

G101

G401

I
4-37

CruiseControl
ControlUnit Input Test
and proceduresin the SRS
SRScomponentsare locatedin this area.Reviewthe SRScomponentlocations.precautions,
section(241beforeperformingrepairsor seryice.
'1. Removethe driver'sdashboardlowercoverand kneebolster{seesection20).
'l4P
connectorfrom the controlunit.

2.

Disconnect
the

3.

Inspectthe connectorand socketterminalsto be surethey are all makinggood contact


and recheckthe system.
lf the terminalsare bent,loose,or corroded,repairthem as necessary,
lf the terminalslook OK, makethe followinginput testsat the connector.
- lf any test indicatesa problem.find and correctthe cause,then recheckthe system.
- lf all the input testsproveOK,the controlunit must be faulty;replaceit.

*: '98- 00 modelswith
AutomaticTransmission.

4-38

www.emanualpro.com

Wire sideol femaleterminals

Disconnestthe lilP connectorfrom the control unit.


Csvity

Wire
BRNAr'VHT

BRN

11

BRN/BLK

GRY

BLK

GRNMHT

LT GRN/
RED
7

LT GRN/
BLK

Under all conditions

Checkfor resistanceto groundl


There should be 40 - 60 0.

Under all conditions

Checkfor resistanceto ground:


There should be 70 - 110 O.

lgnitionswitch ON (ll),
main switch ON and
brakepedaldepressed,
then released

Checkfor voltageto ground:


There should be 0 V with the pedal
depressedand batteryvoltagewith
the pedal released.

. Faultybrakeswitch
. An openin the wire

Under all conditions

Checkfor continuityto ground:


There should be continuity.

. Poor ground (G401)


. An open in the wire

Brakepedaldepressed, Checkfor voltageto ground:


thenreleased
There should be batteryvoltagewith
the pedal depressed,and 0 V with
the pedal released.

Setbuttonpushed

l4

PNK

B l o w nN o . 5 21 ' 1 A
5 lfuse inthe
under-hoodfuse/relaybox
Faultybrakeswitch
An open in the wire

Checkfor voltageto ground:


There should be batteryvoltage.

BlownNo.52 {'15A} fusein the


under-hood
fuse/relay
box
Faultyhornrelay
Faultysevresume
switch
Faultycablereel
An openin the wire

Attach to ground:
Cruiseindicatorlight in the gauge
assemblyshould come on.

E l o w nb u l b
Blown No. 25 (7.5A) tuse in the
under-dashfuse/relaybox
Faultydimming circuit in the gauge
assembly
An open in the wire

Check for voltage between the


ELUA/VHT
@ and BLK O terminalsl
There should be 0 - 5 V or more
-0 - 5 V or more repeatedly.

Faultyvehiclespeed sensor(VSS)
An open in the wire

lgnitionswitch ON {ll}
and main switch ON

Checkfor voltageto ground:


There should be batteryvoltage.

Blown No. 14 (7.5A) fuse in the


under-dashfuse/relaybox
Faultymain switch
An open in the wire

A'/T:Shift leverin E, E
otE
lvl/T:Clutchpedal
releaseo

Checkfor continuityto ground:


There should be continuity.
NOTE: There should be no continuity when the shift lever is in other
positionsor when the clutch pedal is
oepresseo.

Faulty A/f gear position switch 1A,/Tl


Faultyor misadjustedclutch switch

Resumebuttonpushed

RED/BLU

LT GRN

Faultyactuatorsolenoid
Poorground(G202)
An openin the wire

Checkfor resistanceto groundl


There should be 80 - 120 o.

lgnitjonswitch ON {ll}
and main switch ON;
raisethe front of the
ELU^r'r'HT
vehicle,block one wheel
and rotatethe other
wheel slowly.

r3

Possiblecause it result is not obtained

Under all conditions

lgnitionswitch ON lll)

10

Test: Desiredresult

Test condition

fi{/r)
P o o rg r o u n d( G 1 0 1 )
An open in the wire

Rconncttho 14PconnGctorto the control unit.

BLU

Start tho engine.turn


the main switch ON, and
drive the vehicleover 25
mph (40 km/h)with the
crursecontrol set

Checkfor voltageto ground:


There should be approx.5 V

. Faultycruisecontrol unit
. Shod to ground

*: '98 - 00 modelswith AutomaticTransmission.

www.emanualpro.com

4-39

CruiseControl
Main Switch Test/Replacement
1 . Carefullypry the switchout of the instrumentpanel.
Disconnect
the 6P connectorfrom the switch,

Set/ResumeSwitch
Test/Replacement
1 . Disconnectthe bafterynegativecable,then disconnectthe positivecable,and wait at leastthree minutes.

Terminal
sideof male
rermtnats

Disconnect
the driver'sairbagand front passenger's
airbagconnectors(seesection24).
6P CONNECTOR

Removethe dashboardlowercoverand kneebolster.


4.

Disconnect
the 6P connectorbetweenthe cablereel
sub harnessand the main wire harness.

BULES{0.84Wt
Checkfor continuitvbetweenthe terminalsin each
switchpositionaccordingto the table.
Terminal
-_\
5

Wire sideof temaleterminals

;;;
OFF

G-

@o

ON

(9 ,{)

-o o- @ -o

lf there is no continuity,replacethe switch.

Checkfor continuity betweenthe terminalsof the


6P connectorin each switch position accordingto
the table.
\

Terminal

;;;

--_l

o-

S E T( O N )
(ON)
RESUME

Cf-

-o
c

lf there is continuity.and it matchesthe table,


the switchis OK.
a lf there is no continuityin one or both positions,
go to step 6.

4-40

www.emanualpro.com

ActuatorTest
6. Removethe two screws.then removethe switch.
nn-

1 . Disconnect
the actuatorcabletrom the actuatorrod
and the 4Pconnector.

SET/RESUME

Connect battery power to the No. 4 terminal and


groundto the No. 1, No. 2 and No. 3 terminals,

,s

Connecta vacuumpump to the vacuumhose.Then


applyvacuumto the actuator.
r.
VACUUMPUMPGAUGE
0-30 in.Hg.
A973X-041-XXXXX

7 . Checkfor continuitybetweenthe terminalsin each


switchpositionaccordingto the table.
Terminal
-__\

t*,r*
SETION)
(ON)
RESUME
.
.

1e
to

---o
oo- ---o

lf there is continuity,and it matchesthe table,


replacethe cablereel.
lf there is no continuityin one or both positions,
replacethe switch.

Terminalside
ot
maleterminals
The actuatorrod shouldpull in completely.lf the rod
pulls in only part-wayor not at all, checkfor a leaking vacuumIineor defectivesolenoid.

ACTUATOBROD

lf all tests prove OK, reconnectthe cable reel subharnessconnector.


9 . Reconnectthe driver'sairbagand front passenger's
airbagconnectors,and reinstallthe accesspanelon
the steeringwheel.

1 0 . Reconnectthe batterypositivecable.then the negative cable.


1 1 . A f t e r c o n n e c t i n gt h e a i r b a gc o n n e c t o r sc, o n f i r m

proper system operation:Turn the ignition switch ON


(ll);the SRSindicatorlight shouldcome on for about
six secondsand then go off.
(cont'd)

www.emanualpro.com

4-41

CruiseGontrol
ActuatorTest (cont'dl
5.

With voltageand vacuumstill applied,try to pull the


actuatorrod out by hand.You shouldnot be able to
pull it out. lf you can.it is defectrve.

ActuatorReplacement
' t . Pullbackthe boot.
and loosenthe locknut.Then dis-

Ar
1.

connectthe cablefrom the bracket.


Disconnect
the cableend from the actuatorrod.

.J.

groundfrom the No. 3 terminal.The actuDisconnect


ator rod should return.lf it does not return,but the
vent hose and filter are not plugged,the solenoid
valve assemblyis defective.
7.

Repeatsteps 2 through 5. and disconnectground


from the No. l terminal. The actuator rod should
return. lf it does not return,but the vent hose and
filter are not plugged,the solenoidvalve assembly
is defective.

8.

lf you replacethe solenoidvalveassembly,be sure


to use new O-ringson eachsolenoid.

9.

powerand groundfrom the 4Pconnector.


Disconnect
Disconnectthe vent hose from the actuator.Connect
a vacuumpump to the actuatorvent hose port, and
applyvacuum.The actuatorrod shouldpull in comp l e t e l y .l f n o t , t h e v a c u u m v a l v e i s s t u c k o p e n .
Replace
the actuator,

4-42

www.emanualpro.com

3.

Disconnect
the 4Pconnectorfrom the actuator.

4.

Disconnect
the vacuumhosefrom the vacuumtank.
Pullout the vent hose.
Removethe three mounting bolts and the actuator
with the bracket.

ACTUATOR
CABLE

I
4.

ACTUATOR

6.

lf necessary,
disconnectthe cableend from the linkage over the acceleratorpedal,then turn the grommet 90' in the bulkhead.and removethe cable.

7.

Installin the reverseorder of removal,and adjust


free play at the actuator rod after connectingthe
cable(seepage4-43).

ActuatorCableAdiustment

ClutchSwitch Test

'1.

1.

Checkthat the actuator cable operatessmoothly


with no bindingor sticking.
Startthe engine.Hold the engineat 3,000rpm with
no load (A,/Tin E or E position, M/T in neutral)
untilthe radiatorfan comeson, then let it idle.

Disconngctths 2P connector from the clutch switch.

CLUTCHSWITCH2P CONNECTOR
Terminalsideof
maleterminals

Measurethe amount of movementof the actuator


rod until ths cable pulls on the acceleratorlever
(enginespeed startsto increase).Free play should
b e 1 1t 1 . 0m m ( 0 . 4 3i 0 . 0 4i n ) .

ACTUATORROD

LOCKNUTFREEPLAY:11 t 1.0 mm
10.43r 0.04 in)

2.

Removethe clutchswitch,

5.

Checkfor continuitybetweenthe terminalsaccording to the table.

lf free play is not within specs,loosenthe locknut,


and turn the adjustingnut as requirsd,
NOTE: lf necessary,check the throttl cable frso
play (sesection11),then recheckthe actuatorrod
free play.

Terminal

Clutch Switch

OEPRESSED

RELEASED

Retightenthe locknut,and recheckthe free play.


4.

lf necessary,replacethe switch or adjustthe pedal


height(seesectiont2).

st
te

www.emanualpro.com

4-43

CruiseControl
ActuatorSolenoidTest

BrakeSwitch Test
1.

Disconnect
the 4Pconnectorfrom the switch,

2.

Removethe brakeswitch.

1.

the 4P connectorfrom the actuator.


Disconnect

ACTUATOR

{P CONNECTOR

of
Terminalside
maleterminals
Checkfor resistancebetweenthe terminalsaccording to the table.

il',",""*(t)

_\

o- - o

VENTSOLENOID
40-600
Check for continuity between the terminals according to the table.

Terminal

;;;;-t
RELEASED
PUSHED

O-

---o
o- -o

Terminal

Terminalsideof male
termtnals

VACUUM
SOLENOID
SAFEWSOLENOID
40-600

---o

30-500

---o

o-

NOTE: Resistancewill vary slightly with temperais at 68"F(20"C).


ture;specifiedresistance

lf necessary,replacethe switch or adjust pedal height


(seesection19).
VACUUM VALVE

To VACUUM
TANK

4-44

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ActuatorDisassembly

ACTUATORCABLE

ACTUATORERACKET

VACUUM
TANK

)rd'

!l
l

VALVES
Test, page 4-44

www.emanualpro.com

4-45

E ngine
EngineRemovaUlnstallation
................
5-1
CylinderHead/Valve
Train ...................
6-1
E n g i n eB f o c k. . . . . . . . . .
...........7-1
EngineLubrication
...........8-1
IntakeManifold/Exhaust
System ........
9-1
Cooling
.........
10-1

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EngineRemovaUlnstallation
EngineRemoval/lnstallation
. . . . . . . . . . . . . . . . . . .5. -. .2. . .
Removal
.....................5-12
lnstallation

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EngineRemovaUlnstallation
Removal
@

4.

a Make sure iacks and safety stands are placedproperly


and hoist brackets are attached to the correct oositions on the engine.
. Make sure the vehicle will not roll oft stands and fall
while you are working under it.

BATTERY
BASE

NOTEI
. U s e f e n d e rc o v e r st o a v o i d d a m a g i n gp a i n t e ds u r faces.
o To avoid damage.unplugthe wiring connectorscarefully while holdingthe connectorportion.
lvlarkall wiring and hosesto avoid misconnection.
Also, be surethat they do not contactother wiring or
hoses,or interferewith otherparts.
1.

Securethe hood in the open position.

2.

Disconnect
the batterynegativeterminalfirst,thenthe
positiveterminal.

Removethe battervand battervbase.

I x 1.25mm
24 N.m (2.4kgf.m,
17 tbnft)
-t'.-e

F
F
Y

Disconnectthe batterycablesfrom the under-hood


fuse/relaybox and batterypositiveterminal.

5.

Removethe intakeair duct and air cleanerhousino.

INTAKE AIB

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6.

7.

6.

Disconnect
the enginecontrolmodule(ECM)/powerfrom the ECM/
traincontrolmodule(PCM)connectors
PCM.

7.

Disconnect
the main wire harnessconnector.

Disconnectthe enginewire harnessconnectorson


the left sideof the enginecompartment.
ENGINEWIRE
HARNESSCONNECTORS

CONNECTOR

Removethe grommetand wire harnessclamps,then


pull out the EcM/Pclvlconnectors.
6x1.0mm
11 N.m 11.1kgl.m,8lbf.ftl

GROMMET

(cont'd)

www.emanualpro.com

5-3

EngineRemoval/lnstallation
Removal(cont'dl
1 0 . Removethe cruisecontrolactuator(seesection4).
1 t . R e m o v et h e m o u n t i n g b o l t a n d l o c k b o l t , t h e n
removethe P/Spump belt and pump.
MOUNNNG BOLT
8 x 1.25mm
2a N.m 12.4kg{.m, 17 lbtftl

P/S PUMP
BELT

13. Relievefuel pressure{seesection11).


Do not 3mok6 whil working on th6
@
tugl systsm. Koep open flam or spark away from
the work area. Drain fuel only inlo an approved
container.
14. Removethe evaporativeemission (EVAP)control
canisterhoseand tuel feed hose.
33 N.m (3.4kgt.m,

2s tbf.ft)

LOCKBOLT
I x 1.25mm
24 N.m {2.4kgtm, '17lbf.ftl

1 2 . Loosenthe idler pulley bracketbolt and adjusting


bolt, then remove the air conditioning(A,/C)compressorbelt.
ADJUSTINGBOLT
LOCKNUT
8 x 1.25mm
24 N.m {2.4kgf.m, 17 lbf.ftl

ID1TR PULI.f,Y ARACKETBOLT


10r 1.25mm
a{ N.m 14.5lgtm,33 lbf.ft)

5-4

www.emanualpro.com

,%l
*ryft
'fltr
\'t,f
EVAPCC
CANISTERHOSE

he
'.n

'15. Removethe brakeboostervacuumhose,fuel return


hoseand vacuumhose.
'97 - 98 modals:

!d

BRAKEBOOSTER
VACUUM HOSE
'ol

'16. Removethe throttlecableby looseningthe locknut,


then slip the cable end out of the acceleratorlinkage.Take care not to bend the cablewhen removing it. Always replaceany kinkedcablewith a new
one.
97 - 98 modeb:

FUELRETURN
HOSE

99 - 00 modob:
'99 - 00 modob:
BRAKEBOOSTER
VACUUM HOSE

THROTTLE
CABLE

LOCKNUT
ADJUSTING
NUT

(cont'd)

www.emanualpro.com

5-5

EngineRemoval/lnstallation
Removal(cont'd)
17. Disconnect
the powersteeringpressure{psp} switch
connector,and removethe wire harnessclamo.

19. Disconnect
the transmissiongroundcable(M/T).

GROUNDCABI."E

1 8 . Removethe slavecylinderand clutch hose bracket

(Mrr).

NOTE:
. Do not disconnectthe pipe/hoseassembly.
. Do not operatethe clutch pedal once the slave
cylinderhas beenremoved.
. Takecarenot to bendthe pipe/hoseassembly.

R e m o v et h e c o t t e r p i n s , t h e n r e m o v e t h e s t e e l
washers,plasticwashers,shiftcable,and selectcable
from the levers(M/T).

sElEcr
CABI."E
21. Removethe cable bracketfrom the clutch housing
(M/T).

5-6

www.emanualpro.com

30. Disconnectthe primary heatedoxygen sensor(prlthen removeexhaustpipeA


mary HO2S)connector.

22. Removethe radiatorcaP.


use care when removing the radiatol
!@
cap to avoid scalding by hot coolani or steam.

'97 - 98 U.S. models (Cslifornia):

23. Raisethe hoistto full height


24. Removethe front tires/wheels.
25. Removethe guardbar and splashshield.

PRIMARYHO2S
CONNECTOR

SPLASH

GASKET
Replace.
NUT
SELF-LOCKING
8 x 1.25mm
NUT
22 N.m 12.2kgf.m,
8 x 1.25mm
16 lbf.ftl
16 N.m {1.6 kgf.m.
Replace.
12 tbt.ftl
Replace.

6x1.0mm

NUT
SELF.LOCKING
10x 1.25mm
54 N.m 15.5kgf.m,
.() tbf.frl
Replace.

8 x 1.25mm
2,1N.m {2.4 kgf,m, 17 lbl ft)

BAR
9.8N.m{1.0kgf.m, GUARD
7.2tbf.rr)
26. L o o s e nt h e d r a i n p l u g i n t h e r a d i a t o r .D r a i n t h e
enginecoolant(seepage10-51.
the drain
oil or fluid. Reinstall
2 7 . Drainthe transmission
plug using a new washer lsee section 13 (M/T)or section 14 (ly'T)].
28. Drainthe engineoil. Reinstallthe drain bolt using a
new washer{seepage8-4).
29. Bemovethe A,/Ccompressor.Do not disconnectthe
!y'C hoses.

'97 - 98 U.S. modls {ExceptCalifornia):


'99 - 00 models:
PRIMARYHO2S
CONNECTOR
GASKETS
Replace.

ER
lC
EB

GASKET
Replace.
SELF.LOCKING
8 x 'l.25mm
22 N.m (2.2kgf m,
16 rbf.ftl
Replace.

NUT
SELF.LOCKING
8 x 1.25mm
16 N.m 11.6kgf.m,
12 tbt fr)
Replace.

10 x 1.25mm
54 N.m 15.5kgt.m,
40 rbt.ftl
Replace.

{cont'd)

www.emanualpro.com

5-7

EngineRemovaUlnstallation
Removal(cont'dl
31. Removethe shift cable.Take care not to bend the
cablewhen removingit. Always replaceany kinked
cablewith new one (Afl-).

Make marks on the transfercompanionflange and


propellershaftas shown.Usethesemarksto set the
propeller shaft in the proper position when reinstalling(4WD).

OOI{TROLPI

Removethe four bolts securingthe propellershaft,


then separatethe propellershaft from the transfer
companionflange(4WD).

SNAPPIN

sHtFTCABtt
OOVEB

8 x 1.25mm
t2 N.m 12.2lgtr'l'',,
16tbf.ftl

Removethe right damperfork (seesection18).


Disconnect
the suspensionlowerarm balljoints(see
section18),

34. Removethe driveshafts(see section t6). Coat all


precision-finished
surfacewith cleanengineoil. Tie
plasticbagsover the driveshaftends.
E x 1.25mm

32 N.m 13.3lgt.m, 24 lbt'ftl


Replce.
37. Lowerthe hoist,

5-8

www.emanualpro.com

rd
te
n-

3 8 . R e m o v et h e u p p e r a n d l o w e r r a d i a t o rh o s e sa n d
heaterhoses.

4 1 . Removethe radiator(seepage10"4).
42. Removethe IVC hoseclamp.

A/C HOSE

rt,
BT

3 9 . R e m o v et h e t r a n s m i s s i o ng r o u n dc a b l ea n d h o s e
clamp(A,/T).
9.8 'm lt.o klt m,
l.2tutal

GBOUI{DCABLE

6 x l1,0
6x
,0m
mm
m
11 N.m 11.1lof'm,
I tbf.ftl

40. Remove the ATF cooler hoses, then plug the ATF
cooler hoses and, n"" lAfI).

(cont'd)

www.emanualpro.com

5-9

EngineRemovaUlnstallation
Removal(cont'dl
43. Attachthe chainhoistto the engine.

5-10

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44. Removethe left and right front mounts and brackets

46. Removethe uDperbracket.

UPPER

Replace.

M/T:

47. Removethe transmissionmount bracket,then remove


the transmissionmount.
MOUNT/BRACKET

TRANSMISSION

Alf I

45. Removethe rearmount bracketmountingbolt.

MOUNTBMCKET

REABMOUNT

is completelyfree
Checkthat the engine^ransmission
hoses,
and electriand
coolant
hoses,
fuel
of vacuum
calwiring.
150mm (6 in)'
49. Slowlyraisethe engineapproximately
wires
are disconhoses
and
Checkonce again that all
nectedfrom the enginenransmission.
50. Raisethe engineall the way, and removeit from the
vehicle.

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5 - 11

Engine Removal/lnstallation
Installation
Bracket Bolts Torque Specifications:

P/S PUMP
BRACKET

SIDEEIIGII{E
i'OUT{T BRACKET

t t 1.25m.D
2a 'tn (2,4 kgt ft,
17 tbtftl

10 x 1.25mm
54 t$m 15.5tgfm,
iO lbflrl

10 x 125 mm
il,a t*m {4.5 tgt'm,
d, tbtft)

ALTERI{ATOR
BNACKET
A/C @MPRESSOR
BRACIGT

t0 r 125 ]nm
a,l t+Jnll.5 lgf-rn,
3 tbf{tl
8 r 1.25mm
24 N.m 12.4kg{.m;

17tbtfrl

5- 12

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10 x 1.25mrn
,L il.tn {1.5 tgt m, :|:l lbf'ft}

Installthe upper bracket,then tightenthe nuts in the


numberedseauence.

2.

EngineInstallation:
lnstallthe enginein the reverseorderof removal.
Reinstall
the mount bolts/nutsin the followingsequence
Failureto follow these proceduresmay causeexcessrve
noiseand vibration.and reducebushinglife.
1 . I n s t a l lt h e t r a n s m i s s i o nm o u n t a n d b r a c k e t t. h e n
tighten the bolts on the frame side. Do not tighten
the bolts/nutson the transmissionside.

O 12 x 1.25mm
7a N.m {7.5kgf'm,
54 tbf.trl

A 12r1.25mm
7il N.m 17.5kgl'm,
5,r lbt.ft)

A/T:
TM'{SMISSION
MOUNT

12x 1.25mm
6,aN.m16.5kgtr.m,
47 tbt f0

R
R

3.

Installthe rear mount bracketmountingbolt. Do not


tightenthe bolt.

TRANSMISSION
MOUNT BRACKEY

M/T:

TRANSMISSION
MOUNT

12x 1.25mm
64 N.m {6.5kgt.m,
47 tbl.ft)
!, m,

MOUNN G BOLT
Replace.

(cont'd)

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5-13

EngineRemovaUlnstallation
(cont'd)
Installation
4.

T i g h t e nt h e b o l t / n u t so n t h e t r a n s m i s s i o nm o u n t
bracketin the numberedsequence.

5.

Tightenthe rear mount bracketmountingbolt.

AIT:

@ 12 x 1.25mm
?4 N.m {t.5 kgt.h,
5,4lbf.ftl

O 12x 1.25mm
6l .m (6.5kgtm,
47 tbt{r}

M/T:
i?. 12 x 1.25mm
74 N.m {7.5kgf'm.

s/rtbr.ftl

,,.....\.L}
@'...,'..4:

a1l12 x 1.25mm
64 N.m {6.5kgf.m,
47 lbf.ft)

5 - 14

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12 x 1.25mm
59 N.m {6.0 lgl'm, ait lbf.ftl
Replace.

6.

then tightenthe
Installthe rightfront mounvbracket,
boltsin the numberedsequence.

7.

Installthe leftfront mount,then tightenthe bolts/nut


in the numberedseouence.
O t2 r 1.25mm
8il N.m18.5kgt.m,el |bfftl

A/T:
Loosen th is nut,

i! 12x 1.25mm
g N.m {6.5 kgf.m, 47 lbf.ftl
Replace.

(D to x t.zs mm
44 N.m{4.5kgfm, 33 lbf.ft)

O 12 x 1.25mm
59 N.m 16.0kgt ln, , lbfttl
Replace.

@ lo x 1.25mm
a,aN.m14.5kgf.m,
33 tbf.trl

M/T:
Loosenthis nut.

O 10x r.25mm
4/tN.m14.5kgt.m,33lbf.ft)
O 12 x 1.25mm
64 N.m 16.5kgf.m.47 lbf.ft)
Replace.

{cont'd)

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5-15

EngineRemoval/lnstallo
cton
Installation(cont'd)
8.

Tightenthe nut on the right front mount.


AlTi

59 .m 16.0tgt m, (l lbfftl
Replace.

MlTi

12 x'1.25mm
59 N.m 16,0kgt m, /(} lbt ttl
Reolace.

5-16

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9.

Performthe followingchecksand adjustments:


. Checkthat the springclip on the endsof the driveshaftand intermediate
shaftclicksinto place.Use
new springclips.
. Adjustthe shiftcable(seesectionl4).
. Adjustthe throttlecable(seesection11).
. Refillthe enginewith engineoil (seepageg-4).
. Refillthe transmissionwith oil or fluid (seesect i o n 1 3o r 1 4 ) .
. Refillthe radiatorwith enginecoolant(seepage
10_5).
. B l e e da i r f r o m t h e c o o l i n g s y s t e mw i t h t h e
heatervalveopen (seepage l0-5).
. Cleanthe batterypostsand cableterminalswith
sandpaper,assemblethem, then apply greaseto
Dreventcorrosron.
. Inspectfor fuel leakage(seesection1l).
After assemblingfuel line pans,turn on the ignition switch (do not operatethe starter)so that
the fuel pump operatesfor approximatelytwo
secondsand the fuel Iine pressurizes.
R e p e a t h i s o p e r a t i o nt w o o r t h r e e t i m e s ,a n d
checkfor fuel leakageat any point in the fuel line.

Mount and Brackst Bolts/Nuts Torqus Value Specitications:


A: '10x 1.25mm
64 N.m 16.5kgI.m, 47 lb{.ftl
B: 12 x 1.25mm
59 N.m 16.0kgf.m, 43 lblft)
Replace.
C : 1 4x 1 . 5m m
8:l N.m (8.5kgt.m, 6r lbl'ft)
Replace.
D: 10x 1,25mm
,t4 N.m (4.5 kgf'm,33 lbIft)
Er 12x 1.25mm
83 N.m 18.5kgf.m, 61 lbl.ftl

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5-17

CylinderHead/ValveTrain
.............6-2 Camshafts
SpeciafTools
..............6-22
lnspection
ValveClearance
Valves,Valve Springsand Valve Seals
............6-3
Adiustment
................,
6-23
Removal
ValveSeals
.............
6-29
lnstallation
Replacement(cylinderhead
6-5
removalnot requiredl.................
Valve Guides
CrankshaftPulleyand PulleyBolt
6-25
ValveMovement............,,,,.,............
.........6-7
Replacement
.........6-25
Replacement
Timing Belt
.................6-27
Reaming
6-8
Illustratedlndex ...............................
Valve Seats
.............,
6-9
Inspection
......6-28
Reconditioning
6-9
TensionAdjustment........................
...........,.....
6-10
Removal
.............6-11
lnstallation
(CKFI
Fluctuation
Speed
Crankshaft
Sensor
.........6-13
Replacement
CylinderHead
6-14
lllustratedlndex ...............................
.................6-16
Removal
................6-27
Warpage
.............
6-30
lnstallation

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SpecialTools

Ref. No.

Tool Number
07JAA- 001020A
07JAB- 00'10204
OTMAB_ PY3O1OA
07757- PJ1010A
07942- 6570100
07984- 657010D

,61

A)

a!)

a!)

c--E-rr------------

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6-2

Description
Socket,19 mm
H o l d e rH a n d l e
PulleyHolderAttachment,50mm, Offset
ValveSpringCompressorAnachment
ValveGuideDriver,6.6 mm
ValveGuideReamer,6.6 mm

(Xy
1
1

r
1
1
'l

PageRefereflce

6-1
6-7

I 6-7
I
|

6-23,29
6-25,26
6-27

ValveClearance
Adiustment
Adjustthe valvesonly when the cylinderheadtemperature is lessthan 100"F(38"C).
1.

Removethe cylinderheadcover.
Removethe middlecover(seepage6-11).
"UP" mark on the
Set the No. 1 pistonat TDC.The
pulleysshouldbe at the top, and the TDC markson
the pulleysshouldalignwith the pointerson the back

Adjustthe valveson No. 1 cylinder.


Intake: 0.08- 0.12mm (0.003- 0.005inl
Exhaust:0.16- 0.20 mm (0.006- 0.008in)
Loosenthe locknut,and turn the adiustmentscrew
until the feeler gauge slides back and forth with a
slightamountof drag.

LOCI(NUT
9 x 0.75m.n
25 N.m 12.5kgf.m, 18lbf.ft)

POINTER

POINTER

Adiusting Screw Locations:


INTAKE

No.4

No.3

No.2

No. 1

EXHAUST

(cont'd)

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6-3

ValveClearance
Adjustment(cont'dl
6.

Tightenthe locknut,and checkthe clearanceagajn.


Repeatthe adjustmentif necessary.

to brinq
8. Rotatethe crankshaft180"counterclockwise
No. 4 pistonto TDC.
The "UP" marksshould be pointingstraightdown.
Adjustthe valveson No. 4 cylinder.

"UP" MARKS

GAUGE

7.

(camshaft
Rotatethe crankshaft180"counterclockwise
pulleyturns90').
The "UP" marksshouldbe on the exhaustside.Adjust
the valveson No.3 cylinder.

.UP" MARKS

to brino
Rotatethe crankshaft180'counterclockwise
No.2 pistonto TDC.
The "UP" marksshouldbe on the intakeside.Adiust
the valveson No. 2 cylinder.

"UP" MARKS

1 0 . Installthe cylinderheadcover(seepage6-32).
1 1 . Retorquethe crankshaftpulleybolt (seepage6-7).

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ValveSeals
Replacement(cylinderhead removal not required)
The procedureshown below applieswhen usingthe inc a r v a l v e s p r i n g c o m p r e s s o r( S n a p - o nY A 8 8 4 5w i t h
YA8845-2A7/8" auachment). Use approved eye protection.
1. Turn the crankshaftso that the No. 1 and the No. 4
pistonsare at top deadcenter(TDC).
2.

Removethe cylinderheadcover.

3.

Removethe distributor.

4.

L o o s e na n d d i s c o n n e c t h e t i m i n g b e l t f r o m t h e
camshaftpulleys.

5.

at.

Selectthe 7/8 in. diameterlong compressorattachment,and fastenthe attachmentto the front hole of
the leverarm with the speedpin supplied.

9 . Positionthe pistonat TDC,and insen an air adaptor


into the spark plug hole. Pump air into the cylinder
t o k e e p t h e v a l v e c l o s e dw h i l e c o m p r e s s i n gt h e
springsand removingthe valvekeepers.
10. Put shop towels over the oil passagesto prevent
t h e v a l v e k e e p e r sf r o m f a l l i n g i n t o t h e c y l i n d e r
head.
OIL PASSAGE

Removethe camshaftholderbolts.then removethe


camshaftholders,the camshaftsand rockerarms.

lntake Valve Seals


6. Usingthe 6 mm boltssuppliedwith the tool, mount
t h e t w o u p r i g h t st o t h e c y l i n d e rh e a d a t t h e e n d
camshaftholders.The uprightsfit as shown.
7.

Insertthe cross shaft through the top hole of the


two uprights,

OIL PASSAGES

't1. Position
the lever arm under the crossshaft so the
lever is perpendicular
to the shaft and the compressor attachmentrests on top of the retainerfor the
spring being compressed.Usethe rear positionslot
on the leveras shown,

(cont'd)

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6-5

ValveSeals
Replacement(cylinderheadremovalnot requiredl(cont'dl
12. Usingan upwardmotionon the leverarm,compress
the valve spring and removethe keepersfrom the
valvestem.Slowlyreleasepressureon the spring.

22. Put shop towels over the oil passagesto prevent


t h e v a l v e k e e p e r sf r o m f a l l i n g i n t o t h e c y l i n d e r
neao.

1 3 . Repeatstep 11 for the othervalvein that cylinder.


1 4 . Removethe valveseals(seepage6-24).
1 5 . Installthevalveseals(seepage6-29).
1 6 . lnstallthe springs,the retainersand the keepersin
reverseorderof removal.
'17. Repeatsteps9 to 16 for the otherthreecylinders.
Exhaustvalve Seals
18. Usingthe 5 mm bolts suppliedwith the tool, mount
t h e t w o u p r i g h t st o t h e c y l i n d e rh e a d a t t h e e n d
camshaftholders.The uprightsfit as shown.
19. Insert the cross shaft through the bottom hole of
the two uprights.

20. Selectthe 7/8 in. diametershort compressorattach


ment,and fastenthe attachmentto the No. 4 hole of
the leverarm with the speedpin supplied.
t1

Positionthe pistonat TDC,and insertan air adaptor


into the spark plug hole. Pump air into the cylinder
t o k e e p t h e v a l v e c l o s e dw h i l e c o m p r e s s i n gt h e
springsand removingthe valvekeepers.

23. Positionthe lever arm underthe crossshaft so the


leveris perpendicular
to the shaftand the compressor attachmentrests on top of the retainerfor the
spring being compressed.Usethe rear positionslot
on the leveras shown.

24. Using a downward motion on the lever arm, compressthe valvespringand removethe keepersfrom
t h e v a l v e s t e m . S l o w l y r e l e a s ep r e s s u r eo n t h e
spring.
Repeatstep24 for the othervalvein that cylinder.
Removethe valveseals(seepage6-24).
2 1 . Installthe valveseals(seepage6-29).
28. Installthe springs,the retainersand the keepersin
reverseorderof removal.
29. Repeatsteps21 to 28 on the otherthreecylinders.

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o-o

CrankshaftPulleyand PulleyBolt
Replacement
When installingand tighteningthe pulley,follow the procedurebelow.
Clean,removeany oil, and lubricatepointsshown below.
C: Clean
x I Removeany oil
a: Lubricate
CRANKSHAFT
PULLEY
WASHER

CRANKSHAFT

X
X

o
oooo o
o
o
- oooo o

X
X

^ oooo o
o
o
o

6r.
R
o".

Crankshaftpulley bolt size and torque value:


14 x 1.25mm
177N'm (18.0kgf.m,130lbt.ftl
NOTE:Do not use an impactwrenchwhen installing.

HOLDERATTACHMENT.
50 mm, OFFSET
OTMAB- PY3OlOA
SOCKET,19 mm
07JAA- 001020A
available}
{or Commercially

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6-7

TimingBelt
lllustratedIndex
HEAD
CYLINDER
COVER
Referto page6-32
when installing.

kgf.m, 7.2 tbtft)

HEADCOVERGASKET
Replacewhen leaking,
damagedor deteriorated.
Apply liquidgasketat
the eightcornersof the

\
@
Cl

WASHER
Replaceif damaged
or deteriorated,

k6

TIMING BELT
page6-9
Inspection,
Adjustment,page6-9
Removal,page6-10
page6-11
Installation,
SEAL
RUEBER
Replaceil damaged
ot detetiorated.

8 x 1.25mm
37 N.m (3.8kst.m,27lbf ftl

MIDOLECOVER
6x1.0mm
9.8N.m {1.0kgf.m,
1.2lbt.ftl

SEALS
RUBBER
when damaged
Replace
or deteriorated,
LOWERCOVER
ADJUSTINGBOLT
10 x 1.25mm
54 N.m (5.5kgl.m, 40 lbf.ft)

TIMINGBELT
ORIVEPULLEY

PULLEY
CNANKSHAFT
page6-7
neplacement,

R e p l a c e m e n t ,p a g e 6 ' 7

lnstallwith concave
surfacefacingout,
Removeany oaland clean,
SPEEO
CRANKSHAFT
FLUCTUATIONICKF}
SENSOR

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6x1.0mfi
1 1N . m{ 1 . 1k g t m ,
8.0 rbtft)

6x1.0mm
9.8Nm(1.0kgl.m,
7.2 tbl.ft)

BOLT
14 x 1.25mm
177N.m (18.0kgf'm,
130 tbf.fr)
Replacement,
Page6-7
Do not usean impact
wrenchwhen installing.

Inspection

TensionAdjustment

1 . Removethe cylinderheadcover.

NOTE:
. Alwaysadjustthe timing belt tensionwith the engine
coto.
. Always rotatethe crankshaftcounterclockwise
when
v i e w e df r o m t h e p u l l e ys i d e . R o t a t i n gi t c l o c k w i s e
m a y r e s u l ti n i m p r o p e ra d i u s t m e not f t h e b e l t t e n sion.

2.

lnspectthe timing belt for c.acksand oil or coolant


s o a k i n g .R e p l a c et h e b e l t i f i t i s o i l o r c o o l a n t
soaked.Removeany oil or solventthat gets on the
belt.

'1. Removethe cylinderheadcover

lnspectthis
areafor wear.

2.

Set the No. 1 pistonat TDC(seepage.6-12).

3.

Rotatethe crankshaftfive or six revolutionsto set


the belt.

4.

Set the No. 1 pistonat TDC.

5.

Loosenthe adjustingbolt 1/2turn (180')only.

ADJUSTINGBOLT
5,4N.m (5.5 kgf.m,
40 tbtftl
For adiustmentonly,

rotation,

Rotatethe crankshaftcounterclockwise
three teeth
on the camshaftpulley.
3.

After inspecting,retorquethe crankshaftpulleybolt


to 177N.m (18.0kgnm,130lbf.ft).

7.

Tightenthe adjustingbolt to the specifiedtorque.

8.

After adjusting,retorquethe crankshaftpulleybolt to


177N.m (18.0kgf.m,130lbf.ft).

9.

Installthecylinderheadcover(seepage6-32).

Installthe cylinderheadcover(seepage6-32).

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6-9

Timing Belt
Removal
Replacethe timing belt at 105,000miles (168,000km)
accordingto the maintenanceschedule{normalconditions/severe
conditions).lf the vehicleis regularlydriven
in eitherof the following conditions,replacethe timing
belt at 60,000miles(U.S.A.l100.000km (Canada).
- ln very high temperatures(over 110'F,43"C).
- In very low temperatures(under-20"F.-29"C).

5.

Loosenthe mountingnut and locknut,then remove


the altefnatorbelt.
LOCKNUT
I x 1.25mm
2a N.m 12.4kgt m, 17 lblftl

1 . Turn the crankshaftpu\ley so the No. 1 piston is at


top deadcenter(TDC).
2.

Removethe guard bar and splashshield (seepage


5-7).

,l

Loosenthe mountingbolt and lockbolt.then remove


the power steering(P/S)pump belt.
MOUNNNGBOLT
8 x 1.25rnm
24 N.m {2.4 kgt.m, 17 lbf.ftl
10 x 1,25mm
4,1N.m (,1.5kgt m, 33 lbtftl
AELT

6.

Removethe cruisecontrolactuator(seesection4).

7.

S u p p o r tt h e e n g i n ew i t h a j a c k ,t h e n r e m o v et h e
u p p e r b r a c k e t .M a k e s u r e t o p l a c e a c u s h i o n
betweenthe oil Danand the iack.

12 x 1.25mm
74 N.m (7.5kgf m, 54 lbtftl
24 N.m 12.4kgf.m, lt lbf.ftl
BRACKET

4.

Loosenthe idler pulley bracketbolt and adjusting


bolt,then removethe air conditioning(lVC)compres
sor belt(seepage5-4).

6-10

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Installation
8. Removethe cylinderheadcover.

Installthe timing belt in the reverseorderof removal;


Only key pointsare describedhere,

NOTE:Referto page6-32when installingthe cylinder headcover.

1.

9 . Removethe crankshaftpulley(seepage6-7).

GROOVE

POINTER

1 0 . Removethe middle cover and lower cover. Do not


usethesecoversto storeremoveditems.
MTDDLE
COVER

Setthetiming beltdrivepulleyso thatthe No. 1 piston


is at top dead center (TDC).Align the groove on the
timingbeltdrivepulleyto the pointeron the oil pump.

6x1.0mm
9.8N.m {1.0kgt m,

DRIVEPULLEY
Clean.
LOWER
COVER

2.
9.8N.m(1.0kgt.m,7.2lbf.ftl

Set the camshaftpulleysso that the No. I piston is at


TDC.Alignthe TDCmarkson the camshaftpulleysto
the pointerson the backcover.

1 1 . Markthe directionof rotationon the timing belt.

CAMSHAFT
PULLEY
Clean.

12. Loosenthe adjustingbolt 180'.Pushthe tensionerto


removetensionfrom the timing belt, then retighten
the adiustingbolt.

r-t

AINUSTING BOLT
54 N.m (5,5 kgt m,
.(} tbf.rrl

1 3 . R e m o v et h e t i m i n gb e l t .

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POINTER

(cont'd)

6-11

Timing Belt
Installation(cont'd)
3.

Installthe timing belttightlyin the sequenceshown.


J @ AdjustO Timing belt drive pulley(crankshaft)
ing pulley =r @ Water pump pulley r @ Exhaust
camshaftpulley--)@ Intakecamshaftpulley.

9. Checkthat the crankshaftpulley and camshaftpulleys


are both at TDC.

POINTERON

NOTE: Make sure the timing belt drive pulley and


camshaftpulleysare at TDC.

4.

Loosenand retightenthe adjustingbolt to tension


the timing belt.

5.

C l e a n .t h e n i n s t a l l t h e l o w e r c o v e r a n d m i d d l e
cover.
Installthe crankshaftpulley,then tightenthe pulley
bolt (seepage6-7).

1.

Rotatethe crankshaftpulleyabout five or six turns


counterclockwiseso that the timing belt positions
on the pulleys.
Adjustthe timing belttension{seepage6-9).

POINTER

1 0 . lf the camshaftpulleys are not positionedat TDC,


removethe timing belt.adjustthe positionfollowing
the procedureon page6-11.then reinstallthe timing
belt.
1 1 . Installthecylinderheadcover(seepage6-32).
1 2 . After installation,
adjustthe tensionon eachbelt.
. See section4 for alternatorbelt tension adjustmenr.
. See section22 for NC compressorbelt tension
adjustment.
. See section17 for P/Spump belt tensionadjustment.

6-12

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CKFSensor
Replacement
1.

Removethe guard bar and splashshield (seepage


5-7t.

4.

Loosenthe locknutand mountingnut, then remove


the alternatorbelt.
LOCKNUT
8 x 1.25mm
24 N.m (2.4 kgl.m, 17 lbtftl

L o o s e nt h e l o c k b o l t a n d m o u n t i n g b o l t , t h e n
removethe P/Spump belt.

MOUNTING
BOLT
8 x 1.25mm
24 N.m (2.{ kgf.m, 17 lbf.ttl

PUMP

10 x 1.25 mm
a4 N.m (4.5kgt m, 33 lbtft)

BELT
BELT
E

Removethe cylinderheadcover.

6.

Removethe crankshaftpulley(seepage6-7).

7.

Removethe middlecoverand the lowercover.

aJ.

Disconnectthe CKFsensorconnector,then remove


the CKFsensor.

24 N.m 12.4lgf.m, 17 lbl.ftl

Loosenthe adjustingbolt and idler pulley bracket


bolt,then removethe Ay'CcomDressorbelt.
ADJUSTINGBOLT
LOCKNUT
8 x 1.25mm
24 N.m {2.4 kgf.m, 17 lbf.ft)

CKFSENSOR

6x1.0mm
11 N.m {1.r kgnm,8.0lbfft)

|o|'ln PUUCYBMCKETSOLI
l0 r 1.25mm
14 .m 14.5kgl.m,3:'lbtftl

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9.

Install the CKF sensor in reverse order of removal.

6-13

GylinderHead
lllustratedIndex
To avoiddamage,wait until the enginecoolanttemperaturedropsbelow 100'F(38'C)beforeremovingthe cylinderhead.

6x1.0mm
9.8 N.m (1.0kgI.m, 7.2 lbf.ft)
WASHER
Replace
when damaged
or deteriorated,

CYLINDERHEAD
COVEB
Reterto page6 32 when
installingcylinderheadcover.
HEAOCOVERGASKET
Beplacewhen leaking,
damagedor deteriorated.
Apply liquidgasketat
the eightcornersof the

RUBEER
SEAL
R e p l a c ei f
or deteriorated,

8 x 1.25mm
24 N.m (2.4
17 tbtft)
6x1.0mm
9.8N.m (1.0kgf.m.
7.2 tbf.fo
Applyengineoil to the
threads.
Seesection4.
CYLINDEB
HEADPLUG
Replace-

---..-@

CAMSHAFT
HOLDER

0+---.."...s<--

KEY

DOWEL
PIN
OIL SEAL
Replace.
CAMSHAFT
PULLEY
8 x 1.25mm
37 N.m {3.8kgf.m,
27 tbtft)

OILSEAL
Replace.

6x1.0mm
9.8 N.m (1.0kgl.m,7.2lbtftl

6-1 4

www.emanualpro.com

gasket.

takecarenot to fold it or damagethe contactsurface.


a metal
-?Ehandling
Priorto reassembling,
cleanall the partsin solvent,dry them and apply lubricantto any contactparts.

VALVEKEEPERS

CYLINDERHEADBOLT
1 1x 1 . 5m m
85 N.m {8.7kgf.m,6:} lbf.ft)
Tightening,page6'30.
Applyengineoilto the threads.
END PIVOTBOLT
63 N.m 16.4kgl m, 46 lbf.ft)

SPRINGBETAINER

EXHAUSTVALVE
SPRING

INTAKEVALVE
SPRING
INTAKEVALVESEAL
Replace.

EXHAUSY
VALVE
SEAL
Replace.

VALVESPRING
SEAT

EXHAUSTVALVE
GUIDE
page6-25
Inspection,
page6-25
Replacem6nt,
Reaming,page6-27

INTAKEVALVE
GUIDE

HEAD
Removal,page6-16
Warpage,page6 27
Valveseatreconditioning,
page6 28
page6-30
Installation,
EXHAUST
VALVE
INTAKEVALVE
Removal,page6-23
page6-29
Installation,
CYLINDERHEAO
GASKET
Replace.
OIL CONTROL
ORIFICE
Clean.

10x 1.25mm
4,0N.m {i1.5kgf.m.
33 rbf.ft)

O.RING
Replace.

DOWELPIN

8 x 1.25mm
24 N.m (2.4kgf.m,
17 tbf.ft)

www.emanualpro.com

6-15

GylinderHead
Removal
Engineremovalis not required
for thisprocedure.

6.

Loosenthe locknutand mountingnut, then remove


the alternatorbelt.

Make sure iacks and safety stands are

l!@

LOCKNUT
8 x 1.25mm
24 N.m (2.4 kgf.m, 17 lbt.ftl

placed properly, and hoist blackels ale attachgd to the


correctposition on the engine.
NOTE:
o U s e f e n d e rc o v e r st o a v o i d d a m a g i n gp a i n t e ds u r faces.
o To avoid damage,unplugthe wiring connectorscarefully while holdingthe connectorportion.
. To avoid damagingthe cylinderhead,wait until the
enginecoolanttemperaturedrops below 100"F(38'C)
beforelooseningthe retainingbolts.
. Markall wiring and hosesto avoid misconnection.
Also, be surethat they do not contactother wiring or
hoses,or interferewith other parts.
1 . Disconnect
the negativeterminalfrom the battery.

2.

Drain the engine coolant (see page 10-5).Remove


the radiatorcapto speeddraining.

10x 1.25mm
44 N.m (4.5kgt.m. 33 lbf.ft)

BELT
Removethe intakeair duct and air cleanerhousing
(seepage5-2).
4.

R e m o v et h e m o u n t i n gb o l t a n d l o c k b o l t , t h e n
r e m o v et h e p o w e r s t e e r i n g( P / S )p u m p b e l t a n d
pump (seepage5-4).

5.

Loosenthe idler pulley bracketbolt and adjusting


bolt, then remove the air conditioning(A,/C)com,
pressorbelt.
ADJUSTING
BOLT

7.

Removethe P/SOUmobracket.

ADJUSTINGBOLT
LOCKNUT
8 x 1 . 2 5m m
24 N m {2.4ksf.m, 17 lbttt}

l0 x 1.25mm
44 N.m (4.5kgf.m,
33 rbf.ft)

IOLERPULLEYBBACKETBOLT
10 x 1.25mm
44 N.m {4.5 kgtm, 33 lbf ft)

tt\

aA

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o-Io

8.

Removethe throttlecableby looseningthe locknut,


then slip the cable end out of the throttle linkage.
Take care not to bend the cablewhen removingit.
Always replaceany kinkedcablewith a new one.
'97 - 98 modols:

9. Relievefuel pressure(seesection11).
Do not smoke while working on the
@
fuel systom. Kop opon flame or sparks away from
ths work area. Drain fuol only into an approved
containgr.
'10, Removethe evaporativeemission (EVAP)control
canisterhoseand fuel feed hose.

'!X, - 00 modob:

CANISTERHOSE

{cont'd)

www.emanualpro.com

6-17

GylinderHead
Removal(cont'dl
'11. Removethe brakeboostervacuumhose.fuel return
hose,and vacuumhose.
'97 - 98 modsls:

12. Removethe breatherhose and oositivecrankcase


ventilation(PCV)hose,
'97 98 models:

BRAKEBOOSTER

PCVHOSE
BREATHEB
HOSE

VACUUM
HOSE

'99 - 00 models:

BREATHER
HOSE
BRAKEBOOSTEB
VACUUM HOSE

PCVHOSE

6-18

www.emanualpro.com

13. Removethe upper radiatorhose, heaterhose and


water bypasshose.

18. Removethe cylinderheadcover.


CYLINDER

WATERBYPASS

UPPEB
RADIATOR
HOSE

HEATER
HOSE
R e m o v et h e e n g i n ew i r e h a r n e s sc o n n e c t o r sa n d
wire harnessclampsfrom the cylinderheadand the
intakemanifold.
o Fourfuel injectorconnectors
. E n g i n ec o o l a n tt e m p e r a t u r e( E C T )s e n s o rc o n neclor
. Radiatorfan switchconnector
. Coolanttemperaturegaugesendlngunlt connector
. Throttlepositionsensorconnector
. Manifold absolute pressure{MAP) sensor connector
Primary heatedoxygen sensor (primary HO2S)
connector
a ldle air control(lAC)valveconnector
Distributorconnector

19. Inspectthe timing belt (seepage6-9).

Removethe sparkplug capsand distributorfrom the


cylinderhead.
Removethe cruisecontrolactuator(seesection4).
1 7 S u p p o r tt h e e n g i n ew i t h a j a c k ,t h e n r e m o v et h e

u p p e r b r a c k e t .M a k e s u r e t o p l a c e a c u s h i o n
betweenthe oil pan and the iack(seepage6-10).

(cont'd)

www.emanualpro.com

6-19

CylinderHead
Removal(cont'dl
Removethe timing belt (seepage6-10).

2' t. Removethe camshaftpulleysand backcover.

22. Bemove the exhaust manifold bracket and self-locking nuts.


'97 - 98 U.S. modsls (Californial:
GASKET
Replace.

EXHAUSTMANIFOLD
BRACKET

'r
10 x 1.25mm
44 N.m 14.5kgf,m,
33 rbf.ft)
SELF.LOCKING
NUT
54 N.m {5.5kgf.m, .{) lbf.ftl
Replace.
'97 98 U.S. models {Excepi Calitornia}:
'99 0O modeb:
BACKCOVER
GASKETS
Replace.

SELF.LOCKING
NUT
10 x 1.25mm
54 N.m {5.5kgt.m, 40 lbtft}
Replace.

www.emanualpro.com

6-20

10 x 1.25mm
4il N.m (4.5kgf.m,
33 tbf.ftl

2 3 . R e m o v et h e i n t a k em a n i f o l dm o u n t i n gb o l t s a n d
water bvDasshose.

25. Removethe camshaftholderbolts,then removethe


camshaftholdersand rockerarms.Makenote of the
rockerarm Dositions.

ROCKERARM

26. Remove the cylinder head bolts. To prevent


warpage,unscrewthe bolts in sequence1/3turn at a
time; repeatthe sequenceuntil all bolts are loosened.

8 x 1.25mm
2,1N.m 12.4kgt.m,
17 tbf.ft)

CYLINDERHEADBOLTSLOOSENINGSEOUENCE:
24. Loosen the locknuts and adjusting screws,

INTAKE

No. 4

No.3

No.2

N o .1

No.3

No.2

N o .1

EXHAUST

27. Removethe cylinderhead.

www.emanualpro.com

6-21

Camshafts
Inspection
1 . Loosenthe adjustingscrews.

11. Removethe camshaftholders.Measurethe widest


portionof plastigageon eachjournal.

Removethe camshaftholders.
Camshatt-toHoldGrOil Clearance:
Standard {Newl: 0.030- 0.069mm
{0.0012- 0.0027in}
ServicoLimit: 0.15 mm (0.006in)

Markthe rockerarms,then removethem.


4. R e i n s t a l tl h e c a m s h a f ta n d h o l d e r s .T i g h t e nt h e

camshaftholderbolts in a crisscrosspattern,beginning with the innerbolts.


9.8 N.m (1.0kgf.m.7.2lbf.ft)
Seatthe camshaftsby pushingthem toward the distributorend of the headwith a screwdriver.
Z e r o t h e d i a l i n d i c a t o ra g a i n s tt h e e n d o f t h e
camshaft, push the camshaft back and forth and
readthe end play.
CamshaftEnd Play:
StandardlNewl: 0.05- 0.15mm
10.002- 0.005in)
ServiceLimit: 0.5 mm (0.02in)
12. lf camshaft-to-holder
oil clearanceis out of tolerance:
. A n d t h e c a m s h a f th a s a l r e a d yb e e n r e p l a c e d ,
you must replacethe cylinderhead.
. lf the camshafthas not beenreplaced,first check
total runout with the camshaftsuoDortedon Vblocks.
CamshaftTotal Runout:
Standard (N6w): 0.03 mm (0.001in) max.
ServiceLimit
0.04 mm (0.(X)2in)

7 . Unscrewthe camshaftholder bolts two turns at a


t i m e , i n a c r i s s c r o s sp a t t e r n ,T h e n r e m o v e t h e
camshaftholderboltsfrom the cvlinderhead.
8. L i f t t h e c a m s h a f t so u t o f t h e c y l i n d e rh e a d .w i p e
them clean,then inspectthe lift ramps,Replacethe
camshaftif any lobes are pitted, scored,or excessivelyworn.

Rotat6camshatt
while measuring.

Cleanthe camshaftjournal surfacesin the cylinder


head,then set the camshaftback in Dlace.Placea
plastigagestrip acrosseachjournal.

1 0 . Installthe camshaftholders.and torquethe boltsto


the valuesand in the sequenceshownon page6-31.

lf the total runout of the camshaftsis within tolerance,replacethe cylinderhead

lf the total runout is out of tolerance,replacethe


camshaftsand recheck.lf the oil clearanceis still
out of tolerance,replacethe cylinderhead.

NOTE: Do not rotatethe camshaftsduring inspection.

6-22

www.emanualpro.com

Valves,Valve Springs

and ValveSeals
Removal
13. Measurethe cam lobe height.
Cam Lobe Height Standard (Newl
'97 - 98 models:
INTAKE: 33.20,1mm(1.3072in)
EXHAUST:33.528mm (1.3200inl
'99 - 00 models:
INTAKE: 33.716mm 11.327t1in)
mm (1.3200in)
EXHAUST:33.528

l d e n t i f yt h e v a l v e s a n d v a l v e s p r i n g sa s t h e y a r e
removedso that eachitem can be reinstalledin its original Dosition.
1.

socketand plasticmallet.
Usingan appropriate-sized
retainer
to loosenthe valvekeeP
lightlytap the valve
ers beforeinstallingthe valvespringcompressor'

2.

Installthe spring compressor.Compressthe spring


and removethe valvekeeper.

Inspectthis arealor wear.

VALVESPRINGCOMPRESSOR
KD No. 3&!. whh *'5 JAW o.

VALVESPRINGCOMPRESSOR
ATTACHMEUT
07757- PJ1010A
(cont'd)

www.emanualpro.com

6-23

Valves,Valve Springs and Valve Seals


Removal(cont'dl
3.

Installthe valveguide sealremover.

VALVEGUIDESEALREMOVER
LISLEP/N 57900or KD3350or equivalent
(Commerciallv
available)

Intake Valve Dimensions


A Standard{New}: 30.85- 31.15mm
B Standard (New):
G Standard {Newl:
C ServiceLimiti
D StandardlNewl:
D Service Limit:
4.

Removethe valveseal.

6-24

www.emanualpro.com

- 1.226inl
11.21s
- 10/t.10
103.80
mm

{i[.087- 4.098in)
6.580- 6.590mm
(0.2591- 0.2594in)
6.55 mm (0.258inl
1.35- 1.65mm
(0.053- 0.05s in)
1.15mm (0.045in)

Exhausi Valv Dimensions


A Standard(Newl: 27.85- 28.15mm
1 1 . 0 9-61 . 1 0 8i n )
B Standard (Newl:
10,1.00- 10,1.30mm
(il.09i[- it.l06 in)
C Standard {New):
6.550- 6.560mm
10.2579- 0.2583inl
C ServiceLimit:
6.52mm (0.257inl
D StandardlNewl:
1.65- 1.95mm
- 0.077in)
10.065
D Service Limit:
1.45mm (0.057inl

ValveGuides
ValveMovement

Replacement

c l e a r a n c ew i t h a d i a l
1 . M e a s u r et h e g u i d e - t o - s t e m
in the directionof
the
stem
indicatorwhile rocking
normalthrust(wobblemethod),

1.

lntake Valve Stem-to-GuideClearance:


Standard(Newl:0.04- 0.10mm
(0.002- 0.004in)
0.16mm (0.006in)
ServiceLimit

As illustratedbelow, use a commerciallyavailable


air-impactvalve guide driver attachmentmodified
t o f i t t h e d i a m e t e ro f t h e v a l v e g u i d e s . I n m o s t
cases,the same procedurecan be done using the
sDecialtool and a conventionalhammer.

VALVEGUIDEDRIVER
(Commerciallv
available)
6.4 mm

ExhaustValve Stem-to-GuideClearance:
Standard{Newl:0.10- 0.16mm
(0.004- 0.006inl
ServiceLimit: 0,22mm (0.009inl

(0.25inl

_,1-r

,_T-_

*]-'

sz mm
l2.21inl

l r l
'11.3mm
(0.{,r in}

or
VALVEGUIDEDRIVER,
6.6mm
0t9a:I- G5t01q)

l f t h e m e a s u r e m e net x c e e d st h e s e r v i c el i m i t ,
recheckusinga new valve.
2.

lf the measurementis now within the servicelimit,


reassembleusinga new valve.

3.

stillexceedsthe limit,subtractthe
lf the measurement
O.D.of the valvestem,measuredwith a micrometer,
from the l.D. of the valve guide, measuredwith an
insidemicrometeror ballgauge.
T a k et h e m e a s u r e m e n tisn t h r e e p l a c e sa l o n g t h e
valvestem and three placesinsidethe valveguide
The differencebetweenthe largestguide measurem e n t a n d t h e s m a l l e s st t e m m e a s u r e m e nsth o u l d
not exceedthe servicelimit.
lntake Valve Stem-to-GuideClearance:
Standard (New): 0.02- 0.05 mm
{0.001- 0.002in)
ServiceLimit: 0.08 mm (0.003in)

2.

S e l e c tt h e p r o p e r r e p l a c e m e n gt u i d e s .a n d c h i l l
t h e m i n t h e f r e e z e rs e c t i o n o f a r e f r i g e r a t o rf o r
aboutan hour.

3.

Use a hot plate or oven to evenlyheat the cylinder


headto 300"F(150"C).Monitorthe temperaturewith
a cookingthermometer.Do not get the head hofter
than 300'F (150"C);excessiveheat may loosenthe
valveseaIs.

CAUTION: To avoid burns, uss heavy gloves when


handling the heated cylinder head.

ExhaustValve Stem-to-GuideClearance:
Standard(New):0.05- 0.08mm
(0.002- 0.003in)
ServiceLimit: 0.11mm (0.004in)
(cont'd)

www.emanualpro.com

6-25

ValveGuides
(cont'dl
Replacement
Workingfrom the camshaftside,use the driver and
a n a i r h a m m e rt o d r i v et h e g u i d ea b o u t2 m m ( O . l
i n ) t o w a r d s t h e c o m b u s t i o nc h a m b e r .T h i s w i l l
k n o c ko f f s o m e o f t h e c a r b o na n d m a k e r e m o v a l
easier.Hold the air hammerdirectlyin line with the
valveguideto preventdamagingthe driver.

8.

Apply a thin coat of cleanengineoil to the outside


of the new valve guide. Installthe guide from the
camshaftside of the head; use the specialtool to
drive the guide in to the specifiedinstalledheight.lf
you have all 16 guidesto do, you mav have to
reheatthe head.

CAUTION: Always wear satety goggles or a face


shield when driving valve guidss.
5.

Turn the head over and drive the guide out toward
the camshaftside of the head.

ATTACHMENT

Valve Guide Installed Height:


Intake: 13.75- 1i1.25
mm
{0.5,[1- 0.561in)
Exhaust:15.75- 16.25mm
(0.620- 0.640inl

'o C'
6.

li a valve guide won't move, drill it out with a 8.0


mm (5/16in) bit, then try again.Drittguidesonty in
extremecases;you could damagethe cylinderhead
if the guide breaks.

7.

Removethe new guide(s)from the freezer,one at a


tlme, as you needthem.

6-26

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CylinderHead
Reaming

Warpage

NOTE:For new valveguidesonly.

oil clearances(seepageG22)
NOTE: lf camshaft-to-holder
the head cannot be resurare not within specification,
faced.

1. Coatthe reamerand the valveguidewith cuttingoil.


2.

Rotatethe reamer clockwisethe full length of the


valveguide bore.

oil clearancesare within specificalf camshaft-to-holder


tions, checkthe head for warpage.Measurealong the
edges,and threeways acrossthe center.

3.

C o n t i n u et o r o t a t e t h e r e a m e r c l o c k w i s ew h i l e
removingit from the bore.

4.

Thoroughlywash the guide in detergentand water


to removeanYcuttingresidue.

5.

Checkclearancewith a valve(seepage6-25).

6 . Verifythat the valvesslidein the intakeand exhaust


valveguideswithout exertingpressure.

if warpage is less than 0.05 mm (0.002in) cylinder


headresurfacingis not required
lf warpageis between0.05mm (0.002in) and 0.2 mm
(0.008in), resurfacecylinderhead.
Maximum resurfacelimit is 0.2 mm (0.008in) based
on a heightof 132.0mm (5.20in).
PRECISION
STRAIGHTEDGE

REAMERHANDLE

mm
vALvE GUIDEREAMER,6.6
0798i1- 657010O

Cylindr Hesd Height:


Standard{New}:131.95- 132.05mm
- 5.199inl
15.195

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6-27

Valve Seats
Reconditioning
lf the guidesare worn (seepage6-25),replacethem (see
pagee25) beforereconditioning
the valveseats.
1.

5.

Renewthe valve seatsin the cylinderhead using a


valve seat cutter.

After resurfacingthe seat, inspect for even valve


seating:Apply PrussianBluecompoundto the valve
face, and insertthe valve in its original locationin
the head,then lift it and snap it closedagainstthe
seatseveraltimes.
ACTUAL
SEATING
SURFACE

VALVE
SEAT
o

PRUSSIAN

The actualvalve seatingsurface,as shown by the


bluecompound,shouldbe centeredon the seat.
. lf it is too high (closerto the valve stem), you
must make a second cut with the 60" cutter to
move it down, then one more cut with the 45"
cutter to restore seat width.
. lf it is too low (closer to the valve edge), you
must make a second cut with the 30. cutter to
move it up, then one more cut with the 45. cutter
to restoreseat width.

C a r e f u l l yc u t a 4 5 os e a t , r e m o v i n g o n l y e n o u g h
materialtoensurea smoothand concentricseat.
Bevelthe upperedge of the seatwith the 30. cutter
and the lower edge of the seatwith the 60" cutter.
Checkwidth of seatand adjustacco.dingly.

NOTE:The final cut shouldalwavsbe madewith


the 45" cutter,
7.

Makeone more very light passwith the 45ocutterto


removeany possibleburrs causedbv the other cutters.

Insert the intake and exhaust valves in the head,


and measurevalvestem installedheioht.
Intake Vslve Siem Instslted Height:
Standard {Newl: it0.765- 41.235mm
- 1.6234inl
11.6049
SarvicoLimit: itl.il85 mm (1.6333in)
ExhaustValve Stem Installed H6ight:
Standard {New}: 42.755- .235 mm
11.61137- 1.7022 inl
/(|.,185
ServicoLimit:
mm (1.7120in)

Valve Seat Width (lntake and Exhaust):


Standard {N.w}: 1.25- 1.55mm (0.049- 0.051in)
ServicaLimit: 2.0 mm (0.08in)

f-]
VALVESTEM
INSTALLEDHEIGHT

8.

6-28

www.emanualpro.com

lf valve stem installed height is over the service


limit. replacethe valve and recheck.lf it is still over
t h e s e r v i c el i m i t . r e p l a c et h e c y l i n d e r h e a d ;t h e
valveseatin the headis too deeo.

Valves,Valve Springsand Valve Seals


lnstallation
1.

Installthe valvespring and valve retainer.Placethe


end of the valve spring with closely wound coils
towardthe cylinderhead,

Coatthe valve stemswith oil. Insertthe valvesinto


the valveguides.
Checkthat the valvesmove up and down smoothly.

Installthe valve spring compressor.Compressthe


spring,and installthe valvekeepers.

Installthe springseatson the cylinderhead.

VALVESPRINGCOMPRESSOR
lComm6rciallyavailable)
KD No. 383,with *35 JAw or

Installthe valvesealsusingthe specialtool.


NOTE:Exhaustand intakevalvesealsare not interchangeable.
WHITE
SPRING

INTAKE VALVE SEAL

BLACK
SPRING

EXHAUSTVALVESEAL
VALVEGUIDE
SEALINSTALLER
lCommerciallyavailable)
KO3372or equivalnt
ot
07GAD- PH70100

VALVESPRIT{G
OOMPfiESSOR
ATTACHMENT
0775'- PJ1010A
7.

Lightlytap the end of eachvalve stem two or three


times with a plasticmalletto ensureproperseating
of the valve and valve keepers,Tap the valve stem
only along its axisso you do not bendthe stem.

PLASTE

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6-29

CylinderHead
Installation
Installthecylinderheadin the reverseorderof removal:
1.

Cleanthe cylinderheadand blocksurfaces.

2.

Cleanthe oil controlorifice.Installthe cylinderhead


gasket,dowel pins and the oil controlorificeon the
cylinderblock.Always use a new cylinderheadgasket.

CYLII{DER
HEAD
GASKET
Rplace.

4.

Tightenthe cylinderhead bolts in two steps.In the


first step tighten all bolts, in sequence,to about 29
N.m {3.0kgf.m,22 lbf.ft);in the finat step,tighten in
the samesequence
to 85 N.m(8.7kgf.m,63lbf.ft).
Usea beam-typetorque wrench.When usinga preset-typetorque wrench, be sure to tighten slowly
and do not overtighten.
lf a bolt makesany noisewhile you are torquing it,
loosenthe bolt, and retightenit from the 1ststep.

CYLINDER
HEADBOLTSTOROUESEOUENCE:

DOWELPIN

O.RING
Roplace.
DOWEL
PIN

T i g h t e nt h e i n t a k em a n i f o l dm o u n t i n gb o l t s ( s e e
page6-21).
OIL CONTBOL
ORIFICE
Clean.

Apply clean engine oil to the bolt threads and under


the bolt heads.

6 -30

www.emanualpro.com

Installthe exhaustmanifoldbracket.and tightenthe


new self-locking
nuts (seepage6-20).

7.

Placethe rockerarms on the pivots and the valve


s t e m s .P u t t h e r o c k e ra r m s i n t h e i r o r i g i n a lp o s i lrons.
lnstallthe camshafts,then installthe oil sealswith
the open side (spring)facing in. Make sure that the
keywayson the camshaftsare facingup and the No.
1 pistonis at TDC.

'10. lnstallthe camshaftholders.


NOTE:
o " 1 " o r " E ' m a r k sa r e s t a m p e do n t h e c a m s h a f t
holders.
. T h e a r r o w s m a r k e d o n t h e c a m s h a f th o l d e r s
shouldpoint at the timing belt.

't't, Tighten each bolt in two steps to ensure that the


rockersdo not bind on the valves.
Wipe off the excessliquid gasketfrom the No. 1 and
No. 6 camshaftholderswith a shop towel,
Specifiedtorque:
9.8 N.m (1.0 kgf.m, 7.2 lbf.ft)
Apply engine oil to the bolt ihreads.

Clean and dry the cylinder head mating surfaces.


Apply liquid gasket (P/N 08718- 0001 or 087180OO3)
to the head mating surfacesof the No. 1 and
N o . 6 c a m s h a f th o l d e r s o n b o t h t h e i n t a k e a n d
exhaustside.

I?,ITAKE

No. I

EXHAUST
EXHAUST

II{TAKE

Apply liquidgasketto th shadedareas.

(cont'd)

www.emanualpro.com

6-31

CylinderHead
Installation(cont'dl
' 1 3 .A l i g n

t h e m a r k so n t h e c y l i n d e rh e a d p l u g t o t h e
cylinder head upper surface,then installthe cylin
d e r h e a dp l u gi n t h e e n d o f t h e c y l i n d e hr e a d .

1 7 . Installthe timing belt (seepage6-11).

CYLINOER
HEAD

1 9 . T h o r o u g h l yc l e a nt h e h e a d c o v e r g a s k e ta n d t h e
groove.

PLUG
Replace.

'18. Adjust
the valveclearance(seepage6-3).

lnstall the head cover gasket in the groove of the


cylinderhead cover. Seatthe head cover gasketin
the recessesfor the camshaftfirst, then work it into
the groovearoundthe outsideedges.Makesurethe
head cover gasket is seated securely in the corners
of the recesses
with no gap.

1 4 . lnstallthebackcover.

To set the camshaftsat TDC positionfor the No. l


p i s t o n ,a l i g n t h e h o l e s i n t h e c a m s h a f t sw i t h t h e
holes in the No. l camshaftholdersand insert 5.0
mm pin punchesin the holes.Installthe keys into
the camshaftgrooves.
KEYS

I x 1.25mm
37 N m (3.8*gl.m, 27 lbt.tr)
6x1.0mm

9.8N.m(1.0kgtm,
7.2|hrftl
Pushthe camshaftpulleysonto the camshafts.then
tightenthe retainingboltsto the torquespecified.

6-32

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2 1 . Checkthat the matingsurfacesare cleanand dry.


2 2 . Apply liquid gasket,part No. 08718- 0001or 08718
- 0003,to the headcovergasketat the eight corners
of the recesses.

25. Tightenthe nuts in tvvo or three steps.In the final


step, tighten all nuts, in sequence.to 9.8 N.m (1.0
kgf.m,7.2 lbf.ft).

NOTE:
. Do not installthe parts if five minutesor more
h a v e e l a p s e ds i n c e a p p l y i n g l i q u i d g a s k e t .
Instead,reapplyliquid gasketafter removingold
residue.
. After assembly.wait at least 30 minutes before
filling the enginewith oil.

to
Applyliquidgasket
areas.
theshaded

26. C h e c kt h a t a l l t u b e s , h o s e s a n d c o n n e c t o r sa r e
installedcorrectly.

23. Holdthe headcovergasketin the grooveby placing


your fingerson the camshaftholdercontactingsurfaces(top of the semicirclesl.
O n c e t h e c y l i n d e rh e a d c o v e r i s o n t h e c y l i n d e r
head, slide the cover slightly back and forth to seat
the headcovergasket.
24. Inspectthe coverwashers.Replaceany washerthat
is damaged or dete(iorated.

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6-33

En g i n eB loc k
.............7-2 CylinderBlock
SpeciafTools
lllustratedlndex ...................................
7-3
Inspection
..............7-13
Flywheeland Drive Plate
PistonPins
Replacement
..,.,....7-5
Removal
..,.......,,.....
7-14
ConnectingRod and Grankshaft
Installation
.............
7-15
E n dP l a y
. . . . . . . . . . . . . . . . . 7 - 6 Inspection
..............
7-16
MainBearings
ConnectingRods
-7
-14
Cfearance
...............7
Selection
................7
................7-8 PistonRings
Selection
-17
ConnectingRod Bearings
End Gap
.................7
Clearance
...............7-8
Ring-to-GrooveClearance...............
7 -17
................7-9
Replacement
.........7-18
Selection
Pistonsand Crankshaft
Alignment
..............
7-18
Removal
.................7-9 CrankshaftOil Seal
Crankshaft
lnstallation
.............
7-19
Inspection
..............
7-11
Crankshaft
Pistons
lnstalfation
.............7-20
fnspection
..............7-12 Oil Seals
fnstaflation
.............7-20
fnstalfation
....,..,.....7-23

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tl

SpecialTools

Ref, No.

Tool Numbor

07GAF- PH60300
07HAF- P120102
07LAB- PV00100
07LAD- PT30101
07LAF- PR30100
07948- S800101
07749- 0010000
07973- PE00310
07973- PE00320
07973- 6570500
07973- 6570600

@
@
/6

@
@
@
@

Oty

Description

PageReterence

,l

PistonPin Baselnsert
PistonBaseHead
RingGearHolder
SealDriver
PilotCollar
SealDriverAttachment.76 x 80 mm
Driver
PistonPin DriverShaft
PistonPin DriverHead
Piston Base
PistonBaseSpring

7-14,15
1-'t4,15
1-5
1-23
7-14,15
7-'t9,24
7 -'t9, 24
1-14,15
7-14,15
7-'t4,15
7-14,15

1
I
I
1
1
1
1
1
1
1

eE
E
g

0
o

7-2

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lllustratedlndex

Luori""t" "tl internalpartswith engineoil during reassembly.

Applyliquidgasketto the matingsurfacesof the right side coverand oil pump casebeforeinstallingthem.
Jse liquidgasket,PartNo. 08718- 0001or 08718- 0003.
:lean the oil pan gasketmatingsurfacesbeforeinstallingthe oil pan.

WASHER
Replace.

76 x 1.0 mm

y'
9

t:n-

l.zxstm, 8.7lblftl

oIL PAN

to page1-22
when installing
OIL PAN GASKET
Replace.

1 1 x 1 . 5m m
76 N.m {7.8kgl.m, 56 lbf.ft}
Appiyengineoilto the bolt
threaos.
NOTE:Afterlorquing
eachcap,turn the crankshaft
to checkfor binding.

6x1.0mm
9,8N.m (1,0kgf.m,
7.2 tbt.lrl

BEARINGCAP

BAFFI.f PLATE

OOWELPIN

MAIN BEARINGS
page7 8
Selection,
NOTE:New main bearingsmust
be selectedby matchingthe crank
and blockidentification
markings.

otL
6 x ' 1 . 0m m
9.8 N.m {1.0kgtm,
7.2 tbf.ftl
GASKET
Replace.

6x1.0mm
9.8N.m 11.0kgt m,

7.2tbt+tl

CRANKSHAFT
OIL SEAL
Installation,
page7-19
1 2x 1 . 0m m
Replace.
/ , 7 1 N n 1 7. 5
ks{ m 5a lbtft) {a/Tl
&it

ln

OIL PUMP
Overhaul,page8-8
Removal/lnspection,
page8-9
Applyliquidgasket
to mating surface.

WASHERIA/T}

ORIVEPLATEIA/T)
Checkfor cracks.
6x1.0mm
9.8 N.m 11.0kgt.m,7.2lbtft)

8 x 1.25mm

2a N.m(2.akgt.m,---\6/

RIGHTSIDECOVER
Apply liquidgasket
to matingsurface,
CRANIGHAFTSEAL
page8-10
Installation,
Replace-

6x1.0mm
9.8 N.m l'1.0kgf.m,7.2 lbf.ft)

O.RING
Replace.

THRUSTWASHERS
Groovedsides face outlvard,
NOTE:Thrustwasherthickness
is lixed and must not be changed
by grindingor shimming.

(cont'd)

www.emanualpro.com

7-3

lllustratedIndex(cont'd)
NOTE:New rod bearingsmust be selectedby matchingconnectingrod assemblyand crankshaftidentificationmarkings
(seepages7-91.
DIRECTION:
INSTALLANON
PISTON
parts
with
engine
oil
Lubricateall internal
EXHAUST
during reassembly.

l1\AAtr\

\9q9Q9e/
INTAKE

PISTON PIN
Removal,page7-14
page7-15
Installation,
Inspection.page7-16

PISTONRINGS
Replacement.page 7-18
page7-17
Measurdment,
Alignmnt,page7-18

PISTON
page7-12
Inspection,

ENGINCBLOCK
Cylinderbore inspection.pago 7-13
Warpage inspoction,Page7-'13
CONNECTING
End play, page 7-6
page7-14
Selection,

COiINECI'ING ROD
BEARINGS
Clearance,page 7-8
Solection.page7-9

RODBEARINGCAP
CONNECTING
page7-20
lnstallation,
NOTE:Installthe capsso the
bearingrecessis on the
samesideasthe recess
in the rod.
RODCAPNUT
CONNECTING
8 x 0.75mm
31 N.m {3.2kgl.m.
23 tbf.ftl
Apply engine oil to the bolt threads.

NOTE:Aftertorquingeachbearing
to checkfor
cap,rotatethe crankshaft
binding.

7-4

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Inspectthe top ot each cylinder bore


for carbonbuild up or a ridge
beloreremovingthe piston.
page7-10
Removethe ridgeif necessary,

Flywheeland Drive Plate


Replacement
ManualTransmission:
Removethe eight flywheelbolts,then separatethe flyflange.After installation,
tightwheelfrom the crankshaft
en the bolts in the sequenceshown.

ENGINE
BLOCK
12 x 1.0mm
103 N.m 110.5kgf.m,
76 lbf.ft)

RINGGEAR
Inspectring gear
teethfor wear or damage,

RI G GEARHOTDER
07LAB - PV001|X)

AutomaticTransmission:
Removethe eight drive plate bolts, then separatethe
drive platefrom the crankshaftflange.After installation,
tightenthe bolts in the sequenceshown.

/ AzXi{'jA\Ao

12 x 1.0mm
7a N.m
(7.5 kgt.m,5a lbf.ftl

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7-5,

ConnectingRod and Crankshaft


EndPlay
1.

Measurethe connectingrod end play with a feeler


gauge.

3.

ConnectingRod End Play:


Stsndard(Nsw):0.15- 0.30mm
{0.006- 0.012in)
in)
ServiceLimit: 0./t0mm 10.016

2.

SCREWORIVER

lf the connectingrod end play is out-of-tolerance,


installa new connectingrod.
lf it is still out-of-tolerance,
replacethe crankshaft
{seepages7-9 and 7-20).

CrankshaftEnd Play:
Stand.rd (New):0.10- 0,35mm
(0.004- 0.014inl
0.45
mm (0.018inl
ServiceLimit:
4.

7-6

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Pushthe crankshaftfirmly away from the dial indic a t o r ,a n d z e r o t h e d i a l a g a i n s t h e e n d o f t h e


c r a n k s h a f tT. h e n p u l l t h e c r a n k s h a f ft i r m l y b a c k
t o w a r d t h e i n d i c a t o rt;h e d i a l r e a d i n gs h o u l d n o t
exceedthe servicelimit.

lf end play is excessive,inspectthe thrust washers


Reolaceoans as
and thrustsurfaceon the crankshaft.
n e c e s s a r yT. h r u s t w a s h e r t h i c k n e s si s f i x e d a n d
m u s t n o t b e c h a n g e de i t h e rb y g r i n d i n go r s h i m mrng.

MainBearings
Clearance
lf the plastigagemeasurestoo wide or too narrow,
( r e m o v et h e e n g i n e i f i t ' s s t i l l i n t h e v e h i c l e ) ,
removethe crankshaft,and removethe upper half
of the bearing.Installa new, completebearingwith
the same color code (selectthe color as shown on
the next page).and recheckthe clearance,Do not
f i l e , s h i m , o r s c r a p et h e b e a r i n g so r t h e c a p s t o
adjustthe clearance.

1 . T o c h e c k m a i n b e a r i n g - t o - j o u r n aoli l c l e a r a n c e ,

removethe main capsand bearinghalves.


2.

C l e a ne a c h m a i n j o u r n a l a n d b e a r i n gh a l f w i t h a
cleanshoptowel.

3.

Placea strip of plastigageacrosseachmain journal.


NOTE:lf the engineis still in the vehiclewhen you
b o l t t h e m a i n c a p d o w n t o c h e c kc l e a r a n c et,h e
weight of the crankshaftand flywheel will flatten
the plastigagefurther than just the torque on the
cap bolt, and give you an incorrectreading.For an
a c c u r a l er e a d i n g ,s u p p o r t t h e c r a n k w i t h a j a c k
underthe counterweights
and checkonly one bearI n ga I a I r m e .

4.

7.

lf the plastjgageshows the clearanceis still incorrect,try the ne)dlargeror smallerbearing{the color
listedabove or below that one),and checkagain.lf
the proper clearancecannot be obtained by using
the appropriatelarger or smaller bearings,replace
the crankshaftand startover.

R e i n s t a ltlh e b e a r i n g sa n d c a p s ,t h e n t o r q u e t h e
bolts,
1st step:25 N'm (2.5kgf.m,18lbf.ft)
Final siep: 76 N'm 17.8kgl.m, 56 lbf.ftl
NOTE:Do not rotatethe crankshaftduring inspectron.
R e m o v et h e b e a r i n gc a p a g a i n ,a n d m e a s u r et h e
widestpart of the plastigage.
Main Bearing.to.JournalOil Clearance:
Stand8.d {New):
N o .1 , 2 , 4 , 5 J o u r n s l s :
0.02i1- 0.0i12mm (0.0009- 0.0017inl
No. 3 Journal:
0.030- 0.0i18mm (0.0012- 0.0019inl
ServiceLimit: 0.06 mm 10.002in)

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7-7

ConnectingRod Bearings

Main Bearings
Selection

Clearance

Crankshaft Bore Code Location

1.

Removethe connectingrod cap and bearinghalf.


Cleanthe crankshaftrod journal and bearing half
with a cleanshop towel.

Lettershave been stamDedon the end of the blockas a


codeJorthe sizeof eachof the 5 main journalbores.
U s e t h e m , a n d t h e n u m b e r so r b a r s s t a m p e do n t h e
crank(codesfor main journalsize),to choosethe correct
beanngs.
lf the codesare indecipherable
becauseof an accumulat i o n o f d i r t a n d d u s t . d o n o t s c r u bt h e m w i t h a w i r e
brush or sc.aper.Cleanthem only with solventor detergent.

Placethe plastigageacrossthe rod journal.


Reinstallthe bearing half and cap, and torque the
nuts.
Torqus: 31 N.m (3.2 kgf.m. 23 lbf.ft)
NOTE:Do not rotatethe crankshaftduring inspection.
Removethe rod cap and bearinghalf,and measure
the widestpart of the plastigage.
ConnestingRod Bearing-to-JournalOil Clearancc:
Standard {Newl: 0.020- 0.038mm
{0.0008- 0.0015in)
ServiceLimit: 0.05 mm {0.002inl
PLASTIGAGE

Main Journ.l Cod. Locrtions lNumbcB oi Bar3l

lf the plastigagemeasurestoo wide or too narrow,


removethe upper half of the bearing,installa new.
completebearingwith the same color code {select
the color as shown on the next page),and recheck
the clearance.Do not file, shim, or sc.apethe bearings or the capsto adjustthe clearance.

Bearing ld.ntif icrtion


Color code is
on the edge of
the bearing.
I

""""""""

Smallerbearing(rhicker)
Green
Green

Elacl

7- 8

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Alue

7.

lf the plastigageshows the clearanceis still incor


rect,try the next largeror smallerbearing{thecolor
listed above or below that one). and check cleara n c e a g a i n .l f t h e p r o p e rc l e a r a n c ec a n n o t b e
obtainedby usingthe appropriatelargeror smaller
bearings.replacethe crankshaftand startover.

Pistonsand
Crankshaft
Selection

Removal

Connecting Rod Code Location

1.

Numbershave been stampedon the side of each connectingrod as a code for the size of the big end. Use
lhem, and the lettersstampedon the crankshaft(codes
for rod journalsize),to choosethe correctbearings.
lf the codesare indeciDherable
becauseof an accumulat i o n o f d i r t a n d d u s t ,d o n o t s c r u bt h e m w i t h a w i r e
brushor scraper.Cleanthem only with solventor detergent.

Removethe oil pan assembly.


Removethe right sidecover.

Half of numberis
stampedon beanng
cap and the othel
half is stampedon
rod.

Removethe oil screen.


Removethe oil pump.
Connecting Rod Journal Code Locations {Lettersl
OIL SCREEN

8aring ldentif ication


aolor code is on the
edge ol
tne Deanng.

Larger big end bore

2
---------------r.

l l A o r tl l
l l B o ' l l l
l l c o t r l ll l

I l-.. ilril I

t - l

Smaller
'od

Red

OIL PUMP

sma er bearino {thicker)

Pink

Pink

Green

Brown

Green
Brown
Black

Elack

Blue

Green
Green
Brown

5.

Removethe baffleplate.

Smaller
beanng
(thicker)

(cont'd)

www.emanualpro.com

7-9

Pistonsand Crankshaft
Removal(cont'dl
6.

Removethe bolts.To preventwarpage,unscrewthe


b o l t s i n s e q u e n c e1 / 3 t u r n a t a t i m e ; r e p e a tt h e
sequenceuntil all boltsare loosened.

9 . Removethe upper bearinghalvesfrom the connecting


rods,and set them asidewith their respectivecaps.
1 0 . Reinstallthe main caps and bearingson the engine
in properorder.
1 1 . lf you can feel a ridge of metalor hard carbon

around the top of each cvlinder,remove it with a


r i d g e r e a m e r .F o l l o w t h e r e a m e rm a n u f a c t u r e r ' s
i n s t r u c t i o n sl.f t h e r i d g e i s n o t r e m o v e d ,i t m a y
damagethe pistonsas they 8re pushedout.

7.

and main caps/bearRemovethe rod caps/bearings


in order
ings,Keepall caps/bearings

12. Use the wooden handle of a hammer to drive the


pistonsout.

Lift the crankshaftout of the engine.being careful


not to damagethe journals.

1 3 . Reinstallthe connectingrod bearingsand capsafter


rod assembly.
removingeachpiston/connecting
1 4 . To avoid mixup on reassembly,mark each piston/
connectingrod assemblywith its cylindernumber.
NOTE:The existingnumber on the connectingrod
does not indicateits positionin the engine,it indicatesthe rod bore size.

7-10

www.emanualpro.com

Crankshaft
Inspection
1.

Cleanthe crankshaftoil passageswith pipe cleaners


or a suitablebrush.

2.

Checkthe keywayand threads.

Out-of-Roundand TaDer
4.

Alignment
3.

M e a s u r et h e r u n o u to n a l l m a i n j o u r n a l st o m a k e
sure the crank is not bent. The differencebetween
m e a s u r e m e n tosn e a c hj o u r n a lm u s t n o t b e m o r e
thanthe servicelimit.

Measureout-of-roundat the middleof each rod and


main journal in two places.The differencebetween
m e a s u r e m e n tosn e a c hl o u r n a lm u s t n o t b e m o r e
than the servicelimit.
JournalOut-of-Round:
Standard(Newl:0.005mm 10.0002
inl max.
ServiceLimit: 0.010mm (0.000i1in)

CrankshaftTotal IndicatedRunout:
StandardlNew):0.03mm (0.001in) max.
ServiceLimit:
0.04 mm {0.002in)

Measureout-ol'
roundat middle.
DIAL INDICATOR
Rotate two complete
revolut|ons.

Measuretaper
at edges.

Suppon with lathelype tool or V-blocks.

5.

Measuretaper at the edges of each rod and main


journal.The differencebetweenmeasurementson
e a c h i o u r n a lm u s t n o t b e m o r e t h a n t h e s e r v i c e
limit.
JournalTaperi
Standard{Newl:0.005mm 10.0002
inl max.
ServiceLimit: 0.010mm (0.0004inl

www.emanualpro.com

7-11

Pistons

Inspection
L

Checkeachpistonfor distortionor cracks.


Measurethe pistondiameterat distanceA from the
bottom of the skirt.
A: '97 - 98 models15 mm 10.5inl
'99 - 00 models 20 mm 10.8inl

3.

Calculatethe differencebetweenthe cylinder bore


diameter(seepage7-13)and the pistondiameter.
Piston-to-CylinderClearance:
Standard{New):0.010- 0.040mm
{0.0004- 0.0016inl
Limit:
0.05
mm {0.002in}
Service

Piston Diameter:
Standard (New): 8:1.980- txl.990mm
(3.3063- 3.3067inl
Limit:
83.970
mm {3.3059inl
Service

SKIRTDIAMETER

lf the clearanceis near or exceedsthe servicelimit,


inspectthe piston and cylinderblock for excessive
wear.

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7-12

CylinderBlock
Inspection
M e a s u r ew e a r a n d t a p e r i n d i r e c t i o n sX a n d Y a t
three levelsin eachcylinder.lf the measurements
in
any cylinderare beyond the ServiceLimjt, replace
the block.

2.

Checkthe top of the blockfor warpage.


Measurealong the edgesand acrossthe centeras
shown.

SURFACESTO BE MEASURED

Engine Block Warpage:


Standard(New):0.07mm (0.003in) max.
ServiceLimit: 0.10mm {0.004inl

PRECISION
STRAIGHTEDGE

CvlinderBole Size:
Standard{Newl:84.00- 84.02mm
{3.307- 3.308inl
ServiceLimit: 84,07mm (3.310inl
Bore TaDer:
Limit: {Difterencebetween first and third measurement) 0.05mm {0.002in)

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7-13

PistonPins

ConnectingRods

Removal

Selection

1 . Assemble the Piston Pin Tools as shown.

Eachrod falls into one of four toleranceranges(from 0


to + 0.024mm {0 to + 0.0009in). in 0.006mm (0.0002in)
increments)dependingon the size of its big end bore.
lt's then stampedwith a number 1.1.2,3,or 4) indicating
the range.
Y o u m a y f i n d a n y c o m b i n a t i o no t 1 , 2 , 3 , o r 4 i n a n y
engrne.

PISTONBASEHEAO
07HAF -PL20102
PISTONPIN BASEINSERT
07GAF- PH60300

Normal Bore Size:,18.0mm (1.89in)


Inspectthe connectingrod for cracksand heatdamage.

CONNECTINGROD BORE
REFENENCE
NUMBER
Half of numberis stampedon
bearingcap, the other half on
connectno roo.

PISTONBASE
07973- 6570500

Adjustthe lengthA of the pistonpin dflver.


A: 49.70mm 11.957
in)
PISTONPINDRIVER
HEAI
07973- PE00320

R
Ir1

nT--u
ffi-"""-

PISTONPIN DRIVERSHAFT
07973- PEt0310

u_ll

3.

PILOTCOLLAR
07LAF- PR30100
Embossodmarkfacingup.

Placethe piston on the piston base,and pressthe


pin out with a hydraulicpress.Make sure that the
recessedportion of the piston aligns with the lips
o n t h ec o l l a r .

7-14

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PistonPins
lnstallation

The arrow must face the


timing belt sideot the
engineandthe connecting
rod oil hole must face the
rearof the engine.
ROO
CONNECTING

otL Hor.E

1.

Adjust the length B of the piston pin driver and shaft.


B: 49.70mm (1.957in)

PISTONPIN DRIVERSHAFT
0t973 - Pqxtlo

ffi*r,"ron'nl
PILOT COLLAR
OTLAF- PF3O1(x'

PISTONPIN BASEINSERT
07GAF- PH6o3ttO
PISTONBASE HEAD
OTHAF- PL2O102
PISTON BASE
07973 - 6670500

Placethe piston on the piston base and pressthe


p i n i n w i t h a h y d r a u l i cpress. Make sure that the
recessedportion of the piston alignswith the lugs
on the pistonbasehead.

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7-15

PistonPins
Inspection
1.

lMeasurethe diameter of the piston pin.

3.

Piston Pin Diameter:


Standard lNewl: 20.996- 21.000 mm

Oversize:

{0.8266- 0.8268in}
20.998- 21.002mm
(0.8267- 0.8268in)

pistonpins are oversize.


NOIE: All replacement
Piston Pin-to-PistonClearance:
StandardlNewl: 0.010- 0.017mm
- 0.0007in)
10.0004

4.

2.

Zeto the dial indicatorto the pistonpin diameter.

M e a s u r et h e p i s t o np i n t o p i s t o nc l e a r a n c el .f t h e
p i s t o n p i n c l e a r a n c ei s g r e a t e rt h a n 0 . 0 2 4m m
(0.0009inL remeasureusingan oversizedpistonpin.

Checkthe differencebetlveenthe pistonpin diameter and the connectingrod smallend diameter.


Piston Pin-to-ConnectingRod Interference:
Standard(New):0.015- 0.032mm
(0.0006- 0.0013inl

7-16

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PistonRings
Glearance
Ring-to-Groove

EndGap
1.

U s i n ga p i s t o n ,p u s h a n e w r i n g i n t o t h e c y l i n d e r
bore 15 - 20 mm (0.6 0.8 in) from the bottom

After installinga new set of rings, measurethe ring-togrooveclearances:

2.

M e a s u r et h e p i s t o nr i n g e n d - g a pw i t h a f e e l e r
g au g e :
. lf the gap is too small,checkto see if you have
the properringsfor your engine.
. lf the gap is too large,recheckthe cylinderbore
'13.
diameteragainstthe wear limits on page7

Top Ring Clearance:


Standard {New}: 0.055- 0.080mm
- 0.0031inl
10.0022
Service Limit: 0.13 mm 10,005inl

PistonRingEnd-Gap:
Top Ring
Standard(Newl:0.20- 0.30mm
- 0.012inl
10.008
ServiceLimit: 0.60 mm {0.024inl
SecondRing
Standard lNew): 0.i10- 0.55 mm
{0.016- 0.022inl
ServiceLimit: 0.70mm (0.028in)
Oil Ring
Standard(Newl:0.20- 0.50mm
- 0.020in)
10.008
ServiceLimit: 0.70 mm (0.028in)

Second Ring Clearance:


Standard{Newl:0.035- 0.060mm
{0.001'l- 0.0024inl
Service Limit: 0,13 mm 10.005inl

PISTONRING

--:4

ll
ENDGAP-1f-

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7-17

PistonRings
Replacement

Alignment

1 . Usinga ring expander,removethe old pistonrings.

l.

2.

Installtheringsas shown.

C l e a n a l l t h e r i n g g r o o v e st h o r o u g h l yw i t h a
squared-offbroken ring or a ring gtoove cleaner
with a bladeto fit the pistongrooves.

TOP RING

The top ring groove is 1.2 mm (0.042in) wide, rhe


secondring groove is 1.2 mm (0.042in) wide, and
t h e o i l r i n g g r o o v e i s 2 . 8 m m ( 0 . 1 1i n ) w i d e . F i l e
down a bladeif necessary.

'97 - 98 models:

Do not use a wire brush to clean ring lands,or cut


ring landsdeeperwith cleaningtool.
3.

I n s t a l lt h e n e w r i n g s i n t h e p r o p e rs e q u e n c ea n d
position(shownin the right column).

'99 - O0modls:

l-;

NOTE: lfthe pistonis to be separatedfrom the connectingrod, do not installnew ringsyet.

RING EXPANDER

Piston Ring Dimensions:

|-

T f

+-

' 1
A
Top Ring {standard}:
A: 3.1 mm (0.12in)
B: 1.2mm 10.05inl
SecondRing (standard):
A: 3.'1mm (0.f 3 in)
B: 1.2mm (0.05in)
N O T E : T h e m a n u f a c t u r i n gm a r k s m u s t b e t a c i n g
upward.

MARK

ropnrNG+S

z:-\

SECONDRING+

,A-\

o**^o(

ffi+-sPAcER
\zu-\

7-18

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CrankshaftOil Seal
lnstallation
Rotatethe rings in their groovesto make sure they
do not bind.
Positionthe ring end gaps as shownl

SECONDRINGGAP

1.

The sealmatingsurfaceon the blockshouldbe dry


Apply a light coat of oil to the crankshaftand to the
l i p o f t h es e a l .
Drivethe crankshaftoil seal squarelyinto the right
sroecover.

DO NOTpositionany ring gap


at piston thrust surfaces,

DRIVER

Appror.90"

Appror.
90'
TOP RI.IIGGAP
DO NOT position any ring gap
in linewith the pistonpin hole.

OIL RING
GAP
SPACERGAP

lnstallsealwith the
part numberside
facingout.

OIL RINGGAP

is equalall the way around


Confirmthatthe clearance
with a feelergauge.
- 0.8 mm {0.02- 0.03inl
Clearance:0.5

0.5-0.8 mm
{O.02 0.03 in)

NOTE| Referto pages7 23 and 8-10for installation


of the oil oumDsidecrankshaitoil seal.

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7-19

Pistons

Crankshaft

Installation

Installation

1.

1.

Apply a coat of engine oil to the ring groovesand


cylinderbores.

It the crankshaftis alreadyinstalled.


2. Setthe crankshattto BDCfor eachcylinder.
3. Removethe connectingrod caps,and slip shortsec
tions of rubber hose over the threadedends of the
connectingrod bolts.
4. lnstallthe ring compressor,
and checkthat the bearangis securelyin place.
5. Positionthe pistonin the cylinder,and tap it in using
t h e w o o d e nh a n d l eo f a h a m m e r .M a i n t a i nd o w n ward force on the ring compressorto preventrings
trom expandingbeforeenteringthe cylinderbore.
6. Stop afterthe ring compressorpops free,and check
t h e c o n n e c t i n gr o d - t o - c r a n jko u r n a la l i g n m e n t
beforepushingpistoninto place.
7. Installthe rod caps with bearings,and torque the

Apply a coat of engineoil to the main bearingsand


rod bearings.
I n s e r t h e b e a r i n gh a l v e si n t h e c y l i n d e rb l o c ka n d
connect|ngrods.

3.

Holdthe crankshaftso the rod journalsfor cylinders


N o . 2 a n d N o .3 a r es t r a i g hdt o w n .

4.

Lowerthe crankshaftinto the block,seatingthe rod


j o u r n a l si n t o c o n n e c t i n gr o d s N o . 2 a n d N o . 3 .
Installthe rod capsand nutsfinger tight.

NUISIO:

31 N.m (3.2kgf.m,23tbf.ft)
Apply engineoil to the bolt threads.
lf the crankshaft is not installed:
2. Removethe rod caps and bearings,and installthe
flng compressor.
3 . P o s i t i o nt h e p i s t o n i n t h e c y l i n d e r ,a n d t a p i t i n
u s i n gt h e w o o d e n h a n d l eo f a h a m m e r .M a i n t a i n
downwardforce on the ring compressorto prevent
rings from expandingbefore enteringthe cylinder
oore,
4. Positionall the pistonsat top deadcenter.

5.

6.

The arrow must face


the timing belt side
of the engine.

CONNECTING
ROO
OIL HOLE

outward.
Rotatethe crankshaftclockwise,and seat the jour
n a l s i n t o c o n n e c t i n gr o d s N o . 1 a n d N o . 4 , I n s t a l l
the rod caps and nuts finger-tight.Installthe caps
s o t h e b e a r i n gr e c e s si s o n t h e s a m e s i d e a s t h e
recessanthe rod.
C h e c kt h e r o d b e a r i n gc l e a r a n c ew i t h p l a s t i g a g e
(seepage7 8). then lorque the capnuts.
Torque:
3l N.m 13.2kgf.m, 23 lbt.ftl
Apply engine oil to the bolt thleads.

7.

I n s t a ltl h e t h r u s tw a s h e r so n t h e N o . 4 j o u r n a l .

RUBBERHOSES

Line up the mark when


installing connecting rod
cap.

\\

7 -20

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Coat the thrust washer surtacesand bolt threads


with oil.
Installthemain bearingcaps.
Checkclearancewith plastigage(seepage7-7),then
tightenthe bearingcap bolts in 2 steps.

1 0 . Cleanand dry the right sidecover matingsurfaces.


1 1 , Apply liquid gasket,part No. 08718- 0001or 08718
- 0003,evenly to the block mating surfaceof the
right side cover and to the innerthreadsof the bolt
holes.Installit on the cylindrblock

25 N.m {2.5 kgf'm, 18 lbf'ft}


First slsp:
Sscond step: 76 N'm (7.8 kgf'm. 56 lbf'ft)
SEOUENCE
MAIN BEARINGCAPBOLTSTIGHTENING

RIGHTSIDE

NOTE:Wheneverany crankshaftor connectingrod


bearingis replaced,it is necessaryafter reassembly
t o r u n t h e e n g i n ea t i d l i n g s p e e du n t i l i t r e a c h e s
normaloperatingtemperature,then continueto run
15 minutes.
it for approximatelY

6x1.0mm
9.EN.m {1.0 kgt m,
7.2 tbf.ft)
OOWELPINS

NOTE:
. Do not install the parts if five minutes or more
h a v e e l a p s e ds i n c ea p p l y i n gt h e l i q u i d g a s k e t .
Instead,reapplyliquid gasketafter removingthe
old residue.
. After assembly,wait at least 30 minutes before
f i l l i n gt h e e n g i n ew i t h o i l .

(cont'dl

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7-21

Crankshaft
(cont'd)
Installation
1 2 . Apply liquid gasketto the oil pump mating surface
of the block.
1 3 . Apply a light coat of oil to the crankshaft,the lip of
the seal,and the O-rings.

1 6 . Apply liquid gasketon the oil pump and right side


covermatrngareas.
CYLINDER
BLOCK

1 4 . Apply greaseto the lips of the oil seals.

Apply liquid gasket


to these pornts,

Align the innerrotor with the crankshaft,


then install
the oil pump.When the pump is in place,cleanany
excessgreaseoff the crankshaft,
then checkthat the
oil seallips are not distoned.

Applyliquidgsket
to thesepornts.
17. Installthe oil pan gasketand oil pan. Wait no
than five minutesafterapplyingliquidgasket.

{
^

6x1,0mm
9.8 N.m {1.0 kg{.m,
,.2 tbf.ftl

OILPAN

"[z

(..6

GASKET
Replace.

6x1.0mm
9,8 N.m 11.0kg{.m,

7.2lbt.trl

,'t

./o,

DowEL PtN
//

O-RING
Replace.

OIL PUMP

7 -22

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OIL PAN

|
8 x 1.25mm
24 N.m {2.4 kgf.m,
17 tbt.ftl

GASKET
Replace.

Oil Seals
lnstallation
18. Tightenthe boltsand nutsfingertight at six points.

1.

Dry the crankshaftoil sealhousing.


Apply a light coat of greaseto the crankshsftand to
the lips of the seals.
Usingthe specialtool, drive in the timing pulley-end
sealuntilthe driverbottomsagainstthe oil pump.
When the seal is in place,clean any excessgrease
off the crankshaftand checkthat the oil seal lip is
not distorted,

SEALDRIVER
OTLAD- PT3O1OA
lnstallsealwiththe
partsnumberside
facingout.

1 9 . Tighten all bolts and nuts, startingfrom nut O. clocktighteningcan cause


wise in three steps.Excessive
distortionot the oil pangasketand oil leakage.
Torque: 12 N.m (1.2 kgt.m,8.7 lbtft)

(cont'd)

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7-23

Oil Seals
(cont'dl
Installation
4.

l/easurethe flywheel-endsealthicknessand the oil


seal housingdepth.Usingthe specialtool, drive the
flywheel end seal into the rear cover to the point
where the clearancebetweenthe bottom of the oil
seal and the right side cover is 0.5 - 0.8 mm (0.020.03in) (seepage 7-19).Align the hole in the driver
attachmentwith the pin on the crankshaft.

<:
DRIVER
ATTACHMENT
76x80mm
07948- 5800101
I n s t a lsl e a l w i t ht h e
n u m b e rs i d ef a c i n g
out,

7 -24

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EngineLubrication
...".""'8-2
S p e c i aTf o o l s . . . . . . . . . .
.'...8-3
l l l u s t r a t e dI n d e x. . . . . . . . . . .
E n g i n eO i l
. . . . . . . . . . . . ' . . ' . .8. -' .4. '
Inspection
. .-.4. . . . . . . .
R e p l a c e m e n. .t. . . . . . . . . . . . . . . . . . . . . . . . . . ' 8
OilFilter
R e p 1 a c e m e n t . . . . . . . . . . . . . . . . . . . . . . . . . .8. .-.5. . . . . . . . . . .
Oil PressureSwitch
".....8-7
Testing
Oil Pressure
....'.'8-7
Testing
OilPump
. . . . . . . . . . . , . . . .8. .-.8. .
Overhaul.....
....'.'8-9
Removal/lnspection/lnstallation

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SpecialTools

Ret. No.

8-2

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I
I

Tool Number
OTLAD_ PT3O1OA
0 7 9 ' 1-2 6 1 1 0 0 0 1

Description
SealDriver
Oil FilterWrench

Oty
1
1

Pagc Roforance
8-10
8-6

lllustratedIndex

OIL CONTROL
ORIFICE

'--

/o-RrNG
\

,/

\^
O-RING

OILPUMP
Overhaul,page8-8
page8 I
Removal/lnspection,
Apply liquidgasketto
matingsurfaceof engineblock.

./

v,/

Reptace.

'99 - 00 models:
KNOCKSENSOR
31 N.m {3.2 kgf.m.23 lbl.ft)

ENGINEOIL PRESSURE
SWITCH
18 N.m {1.8kgtm, 13lbl.ft)
1/8in. BSPT(BritishStandard
PipeTaper)28 Threads/inch.
Useproperliquidsealant.

DOWELPIN
6x1.0mm
9.8 N.m (1.0kgf.m,
7.2 tbl.ft)

8 x 1.25mm
24 N.m 12.4kgf.m,
17 tbf.ft)

BAFFLEPLATE

6x1.0mm
9.8 N.rn{1.0kgtm,7.2 lbtftl

OIL PAN
GASKET
Replace.

Replace.

OILPAN
Befertopage7 22
w h e ni n s t a l l i n g .

6x1.0mm
9.8 N.m 11.0kgf m,
7.2 tbf.ftl
SCREEN

WASHEB
Replace.

6x1.0mm
12 N.m 11.2kglm,8.7 lblftl

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DRAINBOLT
4,1N.m{,1.5kgf'm,33lbf ft)
Do not overtighten.

8-3

EngineOil
Inspection

Replacement

1 . Parkthe vehicle on level ground, and turn off the


e n g i n e .A l l o w t h e o i l a f e w m i n u t e st o d r a i n b a c k
into the oil pan so the dipstickwill show the actual
levet,

CAUTION:Removethe drain plug caretuly white the


engino is hot; the hot oil may causescalding.

2.

2.

Make certainthat the oil level indicatedon the dipstick is betweenthe upper and lower marks.Insert
the dipstickcarefullyto avoid bendingit.

1 . W a r mu p t h e e n g i n e .
D r a i nt h e e n g i n eo i l .

l f t h e l e v e l h a s d r o p p e dc l o s et o t h e l o w e r m a r k ,
add oil until it reachesthe uppermark.

ORAINBOL
4il N.m {4.5kgtm,33 lbf.ft)
Do not overtighten.

3.

WASHER
Rplace.

Reinstallthe drain bolt with a new washer,and refill


with the recommendedoil.
Requirement API ServiceGrade:Use "Energy
" SJ "Energy
Conserving
or
Conservingll" SH gradeoil. SAE
5W - 30 preferred:You can also
usean oil that bearsthe API
CERTIFICATION
mark.
Capacity

3 . 5{ ( 3 . 7U S q t , 3 . 1l m p q t )
at oil change.
3 . 8/ ( 4 . 0U S q t , 3 . 3l m p q r )
at oil changeincludingfilter.
4.6{ (4.9US qt, 4.0 lmp qt)
afterengineoverhaul.

Change
Inlerval

Every7,500miles(12,000km) or
12 months(Normalconditions)
Every3,750miles(6,000km) or 6
months(Severeconditions).

N O T E : U n d e r n o r m a l c o n d i t i o n s t, h e o i l f i l t e r
shouldbe replacedat everyother oil change.Under
severeconditions,the oil filter should be replaced
a t e a c ho i l c h a n g e .

8-4

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Oil Filter
Replacement
The numbersin the middle of the API Servicelabeltell
you the oil's SAE viscosityor weighl. Selectthe oil for
your vehicleaccordingto this chart:

CAUTION: After the engine has been tun, ths exhaust


pipes will be hot; be carelul when working around the
exhaust manitold.

AmbientTemperature

1 . R e m o v et h e o i l f i l t e r w i t h t h e s p e c i a lo i l f i l t e r
wrench.
lnsoectthe threadsand rubbersealon the new filter.
Wipe off the seaton the engine block,then apply a
light coatof oil to the filter rubberseal.
1 0 0F

-30

-20

-10

40c

NOTE:Useonly filterswith a built-inbypasssystem.

Inspect threads and

A n o i l w i t h a v i s c o s i t yo f 5 W - 3 0 i s p r e f e r r e df o r
i m p r o v e df u e l e c o n o m ya n d y e a r - r o u n dp r o t e c t i o ni n
the vehicle.You may usea 10 W - 30 oil if the climatein
your area is limited to the temperaturerangeshown on
the chart.

-G
oil to rubberseal
Deroreinstalling.

API SERVICELABEL

4.

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R u n t h e e n g i n et o r m o r e t h a n three minutes,then
checkfor oil leakage.

(cont'd)

8-5

Oil Filter
Replacement(cont'd)
Installtheoil filter by hand.

Some filtershave eight numbers(1 to 8) printedon


the surfaceof the filter.

A f t e r t h e r u b b e r s e a l s e a t s ,t i g h t e n r h e o i l f i l t e r
clockwisewith the specialtool.

The followingexplainsthe procedurefor tightening


filtersusingthesenumbers.

Tighten: 7/8 turn clockwise


Tighteningtorque:22N.m (2.2kgt'm 16lbt.ft)

l) Makea markon the cylinderblockunderthe number that showsat the bottomof the filterwhenthe
rubbersealis seated.
2) Tighten the filter by turning it clockwiseseven
numbersfrom the makespoint.For example,if a
mark is made underthe number2 when the rubber seal is seated,the filter should be tightened
untilthe number1 comesup to the markedpoint.

OIL FILTERWRENCH
07912-61 10001

MARK
Numberwhen rubber
seal is seated.

Numberafter tightening.

N u m b e rw h e n r u b ber sealis seated


Numberaftertightening
5.

5
8

6 7

IJ

6 7

After installation.fill the engine with oil up to the


specifiedlevel,run the enginefor more than three
minutes,then checkfor oil leakageand oil level.
GAUTION: Installation using other than the above
procedurecould result in serious engine damage
due to oil leakage.

8-6

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Oil PressureSwitch

Testing

Testing
L

Oil Pressure

wire from the engineoil presRemovethe YEL/RED


sureswrtcn.
Checkfor continuitybetweenthe positiveterminal
and the engine{ground).Thereshouldbe continuity
with the enginestopped.Thereshould be no continuity with the enginerunning.

lf the oil pressurewarning light stayson with the engine


running,checkthe engineoil level.lf the oil levelis correct:
L

Connecta tachometer.

2.

Remove the engine oil pressure switch. and install


an oil pressure gauge.
GAUGE
OILPRESSURE
ADAPTER
(1/8" - 28, BSTP)
available)
{Commercially
(Commercially
available)

ENGINE
OILPRESSURE
SWTTCH
MOUNNNG
HOt-E

PRESSURE
SWTCH
18 N.m {1.8kgf.m,
13 tbr.ftl
Apply liquidsealant
to the threads,

lf the switch fails to operate,checkthe engine oil


level.lf the engineoil level is OK, checkthe engine
orl pressure.

Startthe engine.Shut it off immedjatelyif the gauge


registersno oil pressure.Repairthe problembefore
continuing.
4.

Allow the engineto reachoperatingtemperature(fan


comeson at leasttwice).The pressureshouldbe:
Engino Oil Temperature:176'F (80'C)
Engine Oil Pressure:
At ldle:
70 kPa (0.7 kgt/cm', 10 psil
minimum
Ai 3,000rpm: 3/r0 kPa {3.5 kgt/cm', 50 psi)
minimum
lf oil pressurein not within specifications,inspectthe
oil pump (seepage8-9).

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8-7

Oil Pu mp
Overhaul

OUTERROTOR
pages8-9,1O
Inspection,

6x1.0mm
5 N.m {0.5kgt m. 4lbtft}

DOWELPIN
6xl.0mm
9.8 N m (1.0kg,tm, 7.2 lbf ftl

PUMPCOVER

pages8-9,10
lnspection,
Apply liquidgasket
to the matingsurfaceof
the cylinderblock
when anstalling.

REI-IEFVALVE
Valvemust slidefreely
in the housingbore.
Replace
the valveif it is scored.
8 x 1.25mm
2{ N.m (2.4 kgf m,
17 tbf.fi)

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8 -8

RemovaUlnspection/lnstallation
1.

1 0 . Removethe screwsfrom the pump housing,then


separatethe housingand cover.

D r a i nt h e e n g i n eo i l .

2. Turn the crankshaft,and align the white groove on


the crankshaftpulleywith the pointeron the lower
cover.

3. Removethe cylinderheadcoverand middlecover.


Removethe power steering pump belt, air conditioner belt and the alternatorbelt.
5.

R e m o v et h e c r a n k s h a f tp u l l e y , a n d r e m o v e t h e
lowercover.

6.

Removethe timing belt.

7.

Removethe drive pulley.

8.

Removethe oil pan and oil screen.

9.

Removethe oil pump.

l l . Checkthe inner-to-outerrotor radial clearanceon

rotor clearance
the pump rotor. lf the inner-to-outer
e x c e e d st h e s e r v i c el i m i t . r e p l a c et h e i n n e r a n d
outer rotors.
lnner Rotor-to Outar Rotor RadialClearance
Standard{Newl:0.04- 0.16mm
{0.002- 0.006inl
ServiceLimit: 0.20 mm (0.008in)

orL
PUMP
OLRING
Replace.

Checkthe housing-to-rotoraxial clearanceon the


pump rotor. lf the housing-to-rotoraxial clearance
exceedsthe service limit. replacethe set of inner
and outer rotorsand/orthe pump housing.
Housing-to-RotorAxial Clearance
Standard {New): 0.02- 0.07 mm
{0.001- 0.003in)
So|' ice Limit: 0.15mm (0.006inl

OIL SCREEN

HOUSING

(cont'd)

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8-9

Oil Pump
Removal/lnspection/lnstallation(cont'd)
1 3 . Checkthe housing-to-outer
rotor radialclearance.lf
the housing-to-outer
rotor radialclearanceexceeds
the servicelimit, reDlacethe set of inner and outer
rotorsand/orthe pump housing,
Housing-to-OuterRotor RadialClearance
StandardlNewl: 0.10- 0.19mm
{0.004- 0.007in}
ServiceLimit: 0.20 mm {0.008inl

1 7 . R e a s s e m b lteh e o i l p u m p , a p p l y i n gl i q u i dt h r e a d
lockto the pump housingscrews.
1 8 . Checkthat the oil pump turnsfreely.
1 9 . Apply a light coatot oil to the seallip.

20. Cleanand dry the oil pump matingsurfaces.


2 1 . Installthe two dowel pins and a new O-ringon the
cylinderblock.
Apply liquid gasket,part No. 08718-0001
or 087180003,to the cylinderblockmating surfaceof the oil
pump. Apply the liquid gasketevenly,in a narrow
beadcenteredon the mating surface.Do not apply
liquidgasketto the O-ringgrooves.
Apply liquid gasketto the inner threadsof the bolt
noles.
Apply liquid
gasket alongthe
brokenline.

1 4 . Inspectboth rotorsand the pump housingfor scoring or otherdamage.Replacepans if necessary.


1 5 . Removethe old oil sealfrom the oil pump.
PUMPHOUSING

1 6 . Gentlytap in the new crankshaftoil seal until the


specialtool bottomson the pump.

NOTE:
.

Do not installthe pans if five minutesor more have


elapsedsinceapplyingliquid gasket.Instead,reapply
liquidgasketafter removingold residue.
. After assembly,wait at least30 minutesbetorefilling
the enginewith oil.

8-10

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24. Apply greaseto the lip of the oil pump seal.


Installthe oil pump onto the crankshaft.When the
pump is in place,clean any excessgreaseoff the
crankshaftand checkthat the oil seal lip is not distorted.
lnstallthe oil screen.

2't. Installthe oil pan {seepage7-22).

8 x 1.25mm
24 N.m 12.4kgf.m,
'17tbf.ft)

O-RING
Applyengineoil
Replace.
DOWEL
PIN

6x1.0mm
9.8 N.m {1.0kgf.m,
1.2lbfitl

OIL PUMP

6x1.0mm
9.8Nm(1.0kgf.m,
7.2 tbt ft)

6x1.0mm
9.8N.m (1.0kgf.m.
7.2 tbtftl

OIL SCBEEN

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8-11

IntakeManifold/ExhaustSystem
IntakeManifold
Rep1acement
.......................................
9-2
ExhaustManifold
Replacement
.......................................
9-4
ExhaustPipeand Muffler
Replacement
.......................................
9-6

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IntakeManifold
Replacement
NOTE:
. Use new O-ringsand gasketswhen reassembling.
. Checkfor folds or scratcheson the surfaceof the gasket.
. Replacewith a new gasketif damaged.
'97 - 98 models:
INTAK MANIFOLD
R e p l a c ei f c r a c k e d o r
i f m a t i n g s u r f a c e sa r e
oamageo,

INTAKEAIR
TEMPERATURE
{IATISENSOR
22 N.n 12.2kgl.m,
16 rbf.ftl

8 x 1.25mm
22 N.m 12.2kgtm.
't6 tbf ft)

8 x 1.25mm
22 N.m |.2.2kgl.rn,
'16tbt ftl

I x 1 . 2 5m m
24 N m 12.4kgf m.
17 tbf.ft)
INTAK
BRAC}
INTAKEMANIFOLO
BRACKETB ('98 modell
I x 1.25mm
24 N.m 12.4kgf.m,
17 tbf.ft)

8 x 1.25mm
24 N.m (2.4kgf.m,
17 tbf.ft)

9-2

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8 x 1.25mm
23 N m (2.3kgt m,
17 tbf.ftl

'99 - O0modol3:
6x1.0mm
9.8 N.m 11.0kg{.m,
7.2 tbtltl

NESONATOR

6x1.0mm
9.8 N.m {1.0 kgf.m,
7.2 rbr.ftt
RESONATOR
CHAMBER
BRACKET

O-RING
Replace.
Applyoil to O-RING
betoreinstalling.

GASKET
Replace.

IATSENSOR
2:2N.ml2.2kgl.n,
16tbtftl

l
("\"-\

W\qu
N,1\J

K\*}Gt

'n\
.a,,-\\J "
\ G)s
INTAKEMANIFOLD
Replaceit crackedor
if matingsurfacesare
oamageo.

O.RING
Replace.

O.RING
Replace.
8 x 1.25mm
22 N.m 12.2kgl.m,
16 rbf.ftt

IAC VALVE
8 x 1.25mm
23 N.m (2.3 kgf.m,
17 tbf.ft,
8 x 1.25mm
24 N.m 12.4kgt m,
17 tbt frl
INTAKEMANIFOLD

22 N.m 12,2kgl.m,
16 rbfftl

BRACKET

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9-3

ExhaustManifold
Replacement
NOTE:
. Use new gasketsand self-lockingnutswhen reassembling.
. Checkfor folds or scratcheson the surfaceof the gasket.
. Replacewith a new gasketif damaged.
'97 - 98 U.S. models (Calilornia):

8 x 1.25mm
31 N.m (3.2kgf.m, 23 lbtft)
Replace.
I x 1.25mm
24 N.m (2.4kgl.m,
1? tbf.ft)
8 x 1.25mm
24 N.m (2.i1kgt.m,
17 lbf.ftl

NN

EXHAUST
MANIFOLO
10 x 1.25mm
44 N.m 14.5kgf.m, 33 lbf.ft)
NUT
SELF.LOCKING
8 x 1.25mm
31 N m 13.2kgt.m, 23 lbt'ft)
Replace.

EXHAUSTMANIFOLD
BRACKET
10 x 1.25mm
44Nm{4.5kg{.m.
33 lbf.ftl

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9-4

'97 - 98 U.S. models


{ExceptCalifornia):
'99 - 00 models:

8 x '1.25mm
31 N.m {3.2kgl.m,23lbl.ft)
Beplace.
COVER

(v/\

NL-]
\\ r-------.
'r
\\'

\F=
\\/ ,l
8 x 1.25mm
31 N.m {3.2 kgf.m.23 lbf.ft)
Replace.

MANIFOLD
BRACKET
6x1.0mm
9.8 N m 11.0kgf.m, 7.2 lbf.ft)
44 N.m {4.5kgf.m, 33 lbtftl

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9-5

ExhaustPipeand Muffler
Replacement
NOTE:Use new gasketsand self-lockingnutswhen reassembling.
7 - 98 U.S. models (Calitornial:

MUFFLER

GASKET
Replace.

NUT
SELF.LOCKING
I x 1.25mm
22 N.m (2.2 kg{.m, 16lbt'ftl
Replace.
Tightenthe nuts in stePs,
alternatingside-to-side.

NUT
SELF.LOCKING
10 x 1.25mm
33 N.m {3.4kgt m, 24 lbl.ft)
Replace.

SECONDARY
HO2S
4il N.m lil.5 kgtm,
33 tbf.ft)

PRIMARYHO2S
44 N.m {{.5 kgl.m,
33 tbt.ft)

GASKET
Replace.

S*S:--t-..-_
TWC
Inspection,
seesection1 l
GASKET
Replace.

EXHAUST
PIPEA

NUT
10 x 1.25mm
54 N.m 15.5kgi.m,40lbf'tt)
Replace.

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NUT
SELF.LOCKING
8 x 1.25mm
16 N.m {1.6kgt.m,
12 tbt fr)
Replace.

NUT
SELF.LOCKING
8 x 1.25mm
22 N.m (2.2 kgf.m,
r 6 tbt.ft)
Replace.
Tightenthe nuts in
steps,a'ternating
side-to-side.

6x1.0mm
9.8N.m (1.0kgf.m,
7.2 tbt.ltl

'97 - 98 U.S. models (ExceptCalifornial:


'99 - 00 models:

GASKET
Replace.

MUFFLER

SELF.LOCKING
NUT
8 x 1.25mm
22 N.m (2.2kgf.m, 16 lbl.ft)
Replace.
Tightenthe nuts in steps,
alternatingsideto side.

NUT
SELF.LOCXING
l0 x 1.25mm
33 N.m 13.4kgl.m, 24 lbtft)
Replace.

SECONDARY
HEATED
OXYGENSENSOR
HO2SI
{SECONDARY
4il N.m 14.5kgl.m,
33 tbf.ftl

PRIMABYHEATED
OXYGENSENSOR
(PRTMARY
HO2S)
44 N.m (4.5 kgf.m,
33 tbf.ftl

THREEWAYCATALYTIC
(TWCI
CONVERTER

GASKETS
Replace.

NUT
10x 1.25mm
5a N.m (5.5kgl.m,40 lbf ftl
Replace.

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l n s p e c t i o n ,s e e s e c t i o n 1 1

SELF-LOCKING
NUT
8 x 1.25mm
16 N.m 11.6kgf.m,
12 tbf.ftt
Replace.

NUT
SELF.LOCKING
8 x 1.25mm
22 N,m 12,2kgi'm,
16 tbf.ftl
Replace.
Tightenthe nuts in
steps,alternating
side-to-sade.

x 1.0mm
9.8 N.m {1.0kgf.m,
7.2 rbf.ft)

Cooling
ff f u s t r a t e dI n d e x. . . . . . . . . . .
. . . . .1 O - 2
Radiator
R e p | a c e m e n.t. . . . . . . . . . , . . . . , . . . . . . . . . . . .1. 0
. .-. 4. . . . . .
EngineCoolantRefillingand
Bleeding
. . , . , . . . . . . . . . . . .1. .0.-. 5
.
C a pT e s t i n g
. . . . . . . . . . . . . . .1. .0. .-.7
Testing
......10-7
Thermostat
R e p | a c e m e n.t. . . . . . . . . . . . . . . . . . . . . . . . . . . .1. 0
. .-. 8. . . . . .
Testing
......10-9
Water Pump
l l l u s t r a t e dl n d e x . . . . , . . . . .
.. 10-10
Inspection
. 10-11
R e p l a c e m e n.t. . . . . . . . . . . . . . . . . . . . . . . . . . . .1. 0
. .-. 1.1. . , . .
FanGontrol
ComponentLocationIndex ...............
10-12
C i r c u i tD i a g r a m
. . . . . . . . . .1
. .0. - 1 3
FanMotor Testing
.........10-14
RadiatorFanSwitch Testing .............
10-14
CoolantTemperatureGauge
G a u g eT e s t i n g
. . . . . . . . . . . .1. .0.- 1 5
CoolanttemperatureSending
UnitTesting
. . . . . . . . , . . . .1.0. .- 1 5

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lllustratedIndex

CAUTION:The system is under high pressurewhen the


engineis hot. To avoid dangerol releasingscaldingengine
coolant,removethe cap only when the engineis cool.
Total Cooling System Capacityfincluding 0.6 I (0.63 US
qt, 0.53 lmp qt) for heater and reservoirl:
A/T: 5.9{ {6.2US qt, 5.2 lmp qt)
M/T: 6.0f (6.3US $, 5.3 lmp qt)
6x1.0mm
9.8 N.m 11.0kgf.m.
1.2 tbl.ftl

l f a n y e n g i n ec o o l a n ts p i l l so n t h e paintedportionsof the
body, rinse it off immediately.
C h e c k a l l c o o l i n g s y s t e m h o s e s f o r d a m a g e ,l e a k so r
deterioration and replace if necessar,.
Check all hose clamps and retighten if necessary.

RADIATOR
Enginecoolantrefillingand bleeding,
page10-5
Leaktest,page10 7
Inspectsolderedjointsand
seamsfor leaks.
Blow out din from between
corefins with compressed
air.
lf insects,etc.,are clogging
radiator,wash them off with
RADIATORCAP
low pressurewater.
Pressuretest, page 10-7

ATF COOLER
HOSE
Relerto section14
when installing.
LOWER

cusHroN

FAN MOTOR
6x1.0mm
7 N.m (0.7kgf.m, 5 lbf ftl

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10-2

EngineHoseConnections:

FASTIDLETHERMO
VALVE(A/T onlyl
IDLEAIR CONTROL
IIAC}VALVE

TEF BYPASS
HOSE

THERMOSTAT
HOUSING

CONNECTING
PIPE

VALVE

HOSES

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10-3

Radiator
Replacement
1.

D r a i nt h e e n g i n ec o o l a n t .

5.

R e m o v et h e f a n s h r o u da s s e m b l i easn d o t h e rp a r t s
from the radiator.

2.

R e m o v et h e u p p e r a n d l o w e r r a d i a t o rh o s e s ,a n d
ATFcoolerhoses.

6.

lnstallthe radiatorin the reverseorderof removal.

3.

Disconnect
the fan motor connector.

4.

Removethe radiatorupper bracket,then pull up the


raotalor,
6x1.0mm
9.8 N.m 11.0kgf.m,
7.2 tbl.trl

NOTE:
. Setthe upperand lower cushionssecurely.
. Fillthe radiatorwith enginecooiantand bleedthe air.

RADIATORCAP
RADIATOR

6x1.0mm
7 N.m (0.?kgd.m,5 lbl.ftl
UPPERMDIATOR HOSE

rriItriiii
Relerto section14
when installing.
LOWERCUSHION
CONDENSER
FAN,/SHROUD
ASSEMBLY

DRAINPLUG

RADIATOR
ASSEMBLY

6x1.0mm
7 N.|n 10.7kgt.m,
5 tbt.ftl

www.emanualpro.com

10-4

LOWER

TOR HOSE

EngineCoolantRefillingand Bleeding
1.

Slidethe heaterlemperaturecontrol lever to maxi


mum heat.
Make sure the engine and radiatorare cooi to the
touch.

2.

Removethe radiatorcaP.

3.

L o o s e nt h e d r a i np l u g ,a n dd r a i nt h e c o o l a n t .

Apply liquid gasketto the drain bolt threads,then


reinstallthe bolt with a new washer and tighten it
securely.
6.

Tightenthe radiatordrain plug securely.

7.

Remove,drain and reinstallthe reservoir'Fill the


tank halfwayto the MAX mark with water,then up
to the MAX markwith antitreeze.

DRAINPLUG

4.

Removethe drainbolt from the cylinderblock.

DRAINBOLT
78 N.m {8.0ksl.m, 58 lbtft}

(cont'd)

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10-5

Radiator
EngineCoolantRefillingand Bleeding(cont'dl
M i x t h e r e c o m m e n d e da n t i f r e e z ew i t h a n e q u a l
amountof water in a cleancontainer.
NOTE:
. Always use GenuineHonda Antifreeze/Coolant.
Using a non-Hondacoolantcan result in corros\on, ca\rsng t\e coo\\ng sys\em \o ma\lunct\on
o. fail.
For best corrosion protection,the coolant conc e n t r a t i o nm u s t b e m a i n t a i n e dy e a r - r o u n da t
50% minimum.Coolantconcentrations
lessthan
50%may not providesufficientprotectionagainst
c o r r o s i o no r f r e e z i n g .C o o l a n tc o n c e n t r a t i o n s
greaterthan 60% will impair cooling efficiency
and are not recommended.
Do not use additionalrust inhibitorsor anti-rust
products;they may not be compatiblewith the
coolant.

9. Pour coolantinto the radiatoruD to the baseof the


filler neck.When pouringenginecoolant.do not let
coolantspill on any electricalpans or the paint. lf
any coolantspills,rinseit oft immediately.

Engine Coolant Refill CapacityIincluding 0.6 / 10.63


US $, 0.53 lmp qtl for hoater and ressrvoirl:
A/T: 3.9 f {4.1 US $, 3.4 lmp qtl
M/T: 1.Ot 14.2US $, 3.5 lmp qrl

1 0 . Startthe engine,and let it run until it warms up (the


radiator fan comes on at leasttwice).
1 1 .Turn off the engine.Checkthe level in the radiator,
add coolantif needed.
1 2 . Put the radiatorcap on tightly.then run the engine
againand checkfor leaks.

10-6

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Testing

CapTesting
1.

Removethe radiatorcap, wet its seal with engine


coolant,then installit on the pressuretester.

2.

Applya pressureof 93 - 123kPa(0.95- 1.25kgflcm' ,


1 4- 1 8p s i ) .

3.

1.

Wait until the engineis cool, then carefullyremove


t h e r a d i a t o rc a p a n d f i l l t h e r a d i a t o rw i t h e n g i n e
c o o l a ntto t h e t o p o I t h e f i l l e rn e c k .

2.

Attachthe pressuretesterto the radiator,and apply


a pressureof 93 - 123kPa (0.95- 1,25kgf/cm' ,14 1 8p s i ) .

3.

Inspectfor enginecoolantleaksand a drop in pressure.

4.

Removethe tester,and reinstallthe radiatorcap.

5.

t n d / o rc o o l a n it n
C h e c kf o r e n g i n eo i l i n t h e c o o l a n a
t h e e n g i n eo i l .

Checkfor a drop in pressure.


lf the pressuredrops,repiacethe cap.

TESTER
RADIATORPNESSURE
available)
lCommercially
RADIATOR

RAOIATOR
PRESSURE
TESTER
(Commercially
available)
ADAPTOR
(for 32 mm neck,
low profile)

ADAPTOR
(for 32 mm neck,low Profile)

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10-7

Thermostat
Replacement

THERMOSTAT
HOUSING

RUBBERSEAL
Replace.
THERMOSTAT
COVER

THERMOSTA
Installwith pin up.

RADIATOBFAN

swtTcH
24 N.m {2.4kgtm, l7 lbt.ftl

10-8

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6 x '1.0mm
12 N.m (1.2kgl.m,
8.7 tbtftl

Testing
Replacethe thermostatif it is open at room temperature.
To test a closedthermostat:
1.

Suspendthe thermostatin a containerof water. Do


not let the thermometertouch the bottom of the hot
container.

THERMOMETER

THERMOSTAT

Heat the water, and checkthe temperaturewith a


thermometer.Checkthe temperatureat which the
thermostatfirst opens,and at which it is fully open.
Measurethe lift heightof the thermostatwhen fully
open.
STANDARDTHERMOSTAT
above8.0 mm (0.31in)
Lift height:
169- 176'F(76- 80'C)
opening:
Starts
194'F(90'C)
Fullyopen:

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10-9

Water Pump
lllustrated Index

ENGINECOOLANT
TEMPERATURE
IECTI
SENSOR
18 N.m 11,8kgt.m,

13tbt.ftl
COOLANT
TEMPERATURE
GAUGE
UNIT
9 N.m {0.3kgf.m,
7 tbf.ftt
Applyliquidgasket
to the threads.
6x1.0mm
9.8 N'm (1.0 kgf.m,
7.2 tbt frl

WATEROUTLET
COVER
Apply liquidgaskerpart No.
- 0001or 08718- 0003
087'18
to the mating surface.

RADIATORFAN SWITCH
2il N.m (2.i1kgl.m,
17 tbfft)

WATERPUMP
page10-11
lnspection,

O-RING
Replac.

CONNECTING
PIPE

6x1.0mm
12 N.m 11.2kgf.m,
8.7 tbtftl

10-10

www.emanualpro.com

6xl,0mm
12N.tnn.2 lgl.rn,
8.7 tbf'ft)

Replacement

Inspection
1.

Removethe timing belt (seesection6)

1.

Removethe timing belt (seesection6).

2.

Turn the water pump pulley counterclockwise.


Checkthat it turnsfreely.

2.

Removethe water pump by removingfive bolts

3,

Inspect,repairand cleanthe O-ringgroove and the


matingsurfacewith the cylinderblock.

Checkfor signsof sealleakage.


NOTE:A smallamountol
holeis normal.

"weeping"from the bleed

-<o

@-

II

Replace.

6x1.0mm
't2 N.m 112 kgf m.
8.7 tbf.ftl
4.

lnstall the water pump in the reverse order of removal.

BIIED HOLE

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1 0 - 11

FanControl
ComponentLocationIndex

ftflEffltrl

t lrt

UNDEB.HOOD
FUSE/RELAY
BOX

r-1 a-l

@u!lfl]l

RADIATORFAN RELAY
Test,seesection23

BADIATORFAN
Removal,page 10-10
Test, page 10-14

BADIATORFAN MOTOR
Removal, page 10-2

CONDENSER
FAN MOTOR

10-1 2

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CircuitDiagram

IGNITIONSWITCH
No.41{100A) N0.42140A)

UNDER
OASH
FUSEiRELAY
BOX

6;\
E;';l
wHTsLka
rtF',*",El-l
I

IL^,^,.,

BLK/RED

T*'
I
B LK

oro,

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RAOIATOR
FAN
SWITCH
f C l o s e d: A b o v e )
{ 9 3 0 CJ)
L 199oF

FanControl
FanMotor Testing

Radiator Fan Switch Testing

1 . D i s c o n n e ct ht e 2 Pc o n n e c t o r .

Removingthe radiator fan switch while


E@
the engine is hot can causethe coolant to spray out, seriously scalding you. Always let the enginc and radiator
cool down before removing the radiator fan switch.

RADIATORFAN MOTOR

Terminalside
of
maleterminals
Test the motor by connectingbatterypower to the
N o .2 t e r m i n aal n d g r o u n dt o t h e N o . 1 t e r m i n a l .
lf the motor fails to run or does not run smoothly,
reptacert.

1.

Removethe radiatorfan switchfrom the thermostat


housing(seepage10 '10).

2.

S u s p e n dt h e r a d i a t o rf a n s w i t c h i n a c o n t a i n e ro f
water as shown.

Heat the water, and checkthe temperaturewith a


thermometer.Do not let the thermometertouch the
bottomof the hot container.
Measurethe continuitybetweenthe A and B terminalsaccordingto the table.
Terminal

Tr"ip".a*" \.

op".*i-

196- 203"F
{91- 95.C)
5 - 14"F(3 - 8.C)
SWITCH
lower than the temOFF
p e r a t ur e w h e n i t
goeson
ON

B
o- --o

Bleedthe air from the coolingsystemafterinstalling


the radiatorfan switch(seepage10-5).

10-1 4

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Gauge
GoolantTemperature
GaugeTesting

CoolantTemperatureSendingUnit

1 . C h e c kt h e N o . 2 5 ( 7 . 5A ) f u s e i n t h e u n d e r - d a s h
fuse/relaybox beforetestin9.

1.

2.

Testing

Make sure the ignition switch is OFF,then disconnect the YEL/GRNwire from the coolant temperat u r es e n d i n gu n i t .a n dg r o u n di t w i t h a j u m p e rw i r e .

the YEUGRNwire from the coolanttem


Disconnect
peraturesendingunit.
COOLANTTEMPERATURE

COOLANTTEMPERATURE

POSITIVE
TERMINAL

WIRE
YEL/GRN
(Covered
with
insulation)
YEL/GRN
WIRE
2.
T u r n t h e i g n i t i o ns w i t c hO N { l l ) .C h e c kt h a t t h e
p o i n t e ro f t h e c o o l a n tt e m p e r a t u r eg a u g e s t a r t s
" H " m a r k .T u r n t h e i g n i t i o n
movingtoward the
"H" on the
switch OFF beforethe pointer reaches
g a u g ed i a l .F a i l u r e
t o d o s o m a y d a m a g et h e g a u g e .
l f t h e p o i n t e ro f t h e g a u g e d o e s n o t m o v e a t a l l ,
wire.
checkfor an open in the YEL/GRN
5.

lf the wires are OK, replacethe coolanttemperature


gauge.
l f t h e c o o l a n tt e m p e r a t u r eg a u g ew o r k s ,t e s t t h e
coolanttemperaturesendingunit.

www.emanualpro.com

3.

Using an ohmmeter,measurethe change in resistance betweenthe positiveterminaland the engine


( g r o u n dw
) i t h t h e e n g i n ec o l d a n d w i t h t h e e n g i n e
at operatingtemPerature.
1A5- 212F

Temperature

133.F(56'C)

(8s- 100'c)

Resistance
(0)

137

46-30

lf the readingsare substantiallydifferentfrom the


speciticationsabove, inspectthe coolant level and
t h e c o o l i n gs y s t e m .l f t h e c o o l i n g s y s t e m i s O K ,
replacethe sendingunit.

10-15

Fueland Emissions
......................
11-2
SpecialTools
Component Locations
. . . . , . .1. .1 - 3
l n d e x. . . . . . . . . . . . . . . . . . . . . .
Svstem Description
V a c u u mC o n n e c t i o n .s. . . . . . . . . . , . . . . , . , . . . . . .1.1. .-.9. . . . . . .
. .5. . . . .
E l e c t r i c aClo n n e c t i o n.s. . . . . . . . . . . . . . . . . . . . . . . 1. .1. -. 1
S y s t e mC o n n e c t o r .s, . , , . , . . . . . . . . . . . . . . . . . . . .1.1. .-.3. .6. . , . , .
Troubleshooting
T r o u b l e s h o o t i nPgr o c e d u r e s , . , . . . . . . . . . . . .1. .1. -. .6. 0. . .
Conttol
EngineControlModule/Powertrain
11-67
ModuleTerminalArrangement..............,
1t-75
DiagnosticTroubleCodeChart ....................
I 1-79
How to ReadFlowcharts.......,.....,.,...............

PGM-FlSystem
11-80
SystemDescription.................,.,.,,,...............
Flowcharts
Troubleshooting
EngineControlModule/Powertrain
........11-52
ControlModule
11-90
ManifoldAbsolutePressureSensor.............
11-95
IntakeAir TemperatureSensor ....................
11-99
EngineCoolantTemperatureSensor.,..,.,....
I 1'103
ThrottlePositionSensor ...........,.....,.,.,..,......
PrimaryHeatedOrygenSensor(Sensor1) ... 11-110
SecondaryHeatedOxygen Sensor
. . . . . . . . . . . . .1. 1
. .-.1. 1 7
{ S e n s o2r l
11-121
HeatedOxygenSensorHeater .....................
......11-124
FuefSupplySystem
11-126
,....,.,.....
RandomMisfire
11-128
MistireDetectedin One Cylinder .....-...........
. . . . . . . . . . . .1. 1
. .-. 1 3 0
K n o c kS e n s o r
C K P / T D C / C YSPe n s o r. . . . . . . . . . . . . . . . . . . . . . . . .1. 1. .-.1. .3. .1. . .
....
V e h i c l eS p e e dS e n s o r. . . . . . . . . . . . . . . . . . . . . . . . .1.1. .-.1. .3, 5
11-137
BarometricPressureSensor .....,...,...,.,,........
11-138
ElectricalLoadDetector...,.,..........................
'11-112
................,.,,
CKFSensor
11'117
ECM/PCMlnternafCircuit .............................
.,.,.,.11-148
HO2SReplacement

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ldle Control System


............
11-149
SystemDescription
TroubleshootingFlowcharts
......11-150
ldle ControlSystem
11-152
fdleAir ControlValve ......................,.............
A i r C o n d i t i o n i nSgi g n a l. . . . . . . . . . . . . . . . . . . . . . .I. 1. .-.1. .5. .5. .
. .5. .9. . . .
A l t e r n a t oFr RS i g n a l. . . . . . . . . . . . . . . . . . . . . . . . . . 1. .1. -. 1
t l-161
StarterSwitch Si9na1....................................
PowerSteeringPressureSwitch Signal......11-162
. .6. . . .
B r a k eS w i t c hS i 9 n a 1. . . . . . . . . . . . . . . . . . . . . . . . . .1. .1. .-.1. 6
. .6, .8, . , .
F a s tl d l eT h e r m oV a l v e. , . , . . . . . . . . . . . . . . . . . . . . . . .1. .1. -. 1
..............
11-169
ldle speed setting

FuelSupply System
. . . . . . . . . . . . . . . . . . . .1. 1. .-.1. .7. .1
F u e lL i n e s
11-175
Fittings.....................
FuefTube/Ouick-Conneci
............
11-178
SystemDescription
. . . . . . . . . . . . . . . .1. 1
. .-.1. .7 8
F u e lP r e s s u r g
................,.....
11-179
FuelIniectors
, .1. . . ,
e e 9 u 1 a t o. r. . . . . . . . . . . . . . . . . . . . . . . . .f .1. .- ,1. 8
F u e lP r e s s u rR
....,.,.,.,,,,.,............11-142
FuefFifter
. . . . . . . . . . . . . . . . . . .1. .1. -. .1.8. .3
F u e lP u m p
. . . . . . . . . . . . . . . . . . 1. .1. .-.1. .8.4
F u e lG a u g e
. .8. .5. . .
F u e lG a u g eS e n d i n gU n i t . . . . . . . . . . . . . . . . . . . . . . . .I. .1. -. 1
11-185
Low FuelIndicatorSystem ...........,.,..,...............
. . . . . . . . . .1. .1.- 1 8 7
P G M - FM
I a i nR e l a y
. . . . . . . . . .1. .1.- 1 9 1
Fue|Tank................

IntakeAir System
SystemDescription
AirCleanel
ThrottleCable
T h r o t t l eB o d y . . . . . . . .

............
11-193
, . , . , . . . . . . . . . . . . . 1. .1. .-.1. .9.4
.....................
11-194
. . . . . . . . . . 1. .1. .- 1 9 6

EmissionControl System
...,....,.,.
11-199
SystemD$cription
11-199
...............
TailpipeEmission
11-199
ThreeWay CatalyticConverter..................,.,...,,
11-2O1
PositiveCrankcaseVentilationSystem .,.,,,,.,..,
11-203
EvaporativeEmissionControls.........,.,.,............

SpecialTools
SpecialTools
Tool Number

Ref.No.

q
t3'
, 3 ) l

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11-2

Description

Oty

A 9 7 3 X _ 0 4 1_ X X X X X

V a c u u mP u m p / G a u g e -, 03 0 i n . H g

07JAZ 0010008
07PAZ, 0010100

Vacuum/Pressure
Gauge,0 4 in.Hg
SCSServiceConnector

1
1

07sAz - 001000A
07405- 0040001

BackprobeSet
FuelPressureGauge

2
1

PageReference
'11-201
. 208,214,
2 1 5 , 2 ' t 6 , 2 1, 27 2 0 ,
221, 222,223,224
11 207, 224
11-60,83,88, 1 16,
128,200,205
11-62
1 1 - 1 7 81 ,8 1

ComponentLocations
lndex
'97 - 98 models:

MANIFOLDABSOLUTE
PRESSURE
IMAP} SENSOR
Troubleshooting,
Page11-90
THROTTLEPOSITION(TP}
SENSOR
page11-103
Troubleshooting,

toLEAtRCONTROL
llAcl VAI-VE
page11-152
Troubleshooting,

INTAKEAIRTEMPERATURE
IIATISENSOR
page1'l-95
Troubleshooting.

EMISSION(EVAP)
EVAPORATIVE
CONTROLCANISTERVENT SHUT
VALVE t'98 modll
page11'213
Troubleshooting,

POWERSTEERINGPRESSURE

ELECTRICAL
LOAD
DETECTOR
IELD)(USA modol)
page11-138
Troubleshooting,

lPsPlswtrcH
page11-162
Troubloshooting,

VEHICLESPEED
SENSOR(VSS)
Troubleshooting,
p a g e1 1 ' 1 3 5

CRANKSHAFT
POSTTtON/
TOP OEADCENTER/
CYLINDER
POStTtON
SENSOR
{CKP/TDC/CYP}
(Builtinto the distributor)
page1l-131
Troubleshooting,
ENGINECOOLANT
TEMPERATURE
IECTISENSOR
page11 99
Troubleshooting,

CMNKSHAFT SPEED
FLUCTUATION
ICKF}SENSOR
page1'!-142
Troubleshooting.

EVAPORATIVE
IVAP)PURGECONTROL
SOLENOIDVALVE
Troubfeshooting,page 11'2o5,213

(cont'd)

www.emanualpro.com

11-3

ComponentLocations
Index (cont'dl
39 - 00 models:
MANIFOLDABSOLUTE
PRESSURE
IMAPISENSOR
page11-90
Troubleshooting,
THROTTLEPOSITION{TP)
SENSOR
page11-103
Troubleshooting,

IDLEAIR CONTROLOACIVALVE
page11-152
Troubleshooting,
EVAPORATIVE
EMISSION
(EVAPIPURGECONTROISOLENOIDVALVE
page11-2'13
Troubleshootang,

EVAPOBATIVE
EMISSION{EVAPI
CONTROLCANISTERVENTSHUT
VALVE
page11-213
Troubleshooting,

INTAKEAIR TEMPERATURE
(IAT)SENSOR
page11 95
Troubleshooting,

ELECTRICAL
LOAO
OETECTOR
{ELD)IUSA modet)
Troubleshooting,
page I 1-138

POWEBSTEERING
PRESSURE
tPsPtswtTcH
page11162
Troubleshooting,

VEHICLESPEED
SENSORIVSSI
Troubleshooting,
p a g e1 1 ' 1 3 5

CRANKSHAFT
POSTTTON/
TOP OEADCENTER/
CYLINDER
POStTtON
SENSOR
{CKP/TDC/CYP)
(Builtinto the distributor)
page11 131
Troubleshooting,
ENGINECOOLANT
TEMPERATURE
{ECT)SENSOR
Troubleshooting,
page11 99

11-4

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CRANKSHAFT
SPEED
FLUCTUATION
ICKN SENSOR
page11-142
Troubleshooting,
SENSOR
page'11130
Troubleshooting,

DATA LINKCONNECTOR
{DLC)I16P}
page11'60
Troubleshooting
Procedures,
PRIMARYHEATEDOXYGENSENSOR
1)
HO2SI{SENSOR
{PRIMARY
page11 110
Troubleshooling,

PGM-FI
MAIN RELAY
RelayTesting,page11-l87
Troubleshooting.
page1'1188

,a'=_-_

WAY CATALYTIC
HEATEDOXYGEN
SECONDARY
SENSOR
HO2S){SENSOR2)
{SECONDARY
page11-117
Troubleshooting,
'97 - 98 models:
AIR CLEANER
page11'194
Replacement,

SERVICECHECKCONNECTOR
{2PI
page11-60
Troubleshooting
Procedures,

page1'l-200
Troubleshooting,

POWERTRAIN
CONTROLMODULE
(PCM)(A/TI
page11-60
Troubleshooting
Procedures,
page11'82
Troubleshooting.

THROTTLEBODY(TB)
page11 196
Inspection,
Removal,page11-197
page11-'198
Disassembly,

THROTTLECABLE
page11-194
Inspection/Adjustment,
page11-195
Installation,

VENTILATION(PCV)VALVE
page11-201
Inspection,
FASTIDLE

VALVE (A/T}

I n s p e c t i o n ,p a g e 11 - 1 6 8

(cont'd)

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11 - 5

ComponentLocations
Index{cont'd)
39 - q, models:

THROTTLEBODYITB)
page11-196
Inspection,
Removal,page11-197
page11 198
Disassembly,

THROTTLECABLE
page11 194
Inspectaon/Adjustment,
page I l'195
Installation,

AIR CLEANER
page11-194
Rplacomenl,

CRANKCASE
VENTILATIONIFCVIVALVE
page11 201
lnspection,
FASTIDLETHERMOVALVEIA/T)
page11'168
Inspection,

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11 - 6

FUELPRESSURE
REGULATOR
T e s t i n gp, a g e1 1 - 1 8 1
page11 181
Replacement,

'97 model:

FUELPUMP
Testing,page11 183
page11 183
Replacement,
FUELGAUGESENDINGUNIT
page11 185
FUELVAPORPIPE Testing,

FUELFEEDPIPE
FUELFILTER
page11 182
Replacement,

FUELFILL
CAP

FUELPULSATIONDAMPER

EVAPORATIVE
EMISSION
IEVAP)CONTROLCANISTER
page1'l-205
Troubleshooting.

EVAPORATIVE
EMISSION
IEVAPITWO WAY VALVE
Testing,page11 224
TANK
R e p l a c e m e n t ,p a g e 1 1 1 9 1

-CONNECT
FUEL
FITTINGS
page11-175
Precautions,
page11 175
Disconnection,
page11-176
Connection,
FUELINJECTORS
page11-179
Replacement,

'98 model:
FUELFEEDPIPE
FUELFILTER
page11 182
Replacement,

FUELVAPORPIPE

FUEI-TANK
FUELPUMP
Replacement,
Testing,page11 183
p a g e1 l 1 9 1
page11 183
Replacement,
FUELGAUGESENDINGUNIT
Testing,page1l'185

FUELPULSATIONDAMPER

FUELFILLCAP

EVAPORATIVE
EMTSSTON
IEVAPI
CONTROL
CANISTER
VENT
SHUTVALVE
Troubleshooting,
p a g e1 1 ' 2 1 3

FUELTANK PRESSURE
SENSOR
page1l-209
Troubleshooting,

EVAPORATIVE
EMISSION
IEVAPICONTROLCANISTER
page11-213
Troubieshooting,
FUELRAIL

FUEL

FUELTUBE/OUICK.CONNECT
FITTINGS
page11 '175
Precautions,
page11 175
Disconnection,
page11 176
Connection,

page11-179
Feplacement,
FUELPRESSURE
NEGULATOR
Testing,page11-181
Replacement,
Page11 181

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EVAPORATIVE
EMISSION
{EVAP)EYPASS
SOLENOIDVALVE
page11'213
Troubleshooting,

VAPORATIVE
EMISSION
{EVAP)TWO WAY VALVE
Testing,page11 224
(cont'd)

GomponentLocations
Indexlcont'd)
'99 - (X)modols:

FUELTANK
Replacement,
p a g e1 1 - 1 9 1
FUELVAPORPIPE
FUELPUMP
'11
Testing,page 183
page11_183
Replacement,
FUELGAUGESENDINGUNIT
Testing,page11-185

FUEL FEEDPIPE

FUELFILTER
page11 182
Replacement,

EVAPORATIVE
EMtSStON
IEVAP)
CONTROL
CANISTER
VENT

FUELFILLCAP

SHUTVALVE
Troubleshooting,
p a g e1 1 - 2 1 3

FUELTANK PRESSURE
SENSOR
page1'l'208
Troubleshooting,

EMISSION
EVAPORATIVE
IEVAP)CONTROL
page11-213
Troubleshooting,

FUELPULSATIONDAMPER

FUELRAIL
FUEL
page11-179
Replacement,
FUEL PRESSURE
REGULATOR
Testing,page11-181
page11 181
Replacement,

www.emanualpro.com

EVAPORATIVE
EMISSION
{EVAP)TWO WAY VALVE
Testing,page11-224

,CONNECT
FITTINGS
page11-175
PrecaLrtions,
page11-175
Disconnection,
page176
Connection,
EVAPORATIVE
EMISSION
{EVAPIBYPASS
SOLENOIDVALVE
page11 213
Troubleshooting,

FUEL

VacuumGonnections
'97 model:

To EVAPORATIVE
EMISSIONIEVAPI
TWO WAY VALVE

EVAPOBAIIVE
EMtSStON
IEVAPI
CONTROL
CANISTER

EVAPORATIVE
EMtSStON
tvaP)
PURGECONTROL
VALVE
SOLENOID

FRONTOF
VEHICLE

PBESSURE
REGULATOR

{cont'd)

www.emanualpro.com

11-9

System Description
(cont'dl
VacuumConnections
'97 model:

ENGINE
COOLANT

IT

r|ll

HEATED
oxYGENsENsoR{PRIMARY
Ho2s,
O PRIMARY
SENSOR
lt
HEATED
oxYGENsENsoR{SECoNDARY
O SECONDARY
HO2S.SENSOR
2l
(MAPISENSOR
ABSOLUTE
PRESSURE
) MANIFOLD
cooLANTTEMPERATURE
@ ENGINE
{EcT}sENsoR
(IAI} sENsoR
AIRTEMPERATURE
O INTAKE
SPEED
FLUCTUATION
@ CRANKSHAFT
ICKFISENSOR
O |DLEArRcoNTRoL{tAc)vALvE
@ FASTIDLETHERMovALvE
EoDYITB)
O THRoTTLE
@ FUELINJEcTon
oAMPER
O FUELPULSATIoN
@ FUELFILTEn
(} FUELPRESSURE
REGULATOR

11 - 1 0

www.emanualpro.com

@ FUELPUMP

(D FUELTANK
(D FUELTANK EVAPORATIVEEMISSION(EVAPIVALVE

o AIRCLEANER

@ RESONATOR
(} POSITIVECRANKCASEVENTILATION{PCVIVALVE
EMISSION{EVAP}PURGECONTROL
@ EVAPORATIVE
SOI.'ENOID
VALVE
EMISSION{EVAP)CONTROLCANISTER
@ EVAPORATIVE
EMISSION{EVAPITWO WAY VALVE
@ EVAPORATIVE
(TWC)
@ THREEWAY CATALYTICCONVERTER

'98 model:

To EVAP THREE
WAY VALVE

To EVAP
TWO WAY VALVE

EVAP
PURGE
CONTROL
SOLENOID
VALVE

FRONTOF
VEHICLE

(cont'd)

www.emanualpro.com

11-11

System Description
VacuumConnections(cont'dl
'98 model:

-i*'";-t

G/T only)

f\

COOLANTJ

C PRIMARYHEATEOOXYGENSENSOR(PRIMARYHO2S,
SENSOR1)
(, SECONDARY
HEATEOOXYGENSENSORISECONDARY
HO2S,SENSOR2)
(!)\\\\ss\SNBSS\\\ETRESS\RE\\NQ\SE\SSR
(ECT)SENSOR
G) ENGINECOOLANTTEMPERATUBE
{IAT}SENSOR
O INTAKEAIRTEMPERATURE
(CKFISENSOR
SPEEDFLUCTUATION
@ CRANKSHAFT
O IDLEAIR CONTROL(IAC)VALVE
@ FASTIDLETHERMOVALVE(A/T)
O THROTTLEBODY(TBI
(0) FUELINJECTOR
.1' FUELPULSATIONDAMPER
.14 FUELFILTER
(i FUELPRESSURE
REGULATOR
14 FUELPUMP
(D FUELTANK
EMISSION{EVAPIVALVE
@ FUELTANK EVAPORATIVE

www.emanualpro.com

11-12

C] AIR CLEANER
(O RESONATOR
1iC POSITIVECRANKCASEVENTILATION (PCV)VALVE
6 \$REE$IN\ gN\ NL$\C CON\ER\ER (TNC\
ti\ q\ rpos,xr\tE qN\rssros \E\ aP\ cqN\RoLcaNtsrR
EMISSIONIEVAP)PURGECONTROL
@ EVAPORATIVE
SOLENOIDVALVE
q3 EVAPORATIVE
EMISSTON
IEVAP}CONTROLCANISTER
VENT SHUTVALVE
EMISSION(EVAP)TWO WAY VALVE
@ EVAPORATIVE
EMISSION{EVAP)BYPASSSOLENOID
i EVAPORATIVE
VALVE
SENSOR
9 FUELTANK PRESSURE
EMISSION{EVAP)THREEWAY VALVE
Oi EVAPORATIVE
Qd PURGEJOINT

'99 - 00 models:

To EVAPTHREE
WAY VALVE

To EVAP
TWO WAY VALVE
EVAP
PURGE
CONTROL
SOLENOID
VALVE

FUEL
PRESSURE
REGULATOR
FRONTOF
VEHICLE

(cont'd)

www.emanualpro.com

11 - 1 3

System Description
VacuumConnections(cont'dl
'99 - q) models:

ENGINE
COOLANT

o PRIMARYHEATEDOXYGENSENSORIPRIMARYHO2S,
SENSOR1l
o SECONDARYHEATEDOXYGENSENSOR{SECONDARY
HO2S.SENSOR2l
o MANIFOLDABSOLUTEPRESSURE(MAPISENSOR
IECN SENSOR
@ ENGINECOOLANTTEMPERATURE

@
@
@
@
@
@
@
@
@

(t

INTAKEAIR TEMPERATURE
IIATI SENSOR
SPEEDFLUCTUATION
CRANKSHAFT
{CKF)SENSOR
KNOCKSENSOR(KS}
IDLEAIR CONTROLIIACIVALVE
FASTIDLETHERMOVALVE{A/T}
THROTTLEBODY(TB}
FUELINJECTOR
FUELPULSATIONDAMPER
FUELFILTER
FUELPRESSURE
REGULATOR
FUELPUMP
FUELTANK
FUELTANK EVAPORATIVE
EMISSION(EVAPIVALVE

www.emanualpro.com

11-14

@
@
@
@
@
@
@
@
@
@
@
@

AIR CLEANER
RESONATOR
POSITIVECRANKCASE
VENTILATION(PCV}VALVE
THREEWAY CATALYTICCONVERTERITWCI
EVAPORATIVE
EMISSION{EVAPICONTROLCANISTER
EVAPORATIVE
EMISSIONIEVAPIPURGECONTROL
SOLENOIDVALVE
EVAPORATIVE
EMISSION{EVAPICONTROLCANISTEF
VENTSHUTVALVE
EVAPORATIVE
EMISSIONIEVAPITWO WAY VALVE
EVAPONANVEEMISSION{EVAPIAYPASSSOLENOID
VALVE
FUELTANK PRESSURE
SENSOB
EVAPORATIVE
EMISSIONIEVAPITHREEWAY VALVE
PURGEJOINT

-'97 Model
Electrical
Connections
--- --- -t

f_

l-1r

n l no 3wrcx

(.J

Htl

T:

I
4

-'tl

-'o.:\

-lla^^^

l-

tirr

-]lrL

Dl"ii

I-6,
' ^li lGPl

f----;;l

t l
t l

oa 9I3

ctovEu
A' lGI

aztL@,
FUELll'tlEcToes

aEt30F

|NJ2 3

TDC
3ErcON

catDcP

ctP
SErAOi

Gt ct(iP?

Xo.2

[{J3 A2

cra Tltcl

er2cxP{

CKF
3EN30F

cfl ct(Ftr

TOEIIF-

Dta ELtr

||tL
c|| v!]3

f1

uNx
coi||lEctoh

TL

T'

^cc^r?

^ca 6

c. K.uirE

__-l db
SERVICE
Cl|ECK
@ NEqroi

rtT
qr 3c3
ALTF CI'

t'-

bI. ATPfi

Ei. ATPI

Att lE
FOgn ON
3wltc

6u
I

t *l f

TPDI

GAIXIE
ASSEIBLY

gi7 alP:l

I
I

)r^ l

B2aAtPtX
E'

ila

rt: usA

EII ATPI{P

to l/C CLUTCfl BELAY


to i^Ol^toh F tl REI Y,
@III'C|{AEi FA'I iEL Y

D{NDtir

:
FUSES
(DBACKuP (RADro)(7.sr0.
@ "o^n ttot (tuo)'
*
(DBATfERY(IOOA)
(4oA)*
rcl
o

(DFt E/ flsA).
@ No.13 FUELPU P ('l5A)
O No. 2s METER(7.5A)
(D NO.'I5 ALTERNATORSP SENSOB(7.5A)*
O No. 3i STABTERSIGNAL (7.5A)
*: In lhc und?r.lrood tu$/rclay bor
(cont'd)

www.emanualpro.com

11 - 1 5

SystemDescription
-'97 Model(cont'dl
Electrical
Connections

VALVE
EVAPPUFGECONIROI SOLENOIO

SPEOSENSOR
COUNERSHAFI
SPEEDSENSOF

CONTNOL SOIENOID VALVE A

PFESSUhECOI{TFOL

sotENotDvALvE

Tor lEiLocK coNtFol UNlt

IERi'INAL LOCATIONS

11 - 1 6

www.emanualpro.com

YEL/BLU
FED/BI(

(SErOR
r)
HO2S

l-

(cont'd)

www.emanualpro.com

11-17

System Description
-'97 Model(cont'dl
Electrical
Connections

No.2 FUELIIUECIOF
cl09

11-18

www.emanualpro.com

BLK,TELJflI
BLU rdHT , -----L+
alx

Frrt\rFEl
L-fJl
||

l-

CONDENSERFANFELAY

*1 : USA

(cont'd)

www.emanualpro.com

11 - 1 9

SystemDescription
-'97 Model(cont'dl
Electrical
Connections

-Fc

h- -FE
rF
ARN

B R N :BLK
eLKr

BLKj

BLxj

8Rt,l,'BLxj
ARN,'BI.K.

c113

11-20

www.emanualpro.com

cat.,auxt
LT GAN

BLVBLU

RED

GRN
BLU,

an12
GAUGEASSEI'BLY

I
enr2-{

I
I

A,ryGEABPOSINONSWITCH

*".r".o'-

) Inor.".o"*

CONTROL UNIT

(cont'd)

www.emanualpro.com

11-21

SystemDescription
-'97 Model lcont'd)
ElectricalGonnections

t,l

/8LU l

|l

,J
I

IVTII/BLU -

WHT/LU

l
wltT/BLr(.
(c352
WHT/BLK

rcl ({0A}
HOiXsIOf 05A)
wltT/GRt{

CRN/FEO

GRI{/FO

BLU/ORN

ALU/'IVHT
UNOER]IOOD
fUSE,/FEIAY 8OX

T"*,,*.
".*_f

Btur,tvrr
I-.'|

r'tc3rsrAaIES
SG|I|^L 05 )

BLU/W8T

,ato"nL

;rfi

""r _g!:f
BLK/FED

'I_

FUSE/BELAY BOX

11-22

www.emanualpro.com

*2: USA

(Fromp!9.1r-221

ca32

**r2",-*J-1
YEVGRN
YEvErK --

___-I
BLU?'I'HT
-GRN,/YEL
I
YEVGnN--

"*

--1

PGII.FI
UAIN RELAY

C56-2

trru^n --

_BLK

I
dL

www.emanualpro.com

-]
i\

//--\

- \_-,/ , /
FUELPUMP

11-23

SystemDescription
-'98 - 00 Models
Electrical
Connections

lg il
T
t ( 1 1
BATTERY
\
ffi
\
t.
ro3Ecl,|{r
/
STAFIEF
F
q,t
REL Y

FUEL IUECIONA

lo ^/c clwclr hEL Y


lo iADIAIORFAl{iEt Y,
coittct{3F F l{ FCLAY
Yo|/C all'lc8

att

OAT'OE
alsErELY"

tr
POSll|O|l
S TClt

ovEi-odYE

*1: A/T
'2: USA
*3: '98 modol
*il: '!X) - 00 model!

www.emanualpro.com

(DEAGKuP (RADlo)(75A).
@ HoB sroP (rsAr
(tood'
O BATTERY
(Drci (4oa)'
O Fl E/trl(lsA)r
(ONo.13FUELPUmP(l5A)
O No.2s HETERO.5a)
(DNo.15AITERNATOB
SPSENSoR(7.5A)'
@r.ro.3l STAnTERstcNAL (7.5A)
t: in tha und!..hoodfule/irl.y box

TESTTACHOiIETER
coNr{EctoB
lo CRUISECoNTEOLUNIT+r
TANK
PRESSUFE
SENSOF
SOIENOIDVAIVE
EVAPPURGECONTROL

EVAPCONIFOLCANISTEFVETITSHUTVALVE

sp:rosENsoF*1
COUNIERSHAFT
SPEEDSENSOR'T
coNlRo! solENotDvALvEA*1

H02S
(SENSOF1)

COI'TIFOLUNIT*!
TOINTEFLOCK

rcrocrsgrson*'

TERI/lINALLOCATIONS

(cont'd)

www.emanualpro.com

11-25

SystemDescription
ElectricalConnections- '98 - 00 Models (cont'dl

G]
- l
ct sEt{goh

' c14t
I J/C

llo23 (SEltgOi O

l!to2srfic

11-26

www.emanualpro.com

SECOiD hY
HO2a (aE toh 2)

Iil
I I

Y sExsoF
I

t1 t r- : r E

I
ll
Y s . n s oI R
l |
IL|

. - ac x P I
Y sErsonl

tl
ll

I f-=-r
'""
ILfr l-

I
I|

FI

t q l
r-__:__-)

{o.l

FUELIIUECIOF

No. 3 FUE! IiUECIOn

r - l
l _ , I

(cont'd)

www.emanualpro.com

11-27

SystemDescription
-'98 - 00 Modelslcont,dl
Electrical
Connections

l M

l--

sL( yEL JJ{FiE-l


sLUwnf li,"+l

+
_

8rk

_{lr]]]]]]]

F >rt
i

-4.

w;i-nu-

" l---r

' a

r q - v--J

t_.1

CONOEflSERFANRELAY

rlrA/T
.2: USA
*4: '99 - 00 models

11-28

www.emanualpro.com

elrcvrlJ-l

".o"*'-{l -- 3 |
CONTROI
soLENOroVALV

ca6l

,o""r"*Jffil
"."** {H
I

tT GFtt/wxt

sotEtrolo vALvE

'.,r".u-fffil
,.YGRN'-I
f+<-l

GR/8LX'-11-

FUEI TAIIX
PRESSUBE
SENSOF

To CRt ISE
coNtFol u|{lt

*1 : A/T
(cont'd)

www.emanualpro.com

11-29

SystemDescription
-'98 - 00 Models(cont'dl
ElectricalConneetions

fJ-

F
l

fJ

fJ

f:t

!l T
9RN/
BRN/

BRN/ gLxl
aLKl

atx'

F]

Tl

BLKt

BRN/
aLKl
c121

r=r
BRN/

eLxr

STNFT
@NTFOL
SOICNOIDVALVE

c115

IIAINSIIAFI SPEEDSENSOF
c119

clll
--l

A/t cLulctl
PFESSURE
COIiTTHOL
SOIENOID
VALVE

11-30

www.emanualpro.com

n"t,lonrJ
1"r.]

L : ]

-*"{

r-YEL.cRN--_l
l--

- GRN/BLK
I-

LTGRN1

-BIK/BLU

REO
BtuT

]
-.,]

r.I=
-*i-

]
-::'",1

*I : A/T
+3: '98 model

(cont'd)

www.emanualpro.com

11 - 3 1

SystemDescription
-'98 - 00 Models(cont,dl
Electrical
Connections

OVE&ORVEOFF
[{DtcatoR LlfP

C UqEAASEr|ELY

A/I GEAA PO3MON SWITCH

*tnzaeo'

) ,r*ear_oo,

@lillFo|. ur{tT

* 1 :N f
*4: '99 - 00 modets

11 -3 2

www.emanualpro.com

c$3 c.r'

L*_"."{h

cl/I

crxl

I *,,,,".u:][

-*^;1n-;"*,
u

wF /BLx__1
c35lI

,-wnrzEr-x{

8uc{rHr --l

-!"'*
clfz

u|,|oEF-ftooD
BOI
FUAE/NEIAY

=-

B ITEFY

r-t

Lh-v

BMIG STITCH

E|.UflTT'
YEVORN
cal7
9q/wHr
Et&{lll
BLX/WFI

YEL

{cont'd)

www.emanualpro.com

11-33

SystemDescription
-'98 - 00 Models(cont'dl
Electrical
Connections

PGU.FI
MAII{BEIAY

-YEL/GBN-BLx--

_L

cssr

11-3 4

www.emanualpro.com

cs6-2
,z-_\
p \
-f
l- \
./

"---.,

FUELPUI{P

SystemDescription
SystemGonnectors[EngineCompartmentl-'97 Model

MAIN WIRE
HARNESS

UNOER.HOOD
FUSE/RELAY

..'.'.'

80x
ct21
cl11

cl16

11 - 3 6

www.emanualpro.com

cl15

cl11

I 3 l . l

f,_rr'Hr-lwHr'-------

--l
Ft RE!'wr
lll
ft'-cRN/sLK,

t l

2 l

l r , r l

c 6
eFr
1 1 2 l

cl.t7
r-r=l r 2 l

T!-Isrf,-*--/r*".er*
I]]ll
-;-BLi'uF

c129
.__1-..']..-r
1 1 2 3 l

ffl.E*-------lO

stx,YEL

TtlBru/"Nr----

c35l

c354.'

l4;i;1_s;:a

'-{-l-r

riiiltTf,n

fd,sLK rHr-----l

t-rlBL(
19

cFNnEo

*2: USA

NOTE:o Differentwireswith the samecolor havebeengivena numbersuffixto distinguishthem {for example,YEUBLKl


and YEUBLK,are not the same).
O: Relatedto Fueland EmissionsSystem.
- Connectorwith maleterminals(doubleoutline):View from terminalside
- Connectorwith femaleterminals(singleoutline):View from wire side

(cont'd)

www.emanualpro.com

11-37

SystemDescription
SystemGonnectors[EngineCompartment]-'97 Model {cont'd)

MAIN WIRE
HARNESS

ENGINE
WIBE
HARNESS

www.emanualpro.com

cr03

c105
tusAl

r__F2
1 1

-+
l l 2 l

cr07

c105

r#-r

l r , 2 3 l

cr08

rfjl

1 1 2 l

l l . 2 l

l 3 l . l

I T'*--film----t

[--1;N,/ruo; l]]l]
t,Id&Yr

|.-T;s,,. -

cltxt

l';FELM

.
.

www.emanualpro.com

r--=
lr 2l

u)

----l
li

e@;----

lEl*",]!

N O T E :.

t F l

tl

tildK"ri
t
ltlB$jrma -

t0

r--q
ll 2 l

lEl;.

titna.

{ ' )
\:)
t.;ERN,f
Ttl;Eor-L

-_-]l
-

o
I

D i f f e r e n tw i r e s w i t h t h e s a m e c o l o r h a v e b e e n g i v e n a n u m b e r s u f f i x t o d i s t i n g u i s ht h e m ( f o r e x a m p l e ,
YEUBLK1
and YEUBLK'are not the same).
O: Relatedto Fueland EmissionsSvstem.
- Connectorwith maleterminals(doubleoutline):View from terminalside
- Connectorwith femaleterminals{singleoutline):View from wire side

11 - 3 9

System Description
SystemGonnectorslDashand Floor]-'97 Model

DASHBOARDWIRE
HANNESS
MAIN WIRE
HARNESS

REARHEATEDOXYGEN
SENSOR
SUAHARNESS

WIREHARNESS

www.emanualpro.com

cat2

titT T)l

t]l
filsl].Mr

FT-I
l5l'ri":'*l]]l

lwittost crui.! comrol)


3

,t\./

9 t0 1'l

r\.2

18 t,/

20

1ol,/ /

1 3 1 a 1 1 5 16 ./

ta

lolZmlvv{-l -l
l@is',t'A' t-l

f.Tt.-f f

r$r

l t 4 . l' l
riTLiGN--]]l

I111

rtTa*

lo-6dN'!Hnl .]l

[tltu/cs

c426
rrFr-r
| 1 1 23 l . l

t';l;Kvi-l

fol**"---

NOTE: o Different wires with the same color have been given a number suffix to distinguish them (for example.

YEUBLKland YEUBLK'are not the same).


a O: Relatedto Fueland EmissionsSvstem.

www.emanualpro.com

Connectorwith maleterminals(doubleoutline):View from terminalside


Connectorwith femaleterminals(singleoutline):View from wire side

(cont'd)

11-41

SystemDescription
SystemGonnectors[Dashand Floor]-'97 Model (cont'dl

DASHEOARDWIRE
HARNESS

MAIN WIRE
HARNESS

11-42

www.emanualpro.com

1 t 12 13

9 to

5
l6

'11

l 8 l9

-t
i

(}

NOTE: o Differentwires with the same color have been given a number suffix to distinguish them (for example,

YEUBLKIand YEUBLK'are not the same).


a O: Relatedto Fueland EmissionsSvstem.
a - Connectorwith maleterminals(doubleoutline):View from terminalside

www.emanualpro.com

Connectorwith femaleterminals(singleoutline);View from wire side

(cont'd)

11-43

S)stern Dessr\ptron
SystemConnectorslDashand Floor]-'97 Model {cont'd)

MAIN WIRE
HARNESS
ENGINE
WIRE
HARNESS

//l
tao,

c1z2

(PCM.AI

{PCM.D}

www.emanualpro.com

11-44

c124 (PCM,B)

ct23 {PCM-Al

1 2 \ 3 1 5 6 1 8
1 1 1 2 1 3 r a 1 5 1 6 '11 l 8

iJq

.t

,,

cr26 tPicM-ol

cr25 tPCM-Cl

1
2 3 a 5 X
r r l 1 2 13 l a t 5 t 6

9 1 0

1 1 t 8 19 20

ii)

!t

o
n
n

lit

1 1 1 1 2 t 3 !il

6
'16 I t

9 1 0

't8 t9 20

NOTE:o D i f f e r e n w
t i r e s w i t h t h e s a m e c o l o r h a v e b e e n g i v e n a n u m b e rs u f f i x t o d i s t i n g u i s ht h e m ( f o r e x a m p i e ,
YEUBLKT
and YEUBLK2
are not the same).
O: Relatedto Fueland EmissionsSvstem.
- Connectorwith maleterminals(doubleoutline):View from terminalside
- Connectorwith femaleterminals(singleoutline):View from wire side

www.emanualpro.com

11-45

System Description
SystemConnectorslEngineGompartment]-'98 Model

MAIN WIRE
HARNESS

UNDER.HOOD
FUSE/RELAY
BOX

ENGINE
w|RE
HARNESS

*2: USA

11-46

www.emanualpro.com

ctt5

t'ltl
[.1.1
lSlwHr

-------

lo GnNAUC I
TdTBLx/YEL-----1
fdBtx vNP

fr

\,v
tdTiaotfi-----l
---l
IETcRll,aLX'

ct10

fr

fr

fr

I6rc;iEiF--l- ll
IltIYEr,

ffi

ct19

fr

f'Ttfrl

-'l

l6lcnN'
lo eLU'

tdFLxr-----l

SLKI

L4.lrl

LrsLU

cRY

I O BL|^EL
l6l6tu/rJHr'

I
-

c354*'

NOTE;.
.
.

-1|

fr

16T816rr-----l
lol "."
I
lO

tsTYE'Jrr

G361

r'ft]
GF&aEp

ldTcRN/BrF----lO iEo/BL(

lSTLr GRr/wHr--F ]ilwH----I

Differentwireswith the samecolor havebeengivena numbersuffixto distinguishthem (for example,YEUBLK1


and YEUBLK,are not the s8me).
O: Relatedto Fueland EmissionsSystem.
- Connectorwith maleterminals(doubleoutline);View from terminalside
- Connectorwith femaleterminals(singleoutlinel:View from wire side
(cont'dl

www.emanualpro.com

11-47

System Description
SystemConnectorslEngineCompartmentl-'98 Model (cont'd)

MAIN WIRE

ENGINE
WIRE
HARNESS

www.emanualpro.com

c t5

{usa)

r'ftr

t'ltl
I'l.l
Ttlrsrtsu

ftT,,tHr/FEpi

IET$'rmc' -- I
ftlarxrEl-l
ftlwn/srt
l

NOTE: o Differentwires with the same color have been given a number suffix to distinguish them (for example,

YEUBLKland YEUBLK,are not the same).


o: Relatedto Fueland EmissionsSvstem,
a - Connectorwith maleterminals(doubleoutline):Viow from terminalside
- Connectorwith femaleterminals{singleoutline):View from wire side
(cont'd)

www.emanualpro.com

11 - 4 9

SystemDescription
SystemGonnectorslEngineCompartment]-'99 - 00 Models

MAIN WIRE
HAENESS

UNDER.HOOO
FUSE/RELAY
BOX

ENGINE
WIRE
HARNESS

www.emanualpro.com

cl11

ffir
lilrl
t-lwHn-----t
I ' IGRNtsLI'

f"l".*,.

15

c114

ft

ffi

,g
1lI

c116

cl17

c118

ffi

ffi

Effi-ffiffi

rdTnEDlllHr-----l6lcRN/Buc
-

----

ffi

trhlx,l/vH?

c121

c129

ffi

f'ftf
'1)

c135

Gt51

t6-tBrK

-----_l

l lBrxrEr
lShLU^,/Nrr

l]l I

Gt52

ElzTt)
IiTYvnED-----l
TdTcFN/rHr, FfREp/cFr
l

Gt54.'

-Ell 1 l 23 l

ldTBLxr'rtvii-----l
TitlBL.
I o cFN/Frp
l

*2:USA
NOTE:o Differentwireswith the samecolor havebeengivena numbersuffixto distinguishthem (for example,YEUBLK1
and YEUBLK,are not the same).
a O: Relatsdto Fueland EmissionsSystem,
a - Connectorwith maleterminals{doubleoutline):View from terminalside
- Connectorwith femaleterminals(singleoutline):View from wire side
(cont'd)

www.emanualpro.com

11-51

System Description
SystemGonnectors[EngineCompartment]-'99 - 00 Models{cont'dl

MAIN WIRE
HARNESS

11-52

www.emanualpro.com

c105
(usA)

c104

c103

Ir zl

lslrl
----

f -T;iE;;n

tll

lrlBR,r

FIrt

l1 2l

I '

WNT]FEDI

filBLKry.L ll]I
fu-,wHrcn[ l]l
ftl-wNr/sr't ---l
TaTtNanEc!

c105
{Canadal

c108

c107

r'fifl
-'-l
fi'Iw|r/nE D. -_-l
T'TBt(ryEL
t]l

t lnrtsrr

ffi

ffi
|iTYEULX'
--

-rfnri-r

FfBLK//EL---l-l
l -IREor/Ar

c134
c109

c133

10

ffi

ffi
---l
l-!. IYEUBLK.

c137

c303

----l
FEp/Bru

N O T E :.
.
.

www.emanualpro.com

riaF.\rjrr. - l]l I
ttInEoYEr,

1 " 1 " " '-

fil

Differenw
t i r e s w i t h t h e s a m e c o l o r h a v e b e e n g i v e n a n u m b e rs u f f i x t o d i s t i n g u i s ht h e m ( f o r e x a m p l e .
YEUBLK'and YEUBLK'are not the same).
O: Relatedto Fueland EmissionsSvstem.
- Connectorwith maleterminals(doubleoutline):View from terminalside
- Connectorwith femaleterminals{singleoutline):View from wire side

11 - 5 3

System Description
SystemConnectors[Dashand Floorl-'98 - 00 Models

DASHBOARD
WIRE
HART{ESS

Ita|l{ wtRE
HARIIIESS

REARHEATEDOXYGEN
SENSOR
SUBHAR ESS
LEFTSIDE
WIREHAR ESS

www.emanualpro.com

1 1 -5 4

c4r2

ll,Vt'll
6fswYv-ii----

E-r-

F lwir,L(

--

-l

!E!E!t
LT GRN

/l/lt

rolrr

tHrBLt

l/

r . l , / za

/te

tol./ /llEl1.lt6

r . l/

tl

lwlrhot|t crub. 6.trroll

-ftr

rdT6iffi---l
ET----- ---l
l.T--

r'TfifiI

I'X.l
l ' l . l
l-i'f iifiN
ftTGRY
fdlGiffil
fdlw{rcftr

-----l
----

TdliL,,rw{r----1

I
l @ c R M/ H r '
lO wt{r D' ---l I
TofuLr/,txl-

NOTE:o Differentwires with the same color have been given a number suffix to distinguish them (for example,
YEVBLK1
and YEUBLK' arenot the same).
a O: Relatedto Fueland EmissionsSystem.
a - Connectorwith maleterminals(doubleoutline):View from terminalside
(cont'd)
- Connectorwith femaleterminals(singleoutline):View from wire side

www.emanualpro.com

11 - 5 5

SystemDescription
SystemConnectorslDashand Floorl-'98 - 00 Models(cont'd]
c510

DASHBOARDWIRE
HARNESS

MAINWIEE
HARNESS

'4: '99 - 00 models

11 - 5 6

www.emanualpro.com

rE0

c508
2 3 a
1 l 12 13

6
E 9 10
1 5 1 6 1 1 1 8 1 9 20

|l!

.,

1-t""'

-----l

lo lLrcRN,
I O IsLKM/Hr
l r l
I t lYErrLU
T-ilcirrlLrr

I
t

rdTYEcii-----lll
I

ETGRN/Brxi - lll
fSliaGFNr-

mJv

, - + , ,

lrl2l3l1l

l.f.T'-]

F6EFN-----

ftTcll-l

t 2 l

''l

ftTYEUsr.
t
TstYEr
*4:'99 -00 models

IO IBLK

ftTwHr/BL(---'1
f.ft1.

(for example,
Different wires with the same color have been given a number suffix to distinguish them

and YEUBLK'are not the samol.


YEUBLKT
O: Relatedto Fueland EmissionsSystem
a - Connectorwith maleterminals{doubleoutline):View from terminalside
- Connectorwith femaleterminals{singleoutline);View from wire side

www.emanualpro.com

YEL

I
l]l I

c76t*.

c760

NOTE: .

\:9

vl5l6l

l--l

I a l Y E U c n NftTYEL'BrK

a.a

r,'ffijt

trLtzl
|.-l.T'|

ffi
rcrBr.

c546

c580

c552

(cont'd)

11-57

System Description
SystemConneetorslDashand Floorl-'98 - 00 Models(cont'dl

DASHBOARD
WIREHARNESS

MAIN WIB
HARNESS

ENGINE
WIRE
HARNESS

n
lno,

c,47
(ECM/PCM.A}
c121
(ECM/PCM-8)

(PCM.D}

www.emanualpro.com

cl25 tECM/PCM-C)

c124 {ECM/PCM.B}

c't22

1 I
2 3 a
12 t 3 l t a 't5 t 0 1 1 t 8 t 9

tt

c126 (PCM-O)*,

c127'.

c121*3

c132

C,r47(ECM/PCM-Al

ot33
6

3
1 t 12 l 3

10

l 6 17 la t9

*1:4,/T
*3: '98model
'4:'99- 00models
NOTE:.
.
.

www.emanualpro.com

'1all

Differentwires with the same color have been given a number suffix to distinguish them {for example,
and YEUBLK' arenot the same).
YEUBLK1
O: Relatedto Fueland EmissionsSvstem.
- Connectorwith maleterminals(doubleoutline):View from terminalside
- Connectorwith femaleterminals(singleoutline):View from wire side

11-59

Troubleshooting
TroubleshootingProcedures
How To BeginTroubleshooting
When the MalfunctionindicatorLamp(MlLl has beenreportedon, or there is a driveabilityproblem,usethe appropriate procedurebelowto diagnoseand repairthe problem.
A. Whenthe MIL hascome on:
1. Connectthe Honda PGM Testeror an OBD Il scantool to the 16PData Link Connector(DLC)locatedbehindthe
right sideof the centerconsole.
Turn the ignitionswitchON (ll).
Checkthe DTCand note it. Also checkand note
the freezeframe data.
Referto the DiagnosticTroubleCode Chart and
begintroubleshooting.

NOTE:
. SeetheOBDll scantool or HondaPGMTesteruser'smanualsfor specificoperatinginstructions.
. The scantool or testercan read the DiagnosticTroubleCodes(DTC),freezeframe data,currentdata,and other
EngineControlModule(ECM}/Powertrain
ControlModule(PCM)data.
. Freezeframe data indicatesthe engineconditionswhen the first malfunction,misfireor fuel trim malfunctionwas
detected.lt can be usefulinformationwhen troubleshootino.
B. Whenthe MIL has not come on, but there is a driveabilityproblem,referto the SymptomCharton page 11-64.
C. DTCswill be indicatedby the blinkingof the MalfunctionIndicatorLamp{MlL)with the SCSserviceconnectorconnected.
Connectthe SCS serviceconnectorto ServiceCheckConnectoras shown. {The 2P ServiceCheckConnecrorrs
locatedbehindthe right side of the centerconsole.)Turn the ignitionswitchON 0l).

DATA LINKCONNECTOR
I16PI

www.emanualpro.com

11 - 6 0

ll.

ControlModule{PCM)ResetProcedure
EngineControtModule(EcM)/Powertrain
Eitherof the followingactionswill resetthe ECM/PCM.
.

(see the oBD ll scan tool or


s
use the oBD ll scantool or Honda PGM Testerto clear the ECM' s/PCM'memory.
instructions
)
operating
specific
for
manuals
Tester
user's
HondaPGM

. Turn the ignitionswitchoFF. Removethe BACKUP (RADIO)(7.5A) fuse from the under-hoodfuse/relaybox for
seconos.

10

BACKUP {RADIOII7,5 AI FUSE

FUSE/RELAYBOX

lll. FinalProcedure{this proceduremust be done afterany troubleshooting)


and there are no
1. Removethe SCSServiceConnectorif it is connected.lf the SCSserviceconnectoris connected.
(ll).
oN
is
turnsd
switch
ignition
when
the
on
will
stay
the MIL
DTCSstoredin the ECM/PCM,
2. Do the ECM/PCMResetProcedure.
3. Turn the ignitionswitchOFF
(
the OBD ll scantool orHonda PGMTesterfrom the DataLinkConnector16P)'
4. Disconnect

(cont'd)

www.emanualpro.com

11 - 6 1

Troubleshooting
TroubleshootingProcedures(cont'd)
lf the inspectionfor a particularcode requiresvoltageor resistance
checksat the EcM/pcM connectors,removethe right
kick panel.Unboltthe EcM/PcM.and connectthe backprobesetsand a digitalmultimeteras describedbelow,
checkthe
systemaccordingto the proceduredescribedfor the appropriatecode(s)listedon the followingpages.

@@)@)c,

How to Us6 tho BackprobeS6ts


connectthe backprobeadaptersto the stackingpatchcords.and connectthe cordsto a multimeter.
Usingthe wire insulation as a guide for the contouredtip of the backprobeadapter,gently slidethe tip into the connector
from the wire side
until it comesin contactwith the terminalend of the wire.

Backp.oboAdapto.

BACKPROBE
SET
o'SAZ - (xtlqDA lTwo requir.dl

11-6 2

www.emanualpro.com

DIGITAI.MULTIMETER
(Commarci.llyrvrilabl.l or
KS-AHM-32-@3

CAUTION:
. Puncturingthe insulation on a wile can causepoor ot intelmittent electricalconneciions.
. Bring the tester probe into contact with th terminal from the terminal side of wire htrness Gonnectorsin the engine
probe.
comoartment. Fol temale connectols,iust touch lightly whh the tester probe and do not insgrt lhe

(cont'd)

www.emanualpro.com

11 - 6 3

Troubleshooting
Troubleshooting Procedures(cont'dl
Symptom Chart
Listedbeloware symptomsand probablecausesfor problemsthat DO NOTcausethe MalfunctionIndicator
Lamp(MlL)to
come on. lf the MIL was reportedon, go to page 11-60.
Troubleshooteachprobablecausein the order listed(from leftto right)until the symptomis eliminated,
The probablecauseand troubleshooting
pagereferencecan be found below.
SYMPTOM

PROBABLECAUSE

Enginewill not start


Hardstarting

4 , 2 , 3 , 5 , 2 0 ,' t 5 ,1
2, 4, 12,17,14, 't9

Coldfast idletoo low


Coldfast idle too high
ldle speedfluctuates

7 ,a , 9 ,6 , 1 7
7,8,9,11,10
9 , 7 , 8 ,' t 1 ,1 0

Misfireor rough running

Troubleshootfor misfire on pages '11-126,1|21


2, 10,11,13,'17,18,20
2 , 4 , 1 2 , 1 , 2 0 , 9 , 5 ',t 6

LOl/\/power

E n g i n es t a l l s
OtherProbableCausesfor an enginethat will not start:
- Compression
- Intakeair leakage
- Enginelockedup
- Timing belt
- Startingsystem
- Overheating
- Battery
ProbableCauseList (Forthe DTCCh8rt, see page ll-75.)
ProbableCause
'I

Page

Engine
(ecvtffi
controtruoaute

I 1-178

Fueloressure
PGM-Flmain relav

11-187
5

Section4
't1-'t31,146

6
7

I 't-95
11-152

1'l-168

10
12

11-196
11-'194
'1'l-90

14

11- 103
11-137

11-169
'11

15
16
17
18
'19

20

11 -6 4

www.emanualpro.com

System

11-42

Section14
11- 166
r1-194
11 , 1 9 9
11-203

lgnitionsystem
positionsensorcircuit
Crankshatt
Position/Top
DeadCenter/Cylinder
IntakeAir Temperature(lAT)sensorctrculr
ldleAir Control(lAC)Vatve
Fastidle thermo valve
ldle speedadjustment
Throttle body
Throftlecable
ManifoldAbsoluteP."""rr"ffi
ThroftlePosition(TP)sensor
Barometricpressur"(gnnoAy'Tgear positionsignal
Brakeswitchsignal
Air Cleaner
Three Way CatalyticConverter(TWC)
Evaporative
emission(EVAP)control
Contaminated
fuel

ECM/PCMData
By connectingthe OBD ll scan tool or the Honda PGM Testerto the 16Pdata link connector(OLC),variousdata can be
The itemslistedin the table belowconformto the SAErecommendedpractice
retrievedfrom the ECM/PCM.
The HondaPGMTesteralso readsdata beyondthat recommendedby SAE.
understandingthis datawill help to find the causesof intermittentfailuresor engineproblems.
NOTE:
The ',operatingvalues" given below are approximatevaluesand may be differentdependingon the environmentand
the individualvehicle.
"at
Unlessnotedotherwise. idle speed" meansidlingwith the enginecompletelywarmed up, transmissionin position
turnedotf.
the
A,./C
and all accessories
Parkor neutraland
Data
Diagnostic
TroubleCode
(DTC)

EngineSpeed

VehicleSpeed

Desc.iption

lf no problemis detected,
lf the ECM/PCMdetectsa problem,it will storeit as a
there is no output.
codeconsistingof one letterand tour numbers
code (Poxxx)
Dependingon the problem,an SAE-defined
(P'lxxx)
will be outputto the
code
or a Honda-defined
tester.
Nearlythe sameas
computesenginespeedfrom the signals
The ECN4/PCN4
tachometerindication
sentfrom the CrankshaftPositionsensor.
This data is usedfor determiningthe time and amountof At idle speed:
'97 - 98 models:
fuel iniection.
750t 50 rpm
'99 - 00 models:
730f 50 rpm
The ECM/PCMconvertspulsesignalsfrom the Vehicle
SpeedSensor(VSSIinto speeddata.

The absolutepressurecausedin the intakemanifoldby


Manifold
engineload and speed.
Absolute
Pressure(MAP)

FreezeData

YES

YES

Nearlythe sameas
speedometerindication

YES

With engin6stopped:
Nearlythe sameas atmosphericpressure
At idle speed:
2a - 41 kPa{210- 310
m m H g ,8 . 3- 1 2 . 2i n H g )

YES

With cold engine:


Sameas ambienttemPeratureand IAT
With enginewarmed uP:
approx.163- 2'12'F
(73- 100"c)
0 . 0- 1 . 2 5V
The HeatedOxygenSensordetectsthe oxygencontentin
At idle speed:
to
the
gas
voltage
signals
sends
exhaust
and
the
controls about0.1- 0.9
Basedon thesesignals,the ECM/PCM
ECMiPCM.
the airlfuelratio.Whenthe oxygencontentis high (thatis.
ratio),the
when the ratiois leanerthan the stoichiometric
is
lower.
voltagesignal
Whenthe orygen contentis low (thatis, when the ratio
ratio),the voltagesignal
is richerthan the stoichiometric
is higher.

EngineCoolant The ECTsensorconvertscoolanttemperatureinto voltThe sensoris a thermistor


age and signalsthe ECM/PCM.
Temperature
changeswith coolanttemperawhose internalresistance
{ECT)
ture.The ECM/PCMusesthe voltagesignalsfrom the
ECTsensorto determinethe amountof injectedfuel
HeatedOxygen
Sensor(HO25)
(Primary,
Sensor1)
(Secondary
Sensor2)

Oprating Valuo

YES

NO

(cont'd)

www.emanualpro.com

11 - 6 5

Troubleshooting
TroubleshootingProcedures(cont'd)
Data
HO2S
Feedback
Loop Status

ShortTerm
F u e lT r i m

Descliption
Loop statusis indicatedas "open" or "closed".
Closed:Basedon the HO2Soutput,the ECM/pCMdeterminesthe airlfuelratioand controlsthe amountof
injectedfuel.
Open:ignoringHO2Soutput,the ECM/pCiM
refersto sig,
nalsfrom the TP, MAP,and ECTsensorsto controlthe
amountof injectedfuel.

Operating Value

Freezo Data

At idle speed:closed

YES

The airlfuelratiocorrectioncoefficientfor correctingthe


t:20y"
amountof injectedfuel when HO2Sfeedbackis in the
closedloop status.Whenthe signalfrom the HO2Sis
weak,shortterm fuel trim gets higher,and the ECM/PCM
increases
the amountof injectedfuel.The airlfuelratio
graduallygets richer,causinga higherHO2Soutput.
Consequently.
the shortterm fuel trim is lowered.and
the ECM/PCMreducesthe amountof injectedfuel.
This cyclekeepsthe airfuel ratiocloseto the stoichiometricratiowhen in closedlooDstatus.

YES

LongTerm
F u e lT r i m

Longterm fuel trim is computedfrom shon term fuel


trim and indicateschangesoccuringin the fuel supply
systemover a long period.
lf long term fuel trim is higherthan 1,00.the amountof
injectedfuel must be increased.lf it is lowerthan L00.
the amountof injectedfuel must be reduced.

! 20%

I n t a k eA i r
Temperature
(IAT)

The IAT sensorconvertsintakeair temperatureinto voltage and signalsthe ECrU/PCM.


When intakeair temperature is low, the internalresistance
of the sensor
increases,
and the voltagesignalis higher.

With cold engine:


Sameas ambienttemperatureand ECT

Throttle
Position

Basedon the accelerator


pedalposition,the opening
angleof the throttlevalveis indicateo.

At idle speed:
approx.10%

lgnition
Timing

lgnitiontiming is the ignitionadvanceangleset by the


ECM/PCM.
The ECM/PCMmatchesignitiontiming to the
drivingconditions.

A t i d l es p e e d 1
: 6'1 4.
BTDCwith the SCSservtceconnectorconnected.

NO

Calculated
LoadValue
(cLV)

CLVis the engineload calculatedfrom the MAp data.

At idle speed:
2A- 410/o
At 2,500rpm with no load:
13 - 260/o

YES

www.emanualpro.com

11 _ 6 6

YES

PowertrainControlModuleTerminalArrangement-'97 Model

Wire sideof lemaleterminals

FCM CONNECTORA (32P)


frminal
numlreJ

Wire
color
YEL

NOTE:Standardbatteryvoltageis 12V.
Telminal
nama

lNJ4(No.4 FUEL
INJECTOR)

10

l N J 3( N o . 3F U E L
INJECTOR)
l N J 2{ N o . 2F U E L
RED
INJECTOR)
l N J l ( N o .l F U E L
BRN
INJECTOR)
SO2SHIC(SECONDARY
OXYGENSEN
BLK WHT
HEATED
CONTROL)
SORHEATER
(PRIMARY
PO2SHTC
HEATEDOXYGEN
BLKAr'YHT
SENSORHEATER
CONTROL}
8RN/BLK LGl (LOGICGROUND}
PG1lPOWERGROUND}
BLK

l1

YEUELK

12

BLI(BLU

6
I

BLU

REDryEL

16

GRN/VEL

IGPl lPOWERSOURCE}
IACV{IDLEAIR
CONTROLVALVE}
PCS(EVAPPURGE
CONTFOL
SOLENOID
VALVE)
FLR(FUELPUMPRELAY)

19*

ACC (A,/CCLUTCH
RELAY}
MIL (MALFUNCTION
GRN/ORN INDICATORLAMP}
ALTC(ALTERNATOR
WHT/GRN CONTROL}

20

YEUGRN

22
23

BRN/BLK
BLK

24

YEUBLK

27

GRN

11
18

8LI(RED

Description
Drives No. 4 {uel injector.

Signal
With enginerunning:duty controlled

DrivesNo. 3luel injector.


DrivesNo.2 tuel injector.
DrivesNo. 1 fuel injector.
D ves secondaryheatedoxygen
sensorheater.
Drivesprimary heatedoxygen
sensor heater,

Groundforthe PCMcontrol circuit.


Ground for the PCMpower circuit.
Power sourcefor the PCMcontrol
circuit.
Drives IACV.
Drives EVAPpurge control
solenoidvalve.

DrivesIuel pump relay.


DrivesAy'Cclutch relay.
DrivesMlL.
Sendsalternatorcontrolsignal.

ICM(IGNITION
CONTROL Sendsignitionpulse.
MODULE)
Groundtor the PCMcontrolcircuit.
LG2(LOGICGROUND}
GROUND}
Groundlor the PCMpowercircuit.
PG2{POWER
Power sourcefor the PCMcontrol
IGP2{POWER
SOURCE}
circuit.
FAN
Drives radiator{an relay.
FANC(RADIATOR
CONTROL)

With ignition switch ON {ll): batteryvoltage


Withfully warmedup enginorunning:duty
controlled
With ignition switch ON lll): batteryvoltage
with fully warmed up enginerunning:duty
controll6d
Lessthan 1.0V at all times
With ignition switch ON (ll): batteryvoltage
With ignition switch OFF:0 V
With nginerunning:duty controlled
With enginerunning,enginecoolant
below 154'F(68"C):battery voltage
With enginerunning,enginecoolant
above 154"F(68"C):duty controlled
0 V for two secondsafter turning ignition
switch ON lll), then batteryvoltage
With comoressorON: 0 V
With compressorOFF:bafteryvoltage
With MIL turned ON: 0 V
With MIL turned OFF:bafteryvoltage
With tully warmed-upenginerunning:
battery voltage
load:0'
Duringdrivingwith smallelectrical
With ignition switch ON (ll): bafteryvoltage
With enginerunning:pulses
Lessthan 1.0V at alltimes
With ignition switch ON (ll): batteryvoltage
With engineswitchOFF:0 V
With radiatorfan running:0 V
With radiatorfan stopped:bafteryvoltage

*: USA

{cont'd)

www.emanualpro.com

11-67

Troubleshooting
PowertrainControlModuleTerminalArrangement-'97 Model (cont'dl
PCMCONNECTOR
B I25PI

Wire sideof femaleterminals

PCM CONNECTORB I25P}


Terminel
number

color

RED

8LU//EL

GRN/BLK

YEL

PNK

11

GRN/VVHT

12

WHT/BED
GRN/BLK

RED
16

Oescription

Signal

LS 1A/TCLUTCH
PRESSURE
CONTROL
SOLENOID
VALVE-)

DrivesA,/Tclutch pressurecontrol
solenoidvalve

With ignitionswitchON (ll):duty controlled

LS + (A"/TCLUTCH
PRESSURE
CONTROL
VALVE+)
SOLENOID
CONTROL
SHA(SHIFT
SOLENOID
VALVEA)

DrivesA,/Tclutch pressurecontrol
solenoidvalve

With ignitionswitchON (ll)rduty con


trolled

LCB (LOCK-UP
CONTFOL
VALVEB)
SOLENOID
LCA (LOCK.UP
CONTROL
VALVEA)
SOLENOID

ATPD3(Ay'T
GEAR
POSITION
SWITCH}
SHB(SHIFTCONTROL
VALVE8}
SOLENOID

ILU(INTERLOCK
CONTROL
UNITi
D4IND(04 INDICATOR
LIGHT}

In 2nd,R position.in 2nd and 3rd gearin


D4, D3 position: Batteryvoltage
In lst gearin D4,D3 position,in 4th gear
in D4 position:0 V
Driveslock-upcontrolsolenoid
With full lock-up;Bafteryvoltage
valveB,
With half lock-up:duty controlled
With lock'upON:batteryvoltage
Driveslock-upcontrolsolenoid
With lock-upOFF:0V
gear
position
DetectsA/T
switch In D3 position:0V
ln any otherposition:batteryvoltage
signal._
DrivesshiftcontrolsolenoidvalveB. In 1st,2nd position,in 1st and 2nd gearin
D4,D3 position:Batteryvoltage
In R position,;n 3rd gearin 04, D3,in 4th
gearin D4 position:0 V
Detectsinterlockcontrolunh signal. With ignitionswitchON (ll)and brake
pedaldepressed:battery voltage
With D4 indicatorlightturnedON:battery
DrivesDl indicatorlight.
voltage
With D4 indicatorlightturnedOFF:0 V
D r i v e ss h i f t c o n t r o l s o l e n o i dv a l v e A .

NMSG (MAINSHAFT
Groundtor mainshaftspeedsensor.
S P E E DS E N S O RG R O U N D }

14

1'l

BLU

18

BRN

22

GBN

23

BLU

24

YEL

25

LT GRN

www.emanualpro.com

NOTE:Standardbatteryvoltageis l2 V.
Terminal
name

11 - 6 8

NM (MAINSHAFT
SPEED
SENSOR)
ATPR(A"/TGEAR
POSITION
SWITCH)
ATP2(A./TGEAR
POSITION
SWITCH)
ATP1(4,,/TGEAR
POSTTTON
SWTTCH)
NCSG(COUNTERSHAFT
SPEEDSENSOR
GROUND)
NC (COUNTERSHAFT
SPEEDSENSOR)
ATPD4(M GEAR
POSITION
SWITCH)
ATPNP{A/TGEAR
POSITION
SWITCH)

Detectsmainshaftspeedsensor
srgnal,

With enginerunning:pulses

Detects A/T gear position switch


srgnal.

InRposition:0V
In any otherposition:batteryvoltage
In 2nd position:0 V
In any otherposition:batteryvoltage
ln lst position:0 V
In any otherposition:batteryvoltage

DetectsA/T gear position switch


s r gn a l ,
DetectsA/T gear position switch
s r gn a l ,
Groundtor countershaft
speed
sensor,
Detectscountershaftspeedsensor
srgnal.
DetectsA,/Tgear positionswitch
srgnal.
DetectsA/T gear positionswitch
signal.

With agnitionswitchON (ll),and lront


wheelsrotating:pulses
In D4 positionr0 V
In any otherposition:batteryvoltage
In parkor neutral:0V
In any otherposition:about5 V

C (31PI
PCMCONNECTOR

Wire sideof femaieterminals

C {31PI
PCMCONNECTOR
ferminal
number

't
2
3
4
5

Wire
color

NOTE:Standardbatteryvoltageis 12 V.
Terminal
name

P
CKFP(CKFSENSOR
SIDE)
P
CKPP(CKPSENSOR
BLU
SIDE)
P
TDCP(TDCSENSOR
GRN
SIDE)
P
CYPP(CYPSENSOR
YEL
SIDE)
ACS(A/CSWTTCH
BLU,frED SIGNAL)
SWITCH
STS(STARTER
BLU/ORN SIGNAL)
BLUiRED

BRN

LT BLU

CHECK
SCS(SERVICE
SIGNAL)
K-LINE

10

BACK
VBU(VOLTAGE
WHT/BLU U P )

11

(CKFSENSORM
WHT/RED CKFM

Doscription

Signal

DetectsCKFsensor.

: ulses
W i t h e n g i n er u n n i n g p

Detects
CKPsensor.

With engine running: pulses

DetectsTDCsensor.

With engine running: pulses

DetectscYP sensor.

With engine running: pulses

DetectsA,/Cswitchsignal.

With AJCswitchON:0 V
With A,/CswitchOFF:batteryvoltage
With starterswitchON (lll): baftery
voltage
With stanerswitchOFF:0 V

Detectsstarterswitchsignal.
Detectsservicecheckconnector
signal(thesignalcausinga DTC
indication)
Sendsand receivesscantool
srgnal.
Powersourcetor the PCM
controlcircuit.Powersourcefor
the DTCmemory

With the connectorconnected:0 V


With the connectordisconnected:about
5 V or battery voltage

With ignitionswitchON (ll):pulses


Batteryvoltage at all times

Ground for CKFsensorsignal.

SIDE)

12

WHT

13

RED

14

BLK

I\4 Groundlor CKPsensorsignal.


CKPM(CKPSENSOR
SIDE)
M
TDCM(TDCSENSOR
Groundfor TDCsensorsignal.
SIDE}
M
Groundfor CYPsensorsignal.
CYPM(CKPSENSOR
SIDE}
PSPSW(P/SPRESSURE DetectsPSPswitch signal.

swtTcH)

16

GRN

17

WHT/RED

18

SPEED
VSS(VEHICLE
BLUA/VHT SENSOR)

FR
ALTF(ALTERNATOR
SIGNAL)

FRsignal.
Detects
alternator
VSSsignal.
Detects

At idle with steeringwheel in straight


ahead position:0 V
At idle with steeringwheel at full lock:
battery voltage
With fully warmed up engine running:
0 V-batteryvoltage {dependingon
electricalload)
Wirh ignitionswitch ON (ll) and front
wheels rotating:cycles0 V - 5 V or battery voltage

(cont'd)

www.emanualpro.com

Troubleshooting
PowertrainGontrolModuleTerminalArrangement-'97 Model (cont'd)
O {16PI
PCMCONNECTOR

PCM CONNECTOR
D (I6P)
f.rminal
Wir! color
numbcr
1

RED/BLK

Trminal nam6
TPS ffHROTTLE
POSITION
SENSOR}

Wiresideof f6maleterminals

NOTE: Standard battery voltage is 12 V.


Description
DetectsTP sensor signal.

ECT(ENGINECOOLANT DetectsECTsensor signal.

RED,4/VHT TEMPERATURE
SENSOR

MAP(MANIFOLD
DetectsMAP sensorsignal.
RED/GRN ABSOLUTE
PRESSURE
SENSOR)
VCCl (SENSOR
YEURED
VOLTAGE)
E

GRN/WHT

Signal
With throttlefullv oDen:about4.8V
With throttlefullv closed:about0.5V
With ignitionswitchON {ll):about
0.1- 4.8V (dependingon engine
coolanttemperature)
With ignitionswitchON (ll):about3 V
At idle;about 1.0V
(dependingon enginespeed)

Powrsourcefor MAP sensor.

With ignitionswitchON (ll):about 5 V


With ignitionswitchOFF:0 V

BKSW(BRAKE
SWITCH)

Detectsbrakeswitch signal.

With brakepedalreleased:0V
With brake pedal depressed:battery
voltage

(PRIMARY
PHO2S
HEATED
OXYGEN
SENSOR
1)
SENSOR

Detectsheatedprimary oxygen
sensor(sensor1) signal.

With throttlefully openedfrom idlewith


fully warmed up engine:above0.6V
With throttlequicklyclosed:below
0.4v

IAT (INTAKEAIRTEM.
PERATURE
SENSOR)

DetectsIAT sensor signal.

With ignitionswitchON lll): about


0.1- 4.8V (dependingon intakeair
temperaturel

WHT

RED//EL

10

YEUBLU

VCC2(SENSOR
VOLTAGEI

Providessensor voltage.

With ignitionswitchON (ll):about5 V


With ignitionswitchOFF:0 V

11

GRN/BLK

SG2(SENSOR
GROUND)

Sensorground.

Lessthan 1.0V at all times

12

GRN/WHT

SGl (SENSOR
GROUND)

Groundfor MAP sensor.

Lessthan 1.0V at all times

13

14

SHO2SSG
(SECONDARY
HEATED
RED/YEL
OXYGENSENSOR,
SENSOR2 GROUND)
SHO2S(SECONDARY
HEATEDOXYGEN
WHT/RED
SENSOR,
SENSOR2)

Groundfor secondaryheated
orygen sensor(sensor2).

Detectssecondaryheated
orygen sensor(sensor2)
signal,

With throttlefully openedfrom idlewith


fully warmed up engine;above0.6V
With throttlequicklyclosed:below

0.4v
EL (ELD)
16*

GRN/RED

1 -7 0

www.emanualpro.com

DetectsELDsignal.

With parkinglightsturnedon at idle


about2.5- 3.5V
With low beamheadlightsturnedon
a t i d l e :a b o u t1 . 5- 2 . 5 V

ControlModuleTerminalArrangement- 38 - 00 Models
Engine/Powertrain
A (32P}
ECM/PCMCONNECTOR
5

sca

,/./
t5

,/

It

sTs

l,/
n

2l
s!u

CI

Wire sideot femaleterminals

A {32P)
ECM/FCMCONNECTOR

NOTE:Standardbafteryvoltageis
D93cription

BLU
LT GRNMHT

5',

BLU

RED/YEL

ELIOWHT

10

BRN

l4'r

GRN/8LK
GRNI/EL

17

AL|(/RED

18

GRN/ORN

19

BLU

2WBS{EVAPBYPASS
S O L E N O IV
DA L V E )

Drives EVAP bvoass solonoid valve.

W i t h i g n i r i o n s w i t c h O N { l l ) rb a t t e r y v o l t a g e

VSV {EVAPCONTROLCANIS
TEBVENTSHUTVALVE)
EO N T R OSL I G '
C R S( C R U I SC
NAL)
PCS(EVAPPURGECONTROL
SOLENOIDVALVE)

D.ivesEVAPcontrolcanislervent shut

With ig^ition switch ON (ll): battery voltage

ShiftOownsignalinputfrcmcruisecon

W h e nc r u i s ec o n t r o il s u s e d :p u l s e s

Drives EVAP purge controlsolonoid valve.

S O 2 S H T (CS E C O N D A R V
HEATEDOXYGENSENSOR
HEATERCONTROL)
SCS(SERVICE
CHECXSIGNAL)

Drivessacondaryheatedoxygen sensor

W i t h e n g i n sr u n n i n ge, n g i n ec o o l a n tb, e l o w1 5 4 ' F


(68'C)rbatteryvoltage
W i t h e n g i n er u n n i n ge, n g i n ec o o l a n ta, b o v e1 5 4 " F
{6a'C}rduty conl.olled
With ignitionswitch ON (ll): baneryvoltage
W i t h f u l l yw a r m e du p e n g i n er u n n i n gd: u t y

Detects seNics check conneclor signal


(he signalcausinga DTC indicatjon)

w i t h r h el e r m i n a cl o n n e c t e d :v0
W i t ht h e r e r m i n a l d i s c o n n e c t e d r a b5ovu to r

D 4 I N D( D 4 I N D I C A T O R ) + 3
D I N D( D I N D I C A T O R T I

DrivesD4*3.Dr'indicaior light.

W , r h0 4 ' , O " i n d r c a t ol ri g h tt u r n e dO \ b a t t e r ,

F L R( F U E LP U M PR E L A Y )

Drivssfusl pump relay.

0 V f o r i w o s e c o n d sa f t e r r u ' n i n 9 i g n ' l i o n s w i l c h
ON lll), then banery voltage

ACC(I/C CLUTCHRELAY}

Drivesl,/C clurch rclay.

INDICA.
MIL (MALFUNCTION
TORLIGHT)
EPEED
N E P( E N G I N S
PULSE)

DrivsMlL.

W i t hc o m p r e s s oOr N r 0V
With compressorOFF:batteryvoltage
W i t h M l L t u r n e dO N : 0 V
With MIL turned OFF:batteryvoltage
: ulses
W i t hs n g i n er u n n i n 9 p

FANC{RADIATOR
FANCON
TROL)

Drivesr6diatorfan rslay.
S e n d sa n d r e c e i v ssc a nt o o l s i g n a l .
Detectssecondaryhatdoxygensensor

20

GRN

21

8LU/t/EL

K-LINE

23

WHT/RED

SHO2S(SECONDARY
HEATED
SENSOR2i
OXYGENSENSOR.

21

BLU/WHT
GBN

2f

BLU/BEO

2A'\

WHT/NED

29

Signal

W i t h D 4 * 3D
, * . i n d i c a t olri g h tt u r n e dO F F r 0V

16

26

'12V.

LT GRN

Outputsenginespsed pulse.

With throttlefully openedfrom idle wilh fully


w a l m e du p e n g i n ea: b o v e0 . 6V
with rhrottlequicklyclosed:below 0-4V
Whh staner switch ON (lll): batlery voltage
With srarterswitch OFF:0 V

SWITCHSIG,
STS (STARTER
NAL}

Dotoctssrarterswitch signal.

PSPSW{P/SPsESSUFE
SWITCHSIGNAL)
ACS (Ir'C SWTCH SIGNAL}

DetecrsPSPswitch signal.

At idle with steeing whel in stBighl aheadposition:0 V


At idls with nee ng wheel al full lockr banory voltage

Dtectsly'C switch signal.

With Ay'Cswitch ON:0 V


With l/C swilh OFF:about 5 V

SLU {INTERLOCK
CONTROL
UNIT)
P T A N K( F U E LT A N KP R E S '
S U R ES E N S O R )
E L( E L D }

Orives interlock control unil.

With ignilion switch ON (ll)and brakepedal


depressed: battery vohage

Detoctsfueltank pressuresensorsignal.

W i t h a g n i t i o ns w i t c h O N ( l l ) a n d f u e l f i l l c a p
opensd; about 2.5 v

DetectsELDsignal.

W i r hp a a i n gr i g h t s t u m eodn a t i d l e : a b o u2t. 5- 3 . 5V
W i t h l o w b e a mh e a d l i g h ttsu m e do n a t i d l e :
a b o u t1 . 5 - 2 . 5 V

BKSW(BRAKESWTTCH)

Dstcts brake switch signal.

W i r h b r a k e p e d a l r e l e a s e d : 0V
With brake pedal depressed: battery vollage

GBN/FED
GRN/WHT

W i t h r a d a a t of ar n r u n n i n g : 0V
With radaatorfanstopped:batteryvollage
With ignition switch ON (ll): p'rlses

13: '98 modsl


15: USA

www.emanualpro.com

(cont'd)

11-71

Troubleshooting
'98 - 00 Models
Engine/Powertrain
ControlModuleTerminalArrangement(cont'd)
B {25PI
ECM/PCMCONNECTOR

ECM/PCMCONNECTORB I25PI
Ierminal
Wire color
numbt
1

YEUBLK
BLK
RED
BLU
YEL

Wiresideof femaleterminals

NOTE:Standardbafteryvoltageis l2

Terminsl name

Description

IGPl(POWER
SOURCE) Powersourcefor the ECM/PClvl with ignitionswitchON (ll):batteryvoltage
controlcircuit.
with ignitionswitchOFF:0V
RR O U N D } Ground for the ECM/PClvlcontrol Lessthan 1.0V at all times
P G 1( P O W EG
circuit.

l N J 2( N o .2 F U E LI N J E C - DrivesNo. 2 Iuel injector.

roR)

YEUBLK

10

BLK

PG2(POWER
GROUND} Ground for the ECM/PCMcontrol

'

BRN

l N J l ( N o . 1 F U E LI N J E C
TOR)

crrcurt.
DrivesNo. l tuel injector.

RED

PNK

19*.

20

BRN/BLK

With ignition switch ON (ll): battery


voltage
With engine running: pulses
With ignition switch ON (ll):duty
controlled

A,/Tclutchpressurecontrol
solenoidvalvepowersupply
positiveterminal
Drives OVER-DRIVE
OFF
indicatorlight.

LG1(LOGIC
GROUND)

control Lessthan 1.0V at all times


Groundfor the ECM/PCM
circuit.
Powersourcefor the ECM/PCM Batteryvoltage at all times
controlcircuit.
PowersourcefortheDTCmemory.

BRN/BLK

LG2(LOGIC
GROUND)

23

BLVBLU

IACV{IDLEAIR CON.
TROLVALVE)

11-72

With engine running:duty controlled

LS+(A,,IT
CLUTCHPRES
SURECONTROL
SOLENOIDVALVE+ SIDE)
ODIND(OVER-DRIVE
OFFINDICATOR}

22

www.emanualpro.com

With ignition switch ON (lll: baftery


voltage
With ignition switch OFF:0 V
'1.0
Lessthan
V at all times

Sendsignition pulse.

VBU (VOLTAGE
BACK
WHT/BLU U P )

*2t MlT
*3: '98 model
"4: '99 - 00 models

With ignition switch ON (ll):duty


controlled

rcM {rGNrTroN
coN-

YEUGRN TROL
MODULE)

17*1

With engine running:duty controlled

l N J 31 N o .3 F U E LI N J E C - DrivesNo. 3Iuel jnjector.


TOR)
l N J 4{ N o . 4 F U E LI N J E C - DrivesNo. 4 fuel injector.
TOR)

LS- (A"/TCLUTCHPRES. A,/Tclutchpressurecontrol


SURECONTROL
SOLE, solenoidvalvepowersupply
_ SIDE)
NOIDVALVE
negative
terminal.
IGP2IPOWERSOURCE) Powersourcefor the ECN,I/PCM
controlcircuit.

WHT

8*1

Signal

Ground for the ECN4/PCM


control
ctrcutt,
DrivesIAC valve.

With OVER-DRIVE
OFFindicatorlight
turned ON: 0 V
OFFindicatorlight
With OVER-DRIVE
turned OFF:battery voltage

Lessthan 1.0V at all times


With engine running: duty controlled

ECM/PCMCONNECTOFC (31PI

C (31P)
ECM/PCMCONNECTOR

Wire sideo{ femaleterminal

Termidal

NOTE:Standardbatteryvoltageis 12V.
D.3cription

8LI(WHT

Signal

HEATED
POzSHTC{PRIII4ABY
OXYGENSENSORHEATER
CONTROL)

Drivssprim6ry h$ted oxygsn sensor

Wilh ignition switch ON (ll): baneryvoltsge


With ftrllywarmsd up ngine runnang:duty

CON,
ALTC(ALTERNATOR
TROL)

Sondsalternalorcontrol signsl.

With fully wafmod up ngine rnningrbanry


voltago
Du ng driving with small elsctricallo6d:0 v

2"

WHT/GBN

3'1

FED/8LU

K S( K N O C K
SENSOR)

DstectsKS signal.

With engine knockang:pulses

WHT/RED

FRSIGALTF(ALTERNATOR
NAL}

DetectsalternatorFRsignal.

W t h f u l l y w a r m e du p n g i n er u n n i n g : 0V - b a t t e r y
voltag{dpendingon slsctricalload)

GRN,4trHT

R8 0 U N D }
S G 1( S E N S O 6

Groundfor l/tAP sensor.

Lssthan 1.0v 6t all times

CKPP(CKPSENSOFP SIDE)

DatclsCKPs6nsor.

W i t h n g i n r u n n i n gpr u l s s

CKPI.,I|
{CKPSENSOFM SIDE)

Groundfor CKPsnsor.

15

PHO2S{PRIMARYHEATED
SENSOR1)
OXYGENSENSOR,

Detoctspfimary he6t6doxygenssnsor
{sonso1
r )signal.

with ihfottls fully openedfrom idle with fully,


walm6d up engins:above0.6 V
With throttloquicklyclossd:below 0.4 v

D6tectsMAP snsorsign6l.

W i t h i g n i t i o ns w i t c hO N ( l l ) : a b o u3t V
A t i d l s :a b o u l1 . 0V { d s p s n d i n o
g n e n g i n es p e e d )

VCCl {SENSORVOLTAGE)

Power soufce to MAP snsor.

With ignition switch ON (ll): about 5 V


With ignition switch OFF:0V
W i t h e n g i n ef u n n i n g P
: ulses

BLU

17

RED/GRN

MAP (MANIFOLDABSOLUTE
P R E S S U RSEE N S O R )

18

GRN/BLK

B NOUNDi
S G 2( S E N S O G

19

YEUBED

Lsssthan 1.0V at all tims

20

GRN

TDCP{TDCSENSORP SIDE)

DerecisTDCsensor.

2l

RED

TDCM ITDCSENSORM SID)

Groundfor TDCsensor.

22

BLU/RED

PSIDE)
C K F P( C K FS E N S O R

DstsctsCKFsnsor.

With sngins running: pulsss

23

BLU/WHT

VSS (VEHICLE
SPEEDSEN-

vss signal.
Dstscrs

25

RED//EL

IAT (INTAKEAIR TEMPERA'


T U R ES E N S O B )

DetactsIAT sensorsignal.

W i t h i g n i t i o ns w i t c hO N ( l l ) a n df r o n tw h e e l s
rotaringrcyclss0 v- 6bout 5 V or banryvoltage
With igniiion switch ON (ll):about 0.1 - 4.8 V
(dpndingon iniate air tmpraturc)

26

REO/WHT

ECT{ENCINECOOLANT
TEMPERATURE
SENSOR)

oetsctsECTsensorsignal.

With ignition switch ON (ll): about 0.1 4.8 V


{dopondingon 6ngincoolanllemper6tu16)

27

RED/BLK

TPS (THROTTLE
POSITION
SENSOR)

DotectsTP sensorsignrl.

with rhrottls fully opn: aboui 4.8 v


with throtrl6fullyclosed: about 0.5 v

2A

YEUBLU

VCC2lSENSOR
VOLTAG}

Providssnsorvoltage.

With ignilion switch ON (ll):about 5 V


Whh ignitionswitch OFF:0 V

29

YEL

CYPPICYPSENSO8P SIDE)
CYPM(CYPSENSORM SIDE)

DsrsctsCYPsensor.

With ngins runningrpulsss

Groundfor CYPsansor.

30

BLK

soR)

WHT/RED
CKFM{CKFSENSORM SIDE)
11.AfT 13. '94 model
'2:M/T 14:'99- 0omodsls
.5: USA
31

6.ound lof CKFssnsorsignal.

(cont'd)

www.emanualpro.com

11-73

Troubleshooting
Powertrain Control Module Terminal Arrangement -'98

- 00 Models (cont'dl

ECM/PCMCONNECTOR
D {16P}

PCM CONNECTORD (16P)

Wire sideof lemaleterminals

NOTE:Standardbatteryvoltageis 12V.
Ds4ription
Orivslock'up conrrolsolenoidvalve A.

With lock-upON: b6tteryvoltags


W i t h l o c k - u pO F F : 0V

S H B( S H I F T
CONTROL
SOLENOIO
VALVEB)

Drivesshift controlsolenoid valve B.

In 1st,2nd position,in lst and 2nd gear anD4, D3


(D)11position:batteryvohag
In P, R, N position,in 3rd geaf in D1, D3 (D)*.
position,in 4th gear in D4 (D)*rpositionr0V

GRN/BLK

LC 8 (LOCK,UP
CONTROL
SOLENOIDVALVEB}

Driveslock up controlsolenoidvalve B.

With full lock-up:8atteryvoitage


With half lock'uprdutycontrolled

BLK/YEL

VBSOL(BATTERY
VOLTAGE
F O RS O L E N O IV
DA L V E }

Powrsourceof solenoidvalvs.

With ignition switch ON (ll): batteryvoltage


With ignition switch OFF|0 V

ATPR{AI GEAEPOSITION
SWITCH)

DelsclsA/T gear posrtionswirch srgnal.

SHA (SHIFTCONTROL
SOLENOIDVALVEA)

Drivesshift conrrolsolenoidvalvp A.

In 2nd, R position,an2nd and 3rd ge6r in D4, D3


(D)r' posilion:batleryvoltage
In 1st gear in 04, 03 {D)}. position,in 4th gear in
D 4 ( D ) * .p o s i t i o ni,n P , N p o s i t i o n : 0V

ATPD3(AT GEARPOSITION

DetectsA,/Tgar poshionswirchsign6l.

I n D 3 p o s i t i o n : 0V
h any other posiiion:banryvoltage

YEL

GBN,M/HT

2+1

Sign!l

LCA {LOCK,UPCONTBOL
SOLENOIDVALVEA)

BLU,ryEL

PNK

In any other positjon:battsryvoltage

swrTcH)
O D S W( O V E R . D B I V
SE
W I T C H ) DetectsOVEF-DRIVE
swirch sagnal.

PNK

9''

YEL

10.,

BLU
RED

With Ovor Drivs OFF(O/DOFFindicatorlight


t u r n e dO N ) :0 V
Wilh Ovsr Drivs ON (O/DOFFindicrto.lasht
turned OFF):about 5 V

ATPDI}3,O}I {AT GEAR


POStTtONSWTTCH)
NC (COUNIERSHAFT
SPEED
SENSOR)

DotctsA/T gar positionswirch signal.

I n D 4 r 3O
, * . p o s i t i o n : 0V
In any other posilion:batteryvoltage

Detsctscounlrshaftspeedsensor

With ignition switch ON (ll), and ffonr wheels

N M I I V A I N S H A FSTP E E D
SENSOB)

Detectsmainshaftspeedsensorsign6ls.

W i l h e n g i n er u n n i n gp: u l s e s

N M S G{ M A I N S H A F T S P E E D Groundfor mainshaftspeedsensorSENSOB
GBOUND)
'13*1

LT GRN

8LU
BRN

15.'
t6''
i1:A/T
'2: M/T

GRN
*3:'98 model
*4:'99
00 models

11-74

www.emanualpro.com

ATPNP(AT GEARPOSITION

DelectsA,/Tgear positionswitch signat.

swtTcH)
ATP2(AT GEARPOSFION

DstectsA,/Tgear positionswitch signal.

swrTcH)
ATP1{AT GEARPOSITION

h any othsr position:batteryvoltsgs


DetsctsA/T gear positionswitch signal.

swrTcH)
N C S G{ C O U N T E R S H A F T
SPEED
SENSOR
GROUND}

I n p a r ko r n u t r a l : 0V
h any other posilion:about 5 V

In any other position:htteryvoltage


Grouodfor counterchaftspedsnsor.

DiagnosticTrouble Code (DTCIChart


DTC
(MlLindication*l

Detection ltem

ProbableCause

Pago

P0107

(3)

ManifoldAbsolute
Pressu.eCircuit
Low Input

Openor short in MAP sensorcircuit


MAP sensor
ECMiPCM

't'l-90

P0108

{3)

ManifoldAbsolute
PressureCircuit
H i g hI n p u t

Open in MAP sensorcircuit


MAP sensor
ECM/PCM

11-92

P 0 11 1 * 3

(10)

IntakeAir
TemperatureCircuit
Range/Performance
Problem

P0112

(10)

lntakeAir
TemperatureCircuit
Low Input

Short in IAT sensorcircuit


IAT sensor
ECM/PCM

11-96

P0113

(10)

lntakeAir
TemperatureCircuit
H i g hl n p u t

Open in IATsensorcircuit
IAT sensor
ECM/PCM

'I 1-97

P0116

(86)

EngineCoolant
TemperatureCircuit
Range/Performance
Problem

ECTsensor
Coolingsystem

P0117

(6)

EngineCoolant
TemperatureCircuit
Low Input

P0118

(6)

EngineCoolant
TemperatureCircuit
H i g hI n p u t

Shortin ECTsensorcircuit
ECTsensor
ECM/PCM
Openin ECTsensorcircujt
ECTsensor
ECM/PCM

P0122

\11

ThrottlePosition
Circuit
Low Input

Openor short in TP sensorcircuit


TP sensor
ECM/PCM

11-103

P0123

l7l

ThroftlePosition
Circuit
H i g hI n p u t

Openin TPsensorcircuit
TPsensor
ECM/PCM

11-107

PrimaryHeatedOxygenSensor
Circuit Low Voltage
(Sensor1)

P0131

(1)

P0132

(1)

PrimaryHeatedOrygen Sensor
CircuitHighVoltage
(Sensor1)

P0133

(61)

Primary HeatedOxygen Sensor


Slow Response
(Sensor1)

(41)

PrimaryHeatedOxygenSensor
Heater
CircuitMalfunction
{Sensor1)

P0135

. IATsensor
11-95

Short in PrimaryHO2S{Sensor1)
circuit
PrimaryHO2S(Sensor1)
Fuelsupplysystem
ECM/PCM
Openin PrimaryHO2S(Sensor1) circuit
PrimaryHO25(Sensor1)
ECM/PCM
. PrimaryHO2S(Sensor1)
. Exhaustsystem
. Openor short in PrimaryHO2S(Sensor
'l) heatercircuit
. ECM/PCM

11-99

11 - 1 0 0

11-101

11-110

' 1 11 1 3

11 'I16

11-12'l

*: TheseDTCSwill be indicatedby the blinkingof the MalfunctionIndicatorLamp (MlL)with the SCSserviceconnector


connected.
**: The E (E)*u indicatortightand the MalfunctionIndicatorLamp(MlL)may come on simultaneously.
*1' AIT *3 '97 model +5;'99 - 00 models
*2: MlT *4:'98 model
{cont'd)

www.emanualpro.com

11-75

Troubleshooting
DiagnosticTrouble Code (DTCIChart (cont'd)
DTC

Detectionhem

lMlL indicationl
P0137

(63)

Secondary Heated Oxygen Sensor


Circuit Low Voltage
{ S e n s o r2 )

P0138

(63)

S e c o n d a r yH e a t e dO x y g e nS e n s o r
C i r c u i tH i g h V o l t a g e

P0139

{63)

SecondaryHeatedOxygenSensor

Probable Caus.
Shon in Secondary
HO2S(Sensor2) circuat
Secondary
HO2S(Sensor
2)
ECM/PCM
Openin Secondary
HO2S(Sensor
2)circuit
HO2S(Sensor2)
Secondary
EC|\il/PCM
HO2S(Sensor
2)
Secondary

Page
'n-1t7

1 11 1 8

11-120

lSensor2i
P0141

P0r71

(65)

Second6ry Heated Oxygen Sensor Heater


C i r c u i tM a l f u n c t i o n
( S e n s o r2 )

Openorshonin Secondary
HO2S(Sensor
2)
heatercircuit
EC|V/PCtu

System Too Lean

Fuel supply system


P r i m a r yH O z S( S e n s o r1 )

(45)

Contaminated fuel

't2l

11

1 1124

E x h a u s tl e a k a g e
System Too Rich
P0112

(45)

Fuelsupplvsystem
PrimaryHO2S(Sensor
1)
11124

Contaminated
fuel
Random Mistire
and

Po3ol
P0302
P0303
P0304

ltr \
112|
173i
\74t

P0301
P0302
P0303
P0304

/71 \
112|
173|
\74l

P0325*5

{23)

P033s

{4}

P0336
P0420

P0441*3

I A Cv a l v e
C o n t a m i n a t e df u e l
L a c ko f f u e l

11-126

C y l i n d e r1
C y l i n d e r2
C y l i n d e r3
- C y l i n d e r4
Misfire Detected

F u e li n j e c t o r
Fuel injector circuit
lgnition system

Knock Sensor {KS) Circuit Malfunction

Open or shon in Knock Sensor (KS) circuit


K n o c kS e n s o r( K S )
ECM/PCt\4

11-130

Crankshaft
Position
SensorCircuit

Crankshaft Position Sensor


Crankshaft PositaonSensor circuit
ECl\,l/PCl\,'!

11-131

(4)

Crankshaft Position Sensor


Range/Performance

Crankshaft Position Sensor


Timing belt skipped teeth

11,131

{67)

Catalyst System Efficiency Below


Threshold

Three Way Catalytic convener


Secondary HO2S {Sensor 2)

Evaporative Emission
ControlSystem
Insulficient Purge Flow

EVAP Purge Control Solenoid valve


EVAP Purge Control Solenoid valve circuit
Throttle gody (purge port)
Tubing
PCM

'It 205

F u e l T a n kP r e s s u r eS e n s o rC i r c u i t
Bange/Performance

FuelTank PressureSensor
ECM/PCM

t't-208

(91i

Fuel Tank PressureSensor


Circlit Low Input

{91)

F u e l T a n kP r e s s u r eS e n s o rC i r c u i t
HighInput

OpsnorShortin FuelTankPressure
Sensorcircuit
FuelTankPressureSensor
ECM/PCt\4
Openin FuelTankPressureSensorcircuit
FuelTankPressure
Sensor
ECt /PCt\.1

(92)

P0451*5

P0453*r.5

lgnition system
Fuel supply system

't't 127

't1-200

11-209

11-211

*: TheseDTCSwill be indicatedby the blinkingo{ the MalfunctionIndicatorLamp (MlL)with the SCSserviceconnector


connected.
**: The E (El*s indicatorlight and the MalfunctionIndicatorLamp{MlL)may come on simultaneously,
*1; A/T *3: '97 model *5: '99 - 00 models
*2: MlT *4: '98 model

11-76

www.emanualpro.com

DTC
(MlLindicationl

Dotection ltom

P0500

t17)*,

VehicleSpeed
SensorCircuit
Malfunction

P0501

l17J*1

VehicleSpeed
SensorCircuit
Malfunction

P0505

(14)

P0700
P0715
PO720
P0730
P0740
P0753
P0758

ldle Control
System
Malfunction
Automatic
Transaxle

ProbableCause
VehicleSpeedSensor
VehicleSpeedSensorcircuit
ECtVI
VehicleSpeedSensor
VehicleSpeedSensorcircuit
PCM
IACvalve
ThrottleBody
Fastidlethermovalve*1

Page
11 - 1 3 5

11-135
' ]1 150

Section l4

P1106

(13)

P1107

(13)

P1108

(13)

P1121

(7)

P1122

(7)

P112a

(5)

P1129

Barometric
Pressure
Circuit
Range/Performance
Problem
Barometric
Pressure
Circuit
LowInPut
Barometric
Pressure
Circuit
HighInpur

(Barosensor)
ECM/PCM
11-137

. ECM/PCM
{Barosensor)
11-137

ECM/PCM
{Barosensor)
11,137

Throttle Position
Lower Than
Expected

. TPsensor

ThrottlePosition
H i g h eTr h a n
Expected
ManifoldAbsolute
PressureLowerThan
Expected

' TP sensor

(5)

ManifoldAbsolute
PressureHiqherThan
Expected

' MAPsensor

P1297

(20)

Electrical Load
DetectorCircuit
Low Input

ElectricalLoadDetector
ElectricalLoadDetectorcircuit
ECM/PCM

11 -1 3 8

P1298

(20)

Electrical
Load
Detector
Circuit
HighInput

ElectricalLoad Detector
ElectricalLoad Detectorcircuit
ECM/PCM

11-140

Random lvlisfire

lgnitionsystem
Fuelsupplysystem
MAPsensor
IACvalve
fuel
Contaminated
Lackoffuel

11-126

P1300'3
P0301
P0302
P0303
P0304

7l
72
13
14

11-109

11-'109

. MAPsensor
11-94

1l-94

*: TheseDTCSwill be indicatedby the blinkingof the MalfunctionIndicatorLamp {MlL}with the SCSserviceconnector


connected.
**:The E (E])+sindicatorlight and the MalfunctionIndicatorLamp(MlL)may come on simultaneously.
*1:A,./T "3: '97 model +5:'99 - 00 models
*2: M/T *4:'98 model

{cont'd)

www.emanualpro.com

11-77

Troubleshooting
DiagnosticTroubleCode(DTCIGhart(cont'd)
DTC
{MlLindication}

Detection ltem

ProbableCause

154)

Crankshaft
Speed
Fluctuation
Sensor
Intermittent
Interruption

. CKFsensor

P1336
P1337

i54)

Crankshaft Speed
FluctuationSensor
No Signal

P1359

(8)

CKFsensor
CKFsensorcircuit
ECM,FCM
' CKP/TDC/CYP
sensorcircuit

P1361

(8)

P1362

(8)

P1381

(9)

P1382

(9)

CrankshaftPosition/TooDead
CenterSensorrcylinder
Position
ConnectorDisconnection
Top DeadCenter
SensorIntermittent
Interruption
Top Dead Center
SensorNo Signal

CylinderPositionSensor
Intermittent
Interruption
Cylinder
PositionSensor
No Signal
Evaporative
Emission
ControlSystemLeakDetected
(FuelTank
System)

P1456n.*

{90}

Evaporative
Emission
ControlSystemLeakDetected
(EVAPControlCanister
Svstem)
Pr457n.s

{90)

P1508

(14)

ldleAir Control
ValveCircuit
Failure

Pr607

(-)

EngineControlModule,Powertrain
ControlModule InternalCircuit
FailureA

Pagc
11-142

11-142

11-146

11-131

TDCsensor
TDCsensorcircuit
ECM/PCM
. CYPsensor
CYPsensor
CYPsensorcircuit
ECM/PCM
F u e l f i lcl a p
Vacuumconnection
Fueltank
Fueltankprossure
sensor
EVAPbypasssolenoidvalve
EVAPtwo way valve
EVAPcontrolcanistervent shut valve
EVAPcontrolcanister
EVAPpurgecontrolsolenoid
valve
Vacuumconnection
EVAPcontrolcanister
Fueltankpressure
sensor
EVAPbypasssolenoidvalve
EVAPtwo way valve
EVAPcontrolcanister
ventshutvalve
Fueltank
EVAPpurgecontrolsolenoid
valve
IACvalve
IACvalvecircuit
ECM/PCM
. ECM,FCM

11-131

11-131
11-131

11-213

11-219

11-152

11-147

P1705
Automatic
P1706
Transaxle
P1753
Section'14
P1758
P1768
r: TheseDTCSwill be indicatedby the blinkingoJ the MalfunctionIndicatorLamp (MlL)with the SCSserviceconnector
connected.
**: The Di (E)*5 indicatorlight and the MalfunctiontndicatorLamp (MlL)may come on simultaneously.
*1: A[f
*3;'97 model *5: '99 - 00 models
*21M/f *4: '98 model

11-7 8

www.emanualpro.com

How to ReadFlowcharts
A flowchartis designedto be usedfrom startto final repair.lt's likea map showingyou the shortestdistance.But beware:
lf you go off the "map" anywherebut a "stop" symbol,you can easilyget lost.

brARn
tw"t
t.-OotO
FcTloNl
@
fS-OPl
(boldtype)

Describes
the conditionsor situationto starta troubleshooting
flowchart.
Asksyou to do something;performa test,set up a conditionetc.
Asksyou aboutthe resultof an action,then sendsyou in the appropriatetroubleshooting
direction.
The end of a seriesof actionsand decisions,describesa final repairactionand sometimesdirectsyou to
an earlierpart of the flowchartto confirmyour repair.

NOTE:
. The term "lntermittentFailure"is used in thesecharts.lt simply meansa systemmay have had a failure,but it checks
out OK at this time. lf the MalfunctionIndicatorLamp (MlL)on the dash does not come on, checkfor poor connections
or loosewires at all connectorsrelatedto the circuitthat you are troubleshooting(seeillustrationbelow).
. Most of the troubleshootingflowchartshave you resetthe EngineControlModule (EcM)/Powertrain
ControlModule
(PCM)and try to duplicatethe DiagnosticTroubleCode(DTC).lf the problemis intermittentand you can't duplicatethe
code,do not continuethoughthe flowchart.To do so will only resultin confusionand, possibly,a needlesslyreplaced
ECM/PCM,
o "Open" and "Short" are common electricalterms.An open is a breakin a wire or at a connection.A short is an accidental connectionof a wire to ground or to anotherwire. ln simple electronics,this usuallymeanssomethingwon't
work at all. In complexelectronics(likeECM'S/PCM'S),
this can sometimesmeansomethingworks,but not the way it's
suooosedto.

LOOSE

www.emanualpro.com

11-79

PGM-FISystem
SystemDescription
INPUTS
CKP/TDC/CYP
Sensor
CKFSensor
MAP Sensor
ECTSensor
IAT Sensor
TP Sensor
PrimaryHO2S
SecondaryH02S

vss

KS*5
BAROSensor
ELD*6
StarterSignal
ALT FRSignal
Air ConditioningSignal
Ay'TGearPositionSignal*1
BafteryVoltage(lGN.1)
BrakeSwitchSignal
PSPSwitchSignal
*5
FuelTankPressuae
Sensor*4.

ENGINECONTROL
MODULE(ECM)/
POWERTRAIN
MODULE(PCM)
CONTROL

|iuel 1"j""- Th,rhg""d Drrafr";-l

OUTPUTS
FuelInjectors
PGM-FlMain Relay(FuelPump)
MIL
IACValve
Ay'CCompressorClutchRelay
RadiatorFanRelay
CondenserFanRelay
ALT

tcM
Et*-.nt"tdt"cont.orl

to,r*,c;;trffi;]
.
l.----.---:.
Lrgnrnon|lmrngLonrrorI

B*k',p Fr""il]
Ecir/PcM
m;"t-ll-r*'io*l

Countershaft
SpeedSensor*1
MainshaftSpeedSensor*r
OVER-DRIVE
SwitchSignal*s

EVAPPurgeControlSolenoid
Valve
PrimaryHO2SHeater
SecondaryH02S Heater
EVAPBypassSolenoidValve*a*5
EVAPControlCanisterVent Shut
DLC
Lock-upControlSolenoidValve*l
Shift ControlSolenoidValve*1
Ay'TClutch PressureControl
SolenoidValve*1
D4 IndicatorLight'1*3,*a
D IndicatorLight,l *5
OVER-DRIVE
OFFIndicator
Lighl*t *:
* 1 :A / T
'2: M/f

{ 3 : ' 9 7m o d e l
+4:'98 model
*5: '99 - 00 models
"6: USA

PGM-FlSystem
The PGM-Flsystemon this model is a sequentialmultiportfuel injectionsystem.
Fuel iniecior Timing and Duration
The ECM/PCMcontainsmemoriesfor the basicdischargedurationsat variousenginespeedsand manifoldpressure.The
basicdischargeduration,after being read out from the memory,is further modifiedby signalssentfrom varioussensors
to obtainthe final dischargeduration.
ldle Air Control
ldle Air ControlValve(lACValve)
When the engineis cold,the Ay'Ccompressoris on, the transmissionis in gear,the brakepedalis depressed,
the P/Sload
is high,or the alternatoris charging,the ECM/PCM
controlscurrentto the IACValveto maintainthe correctidle speed.
lgnition Timing Control
o The ECM/PCMcontains memoriesfor basic ionition timing at various engine speedsand manifold air flow rates.
lgnitiontiming is alsoadjustedfor enginecoolanttemperature.
. A knockcontrolsystemwas adoptedwhich setsthe idealignitiontiming for the octaneratingof the gasolineused.*s
Other Control Funstions
1. StartingControl
Whenthe engineis started.the ECM/PCMprovidesa rich mixtureby increasingfuel injectorduration.
2. FuelPumpControl
. When the ignition switch is initiallyturned on (ll). the ECMiPCMsupplisground to the PGM-FImain relay that
suppliescurrentto the fuel pump for two secondsto pressurize
the fuel system.
. When the engineis running,the ECM/PCMsuppliesground to the PGM-FImain relaythat suppliescurrentto the
fuel oumo.
. When the engineis not runningand the ignitionis on, the ECM/PCMcuts groundto the PGM-FImain relaywhich
cuts currentto the fuel pump.

11 - 8 0

www.emanualpro.com

5.

Fuel Cut-off Control


. Duringdeceleration
with the throttlevalveclosed,currentto the fuel injectorsiscutoffto improvefueleconomyat
speedsover 970 rpm ('97- 98 models),920 rpm ('99- 00 modelsl.
. Fuelcut-offactionalso takes placewhen enginespeedexceeds6,500rpm ('97 - 98 models),6900rpm ('99 - 00
models),regardlessof the positionof the throttlevalve,to protectthe enginefrom over-rewing.
With Ay'Tmodel.the PCMcutsthe fuel at enginespeedsover 5,000rpm when the vehicleis not moving.*'
4,./CComoressorClutch Relav
When the ECM/PCMreceivesa demandfor coolingfrom the air conditioningsystem,it delaysthe compressorfrom
beingenergized,
and enrichesthe mixtureto assurea smoothtransitionto the Ay'Cmode.
Evaporative
Emission(EVAP)PurgeControlSolenoidValve
Whenthe enginecoolanttemperatureis above 154"F(68'C),the ECM/PCMcontrolsthe EVAPpurgecontrolsolenoid
valvewhich controlsvacuumto the EVAPpurgecontrolcanister,
Alternator Control
The systemcontrolsthe voltagegeneratedat the alternatorin accordancewith the electricalload and driving mode.
which reducesthe engineloadto improvethe fuel economy.

PCMFail-safe/Back-upFunctions
1. Fail-safe
Function
When an abnormalityoccursin a signalfrom a sensor,the ECM/PCMignoresthat signal and assumesa pre-pre
grammedvaluefor that sensorthat allowsthe engineto continueto run.
2. Back-upFunction
When an abnormalityoccursin the ECM/PCMitself,the fuel injectorsare controlledby a back-upcircuitindependent
of the systemin orderto permitminimaldriving.
3. Self-diagnosis
FunctionIMalfunctionIndicatorLamp (MlL)l
When an abnormalityoccursin a signalfrom a sensor,the ECM/PCMsuppliesgroundfor the MIL and storesthe DTC
in erasablememory.When the ignition is initiallyturned on {ll),the ECM/PCMsuppliesground for the MIL for two
secondsto checkthe MIL bulb condition.
4. Two Trio DetectionMethod
To preventfalseindications,
fuel metering-related.
idle control
the Two Trip DetectionMethodis usedfor the HO2S*1,
system,ECTsensorand EVAPcontrol systemself-diagnostic
functions.When an abnormalityoccurs,the ECM/PCM
storesit in its memory.When the same abnormalityrecursafter the ignitionswitch is turned OFFand ON (ll) again,
the ECM/PCMinforms the driver by lighting the MlL. However,to ease troubleshooting,this function is cancelled
when you jump the servicecheckconnector,The MIL will then blink immediatelywhen an abnormalityoccurs.
5. Two (or Three)DrivingCycleDetectionMethod{'97 model)
A "DrivingCycle"consistsof startingthe engine,beginningclosedloop operation,and stoppingthe engine.lf misfiring that increasesemissions or EVAPcontrol system malfunction is detected during two consecutivedriving cycles.
or TWC deteriorationis detectedduringthreeconsecutivedrivingcycles,the ECM/PCMturnsthe MIL on. However,to
easetroubleshooting,
this functionis cancelledwhen you jump the servicecheckconnector.The MIL will then blink
immediatelywhen an abnormalityoccurs.
*1: '97 - 98 models
*2: '99 - 00 models

www.emanualpro.com

PGM-FISystem
Powertrain Control Module {PCM}-'97
The Malfunction lndicator LamD
(MlL) nev6r comes on {evenlor
two seconds) after ignition is
turned on (lll, or it's on dimly
and flickers.

Model

NOTE:lf this symptomis intermiftent,


checkfor a loosefuse No.25 METER(7.5A) in the
underdashf{rse/relay
box, a poor connectionat PCMterminalA18, or an intermittent
openin the GRN/ORN
wire betweenthe PCM(A18)and the gaugeassembly.

Turnthe ignitionswitchON {ll}.


ls the chargingsystemlighton?
-

Rep.ir short or opon in tho


wire batween No. 25 METER
(7.5Alfuso and gauge a$mbty.
R6pl.cNo. 25 METER17.5Al
fus.

PCM OON ECTORA {32P}


PGl IBLKI

Try to stan the engine.

Doesthe enginestart?

Chocktor.n open in th6 wire3


{PG1,PG2linesl:
1. Turn the ignitionswitchON (ll).
2. Measurevoltage between
body ground and PCM connectorterminalsA10 and A23
individually.
Check for an opn in the wir6 or
bulb (MlL linl:
1. Turn the ignitionswitchOFF.
2. Connectthe PCM connector
terminalA18 to body ground
with a iumperwire.
3. Turnthe ignitionswitchON {ll).

ls thorelssthan 1.0V?

Substituto . known-good PCM


and rcheck.ll symptom/indication goss away, rcplacathe original PCM.

l s t h e M I Lo n ?
-

Substitut6 a known-good PCM


and rocheck.ll 3ymptom/indication goes away, replacethe o.igin.l PCM.

11-42

www.emanualpro.com

Wire side of female terminals

npeir open in tho wirelsl


hwoon PCM and Glol (loc!t.d
at thc tha.mo3tat houling thrt
htd moro th.n 1.0V.

A {32PI
PCMCONNECTOR

R6pai. open in th. wilei


belwoon rcM lAl8l dnd g.uge
a3rombly.
Roolacthe MIL bulb.
Wire sideot temaleterminals

The Malfunciion lndicator Lamo


{MlL) stavs on o. comes on aftel
two seconds,

Check the Oiegnosiic Trouble


Code(DTC):
1 . C o n n e cat n O B D l l s c a nt o o l
or HondaPGMTester.
2. Turnthe ignitionswitchON 1lli.
3. Read the DTC with the scan
tool or HondaPGII Tester.

Are any DTCIs)indicated?

Ch6cklh6 DTCby MIL indication:


1. Turnthe ignitionswitchOFF.
2. Connectthe SCSserviceconn e c t o rt o t h e s e r v i c ec h e c k
connector.
3. Turnthe ignitionswitchON (ll).

NOTE:
. Whenthereis no Diagnostic
TroubleCode(DTC)stored,the MIL will stay on if the SCS
serviceconnectoris connected
andthe ignitionswitchis on.
. lf this svmotomis intermittent,
checkfor:
- A looseFl E/M(15Aifuse in the underdashtuse/relay
box
- A looseNo. 13 FUELPUMP{15A) fuse in the under-dash
fuse/relay
box
- An intermittentshort in the wire betweenthe PCM(C7)and the servicecheckcon-

An intermittentshortin the wire betweenthe PCM(A18)and the gaugeassembly


An intermittentshon in the wire betlveenthe PCM(D4)and the MAP sensor
An intermiftentshortin the wire betweenthe PCM{D10)and the TP sensor.
PGM-Flmain relay.
'See the OBD ll scantool or HondaPGM Testeruser'smanualslor specilicoperating
instructions,

Go to troubleshootingprocedures
(spage11501.
NOTE:An openor shortin the wire betweenthe PCM(C8)and the DLCwill keepthe
with the PCM.You shouldioterpret
scantool or HondaPGMTesterlrom communicating
this as no DTCSare indicated.

Doesthe MIL indicateany DTc?

Repair opon or short in wi.6


between the PCM (C8) and
Data Link Connector.
Go to troubloshooting procedurs {3eepage 11-601.
PCMCONNECTOR
c l3lPl
scs .BRNI

Try to startthe engine.

Doesthe enginestart?

C h e c kt o r a s h o r t i n t h e w i r e
{SCSline):
1. Turn the ignition switch OFF
a n d t u r n t h e i g n i t i o ns w i t c h
oN flt).
2. Measurevoltagebetweenthe
P C M c o n n e c t o rt e r m i n a lC 7
and body ground.

ls thereapprox.5 V?

(To page1'l-84)

www.emanualpro.com

lTo page11 84)

Wire sid6of fmaleterminalg

Repairshort to body ground in


the wire between PCM lCTl and
servicecheck connector.

(cont'dl

11-83

PowertrainControlModule (PCM)-'97

Model (cont'dl

( F r o mp a g e 1 1 8 3 )

Checkfor a short in the wire (MlL


line):
1. Turnthe ignitionswitchOFF.
2. Disconnect
the PCMconnector
A {32P).
3. Turnthe ignitionswitchON (ll).

lsthe MILON?

Repairshort to body ground in


the wire between the PCM {418}
and MlL.

Substitute a known-good PCM


and recheck. lf symptom/indication goes away. replace the original PCM.

InspectFl E/M (15 A) fuse in the


undeFhoodfuse/relaybox.
-

Reoair shod in the wire


between Fl E/M {15 A} fuse
and PGM-FImain relav.
ReplaceFIE/M 115A)fuse.

InspectNo. 13 FUELPUMP(15Ai
fuse in the underdashfuse/relay

CheckloJ a short in a sensor:


1. Turnthe ignit;onswitchON (ll).
2. Disconnectthe 3P connector
of eachsensorone at time:
. MAPsensor

( T op a g e1 1 - 8 5 )

1 1 -8 4

www.emanualpro.com

Repair short in lh wire


bolween No. 13 FUEL PUMP
115A) Iuse and PGM-FImain

ReplaceNo. 13 FUELPUMP
115A) fuse.

(Frompage 11-84)

Does the MIL go off.,

Reolacethe Sensor that caused


the lighl lo go out.

Check for a short in the wires


lvCC linesl:
1. Turnthe ignitionswitchoFF.
2. Disconnectthe PCM connec
tor D (16P).
3. Checkfor continuitybetween
bodygroundand PCMconnec
tor terminalsD4 and Dl0 indi
vidually.

D (16PI
PCMCONNECTOR
VCCl NEL/RED}

Wiresideof femaleterminals
Repair shorl lo body ground
in the wile between the PCM
{D4}and the MAP sensor.
Repairshort to body ground in
th wire between the PCM
lol0l and the TPsensor.

PCMCONNECTOR
A (32PI

Check tor an open in the wires


llGPline3l:
1 . D i s c o n n e ctth e f u e l i n j e c t o r
connectorsand IAC valve con
2. Turnthe ignitionswitchON (lli.
3 . [ , 4 e a s u r ev o l t a g e b e t w e e n
b o d y g r o u n d a n d P C Mc o n '
nectorterminalsA'11and A24
individually.

Checkfor an open in the wires


{LGlinesl:
1. Turnthe ignitionswitchOFF.
2, Reconnect
all sensorconnectors,
3. Reconnectthe PCMconnector
D (16P).
4. Turnthe ignitionswitchON (ll).
5 , M e a s ur e v o l t a g e b e t w e e n
b o d y g r o u n d a n d P C Mc o n
nectorterminalsAg a^d 422
individually.

l s t h e r e l e s st h a n 1 . 0 V ?

R e p a i ro p e n i n t h e w i r e ( s l
boiween the PCM 1A11,A24)
and the PGM-Flmain relav.
Chck lor poor connections
or loose wires at ihe PGM-FI
main relay.
Tesi lhe PGM-FImain relav
{seep.g6 1l-1871.

Wire side of lemale terminals

R6pair open in the wire{sl


between the PCM {A9. A22l and
G101 {located at the thetmostat
housing)that had morethan 1.0V.

Substituto a known-good PCM


and rechck.It symptom/indication goos away, replacethe original PCM.

www.emanualpro.com

11 - 8 5

PGM-FISystem
Engine
Module/PowertrainControlModule(ECM/PCM)
'98 - 00Gontrol
Models
Tho Maltunction Indicator Lamo
(MlL) n6Yor como3 on leven lor
two laconds) rft6r tho ignhion is
turnod ON {lll.

Turnth6 ignitionswitchON (ll).

NOTE:
. lf this symptom is intermittent,checktor:
- A looseFl E/M{15A) fuse in the under-hood
fuse/relay
box
- A looseNo. 25 METER{7.5A) fusein the under-dash
fuse/relay
box
- A looseNo. 13FUELPUMP(15Alfuse in the underdashfuse/rolay
box
- An intermiftentshort in the wire betweenthe ECM/PCM
(A18)and the gaugeassem-

(C19)and the MAPsensor


An intrmiftent
shortin the wire betweenthe ECM/PCM
An intermiftentshort in the wire betweenrhe ECM/PCM(C28),the TP sensor,the
EGRvalvelift sensorand/or{ueltank Dressure
sensor
A laulty PGM-FImain relay

ls the low oil pressurelighton?


-

Repair lhort or opcn in tho


wire between the No. 25
METER17.5Al fu3e snd the
gaugeassembly.
Repl.co the No. 25 METER
17.5Al fus.
ECM/PCMCONNECTOR
A (32P}

Try to start the engine.


Chockfor an opsn in th wiro or
bulb {MlL line,:
1. Turnthe ignitionswitchOFF.
2. Connectthe ECM/PCMconnectorterminal A18 to body
groundwith a iumperwire.
3. Turn the ignitionswitch ON (ll).

Wiresideof femaleterminals

ls th6 MIL on?

Turnthe ignitionswitchOFF.
Inspectthe Fl E/M 115A) tuse
in the undeFhoodfuse/relay
box.

Substitute a known-good ECM/


PCM and rochock. lf rymptom/
indication goes eway, replace
tho o gind ECM/PCM.

Repair short in the wire


between lhe Fl E/M (15 Al
f u s G a n d t h e P G M - F lm . i n
.slay.
R o p l s c et h F l E / M ( 1 5 A l
fu3.

I n s p e c t h e N o . 1 3 F U E LP U M P
(15A) fuse in the under-dash
fuse/relaybox.
-

(Topage11-871

www.emanualpro.com

Repair short in th6 wire


between tho No. 13 FUEL
P U M P 1 1 5A ) l u s e a n d t h e
PGM-FImain .elay.
R e D l a c et h o N o . 1 3 F U E L
PUMP115Al tuse.

Rep.ir open in the wi.os


botween the ECM/FCM lA18l
and the gaugo rasombly.
Roplecethe MIL bulb.

(Frompage11-86)
ECM/FCMCONNECTOR
A {25PI
IGPl
(YEL/BLK)

Chck tor rn opon in tha wiioa


(lGPlino.):
1. Disconnectthefuel injctorand
IACvalveconnectors.
2. Turn the ignitionswitchON {ll}.
3. Measurevoltage between
body ground and ECM/PCM
connctorterminals B'l and
89 individually.

10

20

vXv)iiP2
rELlBLK)

't3

11

17

23

21

Wire sideof lemaleterminals


-

ls there batteryvoltage?

2
I
19

Repaii opon in th6 wirc{3l


betw.6n tho ECM/PCM (B1.
B g l l n d t h o P G M - F Im a i n
roby.
Chock for poor connactions
or loo3 wiJo3 at the PGM-FI
main ralry.
T.st the PGM-FImtin r.lay
(soop.ge 11-1871.

Chack for an opon in tho wire3


{PG,LG lino3l:
1 . R e c o n n e ctth e l u e l i n i e c t o r
and IACvalveconnectors.
2. Measurevoltage between
body ground and ECM/PCM
connectorterminals82, 810,
820 and 822 individually.

lstherelessthan1.0V?

Chock for a shon in the wira3


{VCCI, VCC2lin..l:
Measurevoltage betweenbody
ground and ECM/PCN4
connector
terminalsC19and C28individuallv.

ls thereapprox.5V?

B.pair open in the wiroltl


b.twocn tho ECM/PCM .nd
G101 lloc.t6d rt th. thormoiat
houingl that had mo.e than 1.0 V.
ECM/PCMCONNECTOR
C {3'IP}
|

Chock lor a short in r snsor:


While measuring voltage
betwoen body ground and ECM/
P C M c o n n e c t o rt e r m i n a l s C 1 9
and C28 individually,disconnecl
the 3P connector ol each sensor
one at time:

2 i 3

s /

't6 1 7 1 8 1 9 20 21\22
26 27 2el E 30 31

vcc2

kt

(YEL/BLUI

vccl

(YEL/RED)

Wire sideof
lemaleterminals

. TP sensor
. Fueltankpressuresensor

ls there approx. 5 V?
Sub3lhuio . known-good ECM/
PCM .nd rcch6ck. lf tymptom/
indic.tion go.3 away, rapl.ce
th. original ECM/PCM.

Rooairahort in tho wire btwoen


tho MAP sen3or.TP sensor, Fuel
tank DreaaureSonsor and the
ECM/PCMtC19,C28).

R e p l e c et h e r o n s o r t h t t h a d
approx. 5 V.

lcont'd)

www.emanualpro.com

11-47

PGM-FISystem
EngineControlModule/Poweftrain
ControlModule(ECM/PCM)

'98 - 00 Models (cont'dl


The Malfunction lndicator Lamo
lMlll 3lays on or comes on after
two 3econds.

Check the Dirgnostic Troublo


Cod (DTCI:
'1.
Connecta scantool or Honda
PGMTester.
2. Turnthe ignitionswitchON (ll).
3. Readthe DTC with the scan
tool or HondaPGMTester.

NOTE:
. When there is no DiagnosticTrouble Code IDTC)stored,the MIL will stay on iI the SCS
serviceconnectoris connectedand the ignitionswitch is ON (ll).
. lf this symptom is intermittent,checkfor:
- An intermittentshort in the wire betweenthe ECM/PCM(A10)and the servicecheck
connoctor
- An intermittentshort in the wire between the ECM/PCM(At8l and the gauge
assemDty
. See the OgD ll scantool or HondaPGMTesteruser'smanualsfor specificoperating
rnstructions.

Go to troublGhooting procadura.
(3c prg l lS0l

check tho DTc by MIL indication:


1. Turnthe ignitionswitchOFF.
2. Connectthe SCS serviceconnector to the service check
connector,
3. Turnthe ignitionswitchON (ll).

Doesthe MIL indicateany DTC?

Ropair op.n ol Bhort in wiro


b.twe.n thc ECM/FCtrl (A21)
and D.i. Link Connoctor.
Go to troublo3hootlng procdur6. lt o pag. 11.6lrl

Try to start the engine.

Doesthe enginestan?

Sub3titute r known"good ECM/


PCM .nd roch.ck. lt .ymptom/
indic.tion gooa awsy, repl.co
the origin.l ECM/PCM.
ECM/FCMCONNECTOFA {32P)

Check tor a 3hort in the wire


ISCSlinel:
1. Turn the ignition switch OFF
and turn the ignition switch

o N{ ) .

2- Measurevoltage between
body groundand the ECM/
PCi, conneclorterminalA10.

Ropria ahort to body ground in


tho wi.c Mwe.n tho ECM/PCM
lA10l and aarvic. check connsctor.

lTo page1l-89)

11-88

www.emanualpro.com

Wire sideof femslet6rminals

(Frompage11-88)

Checktor a short in the wire (MlL


linel:
1. Turnthe ignitionswitchOFF.
2. Disconnectthe ECM/PCMcon
nectorA (32P).
3. Turnthe ignitionswitchON (lli.
Repairshort to body ground in
the wire btwe.n the ECM/PCM
lA18) and tho MlL.
Substituto a known-good ECM/
PCM .nd recheck. lf symptom/
indication goo3 .way, replace
th original ECM/PCM.

www.emanualpro.com

1-89

PGM-FISystem
ManifoldAbsolutePressure(MAPISensor
The scan tool indicatesDiagnosticTrouble Code (DTC)POl07:A low input (high vacuum) problem in the
ManifoldAbsolutePressure(MAP)sensor,
The MAP sensorconvensmanifoldabsolutepressureinto electricalsignalsand inputsthe ECM/pCM.

OUTPUI
VOLTAGE

tvl3.s
3.0
2.5
2.O
1.5
1.0
0.5

r o - 1 5 ^ 1 o 25
30 lin.H9) GAUGE
.5
READIT{G
100 200 300 a00 5oo 6fi, 7d)
lmmHgl

Th6 MIL has ben reoorted on.


DTCP0107is 3tored.

Problomverification:
1. Turn the ignitionswitchON lll).
2. Checkthe lvlAPwith the scan
root.

ls approx.101kPa(760mmHg,
30 in.Hg),2.9
V indicated?

lrtormittem tailu.e, lystam b OK


at thb timo. Checktor poor connoctions or loosa wird at C131
(MAP rensor) and rt the ECM/
PCM.

Check for an op6n in wi.o IVCC1


linel:
1. Turn the ignitionswitchOFF.
2. Disconnectthe MAP sensor
connector,
3. Turn the ignitionswitch ON {ll}.
4. Measurevoltage between the
MAP sensorconnectorNo. 1
termanal
and No. 2 terminal.

ls thereapprox.5 V?

(Topage11-91)

11-90

www.emanualpro.com

MAP SENSOR3P CONNECTOR


IC131I

vccl

(YEL/RED}

Roprir opn in the wir6 bstween


tho ECM/PCM(D4,C19*l and the
MAP sensor.

Wiro side ol temale terminals

{Frompage11-90)

Chocktor .n open or short in the


MAP 3n30r:
C h e c kt h e M A P w i t h t h e s c a n
tool.

ls approx.2 kPa(15mmHg,
V or lessindi0.6in.Hg),0.1
cated?

(C131I
MAP SENSOR3P CONNECTOR

Chock for a lhort in the wire


(MAPlinol:
1. Turnthe ignitionswitchOFF.
2 . D i s c o n n e c tt h e E C M / P C M
connectorD (16P),(C131P))*.
3. Checkfor continuitybetween
the MAP sensorconnectorNo.3
terminaland body ground.

Rp.ir 3hort in the wire bstwcen


tho ECM/PCM(D3,C17') rnd tho
MAP 3rnsoi.

Wire sideof lgmaleterminals

Sub3lilut. . known-good ECM/


PCM and rocheck. lf normal MAP
k indic.tcd, r.pl.co thc originrl
ECM/PCM.

(cont'd)

www.emanualpro.com

11 - 9 1

PGM-FISystem
Manifold Absolute Pressure(MAP)Sensor (cont'd)
The scan tool indicatesDiagnosticTrouble Code (DTC)P0108:A high voltage (low vacuum) problem in the
[tn,t
|jg nn-] ManifoldAbsolutePressure(MAP)
sensor.
The MIL has boen reportedon.
DTCm108 is slored.
Problemveritication:
1 . S t a r tt h e e n g i n e .H o l d t h e
engine at 3,000rpm with no
load (in Parkor neutral)until
the radiatorfan comeson, then
letit idle.
2. Checkthe MAP with the scan
tool.
ls 101kPa{760mmHg,30in.Hg),
2.9V or higherindicated?

Intermittent tailuro, system i3 OK


at this time. Checktor ooor connections or loose wires at C131
IMAPs6nsor)snd the ECM/rcM.
MAP SENSOR3P CONNECTOR
IC131I

Check Ior an open in the MAP


sensor:
1. Turnthe ignitionswitchOFF.
2 . D i s c o n n e ctth e M A P s e n s o r
3P connector.
3. lnstall a jumper wire between
the MAP sensor3P connector
terminals
No.3 and No.2.
4. Turnthe ignitionswitchON {ll).
5. Checkthe MAP with the scan
tool.

tcRN/wHrll

IIRED/GRN|

Wire side of female terminals


ls 10'lkPa(760mmHg,30in.Hg),
2.9V or higherindicated?

vccl
IYEL/RED}

Check for an open in wire (SGl


liDel:
1. Removethe jumperwire.
2. Measurevoltagebetweenthe
MAP sensor 3P connectorterminalsNo. 1 and No-2.
ls thereapprox.5 V?
YES

R6p.ir open in the wire betwoen


the ECM/PCM(D12,CTrl and the
MAP sensor.

Check for an open in the wire


(MAPline):
1. Turnthe ignitionswitchOFF.
2. lnstall a iumper wire on the
PCMconnectorsbetweenD3
and D12.
3. Turnthe ignitionswitchON (ll).
4. Checkthe MAP wirh the scan
tool.
ls 101kPa1760mmHg,30 in.Hg),
2.9V or higherindicated?

D I16PI
PCMCONNECTOR
JUMPERWIRE

Ropair opon in the wire between


the PCM {D3, .nd the MAP son3('t.

sGl
IGRN/WHTI
Wire side of lemale termin6ls

(To page11,93)
': '98- 00 models

1 1-92

www.emanualpro.com

(Frompage11-92)

I
Check for an open in the wire
{MAPlinel:
1. Turnthe ignitionswitchOFF.
2 . I n s t a l la j u m P e rw i r e o n t h e
ECM/PCMconnectorsbetlveen
C7andC17.
3. Turnthe ignitionswitchON (ll)
4. Checkthe MAP with the scan
tool.
ls 101kPa(760mmHg,30in.Hg),
2.9V or higherindicated?

Bopairopn in the wi.es between


the ECM/PCM(c1?l and the MAP
5en30t.

Substitute a known'good ECM/


PCMand recheck.lf normal MAP
k indicated, replace the o.iginal
ECM/PCM,

(cont'd)

www.emanualpro.com

11-93

PGM-FISystem
ManifoldAbsolutePressure(MAP)Sensor(cont'dl
The scan tool indicatesDiagnosticTroubleCode (DTC)P1128:ManifoldAbsolutepressure(MAp) lower than
exoected.
-

The MIL has be6n rportedon.


DTCPl128 is stored.

Problomverification:
1. Turnthe ignitionswitchON1lli.
2. Checkthe MAP with the scan
tool,

ls 54.1kPa(406mmHg,16.0in.Hg),
1.61V or higherindicated?

I to.mittent failure, 3ydom i! OK


al thbtimc,

The scan tool indicatesDiagnosticTroubleCode (DTC)P'l129:ManifoldAbsolutePressure(MAP)higherthan


expected.
-

The MIL has boenreportodon.


DTCPl129 is stored.

Problemveritication:
1 . S t a r tt h e e n g i n e .H o l d t h e
engine at 3,000rpm with no
load lin Parkor neutral)until
t h e r a d i a t o rf a n c o m e s o n ,
then Iet it idle.
2. Checkthe MAP with the scan
tool,

ls 43.3kPa(325mmHg,12.8in.Hg),
'1.32
V or lessindicated?

www.emanualpro.com

11 -9 4

Intarmittani fuilure, systom i3 OK


at this time.

IntakeAir Temperature(lAT)Sensor
problemin
The scantool indicatesDiagnosticTroublecode (DTC)P0111:A ranoe/performance

1P0111
| ('97model)the lntakeAir TemDerature(lAT)Sensorcircuit.

of the thermistordecreasesas the intake


The resistance
The IAT Sensoris a temperaturedependantresistor(thermistor).
air temDeratureincreasesas shown below
-

The MIL has beenreportedon.


DTCP0111is stored.
Or lrom ProbableCauseList.

RESISTANCE
IKOI

Problemvetification:
1. Turnthe ignitionswitchOFF.
the IAT sensor2P
2. Disconnect
connector,
3. Removethe IATsensor.
4. Reconnectthe IAT sensor2P
connector,
5. Leavethe IATsensoretposed
to ambienttemPerature.
6 . T u r n t h e i g n i t i o ns w i t c hO N

. 3' aa ro. r?a arl ,.t r.fl


20 0 to ao ao aa ioo t2otocl

INTAKEAIB TEMPERATURE

flr).

7. check the IAT with the scan


tool-

Rplacethe IAT son3or.

Checkthe IAT sensor output:


1. Warm the IAT sensor with a
hair dryer.
2. Checkthe IAT with the scan
tool.

Did the IATrise2.0'F(1.0'C)


or morefrom the ambient
temperature?

Intermittent f.ilure, aY3temis OK


ai this tim6.

Replacethe IAT sensor.

(cont'd)

www.emanualpro.com

11 - 9 5

PGM-FISystem
IntakeAir Temperature(lAT)Sensor(cont'dl
The scantool indicatesDiagnosticTroublecode (DTC)P0112:A low voltage(hightemperature)problem
in the
IntakeAir Temperature0AT)sensorcircuit.
The IAT Sensoris a temperaturedependantresistor(thermistor).
The resistance
of tho thermistordecreasesas the intake
air temperatureincreasesas shown below.
-

RESISTANCE
IKO)

The MIL has been reDonedon.


OTCm112 is stored,
Or from ProbableCausList.

Problemvsrification:
1. Turnthe ignitionswitchON flt).
2. Checkthe IAT with the scan
tool.
-. 32 aa rorr 1?a 2ra 2aa f.el
-m 0 20 rto ao i0 too l2ofcl

INTAKEAIR TEMPERATUR

ls 302'F (150'C)or higher (or


H - L i m i ti n H o n d a m o d e o f
PGMTesterior 0 V indicated?
ls the correctambienttemperatureindicated,,?

Beplocetho IAT sensor.


It the engineis warm,it will b higher than ambienttemperature.

Check for a short in the IAT sensot:


1. Disconnect
the IAT sensor2p

Intermittent failure, system i3 OK


at this time. Ch6ckfor poor connectiona o. loose wires rt C133
{lAT snsorl and rt th6 ECM/pCtr4.

2. Checkthe IAT with the scan


tool.

ls 302"F{150"C)or higher{or
H - L i m i ti n H o n d am o d e o f
PGMTester)or 0 V indicated?

Raplacethe lAT aensor.


IAT SENSOR2P CONNCCTOR
(C'33I

Chckfor a short in the wir6 llAt


linel:
1. Turn the ignitionswitchOFF.
2. Disconnectthe ECM/PCMconnector{D (16P},
C (31P)').
3. Checkfor continuitybetween
the IATsensor2P connectorter
minalNo.2andbodyground.

'

A
9)

)
/

tAr
(RED/YEU

-L

Wi16sideof femsleterminals
Repairshort in the wi.o botween
th6 ECM/rcM {D8,C25*l and th6
IAT 3ensor.
Substitute a known-good ECM/
PCM and recheck. lf normel IAT
is indicaled, replace the original
ECM/PCM,
*: '98- 00 models

11 - 9 6

www.emanualpro.com

The scantool indicatesDiagnosticTroubleCode(DTC)P0113:A high voltage(low temperature)problemin the


IntakeAir Temperature(lAT)sensorcircuit.

The MIL has beenreportedon.


OTCP0113is stored.

Problemvrification:
1. Turnthe ignitionswitchON (ll).
2. Checkthe IAT with the scan
tool,

ls -4'F (-20"C)or less(or L Limit


in Hondamode of PGMTester)or
5 V indicated?

Intermiftent failure, syatem is OK


at this time. Ch.ck for Door connections or loose wires at c133
llAT s6nsorland at the ECM/
PCM.

sG2
{GRN/BIIO

Checklor an open in the IAT sensor:


1. Disconnectthe IAT sensor2P
connector,
2. Connectthe IATsensor2P con
n e c t o r t e r m i n a l sN o . 1 a n d
No.2 with a ,umperwire.
3. Checkthe intakeair tempera'
ture with the scantool.

ls -4'F (-20"C)or less(or L-Limit


in HondamodeoI PGMTester)or
5 V indicated?

ICl33I
IAT SENSOR2P CONNECTOR

JUMPENWNE
IAT IRED/YELI
Wire side ol female terminals

Replacethe IAT sensor.

YES

_!!7rqd9ll_____FCM CONNECTOR
O IT6PI

Checklor en opan in the wires


llAT, SG2 lines):
1. Turnthe ignitionswitchOFF.
2. ConnectPCM connectorterm i n a l sD 8 a n d D 1 1w i t h a
3. Turnthe ignitionswitchON lll).
4. Checkthe IAT with the scan
tool.

IAT IRED/YEL)

sG2
IGRN/BLK}

JUMPER
w|BE
ls -4"F {-20"C)or Iess(or Llimit
in Hondamodeot PGMTester)or
5 V indicated?

Rgpairopen in the wires btween


the PcM (D8. D11) and rhe IAT
3en30r,

Wiresideof female
terminals

(cont'd)
(Topage11-98)

www.emanualpro.com

11-97

PGM-FISystem
IntakeAir Temperature(lATl Sensor(cont'd)
(Frompage11,97)

ECM/PCMCINNECTORC t3lPl

Checkfor an open in the wires


{lAT,SG2lines):
1. Turnthe ignitionswitchOFF.
2. ConnectECM/PCMconnector
terminalsC18and C25with a
jumperwire.
3. Turnthe ignitionswitchON (ll).
4. Checkthe IAT with the scan
tool.
ls -4'F 1-20"C)or less(or L limit
in Hondamodeof PGMTesterior
5 V indicated?

2
./

23

5
7
I I
16 1 7 1 8 19 20 21 22

4 Wp,

IAT{RED/YELI

29 c) 31
sG2{GRN/BLK)

JUMPERWIRE
Wire sideof fernaleterminals
Repsir opn in the wirca batween
the ECM/PCM1C18,C25l and the
IAT snsor.

Substitute a known-good ECM/


PCM rnd recheck, lf normal IAT
is indicated, leplaco the originsl
ECM/PCM.

'l
11 - 9 8

www.emanualpro.com

(ECTISensor
EngineGoolantTemperature
problem in the Engine
The scan tool indicatesDiagnosticTrouble Code (DTC)P0116:A range/performance
CoolantTemperature(ECT)Sensorcircuit.
as the engine
of the thermistordecreases
The resistance
The ECTSensoris a temperaturedependantresistor(thermistor).
coolanttemperatureincreasesas shown below
RESISTANCE
tk0l

- 4 3 2 6 8 r 0 a r a 0 1 7 62 1 22 a E{ ' r )
-2O O 20 ito tO .o ! t2O I c)

THERMISTON

ENGINE COOLANT TEMPERATURE

NOTE:lf DTC P0117and/or P0118are stored at the same time as DTC P0116,troubleshootthose DTCSfirst, then troubleshootDTCP0116.
PossibleCause
a ECTsensordeterioration
. Malfunctionin the thermostatand coolingsystem
Troubleshooting Flowchart
-

The MIL has benroportedon.


DTCP01'16is stored.

Probl6mverification:
1 . S t a r t t h e e n g i n e .H o l d t h e
engine at 3,000 rpm with no
load (in Parkor neutral)until
t h e r a d i a t o rf a n c o m e s o n ,
then let it idle.
2. With the scan tool, checkthe
ECT.

ls 176- 200'F(80- 93"C)or


0.4-0.TVindicated?

Intermittent failure, sYstemb OK


at this tim6. Check lhe thermostat and the cooling 5y3tom.

Check the thermostat and the


cooling system. It thy are OK,
reolacethe ECTseNor.

(cont'd)

www.emanualpro.com

11 - 9 9

PGM-FISystem
EngineCoolantTemperature(ECTISensor{cont'd)
:[F011'
-

The.scantool indicatesDiagnosticTroubleCode(DTC)P0117:A low voltage(hightemperature)problemin the


EngineCoolantTemperature(ECT)sensorcircuit.

The MIL has been rooortodon.


DTCml17 is sto.od.

Problemverification:
1. Turn the ignitionswitchON {ll).
2. Checkthe ECTwith the scan
tool,

ls 302"F(150'C)or higher(or
H Limitin Hondamodeot
PGMTester)or 0 V indicated?

Intermittont f.ilure, sysiom is OK


at thk time. Checkfor poor connections or loo3e wire3 at C1lil
(ECT sensorl and et the ECM/
PCM.

Checkfor a Bhort in the ECTsen301:

'1. Disconnect
the ECTsensor2P
connefior,
2. Checkthe ECTwith the scan
tool.

ls 302"F(150"C)orhigher(or
H-Limitin Hondamodeof
PGMTester)or 0 V indicated?

ECTSENSOR2P CONNECTOR
{C114I

C h e c kf o r r s h o r l i n t h e w i r s
(EgTlinel:
1. Turnthe ignitionswitchOFF.
2. Disconnectthe ECM/PCMconnectorD (16P),(C(31P)*1.
3. Checktor continuitybetween
the ECTsensor2Pconnectorter
minalNo.1 and bodyground.
Wire sideof femaleterminals
ls therecontinuity?

Substitute a known-good ECM/


PCM and recheck.It normal ECT
i! indicatod, replaco the oiiginal
ECM/PCM.
*:'98 - 00 models

1-1

www.emanualpro.com

Repairshort in the wir between


the ECM/FCM(D2,C26rl ,nd th6
ECTsenaor.

The scantool indicatesDiagnosticTroubleCode{DTC)P0118:A high voltage{low temperature)problemin the


EngineCoolantTemperature(ECT)sensorcircuit.
The MIL has benreportedon.
DTCP01'18is stord.

Problemverification:
1. Turnthe ignitionswitchON {ll).
2. Checkthe EcT with the scan
tool-

ls -4"F (-20'C)or less(or L-Limit


in Hondamodeot PGMTester)or
5 V indicated?

Intermiftent tailu.,3ystem is OK
at this time, Checl foJ poor connction3 or loose wires et C1'14
(ECT ren3or) and at the ECM/
PCM.

ECTSENSOR2P CONNECTOB(C11ill

Checkfor an open in the ECTsen-

ECT
(ncD/wlrT)

1. Disconnect
the ECTsensor2P
connector.
2 . C o n n e c tt h e E C Ts e n s o r2 P
connectorterminalsNo. 1 and
No.2 with a jumperwire.
3. Checkthe ECTwith the scan
tool.

JUi,IPEBWNE

sG2
(GRN/8LKI

Wirc side of lemale terminals

ls -4'F (-20'C) or less (or L'Limit


in Hondamodeof PGMTester)or
5 V indicated?

('97model)
D {T6PI
PCMCONNECTOR
JUMPERWIRE

ECT
IREDAAIHT)

Checkfor an open in the wiies


{ECT,SG2 lines):
1. Turnthe ignitionswitchOFF.
2. ConnectPCM connectorter
m i n a l sD 2 a n d D 1 1 w i t h a
iumperwire.
3. Turnthe ignitionswitchON {ll}.
4. Checkthe ECTwith the scan
tool,

ls -4"F (-20'C)or less(or L-Limit


in Hondamodeof PGMTesterior
5 V indicated?

IGRN/BLX}

Wire sideoI femaleterminals

Repairopen in th6 wire! botwen


the PCM lD2, D'l1l and the ECT
3n30t.

(To page11-102)

(cont'd)

www.emanualpro.com

11 - 1 0 1

PGM-FISystem
EngineGoolantTemperature(ECTISensor(cont'dl
( F r o mp a g e1 1 1 0 1 )

Chacklor an open in the wires


(ECT,SG2 lines):
1. Turnthe ignitionswitchOFF.
2. ConnectECM/PCMconnector
terminalsC18 and C26with a

ECM/PCMOONNECTOR
C 13lPI
1

3. Turnthe ignitionswitchON (ll).


4. Checkthe ECTwith the scan
tool.

7
I 9
't8 '19
,/ 16 1 7
20 n

ECTIRED/WHTI

sG2(GRN/BLK)

JUMPERWIRE
Wiresideof temaleterminals

ls -4"F (-20"C)or less(or L-Limit


in Hondamodeof PGMTesterlor
5 V indicated?

Substitute a known-good ECM/


PCM and rech.ck. lf normal ECT
is indicrted, replace ths originsl
ECM/PCM.

11-102

www.emanualpro.com

Ralpairopen in tho wir6s b6twen


tho ECM/PCM1C18,c26l 6nd tho
ECTsensor.

ThrottlePosition(TPlSensor
The scan tool indicatesDiagnosticTroubleCode (DTC)P0122:A low input (voltage)problem in the Throttle
Position(TP)sensorcircuit.
lt is connoctedto the throttlevalve shaft.As the throttle positionchanges,the throftle
The TP Sensoris a potentiometer.
positionsensorvariesthe voltagesignalto the ECM/PCM.
'97

BRUSH
HOI,I'ER

mod6l:
-

The MIL h.3 been reoorted on.


OTC m122 b 3tored.

OUTPUT VOLTAGE IVI


5
4

Problemvorificalion:
1 . S t a r tt h e e n g i n e .H o l d t h e
engine at 3,000rpm with no
load (in Parkor neutralluntil
t h e r a d i a t o rf a n c o m e s o n ,
then turn the ignition switch
OFF.
2. Turn the ignitionswitchON (ll).
3 . C h e c kt h e t h r o t t l e p o s i t i o n
with the scantool.

3
2
1
0

THROITLE
OPCNIiIG
FUTI
IHROTTI"E

TP SENSOR3P CONNECTOR
{Cl3OI
ls there approx. 10%when the
throttle is fully closedand
approx.90%when the throttle
is fully opened?

Intormittent feilu?e, 3y3tem is OK


at thb iime. Checktor poor connodiona or loose wiros at C130
tTPloNorl .nd rt th PCM.

Check tor an open in the wire


{vOC2linel:
1. Turnthe ignitionswitchOFF.
2. Disconnectthe TP sensor3P
connector,
3. Turnthe ignitionswitchON lll).
il. Measure voltage between
the TP sensor3P connectorterminalsNo.1 andNo.3.

vcc2
IYEL/BLUI

Wi.6 6ide ot fgmaleterminsls

D I16PI
PCMCONNECTOR

ls thereapprox.5V?

Checkto. an open in wir6 {VCC2


linel:
Measurevoltage between PCM
connector
terminals010 and D11.
Ch6ckto. an opon or shon in TP
sonaol:
1. Turnthe ignitionswitchOFF.
2, At the sensor side, measure
r e s i s t a n c eb e t w e e nt h e T P
sensor3P connectorterminals
No. 1 and No. 2 with the throttle fullyclosed.

ls thereapprox.5 V?

(GRN/BLX)

Wiresideof femaleterminals
Repairopen in the wirc between
PCM{D10}and TP 3ensor.

Sub3tituto . known-good PCM


and rechock. It proscribed voltag. b now availablo.rcplacoth6
originsl PCM,

( T op a g e1 1 - 1 0 4 )
Terminalsideof maleterminals

www.emanualpro.com

(cont'd)

11 - 1 0 3

PGM-FISystem
ThrottlePosition(TP)Sensor(cont'd)
(Frompage11 103)
TP SENSOR3P CONNECTOR
ls thereapprox.0.5- 0.9kO?

Chockfor an open or short in the


TP sensor:
Measureresistancebetweenthe
T P s e n s o r3 P c o n n e c t otre r m i n n a l sN o . 2 a n d N o . 3 w i t h t h e
throttlet!lly closed.
Terminalsideof maleterminals
ls thereapprox.4.5kO?
PCMCONNECTOR
D I16PI
Check to. an open in the PCM
(TPSlinell
1 . R e c o n n e ct th e T P s e n s o r3 P
connector.
2. Turnthe ignitionswitchON (ll).
3. Measurevoltage between
PCMconnectorD (16P)termin a l sD 1a n dD 1 l .

TPS IREO/
BLK)

SG2 (GRN/BLKI

Wiresideol femaleterminals
ls thereapprox.0.5V whenthe
throftle is fully closedand
approx.4.5V when the throttle
is fullyopened?

Substitute a known-good PCM


and recheck. It orescribod voltage is now available,roplacothe
o.iginal PCM.

Repairshort in the wire bstween


the PCMlDl)snd the TP ssnso..

11-104

www.emanualpro.com

'98 - 00 model3:
The MIL has boon reDortod on.
DTCm122 b rtorod.

P.oblom veiification:
1. Start the engine.Hold the
engine at 3,000rpm with no
load (in Parkor neutral)until
t h e r a d i a t o rt a n c o m e s o n ,
then turn the ignition switch
OFF.
2. Turnthe ignitionswitchON lll).
3 . C h e c kt h e t h r o t t l e p o s i t i o n
with the scantool.
TP SENSOR3P CONNECTOR
{C130}
ls thereapprox.10%whenthe
throttle is fully closedand
approx.90%when the throttle
is fully opened?

Intarmittent failure. system is OK


at thia time. Checkfor poor connctions or loolo wires rt C130
ITPs.nsorl and.t the ECM/FCM.

Checkfor an opon or short in tho


wire {VCC2linel:
1. Turnthe ignitionswitchOFF.
2. Disconnectthe TP sensor3P
connedor,
3. Turn the ignitionswitchON (ll).
4 . M e a s !r e v o l t a g e b e t w e e n
the TP snsor3P connectorterminalsNo. 1 andNo.3.

vcc2

sG2
IGRN/BLKI

IYEUBLUI

Wire side oI Iemale lerminals

C (31P}
ECM/PCMCONNECTOR

sG2IGRN/BLKI
1

a
,l -

18 sl./|

ls thereapprox.5 V?

/ 1 6 17

gJ lzgi3osrI
T ^
vccz {YEL/8LUl

23
Checklor an opon in wiro IVCC2
linel:
Measurevoltage betweenECM/
rcM connectorterminalsC'18and

zzl
lrs]zolzr

25

27)

Wire sid6of temaleterminals

c2a.
Chockfor en opn or Bhort in TP
3an30r:
1. Turnthe ignitionswitchOFF.
2. At the sensor side, measure
r e s i s t a n c eb e t w e e nt h e T P
sensor3P conneclorterminals
No. 1 and No. 2 with the throttle fullyclosed.

(To page11-106)

ls lherapprox.5 V?

B.psir opon in the wire b{woon


tho ECM/PCM {C281and th6 TP
3en!xtt.

Subslitute e known-good ECM/


PCM .nd r.chock. lf pro3cribed
voltrge iB now rYrilablo, replaca
th. originll ECM/PCM.
Terminalsideof maletorminals

(cont'd)

www.emanualpro.com

11 - 1 0 5

PGM-FISystem
ThrottlePosition(TPlSensor(cont'dl
(Fromp6ge11-105)
TP SENSOR3P CONNECTOR
ls there approx. 0.5 - 0.9 kO?

Chockfor rn opn or 3hort in tho


TP sonsor
Measure resistancebetween the
TP sensor 3P connectorterminals
No. 2 and No. 3 with the throttle
fully closed.
Terminalside of mal6 terminals
ls thre approx. 4.5 k0?

ECM/PCMCONNECTOR
C {31P}

Check lor an open in the ECM/


PCM ITPSlinel:
1. Reconnect
the TP sensorcon'
nector.
2. Turn the ignitionswitchON {ll).
3. Measurevoltage between
ECM/PCMconnectorC (31P)
terminalsC18and C27.

7 l

la

1 6 17 t 8 1 9 l m

23

27 t l

TPS IRED/BLK)

l 2 e30 31

Lle (GRN/BLKI
{9}

Wire sideol temaletorminals


ls thgre6pprox.0.5V when the
throttle is Iully closedand
approx.4.5V when the throttle
is lully opened?

Raoai. ahort in th wira lrltw.an


the ECM/PCM (C181lnd th TP
3n3rot.

11 - 1 0 6

www.emanualpro.com

Subrtituto . known-good ECM/


PCM rnd rocheok. lI pro.cribed
voltaga ia now rvailablc, rcpl.ce
th. o.igln.l ECM/PCM.

The scantool indicatesDiagnosticTroubleCode(DTC)P0123:A high voltageproblemin the ThrottlePosition


(TP)sensorcircuit.
The MIL hlr brn r.9ort.d on.
DTCP0123ir stored.

Pioblom vorificltion:
1 . S t a r t t h e o n g i n 6 .H o l d t h
ongine at 3,000rpm with no
load {in Parkor neutral)until
t h 6 r a d i a t o rf a n c o m e s o n .
then turn the ignition switch
OFF,
2. Turn the ignitionswitchON (ll).
3 . C h e c kt h e t h r o t t l e p o s i t i o n
with the scantool.

ls therespprox. 1oyowhen tho


throttle is Iully closedand
approx.90%when the throttle
is tully opend?

Intarmittant tailuro, ryrtern b OK


at this timo. Chocklor poor connections or loo3o wir3 at C130
ITP 3orcorl .nd at tho ECM/FCM.

TP SENSOR3P @]{NECTOR IC13O}

sG2
(GnN/Br.Xl
Choct toJ an opcn in th6 TP s6n3t']:
1. Turnthe ignitionswitchOFF.
2. Disconnectthe TP sensor3P
connectol,
3. Turn the ignitionswitchON (ll).
4. At the wir6 harnossside, measuro voltage betweonthg TP
sensor 3P connectortrminals
No. 1 and No.3.

vocr
tYEt/8LU)

Wiro side of fom.le terminals

ls thereapprox.5V?

('97model)
PCMCON'{ECTOFD I16PI
Chack for an oDan in tha wira
(SG2linel:
M6asu16voltage b6tween PCM
connctorterminalsDl0 and D'!1.

{GBIT/BLKI
ls there approx. 5 V?

R.pai. opcn in tha wira botwcon


tho PcM {o111rnd the TP 3en3('t,

Wire side ot femaleterhinals

(Topage11-108)

(cont'd)

www.emanualpro.com

11-107

PGM-FISystem
ThrottlePosition(TP)Sensor(cont'dl
(Frompage11-107)

ECM/PCMCONNECTOR
C {31PI

Check lor an open in the wirc


(SG2line):
Measurevoltage betweenECM/
PCMconnectorC (31P)terminals
C18and C28.

ls thereapprox.5 V?

Ropairopen in th wire betweon


rhe ECM/PCM(Cl81.nd the TP
56nSOl,

Substitute a known-good ECM/


PCM and rocheck.lf pre3cribed
voltago is now avaibble, replace
tho origin.l ECM/PCM,

11 - 1 0 8

www.emanualpro.com

Wire sideof temaleterminals

Pl121 lThescantool indicatesDiagnosticTroubleCode{DTC)Pl121;ThrottlePosition(TP)lowerthanexpected.


-

The MIL has been reportedon.


DTCPl121 is stored,

Problemveritication:
1. Turnthe ignitionswitchON (ll).
2 . C h e c kt h e t h r o t t l e p o s i t i o n
with the scantool.

ls 14.1%(12.97.)*
or higher
indicatedwhen the throttleis
fullyopened?

Intormittent failur6, systom is OK


at this lime.

I Pl122 | The scantool indicatesDiagnosticTroubleCode(DTC)P1122:ThrottlePosition(TP)higherthanexpected.


-

The MIL has benreoortedon.


OTCP1122is dored.

Problemverification:
1. Turnthe ignitionswitchON lll).
2 . C h e c kt h e t h r o t t l e p o s i t i o n
with the scantool.

(16.9%)'or less
ls'17.670
indicatedwhen the throftle is
lully closed?

IntermitteDt tailu.o, system is OK


at thb time.

*:'99 - 00 models

www.emanualpro.com

1-109

PGM-FISystem
PrimaryHeatedOxygenSensor(PrimaryHO2S)(Sensor1)
In operation,
The HeatedOxygenSensors(HO2S)detectthe oxygencontentin the exhaustgas and signalthe ECM/PCM.
the ECM/PCMreceivesthe signalsfrom the sensorand variesthe durationduring which fuel is iniected.To stabilizethe
sensor'soutput,the sensorhasan internalheater.The PrimaryHO2S(Sensor1) is installedin exhaustpipeA.

sNsoR

HO2S:

TERMINALS

VOLTAGEIVI

ztRcoNtA
EI.IMENT

HEATER
HEATEB
TERMINALS

RICH- AIR. . LEAN


FUEL
NATO

The scan tool indicatesDiagnosticTroubleCode (DTC)P0131:A low voltage problem in the PrimaryHeated
OxygenSensor(HO2S){Sensor1} circuit,
37 - 98 models:
The MIL has been reoorted on.
DTC P0131 is stoied.

Problemverification:
1. Do the ECM/PCMResetProceoure.
S t a r t t h e e n g i n e .H o l d t h e
engine at 3,000rpm with no
load (in Parkor neutral)until
the radiatorfan comeson.
Test-drivewith the A/T in E
position(M/T in 4th gear)
Check the Primary HO2S
{Sensor1} output voltagewith
the scantool during acceleration usingwide openthrottle.
Intermittent f.ilure, system is OK
at this time. Check fo. poor connections or loose wirer at C111
(Primary HO2S,SeGor 1) and at
rh ECM/FCM.
Checkthe fuel pressure(seepage
11-178).

Repairthe fuel supply system.

{ T op a g e1 1 ' 1 1 1 }

1 1 - 11 0

www.emanualpro.com

{ F r o mp a g e1 1 - 1 1 0 }

Checktor a shorl in the HO2S:


1. Turnthe ignitionswitchOFF.
the PrimaryHO2S
2. Disconnect
(Sensor'1i
4Pconnector.
3. Startthe engineand let it idle.
4. Check the Primary HO2S
(Sensor1)outputvoltagewith
the scantool.

Doesit stay at 0.1 V or less?

Replacethe HO2S{Sensor1).
(Cl111
PRIMARYHO2Sls.n.or 'l I 4P CONNECTOR

Check for a short in the wir


(PH02Slinel:
1. Turnthe ignitionswitchOFF.
2. Disconnectthe ECM/PCMconnector(D (16P),C (31P)*).
3. Checktor continuitybetween
the PrimaryHO2S{Sensor1)
4 P c o n n e c t o tre r m i n a lN o . 1
and body ground.

PHO2S ---'t
rwHTr T-T-l
T-1 1 2l

6 t lr___J_J
r rl
Y

Wire sideof temaleterminals


Repairshort in tho wire botwesn
the ECM/PCMlD7, C16*) .nd th6
Prim.ry HO2S(Snsor11.

Substituto a known-good ECM/


PCM and recheck. ll 3ympiom/
indicationgoes away. raplaceth.
origin.l ECM/PCM.

(cont'd)

www.emanualpro.com

11-111

PGM-FISystem
PrimaryHeatedOxygenSensor(PrimaryHO2SI(Sensor1l (cont'd)
'99 - 00 models:
-

The MIL has bsen reported on.


DTCP0131ir storod.

Problemve fication:
1. Do the ECM/PCMReset Procedure,
2. Start the engine. Hold the
engine at 3,000rpm with no
load {in Parkor neutral)until
lhe radiatortan comeson.
3. Check the Primary HO2S
(Sensor1) oltput voltage with
the scantool during acceleration usingwide opnthrottle.
Doesthe voltage stay at 0.5 V
or less?

Inl.rmittant failura, 3yrtam i! OK


at thb tim.. Ch.ck tor poor connectiona oa looaa wlraa al C111
{Pri|n.ry HO2S,Son3or 1l .nd .t
tho ECM/FCM,

Checktho fuel pressure(seepago


1r,178).

R.p.ir th. ful lupply ry!t.m.

Chocklor a short in tho HO2S:


1. Turnthe ignitionswitchOFF.
2. Disconnectthe Primary HO2S
(Sensor1) 4Pconnector.
3. St6rtthe engineand lot it idle.
4. Check the Primary HO2S
(Sensor1) output voltage with
the scantool,

Does it stay 6t 0.5 V or less?

Chock for a short in tho wirc


(PHO2Slino):
1. Turnthe ignitionswitchOFF.
2. Disconnectthe ECM/PCMconnectorC (31P).
3. Check tor continlity between
the PrimaryHO2S{Sensor'l}
4P connectorterminal No. I
and body ground.

Rephc. th6 HO2S(S.n3or 11.

PRIMARYHO2S(Son.or 1l aP CONNECTOR
|C111)

PHO2S T--1
rwHTr f-T---]
--1 1 2l
I

t---

t6)lslrl
v L__r__J

_L

Wire sideol femaleterminals


Ragah rhort in tha wira balwoan
t h . E C M / P C M{ C l 6 1 r n d t h c
Prirn.ry HO2S(S.n3or 11.
Substltut6 a known-good ECM/
PCM and recheck. lf rymptom/
indicrtion 00os away, raplaco thc
original ECM/PCM.

www.emanualpro.com

11-112

The scan tool indicatesDiagnosticTroubleCode (DTC)P0132:A high voltage problemin the PrimaryHeated
OxygenSensor{PrimaryHO2S)(Sensor1) circuit.
'97 - 98 models:

Problemverification:
1. Do the ECM/PCMResotPro,
ceoute,
2. Start the engine.Hold the
engine at 3,000rpm with no
load (in Parkor neutral)until
the radiatorfan comeson.
3. Test-drive with the Ay'Tin E
position(M/Tin 4th gear).
4. Check the Primary H02S
{Sensor1}outputvoltagewith
the scantool duringdeceleration using completelyclosed
throttle.
Does the voltage stay at 1.0 V

Intormittent l.ilure, 3ystem ia OK


at thb timo. Chcck fo. poor connections01 looso wi.es at C111
{Prim!ry HO2S, Sensor 1} and
ECM/PCM.

Checkfor an open in th6 Primary


H()2S:
1. Turnthe ignitionswitchOFF.
2. Disconnect
the PrimaryHO2S
(Sensor1)connector3 . C o n n e c tt h e P r i m a r yH O 2 5
lSensor1) 4P connector
termin a l sN o . 1 a n d N o . 2 w i t h a
jumperwire.
4. Turnthe ignitionswitchON (ll).
5. Check the Primary HO2S
(Sensor1) output voltagewith
the scantool,

sG2

PHO2S
IWHTI

IGRN/
BLK}

Wire sideot femaleterminals

ls there1.0V or more?

{'97 model}

Chck for an opon in the wires


(PHO2S,SG2linesl:
1. Turnthe ignitionswitchOFF.
2. ConnectPCM connectorterm i n a l sD 7 a n d D l 1 w i t h a

PCMCONNECTOR
D {16PI
JUMPERWIRE
PHO2SIWHTI

SG2 IGRN/BLK}

3. Turnthe ignitionswitchON (ll).


4. Check the Primary HO2S
{Sensor1) output voltagewith
the scantool.
ls there1.0V or more?

{ T op a g e1 1 - 1 1 4 )

www.emanualpro.com

Roprir opon in the wire betweon


tho PCM {D7 01 D11l and the
Primsry HO2S{S6nsor1).

Wire sideof temaleterminals

I
(cont'dl

11-113

PGM-FISystem
PrimaryHeatedOxygenSensorlPrimaryHO2S){Sensor1} {cont'dl
( F r o mp a g e ' 1 1 - l 1 3 )

Ch.ck for an open in the wire


(PHO2Slinel:
1. Turnthe ignitionswitchOFF.
2. ConnectECM/PCMconnector
terminalsC16and C18with a

ECM/PCMCONNECTOR
C {31PI

3. Turnthe ignitionswitchON {ll).


4. Checkthe Primarly H02S
(Sensor1) outputvoltagewith
the scantool.
ls there1,0V or more?

Substitute a known-good ECM/


PCM and rachck.lt 3ymptom/
indication goos away, replace
the origin.l ECM/PCM.

11-114

www.emanualpro.com

Rp.ir open in the wire bqtwen


t h e E C M / P C M ( C 1 6 1a n d t h
PrimaryHO2S(Sen.or'l).

'99 - 00 modols:
Th6 Mll has bon reDortodon.
DTCml32 is itorod.

Problemvorification:
'1. Do the ECi!4/PCM
ResetPro
cedure,
Start the ongine.Hold the
engine at 3,000rpm with no
load (in Parkor neutral)until
the radiatorfan comeson.
Check the Primary HO2S
lSensor1) outputvoltagewith
the scan tool during decelelation using completelyclosed
throftle.

Doos the voitage stay at 1.5 V


or more?

Int.rmitt .fi tailuro, syltom b OK


at thit tima. Checkfor poor connactiona oi loo3a wirar !t Cltl
(Primrry HO2S,S.nror 1) .nd .t
th. ECM/FCM.

PRIMARYHOzS (S6n!or 1l aP
CoNNECTORlcltl)

Pt()2s
IWHTI

Checkfor an opsn in the Prlmary


HO2S:
1. Turnthe ignitionswitchOFF.
2. Disconnect
the PrimaryHO2S
(Sensor1)connector.
3 . C o n n e c tt h e P r i m a r yH O 2 S
(Sensor1) 4P connectort6rmin a l sN o . 1 a n d N o . 2 w i t h a
iumperwire.
4. Turn the ignitionswitchON (ll).
5, Check the Primsry H02S
(Sensor1) output voltagewith
the scantool,

sG2
{GRN/
BTJ(I

Wire side of tem6leterminsls

lsthere 1.5V or more?

Check for an op6n in th6 wiro


{PHO2Sline):
1. Turntho ignitionswitchOFF.
2. Connect ECM/PCMconnector
terminalsC16 and C18with a
iumperwire.
3. Turnthe ignitionswitchON lll).
4. Check the Primary HO2S
(Sensor1) outputvoltagewith
the scantool.

ECM/PCMCONNECTOR
C (31P}
2
23

7
8 9
't8
1912A
0 22
/ 1 6 17
E
29 g) 31

PHO2S{WHTI
ls there1.5V or more?

Ropair opon in thc wire bc{w.cn


t h e E C M / P C M{ C l 6 } . n d t h e
PrimaryHO2S{Snror 1}.

sG2IGRN/BLKI

JUMPERWIRE
Wire sideol temalet6rmin6ls

Substituto a known-good ECM/


PCM snd rochock.lf 3ymptom/
indicetion goa awry, roplaca tho
origin.l ECM/PCM.
www.emanualpro.com

(cont'd)

1 1- 11 5

PGM-FISystem
Primary Heated Oxygen Sensor (PrimaryHO2S)lSensor 1) (cont'd)
scantool indicatesDiagnosticTroubleCode(DTC)P0133:A slow responseproblemin the PrimaryHeated
tFO133
\ lhe
:
Oxysen Sensor (Primarv HO2S\ (Sensor 1) circuit.
Description
By controllingthe airlfuelratiowith a PrimaryHO2S(Sensor1) and a SecondaryHO2S(Sensor2), the deteriorationof the
PrimaryHO2S(Sensor1) can be evaluatedby its feedbackperiod.When the feedbackperiodof the HO2Sexceedsa cer
tain valueduringstabledrivingconditions,the sensorwill be judgedas deteriorated.
When deteriorationhas beendetectedduringtwo consecutive
trips,the MIL comeson and DTCP0133will be stored.
NOTE: lf DTCP0131,P0132and/or P0135are storedat the same time as DTCP0133.troubleshootthose DTCSfirst, then
troubleshootDTCP0133.
PossibleCause
. PrimaryHO2S(Sensor1) Deterioration
. PrimaryHO2SHeater(Sensor1) Deterioration
. Exhaustsystemleakage
Troubleshooting Flowchart
-

The MIL has b6n reoortedon.


DTCP0133is stored.

ProblemVerilication:
'1. Do the ECM/PCMResetPro
cedure.
2. Connectthe scantool.
3. Start the engine.Hold the
engine at 3,000rpm with no
load lin Parkor neutraliuntil
the radiatorfan comeson.
4. Connectthe SCSservicecon
nector.
5. Test-driveunderthe following
condations,
55 mph (89 km/h) steady
speed
- M in @ position(E posi
tion and Over DriveON)*,
(M/Tin sth gear)
- Until readinesscode comes

Intermittent failure, system is OK


at this time. Checktor poor connectionsor loose wires at C111
(Primary HO2S,Sensor 1) and al
the ECM/PCM.
Replacethe Primary HO2S {Sensor 11.

1 1 - 11 6

www.emanualpro.com

SecondaryHeatedOxygenSensor(SecondaryHO2S)(Sensor2)
The scantool indicatesDiagnosticTroublecode (DTC)P0137:A low voltageproblemin the secondaryHeated
OxygenSensor(SecondaryHO2S)(Sensor2) circuit.
The MIL hrs been reported on.
DTC P0137 is stored.

Problemveritication:
1. Do the ECM/PCMResetPro'
cedure.
2 . S t a r tt h e e n g i n e .H o l d t h e
engine at 3,000rpm wilh no
load (in Parkor neutral)untal
the radiator{an comeson,
3 . C h e c kt h e S e c o n d a r yH 0 2 S
l S e n s o r2 ) o u t p u tv o l t a g ea t
3,000rpm with the scantool.

Doesthe voltage stay at 0.3 V


or less?

lnlermittent failure, 3ystem i5 OK


at this time. Checktor Poor con'
noction3 or loose wires at C127
{locatod on ECM/PCM bracket},
C721 (Secondary HO2S, Sensor
2l and at the ECM/PCM.

Checkfor a short in the Secondary


HO2S:
1. Turnthe ignitionswitchOFF.
2 . D i s c o n n e c tt h e S e c o n d a r y
HO2SlSensor2) 4Pconnector.
3. Startthe engine.
4 . C h e c kt h e S e c o n d a r yH O 2 5
(Sensor2) outputwith the scan
tool.

HO2Sls.nlor 2)
SECONDARY
4P CONNECTOBlC721l
C h e c kl o r a s h o r t i n t h e w i r e
(SHO2Slinel:
1. Turnthe ignitionswitchOFF.
2 . D i s c on n e c t t h e E C M / P C M
connector{D (16P},A (32P}').
3. Check for continuity between
the SecondaryHO2S(Sensor
2i 4PconnectorterminalNo. 1
and bodyground.

Wire sideof lemaleterminals


Reoairshort in the wire btwoen
rhe ECM/PCM|D14, 423*l and
the SecondaryHO2S{Sensor2).

Substitute a known-good ECM/


PCM and rocheck.lf symptom/
indication goes away, replace
the original ECM/PCM.

(cont'd)

*: '98 - 00 modeis
www.emanualpro.com

11-117

PGM-FISystem
SecondaryHeatedOxygenSensor(SecondaryHO2SI(Sensor2l (cont'dl
The scantool indicatesDiagnosticTroubleCode(DTC)P0138:A high voltageproblemin the SecondaryHeated
OxygenSensor(SecondaryHO2S)(Sensor2) circuit.
The MIL hra bon Eported on,
OTCm138 b stor.d.

PJoblcmv6dtic.tion:
1. Do the ECM/PCMResotProcedure,
S t a r t t h e e n g i n e .H o l d t h e
engine at 3,000rpm with no
load (in Parkor neutral)trntil
the radiatorlan comeson.
Check the Secondary HO2S
(Sensor2) outpl.rtvoltage at
3,000rpm with the scantool.

Doesthe voltage stay at 0.6 V


or more?

Int.rmitto
tailurc, syst.m b OK
rt ihi! timo. Chack fo. poo. oonnoctioni or looaa wiiaa at C127
lloc.ted on EcM/PcM br.cket),
C721 (Second!ry llO2S, Sonlol
2).nd at th. ECM/PCM.

Chockfor an opon in the Socondary


HO2S:
1. Turn the ignitionswitchOFF.
2 . D i s c o n n e c tt h e S e c o n d a r y
HO2S(Sensor2) 4P connector.
3. Connectthe SocondaryHO2S
(Sensor2) 4P connectorterminalsNo. 1 and No. 2 with a

SECONDABYHO2S (Sonror 2)
1P CONNECTORrC721l

sHo2s
{WHT/REDI

4. Turn the ignitionswitchON {ll}.


5 . C h e c kt h e S e c o n d a r yH O 2 S
{Sensor2) output voltagewith
the scantool.

sH()2sG
IGFN/WHTI

Wire side of female terminals

ls there0.6V or more?

('97model)
Ch6ck for an open in thg wiro3
(SH()2S,SG2 line3l:
1. Turnthe ignitionswitchOFF.
2. ConnectrcM connectorterminals 014 and D13 with a
J!mper wite.
3. Turnthe ignitionswitchON (ll).
4 . C h e c kt h e S c o n d a r yH O 2 S
( S n s o r2 ) o u t p u t v o l t a g e
with the scantool.

lsthere0.6V or more?

{ T op a g e1 1 - 1 1 9 )
www.emanualpro.com

1 1 - 11 8

PCMCOI{NECTOR
D {16PI

sHo2sG
(RED/YELI
JUMPERWIRE

Rapair op6n in tho wir. b{woan


tho PcM lDla or Dl3l .nd tho
S.condlry HO2S{Senlor 21.

Wirc sideol lemaleterminals

( F r o mp a g e1 1 - 1 1 8 )

('98- 00 models)
ECM/PCMCONNECTORS
A l32Pl
Check for an open in tha wire
ISH()2Slinel:
1. Turnth ignitionswitchOFF.
2. ConnectECM/PCMconnector
terminalsA23 and C18with a
iumperware.
3. Turnthe ignitionswitchON (ll).
4. Checkthe Secondary HO2S
(Sensor2) output voltage with
the scantool.

ls there 0.6 V or more?


L _._._ _

SHO2SW}iT/RED)| JUMpERW;RE

Repairopon in tho wire botwaen


t h e E C M / P C Ml A 2 3 l a n d t h e
Second.ry HO2S(Sonsot21.

Wire sideof fomaleterminals


I

Substitute a known.good ECM/


PCM .nd recheck. It symptom/
indication goes rway, replace
the origin.l ECM/PCM.

(cont'd)

www.emanualpro.com

1 1 - 11 9

PGM-FISystem
SecondaryHeatedOxygenSensor(secondaryHO2SI(sensor2l (cont,d)
-lTol3al
-

The scantool indicatesDiagnostic


TroubleCode(DTC)P0139:A slow responseprobtemin the SecondaryHeated
UxygenSensor(HO2S)(Sensor2l circuit.

The MIL has ben reoortedon.


DTCP0139is storad.

Problmve.itication:
1. Do the ECM/PCMResetPro
cedure,
S t a r tt h e e n g i n e .H o l d t h e
engine at 3,000rpm with no
load (in Parkor neutral)until
the radiatorfan comeson.
C h e c kt h e S e c o n d a r yH O 2 S
(Sonsor2) output at 3,000rpm
with the scantool.

Doesthe voltagestaywithin
0.3- 0.6V for two minutes?

1 1 -1 2 0

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lntehittont failure, 3ystem is OK


at this time. Chock for poor connections o. loose wi.es at C127
(located on ECM/PCM brackt),
C721{SecondaryHO2S,Sensor2l
and at the EcM/PcM.

HeatedOxygenSensor(HO2S|Heater
scantool indicatosDiagnosticTroubleCode
Fol3slThe
{PrimarvHO2S)(Sensor1) Heatercircuit.
indicatesDiagnosticTrouble Code
F o 1 1 t The
l scantoolHO2S)
(Secondary
(Sensor2) Heatercircuit.
-

(DTC)P0135:A problemin the PrimaryHeatedOxygenSensor

(DTC)P0141:A problem in the SecondaryHeatedOxygen Sensor

Th6 MIL h.. bocn roponod on.


DTC P0135,and/oi mlal are
stored.

Probl.m verification:
1. Do the ECM/PCMResotProcedure,
2. Startthe engine.

Int.rrnittaii frilurc, awtom ir OK


at thi3 time. Chocklor poor conn.ctiona or loosa wiro3 !t C111
lPrim.ry HO2S, Sen3o. 11.C12?
llocatcd on ECM/PCM br.ck.t),
C721 lsocond.ry Ho2s, s.n3or
2r and at tho ECM/PCM.

Ch.ck ior an opon or shoYt in the


HO2S:
1. Turnthe ignitionswitchOFF.
2. Disconnoctthe Ho2s (Primary
or Secondary*)(Sensor1 or
Sensor2)4P conneclor.
3 . A t t h e H O 2 Ss i d e , m e a s u r e
resistancebetween the HO2S
4P connectorterminalsNo. 3
a n dN o . 4 .

PBIMARYHO2Sls.n.or ll 4P
CONNECTOR(CI 11I, SECONDARY
HO2Sls.n.o.2l aP CONNECTOR
lc721l.

Terminalsideof maletrminals

ls there10- 40 0?

C h e c kf o r c o n t i n u i t y b e t w e e n
body ground and the HO2S 4P
c o n n e c t o rt e r m i n a l sN o . 3 a n d
No. 4 individually.
PRIMARYHO2Slson.o. 1l aP
CONNECTOR{Cl 11}, SECONDARY
HO2Sls.nror 214P CONNECTOR

tcr21l.
Checktor an op6n or 3hort in the
wires IPO2SHTC, SO2SHTC'
linel:
1. Turnthe ignitionswhchON {ll).
2. Moasurevoltage between the
HO2S4P connectorterminals
N o . 3a n dN o . 4 .

('97model:To page'11-122)
('98- 00 models:To page11-'123)

so2sHTc
tBLK/WHn.

PO2SHTC
(BLK/
WHTI
tGl
IBLKAAIHTI'

Wire sid of lemale terminals

('97model:To page'11-122)
1'98- 00 modelslTo page11-123)

(cont'd)

*: P0141
www.emanualpro.com

11-121

PGM-FISystem
HeatedOxygenSensorIHO2S)Heater(cont'd)
{'97model)
PRIMARYHO2S(S.nsor 1) ap CONNECTOR
{cl111

Chockfor en open or lhort in the


wire (lG1 line):
M e a s u r ev o l t a g e b e t w e e nt h e
HO2S4P connectorterminalNo.
3 ( s e c o n d a r yN: o . 4 ) a n d b o d y
ground,

| 1 1 2|

|.i-l
1 3. l

'ot X(9
tErK/
Reprir op6n or 3hort in thc wirc
betwo.n th No. 15 ALTERNATOR SP SENSOR(7.5 Al fu!. rnd
tho HO2S(Primary.Socond.ry*).

Chck for an open in the wire


(PO2SHTC,
SO2SHTC.lin):
1. Turnthe ignitionswitchOFF.
2. Reconnectthe HO2S4P con-

-L

Wiresideof femaleterminals

SECONDARY
HO2S
ISENSOR214P CONNECTOR

lcr21l,

3. Disconnectthe PCM connector A (32P).


4. Turnthe ignitionswitchON (ll).
5 . M e a s u r ev o l t a g e b e t w e e n
PCM connectortrminals46
andA10(A5andA10)*.

ls thero0.1V or less?

YELI

IGl IBLK/WHTI

Bepair opon in the wiro botwoon


the PcM (A6. A5lr and tho Ho2s
{Prim.ry, Socond!ryr}.

Wire sideol femaleterminals

Substitute a lnown-good PCM


and recheck. lt 3ymptom/indication goes away, .oplacothe original PCM.

( F r o mp a g el 1 - 1 2 1 )

Wire sideof femaleterminals


Check fo. a ahort in the wire
SO2SHTC.lins):
IPO2SHTC,
1. Turn the ignirionswitchOFF.
2 . D i s c o n n e c tt h e P C M c o n nector A {32P).
3. Checklor continuily between
the PCM connectorterminal
46 (A5)*and body ground.

So2HTCIALK/WHTI*PO2SHTCIBLK/WHTI

Bopair short in the wire lrotwsen


tho PC{r4{A6, A5rl and the HO2S
lPiimary, Scondary.l.
Substitute a known-good PCM
and .echgck. lf 3ymptom/indication gos awry. repl.cethe original PCM.

11-1 2 2

www.emanualpro.com

('98- 00 models)

HO2S{S.n3or 1l aPCONNECTOR
PRIMARY
lc111l
Check for an open in the witoa
(lGP,lGl'lino):
Mgasurevoitage betweenthe primary HO2S4P connectorterminal
No. 3 (secondaryHO2S:No. 4) and
body ground.

1 1 2 l

r--T -

lL-.IJ------J
3 t . l

Bepair opan or short in tho wilo


bdtween th6 nlo. 15 ALTERNATOR
SP SENSOR17.5Al fu$ .nd th6
HO2S{Primrry, Scondtrytl.

Wiresideof femaleterminals
HO2S
SECONDARY
{SENSOR2} 4P CONNECTOR
(c7211'

Chock lor sn opon in the wires


SO2SHTC'lincl:
IPO2SHTC,
1. Turnthe ignitionswitchOFF.
2. Reconnectthe HO2S4P connector.
3. Disconnectthe ECM/PCMconnector C (31P)(ECM/PCMconneaor A (32P))*.
4. Turnthe ignitionswitchON (ll).
5. Moasurevoltage between
ECM/PCMconnectorterminals
82 andCl (82andA8)*.
ls there0.1V or less?

lcl /5'
tErK/ g,
YELI I

IGl IBLK/WHT}

Wire sideof femaleterminals


Repsir opsn in tha wire between
tho ECM/PCM(C1, A8.) .nd the
HO2SlPrimsry,Socond.ry*}.

ECM/FCMCONNECTORS
PGl (BLK}

Sub.titute a known-good ECM/


PCM and rocheck. lf iymptom/
indicrtion goes away, repbce
the original ECM/PCM.

lFrom page11-12'!)

Chock lor a short in the wi.es


(PO2SHTC,
SO2SHTC'linol:
1. Turnthe ignitionswitchOFF.
2. Disconnectthe EcM/PcM connector C {31P)lECM/PCMconnectorA (32P))*.
3. Check for continuity between
ECM/PCMconnectorterminal
Cl (A8)*and bodyground.
ls therecontinuity?

Roolir 3hort in th. wiro betwoon


the ECM/PCMlC1, A8'l and the
HO2S(Primary,S6condary*).

Sub3tituie s known-good ECM/


PCM and rech6ck. It symptom/
indicaiion goes away. lgplaco
th6 origin.l ECM/PCM.
: P0'14'l

www.emanualpro.com

Wire sideof lemaleterminals

11-123

PGM-FISystem
Fuel Supply System
[POliil

The"""ntool indicatesDiagnosticTroubteCode(DTC)p0'171:Thefuet
systemistoo lean.

[Fo17ZJ rh""""ntool

indicatesDiagnosticTroubtecode {DTc)p0172:Thefuelsvstemistoorich.

Description
By monitoringthe LongTerm Fuelrrim, long term malfunctionsin the fuel systemwill be detected.
lf a malfunctionhas beendetectedduringtwo consecutive
trips,the MIL will come on and DTc p0171and/orpol72 will be
stored.
NOTE: lf someof the DTCSlistedbeloware storedatthesametimeas DTCP017'land/orp0172,troubleshootthose DTcs
first,then troubleshootDTCP0171and/orPO1i2.
P0107,P0108,P1128,P'1129:
MAP Sensor
P0135:PrimaryHO2S(Sensor1)Heater
P0137,P0138:SecondaryHO2S{Sensor2)
P0141:SecondaryH02S (Sensor2) Heater
P0441*r:EVAPSystemlnsufficientPurgeFtow
P1456*,,P'l457*?i EVAPSystem Insufficientpurge Ftow

* 1 : ' 9 7m o d e l
*2: '98 - 00 models

PossibleCause
DTCP0171
too lean

FuelPumpinsufficientflow/pressure
FuelFeedLineclogged.leaking
FuelPressureRegulatorstuckopen
FuelFilterclogged
FuelInjectorclogged,air leakage
Gasolinedoesn'tmeet Owner'sManualspec.
PrimaryHO2S(Sensor1) deteriorated
ValveClearance
Exhaustleak

DTCP0172

FuelPressureRegulatorclogged,stuckclosed
FuelReturnPipeclogged
FuelInjectorleaking
Gasolinedoesn'tmeetOwner'sManualspec.
PrimaryH02S (Sensor1) deteriorated
EVAPPurgeControlSolenoidValveleaking,stuckopened
ValveClearance

flch

11 -1 2 4

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TroubleshootingFlowchart
-

The MIL has beenrePortedon


DTC P0171 andlot P0172 are
stored,

ls the lLrelpressuretoo high


Checklhe Primaty HO2S:
1 . S t a r tt h e e n g i n e .H o l d t h e
engine at 3,000rpm with no
load (in Parkot neutral)until
the radiatorfan comeson
2 . C h e c kt h e P r i m a r yH O 2 S
( S e n s o r1 ) o u t P u tw i t h t h e
scantool.

Doesit stayat lessthan0.3V


or morethan 0.6V?

Checkfor a sticking or leaking


EVAPpurge control solenoid
vacu
With a vacuumpump,aPPIY
u m t o t h e E V A PP u r g ec o n t r o l
s o l e n o i dv a l v e f r o m t h e i n t a k e
manifoldside.

Doesit holdvacuum?

Checkth6 valve clearancsand


adjust il necessary. It the valv
clearancesare OK, replace the
fuel iniectors.

www.emanualpro.com

Checklh fuel pumP. fuel faed


pipe. fuel fiher, and luel Prossurc
.eguhior.

Checkthe lu6l pressuroregulator


and tusl relum PiPe.

PGM-FISystem
RandomMisfire
lF()gool",tftod-'

The scantool indicatesDiagnosticTroubleCode (DTC)


pO3O4;
Random
misfire.

andsome
orlpiogolthroughTo3otiP0300*,,P1300*1and someof po30t-

Descriotion
Misfiredetectionis accomplishedby monitoringthe crankshaftspeedwith the crankshaft
speedfluctuation(cKF)sensor
which is attachedto the crankshaft.
lfmisfiring strongenoughto damagethe catalystis detected,the MIL will blinkduring
the time of its occurrence,
and DTc
P0300*' P1300*1
,
and some of DTCsP03olthrough P0304will be stored.Then,after misfirehasceased,
the MtL will come
on,
lf misfiringthat increasesemissionsis detectedduring two consecutivedriving
cycles,the MIL will come on, and DTc
and some of DTCSp0301through p0304wi be stored.
NOTE:lf some of the DTCSlistedbeloware storedat the sametime as a misfireDTc,
troubleshootthose DTcsfirst. then
troubleshootthe misfireDTC.
P0106,P]128,P1'129;
MAp sensor
P0171.P0172;Fuetmetering
P0505:ldle Control Svstem
P1336,P1337;CKFsensor
P1361,P1362:TDCsensor
Pl381.Pl382:CYPsensor
*1:,97 model
P1508:IACvalve
*2: '98 - 00 models
PossibloCaus
. Fuelpump insufficientfuel pressure,amountofflow
. Fuelline clogging.blockage,leakage
. Fuelfilter clogging
a Fuelpressureregulatorstuckopen
. Distributormalfunction
. lgnitioncoil wire open,leakage
. lgnitioncontrolmodulemalfunction
. Valvescarbondeposit
a Compressionlow
a Fueldoes not meetOwner'sManualspec.,lackoffuel
Troubleshooting
By test-driving,determinethe conditionsduring which misfireoccurs.Depending
on these conditions,test in the order
describedin the table below.

\
[

Possible
cause
-....
;;;;-

Condition
Only low rpm and load

Crankshaft
speedfluctuation
sensor

Fuel
pressure

Distributorand
lgnitionwires

tcM

section6

11-178

section 23

section 23

,6)

Valve
Clearance
section 6

Only accelerating

Only high rpm and load

,a'

Not specification

G\

NOTE:lf misfiredoesn'trecur,some possiblecausesare fuel that doesn'tmeet owner'smanual


spec,lackof fuel, carbon
deposits on spark plu9, etc.

11-1 2 6

www.emanualpro.com

MisfireDetectedin OneCylinder
Ipffi1]

ThescantootindicatesDiagnosticTroubleCode(DTC)P0301:Cylinder1 misfiredetected.

lF03O2l 16".""n toot indicatesDiagnosticTroubleCode(DTC)P0302;Cylinder2 misfiredetected.


I P0303 | fne scantool indicatesDiagnosticTroubleCode(DTC)P0303:Cylinder3misfiredetected.
Cylinder4 misfiredetected
lF0il04l 16" ""un tool indicatesDiagnosticTroubleCode(DTC)PO3O4:
Description
(CKF)sensor
Misfiredetectionis accomplishedby monitoringthe crankshaftspeedwith the crankshaftspeedfluctuation
which is attachedto the crankshaft.
and DTC
lf misiiringstrongenoughto damagethe catalystis detected,the MIL will blinkduringthe time of its occurrence.
on.
MIL
will
come
the
has
ceased,
misfire
after
the
Then,
will
be
stored.
P0304
and/or
P0303
P0301,P0302,
DTc
lf misfiringthat increasesemissionsis detectedduring two consecutivedriving cycles.the MIL will come on, and
P0301,P0302,P0303and/orP0304will be stored.
first,then
NOTE:lJ some of the DTcs listedbelow are storedat the sametime as a misfireDTc, troubleshootthose DTcs
troubleshootthe misfireDTC.
P0107,P0108,P'n2a,P1129tMAP sensor
'l P0112tFuel suPP|Ysystem
Po'17
,
P0441:EVAPinsufficientPurgeflow
P1336,P1337:CKFsensor
P1359,Pl361,P1362:TDCsensor
Pl381,P1382:CYPsensor
PossibleCause
. Fuelinjectorclogging,fuel leakage,air leakage
. Fuelinjectorcircuitopen or shorted
. Sparkplug carbondeposits,fouling,malfunction
. lgnitionwires open,leaking
. Distributormalfunction
. Compressionlow
. Valveclearanceout of specification

(cont'd)

www.emanualpro.com

11-127

PGM-FISystem
MisfireDetestedin OneCylinder(cont'dl
Troubl93hootingFlowchart
-

Th. MILh!3 b6onr.portod on.


DTCm30r, P0302,m303. or
P0304is indicated.

Ch.ck tho fuol inicctor tunction:


Startthe engino,and listenfor I
clickingsoundat the fuol injector
in the problmcylinder.

The illustration shows


'97 - 98 models,'9900 models
are similar.
Checkfor an open or short in the
harnessbetweenthe ECM/PCM
and the luel injector.

Boprir opan or 3hort in tha wlre.

Problom vorification:
1. Atter chackingthe lrezedata,
do the ECM/PCMReset Procedure.
2. Exchange
the sparkplug from
the problemcylinderwith one
ol anothercylinder.
3. Connectthe SCS service connector.
4. Tost-drivethe vohicleseveral
times in the rangool the freeze
data.

(Topage'11-129)

1 1 -1 2 8

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Roplacoth. tuel inioctor.


Substitut. . known-good
E C M / P C M. n d r o c h o c k .I t
3ym ptom/ indicati on go.3
a w . y , r e p l a c et h e o l i g i n a l
ECM/PCM.

NOTE:
.lf there is no freezedata ol misfiring,
just clearthe DTC.
.lf there is no freezedata ot misfiring,
test drives under various conditions
are necessary,

( F r o mp a g e1 1 - 1 2 8 )

ls DTCP0301,P0302,P0303,
or P0304indicated?

ooesthe misfireoccurin the


othercylinder?

Check lor fuel iniector maltunct|on:


1 . E x c h a n g et h e f u e l i n j e c t o r
f r o m t h e p r o b l e mc y l i n d e r
with one from anothercylinder.
2. Letthe engineidlefor two min
utes.
3. Test'drivethe vehicleseveral
times in the rangeof the freeze
data,

ls DTCP0301,P0302,P0303,
or P0304indicated?

Doesthe misfireoccurin the


othercylinder?

lntormittent misfire due lo spark


plug fouling, etc. (no mislire at
this tim).

Replacethe faulty spark Plug.

NOTE:lf there is no freezedata of mis


firing, test drives under variouscondi_
tionsare necessary.

lntermittent misfiro due lo bad


contrct in the fuel iniector connector {no misfire at this time).

Replacelhe faulty luel inlector.

Checkfollowing items
- Valvo clearance
- Cvlinderlak-down
- Compression
- Crsnkshaft Speed Fluctuation
ICKF)sensol

www.emanualpro.com

11-129

PGM-FISystem
KnockSensor{KSl
('99- 00 models)The scantool indicatesDiagnosticTroubloCode(DTC)P0325:A malfunctionin the circuitof
the KnockSensor(KS).
-

The MIL has been rooortedon.


DTCm325 is storod.

Problemverification:
1. Do the ECM/PCir,ResetPro
cedure,
2 . S t a r t t h e e n g i n e .H o l d t h e
engine at 3,000rpm with no
load (in Parkor neutral)until
t h e r a d i a t o rt a n c o m e s o n ,
then let it idle.
3 . H o l d t h e e n g i n e a t 3 , 0 0 04,000 rpm for at least 60 seconds,
Intermittent lailu.e, 3ystom is OK
at thi3 tim. (te3t drive m.y be
nacalLrYr.
Chock to. poor connsctions ol
loora wiros rt C137 lknock aon.o. (KS))and ar the ECM/FCM.
Chck tor a short in the wir6 {KS
linel:
1. Turnthe ignitionswitchOFF.
2, Disconnectthe knock sensor
lP connector.
3. Checklor continuitybetween
E C M / P C Mc o n n e c t o rt e r m i
nalsC3and body ground.

ECM/PCMCONNECTOR
C 131P}

Replil rhort in the n irg b6{wocn


tho ECM/PCMlc:ll and the knock
sngr1.
Check fo..n open in the wire
{KSline):
C h e c kf o r c o n t i n u i t y b e t w e e n
ECM/PCMconnector terminal C3
and knocksensorconnectorter,
m i n a lN o .1 .

Wiresideof femaleterminals

KS 1P CONNECTOR
IC13?'

KS
IRED/BLU)
Wire side ol female
termtnals

ls therecont;nuity?

B.pair opon in the wirc lrotween


lho ECM/PCMlctl and thc knock
acnsor.

Substitutea known-goodknock
sensorand recheck.

NOTE: Torquethe knocks6nsorto


31 N.m (3.2kgl.m, 23 lbf.ft).

ls DTCP0325indicated?

Bcpl.ce the originalknock 3nsor,

ECM/PCMCONNECTOR

KS
c (31P)
(BED/BLU)

Wire sideot femaleterminals

Substituto a known-good ECM/


PCM and .echeck. lf 3ymptom/
indication goes away, replace
the original ECM/PCM.

11 - 1 3 0

www.emanualpro.com

Sensor
Position(CKP/TDC/CYPI
CrankshaftPosition/TopDeadGenter/Gylinder
scantool indicatesDiagnosticTroubleCode
tro-rslThe
sensorcircuit,

(DTC)P0335;A malfunctionin the CrankshaftPosition(CKP)

problemin the Crankshaft


The scantool indicatesDiagnosticTroubleCode(DTC)P0336:A range/performance

1Tffi61 Position{CKP)sensorcircuit.
The

tool indicatesDiagnosticTroubleCode {DTC)P1361:Intermittentinterruptionin the Top DeadCenter

scan
tF136t(TDC)
sensorcircuit.
The scan
fPfa6r-1
ci.cuit.

tool indicatesDiagnosticTroubleCode (DTC)P1362:No signalin the Top DeadCenter(TDC)sensor

tool indicatesDiagnosticTroubleCode(DTC)P1381:Intermittentinterruptionin the CylinderPosition

The scan
tF138tl(CYP)
sensorcircuit.

The scantoot indicatesDiagnosticTroubleCode {DTC)P1382:No signalin the CylinderPosition(CYP}sensor

I-Pi382lcircuit.

Description
The CKPSensordeterminestiming for fuel injectionand ignitionof eachcylinderand also detectsenginespeed.The TDC
Sensordeterminesignitiontiming at start-up{cranking)and when crankangle is abnormal.The CYPSensordetectsthe
Sensoris built into the distribupositionof No. 't cylinderfor sequentialfuel injectionto eachcylinder.The CKP/TDC/CYP
ror.
NOTE:lf DTCP1359is storedatthesametimeas DTCP0335,P0336,Pl361,P1362,P1381and/orP1382,troubleshootDTC
P1359first,then troubleshootthose DTCS.

'97 model:
-

The MIL has ben reportedon.


DTC P0335, P0336, P136' 1,
P1362,Pl341 and/oi P1382are
stored.

lOP
DISTRIBUTOR
CoNNECTOR(Cl211
TDCPIGRNI

CYPPIYELI

Problemverific.tion:
1. Do the PCMResetProcedure.
2. Startthe engine.
ls DTCP0335,P0336,P1361,P1362,
P1381and/orP1382indicated?

Ch.ck for an open in tho CKP/


TDC/CYPsensor:
1. Turn the ignitionswitchOFF.
the distributor10P
2. Disconnect
connector.
3. Measureresistancebetween
the terminalsof the indicated
sensor(seetable).
ls there 350 - 700 o?

Intermittent lailure, 3yd6m i3 OK


at thb tims. Chcck tor poor connections ol looso wire3 si C12'l
ldistributor) .nd .t the PCM.

CYPM(BLKI
TIrcMIREOI

Terminalsideof
maleterminals
S E N S O E DTC

Replacetho distributor ignition


housing {sea3ection41.

SENSOB

WIRE
PCM
E R M I N A I COLOR

P0335
P0336

CKP

c2

c12

TDC

P1361
P1352

P' I381
P1342

3
't0

CYP

8LU

GRN

c13
c4
c14

RED
YEL
BLK

{cont'd)
(To page11-132)

www.emanualpro.com

11-131

PGM-FISystem
Grankshaft
Position/Top
DeadCenter/Cylinder
Position(CKP/TDC/CYPI
(cont'd)
Sensor
DISTRIBUTOR
10PCONNECTOR
tCl2l)

{ F r o mp a g e 1 ' 1 - 1 3 1 )

CKP P
IBLUI

TDCP {GRNI

Check for a short in the CKP/


TDC/CYPsensor:
C h e c kf o r c o n t i n u i t yt o b o d y
ground on both terminalsof the
indicatedsensorindividually(see
t a b l eo n p a g e1 l 1 3 1 ) .

ls therecontinuity?

Rplacthe distributor ignition


housing {seesection4}.

Chckfo. an open in the wires


lines):
{CKP/TDC/CYP
'1. Reconnect
the distributor10P
connector.
2. DisconnectPCMconnectorC
(31P).
3. Measureresistancebetween
the terminalsof the indicated
sensoron the PCMconnector
o n p a g e1 l 1 3 1 ) .
lseetable

ls there350- 7000?

Terminalsideof
maleterminals

Repairopen in the indicated sensor wires {se6 table on page 11131).

PCMCONNECTORS
C I31P)
CKPP TDCP CYPP
IBLU) IGRNI IYEL}

Check tor a short in the wires


linesll
{CKP/TDC/CYP
C h e c kf o r c o n t i n u i t y b e t w e e n
body groundand PCMconnector
terminalsC2,C3and/orC4 individ-

ls therecontinuity?

Substitute a known-good PCM,


and recheck.lf symptom/indication goes away, rplacelhe original PCM.

www.emanualpro.com

RDairshort in the indicatodsensor wires lsee table on page 1113rI.

{WHT)

IREDI IBLK)
Wiresideof
female
terminals

CKPP

TDCP

CYPP

'98 model:
1OP
DISTRIBUTOR
CoNNECTOR(C121)
TDCP(GRN)
CYPP(YEL}

'98 - 00 models:

'99 - 00 modelr:
8P
DISTRIBUTOR
coNNECTOR{C121)
TDCP (GNN}
CYPP IYEL}

The MIL ha3beenreoortedon.


DTC P0335. P0336, P1361,
P1362.P1381andlor P13V are
stord,
Problemverification:
1. Do the ECM/PCMResetPro
cedure.
2. Startthe engine.

TDCM(REDI
CYPMIBLKI
Terminalsideof maleterminals
Intermittant tailure, svstom is OK
at this time. Check for poor connections or loose wirgs al C121
{distributo.l .nd at the ECM/
PCM.

ls DTCP0$5, m$6, Pl361,P1362,


P1381and/orPl382 indicated?

Check for an open in th6 CKP/


TDC/CYPsensor:
1. Turnthe ignitionswitchOFF.
2. Disconnect
the distributor10P
(8P)*connector.
3, Measureresistancebetween
the terminalsof the indicated
sensor{seetable).

CYPM IBLKI

TDCM (RED}
sideof maleterminals
Terminal
S E N S O R DTC

SENSOR
ECM/PCM WIRE
ERMINAT
I E R M I N A I COLOR
):'99mode

P0335
P0336

8 (6)

c8
c9

BLU

CKP

P1361
Pl362

2 (3)

c20

GBN

TDC

9 (7)

c21

RED

3 (4)

c29

YEL

1 0{ 8 )

c30

BLK

CYP

P]381
P]382

1 t2)

Rephce the distributor ignition


houaing l3e93oction4).

ls there350 7000?
'98

modeli

TDCP {GRNI

Check for a short in the CKP/


TDC/CYPsnsor:
C h e c kf o r c o n t i n u i t yt o b o d y
ground on both terminalsof the
indicatedsensorindividually(see
table).

Replacotho distributor ignition


housing lsee soction tll.

Check for an opn in th6 wires


linesl:
ICKP/TDC/CYP
1. Reconnect
the distributor10P
(8P)*connector.
2. Disconnect
ECM/PCM
connector C (31P).
3. Measureresistancebetween
the terminalsof the indicated
sensoron the ECM/PCMcon
nector(seetable).

ls there350 700O?

C {31P)
ECM/PCMCONNECTOFS

CKP P
{BLU)

Repairopen in the indicated sensor wires lsee t.ble).


':'99 - 00 models

TOCP
IGRNI
CYPP
(YEL)

(Topage11-134)
femaleterminals

www.emanualpro.com

CKPM
IWHT)

(RED)
CYPM
(BLKI

(cont'd)

11 - 1 3 3

PGM-FISystem
GrankshaftPosition/TopDeadCenter/CylinderPosition(CKP/TDC/CYPI
Sensor{cont'd}
(Frompage11 133)
C {3IPI
ECM/PCMCONNECTOR

Chock lor r 3hon in tho wirer


lin6):
ICKP/TDC/CYP
C h e c kf o r c o n t i n u i t y b e t w e e n
body groundand ECM/PCMconnectorterminalsC8, C20 and/or
C29individually.

Rep.ir lhort in ths indicatedsonaor wiroa 136otable on prge 11133).


Substituto r known-good ECM/
PCM, and .6chock. tf 3ymptom/
indication goe3 swey, replrce
tho original ECM/PCM.

11 -1 3 4

www.emanualpro.com

Wire sideof femaleterminals

Vehicle Speed Sensor (VSSI


|posoll-'
lPosoo-]-'.

The scantool indicatesDiagnosticTroubleCode{DTC}P0500*' orP0501*r:A range/perfor* I ; A/T


mancein the VehicleSpeedSensor(VSS)circuit.
*2i Mfi

'97 modol:
FCM CONNECTORS

The MIL hes boen roported on.


DTCm501 is 3tord.

A t32Pl
LG1

(BRN/BLK)
Problomverificetion:
1. Test'drivethe vohicle.
2. Checkthe vehiclespeedwith
the scantool,

ls the correctspeedindicated?

Chockfor an open in tho PiCM:


1. Turnthe ignitionswitchOFF.
2. Block the rear wheels and set
the parkingbrake.
3. Jack up the lront of the vehicle
and support it with salety
stands.
4. Turn the ignitionswitchON (ll).
5. Elockthe right front wheel and
slowly rotate the left tront
wheel by hand.
6. Measurevoltage between
PCMconnectorterminalsC18
and A9.
Doesthevoltagepulse0 V
and 5 V or batteryvoltage?

lntormittent tailure, rystom b OK


at thia timo. Chocktor poor connection3 or 10o3owires rt C129
lvss) .nd rr rhe Pcfr4,

N O T E :D o n o t u s e t h e e n g i n et o t u r n t h o
front wheels with th6 rear wheels on the
ground. The 4WD system will engage and
the vehiclewill suddenlvIurchforward.
Wire side ot femaleterminals

Substitulc a known-good PCM


and .och6ck. It symptom/indicd.
tion go.a away, .cplacotho originel FCM.
LGl

{BRN/BLKI
Checkfor a .hort in the PCM:
L Turnthe ignitionswitchOFF.
2 . D i s c o n n e c tt h e P C M c o n '
nectorC (31P).
3. Turnthe ignitionswitchON (ll).
4 . E l o c kt h e r i g h t f r o n t w h e e l
and slowly rotate the left front
5. MeasurevohagebetweenPCM
connectorterminalsC18 and
A9.
Doesthevoltagepulse0 V
and 5 V or batteryvoltage?

www.emanualpro.com

Substituto e known-good PCM


and rochock. f rymptom/indication goos rwry, roplsc. tho originalFCM.

Repair short in the wire


between the PCM lC18l,
cruise control unit, speodometer, and VSS,
Repair opon in the wire
between the PCM {C181.nd

rhevss.
f wire is OK. tost lho VSS l3oo
soction 231.

(cont'd)

11-135

PGM-FISystem
VehicleSpeedSensor(VSSI{cont'd}
'98 - 00 models:
-

ECM/PCMCONNECTORS

The MIL ha3 beenreDonedon.


DTC P0500" or P0501*1i3
3torod.

B t25Pl

Probl6mverification:
1. Test-drive
the vehicle.
2. Checkthe vehiclespeedwith
the scantool,

ls the correctspeed indicated?

Checkfor rn open in the ECM/


PCM:
l Turnthe ignitionswitchOFF.
2. Elockthe rearwheelsand set
the parkingbrake.
3. Jack up the front oI the vehicle
and support it with satety
stands.
4. Turn the ignitionswitchON {ll}.
5. Blockthe right front whoel and
slowly rotate the lett front

Intermittont failu.e, svstem is OK


at thk time. Check for poor connection! or loose wiros at C129
lvss) .nd ar the EcM/PcM.

NOTE(4WD):Do not use the engineto turn


the front wheelswith the rearwheelson the
ground. The 4WD system will engage and
the vehiclewill suddenlylurchforward.

Wiresideof femaleterminals

6. Measurevoltage between
E C M / P C Mc o n n e c t o rt e r m i nals820 and C23.
Doesthe voltage pulse between
0 V and 5 V or battery voltage?

Substitute a known-good ECM/


PCM and rochock. ll symptom/
indicetion 9063 away, .oplace th
origin.l ECM/PCM.

B (25P)

Check for a short in the ECM/


PCMI
1. Turn the ignitionswitchOFF.
2 . D i s c o n n e c tE C M / P C Mc o n
nectorC 131P).
3. Turn the ignitionswilch ON {ll).
4 . B l o c kt h e r i g h t f r o n t w h e e l
and slowly rotatethe left front
5. MoasurevoltagebetweenECM/
PCMconnectorterminals820
and C23.

Doesthe voltage pulse betlveen


0 V and 5 V or battery voltage?

R.pair short in the wiro


betwen the ECM/PCMlC23)
.nd tho VSS.
Roprir open in th6 wire
botweon the ECM/PCMlc23l
and th6 vss.
It wirc is OK, te3t ihe VSS
(!e soetion23).

*2:Mft

11 - 1 3 6

www.emanualpro.com

Sub.titute a known-good ECM/


PCM and rschock. It rymptom/
indication goos .w.y. replece
rhe original ECM/PCM.

BarometricPressure(BARO)Sensor
problemin the Barometric
The scantool indicatesDiagnosticTroubleCode(DTC)P1106:A range/performsnce
Pressure{BARO)Sensorcircuit.
The MIL has been reDortedon.
OTCPl106b slored.

Problemve.ification:
1. Oo the ECM/PCMreset pro'
ceoure.
2. Start the engine.Hold the
engine at 3,000rpm with no
load (;n Parkor neutral)until
the radiatorlan comeson, then
letit idle.
3. Connectthe SCSserviceconnector,
4. Test'drivewith the A/T in E
position,M/T in 4th gear.
5. AccelerateIor five seconds
usingwide openthrottle.

ls DTCP1106indicated?

Intermittent fsilure, sy3tom i5 OK


at this time.

Substitute a known-good ECM/


PCM .nd recheck.It symptom/
indication goes away, replacethe
origioal ECM/PCM.

fTiloz l The scantool indicatesDiagnosticTroubleCode(DTC)P1107:A low voltageproblemin the Barosensorcircuit.


The scan tool indicatesDiagnosticTrouble Code
tP11o8l
circuit.
-

(DTC)Pl108: A high voltage problem in the Baro sensor

The MIL h.3 ben roportdon.


OTCPl10?or Pl108i3 stored.

Problomveritic.lion:
L Do the ECM/PCMResetProcedure.
2. Turnthe ignitionswitchON (lli.

ls DTCP1107or P1108indicated?

Sub3tituto a known-good ECM/


PCM and rcch6ck. ll symptom/
indication 9oo3 away. .oplaco
rho o.igin.l ECM/PCM.

www.emanualpro.com

Intarmittoni failure, lystom b OK


at thb time.

PGM-FISystem
ElestricalLoadDetector(ELDI(USAModell
The scan tool indictesDiagnosticTrouble Code (DTC)P1297:A low voltage problem in the ElectricalLoad
Detector(ELD)circuit.
'97 model:

Problemvsriticltion:
1. Do the PCMFesetProcedure.
2. Startthe engine.
3. Turn on the headlights.

ls DTCP1297indicated?

Intormittent lailuic, 3vstom k OK


at thk time. Ch.ck tor poor connections or loose wiro3 at C127
(loc.ted on PCM b.sckot), C354
{ELO,.nd at tho FCM.
ELD3P CONNECTOR
{C354I

Ch.ck for 3hort in lho ELD:


Measurevoltage between body
groundand the ELD3P connector
t e r m i n aNl o . 3 .

--+l 1 L 2 l 3 l
lerO) tcnrulaeot

ls thereapprox.4.5V?

Wire sideot femaleterminals

PCMCONNECTOR
D I16P)

Checkfor a short in tho wire IEL


linel:
1. Turnthe ignitionswitchOFF.
2. DisconnectPCM connector D
(16P).
3. Checkfor continuitybetween
body ground and PCMconnec
tor terminalD16.

Wire sideof femaleterminals


Rcpair 3hort in tho $rire botwon
the PcM lDl6l and tho ELD.

Substituto a known-good PCM


and rocheck. lf 3ymptom/indic.tion goos !w!y, repl.ce the original PCM.

11 - 1 3 8

www.emanualpro.com

98 - 00 mod6l3:
-

OTCPl17 is 3tored.

Problcm vcrificrtion:
1. Do the ECM/PCMResetProcedure,
2. Startthe engine.
3. Turn on the headlights.

ls DTCP1297indicated?

Intcrmittent tailuro, ryrtom ir OK


!t thi3 timo. Ch.ck tor poor connectiont or looao wire! at CXl54
IELD)rnd at rh6 ECM/PCM,

Chockfor 3hort in tho ELD:


Measurevoltage between body
groundand the ELD3P connector
terminalNo.3.

ELD3PCONNECTOR
ICAs4I

-I

f 2_ l l 3, l

l---r'.
&)

iGRN/RED)

Wire sideof temaleterminals

ls there approx. 4.5 V?

ECM/PCMCONNECTOR
A I32P)
Chcck lor a 3horl in tho wiio (EL
linol:
1. Turnthe ignitionswitchOFF.
2 . D i s c o n n e c tE C M / P C Mc o n nectorA (32P).
3. Check for continuity between
body ground and ECM/PCM
connctortrminalA30.
Wire sid6of femaleterminals
Ropairshon in thc wira botwocn
tho PcM (A301rnd rho ELD.

Sub.tituto a known.good ECM/


PCM .nd rocheck. ll lymptom/
indication gocs .w!y. replsce
th6 o.iginal ECM/PCM,

(cont'd)

www.emanualpro.com

1 1- 1 3 9

PGM-FISystem
ElectricalLoadDetestor(ELDI(USAModel)(cont'dl
The scan tool indicatesDiagnosticTrouble Code {DTC)Pl298; A high voltage problem in the ElectricalLoad
Detector(ELD)circuit.
97 modsl:

ELD3P CONNECTOR
{C35,'I
Problamverification:
1. Do the PCMResetProcedure.
2. Startthe engine.
3. Turn on the headlights.
Intermittent tailuro, systcm is OK
.t this time. Chack for ooor connoction! or looro wire3 at C127
{locaied on PCM brackot), C35{
{ELDIand .t tho PCM.
Chack for an opan in tho wile
llGl linol:
1 . T u r n t h g i g n i t i o na n d h e a d lightsOFF.
2. Disconnectthe ELD3P connector.
3. Turn the ignitionswitchON {ll).
4. M6asurevoltage btwen
body ground and the ELD 3P
connoctorterminalNo. 1.

WiresidooI lemaleterminals

rlzlrl
--T_ow
/6\ IBLKI

Y
Repail opn in th. wire btwsn
t h o N o . 1 5 A L T E R N A T O RS P
S E N S O R1 7 . 5 A ) t u s e i n t h e
under-dlrh fuso/r.lay box and
th6 ELD.

EL {GRN/NEDI

Chock lol !n open in the wire


IGND linel:
'1. Turn the ignition switch and
headlights
OFF.
2. Disconnectthe ELD 3P con
neqor,
3. Check for continuity between
body ground and the ELD3P
connectorterminalNo.2.
Ropairopon in th6 wi.e betweon
th. ELDconnectorrnd GiO2,

Wire sideof lemaleterminals


PCMCONNECTORS

Ch.ck lo. an open in th wiro (EL


line):
Checkfor continuity between the
ELD3P connectorterminalNo. 3
and PCMconnectorterminal016.
ls therecontinuityT

R6pafuop6n in tho wire between


the PCM{D161sndth6 ELD.
Subltituto . known-good PCM
and rachock, f symptom/indic.tion goes awry, ropl.ce the origin.l PCM.

Chock for . malfunction in the


ELD:
1 . R e c o n n e ctth e E L D 3 P c o n neclor,
2. Start the engineand allow it
to idle.
3. While measuring voltage
betweenPCM connectorter
m i n a l s0 1 6 a n d A 9 . t u r n t h e
headlights
on (low).

Doesthe voltagedrop?

Wire sideof lemaleterminals

1 1 -1 4 0

www.emanualpro.com

38 - 00 modeb:

Problemverification:
1. Do the ECM/PCMResetPro
ceoure.
2. Stanthe engine.
3- Turn on the headlights.
ls DTCP1298indicated?

Check lor an open in the wire


(lG1line):
' 1 . T u r n t h e i g n i t i o na n d h e a d lightsOFF.
2. Disconnectthe ELD3P connector.
3. Turnthe ignitionswitchON (ll).
4 , M e a s ur e v o l t a g e b e t w e e n
body ground and the ELD3P
'1.
connectorterminalNo.

ELO3PCONNECTOR
{c35/rl

Intermittent feilure, sysl.m is OK


at this time. Checkfor ooor connections or loose wires at C354
(ELDIand at the ECM/PCM.

Wire sideot temaleterminals

ELD3P CONNECTOR
{C35,lt

Reprir open or short in th6 wire


botweon the No. 15 ALTERNATOR SP SENSOR{7.5 Al fuse in
the under-drah fuse/relay box
and the ELD.

Wiresideof femaleterminals

Check tor an opon in tho wire


{GNDline}:
1. Turn the ignition switch and
headlights
OFF.
2. Disconnectthe ELD 3P con
nector.
3. Check for continuity between
body ground and the ELD 3P
connectorterminalNo.2,
Repairopon in the wire between
the ELDconneclor and GilO2.

Ched(fo. an opn in the wir (ELlinel:


Checkfor continuity between the
ELD3P connectorterminalNo. 3
and ECM/PCMconnectorterminalA30.

EL IGRN/RED}
Wire sideof female
termrnars
Repairopn in tha wile botwecn
the EcM/PCM lA30l .nd rhe ELD.

ECM/PCMCONNECTORS
A l32P)

Checkfor s malfunction in lhe ELD:


1 . R e c o n n e ctth e E L D 3 P c o n nector.
2. Start the engine and allow it
to idle.
3 . W h i l e m e a s u r i n gv o l t a g e
between ECM/PCMconnector
terminalsA30 and 820, turn
the headlightson (low).

Wire sideof femaleterminals


Substiiute a known-good ECM/
PCM and recheck. It symptom/
indication goos away, replace
the original ECM/PCM.
www.emanualpro.com

11-141

PGM-FISystem
GrankshaftSpeedFluctuation(CKF)Sensor
Tj":""l.tool indicatesDiagnosticTroubleCode(DTCIP1336:Intermittentinterruptioninthe Crankshaft
Speed
fF13361l
:
Fluctuation(CKF)sensorcircuit.
The scan tool indicatesDiagnosticTrouble Code (DTC)P1337:No signal in the CrankshaftSpeedFluctuation(CKF)
sensorcircuit.
Description
The diagnosticsystemhas a pulserrotor on the crankshaftand a pulsepick-upsensoron the engineblock.The ECM/PCM
monitorsthe crankshaftspeedfluctuationbasedon the CKFsensorsignal,and judgesthat an enginemisfireoccurredif
the fluctuationgoes beyonda predetermined
limit.

37 mod.l:
-

Tho MIL ha3been reportedon.


DTC P1336and/or P1337are
stored.

Problemverificrtion:
1. Do the PCMResetProcedure.
2. Startthe engine.

CKFSENSOR

Intermittent {ailure,systom is OK
.l thia timo. Ch6ck tor poor connections or loose wir$ at Clorl
ICKFsonsorl .nd at tho PCM.
Chocktor an opon in th6 CKF.en'
30r:
1. Turn the ignitionswitchOFF.
2. Disconnect
the CKFsensor2P
connector,
3, Measure the resistance
b e t w e e nt h e C K Fs e n s o r2 P
connectorterminalsNo. 'l and
No.2.

ls there1.6-3.2 kO?

CKFSENSOR2P CONNECTOR
IClO4I
T:]
l-r'r Lll
l' 1' z' L' l
CKFP
I lcKFM
talu/aeotfdJ twxrneor

\-7

Checkfo. a short in the CKF3ensot:


C h e c kf o r c o n t i n u i t y b e t w e e n
body groundand the CKFsensor
2P connectorterminalsNo. 1 and
No.2 individually.

(Topage11-113)

1 1 -1 4 2

www.emanualpro.com

Terminal side of male terminals

{ F r o mp a g e1 1 - 1 4 2 )
PCMCONNECTOR
C 13lPI
Chock to. an open in the wires
(CKFlin06l:
1. Reconnect
the CKFsensor2P
connector,
2. D;sconnectthe PCM connect o rC ( 3 1 P ) .
3. Measureresistancebetween
PCM connectorterminalsC1
a n dC l 1 .
Wire sideof lemaleterminals
ls there1.6- 3.2k0?

Ropair open in the wire betwoon


tho PCM lcl, Cl1l and th6 CKF
!6naor.
CKFP
IELU/REDI

Chock tor a short in the wires


(CKFlino3):
C h e c kf o r c o n t i n u i t y b e t w e e n
body ground and PCMconnector
terminalCl.

Rcoair short in thc wire btween


the PCM{Cl I and the CKF.en!o..

Subsiituto r known-good PCM


and r6chock. lf symptom/indication goe3away, roplacothe origin.l rcM.

(cont'd)

www.emanualpro.com

11-143

PGM-FISystem
GrankshaftSpeedFluetuation(CKFISensor(cont'dl
.98 - 00 modols:
-

The MIL has boon reportedon.


DTC P1336and/or P1337are
stored.

ProblGmverification:
1. Do the ECM/PCMResetProcedure,
2. Stanthe engine.
Inte.mittant failuro, 3y*om b OK
at thb tima. Chack lor ooor connections or looso wirea at C10a
{ C K Fs e n s o r la n d . t t h e E C M /
PCM,
Chgckforun open in tho CKFsonsori
1. Turnthe ignitionswitchOFF.
2. Disconnectthe CKFsensor 2P
connector.
3. Measure the resistance
between the CKF sensor 2P
connectorterminalsNo. 1 and
No.2.

IClO'I
CKFSENSOR2P CONNECTOR
r-:-i-_l

tr_-

l, 1, -2 l' l
CKFP

ICKFM

tsLuneotTOl
wlrrneo)
\7

lsthere1.6- 3.2kO?

Terminalsideof maleterminals
Checkfor a short in the CKFsenC h e c kl o r c o n t i n u i t y b e t w e e n
body groundand the CKFsensor
2P connectorterminalsNo. 1 and
No.2 individually.

r:l

t !E l
.KFPXA"*."
\:f
talurneor

(Topage11'1451

11-144

www.emanualpro.com

rwxvneor

C (31P)
ECM/PCMCONNECTOR
CKFP
IBLU/REDI

Check for an open in the wires


ICKFlinca):
1. Feconnectthe CKFsensor2P
connector.
2. DisconnectECM/PCMconnect o rC ( 3 1 P ) .
3. Measureresistancebetween
E C M / P C Mc o n n e c t o rt e r m i '
nalsC22and C31.

ls there1.6- 3.2kO?

1 2

,/ 2s

7
8
1 6 1 7 1 6 't9 20 21 22
26 27 28
29 3() 3 l

__l (oI
-l
T

M
CKFM
(WHT/BEOI
Wi16sideof l6maleterminals
Repairopon in the wir6 botwoon
the ECM/PCM1C22,glll lnd th6
CKFs6n3or.

( F r o mp a g e1 1 - 1 4 4 )
C (31PI
ECM/PCMCONNECTOR
CKFP
{BLU/RED)

Check for a shorl in the wires


(CKFlines):
C h e c kl o r c o n t i n u i t y b e t w e e n
body ground and ECM/PCMcon
nectorterminalC22.

ls therecontinuity?

Repairshort in tho wire between


the ECM/PCM{C221and rh. CKF

Wire sideof femaleterminals

Substitute a known-good ECM/


PCM and recheck. lf svmptom/
indication goes away. replace
the original ECM/PCM.

www.emanualpro.com

11-145

PGM-FISystem
Sensor
CrankshaftPosition/TopDeadCenter/CylinderPosition(CKP/TDC/CYP)
The scantool indicatesDiagnosticTroubleCode (DTC)P 1 3 5 9A: problemin the CrankshaftPosition/TopDead
sensor circuit.
Center/CvlinderPosition tCKP/TDC/CYP)
-

The MIL has been reoortedon.


DTCP1359is stored.

Problemverific.tion:
1. Do the ECM/PCM
ResetProcedure.
2. Startthe engine.lf the engine
won't start, crank it continuouslyforat least15seconds.

ls DTCP1359indicated?

C h e c kf o r p o o r c o n n e c t i o n so r
loosewires betweenthe distribu'
tor andthe EcM/PcM.

Substitute a known-good ECM/


PCM, and recheck. ll symplom/
indication goes away, replacethe
original ECM/PCM.

1 1 -1 4 6

www.emanualpro.com

Intermitteni lailure, system is OK.


Check for ooor connectionsor
loos wires al C121 {distributor}
and at the ECM/PCM.

ECM/PCMInternalCircuit
lFi6oil
-

Th" """n tool indicatesDiagnosticTroubleCode{DTC)P1607:An ECM/PCMInternalCircuitProblem.

The MIL has been reoortedon.


DTCPlmT is slor6d.

Problomveritication:
1. Do the ECM/PCMResetPro
2. Turnthe ignitionswitchON (ll).
3, Waitthreeseconds,

ls DTCP1607indicated?

Sub3tiiut a known-good ECM/


PCM and recheck.lf symptom/
indicationgoes away, replacethe
originalECM/rcM.

www.emanualpro.com

11-147

PGM-FISystem
HO2SReplacement
1.

Disconnect
the HO2S4P connector,and removethe
HO2S.

PRIMARYH02S:

PRIMARYHO2S
4P CONNECTOR

02 SENSOR
WRENCH

PRIMARY
HO2S
44 N.m
{4.5kgt m,33lbf.ftl

SECONDARY HO2S:

SECONDARY
HO2S
4,0N.m (4.5 kg{.ft, 33 lbtftl

2.

Installthe HO2Sin reverseorderof removal.

11-1 4 8

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ldle Control System


SystemDescription
The idle speedof the engjneis controlledby the ldle Air Control(lAC)Valve'
The valvechangesthe amount of air bypassinginto the intakemanifoldin responseto electriccurrentcontrolledby the
Whenthe lAc valve is activated,the valveopensto maintainthe properidle speed.
ECM/PCM.
YEL/
BLK

FromPGM'FI
TMAIN RELAY

VARIOUS
SENSORS

IAC VALVE
INTAKEMANIFOLD

After the enginestarts,the IACvalve opensfor a certaintime. The amountof air is increasedto raisethe idle speed
about 150- 300 rpm.
when the cootanttemperaturets row, the lAc valve is openedto obtain the proper fast idle speed The amount o{
bvoassedair is thus controlledin relationto the enginecoolanttemperature
and the scantool does not indicateDiagnosticTroubleCode(DTC)P0505
When the idle speedis out o{ specification
items:
or P1508,checkthe following
. Adjustthe idle speed(seepage11-169,170)
. A i r c o n d i t i o n i nsgi g n a (l s e e p a g e l l - 1 5 5 1
. A L TF Rs i g n a (l s e ep a g e1 l - 1 5 9 )
. Starterswitchsignal(seepage11-16'1)
. A,/Tgear positionsignal(seesection14)
. P S Ps w i t c hs i g n a (l s e e p a g e l l - 1 6 2 )
. Brakeswitchsignal(seepage11-165)
. F a s ti d l e t h e r m o v a l v (es e ep a g e ' 1 11 6 8 )
. Hosesand connecttons
. IACvalveand its mountingO-rings
4.

lf the aboveitemsare normat,suDslitutea known-goodIACvalveand readjustthe idle speed{seepage 11-169,170)


lf the idle speedstill cannot be adjustedto specification(and the scantool does not indicateDTC P0505or Pl508)
after IAC valve reolacement,substitutea known-goodECM/PCMand recheck lf symptom goes away' replacethe
originalECM/PCM.

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11-149

ldle Control System


ldle ControlSystem
I P0505 | The scantool indicatesDiagnosticT.oubleCode(DTCIPO5O5:
ldlecontrolsvstemmattunction.
NOTE:lf DTCP1508is storedat the sametime as DTCP0505,troubleshootDTCP1508first.then troubleshootDTCp0505.
PossiblsCause
. IACvalvemechanicalmalfunction
. Throttlebody cloggedport,improperadlustment
. Intakemanifoldgasketleakaging
. Intakeair hoselooseleakaging
. Vacuumhose leakaging
a ECTsensorincorrectoutput
. ThrottlePositionsensorincorrectoutput
TroubleshootingFlowchart
The MIL has been reDortedon.
DTCP0505is sto.ed.

Problemverificationi
1. Start the engine.Hold the
engine at 3,000rpm with no
load (in Parkor neutral)until
the radiatorIan comeson, then
let it idle.
2. With the scan tool, checkthe
lollowingitems.
- Throttleposition should be
approx. 10%with the throttle {ully closed.
- E n g i n ec o o l a n tt e m p e r a
ture shorJldbe 194- 205'F
(90- 96"C).
lf they are not within the
spec.,repairthe faultysensor circuit.
3 C h e c kt h e e n g i n e s p e e d a t
idle with no-loadconditions:
headlights,blower fan. rear
defogger,radiatorlan, and air
conditionerare not operaling,

ls it 750{730)*i 50 rpm?

Inte.mittent failure. syltem is OK


at this time.

ls il 700(680)'rpm or less?

l:'99 - 00 models

{ T op a g e1 1 - 1 5 1 )

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( T op a g e1 ' l - 1 5 1 )

(Frompage11-150)

Checkthe IAC valve:


the 2P connectorfrom
Disconnect
the IACvalve.

Doesthe enginespeeddroP
or the enginestall?

Adiust the (basel idl speed lsee


page11-169,1t0).Itihe ba3eidle
speed cannot be adiustd, clean
the Dorts in the throttle body.

UPPER

{ F r o mp a g e1 1 - 1 5 0 }

Checkthe tast idle lhermo valve:


1. Turnthe ignitionswitchOFF.
2 . R e m o v et h e i n t a k ea i r d u c t
from the throttle body.
3. Startthe engineand let it idle.
4. Put your finger on the lower
pon in the throttlebody.

THERMOVALVE
(A/Tonlyl
Doesthe enginespeeddrop?

Checkenginecool.nt leveland for


air in the cooling sy3lem. lf OK,
reolacethe f.st idle thermo valve.

Putyour Iingeron the uPPerPort


in the throttlebody.

Doesthe enginespeeddroP?

Adjust the idle spoed lsee Page


11-169.1701.lf the adiustment
does not correct lhe problem,
r.olace the IAC valve.

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Check for vacuum leaks, make


sure the throttle valve is com'
pletely clo3ed.and repair as nec-

ldle Control System


ldle Air ControlllAC)Valve
The scan tool indicatesDiagnosticTrouble Code (DTC)Pl508: A probtem in the ldle Air ControtflAC)varve
circuit.
The IACValvechangesthe amountof air bypassingthe throttlebody in responseto a currentsignalfrom the ECM/PCMin
orderto maintainthe properidle speed.
From AIR To INTAKE
CLEANER MANIFOLD

37 model;
The MIL has beon .eportd on.
OIC Pl508 is sto.ed.

Problemveiification:
1. Do the PCMResetProcedure.
2. Startthe engine,and warm it
up to normal operatingtemperature.

ls DTCPl508indicated?

Inte.mittent failure, systcm b OK


at thi3 time. Checktor poo. connections or loose wircs at C132
(lAC v.lvel and at the PCM.
IAC VALVE2P CONNECTOR
{C132}

Check lor an open in the wir6


{lGPl lins}:
1. Turnthe ignitionswitchOFF.
2. Disconnectthe IAC valve 2P
connector.
3. Turn the ignitionswitchON {ll).
4. Measurevoltagebetweenbody
ground and the IAC valve 2P
connectorterminal No.2.

,f\

rcp'
IYEL/BI.(I

I- 2df -) 1

Y
Wir side of female terminals

Repairopen in the wire trctwoon


tha IAC v!lv6 and the PGM-Fl
main relly.
PCMCONNECTOR
A I32PI
Chockfor an opan o. short in tho
wi.e (lACv linel:
1. Turn the ignition switch OFF
and reconnectthe IAC valve
2P connector.
2. Disconnectthe PCMconneclor
A (32P).
3. Turn the ignitionswitchON {ll).
4 , M e a s u r ev o l t a g e b e t w e e n
body ground and PCM connectorterminalA12.

{ T op a g e1 l - 1 5 3 )

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tacv
IBLK/
BLU)
Wire sideof femaleterminals

( F r o mp a g e1 1 - 1 5 2 )

ls therebafteryvoltage?

Bepair opn or short in the wire


betweon th PCM {A121and the
IAC vrlve.

Checkthe IAC valve function:


Momentarilyconnect PCM con'
n e c t o rt e r m i n a l sA 1 2 a n d A 1 0
with a iumoerwire severaltimes,
Wire sideof femaleterminals
Doesthe IACvalveclick?

Substitute . known-good PCM


and rcheck, lt 3ymptom/indication goes away, replacothe origi_
nalPCM,

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1-153

ldle Air Control(lAC)Valve{cont'd}


'98 - 00 models:
The MIL has boen r.ported on.
DIC Pl 508 b 3tored.

Problemveritication:
L Do the ECM/PCMResetProcedure.
2. Startthe engine,and warm it
up to normal operatingtemperature.

ls DTCP1508indicated?

Intrmittent failure, systom is OK


al lhis timo. Check lor poor connections or looro wirca at C132
(lAc vrlvel and .t rho EcM/PcM.
IAC VALVE2P CONNECTOR
{C132I

Chock tor an open in the wir6


llGPl linel:
1. Turnthe ignitionswitchOFF.
2. Disconnectthe IAC valve 2P
connector,
3. Turnthe ignitionswitchON (ll).
4. Measurevoltagebetweenbody
ground and the IAC valve 2P
connectorterminaI No, 2.

rcpt

F\

*l
tYELrBLxl
I2/'-

rf)
Y

Wire side ot fem.le terminals


Repairopon in the wira botwoon
the IAC valve and tho PGM-FI
main aalay.
B (25PI
ECM/PCMCONNECTOR

Checktor an open or short in the


wire (IACVlinel:
1. Turn the ignition switch OFF
and reconnectthe IAC valve
2P connector.
2 . D i s c o n n e c tE C M / P C Mc o n nectorB {25P).
3. Turn the ignitionswitchON {ll}.
4. Measurevoltage between
body ground and ECM/PCM
connectorterminal823.

9
19

2
'to

5
1l

21 22

20

13

t7

23

tAcv
(BLK/BLUI

Wiresideof femaletorminals
ls there batteryvoltage?

Checkthe IAC valve func,tion:


Momentarilyconnect ECM/PCM
connectorterminals823 and 82
with a jumperwire severaltimes.

Ropair open or short in thg wire


between tho ECM/FCMlB23l and
the IACvalve.

PG1
{BLKI
1

2 |

t 3 4 5

9 1 0
1 1 13
19
20 | 121)22

8
17

tAcv
(BLK/
BLU)

Does the IACvalve click?

Subslitute . known-good ECM/


PCM .nd rechock.lf symptom/
indication goes aw.y, replac.
th original ECM/PCM.
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JUMPERWIRE

Air ConditioningSignal
This signalsthe EcM/PcMwhen there is a demandfor coolingfrom the air conditioningsystem.
'97 modol:

Chock for a shorl in thc wiro


(ACSlinol:
1. Turnthe ignitionswitchOFF.
2. Disconnectthe A/C pressure
switch2Pconneclor.
3. Turnthe ignitionswitchON (ll).
, 1 . [ I e a s ur e v o l t a g e b e t w e e n
PCM connectorterminalsC5
andA9.

Wiresideof lemaleterminals

C (31PI
PCMCONNECTOR
ACS IBLU/RED)
Check for . .hon in the wire IAGS
linel:
1. Turnthe ignitionswitchOFF.
2. DisconnectPCM connectorC
(31P).
3. Check for continuity between
body ground and PCM connectortorminalC5.
Wiresideof femaleterminals

Reoaii short in tho wire btwoen


rh6 PCM (Csl and the A/C pres3urc 3witch.

Check tor an opon in the wite


(ACClino):
1. TLrrnthe ignitionswitchOFF.
2. Roconnectthe A/C pressure
switch2Pconnector.
3. Turn the ignitionswitchON (ll).
4 . M o m e n t ar i l y c o n n e c t P C M
c o n n e c t o tr e r m i n a l sA 9 a n d
417 with a iumper wire sev'
eraltimes,

(To page11-156)

Subcdtrte a known{ood PCM


and recheck. lf pr6actibed voltage is now av{ilable, roplace
the origind PCM,
Soethe eir conditionorin3pclion lsee soction221.

A (:TIPI
PCMCONNECTOR
JUMPERWIRE

Wire sideoI Iemaleterminals

(cont'd)

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1 1 - 15 5

ldle GontrolSystem
Air ConditioningSignal(cont'dl
(Frompage11-'155)

Ch6ck for an open in th wire


(ACClinel:
Momentarilyconnectthe underhood fuse/relaybox 9P connector
t e r m i n a lN o . 5 t o b o d y g r o u n d
with a jumperwire severaltimes.

ls therea cl;ckingnoisefrom
the 4!/Ccompressorclutch?

ls therea clickingnoisefrom
the 4!/Ccompressorclutch?

UNOER.HOOD
FUSE/RELAY
BOX 9P CONNECTOR
tqt52)
1

JUMPER
WIRE

ACC IBLK/REDI
IBLK/R
Wire sideof female
termrnats

See air condiiioner inspection


{seesection221.

Repai. op6n in the wire betwoen


the PcM (A17) and tho A/C
clutch relay.
PCMCONNECTORS

A t32Pl

C t3rp)

Checkthe A/C operation:


1. Startthe engine.
2. Turnthe blowerswitchON.
3. Turn the A"/Cswitch ON.

Wire sideol lemaleterminals

Doesthe A,/Coperate?

Check for an open in the wire


(ACSline):
Measurevoltage between PCM
connectorterminalsAg and C5.

Air conditioningsignal is OK.


ls therelessthan 1.0V?

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Subqtitute a known-good FCM


.nd rch6ck.lt 3ymptom/indication goes awav, replece the
originalrcM.
Soe th eir conditioner in3pection (s6aec.tion22).

Repair open in the wire between


the PCMlCSland the A/C awitch.

'98 - 00 models:

ECM/PCMCONNECTORS
A {32P1

Check for a shott in the wire


{ACSlinel:
1. Turnthe ignitionswitchOFF.
2. Disconnectthe A/C Pressure
switch2Pconnector.
3. Turnthe ignitionswitchON (ll)
4. Measurevoltage between
E C M / P C Mc o n n e c t o rt e r m l
nalsA27 and 820.

A (32PI
ECM/PCMCONNECTOR

ls there batteryvoltage?

Checktor . short in the wire IACS


linel:
1. Turnthe ignitionswitchOFF.
2. DisconnectECM/PCMconnector A (32P).
3. Checkfor continuitybetween
body ground and ECM/PCM
connectorterminalA27.

Wiresideof femaleterminals

ls therecontinuitv?

R.oak short in the wile between


rhe ECM/PCM(A271and the A/C
Dressureswitch.

ECM/PCMCONNECTORS
Check for an open in the wire
(ACCline):
'1. Turnthe ignitionswitchOFF.
2. Reconnectthe A/C Pressure
switch2Pconneclor.
3. Turn the ignitionswitchON (ll).
4 . M o m e n t a r i l yc o n n e c tE C M /
PCMconnectorterminalsA17
a n d 8 2 0 w i t h a j u m P e rw i r e
severalllmes,

{To page11 158)

Sub6titute a known{ood ECM/


rcM and recheck. lf pte6cribed
voltage i3 now available,re'
pl.ce the origioalECM/rcM.
Seeih6 air conditionerinspection (s6esection221.

A (32P1

ACC(BLK/REOI

(BRN/BLKI
JUMPERWIRE LG1

{cont'd)

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11-157

ldle ControlSystem
Air Gonditioning
Signal(cont'd)
(Frompage'11,157)

ls therea clickingnoiselrom
the y'y'Ccompressorclutch?

Check Ior dn opon in the wiro


IACClinel:
Momentarilyconnectthe underhood fuse/relaybox 9P connector
t e r m i n a lN o . 5 t o b o d y g r o u n d
with a jumperwire severaltimes.

ls therea clickingnoisefrom
tho A,/Ccomprossorclutch?

Repai. open in th6 wiro lrtwlan


the ECM/PCMlAl7l .nd tho A/C
clutch rolay.

UNDER-HOOD
FUSE/RELAY
BOX9PCONNECTOR
{G'52I

JUMPER
WIRE

3 a

(BLK/R
ACC(BLK/RED'
Wire side otfemale
ot
terminals

Sae rir conditional in3paction


lroa saction 221.

ECM/PCMCONNECTORS

Check tho op.ration of tho A/C:


1. Stan the engine.
2. Turnthe blowerswitchON.
3. Turn the Ay'Cswitch ON.

Doesthe !y'C operate?

ChGGkfor an open in the wi.e


IACS linel:
Measurevoltage betweonECM/
P C M c o n n e c t o rt e r m i n a l sA 2 7
and 820.

Wiresidof femaletorminals

Air conditioning 3ignal i3 OK.


ls voltagelessthan 1.0V?

Sub6lftna a known{ood ECM/


PCM and rechock. lf symptom/indicetion goes away.
roplacethe originalECM/rcM.
See the ah conditionor inspoction {3esection 22},

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Rap.ir opon in the wir6 bdtunaan


rh. Ecil/FcM lA27l rnd rh. A/c
rwitch.

Alternator(ALT)FRSignal
This signalsthe ECM/PCMwhen the Alternator(ALTIis charging.
PCMGONNECTORS

,97 modet:
Inspectionot ALT FRSignal.
C h e c kl o r a s h o r t i n t h e w i r e
{ALT F line}:
1. Disconnectthe 4P 13Pi*con
nectorfrom the ALT.
2. Turnthe ignitionswitchON (ll)
3, Measurevoltage between
PCMconnectorterminalsC17
and A9.

ls thereapprox.5 V?

Checkth ope.ation of the ALT:


1. Turnthe ignitionswitchOFF
2. Reconnectthe ALT 4P {3Pi*
connectorto the ALT.
3. Start the engine.Hold the
engine at 3,000rpm with no
load (in Parkor neutral)until
t h e r a d i a t o rf a n c o m e s o n ,
then let it idle.
4. Measurevoltage between
PCMconnectorterminalsC17
and A9.
when
Doesthe voltagedecrease
headlights
and reardefoggerare
turnedon?

Chd( for an opn in tho wire IALT


F linel:
1. Turnthe ignitionswitchOFF.
2. Disconnectthe negativebattery cablelrom the battery.
3. DisconnectPCMconnectorC
(31P).
4. Disconnectthe 4P (3P)*connectorlrom the ALT.
5. Connectthe ALT 4P (3P)* connectorterminalNo. 4 (No. 1)*
to body groundwith a iumper

wire sideof femaleterminals

c (31P|
Check for a short in the wire
(ALT F linel:
1. Turnthe ignitionswitchOFF.
2. Disconnectthe negativebat'
tery cable from the battery.
3. DisconnectPCM connectorC
(31P).
4. Checkfor continuitybetween
b o d y g r o u n da n d P C Mc o n
nectorterminalC17.

Ropeirshort in the wir6 betweon


the PCM lC17l and the ALT.

Substitut. a known-good PCM


and recheck. lf prescribed voltage is now availablo,replacethe
originalPCM.

ALT FRsignal b OK.


(C1O5I
ALT CONNECTOR
lP
ALT F
r-F-

lll2llw|{frREDl
-| 3 . r - ' l

wne
lruueen

JUMPER
WIRE

wire side ol fmale terminals


C I31P)
PCMCONNECTOR

6. Check for continuity between


body ground and PCN4con'
nectorterminalCl7.
ls therecontinuity?

3Pr

ALT F IWHT/REDI
Repair open wi.e between the
PCMlCl7l and the ALT.
Wire sideof femaleterminals

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11 - 1 5 9

ldle GontrolSystem
Alternator(ALT)FRSignal(cont'dl
'98 - 00 modols:

ECM/PCMCONNECTORS

B (25P)

Inspctionof ALT FRSignsl.

AI.T F IWHT/REDI
Check fo. a shon in th. wire {ALT
F linel:
1. Disconn6ctthe 4P (3P)*connectorfrom the ALT.
2. Turnthe ignitionswitchON {ll).
3. MeasurevoltagebetweenECM/
PCM connectorterminalsC5
and 820.

ls thereapprox.5 V7

Checkthe opcration of the ALT:


1. Turnthe ignitiooswitchOFF.
2. Reconnectrhe ALT 4P (3P)*
connectorto the ALT.
3. Start the engine.Hold the
engine at 3,000rpm with no
load (in Parkor neutral)until
t h e r a d i a t o rl a n c o m e s o n ,
then let it idle.
4. MeasurevoltagebetweenECM/
PCM connectorterminalsC5
and 820.

Doesthe voltage decreasewhen


headlights
and reardefoggerare
turnedon?

Wire sideof femaleterminals

Chck for a sho.t in iho wirc lAlT


F lino):
1. Turnthe ignitionswitchOFF.
2. Disconneclthe negativebat,
tery cablefrom the battery.
3. DisconnectECM,PCMconnect o r C( 3 1 P ) .
4. Checkfor continuitybetwoen
body ground and ECM/PCM
connectorterminalc5.

ECM/PCMCONNECTOR
C {31PI

Wire sideof femaleterminals


Roprir lhort in tho wirc bstween
tho ECM/PCM{Csl and the ALT.

Substitut. r known-good ECM/


PCM and roch.ck. It Droscrib.d
voltage b now lvrilabls, .eplacc
th. o.igin!l ECM/PCM.

ALT FR3ignol is OK,


(C1I}5I
ALT CONNECTOR
4P

Chocklor an opon in tha wire (ALT


F linel:
1. Turnthe ignitionswitchOFF.
2. Disconnectthe negativebattery cablefrom the battery.
3 . D i s c o n n e c tE C M / P C Mc o n nectorC (31P).
4. Disconnectthe 4P 13P)*con,
nector from the ALT.
5. Connectthe ALT 4P {3P)*connectorterminalNo. 4 1No.1)*
to body groundwith a jumper

rH] Arr F
l'l'ltwHr/REo)

l3laF1
WIRE
I JUMPER
+

Wire sideof femaleterminals

6. Check for continuity betwen


body ground and ECM/PCM
connectorterminalC5.
ls therecontinuity?

JUMPER
WIRE

ECM/PCMCONNECTOR
C {31P}
ALT F {WHT/REDI
Rsprir opan wiro batw.en tho
ECM/PCMlcsl .nd th. ALT.

Wire sideot Iemaleterminals


": Canada

11 - 1 6 0

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Starter Switch Signal


when the engineis cranking.
This signalsthe ECM/PCM
'97 model:
in E or E position.
Transmission
PCMCONNECTORS

c t31P)

A {32P}
Checkfor an opan ot short in the
wire (STSlinel:
Measurevoltage between PCM
c o n n e c t o tre r m i n a l sC 6 a n d A g
w i t h t h e i g n i t i o ns w i t c h i n t h e
start(lll)position.

LGl
(BBN/BLK)

STS(BLU/ORNI

Wire sideof femaleterminals

ls there batteryvoltage?

lnspectthe No. 31 STARTERSIGNAL (7.5A)Illse in the under'dash

Starter swiich signal i3 OK.


-

Reoair short in the wire between the PCM lc6l and th.
No. 31 STARTERSIGNAL175
A) tuse ot the PGM-FImain
reray.
Reolacethe No. 31 STARTER
SIGNALt7.5Altu.e.

Repairopon in the wire betweon


rh6 PCM lc6l and the No 31
STARTERSIGNAL17.5A)fuse.

'98 - 00 models:
NOTE:
. M/T:Clutchpedalmustbedepressed.
. A/T:Transmission
in E orE position
A (32P)

ECM/PCMCONI{ECTORS

Checktor an open or short in the


wir (STSline):
Measurevoltage betweenECM/
P C M c o n n e c t o rt e r m i n a l sA 2 4
and 820 with the ignitionswitch
in the startposition(lll).

ls therebatteryvoltage?

SIG
Inspectthe No. 31 STARTER
NAL(7.5A){usein the under-dash

Wire sideoI femaleterminals


-

Starter switch 3ignal is OK.


-

Reoair shorl in the wire


betwen the ECM/PCMlA2,fl
and the No, 31 STARTERSIGNAL t7.5 Al tu3 ot the PGM'
Fl main rclay.
Repl.c. tho No. 31 STARTER
SIGNAL17.5Al fu3e.

Repairopon in tho wire between


the ECM/PCM{A241and the No
31 STARTERSIGNAL(7.5A) tu3e
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11 - 1 6 1

ldle GontrolSystem
PowerSteeringPressure(PSP)Switch Signal
This signalsthe ECM/PCM
when the power steeringload is high.
'97 model:
Inspectionot PSPswitch signal.

Checkfor an open in the wire {PSP


SYVline):
1. Turnthe ignitionswitchON (ll).
2. Measurevoltage between
PCN4
connectorterminalsC16
and A9.

ls therelessthan 1.0V?

Wire sideof femaleterminals


Checktor an open in lhe wire (PSP
SW linel:
1. Turnthe ignitionswitchOFF.
2. Disconnectthe PSPswitch 2P
connecror,
3. Turnthe ignitionswitchON (ll).
4. At the harnessside, connect
the PSPswitch 2P connector
t e r m i n a l sN o . 1 a n d N o . 2
with a jumperwire.
5, Measutevoltage between
PCMconnectorterminalsC16
and A9.

PSPSWTTCH
2P CONNECTOR
1C135)
PSPSW (GRN)
JUMPERT_7

vnRE t--f

r)

GNDIBLK}
Wire3id6of femaleterminals
-

Check the operation oI lhe PSP


switch:
1. Stanthe engine
2. Turnthe steeringwheelto the
full lockposition*.
3. MeasurevoltagebetweenPCM
connectorterminalsC16 and
A9.

ls therelessthan 1.0V?

ls there batteryvoltage?

PSPswitch signal is OK.


*: Do not hold the steeringwheel
at tull
lock for more than five seconds,

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(To page11-163)

Ropsir open in the wi.e betwoon the PCM lcl6l and the
PSPswitch.
Ropdir open in BLK wire between the PSP switch and
G101.

{ F r o mp a g e 1 1 1 6 2 )

PCMCONNECTORS
C h e c kf o r a s h o r t i n t h e P S P
swilch:
1. Turnthe ignitionswitchOFF.
2. Disconnectthe 2P connector
from the PSPswitch.
3. Turnthe ignitionswitchON (ll).
4 . l l e a s ur e v o l t a g e b e t w e e n
PCMconnectorterminalsC16
and A9.

Wire sideof femaleterminals

c t3lPl

Checktor a short in the wire (PSP


SW linol:
1. Turnthe ignitionswitchOFF.
2. DisconnectPCMconnectorC
(31P).
3. Checkfor continuitybetween
body ground and PCMconnector terminalC16.

Reoairshort in the wire betwoon


rhe PCM {C16)and the PSP
3witch.

Substitute a known-good PCM


and rocheck.lf proscribodvoltage b now available,replacethe
original PCM.

(cont'd)

www.emanualpro.com

1 1- 1 6 3

ldle ControlSystem
PowerSteeringPressure(PSP)Switch Signal(cont'dl
'98 - 00 models:
ECM/FCMCONNECTORS

Inspectionof PSPswilch 3ignal.

Chcktor rn opon in the wire (PSP


SW line):
1. Turnthe ignitionswitchON {ll).
2. MeasurevoltagebetlveenECM/
PCMconnectorterminals426
and 820.

ls therelessthan 1.0V?

Chockfor an open in the wire IPSP


SW lin):
1. Turnthe ignitionswitchOFF.
2. Disconnect
the PSPswitch2P
connector,
3. Turnthe ignitionswitchON (ll).
4. At the wire side.connectthe
PSPswitch 2P connectorter
m i n a l sN o . 1 a n d N o . 2 w i t h a

Wiresideof femaleterminals
PSPSwlTCH 2P CONNECTOR
ICl35}
PSPSW IGRNI
JUMpER f-7

wtRE L-5 rl

5. MeasurevoltagebetweenECM/
PCM connectorterminals 426
and 820.

GND (3LX}
Wire sideof lemaleterminals
-

Check the opration of the PSP


switch:
1. Stanthe engine
2. Turn steeringwheelto the full
lockposition*.
3. MeasurevoltagebtweenECM/
PCMconnectorterminalsA26
and 820.

lstherelessthan 1.0V?

ls there batteryvoltage?

PSPswitch signal is OK.


*: Do not holdthe steeringwheelat lull
lockfor morethan five seconds.

www.emanualpro.com

11-164

(Topage 11-165)

Ropai. open in the wire betweon th6 ECM/PCM (A26)


and th6 PSP.witch.
R6p.ir open in BLK wire between tho PSP 3witch and
G1 0 1 ,

{Frompage11 164i

ECM/PCMCONNECTORS

C h e c kf o r a s h o r t i n t h e P S P
switch:
1. Turnthe ignitionswitchOFF.
2, Disconnectthe 2P connector
from the PSPswitch.
3. Turnthe ignitionswitchON (ll).
4. MeasurevoltagebetlveenECM/
PCMconnectorterminalsA26
and 820.
Wiresideof femaleterminals

A l32Pl

Checklor e 3hort in the wire IPSP


SW linell
1. Turnthe ignitionswitchOFF.
2 . D i s c o n n e c tE C M / P C Mc o n nectorA (32P).
3. Checkfor continuitybetween
b o d y g r o u n da n d E C M / P C M
connectorterminalA26.
Wiresideof femaleterminals

ReDairshort in the wir bstween


the ECM/PCM(A26)and the PSP
switch.

Substitute a known-good ECM/


PCM and rechock. It Drescribod
voltago is now available,roplace
the origin.l ECM/PCM,

www.emanualpro.com

11 - 1 6 5

ldle ControlSystem
BrakeSwitch Signal
This signalsthe ECM/PCM
when the brakepedalis depressed.
Inspctionof Brak. Switch Signal.

Are the brakelightson without


pressingthe brakepedal?

Inspectthe HORN,STOP{15 A)
fuse in the undeFhoodluse/ relay
box.

Do the brakelightscome on?

Reoair short in the wire between th b.ake switch and


th6 HoRN, STOP{15 A)luso,
Replacothe HoRN, STOP (15
Al fuse.

'-

('97model)
-_-

Check tol .n open in the wire


{BXSWlinel:
1. Pressthe brakepedal.
2. MeasurevoltagebetweenrcM
connectorterminaisD5 and Ag
with the brakepedal pressed.

Il

Repair op6n in the wir between the brake switch and


tho HORN,STOP(15 Allus6.
Inspect the brrke switch (see
aection l9l.

a t32P)

PCMCONNECTORS

BKSW
(GRN/WHT)

Wire sideof femaleterminals


Reprir open in the wire between
the PcM lD5l rnd the brake
switch.

(Topage11-167)

11 - 1 6 6

www.emanualpro.com

D ll6Pl

(Frompage11-166)

ECM/FCMOONNECTORS

Chock for en open in the wire


(BKSWline):
1. Pressthe brakepedal.
2. MeasurevohagebetweenECM/
PCM connectorterminals A32
and 820 with the brakepedal
pressed.

Ropairopon in tha wire bstwson


r h e E C M / P C Ml A 3 2 l r n d t h e
brako switch.
Wiresideof femaloterminals

Brakeswitch signd b OK.

www.emanualpro.com

11-167

ldle ControlSystem
Fastldle ThermoValvelA/T)
Description
To preventerraticrunningwhen the engine is warming
up, it is necessaryto raisethe idle speed.The fast idle
t h e r m o v a l v e i s c o n t r o l l e db y a t h e r m o w a xp l u n g e r .
When the engine is cold, the engine coolantsurrounding the thermowaxcontractsthe plunger,allowingadditional air to be bvDassedinto the intakemanifoldso that
the engineidlesfaster.Whenthe enginereachesoperating temperature.the valve closes,reducingthe amount
of air bypassinginto the intakemanifold.
IDLE
ADJUSTING

Inspgction
NOTE:The fast idle thermo valve is factoryadjusted;it
shouldnot be disassembled.
1.

Removethe intakeair ductfrom the throttlebody.

2.

Startthe engine,

3.

Put your finger over the lower port in throttlebody,


and makesurethat there is air flow with the engine
cold (enginecoolanttemperaturebelow 86"F,30'C).

lf there is no air flow, replacethe fast idle thermo


valveand retest,
IDLE
THERMO
VALVE

O-RINGS
Replace.

AIR BYPASS VALVE

11.0kgfl.m,7.2 lbl.ftl

Startthe engine.Holdthe engineat 3,000rpm with no


load (in Parkor neutral)until the radiatorfan comes
on, then let it idle.
Checkthat the valve is completelyclosed.lf the valve
is leaking,the idle speedwill drop when you coverthe
lowerpon. Checkthe enginecoolantleveland for air
in the enginecoolingsystem{seesection10).lf the
cooling system is OK, replacethe fast idle thermo
valveand recheck.

11-168

www.emanualpro.com

ldle Speed Setting


Adjust the idle sp6ed,if necessary,by turning the
idle adjustingscrew.

Inspoction/Adiustmont
37 modsl:

IDLE

NOTE:
. Before setting the idle speed, check the following
items:
- The MIL has not beenreportsdon.
- l g n i t i o nt i m i n g
- Sparkplugs
- Air cleaner
- PCVsystem
. lcanada) Pull the parking brake lever up. Stan the
engine,then checkthat the headlightsare off.
1.

Startthe engine.Hold the engineat 3,000rpm with


no load (in Park or neutral) until the radiator fan
comeson, then let it idle.
Connecta tachometeror a HondaPGMTester.
Disconnectthe 2P connectorfrom the ldle Air Control (lAC)valve.
Turn the ignitionswitchOFF.
IAC VALVE

7 . Reconnectthe 2P connector to the IAC valve, then


remove the BACK UP (RAD|Ol(7.5 Al fuse in the
under-hood fuse/rslav box for 10 seconds to reset
the PCM.
Restartand let the engine idle with no-loadconditions for one minute,then checkthe idle speed.
NOTE: (CanadalPullthe parkingbrakelever up. Stan
the engine,then checkthat the headlightsare off.

lf the enginestalls,restartthe enginewith the accelerator pedal slightly depr6ss6d,Stabilizethe rpm at


1,000,then slowly releasethe pedaluntil the engine
idles.
C h e c k i d l i n g i n n o - l o a d c o n d i t i o n s :h s a d l i g h t s ,
blowerfan, rear dfogger,radiatorfan, and air conditionerare not operating.
ldle spood should b.:
{80 t 50 rpm {in Park or noutr.ll

ldlo Epedrhould be:


75Ot 50 rpm (in P.rk or noutr.ll
Let the engine idl6 for one minute with the headlights(Low)ON, and checkth idl speed.
ldle lpcod 3hould bo:
750 t 50 ]pm (in Park or nautlal)
Turn the headlights off. Let th engine idle for one
minute with the headlights (Low) ON, heater fan
switch at Hl and air conditioneron. then checkthe idle
sDeeo.
ldl. specd should b6:
7d) 1 50 rpm {in Park or nautral}
see the
lf the idle speed is not within specification,
(cont'd)
symptomcharton page11-64.

www.emanualpro.com

11 - 1 6 9

ldleControlSystem
ldle Speed Setting (cont'd)
38 - 0Omod6l3:
NOTE: Beforesettingthe idle speed,checkthe following items:
- The MIL has not beenreportedon.
- lgnitiontiming
- Sparkplugs
- Air cleaner
- PCVsystem
1.

lf necessary,adjust the idle speed,by turning the


idle adjustingscrew.
After adjustingthe idle speed,recheckthe ignition
timing (seesection4). lf it is out of spec,go backto
steo 4.
tDt.E
ADJUSTING

Startthe engine.Holdthe engineat 3.000rpm with


no load (in Park or neutral) until the radiator fan
comeson, then let it idle.
Connecta tachometer.
Disconnectthe IACvalve 2P connectorand the EVAP
purge control solenoid valve 2P connector.

CONTROL
SOLENOIDVALVE

VALVE
SOLENOID
lf the enginestalls,restartthe enginewith the accelerato. pedal slightly depressed.Stabilizethe rpm at
1,000,then slowly releasethe pedaluntil the engine
idles.
Chekthe idle in no-loadconditions:headlights,blower fan, rear defogger,radiatorfan, and air conditioner
are not operating,
ldle speed should bo:
480 t 50 rpm {in PErkor noutrall

11-170

www.emanualpro.com

6. Turn the ignitionswitchOFF.


7. Reconnectthe 2P connectorsto the IAC valve and
the EVAPpurgecontrol solenoidvalve,then do the
ECM/PCMreset procedure.
8. Restartand idle the enginewith no-loadconditions
for one minute,then checkthe idle speed.
ldle speod should be:
,98 model:
750 t 50 rpm tin Park or neutral)
'9!l - 00 modsls:
730 i 50 lpm lin Psrk or neutral)
NOTE:lf the idle speed increasesto 780 t 50 rpm
(770 1 50 rpml*, this means the EVAPsystem is
purgingthe canister.To stop the purgingtemporarily, raisethe enginespeedabove 1,000rpm with the
pedal,then slowly releasethe pedal.
accelerator
*: '99 - 00 models
9. Let the engine idle for one minute with the headlights(Low)ON, and checkthe idle speed.
ldle speed should be:
38 mod6l:
750 f 50 rpm (in Palk or neutrall
'99 - 00 modols:
730 t 50 rpm (in Palk or neutral)
10. Turn the headlightsoff. Let the engine idle for one
minutewith the heaterfan switchat Hl and air conditioneron, then checkthe idle speed.
ldls spqed should be:
'98 model:
780 t 50 rpm (in Park or neutrall
'99 - 00 modls:
7701 50 rpm lin Park or neutral)
lf the idle speed is not within specification.
see the
SymptomCharton page11-64.

FuelSupplySystem
FuelLines
Check fuel system lines, hoses, fuel filter, and other components for damage, leaks or det6rioration, and rplace it neces-

sary.
'97 model:

33N.m
(3.4kg(.m,2s lbf.ftl

27 N.m
12.8kg{.m,21 lbf.ft)

'98 model:

27 N.rn
(2.8 kgl.m, 21 lbf.ft)

www.emanualpro.com

(cont'd)

11-171

Fuel Supply System


FuelLines(cont'dl
'99 - 00 models:

33 N.m
(3.4kgl.m.25lbtftl

11-172

www.emanualpro.com

'97 model:
Checkall hoseclamps,and retightenif necessary.

{"2
/\

FUEL
FILTER

,"1
<,,

___--tJ

FUELTUBE/
OUICK-CONNECT
FITTINGS

' ^ s
,4\-') |
EVAPORATIVE
EMISSION{EVAP}
CONTBOL
CANISTER

ft\

q'l

/'------/
,

To FUEL
PRESSURE
REGULATOR

Clampin the middle

(cont'd)
10-14mm
(0.39- 0.55 inl
www.emanualpro.com

11-173

Fuel Supply System


Fuel Lines (confd)
'98 - (X)models:
Checkall hoseclamps,and retightenif necessary.
SASE
GASKET
Replace.

FUEL
FILTER

To FUEL
PRESSURE
REGULATOR
C l a m pi n t h e m i d d l e

10-14mm
(0.39- 0.ssin)

11-174

www.emanualpro.com

Fittings
FuelTube/Ouick-Gonnect
Procautions

Disconnection

Do not smoke whils working on the fuel


@
syst6m, Koop open flames away from your work ar9a.

Do not smoke while working on the fuel


!@
syst6m. Keep open flames away from your work area.

The fuel tube/quick-connect


fittings assemblyconnects
the in-tankfuel pump with the fuel feed pipe.For removing or installingthe fuel pump and fuel tank, it is necesfittings.
saryto disconnector connectthe quick-connect
Payattentionto following;

1.

Disconnect
the batterynegativecable.

2.

Removethe fuel fill cap to relievefuel pressurein


the tank.

3.

Relievefuel pressure(seepage 11-178).

4.

Checkthe fuel quick-connectfittings for dirt, and


cleanif necessary.

5.

Hold the connectorwith one hand and pressdown


the retainertabs with the other hand.then pull the
connectoroff.

fittings assemblyis not


The fuel tube/quick-connect
heat-resistant;
be carefulnot to damageit duringweldprocedures.
ing or otherheat-generating
The fuel tube/quick-connect
fittings assemblyis not
acid-proof;do not touch it with a shop towel which
was used for wiping batteryelectrolyte.Rplacethe
fittings assemblyif it came
fuel tube/quick-connect
into contactwith electrolyteor somethinosimilar.

NOTE:
. Be carefulnot to damagethe pipeor other parts.
Do not usetools,
. lf the connectordoes not move,keepthe retainer
tabs presseddown, and alternatelypull and push
the connectoruntil it comesoff easily.
. Do not removethe retainerfrom the pipe; once
removed,the retainermust be replacedwith a
new one.

. Whenconnectingor disconnecting
the fuel tube/quickconnectfittings assembly,be carefulnot to bend or
twist it excessively,Replaceit if damaged,
A disconnectedquick-connectfittings can be reconnected,
but the retaineron the mating pipe cannot be reusedonce
it has been removed from the pipe. Replacetha retainer
.
.
.
.

LOCKII{G PAWL

replacingthe fuel pump.


replacingthe fuelfeed pipe,
it has beenremovedfrom the Dioe,
it is damaged.

RETANENTAB

@NNCCTOR
Pressdown.

6.

Checkthe contactareaof the pipe for dirt and damage.


. lf the surfaceis dirW,cleanit
. lf the surfaceis rusty or damaged,replacethe fuel
pump or fuelfeedpipe,

RCTAINER

FUELTUBE

CONTACTANEA
CONNECTOR
CONNECTOR
RETAINER

{cont'd}

www.emanualpro.com

11-175

FuelSupplySystem
FuelTube/Ouick-Connect
Fittings{cont'd)
7.

To prevent damage and keep out foreign matter.


coverthe disconnected
connectorand oioe end with
plasticbags.

Connection
Do not smoke white working on the fuel
E!@
system. Keepoper flamss away flom your work atea.
1.

Checkthe pipe contact area for din and damage,


and cleanif necessary.

COiITACT AiEA

PL TSnCEAGS

Insena new retainerintothe connectorif the retainer


is damaged,or after
. replacingthe fuel pump.
. replacingthe fuel feed pipe.
. removingthe retainerfrom the pipe.

AASE
GASKET
Beplace.

11-176

www.emanualpro.com

3.

Beforeconnectinga new fuel tube/quick-connect


fitt i n g a s s e m b l y ,r e m o v et h e o l d r e t a i n e rf r o m t h e
mating pipe.

with the
tabs pulled
apart, remove
and discard
the retarner

4.

Ncw FUELTUBE/
OUICK.CONNECT
FI?TINGASSEMBLY

Align the quick-connectfittings with the pipe. and


align the retainerlockingpawls with the connector
grooves.Then pressthe quick-connect
fittingsonto
the pipe until both retainerpawls lock with a clickI n gs o u n d .
NOTE:lf it is hardto connect,put a smallamountof
n e w e n g i n eo i l o n t h e p i p ee n d .

www.emanualpro.com

5.

Makesure the connectionis secureand that the pawls


are firmly lockedinto place;checkvisually and by
pullingthe connector.

6.

Reconnectthe batterynegativecable,and turn the


i g n i t i o ns w i t c hO N ( l l ) .T h e f u e l p u m p w i l l r u n f o r
abouttwo seconds,andfuel pressurewill rise.Repeat
two or threetimes,and checkthat thereis no leakage
in the fuelsupplysystem.

FuelSupplySystem
SystemDescription
The fuel supply system consistsof a fuel tank, in-tank
high-pressure
fuel pump. PGM-Flmain relay,fuel filter,
fuel pressureregulator,fuel injectors,and fuel delivery
and return lines.This system deliverspressure-regulated fuel to the fuel injectorsand cuts the fuel delivery
when the engineis not running.

FuelPressure

Inspection
1,
2.

Relievefuel pressure.
Removethe 12 mm banjobolt on the fuel filterwhile
holding the fuel filter with anotherwrench.Attach
the 12 mm fuel pressureadapterbolt and the special
tool.

FUEL
PRESSURE
GAUGE
07406- 0040001

FUELPRESSURE
REGULATON

Relieving
Beforedisconnectingfuel pipes or hoses,releasepressure from the system by looseningthe 12 mm banjo
bolt on the too of the fuel filter.

Do not smoke while working on the fuel system.


Kep open flames or sparks away from your work
area,
Be sure to relieve fuel pressurewhile the ignition
switch is off.
1.

Write down the frequenciesfor the radio's preset


buttons.
Disconnectthe batterynegativecablefrom the battery negativeterminal.
Removethe fuel fill cap.
Use a box end wrench on the 12 mm banjo bolt at
the fuel filter while holdingthe fuel filter with another wrench.
Placea rag or shoptoweloverthe '12mm banjo bolt.
Slowly loosenthe 12 mm banjo bolt one complete
rurn
12mm BANJo
BOLT

SHOPTOWEL
NOTE: Replacethe washers whenever the 12 mm
baniobolt is loosenedor removed.

www.emanualpro.com

11-178

The illustration
shows
'97 - 98 models,
'99 - 00 modelsare similar.

Startthe engine.Measurethe fuel pressurewith the


engineidling and the vacuumhose of the fuel pressure regulatordisconnectedfrom the fuel pressure
regulatorand pinched.lf the enginewill not start,
turn the ignitionswitchon (ll),wait for two seconds,
turn it off, then back on again and read the fuel
pressure.
Pressureshould be:
'97 - 98 modls:
260 -31O kPa 12.7- 3.2 kgf/cm,, 38 - 46 psil
'99 - 0Omodels:
270 - 32OkPa Q.A - 3.2 kgf/cm', ifo - /U psil
Reconnectvacuumhoseto the fuel pressureregulator.
Prgs3ureshould be:
'97 - 98 models:
210 - 25OkPa 12.1- 2.6 kgf/cm', 30 - 37 psi)
'99 - 00 models:
22O-26iJ kPa 12.2- 2.7 kgt/cm', 31 - 38 psi)
lf the fuel pressureis not as specified,first checkthe
fuel pump (seepage 11-183).lf the fuel pump is OK,
checkthe following:
. l f t h e f u e l p r e s s u r ei s h i g h e r t h a n s p e c i f i e d ,
inspectfor:
- Pinchedor cloggedfuel returnhoseor line.
- Faultyfuel pressureregulator(see page 11181).
. lf the fuel pressureis lower than specified.inspect
for:
- Cloggedfuel filter.
- Faulty fuel pressureregulator(see page 111811.
- Fuelline leakage.

FuelInjectors
R6placomoni
1. Relievethe fuel pressure(seepage 11-178).
2. Removethe resonato.chamber('99- 00 models).

S
O.RING
Beplace.

Disconnectthe connectorsfrom the fuel injectors, and disconnectthe IAT sensor 2P connector ('97 - 98 models) and
EVAPpurge control solenoid valve 2P connctor ('97 - 98 models),
Disconnectthe PCVvalve and the vacuum hose from the fuel pressureregulator.
Placea shop towel overthe fuel returnhose,then disconnectit from the fuel pressureregulator.
Removethe retainernuts on the fuel rail.
Disconnect
the fuel rail.
7, Removethe fuel injectorsfrom the intake manifold.
'97 - 98 model3:
EVAPPURGE
CONTROL
SOLENOID
VALVE2PCONNECTOR
FUELPULSATION

IAT SENSOR
2P CONNECTOR

12 N.m
{1.2 kgt'm,
8.7 tbtft)
FUEL
PRESSURE
REGULATOR
O.RING
CUSHION
Replace.
SEAL
RING
Replace.

www.emanualpro.com

FUEL
PRESSURE
REGULATOR
O.RING
Replace.
CUSHION
RING
Replace.
SEAL
RING
Replace.

11-179

FuelSupplySystem
FuelInjectors{cont'dl
8. Slidenew cushionringsonto the fuel injectors.
9 , C o a tn e w O - r i n g s w i t ch l e a ne n g i n eo i l , a n dp u t t h e mo n t h e f u e li n i e c t o r s .
'10. lnsertthe fuel injectorsinto the fuel rail first.
p r e s st h e m i n t ot h e i n t a k em a n i f o l d
nngineoil,and
1 1 . C o a t n e w s e arl i n g s w i t h c l e a e
12. To preventdamageto the O-rings,installthe fuel injectorsin the fuel rail first, then installthem in the intakemanifold.
FUELRAIL

The ill!strationshows
'97 -98 models,'99- 00 models
are similar.

13. lnstalland tightenthe retainernuts.


14. Connectthe vacuumhosesand fuel returnhoseto the fuel pressureregulator.
15. Connectthe PCVvalve.
16. Connectthe connectorsto the fuel injectors,the IAT sensor('97 - 98 models),and the EVAPpurge controlsolenoid
valve{'97- 98 models).
1 1 . Coata new O-ringwith cleanengineoil, and installthe resonatorchamber('99- 00 models).
1 8 . Turn the ignition switch ON (ll), but do not operatethe starter.After the fuel pump runs for approximatelytwo seconds,
the fuef pressurein the fuel linerises.Repeatthis two or threetimes,thencheckwhetherthereis any fuel leakage.

11 - 1 8 0

www.emanualpro.com

FuelPressureRegulator
Replacement

Tesiing
1.

Attachthe specialtool and the 12 mm fuel pressure


adapterbolt to the fuel filter (seepage 1l-178)

'1. Placea shop towel under the fuel pressureregulator, then relievefuel pressure(seepage 11-1781.

2.

Startthe engine.

2.

Disconnect
the vacuumhoseand fuel returnhose.

Prasgureshould be:
'97 - 98 models;
260- 310 kPa (2.7- 3.2 kgl/cm' ,38 -,16 psi)
'9!t - 00 models:
27O- 32o kPa l2-8- 3.3 kgf/cm', 40 - /l7 psil
(with the lugl pressure rsgulator vacuum hose disconnestedand pinched)

3.

Removethe two 6 mm retainerbolts and the fuel


pressurereguralor.

12 N.m
(1.2kgf.m,
8.7 tbf.ft)

FUEL
PRESSURE
GAUGE
07406 - 0040001
CLAMP

Replace.

FUELPRESSURE
NEGULATOR

shows
Theillustration
'97- 98models,'99
-00 models
aresimilar.

Reconnectthe vacuum hose to the fuel pressure


regulalor.
4.

Checkthat the fuel pressureriseswhen the vacuum


hosefrom the fuel pressureregulatoris disconnected agarn.

shows
Theillustration
'99 00models
'97- 98models,
similar.
are

Apply cleanengineoil to a new O-ring.and carefully


installit into its properposition.
Install the fuel pressure regulator in the reverse
orderof removal,

l f t h e f u e l p r e s s u r ed i d n o t r i s e , r e p l a c et h e f u e l
pressureregulator.

www.emanualpro.com

11 - 1 8 1

FuelSupplySystem
FuelFilter
Replacamont

.
.

Do not smoke whilo working on tuol syslom,


Keepopen flame away from your work area.
While rsplscingths fuolfihor. bo carefulto kop a safe
distanca betweon baftsry tarminals and any tools,

The fuel filter should be replacedwheneverthe fuel Dressure drops belowthe specifiedvalue*with the fuel pressure regulatorvacuum hose disconnected
and pinchedl
after makingsure that the fuel pump and the fuel pressure regulatorare OK.

12 mm
SEAUNG
BOLT
33 hl.m
l3.a kgt m,
25 lbt frl

i: '97 - 98 modelsi 260 - 310 kPa


12.7- 3.2 kgllcm2,3g 46 psil
'99 - 00 mod6fs:
270 - 320 kP8 12.8- 3.2 kgilcm2, 40 il7psi)
1,

Placea shop towel underand aroundthe fuel filter.

2.

Relievefuel pressure(seepage l1-l7B).

3.

Removethe enginewire harnessbracketand power


steeringfeed hoseclamp.

4.

Removethe banjo bolt and the fuel feed pipe while


supportingthe fuel filter with another wrench. as
snown.
Removethe fuelfilter clampand fuel filter,
Install the new fuel filter in the reverse orde. of
removal,and notetheseitems:
.
.

Whenassembling,use new washersas shown.


C l e a nt h e f l a r e d j o i n t o f h i g h p r e s s u r en o s e s
thoroughlybeforereconnecting
them.

11 -1 8 2

www.emanualpro.com

9.8 N.|n
11.0kgf'm,
t.2 tbt.ftl

FuelPump
Testing

Raplac6mont

lf you suspect a problem with the fuel pump, checkthat


the fuel pump actuallyruns;when it is oN (ll),you will
hearsome noiseif you hold your ear to the fuel fill port
with the fuel fill cap removed.The fuel pump shouldrun
for two secondswhen ignition switch is first turned ON (ll).
lf the fuel pump does not make noise,checkit as follows:

1.

Foldthe left rear seatcushionforward,and remove


the baseframe cover(seesection20).

2.

Removethe accesspanelfrom the floor.

3,

Relievethe fuel pressure(seepage 11-178).

4.

the fuel lines.


Disconnect

5.

the 5Pconnectorfrom the fuel pump.


Disconnect

6.

Removethe fuel pump mountingnuts.

7.

Removethe fuel pump from the fuel tank.

8.

I n s t a l lt h e f u e l p u m p i n t h e r e v e r s eo r d e r o f
removal.

1.

Foldthe left rear seat cushionforward,and remove


the baseframe cover (seesection 20).

2,

Removethe accesspanelfrom the floor.

3.

Make sure the ignition switch is OFF,then disconnectthe fuel pumP5P connector.

4.

Connectthe PGM-FImain relay7P connectortermrnal No. 4 and No, 5 with a jumperwire.


PGM.FIMAIN
(Cit:}2l
RELAY7P CONNECTOR

I'TtlJil
-r'-r
t f

l . l 5 l 5 1 7 l

,frTt-

, a t \.
tcl tyEL/cRNl
FUELpUMp LrrYEL/cRNl I
I
Wirsideof
JUMPER
femaleterminals
WIRE

5.

Checkthat battery voltage is available between the


fuel pump 5P connectorterminal No. 4 and body
groundwhen the ignitionswitchis turnedON (ll).
{C562}
FUELPUMP5PCONNECTOR
2

FUELPUMP
(YEL/GRNI
wire sideof
femaleterminals

l f b a t t e r yv o l t a g e i s a v a i l a b l e ,c h e c kt h e f u e l
pump ground. lf the ground is OK, replacethe
fuel oumo.
lf there is no voltage,checkthe wire harness(see
p a g e1 1 - 1 8 8 ) .

www.emanualpro.com

11-183

FuelSupplySystem
FuelGauge
Tssting

Turnthe ignitionswitchOFF.

NOTE:Referto section23 for the fuel gaugesystemcircuit diagram.


'1.

Checkthe No. 25 METER(7.5A) fuse in the underdash fuse/relaybox before testing.

2.

Foldthe left rear seatcushionforward,and remove


the baseframe cover{seesection20).

3.

Removethe accesspanelfrom the floor.

4.

Disconnect
the 5Pconnectorfrom the fuel pump.

5.

Measurevoltage betweenthe 5P connectorterminalsNo.2 and No. 5 with the ignitionswitchON ( ).


Thereshouldbe between5 and 8 V.

FUELPUMP
5P CONNECTOR

tc56al

Wire side of female trminals

a lf the voltageis as specified,


go to step 6.
a lf the voltageis not as specified,
checkfor:

an open in the YEUBLKor BLKwrre.


poor ground (c552).

1 1 -1 8 4

www.emanualpro.com

7 . Attach a jumper wire betweenthe No. 2 and No. 5


terminals,then turn the ignitionswitchON fll).
Checkthat the pointerof the fuel gaugestartsmoving toward the "F" mark. Turn the ignition switch
OFF before the pointer reaches"F" on the gauge
dial. Failureto do so may damagethe luel gauge.
NOTE:The fuel gaugeis a bobbin (cross-coil)
type,
hencethe fuel level is continuouslyindicatedeven
w h e n t h e i g n i t i o ns w i t c h i s O F F ,a n d t h e p o i n t e r
movesmore slowlythan that of a bimetaltype.
.
.

lf the pointerof the fuel gaugedoes not move at


all. replacethe gauge.
lf the gauge is OK, inspectthe fuel gauge sendingunit.

FuelGaugeSendingUnit
Tgsting
Do not smoke while working on tho fuel
@
systom. Keop open flamo 8waYfrom your work araa.
1.

Foldthe left rearseat cushionforward,and remove


the baseframe cover(seesection20).

2.

Removethe accesspanel.

3.

With the ignitionswitchOFF.disconnectthe 5P connectorfrom the fuel pump.

4.

Relievefuel pressure(seepage 11-178).

5.

Disconnect
the fuel lines.

6.

Removethe fuel pump,

7.

Measurethe resistancebetweenthe No. 2 and No. 5


terminalsat E (EMPTY),1/2(HALFFULL)and F (FULL)
by movingthe float.

lf you do not get the above readings,replacethe


fuel pump.

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11-185

FuelSupplySystem
Low Fuel Indicator System
Indicator Light Testing

8.

NOTE:Referto section23forthe lowfuel lndicatorcircuit


clragram.
1.
2.

Checkthe No. 25 METER(7.5A) fuse in the underdash fuse/relaybox before testing.


Parkthe vehicleon levelground.

Add 4 / of fuel (1.1U.S.Gal,0.9 lmp. Gal).The light


shouldgo off within four minutes.
.

lJ the light does not go off, checkfor:


- a short in the GRNA/ELwire between the fuel
gaugesendingunit and fuel gaugeassembly.
- faultygaugeassembly.
. lf the light goes off, the low fuel indicatorlight is

oK.
Do not smoke while working on the
@
fuel system. Keep open flame away trom the work
aroa. Drain fuel only into an approved container.
D r a i n t h e f u e l i n t o a n a o D r o v e dc o n t a i n e r T
. hen
installthe drain bolt with a new washer.
Add lessthan 8 f (2.1U.S.Gal. 1.8lmp. Gal)of fuel,
and turn the ignitionswitchON {ll).The low fuel indicatorlightshouldcome on within four minutes.

INDICATONLIGHT

lf the light comes on within four minutes,go to


step8.
lf the lightdoesnot comeon withinfour minutes. go to step 5.

7.

Removethe seatcushion(seesection20).
Removethe fuel tank accesspanel from the floor,
and disconnectthe 5Pconnectorfrom the fuel pump,
Connectthe No. 1 and No. 2 terminalswith a jumper
wire.
.
.

l f t h e l i g h t c o m e s o nc, h e c k t h es e n d i n gu n i t .
lf the light does not come on, checkfor:
- a n o p e n i n t h e G R N / y E Lw i r e b e t w e e nt h e
fuel unit and fuel gaugeassembly.
- blown bulb.
- poor ground (G552).
(C562)
FUEI-PUMP5PCONNECTOR
WIRE
JUMPER
IGRN/YEL}

Wiresidol temleterminals

1 1 - 18 6

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PGM-FIMain Relay
Description
The PGM-Flmain relav actuallvcontainstwo individual
relays.This relay is locatedat the passengerside of the
cowl. One relay is energizedwheneverthe ignitionis on
w h i c h s u p p l i e st h e b a t t e r yv o l t a g et o t h e E C M / P C M ,
power to the fuel injectors,and power for the second
relay. The second relay is energizedfor two seconds
when the ignition is switchedon, and when the engine
is running,to supplypowerto the fuel pump

PGM.FI
MAIN RELAY

Belay Testing
N O T E :l f t h e e n g i n es t a r t sa n d c o n t i n u e st o r u n , t h e
PGM-FImain relayis OK.
1.
2.
3.

R e m o v et h e g l o v e b o xa n d t h e p a s s e n g e r 'ds a s h boardlowercover (seesection20).


Removethe PGM-FImain relay
Aftachthe batterypositiveterminalto the No. 2 terminal and the batterynegativeterminalto the No. 1
terminal of the PGM-Flmain relay.Then checkfor
continuitybetweenthe No. 5 terminaland No. 4 terminal of the PGM-FImain relay
. lfthere is continuity,go on to step3.
. lf there is nocontinuity,replacethePGM-Flmain
relavand retest.
No.2

No.5 No.5
To lGN.1

To GROUND

To ST. SWITCH
To ECM/PCM
CONNECTOR
TERMINAL
A16
(FLR)

To BAT O
To FUELPUMP
To ECM/PCM
CONNECTOR
TERMINAL
(411and A24,
Bl .nd Bgal
(IGP)

To FUELPUMP

98- 00 models
Attachthe battervDositiveterminalto the No. 5 terminal and the batterynegativeterminalto the No. 3
termjnalof the PGM-Flmain relay.Then checkthat
there is continuitybetweenthe No. 7 terminal and
No. 6 terminalof the PGM-FImain relay.
. lf there is continuity,go on to step 4.
. lf there is nocontinuity,replacethePGM-Flmain
relayand retest.
5 . Attachthe battervoositiveterminalto the No.6 terminal and the batterynegativeterminalto the No. 1
terminalof the PGM-Flmain relay.Then checkthat
there is continuitvbetweenthe No. 5 terminal and
No. 4 terminalof the PGM-Flmain relay.
. lf thereis continuity,the PGM-Flmain relayis OK.
P G M - Fm
I ain
. l f t h e r ei s n o c o n t i n u i t yr,e p l a c e t h e
(cont'd)
relayand retest.

www.emanualpro.com

11-147

FuelSupplySystem
PGM-FIMain Relay(cont'dl
Troubleshooting
-

Enginewill not start.


InsDection ol PGM-FI main
relay and relay harness,
PGM.FIMAIN RELAY7P CONNECTOR
lc(}21
GND

Check fo. an open in the wire


IGNDlinol:
1. Turnthe ignitionswitchOFF.
2. Disconnectthe PGM Fl main
relay7P connector.
3. Checkfor continuitybetween
the PGM'FImain relay7P connectorterminalNo.3 and body
ground.

trTr]--Flq
FI,Til'I A

Wire sideot femaleterminals


Repairopcn in th wire between
the PGM-FImain relavand G101.

Checktor an open or short in the


wiro (BATline):
M e a s u r ev o l t a g e b e t w e e nt h e
PGM'FImain relay 7P connector
terminalNo.7 and bodyground.
ls there bafteryvoltage?
-

Repai. open or short in lhe


wir6 belween the PGM-FI
main relay and the Fl E/M (15
Al fu3e.
Replace
th6 FIE/M (15Altus6
in th under-hood fuse/.6lay

Checklor an open or short in the


wire (lGl line):
L Turn the ignitionswitch ON (ll).
2. Measurethe voltage between
the PGM-FImain relay7P con
nectorterminalNo. 5 and body
ground.
-

Checkfor an open or short in the


wire {STSline):
1. Turnthe ignitionswitchto the
START(lll)position.
NOTE:
. M/T: Clutch pedal must be
depressed.
. A/T: Transmissionin E or
Elposition.
2. Measurethe voltage between
t h e P G M - F lm a i n r e t a y7 P
connectorterminalNo. 2 and
body ground.

('97model:To page11-189)
('98 00models:Tp
o a g e1 l 1 9 0 )

11 - 1 8 8

www.emanualpro.com

Repair open or shorl in the


wire between the FGM-FImain
relayand the No. 13 FUEL
PUMP115A) tuse.
Replacothe No. 13RJELPUMP
115A) luse in the und6.-d$h
fuso/ relav box.

Repair open or short in the


wire betwen the PIGM-FIm.in
rclay and th No. 31 STARTER
SlGllAL 17.5A) tuse.
Repl.ce the No. 31 STARTER
SIGNAL 17.5Al tuse in the
under-dashtuse/relaybox.

lFrompage11 188)

-t

('97model)
(C432I
PGM.FIMAIN RELAY7P CONNECTOR
FLR
IGRN/YELI

Ch6ck lor an open in the wir


{FLRline):
1. Turnthe ignitionswitchOFF.
2. Disconnectthe PCM connector A (32P).
3. Checkfor continuitybetween
the PGM-FImain relay 7P connectorterminal No. 1 and PCM
terminalA16.
connector
Wire sideof lemaleterminals
Repairopen in the wire be{weon
the PCM lAl6l and the PGM-FI
main relay.

Checkfor an open in the wirs


{lGP1,lGP2lins):
'1. Reconnect
the PCMconnector
A (32P).
2 . R e c o n n e ct th e P G M ' F lm a i n
relayconnector.
3. Turnthe ignitionswitchON (lli.
4. MeasurevoltagebetweenPCM
connectorterminalsA11 and
A 1 0 , a n d b e t w e e nA 2 4 a n d
A10.

IGP2
(YEL/BLK)

ls therebatteryvoltage?
-

Repair open in the wir bet'


ween th PCM {A11,A2ia}end
the PGM-FImain relay.
Reolscethe PGM-FImain rolaY.

Checktor an open in the PCM:


1. Turnthe ignitionswitchOFF.
2 , M e a s ur e v o l t a g e b e t w e e n
PCMconnectorterminalsA16
a n d A 1 0w h e nt h e i g n i t i o n
switch is first turned ON {ll) for

ls there'1.0V or less?

Substitute a known-good PCM


and recheck. lf ptesctibed volttge
is now available,roplacotho orig'
in.lPCM.

(cont'd)
C h e c k t h e P G M - F lm . i n . e l a V
(seepage11-187).
_l
www.emanualpro.com

1 1 - 18 9

FuelSupplySystem
PGM-FIMain Relay(cont'dl
(Frompage11,188)
('98- 00 models)

-l

PGM.FIMAIN RELAY7P CONNECTOF(C2)


Check lor an open in the wire
(FLRline):
1. Turn the ignitionswitchOFF.
2. Disconnectthe ECM/PCMcon
nectorA (32P1.
3. Checkfor continuitybetween
the PGM-FImain relay7P connectorterminalNo. '1and ECM/
PCMconnectorterminal416.
Wiresidof femaleterminals
Repaiaopen in the wire between
the EcM/PcM lAl5l .nd the
PGM-FIm.in relay.

Check for an open in the wires


llcPl,lGP2linos):
1. Reconnectthe ECM/PCN4
connector I (25P).
2. Reconnectthe PGM Fl main
retayconnector.
3. Turn the ignitionswitchON l).
4, Measurevoltage between
ECM/PCMconnectorterminals
B1 and 82, and between 89
and 82.

ECM/PCMCONNECTOR
B I25PI

Dde"Jt;;li
L-F-T-PGl
(BLK}
3

s l 1 0

IGP2
(YEL/BLKI 1 9

Ropai. open in tho wire b6twen th. ECM/PCM lBt, Btl


.nd the FGM-FImain rd.y.
Rplacth6 FGM+| main retay,

20

11

13
21 22

8
17

Wire side of female terminals

ECM/PCMCONNECTORS
Chock for an open in the ECM/
PCM:
1. Turnthe ignitionswitchOFF.
2, Measurevoltage between
ECM/PCMconnectorterminals
416 and 82 when the ignition
switch is first turned ON (tl) for

ls there1.0V or less?

a t32Pl

Subrtitute e known-good ECM/


PCM and recheck. lf prescribsd
voltage b now ovrihble, replaco
the originelECM/PCM.
Wiresideof fmaleterminsls

Check the PGM-FI main.elav


(s6epage 11-1871.

11 - 1 9 0

www.emanualpro.com

FuelTank
Replacement
Do not smoke while working on fuol systam Keep open flame away from your work area'

@
1.
2.
3.
4.
5.
6.
7.
8.
g.

Relievethe fuel pressure(seepage11-178).


Foldthe left rearseatcushionforward,and removethe baseframecover{seesection20).
Removethe accesspanelfrom the floor.
and 6P connector(C580)('98-00 models)'
the 5Pconnector1C562)
Disconnect
fittings{seepage 11-175}
Disconnect
the fuel returnhoseand quick-connect
jackstands.
Jackup the vehicle,and supportit with
Removethe middlefloor beam.
Removethe drain bolt, and drainthe fuel into an approvedcontaaner.
the hoses(seepage 11-173,174).slide backthe clamps.then twist hosesas you pull, to avoid damaging
Disconnect

them.
10. Placea jack,or othersuppon,underthe tank
11. Removethe strapnuts,and let the strapsfall free
12. Removethe fuel tank.lf it stickson the u ndercoatappliedto its mount,carefully pry it off the mount,
'13. lnstallthedrain bolt with a new washer,then coatthe drain bolt with Noxrust1248'
Allow the Noxrustto dry for 20 minutes.
14. Installpartsin the reverseorderof removal.
'97 modol:
AOCESSPANEL

CONNECTOR

DRAINEOLT
49 N.m
15.0kgf'm,
36 rbt frl
www.emanualpro.com

(cont'd)

11 - 1 9 1

FuelSupplySystem
FuelTank (cont'd)

,98 - 00 models:

5P CONNECTOR
6P CONNECTOR

38 N.m
(3.9ksf.m,28lbtftl

11-192

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Intake Air System


SystemDescription
The systemsuppliesair for all engine needs.lt consistsof the intakeair pipe,Air Cleaner,intakeair duct, ThrottleBody
(TB),ldle Air Control(lAC)Valve,fast idle thermo valve,and intakemanifold.A resonatorin the intakeair pipe provides
additionalsilencingas air is drawn into the system.

YEL| BLK

Fiom PGM'FI
MAIN RELAY

vaRtous
SENSORS

IDLE
THERMO

INTAKEMANIFOLD

lJ-_iuo'u'j"'

FESONATON

THROTTLE
BODY(TB)
INTAKE
AIR DUCT

www.emanualpro.com

11 - 1 9 3

IntakeAir System
Air Cleaner

ThrottleCable

Air CleanerEloment Rsplacomsnt

Inrpection/Adiustmcnt

NOTE:Do not cleanthe air cleanerelementby blowing


it off with compressedair,

1.

Stan the engine.Hold the engineat 3,000rpm with no


load (in Parkor neutral) until the radiatorfan comes
on, then let it idle.

2.

Checkthat the throttlecableoperatessmoothlywith


no bindingor sticking.Repairas necessary,

3.

Checkcable free play at the throttle linkage.Cabte


deflectionshouldbe 10- 12 mm (3/8- 1l2in.l.

'97 - 98 modols:
CABLE
BRACKET

m
DEFLECTION
10-12mm
BIA- 112i^l

LOCKNUT

'99 0O modsls:
DEFLECTION
l0-12mft
Bla - 112inl

AIR CLEANERELEMENT
No.mal conditions:
Replaceair cleanerelementevery
30,000miles{48,000km) or 24
monthswhichevercomesfirst.
Severecondition3:
Replaceair cleanerelementevery
15,000miles124,000
km) or 12
monthswhichevercomestirst.

NUT
lf deflectionis not within specs,loosenthe locknut,
turn the adjustingnut untilthe deflectionis as specified,then retightenthe locknut.
With the cableproperlyadjusted.checkthe throttle
valve to be sure it opens fully when you push the
acceleratorpedal to the floor. Also check the throttle valve to be sure it returns to the idle position
whenever you releasethe acceleratorpedal.

11-194

www.emanualpro.com

'97 - 98 modals:

lnstellation
1.

Openthe throttlevalvefully,then installthe throttle


cable in the throttle linkage,and install the cable
housingin the cablebracket.

lhere shouldbe
no clearance.

97 - 98 modols:
CABLE

LINKAGE
THRoTTLE

AD.'USTINGNUT
9.8 N.m
(1.0 kg{.m,
7.2lbllrl

'99 - 00 modeb:
LOCKNUT

INNERCABLE

CABLE
BRACKET

'99 - (Xl modols:


ADJUSTING

BRACKET
2.

Sta.t the engine.Hold the engineat 3.000rpm with


no load (in Park or neutral) until the radiator fan
comeson, then let it idle.
Hold the cable sheath,removingall slackfrom the
cable.
Set the locknut on the cable bracket.
Adiustthe adjustingnut so that its free play is 0 mm.
Rimove the cable sheath from the throttle bracket,
resetthe adjustingnut and tightenthe locknut.

www.emanualpro.com

9.8 N.m
l'1.0kgt'm,
7.2 tbr.ft)

IntakeAir System
ThrottleBody
Doscription
The throttle body is a single-barrelside-drafttype. The
lower portion of the throttle valve is heatedby engine
coolantfrom the cylinderhead.The idle adjustingscrew
which regulatesthe bypassair is locatedon the top of
the throttlebodv.

lnspection
Checkthat the throttlecableoperatessmoothlywithout
bindingor sticking.
lf thereare any abnormalities,
checkfor:
. Excessive
wear or play in the throftlevalveshaft.
. Sticky or binding throttle lever at the fully closed positton.
. Clearancebetweenthrottle stop screw and throttle
leverat the fully closedposition.
97 - 98 models:
THROTTLE
LINKAGE

The illustration
shows
'97 - 98 models,'9900 rnodels
are similar.

THROTTLELINKAGE

Replacethe throttle body if there is excessiveplay in the


throttlevalveshaftor if the shaft is bindingor sticking.

11 - 1 9 6

www.emanualpro.com

Removal
'97 - 98 models:

GASKET
MAP SENSOR

R \ t

,:4W)
TP SENSOR

FASTIDLETHERMO
VALVE(A/T onlyl

'99 - O0models:

TP SENSOR

F(

\g-.-'

22 N.m
12.2kgl m,
16 tbtft)

NOTE:
. Do not adjustthe throttlestop screw.
. After reassembly,
adjustthe throftlecable(seepage11-194).
. The TP sensoris not removable.

www.emanualpro.com

FASTIDLETHERMO
VALVElA/T only)

(cont'd)

11-197

IntakeAir System
ThrottleBody (cont'd)
Disassembly

O-RING{A/l only)
Replace.

ADJUSTING
SCREW

IDLETHERMO
VALVE (A/T only)

9.8 N.m
(1.0kgl.m,7.2lbf.ftl
The illustration
shows'97- 98
models,'99 00 modelsare similar.

11 - 1 9 8

www.emanualpro.com

EmissionControlSystem
SystemDescription

ThreeWayCatalyticConverter(TWCI

T h e e m i s s i o nc o n t r o l s y s t e m i n c l u d e s ,a T h r e eW a y
CatalyticConverter{TWC),PositiveCrankcaseVentilation
(PCV)svstem and EvaporativeEmission(VAP)Control
system.The emissioncontrol system is designedto meet
federaland stateemissionstandards.

DsscriDtion

TailpipeEmission

Three Way Catalytic Convertsr lTwcl:


The Three wav CatalvticConverter (TWC) is used to
converthydrocarbons(HC),carbonmonoxide(CO),and
oxides of nitrogen(NOx) in the exhaustgas to carbon
dioxide(COr),dinitrogen(Nr)and water vapor,

Inspsction
Do not smoke during this procsdura. Keep
!@
any open tlame away from your work area.
1.

Startthe engine.Hold the engineat 3,000rpm with


n o l o a d ( i n P a r ko r n e u t r a l )u n t i l t h e r a d i a t o rf a n
comeson, then let it idle,
Connecta tachometer.
adjustthe idle speed,(see
Checkand, if necessary,
p a g e1 1 - 1 6 91, 7 0 ) .

4.

Warm up and calibratethe CO meteraccordingto the


instructions.
metermanufacturer's
heaterblower,rear
Checkidle COwith the headlights,
off.
windowdefogger,coolingfan,and air conditioner
(Canada)Pull the parkingbrake lever up. Start the
engine,then checkthat the headlightsare off.
0 . 1 %m a x i m u m .
C Om e t e rs h o u l di n d i c a t e

{cont'd)

www.emanualpro.com

11 - 1 9 9

EmissionControlSystem
ThreeWay CatalyticConverter{TWCI(cont'd}
1P0420 Thescantool indicatesDiagnosticTroubleCode(DTC)P0420:Catalystsystemefficiencybelowthreshold.
DescriDtion
This systemevaluatesthe catalyst'scapacityby meansof the HO2S(Primaryand Secondary)outputduring stabledriving
hasbeendetectedduringthreeconsecutive
drivingcycles,the MILcomeson and DTCP0420will
conditions.lf deterioration
be stored.
NOTE:lf some of the DTCSlistedbelow are storedat the same time as DTCP0420,troubleshootthose DTCSfirst. then
troubleshootDTCP0420.
P0137,P0138:SecondaryHO2S(Sensor2)
P0141:SecondaryHO2S(Sensor2) Heater
PossibleCause
. IWC Deterioration
. Exhaustsystemleakage
Troubleshooting Flowchart
-

The MIL has been reDoriedon.


DTCP0420is stored.

Problemverification:
1. Do the ECM/PCM
ResetProce
dure,
2 . S t a r tt h e e n g i n e .H o l d t h e
engine at 3,000rpm with no
load (in Parkor neutraliuntil
the radiatorfan comeson.
3. Connectthe SCSservicecon
nector.
4. Test-drive40 - 55 mph (64- 88
km/h)for approx.lwo minutes.
Then deceleratefor at least3
secondswith the throftlecom
p l e t e l yc l o s e d .T h e n r e d u c e
t h e v e h i c l es p e e dt o 3 5 m p h
1 5 6k m / h ) ,a n d t r y t o h o l d i t
u n t i l t h e r e a d i n e s sc o d e

ls DTCP0420indicated?

Checkthe TWC (seesection 9).


lI nocessary,replacethe TwC.

11-200

www.emanualpro.com

Intermittent tailure. system is OK


at this time.

PositiveGrankcase
Ventilation(PGVISystem
Description

Inspoction

T h e P o s i t i v eC r a n k c a s eV e n t i l a t i o n( P C V )s v s t e m i s
designed to prevent blow-by gas from escaping to the
atmosphere.The PCVvalve contains a spring-loaded
plunger,When the enginestarts,the plungerin the PCV
valve is lifted in proportionto intakemanitoldvacuum and
the blow-by gas is drawn directlyinto the intakemanifold.

1.

Checkthe PCVhosesand connectionsfor leaksand


clogging.

'97 - 98 models:

'99 - (X)
models:

i/lAlrllFOLD
-: BLOW.BY VAPOR
-: FRESHAIR

BREATHER
HOSE

(cont'd)

www.emanualpro.com

11-201

EmissionControlSystem
PositiveCrankcase
Ventilation(PCV)System(cont'dl
2.

At idle,makesurethere is a clickingsoundfrom the


PCVvalve when the hose betweenthe PCVvalve
and intakemanifoldis lightly pinchedwith your fingers or pliers.

'97 - 98 models:

Gently pinch here.

'99 - 00 modelsi

Gentlypinchhere.

lf there is no clickingsound, checkthe PCVvalve


grocrmet for cracksor damage,lf the grommet is
OK, reDlacethe PCVvalveand recheck.

11-202

www.emanualpro.com

Evaporative
Emission(EVAP)Controls
Description:
The evaporativeemissioncontrolsare designedto minimizethe amount of fuel vapor escapingto the atmosphere.The
systemconsistsof the followingcomponents:
A.

EvaporativeEmission(EVAPIControl Canister
An EVAPcontrolcanisteris usedfor the temporarystorageof fuel vapor until the luel vapor can be purgedfrom the
EVAPcontrolcanisterinto the enqineand burned.

B. Vapor PurgeConirolSystem
EVAPcontrolcanisterpurgingis accomplishedby drawingfreshair throughthe EVAPcontrolcanisterand into a pon
on the intakemanifold.The purgingvacuumis controlledby the EVAPpurgecontrolsolenoidvalve.
E V A P P U R G EC O N T R O LS O L E N O I DV A L V E D U T Y C O N T R O L L E D
AFTER
S T A R T I NE
GN G I N E

ENGINECOOLANTTEMPERATURE
ABOVE154"F(68'C)
C.

FuelTank Vapor Control System


Whenfuel vapor pressurein the fuel tank is higherthan the set valueof the EVAPtwo way valve,the valveopensand
regulatesthe flow ot fuel vaporto the EVAPcontrolcanister.
'97 model:
EVAP
PURGE
CONTROL
From
No. 15
/ALTERNATOR
I sP SENSORr7.sAt
(in the under-dash
fuse/relaybox)

VALVE
BLK/
YEL

VARIOUS
SENSOR
FEESHAIF

BLK

FUEI-TANK

INTAKEMANIFOLD

(cont'd)

www.emanualpro.com

11-203

EmissionGontrolSystem
EvaporativeEmission(EVAP)Controls(cont'dl
'98 - 0Omodels:

EVAP
THREEWAY
VALVE

EVAP
CONTROL
CANISTER
VENTSHUT
VALVE

Frofi

< NO.15

BLK/WHT

'EL/BLU
._^_-:.*,"..
GRN/BLK

<3|ltAIS"o[..^,
1inthe under-dash
tuse/relay
box)

BLU
L

VARIOUS
SENSOR

LT GRN/WHT ,

RED/YEL

EVAP
TWOWAY
VALVE

EVAP
BYPASS
SOLENOID

EVAPPURGE
CONTROL
SoLENOtO
VALVE

SLK

VALVE
FUELTANK

MANIFOLD

11-204

www.emanualpro.com

'97 model:
The scan tool indicatesDiagnosticTrouble Code (DTC)P0441:EvaporativeEmission(EVAP)control system
insufficientpurgeflow.
Description
By monitoringthe purge line vacuumwith the MAP sensor,the PCM can detectinsufficientEVAPcontrol system purge
flow.
PossibloCause
. EVAPPurgeControlSolenoidValve
. EVAPPurgeControlSolenoidValveCircuit
. EVAPControlCanister
. VacuumLines
. PCM
TroubleshootingFlowchart
Th MIL has ben reooited on.
DTCP0441is .tored.
Problemverificationl
1 . S t a r tt h e e n g i n e .H o l d t h e
engine at 3,000rpm with no
load (in Parkor neut.al)until
the radiatorfan comeson.
2. Do the PCMResetProcedure.
3. Connectthe SCSserviceconnector,
4. Test drive underfollowingcon'
ditionson the road.
- without any electricalload
- Transmission
in @ or @
position
- Engine speed between
- 2,4OO
1,2OO
rpfi.
- Decelerate
from 50 mph (80
km/h)to15mph (24km/h)
ls DTCP0441indicated?

Intermittent trilure, sydern is OK


at this time. Checkfor Door connections or loose wir3 at C108
IEVAP purge control solonoid
valvol .nd at the PCM.

Checktor an open in the wire (lcl


linel:
1. Turnthe ignitionswitchOFF.
2 . D i s c o n n e ctth e E V A Pp u r g e
controlsolenoidvalve2P connector.
3. Turnthe ignitionswitchON (ll).
4. Measurevoltagebetweenbody
ground and the EVAPpurge
control solenoidvalve 2P connectorterminalNo. '1,
ls there batlery voltage?

EVAPPURGECONTROL
SO1TNOIDVALVE2P
CoNNECTOR(C108)

(v)
YL

Wire side of female


termrnals
Rpafuopen in thc wir6 btwen
thG EVAP purge control solenoid
valve and the No. 15 ALTEBNATORSP SENSOR(7.5A)fuse.

(To page11'206)

(cont'd)

www.emanualpro.com

11-205

EmissionControl System
EvaporativeEmission(EVAP)Controls(cont'dl
(Frompage11-205)

PCMCONNECTOR
A (32PI
PG1(BLKI

Chsck th6 EVAP purgo control


solonoidvalve:
' L R e c o n n e ctth e E V A Pp u r g e
controlsolenoidvalve2P connector.
2. ConnectPCMconnectortermi
nals 415 and A10 with a

Does the solenoid valve click


when the jumper is connected?

PCSIRED/YELI
JUMPERwlRE

Wire side of femaleterminais

Chscl to. an op6n or 3hort in th


wiro (PCSlin6):
Measurevoltage between PCM
connectorterminalA15 and body
grouno,

ls there batteryvoltage?

Chockfor . .hort in tho wiJe IPCS


line):
1. Turnthe ignitionswitchOFF.
2. Disconnectthe PCMconnector A (32P).
3. Disconnectthe EVAP purge
controlsolenoidvalve2P connector,
4. Checkfor continuitybetween
body ground and PCM connectorterminalA15.

Rooair short in tho wir6 bctween


the EVAP purge control 3olenoid
valvo and tho PCM(A151.

Checkthe vacuum lin6:


Checkthe vacuum linesof EVAP
systemtor misrouting,leakage,
brsakagoand clogging.

Are the vacuumlinesOK?

(Topago11'207)

11-206

www.emanualpro.com

Ropair open in the wir6 betwoon


the EVAP pu]go control .olonoid
v.lve end the PCM(A15).

(Frompage11-206)

<\

Chack iho EVAP purge control


solenoidvalve:
1. Disconnectthe vacuum hose
trom the EVAPcontrolcanister.
2, Connectthe vacuumpump to
the hoseand applyvacuum,
EVAPCONTNOL
CANISTER

VACUUM
PUMPI
GAUGE,
0-30 in.Hg
4973X 0il1 -

xxxxx
Doesit hold vacuum?

Chgckthg EVAPcontrol csnbter:


1. Reconnectthe vacuum hoseto
the EVAPcontrolcanister.
2. Connecta vac!um gauge to
the purge air hose.
3. ConnectPCM connectorter
m i n a l sA 1 5 a n d 4 1 0 w i t h a
jumperwire.
4. Stanthe engine.
5. Checkthe vacuum.

JUMPEFWIRE
wire side of femaleterminals

Checkthe EVAPtwo way valve


(seepage11'224).

Doesthe EVAPtwo way valve


work properly?

Rapbcethe EVAPtwo wey valve.


VACUUM/PRESSURE
GAUGE
0-4 in.Hg
07JA2 - ml(x)o8

Substitute a known-good PCM


and rechock. It symptom/indication gocs away, roplacgtho originrl rcM.

{cont'd)

www.emanualpro.com

1 1-207

EmissionControlSystem
EvaporativeEmission(EVAP)Controls(cont'd)
99 - 00 models:
The scan tool indicatesDiagnosticTrouble Code {DTC)P0451:The Fuel Tank Pressuresensor circuit range/
oerformanceDroblem.
-

The MIL har been rooortdon.


DTCP0451b storod.

ECM/PCMCONNECTORS

a t32Pl
Check lor th6 tu6l tank prssure
len30r:
1. Do the ECM/PCM
ResetProce,
oure.
2. Removethe fuelfill cap.
3. Turnthe ignitionswitchON (ll).
4. Monitor the FTPSensorvolt
a g e w i t h t h e H o n d aP G M
T e s t e r ,o r m e a s u r ev o l t a g e
between ECM/PCMconnector
terminalsA29 and C18.

ls thereapprox.2.5V?

Check for the fuel tank piessure


Sensot:
L Disconnectthe hose between
the EVAPtwo way valve and
the fuel tank pressuresensorat
the EVAPtwo way valveend.
2 . C o n n e c ta v a c u u mp u m p t o
the openend ofthat hose.
3. Turn the ignitionswitchON (lll.
4. Monitor the FTPSnsorvoltage with the Honda PGM
T e s t e r ,o r m e a s u r ev o l t a g e
between ECNI/PCNI
connector
t e r m i n a l sA 2 9 a n d C 1 8 ,a n d
carefullyappiyvacuumon the
hose one strokeat a time.
5. The voltageshould smoothly
dropfrom the staningapprox.
2.5 V down to approx. 1.5 V.
STOPapplyingvacuumwhen
the voltage drops to approx.
1 . 5 V o r d a m a g et o t h e t u e l
t a n k p r e s s u r es e n s o r m a y

PTANKILT GRNI

SG2 {GRN/BLK)
Wire sideof {emaleterminals
Chock tho vacuum lin6s tor
rGlriction o. blockago repair as
necessary.lf OK, roplacethe fuel
tank Drer3ursentor.

FUELTANK
PRESSURE
SENSOR

VACUUM
-30 in.H9
PUMP/GAUGE.0
A973X- 041 XXXXX

WAYVALVE
Doesthe voltage drop to approx.
1 . 5V a n dh o l d ?

Intermittent tailuro. sv3tem is OK


at this tim. Chack to. poor connction6 or 10036hose at fu6l
tank pres3ure ionsor and fuel
trnk.

11-208

www.emanualpro.com

'98 - 00 modls:
The scantool indicatesDiagnosticTroubleCode(DTC)P0452:A low voltageproblemin the FuelTank Pressure
sensof.
The fuel tank Dressuresensorconvertsfuel tank absolutepressureinto electricalsignalsand inputsthe ECM/PCM.
OUTPUT
VOLTAGE
tvl
{.5

Th. MIL has been reoortedon.


DTCm452 is stored.
Checkthe vacuum lin6:
Checkthe vacuumlinesof the fuel
tank pressuresensorfor misrout
ing, leakage,breakageand clogging.

0,5
-? KPA
(-50 mmHg,
-2 in.Hgl

+7 kPr
l5OmmHg,
2 in.Hgl
PRESSURE

Are the vacuumlinesOK?


A (32P)
ECM/PCMCONNECTOR
Problemveriticstion:
1. Do the ECM/PCM Reset
Procedure2. Removethe luelfillcap.
3 . T u r n t h e i g n i t i o ns w i t c hO N
flr).
4. Monitor the FTPSensorvolt'
age with the Honda PGM
T e s t e r ,o r m e a s u r ev o l t a g e
b e t w e e nb o d y g r o u n d a n d
ECM/PCM
terminalA29.
ls lhereapprox.2.5V?

Intermittent failuro, system is OK


at this lima. Chacklor Door connections or loose wi.es at C580
llocrted rt access panell, C646
lluel tank Daessuresensor) and
at the ECM/PCM.

Checklor an open in wir lVeC2


line):
1. Turnthe ignitionswitchOFF.
2. Reinstallthe
fuel fill cap.
3. Disconnectthe fuel tank pressuresensor3P connector,
4. Turnthe ignitionswitchON (ll).
5- Measurevoltage betweenthe
fLreltank pressuresensor3P
connectorNo. 1 terminaland
N o . 2t e r m i n a l .
ls thereapprox.5 V?

Wire sideot femaleterminals

FUELTANK
PRESSURE
SENSOR
3PCONNECTOR
tc6a6l

voc2
(YEL/BLUI

Wire sideol fsmaleterminals


Replir opon in the wire btwen
th6 tuel tank pressurelensot and
the ECM/PCM{A29).

(cont'd)

YES
( T op a g e1 1 - 2 1 0 )
www.emanualpro.com

11-209

EmissionControlSystem
EvaporativeEmission(EVAP)Controls(cont'dl
(Frompagel1'209)

FUELTANK
PRESSUNE
SENSOR
3PCONNECTOR
tc646l

Check lor a short in the wire


IPTANKIine}:
Measurevoltagebetlveenthe fuel
tank pressuresensor3P connector
No.3terminaland No.2terminal.

ls thereapprox.5V?
Wire side of female terminals
Check for a short in the wire
(PTANKline):
1. Turnthe ignitionswitchOFF.
2 . D i s c on n e c t t h e E C M / P C M
connectorA {32P).
3. Checkfor continuity between
the fuel tank pressuresensor
3P connectorNo. 3 terminals
and bodyground.

Repairshort in the wira betwgon


the fuel trnk prossures6nsorand
tho ECM/PCMlA29).

Sub.tituto a known-good ECM/


PCM and rcheck. lf 3ymptom/
indication goer !way. replace
th6 original ECM/PCM.

11 -2 1 0

www.emanualpro.com

'98 - 00 modals:
The scantool indicatesDiagnosticTroubleCode(DTC)P0453:A high voltageproblemin the FuelTankPressure
sensor.
Thc MIL has b6on ropottcd on.
DTCmia53is dorcd.

Ch6cktho vacuum linos:


C h e c kt h e v a c u u m l i n e s o f t h e
fueltank pressuresensorlor misrouting, leakage,breakageand
cloggrng.

A {32PI
ECM/PCMCONNECTOR

Are the vacuumlinesOK?


PTANK ILT GRN)
Problornverification:
1. Do the ECM/PCM Reset
Procedute.
2. Removethe fuel fill cap.
3. Turn the ignition switch ON

trminals
Wire sidoot fema16

{[).

4. Monitor the FTPSensorvoltage with the Honda PGM


Tester, or measure voltage
b e t w e e nb o d y g r o u n d a n d
terminal429.
ECM,PCM

ls thereapprox.2.5V?

Intarmittent tailuro, sv3iom b OK


at this timo. Chock for poor connection3 or loo$ wire3 at C580
(locstod .t .cc$r p.nell, C6a6
(fucl tank pros3ure son3orl and
.t the ECM/FCM.

Check lor an open in tho wiro


lSG2lin6l:
1. Turnthe ignitionswitchOFF.
Iuel fill cap.
2. R6installthe
3. Disconnectthe Iu6l tank pres_
suresensor3P connector,
4. Turn the ignitionswitchON (ll).
5. Masurevoltago between the
tuel tank pressuresensor3P
'!
connectorterminalsNo. and
No.2.

ls thereapprox.5 V?

Chck for an opon in tho wiro


(PTANKlinel:
M e a s u r ev o l t a g e b e t w e e nt h e
fuel tank pressuresensor3P connectorNo. 3 terminaland No. 2
terminal.

FUELTANX
Pf,ESSUBESENSOR
3p CONNECTOR{C6,a6l

vcc2
IYEL/BLUI

sG2
(GRN/BLK}
Replir opn in th. wi.c b{ween
tha fuel tank Dio'sute sansot and
tho EC|,/PCM {Cl8}.

Wire sideot femaleterminals

sG2
IGRN/BLKI

3
PTANK
ILT GRNI

ls thereapprox.5 V?
(cont'd)
\To page 11-212)
www.emanualpro.com

11-211

EmissionControlSystem
EvaporativeEmission(EVAP)Controls(cont'dl
( F r o mp a g e1 1 , 2 1 1 )
ECM/PCMCONNECTORS
Check fo. an open in the wire
(PTANKlinel:
Measurevoltage betweenECM/
PCMconnectorterminalsA29 and
c18.
PTANK {LT GRNI
ls thereapprox.5V?

Ropairopen in the wire betweon


the ECM/PCM{A291and tho fuol
tank pressule3ensor.

Substitute a known-good ECM/


PCM and recheck. lf symptom/
indication goes away, rplace
tho originrl ECM/PCM.
SG2 (GRN/BLK}
Wire sideof temaleterminals

11-2 1 2

www.emanualpro.com

'98 - 00 models:
Emission(EVAP)controlsystemleak
The scantool indicatesDiagnosticTroublecode (DTC)P1456:Evaporative
detected{fueltank system).
Troubleshooting Flowchart
-

The MIL has been reported on.


DTC P1456 is stored.

Check the fuel fill cap:


Checkthe fuel fill cap (the caP
must be a gray OEM cap and be
"clicks"
to
t i g h t e n e d a t l e a s tt h r e e
p r o p e r l y s e a lt h e s y s t e m ) -

ls the properfuel fill cap installed


and properlytightened?

Replaceor tighton the cap.

Checkthe lueltill cap seal:


Checkthe fuel fill capseal.

ls the tuel fillerpipedamaged?

Fuel till caD is OK. Do the luel


tank pressureSensortest (see
page 11-2111.(EVAP Purge control solenoid valve tsl (seePage
11-2151.1r

Replacethe luelfiller pipe.

' : ' 9 9 - 0 0m o d e l s

(cont'd)

www.emanualpro.com

11-213

EmissionControlSystem
EvaporativeEmission(EVAPIControls(contd)
lP14s6l("ont,a)

Fueltank pros3uresensortost.
(Thecontinuetion of DTCPl456
t.oubls3hooting.,

ECM/PCMCONNECTORS

Chockthe tusl trnk pr3suresensor:


1. Removethe fuel fill csp.
2. Turn the ignitionswitchON fll).
3. Monitor the FTPSensorvohage with th Honda PGM
T e s t e r ,o r m e a s u r ev o l t a g e
between ECM/PCMconnctor
terminalsA29and C18.
SG2 IGRN/BLKI
ls there approx. 2.5 V?

Checkthe fuel t nk pressuae3ensor:


1. Turnthe ignitionswitchOFF.
2. Disconnectthe hose between
the EVAPtwo way valve and
the tueltank pressuresensorat
the EVAPtwo way valveend.
3 . C o n n e c ta v a c u u mp u m p t o
the openend ofthat hose.
4. Turn the ignitionswitchON 0l).
5. Monitor the FTPSensorvoltage with the Honda PGM
Testet, or measure voltage
between ECM/PCMconnector
t e r m i n a l s4 2 9 a n d C 1 8 ,a n d
carefullyapplyvacuumon the
hose one strokeat a lime.
6. The voltageshould smoothty
drop from the staning approx.
2.5 V down to approx. 1.5 V.
Stop applyingvacuum when
the voltagedrops to approx.
1 . 5 V o r d a m a g et o t h e f u e l
t a n k p r e s s u r es e n s o r f i a y
occur,

Doesthe voltage drop to approx.


1.5V and hold?

11-2 1 4

www.emanualpro.com

Choct ths vacuum linsr for


ra3triction o. blockago ropair a!
nect*rary. It OK, replaca the fu6l
tank praituJc sentot.

Wire sideoI femaleterminals

FUEI-TANK
PRESSURE
SENSOR

VACUUM
- 30in.Hg
PUMP/GAUGE,0

A973X - ill -

xxxxx

EVAP TWO
WAY VALVE

Fu.l tank pressu.c anlor b OK.


Oo thc EVAP pulge control
solenoid valve toat (3prgo 112151.

EVAP purge control 3olnoid


valve test.
{Tho continu.tion of DTC Plil56
trouble3hootin9.)

VACUUM
- 30 in.Hg
PUMP/GAUGE,0
A973X- 041 -

xxxxx

Check the EVAP purge control


solenoidvalve:
1. Disconnectthe vacuum hose
trom the EVAPcontrolcanist e r , a n d c o n n e c ta v a c u u m
pumpto the hose.
2. Turnthe ignitionswitchON (ll).
3. Applyvacuumto the hose.

Doesthe valvehold vacuum?

EVAP
CONTROL
CANISTER

EVAP purge contlol solenoid


v.lvo is OK. Do the EVAP bypai3
solenoid valve test (see Page 112161
EVAPPURGECONTROLSOLENOID
(Cl08}
VALVE2P CONNECTOR

Check tho EVAP purge control


solenoidvalve:
't. Turnthe ignitionswitchOFF.
2 . D i s c o n n e ctth e E V A PP u r g e
controlsolenoidvalve2P connector,
3. Checkfor continuity between
t h e E V A P p ur g e c o n t r o l
solenoidvalve 2P connector
t e r m i n a lN o . 2 a n d b o d Y
ground,

Wiresideof
female
terminals

Check for s short in the wire


{PCSlinel:
1 . D i s c o nn e c t t h e E C M / P C M
connectorA {32P).
2. Checkfor continuitybetween
the EVAP purge control
solenoidvalve 2P connector
terminalNo. 2 and body
ground.

ls there continuity?

neprir short in tho wite bot$reon


the ECM/FCMlAGl and thc EVAP
purge control 3olenoidvalve.

Substitut a known-good ECM/


PCM and recheck. lf symptom/
indication goe3 away. repl.ce
thc originsl ECM/PCM.

(cont'd)

www.emanualpro.com

1 1-215

EmissionControlSystem
EvaporativeEmission(EVAPIControls(cont,dl
(conro)
1T1456I
EVAPbypa3ssolenoid valve test.
(The continuation ot DTC P1456
troubleshooting.l

VAP
BYPASS

SoLENOtO
VALVE

Checkthe EVAP bypasssotenoid


1. Disconnectthe vacuum hose
from the EVAPtwo way valve,
and connecta vscuum pump
to the hose,
2 . C o n n e c t h e E C M / P C Mc o n nectorterminal 43 to the body
groundwith a jurnperwire.
3. Turnthe ignitionswitchON 0t).
4. Applyvacuumto the hose.

ECM/PCMCONNECTOR
A I32P)
2WBS (BLU}
/ 3

4l

o /

7,x , /

1 6 1 7 1 8 't9 2 0 2 1 1 /
26 27
2A 29 solT

VACUUM
PUMP/
GAUGE.
0 -30 in.Hg
A373X041 -

to
z3
32

JUMPERWIRE

Wiresideof femaleterminals

xxxxx

Doesthe valvehold vacuurn?

EVAP bypass solenoid valve/


EVAP two way valve is OK. Do
th6 EVAP control crnister vent
shut vafvele3t lso page 11-2'111.
EVAPBYPASSSOLENOID
VALVE2P CONNECTOR
lcorlTl

Check for an opn in the wir


(2WBSline):
1. Turnthe ignitionswitchOFF.
2. Disconnectthe EVAPbypass
solenoidvalve2P connector.
3. Checkfor continuity between
t h e E V A P b y p a s s s ot e n oi d
v a l v e2 P c o n n e c t o tre r m i n a l
No.2 and body ground.

2WBS
(BLU}

Wire sideof
female
termrnats
Repairopen in the wire between
the EVAP bypass solenoid valv.
and ECM/PCMlA3).
tGl
IBLK/WHT}

Chack tor an op6n in the wire


llcl line):
1. Turnthe ignitionswitchON l).
2. Measurevoltagebetweenthe
EVAPbypasssolenoidvalve
2 P c o n n e c t o tre r m i n a lN o . l
and body ground.

Replacethe EVAP byps.,s solonoid


vatus and O-ring3.

Ropairo,penin the wire botwoen


th6 EVAP bypa$ sotenoid vatvo
a n d N o . 1 5 A L T E R N A T O RS p
SENSOR(7.5Altuso.

1 1 -2 1 6

www.emanualpro.com

-/

VACUUM
- 30 in.Hg
PUMP/GAUGE,0
A973X- 041 XXXXX

EVAP control canister vent shut


valvelst,
lThe conlinualion ot DTC P1456
troubleshooting.)
EVAP
THREE
Check the EVAP control cankter
vent 3hut valve:
1. Disconnectthe vacuum hose
from the EVAPthreeway valve,
and connecta vacuumPUmP
to the hose.
2. Turnthe ignitionswitchON (ll).
3. Applyvacuumto the hose

Doesthe valvehold vacuum?

VALVE

EVAP control crnisier vent lhul


valve is OK. Do the v.cuum
hoses and connections te3l lsee
page11-218).

EVAP
CONTROL
CANISTER

EVAPCONTROL
CANISTERVENT SHUT
IC361)
VALVE2P CONNECTOR

r+
l 1
f

Chock the EVAP control canbtel


vent shul valvo:
1. Turn the ignitionsw;tchOFF.
2. Disconnectthe EVAPcontrol
c a n i s t e rv e n t s h u t v a l v e 2 P
connector.
3. Checkfor continuitybetlveen
the EVAPcontrol canistervent
shutvalve2Pconnectorterminal No. 1 snd body ground.

t 2 l

1 VSV

(o) tLTcnrulwxrt

1
Wire sideof femaleterminals

Roplacthe EVAPcontlol canbt]


venl shut valve and O-ring.

Chock lor a short in the wire


(VSV lino)r
1 . D i s c on n e c t t h e E c M / P C N 4
connoctorA (32P).
2. Checkfor continuitybetween
the EVAPcontrol canistervent
shutvalve2Pconnectorterminal No. 1 and body ground.

EVAP
CONTROL
CANISTER
VENT
SHUT
VALVE
O.RING
Replace.

Reorir 3hort in tho wiro bgtweon


the EC1I/I/PCMlAal .nd the EVAP
codrol canbtor vent shut valv6.

Substitute a known.good ECM/


PCM and recheck. lf symptom/
indicrtion goes awaY, replace
the original ECM/PCM.

ILT GRN/WHT)

(cont'd)

www.emanualpro.com

1 1- 2 1 7

EmissionControlSystem
EvaporativeEmissionIEVAPIControls(cont'd)
lTi,t56l ("onto)
Vacuum hoses and connections
telit.

(The continuarion of DTC P1456


troubleshooiing.l

C h e c kt h e v a c u u m h o 3 e s a n d
connect|ons:
C h e c kt h e f o l l o w i n g p a r t s f o r
l e a k sa t a t m o s p h e r i cp r e s s ur e
{seepage11-204).
. Fueltank
. Fuelfill cap
. F u e l f i l pl i p e
. EVAPtwo way valve
. Fueltankpressuresensor

Repairor replacothe parts.

Substitute a known-good ECM/


PCM and recheck.lf symptom/
indication goes away, replac
the original ECM/PCM.

1 1 -2 1 8

www.emanualpro.com

'98 - 00 modls:
Emission(EVAP)Controlsystemleak
The scantool indicatesDiagnosticTroublecode (DTc)P1457:Evaporative
detected(EVAPcontrolcanistersystem).
Troubl6shootingFlowchart
-

('98 model only)

_]

The MIL has been rePortedon.


DTCP1,157is storod.

Do the fuel tank Pressuresensor


test {seepage11-214).

ls the {ueltankpressuresensorOK?

Do the EVAP Purge contlol


solenoid valve test lsea Page 1l_
220t.

(cont'dl

www.emanualpro.com

11-219

EmissionControlSystem
EvaporativeEmission(EVAP)Controls(cont,dl
iTl457l ("ont'or
- The MIL has been reportedon.
- DTCP1457is stored.
{EVAP purge control solenoid
valve test.l*

Check the EVAP purge conrrol


30lenoidvelve:
L Disconnectthe vacuum hose
from the EVAPconlrol canis,
t e r , a n d c o n n e c ta v a c u u m
pump to the hose.
2 . C o n n e c t h e E C M / P C Mc o n
nectorterminalA6 to the body
groundwith a jumperwire.
3. Turnthe ignitionswitchON (tl).
4. Applyvacuumto the hose.

Doesthe valvehold vacuum?

VACUUM
PUMP/GAUGE,
O-30 iN.Hg
A973X- 0rl -

xxxxx
'\)

AP
CONTROL
CANISTER

Check for an open in the wire


(lGl line):
1. Turnthe ignitionswitchON t).
2. Measurevoltage between the
EVAPbypasssolenoidvalve2p
coonectorterminalNo. 1 and
body ground.

ls there battery voltage?

Repah open in lhe wir6 betwoen


the EVAP pu.ge cont.ol solonoid
vdlvo and No. 15 ALTERNATOR
SP SENSOR{7.5Al fu!.
*: Continuedfrr '98 model

1 -220

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4
5
8 /
,/3
't6 1 7 1 8 l 9 20
,,/ 14 ,/
,/ 26
29 30

't0
24

JUMPER
WIRE

Wire sideof lemaleterminals


EVAPpurge control solenoid
valve is OK. Oo the EVAPbypass
solenoid valve t3t {see psge 1l221t.

Check for an open in the wire


(PCSline):
1. Turnthe ignitionswitchOFF.
2 . D i s c o n n e ctth e E V A Pp u r g e
controlsolenoidvalve2P con
nector,
3. Checkfor continuitybetween
t h e E V A P p ur g e c o n t r o l
solenoidvalve 2P connector
t e r m i n a lN o . 2 a n d b o d y
grouno,

ls therecontinuity?

ECM/PCMCONNECTOR
A {32P}
PCS(RED/YELI

EVAPPURGECONTROLSOI.ENOID
VALVE2P CONNECTOR
(Cl08)
PCS
IRED/YELI

female
termanals

Ropairopn in th6 wire between


the EVAP purge control 3olenoid
velve and ths ECM/PCM(A61.

EVAP
BYPASS
SOLENOID
VALVE

EVAPbypasssolenoidvalv test.
{The continuation of DTC P1457
troubleshooting.l

FUELTANK
SENSOR
PRESSUBE
EVAPTWOWAY
VALVE

Checkthe EVAP bypass 3olenoid


VACUUM
PUMP/
GAUGE,
0-30 in.Hg
A973X041 -

1. Disconnectthe vacuLlmhose
from the EVAPtwo way valve,
and conned a vacuumPUmP
to the hose.
2. Turnthe ignitionswitchON (ll).
3. Applyvacuumto the hose

Does the valve hold vacuum?

xxxxx

EVAP bvpas3 30lsnoid vrlvo/


EVAPtwo way v.lve is OK. Do
the EVAP control canisler vent
3hut v.lve te3l (seePsge11'2221.
EVAPAYPASSSOLENOID
(C647}
VALVE2P CONNECTOR

Ch6ckthe EVAP byp.ss solenoid


'1. Turnthe ignitionswitchOFF
2. Disconnectthe EVAPbypass
solenoidvalve2P connector.
3. Check{or continuitybetween
t h e E V A P b y p a s s s o l e n oi d
v a l v e 2 P c o n n e c t o tre r m l n a l
No.2 and body ground

t.'-+l

t1t?l
| 2wBs

(d1terul

Y-L
ReDlacethe EVAPbypass 3olenoid
valveand O-rings.

C h e c kf o r a s h o r t i n l h e w i r e
{2WBSlinel:
connec
ECM/PCM
1. Disconnect
tor A (32P).
2. Checklor continuity betlveen
t h e E V A P b y p a s s s o l e n oi d
valve 2P connectortermrnal
No.2 and body ground.

ls therecontinuitY?

Wire sideof
female
terminals

2WBS
(BLU}

@)

Rcpsir short in th. wire bgtwoen


the EcM/PCtrl lA3l lnd the EVAP
bypa$ solenoidvalvo.

Sub3tiiute . known'good ECM/


PCM End recheck.lI sYmptom/
indication goe3 away, tePlace
the originalECM/PCM.

(cont'd)

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11-221

EmissionControlSystem
EvaporativeEmission(EVAP)Controls(cont,dl
lT145il ("ont'o)

VACUUM
- 30 in.Hs
PUMP/GAUGE,0
A973X- 041 -

EVAP control canistor vent shut


valve t6t.
(The continuation of DTC p1457
troublahooting.)

xxxxx

ECM/PCMCONNECTOR
A {32PI

vsv
{LTGRN/WHT)

Chcck the EVAP control c.nirt6l


vent ahut vrlve:
1. Disconnectthe vacuum hose
trom the EVAPthreway valve,
and connecta vacuum pump
to the hose.
2. Connectthe ECM,PCMconn6c,
t o r t e r m i n a lA 4 t o t h e b o d y
groundwith a jumper wire.
3. Turn the ignitionswitchON fil).
4. Applyvacuumto the hose.

Doesthe valvehold vacuum?

l 4 / 1 6 1 7 l 8 't9 20 2l
26 27
2a 29 30

EVAP
THREE

10
23

JUMPER

WIRE

VATVE
\

Wiresideof femaleterminals

't

EVAP
CONTROL
CANISTER
EVAP control crni3ter v6nt shut
velve b OK. Do the canistsr syslern loak test {3eepage 11-2231.

EVAPCONTROL
CANISTERVENT SHUT
VALVE2P CONNECTOR
{C361}

riEr

r+J

I vsv

Check for an open in the wire


IVSV linGll
1. Turnthe ignitionswjtchOFF.
2. Disconnectthe EVAPcontrol
c a n i s t e rv e n t s h u t v a l v e 2 p
connector.
3. Check for continuity between
the EVAPcontrol canistervent
shul valve 2P connectorterminal No. l and body ground.

/A\ {Lr GRN/WHT|

Y
I

Wiresideof femaleterminals

EVAP
CONTROL
CANISTEF
VENT
SHUT
VALVE

Ropril op6n in tho wire botweon


the EVAP control canister v6nt
shut v.lve and the ECM/PCM
(A41.

(}BING
Replace.

Check tor an open in the wire


(lGl line):
1. Turn the ignitionswitch ON l).
2. Measurevoltage between the
EVAPcontrolcanistervent shut
valve 2P connectorterrninal
No. 1 and body ground.

RoplacethG EVAP cont.ol canister Yentshut velve and O-ring.

Repai. opon in the wire betwoen


th6 EVAP control canister vont
shut valve .nd No. 15 ALTERNATOB SP SENSORt?.5 Alfus6.

11-222

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ffil r c r
e

(BLK/wHr)

24

EVAP
CONTROL
Canbter system leak test
{Thecontinuation of DTCP1457
trouble3hootin9.)

Chock the EVAP control canister


vent shut valve line and connoc'
tonS:
1. Turnthe ignitionswitchOFF
2. Connectto three'waytee fit_
tings into the hose from the
EVAPcontrol canisterto the
EVAPtwo way valve. Connect
the fuel tank pressuresensor
to one of the tee fittings and
the vacuum PumPto the other'
3. Removethe vent hose from
the EVAPcontrol canistervent
shut valveand cap the Pon to
sealthe fresh air vent Ior the
EVAPcontrol canister.
4. Turnthe ignitionswitchON (ll).
5. While monitoring the FTP
Sensorvoltagewith the Honda
P G M T e s t e r ,o r m e a s u r a n g
v o l t a g e b e t w e e nE C M / P C M
connectorterminalsA29 and
C18slowly PumPthe vacuum
pump using a strokeevery 1 2 seconds.
6 . C o n t i n u et o P u m P v a c u u m
u n t i l t h a t v o l t a g ed r o P st o
approx.1.5V.
N O T E :M a k e s u r e t h a t t h e
e n g i n ec o o l a n tt e m P e r a t u r e
stillabove95'F(35'ClandYour
vacuumPumPhasno leak
7 . M o n i t o r t h a t v o l t a g ef o r 2 0
seconds.

Doesthevoltagedrop to 1.5V
and holdsat least20 seconds?

lGpct the EVAPcontrol cani3tel


vent 3hut valvo line and connec_
tion5.

EVAP
FUELTANK
BYPASS
SENSOR
SOLENOID
EVAPTWOWAY
VALVE
VALVE
EVAP
THREE
VALVE

EVAP
CONTROL
CANISTER

ttrrL
t a
VACUUM
PUMP/
GAUGE,
0 - 30 in.Hg
A973X041 XXXXX

FITTINGS

ECM/PCMCONNECTORS
A {32P)

PTANKILT GRN)
Check the EVAP Pu.ge control
solenoidvalve line and connections:
1. Turnthe ignitionswitchOFF.
2 . D i s c o n n e ctth e P u r g e l a n e
hose from the EVAPcontrol
canisterand Plugthe Port
3. Turnthe ignitionswitchON (lli.
4. While monitoringthe FTP
Sensorvoltagewith the Honda
P G M T e s t e r ,o r m e a s u r i n g
v o l t a g e b e t w e e nE C M / P C M
connectorterminalsA29 and
Cl8 slowly PumPthe vacuum
pump using a strokeevery 1 2 seconds.
5 . C o n t i n u et o p u m p v a c u u m
u n t i l t h a t v o l t a g ed r o P st o
approx.1-5V.
N O T E :M a k e s u r e t h a t t h e
e n g i n ec o o l a n tt e m P e r a t u r e
andYour
stillabove95'F(35"C)
vacuumpumphasno leak6 . M o n i t o r t h a t v o l t a g et o r 2 0
seconds.

Does the voltage drop to 1.5V


and holds at least 20 seconds?

Reolacethe EVAPconirol canister.

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VENT
SHUT
VALVE

c (31Pt

SG2 {GRN/BLK)
Wiresideof femaleterminals

Inlpect tho EVAP Putge control


solenoid valvo line and connec'
tion3. It th6y lro OK, do the EVAP
two way valve te3t (seo page 112211.

{cont'd)

11-223

EmissionControlSystem
EvaporativeEmission(EVAP)Controls(cont,dl
EvaporativeEmission (EVAP)Two Way Valve Testing
'97 model:

1.
2.

1.

Removethe fuelfill cap.

2.

R e m o v et h e v a p o r I i n e f r o m t h e E V A Pt w o w a y
valve on the fuel tank, and connectit to a T_fitting
f r o m a v a c u u mg a u g ea n d a v a c u u m p u m p a s
shown.

VACUUM
PUMP/GAUGE,
0 - 30 in.Hg
A973X-041-XXXXX

.98 -

0Omodels:
Removethe fuel fill cap.
R e m o v et h e v a p o r l i n e f r o m t h e E V A Pt w o w a y
valve{locatedabovethe EVAPcontrolcanister).and
c o n n e c ti t t o a T - f i t t i n gf r o m v a c u u mg a u g e a n d
vacuumpump as shown.

VACUUM/PRESSUFE

VACUUM,/
PRESSURE
GAUGE
otJAz - 001rDoB
T-FITTING
VACUUM PUMP/
GAUGE,0- 30 in.Hg
A973X- 041 -

xxxxx

T-FITTING
T-FITTING

3 . A p p l y v a c u u m s l o w l y a n d c o n t i n u o u s l vw h i l e
watching the gauge.The vacuum should stabilize
momentarilyat 0.7- 2.0 kpa (5 - 1SmmHg,0.2_ 0.6
in.Hg).
l f t h e v a c u u m s t a b i l i z e s( v a l v e o p e n s ) b e l o w
0 . 7 k P a ( 5 m m H g , 0 . 2 i n , H g )o r a b o v e 2 . 0 k p a
(15 mmHg,0.6 in.Hg),installa new valveand retest.
4.

A p p l y v a c u u m s l o w l y a n d c o n t i n u o u s l yw h i l e
watchingthe gauge.
The vacuum should stabilizemomentarilyat O.g_
2.1 kPa(6 - 16 mmHg,0.2- 0.6 in.Hg).
l f t h e v a c u u m s t a b i l i z e s( v a l v e o p e n s ) b e l o w
0 . 8 k P a ( 6 m m H g , 0 . 2 i n . H g )o r a b o v e 2 . 1 k p a
(16 mmHg,0.6 in.Hg),installa new valveand retest.
Move the vacuum pump hosefrom the vacuumfitting to the pressurefitting. and move the vacuum
gauge hose from the vacuum side to the pressure
side as shown.

Move the vacuum pump hosefrom the vacuumfit_


ting to the pressurefitting, and move the vacuum
gauge hose from the vacuum side to the pressure
side as shown.

PiESSURE
SIDE

5.

Slowly pressurize
the vapor line while watchingthe
gauge.The pressureshouldstabilizeat 1.3- 4.7 kpa
( 0 - 3 5 m m H g ,0 . 4- 1 . 4i n . H g ) .
. l f t h e p r e s s u r em o m e n t a r i l ys t a b i l i z e s( v a l v e
opens)at 1.3- 4.7 kpa (10 - 35 mmHg, 0.4 _ 1.4
in. Hg),the valveis OK.
. lf th6 pressurestabilizes
below 1.3kpa fio mmHg,
0.4 inrHg)or above4.7 kpa (35 mmHg, 1.4 in.Hg),
installa new valve and retest.

11-224

www.emanualpro.com

5.

Slowly pressurizethe vapor line while watchingthe


gauge.
The pressureshould stabilizemomentarilvabove
1 . 0k P a( 8 m m H g ,0 . 3i n . H g ) .
a l f t h e p r e s s u r em o m e n t a r i l ys t a b i l i z e s( v a l v e
o p e n s )a b o v e 1 . 0 k P a ( 8 m m H g .0 . 3 i n . H g ) t, h e
valveis OK.
. lf the pressurestabilizesbelow ,|.0kpa {g mmHg.
0.3 in.Hg),installa new valveand retest.

Transaxle
...........12-1
Clutch
. . . . . . . . . . . . . . . . . . . . .1. .3. -. 1
...
M a n u a lT r a n s m i s s i o n
. 4-1
A u t o m a t i cT r a n s m i s s i o .n. . . . . . . . . . . ..........1
... 15-1
Differential
... 16-1
Driveshafts

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Clutch
12-2
..........'
Tools....,.....
Speciaf
.'." 12'3
lllustratedlndex...........
ClutchPedal
........."."."".12-4
Adjustment
ClutchMasterCylinder
'." 12'5
RemovaUlnstallation
SlaveCylinder
.'.. 12-6
Removal/lnstallation
PressurePlate
..'." 12-7
RemovaUlnspection
ClutchDisc
."'.. 12-8
Removal/lnspection
Flywheel
12-9
......................
Inspection
12-9
.......................................
Replacement
ClutchDisc,PressurePlate
12-10
....................'
lnstallation
ReleaseBearing
......12'11
Removal/lnspection
12-12
.....................
lnstaflation

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SpecialTools

Rel.No.

a
IA

@
!c,
Lo,

Tool Number
OTJAF- PM70,I1A
07NAF- PR30l00
07LAB- PV00100
or
07924- PD20003
07746 0010100
07749- 0010000
07936- 3710100

Description
ClutchAlignmentDisc
ClutchAlignmentShaft
R i n gG e a rH o l d e r

1
1
1

Attachment,32 x 35 mm
Driver
H an dl e

b)

2-2

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Oty

1
1

PageReference
|

I
I

t2-7
12-7, A, ' t0,11
1 2 - ,79 , 1 0 ,1 ' l

12-10
12-10
1 2 - 7, a , 1 0 , 1 1

lllustratedIndex

NOTE:
. Wheneverthe transmissionis removed,cleanand greasethe releasebearingslidingsurface
.lfthepansmarked*areremoved,theclutchhydraulicsystemmustbebled(seepage12-6).
and twisting.
. Inspectthe hosesfor damage.leaks.interference,

LOCKPIN

*CLUTCHLINE
19 N.m (1.9kgj.m,
14 tbtft)

PEDALPIN

.RESEFVOIR
HOSE

8 x 1.25mm
13 N.m {1.3kgf m,9.4lbtft)

*RESERVOIR
TANK

.o-.9r

CLUTCHPEDAL
Adjustment,page12-4

*CI-UTCHMASTERCYLINDER
page12-5
Femoval/lnstallation,

WM\,".0-ffi-P"8Nmlloks{m'

6x1.0mm
9.8 N.m (1.0kgf.m,
7.2 tbf.ft)
*CLUTCHLINE
15 N.m (1.5kgt m,
11 tbr.ft)

CLUTCHDISC
page 12-8
Removal/lnspection,
page12,13
Installation,

*CLUTCHLINE
24 N.m {2.4 kgf.m,
17 tbf.ft)
8 x 1.25mm
25 N.m {2.6kgt m,

19rbf.ftt
FLYWHEEL
page12I
Inspection,
page12-9
Repiacement,
1 2x 1 . 0m m
103N.m (10.5kgtm,75.9lbf ftl
PLATE
PRESSURE
page'12-7
Removal/lnspection,
page'1213
Installation,
RELEASEBEARING
page12-1'!
Removal/lnspection,
page12-12
Installation,
*CLUTCHLINE
15 N.m (1.5kgt m,
11 tbf.ft)

www.emanualpro.com

I x 1.25mm
22 N.m 12.2kgl'm, 16lbfft)

12-3

ClutchPedal
Adiustment
NOTE:
. T o c h e c k t h e c l u t c h i n t e r l o c ks w i t c h a n d c l u t c h
switch,seesection23.
. The clutchis self-adjusting
to compensatefor wear.
CAUTION:lf there is no clearancebstwan the master cylinder piston and push rod, ths roloasebearing
is held againsi the diaphragm spring, which can
resuh in clutch slippageor other clutch probloms.
1.

LoosenlocknutA, and backoff the clutchswitch(or


sdjustingbolt) until it no longertouchesthe clutch
peoar.

2.

LoosenlocknutC, and turn the push rod in or out to


get the specifiedstroke (@) and height (@) at the
clutchoedal.

3.

TightenlocknutC.

4.

Thread in the clutchswirch (or adjustingbolt) until


it contactsthe clutchoedal.

5 . Turn the clutchswitch{or adjustingbolt} in an additional3/4to 1 full turn.


TightenlocknutA.
7 . LoosenlocknutB on the clutchinterlockswitch.
8 . Measurethe clearancebetweenthe floor board and
clutchpedalwiththe clutchpedalfully depressed.
q

Releasethe clutchpedal 15 - 20 mm (0.59- 0.79in)


from the fully depressedpositionand hold it there,
Adjustthe positionof the clutchinterlockswitch so
that the engine will start with the clutch pedal in
this position.

1 0 .TightenlocknutB.

LOCKNUT B
9.8 N.m 11.0kgf.m, 7.2 lbf.ftl
CLUTCHINTERLOCK
SWITCH
CLUTCHSWTTCH
{or ADJUSTINGBOLTI
L(rcKNUT A
9.8 N.m {1.0kg{.m,7.2 lbf.ftl

CLUTCHMASTERCYLINDER
PUSHROD
Pedal in contact with swhch
LOCKNUTC
18 N.m (1.8kgf.m,13lbtftl

a_-_--/

@
@
@
o

at PEDAL):135- 1itsmm (5.31- 5.71in}


{STROKE
(TOTALCLUTCHPEDALFREEPLAY)i7-22mm (0.28-0.87in) inctudethe pedatptay 1 - 9 mm (0.0it- 0.35inl
(GLUTC,H
PEDALHE|GHTI:ltxt mm (7.20inl ro rhe ftoor
(CLUTCHPEDALDTSENGAGEMENT
HEtcHTl: 72 mm {2.txtinl minimum to the floor

12-4

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GlutchMasterCylinder
Removal/lnstallation
CAUTION:
. Do not spill brake fluid on the vehicle; it may damage
the paint; if brake tluid does contact the paint. wash
it off immediately with water.
. Plug the end ol the clutch line and leservoir hose
with a shop towel to prevent brake tluid trom coming
out.

4.

Prv out the lock pin, and pull the pedal pin out of
the voke.Removethe nuts.
NUTS
I x 1.25mm
13 N.m t1.3kgt.m,g.illbtft)

' t . The brakefluid may be suckedout through the top


of the mastercylinderreservoirwith a syringe.
Disconnectthe clutch line and reservoirhose from
the clutchmastercylinder,

9.8N.m11.0kst m,
7.2tbf.ftl

5,

Removethe clutchmastercylinder.

CLUTCHLINE
19 N'm 119 kgJm'
14 lbf.frl

Remove the reservoir from the engine compartment


bulkhead.

MASTER
CLUTCH
CYLINDEF
I n s t a l lt h e c l u t c h m a s t e rc y l i n d e r i n t h e r e v e r s e
orderof removal.
NOTE:Bleedthe clutchhydraulicsystem{seepage
12-61.

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12-5

SlaveCylinder
RemovaUlnstallation
CAUTION:
. Do nol spill braketluid on the vehicle;itmaydamage
the paint; if brake fluid dos contast the paint, wash
it off immediately with water.
. Plug the end of the clutch line with a shop towel to
prevcnt brake tluid from coming out.

3.

I n s t a l lt h e s l a v ec y l i n d e ri n t h e r e v e r s eo r d e r o t
removal.
NOTErMake sure the boot is installedon the slave
cylinder.
CLUTCH
LINE
15N.m(i.Skgf.m,lt tbf.ftl

High Temp Urea crease (p/N 087989002).


: BrakeAssemblyLube or equivalentrubber
grease.

.6|l,Super

1.

SLAVECYLINDER

Disconnect
the clutchline from the slavecvlinder.

.-lG

(P/N08798- 90021

E x 1.25mm
22 N.m (2.2kgt.m,
16 tbtft)

(BrakeAssembly
Lube)
Bleed the clutch hydraulic system.

2.

Removethe slavecylinderfrom the clutchhousing.

Attacha hoseto the bleederscrew,and suspend


the hosein a containerof brakefluid.
Makesurethere is an adequatesupplyof fluid at
the clutchmastercylinder,then slowly pump the
clutchpedaluntil no more bubblesappearat the
bleederhose.
Refillthe clutch mastercylinderwith fluid when
qone.
A l w a y s u s e G e n u i n eH o n d aD O T 3B r a k eF l u i d .
Using a non Hondabrakefluid can causecorrosion and decreasethe life of the system.
Confirm clutch operation,and checkfor leaking
fluid.

BLEEDER
SCREW
7.8 N.m (0.8 kgf.m.5.8 lbt.ft)

12-6

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PressurePlate
Removal/lnspection
1 . Checkthe diaphragmspringfingersfor heightusing
the specialtools and a feelergauge.
StandardlNewl: 0.6 mm {0.02in) max.
ServiceLimit: 0.8 mm (0.03in)

4.

Inspectthe pressureplate surfacefor wear, cracks,


a n db u r n i n g .

5.

Inspectthe fingersof the diaphragmspringfor wear


at the releasebearingcontactarea.

HANDLE
07936- 3710100
CLUTCHALIGNMENTDISC
- PM7O11A
OTJAF
CI.UTCHALIGNMENTSHAFT
07NAF- PR30100

FEELER
GAUGE

PRESSURE
PLATE

lf the height is more than the servicelimit, replace


the pressurePlate.
2.

6.

l n s t a l lt h e s D e c i a l l o o l sa s s h o w n .

Inspectfor warpageusinga straightedge and feeler


gauge.Measureacrossthe pressureplate.
in) max.
StandardlNew):0.03mm 10.001
ServiceLimit: 0.15mm (0.006inl

PLATE
PRESSURE

RINGGEARHOLDER ADJUSTERNUT

ADJUSTER
BOLT

ENGINEBLOCK

GAUGE
FEELER

BOLT
NUT

WASHER

T o p r e v e n tw a r p i n g ,u n s c r e wt h e p r e s s u r ep l a t e
mounting bolts in a crisscrosspattern in several
steps.then removethe pressureplate.

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lf the warpage is more than the service limit,


replace the pressure plate.

12-7

GlutchDisc
Removal/lnspection
'1. Removethe
clutchdiscand specialtools.

4.

Measurethe rivet depth from the lining surfaceto


the rivets,on both sides.
Standard(New):1.2- 1.7mm 10.05- 0.07in) min.
Service Limit:
0.2 mm {0.008inl

CLUTCHDISC

Inspectthe lining of the clutchdisc for signsof slipping or oil. lf the clutch disc is burned blackor oil
soaked,replaceit.
Measurethe clutchdiscthickness.
Standard(New):8.,1-9.1 mm (0.33- 0.36in)
ServiceLimh: 6.0 mm (0.2,1in)

LINI G SURFACE

CLUTCHDISC

l f t h e r i v e t d e p t h i s l e s s t h a n t h e s e r v i c el i m i t ,
replacethe clutchdisc.

lf the thicknessis lessthan the servicelimit, reDlace


the clutchdisc.

12-8

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Flywheel
Replacement

Inspection
L

lnspectthe ring gearteethfor wear and damage.

Installthespecialtool as shown.

2.

Inspectthe clutch disc mating surfaceon the flywheelfor wear,cracks,and burning

2.

Removethe flywheelmountingbolts in a crisscross


patternin severalsteps,and removethe flywheel.

3.

Measurethe flywheel runout using a dial indicator


through at leasttwo full turns. Pushagainstthe flywheel each time you turn it to take up the crankshaftthrustwasherclearance.

MOUNNNG
BOLTS

N O T E :T h e r u n o u tc a n b e m e a s u r e dw i t h e n g i n e
installed.
Standard (Newl: 0.05 mm (0.002in) max.
ServiceLimit: 0.15mm {0.006inl
lf the runout is more than the servicelimit, replace
the flywheeland recheckthe runout
FLYWHEEL

FLYWHEEL

RINGGEARHOLDER
07LAB- PV00r00
ol

07924 - PD20003

3.

Removethe ball bearingfrom the flywheel.

RINGGEAR

Turnthe innerraceot the flywheelbearingwith your


finger.The bearingshould turn smoothly and quietly. Checkthat the bearingouter racefits tightly in
the tlywheel.lf the racedoes not turn smoothly,quietly,or fit tight in the flywheel,replacethe bearing.

FLYWHEEL

BALLBEARING

(cont'd)

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12-9

Flywheel
Replacement(cont'dl
Drive the new bearing into the flywheel using the
specialtools.
HANOLEDRIVER
07749-

Clutch Disc,PressurePlate
Installation
1.

Installthe ring gear holder.


CLUTCHALIGNMENTSHAFT
07NAF- PR30100

ATTACHMET{T32x35mm
07746-O010100

FLYWHECI-

CLUTCHDISC

RINGGEARHOLDER
07LAB_ pvoot(x)or
07924_ PD20003

Align the hole in the flywheel with the crankshaft


d o w e l p i n , a n d i n s t a l lt h e f l y w h e e l .I n s t a l lt h e
mountingboltsfinger-tight.
I n s t a l lt h e s p e c i a lt o o l , t h e n t o r q u e t h e f l y w h e e l
mounting bolts in a crisscrosspattern in several
stepsas shown.

Apply greaseto the spline of the clutch disc,then


installthe clutchdisc usingthe specialtools.
N O T E :U s e o n l y S u p e rH i g h T e m p U r e aG r e a s e
(P/N08798- 9002).

Torque:
12x 1.0mm
r03 N.m(10.5kgl.ln,
75.9tbtftl

lnstallthe pressureplate.

PRESSURE
PLATE

12-10

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ReleaseBearing
Removal/lnspection
4.

Torquethe mountingbolts in a crisscrosspatternas


shown.Tightenthe bolts in severalstepsto prevent
warpingthe diaphragmspring.

1.

Removethe releasefork boot from the clutchhousIng.


RELEASE
BEABING

8 x 1.25mm
25 N.m (2.6kgf.m,19lbfft)
RELEASE
FORK
BOOT

RELEASEFORK

Removethe releasefork and releasebearingfrom


the clutchhousing.
Checkthe releasebearingfor play by spinningit by
h an d .
NOTE:The releasebearingis packedwith grease.
Do not wash it in solvent.
5.

Removethe specialtools.

6.

Checkthe diaphragmspring fingersfor height (see


page 12-7]'.

lf there is excessiveplay, replacethe releasebearing with a new one.

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12-11

ReleaseBearing
lnstallation
NOTE: Use only Super High Temp Urea Grease(P/N
08798- 9002).

3.

Move the releaselork right and left to make sure


that it tits properly againstthe releasebear'rng.and
that the releasebearingslidessmoothlY.

the releasebear1. With the releasefork slid bet\iveen


ing pawls. installthe releasebearingon the mains h a f tw h i l e i n s e r t i n gt h e r e l e a s et o r k t h r o u g ht h e
hole in the clutchhousing.

-6.l

(P/N08798-

r iz]))

lPlN 08798- 9002)


0.,1-1.0I (0.01- 0 04 ozl

(P/N08798
9002)

| (,4\1t1t

/\[w

RELEASE
FORK
BOOT

4.

(P/N08798 9002)
1 . 0- 1 . 6g
{0.0,1- 0,06 ozl

Align the detentof the releasefork with the release


f o r k b o l t , t h e n p r e s s t h e r e l e a s ef o r k o v e r t h e
releasefork bolt sequarelv.

12-12

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Install the releasetork boot; make sure the boot


sealsaroundthe releasefork and clutchhousing.

ManualTransmission
Diffrential
l n d e x. . . . . . . . . . . . . . . . . . . . . .
. . . . . . .1. .3 - 3 8
BacklashInspestion..,....,.,.....................,......,
13-38
FinalDrivenGearReplacement....................
13-39
TaperedRoller Bearing
Replacement
.............
13-39
BearingOuterRaceReplacement......,.,........
13-i10
TaperedRoller Bearing Preload
Adiustment
...............
13-il1
Oil SealReolacement....................................
13-/l:}
TransferAssembly
lllustratedIndex
.............
13-il4
Inspection
..,....,.,......,......
13-46
Disassembly
...................
13-47
Transfer Drive Gear Bearing
Replacement
...,..................,.......................
13-ilg
Transfer Driven Gear Shaft Bearing
Replacement..............................................
13-ilg
TransferShaft Disassembly/
Reassembly
..............
13-50
Transler Cover A Bearing Outer Race
Rep1acement.........,.,.,..........,....,...,.........,.,
13-50
Transter Housing Bearing Outer Race
R e D 1 a c e m e n t . . . . . . . . . . . . . . . . . . . . . . . . . . . .1. 3. .-.5. .1. . . . . . . . . . . .
Reassembly
13-52
..-............,...
Mainshaft Bearing/OilSeal
Beplacement
..................
13-62
CountershaftBearing
Replacement.,,.,.,.,
..,......
13-63
Mainshaft Thrust Clearance
Adiustment
....................
13-6,1
TransmissionAssembly
Reassembly
13-67
.,.,.,.,..,.,....,.,
fnstaffation
13-72
.,.,.............,...
Gearshift Mechanism
O v e r h a u.l. . . . . . . . . . . . . . .
.........13-17

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SpecialTools
SpecialTools
Ref. No.

o
o

Dsscription

1
1
1
'l

@
@

DriverAttachment
MainshaftHolder
MainshaftBase
PreloadInspectionTool
AdjustableBearingRemoverSet
Driver Attachment
Pilot,28 x 30 mm
Attachment,40 x 50 mm
CompanionFlangeHolder
Attachment,32x 35 mm
Attachment,42 x 47 mm
Attachment,52 x 55 mm
Attachment,62 x 68 mm

@
@

07746- 0010600
07746- 0030100

Attachment,72 x 75 mm
Driver,40 mm l.D.

1
1

@
@
@

07746- 0030300
07746- 0030400
07749- 0010000

Attachment.30 mm l.D.
Attachment,35 mm l.D.
Handle

@
@

07947- SD90200
07979- PJ40001

@
-o
\9'

a
@
6r

,d,

I A

a5-z

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1
1

Page Roterence
13-43
13-66
13-66
13-41
13-62.63
13-43,53
13-43
13-39,49
13-48,54,57,58
13-18,68
13-27,34,62
13-40.51
't3-40,50.51,61,
oz, oJ
13-40
13-27,34,35, 49,
tJ-5C

13-66

ta\

o@(9

1
1
1
1
1
1
'I

13-27,34
13-14,27.34,40,
43, 49, 50, 51, 53,
61,62,63,68
'13-49

Attachment
MagnetStandBase
* Must be usedwith commerciallyavailable3/8" - 16SlideHammer.

. A

Oty

07GAD- PG40100
07GAJ- PG20110
07GAJ- PG20130
07HAJ - PK40201
07JAC- PH80000
07JAD- PH80101
07JAD - PH80400
07LAD- PW50601
07RAB- 0020000
07746- 0010100
07746- 0010300
07746- 0010400
07746- 0010500

,6)

ll

Tool Number

G)

(oo@(9(}

Back-upLight Switch

Maintenance
Fluid
Transmission

Test/Replacement

NOTE:Checkthe fluid with the engineOFFand vehicle


on levelground.

1.

1.

the connectorsfrom the switch.


Disconnect

R e m o v et h e f i l l e r p l u g . t h e n c h e c kt h e l e v e l a n d
conditionof the fluid.
PLUG
FILLER
44 N.m{4.5kgf.m.33 lbfftl
\

TerminalsideoI
malelerminals

PtopetLevel

ll

/
\--ril
HllllllTl /
Hllllrlll
/
_rf-F{--rno."."
l l
| |

BACK.UP LIGHTSWTTCH
r 25 N.m 12.5kgt m, 18 lbf.ftl

Replaco.

The fluid level must be up to the filler hole. lf it is


belowthe hole,add fluid until it runs out. then reinstallthe tiller plug with a new washer.

WASHER
Replace.

lf the transmissionfluid is diny, removethe drain


plug and drainthe fluid.
PLUG
FILLEB
a,aN.m 14.5kgf..n.33 lbt'ftl

Checkfor continuity betweenthe No. 1 and No. 2


terminals.
There should be continuitywhen the shift lever
tnto reverse.
. T h e r e s h o u l d b e n o c o n t i n u i t yw h e n t h e s h i f t
leverin positionexceptreverse,

lf necessary,replacethe switch.

DRAINPLUG
39 N m (4.0 kgf.m,29 lbf'ft)

WASHER
Replace.

R e i n s t a ltl h e d r a i n p l u g w i t h a n e w w a s h e r .a n d
refillthe transmissionfluid to the properlevel.
NOTE:The drain plug washershouldbe replacedat
everyfluid change.
Reinstallthe filler plug with a new washer.
Fluid Capacity
1.7/ {1.8US qt, 1.5lmp qtl at oil change
2.1 ! 12.2US qt, 1.Almp qtl at overhaul
Alwavs use GenuineHonda Manual Transmission
Fluid (MTF).Using motor oil can causestiffershiftind becauseit doesnot containthe properadditives.

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13-3

TransferAssembly
lnspection
Make sure tifts, iacks, and satety stands
@
are placed properly (seesection 1).
L

Raisethe front of the vehicle,and support it with


safetystands(seesection1).

2.

Set the parkingbrake,and block both rear wheels


securely.

3.

Shiftto neutraloosition.

4.

Make a referencemark acrossthe DroDellershaft


and the transferassemblyflanges,
REFERENCE

6.

STANDARD:0.06- 0.16 mm (0.002- 0.006in)

COMPAf{IONFI-ANGE

1.

8 x 1.25mm
32N.m(3.3kg{.m.
24 rbf.ftl
Replace.
5.

S e p a r a t et h e p r o p e l l e r s h a f t f r o m t h e t r a n s f e r
assemDty.

13-4

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Set a dial indicatoron the transferassemblyflange,


then measurethe transfergear backlash.

lf the measurementis out of specification,


remove
the transferassemblyand adjusttransfergear backlash(seepage13-44thru '13-61).
C h e c kt h e t r a n s f e ro i l s e a l f o r d a m a g ea n d f l u i d
teaKs.
lf oil sealreplacement
is required,removethe transfer assembly,replacethe oil seal, and adjust the
total startingtorque (seepage 13-44thru 13-61).
NOTE:Do not replacethe oil sealwhen the transfer
assemblyis installedon the transmission.

Removal
Make sure the lifts, i8cks. and safety stands
!@@
properly
placed
are
{seesection 1}.
1.

Raisethe front of the vehicle,and support it with


safety stands (seesection 1).

2.

Set the parkingbrake,and block both rear wheels


securely.

3.

D r a i nt h e m a n u a lt r a n s m i s s i o fnl u i d R e i n s t a ltlh e
drain plug with a new sealingwasher.

4.

Disconnectthe heatedoxygen sensor (HO2S)connector.

6.

Make referencemarks across the propeller shaft


and the transferassemblyflanges'
REFEREI{CEi'ARKS

Replace.

7.

S e p a r a t et h e p r o p e l l e r s h a f t f r o m t h e t r a n s f e r
assemblyflanges,
Removethe rear stiffener, then remove the transfer
assembly.

SELF.L(rcKNG
NUT
Replace.
SELF-LOCKI'{G
NUT
Replac.

5.

NOTE: While servicingthe transfer assembly,do


not allow dust or otherforeignparticlesto enterthe
transmission.

RemoveexhaustoipeA.

Replace.

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13-5

TransferAssembly
lnstallation
1.

Installa new O-ringon the transferassembly.


8 x 1.25mm
24 N.m (2.4 kgt m,
17 rbt.ftl

6.

Installthe exhaustpipeA,

10 x 1.25mm
44 N.m (4.5 kgJ.m,
GASKET

EXHAUSTPIPEA

HO2SCONNECTOR

DOWELPIN

TRANSFEB
ASSEMBLY

Replace.

2.

Cleanthe areaswhere the transferassemblycon


tacts the transmissionwith solvent or carburetor
cleaner,and dry with compressedair. Then apply
MTFto the contactareas.

10 x 1.25 mm
54 N.m (5.5 kgt m,
40 tbtftt
Replace.
SELF.LOCKING

NUT
8 x 1.25mm
16 N.m {1.6kgf.m,
12 tbt.ft)
Replace.

8 x 1.25mm
zzN.m l2.2kg!-m,
16rbf.trt
Replace.

Installthetransferassemblyon the transmission.


N O T E :W h i l e i n s t a l l i n gt h e t r a n s f e ra s s e m b l yo n
the transmission,do not allow dust or other foreign
particlesto enterthe transmission.
lnstallthe rearstiffener.
Installthe propellershaft to the transferassembly
by aligningthe referencemarks,
8 x1.25mm
32 N.m 13.3kg{.m,
24 tbf.ftl

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REFERENCE
MARKS

7.

Connectthe heatedoxygensensor(HO2S)connector.

8.

Relillthe transmissionwith MTF(seepage 13-3).

9.

Startthe engine,and run it to normaloperatingtemp e r a t u r e( t h e r a d i a t o r t a n c o m e s o n ) . T u r n t h e


engineoff. and checkfluid level.

TransmissionAssemblY
Removal

@
FMak.

sw. iack" and safety stands are placed propelly, and hoist bracketsare attached to collect position
on the engine,
. Apply parking brake and block rear wheels so vehicle
will not roll off stands and lall on you while working
under it.

4.

D i s c o n n e c t h e s t a r t e r c a b l e sa n d t r a n s m i s s i o n
groundcable.

CAUTION:Use fender coversto avoid damaging painted


surfaces.
1.

the negative{-) cablefirst,then the posDisconnect


itive(+)cablefrom the batterY.

2.

Removethe intakeair duct and air cleanerhouslng


(seesection5).

3.

Removethe slavecylinderand clutchhosebracket'


NOTE:
. Do not operatethe clutch pedal once lhe slave
cvlinderhas beenremoved.
. Takecarenot to bendthe clutchline.

TRANSMISSION
GROUNDCABLE

Disconnectthe back-uplight switch connectorand


wire harnessclamP.

WIREHARNESSCLAMP

(cont'd)

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13-7

TransmissionAssembly
Removal(cont'dl
6.

R e m o v et h e c o t t e r p i n s , t h e n r e m o v e t h e s t e e l
w a s h e r s ,p l a s t i cw a s h e r s .s h i f t c a b l e ,a n d s e l e c t
cablefrom the levers.

9 . R e m o v et h e f o u r u p p e r t r a n s m i s s i o nm o un t i n g
bolts.

MOUNNNG BOLTS

1 0 . Draintransmissionfluid (seepage '13-3).


1.

Removethe cablebracketfrom the clutchhousing.

8.

Disconnectthe vehiclespeedsensor(VSS)connector.
-------------.2

13-8

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1 1 . Removethe guardbar and the splashshield.

12. Disconnectthe heatedoxygen sensor(HO2S)connector,then removethe exhaustpipe A.

15. Removethe cotter pins,and castlenuts.then separate the ball iointsfrom the lower arm (seesectlon
18).
OAMPERPINCHBOLT

GASKET
Replace.
HO2SCONNECTOR

CASTLENUT
NUT
Replace.

NUT
Replace.

DAMPERFORK

FOFK
EOLT

Replace.

EXHAUST

SELF.LOCKING
Replace.

GASKET
Replace.

Mark referencemarks on the joint of the transfer


and the propellershaft.

1 6 . Removethe right damper tork bolt, then separate


right damperfork and damPer.
1 7 . Pry the right driveshaftout of the differential,and
pry the left driveshaftout of the intermediateshaft
(seesection18).
1 8 . Pull out the inboardioint, and removethe right and
left driveshaft(seesection18).
1 9 . Tie plastic bags over the driveshattends. Coat all
precisionfinishedsurfaceswith cleanengineoil

MABKS
REFERENCE

8 x 1.25mm
Replace.
1 4 . S e p a r a t et h e p r o p e l l e r s h a f t f r o m t h e t r a n s f e r
assemDly.

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{cont'd}

13-9

TransmissionAssembly
Removal(cont'd)
20. Removethe intermediate
shaft.

2 1 . Tie plasticbagsoverthe both endsof the intermediate shaft. Coat all precisionfinished surfaceswith
cleanengineoil.
Removethe rear engine stiffene.and clutch housIng cover.

23. Removethe right front mounvbracket.

RIGHTFRONT
MOUNT/BRACKET
P l a c ea j a c k u n d e r t h e t r a n s m i s s i o nr,a i s e i t j u s t
enough to take it off of the mounts, then remove
the transmissionmount bracketand transmission
mount.
TRANSMISSIONMOUNT

MOUNT BRACKET

13-10

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25. Removethe transmissionmounting bolts and the


rearenginemountingbolts.

REARENGINEMOUNTINGBOLTS
Replace.

28. Removethe releasetork boot. releasebearing,and


releasefork from the clutchhousing
RELEASE
BEANING

TRANSMISSION

Pull the transmissionaway from the engine until it


clearsthe mainshaft,then lower it on the transmission jack.
NOTE:Takecarenot to bendthe clutchline.
Removethe startermotor and hose clampfrom the
transmissionhousing.

STARTER
MOTOR

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1 3 - 11

TransmissionAssembly
lllustrated Index
Referto the drawingbelowfor the transmissiondisassembly/reassembly.
Cleanall the pans thoroughlyin solvent,and drv with comoressedair.
I

LuUri""r"uttthe partswith MTFbeforereassembly.

NOTE:
t This transmissionusesno gasketsbetweenthe major housings;use liquid gasket(p/N
0g718- 0001or oE7l8 - 0003)
(seepage 13-69,71).
. Alwayscleanthe magnet@ wheneverthe transmissjonhousingis disassembled.
. Inspectall the bearingsfor wear and operation.

C) sHrFr FoRKASSEMBLY
. I n d e xp a g e l, 3 - 2 1
(a MAINSHAFTASSEMBLY
. I n d e xp a g e 1
, 3-23
(9 28 mm WASHER
) 28 mm SPRTNG
WASHER
O BALLBEARING
a6)OIL SEALReDlace.
(D 14 x 20 mm DOWELptN
G) couNTERSHAFTASSEMBLY
.lndex page,13-28

13 -1 2

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aol NEEDLESET PLATE

@ NEEDLEBEARING

o OILGUIOEC PLATE

@ MAGNET
@ DIFFERENTIAL
ASSEMBLY
.lndex page,13-38

(DO-nlNGBeplace.
i9 TRANSFERASSEMBLY
'13,44
.Index page,

@ OILSEALReplace.
@ VEHICLESPEEDSENSOR
@ CLUTCHHOUSING
(9 REVERSELOCKCAM
@ REVEESESHIFTHOLDER
@ REVERSEIDLEGEAR
@ REVERSEGEARSHAFT

e3THRUSTWASHER,20x 36 x 2
@ COLLER,15 x 20 x 20

C) TRANSMISSIONHANGER
BOLT
O INTERLOCK
O 32 mm SEALINGBOLT
@ STEELBALL{5/16 in.)
26.1mm {1.03in.l
) SPRING
@ wasHER Replace.
O sET BALLscREw
@ WASHERReplace.
) FLANGEBOLT
@ oll SEALReplace.
@ DRAINPLUG
@ WASHERReplace.
@ FILLERPLUG
@ WASHERReplace.

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(9 10 x 12 mm DOWELPIN
(D SPRING
in.l
25.6mm 11.01
' THRUSTWASHER
@} SHIFTARM C
(3 CONICALSPRINGWASHER
BOLT
@ SPECTAL
8] SHIFTARM COVER
@ OILSEALReplace.
! SHIFTLEVER
CAP
@I BREATHER
(2! SHIFTARM SHAFTASSEMBLY
PINReplace.
@ SPRING
O SELECTARM

!} THRUSTWASHER
SELECT
@ sTH/REVERSE
RETURNSPRING
@ SELECTRETURNSPRING
) OIL GUTTERPLATE
@ 78 mm SHIM
@ OIL GUIOEM PLATE
@ SELECTSPRINGBOLT
@ OILSEALReplace.
@ SELECTLEVER
O BACK.UPLIGHTSWITCH
@ WASHERReplace.
HOUSING
OOTRANSMISSION

13-13

TransmissionAssembly
Disassembly
1.

Removethe transferassemblv.

3.

Removethe interlockbolt.
SELECTARM

O-RING
Replace.

SHIFTARMSHAFT
Turn the selectlevercounterclockwise,
then remove
the shift arm A finger from the groove of the shift
forks.

Removethe shift arm cover assembly,and wiDe it


cleanof the sealant.
5.

T u r n t h e s h i f t a r m s h a f t c o u n t e r c l o c k w i s ea n d
removethe selectarm fingerfrom the grooveof the
shift arm A. then removethe shift arm shaft assemblv.

6.

Removethe vehiclespeedsensor(VSS).

SHIFTARM COVERASSEMBLY

10x 12 mm DOWELptN

13-14

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7.

Removethe set ball screws,washers,springs,steel


balls.and back-uPlight switch.

9. Removethe transmissionhousing mounting bolts


in a crisscrosspauernin severalsteps.

STEELBALL
D. 5/16 in

LIGHTSWITCH

8.

Removethe flangebolt. drainplug, and filler plug

10. Removethe 32 mm sealingbolt

FILLERPLUG
DRAINPLUG
WASHER
Replace.

WASHER
Replace.

FLANGEBOLT

' It . Expandthe snap ring on the countershaftball bearing, and removeit from the groove using a pair of
snap ring plier.
Separatethe transmissionhousingfrom the clutch
housing.
R e m o v et h e d o w e l p i n s ,a n d w i p e i t c l e a no f t h e
sealant.
(cont'd)

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13-15

TransmissionAssembly
Disassembly(cont'dl
1 4 . R e m o v et h e o i l g u t t e rp l a t e ,7 8 m m s h i m , a n d o i l
guide M plate.

1 6 . Removethe spring pin using the pin punch and a


pair of diagonalcutters.

OIL GUTTERPLATE

PIN PUNCH,5.0 mm

Replace.
OIL GUIDEM PLATE

17. Removethe selectlever,springs,washer,and select


arm.
15. Removethe selectspringbolt.

SELCTLEVER

SELECTSPRINGBOLT

OIL SEAL
Replace.

THRUSTWASHER

SELECTARM

18. Removethe oil seal.

13-16

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23. Removethe mainshaftand countershaftassemblies


with the shiftforksfrom the clutchhousing.

19. Removethe reverselockcam.

NOTE;Beforeremovingthe mainshaftand countershaft assemblies,tape the mainshaftsplineto protect it.

COUNTEBSHAFT
ASSEMBLY

20. lf necessary,checkthe clearanceof the reverseshift


holder(seepage13-20).

2 ' t . Removethe reverseshift holder.


Tapethe main'
shaftsplines.

WASHER

SPRINGWASHER

HOUSING

HOLOER

24. Removethe differential asssmbly.

22. '97 - 99 models: Removethe reversegear shaft and


the reverseidler gear.
'00 model: Remove the reverse gear shaft, reverse
idler gear,thrustwasherand the coller.

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13-17

Shift Arm Cover/ShiftArm Shaft Assembly


Disassembly/Reassembly
Shift Arm CoverAssmbly
1.

5.

Installthe oil seal in to the shift arm coverusinothe


sDecialtools.

Removethe breathercap and set ball screw,washer,


spring.and steelball.

HANOLE
07749- 0010000
ATTACHMENT,
32x35mm
077a6- 0010100

BREATHER
CAP
OIL SEAL
Replace.

STEELBALL
D. 5/16 in,

SPRING
L,25.6mm (1.01in.l
T BALLSCREW
22 N.m 12.2kgtm, 16lbf.ftl
Remove the special bolt and conical spring washers.

6.

Reassemble
the shift arm cover in the reve.seorder
of disassembly.

Shift Arm Shaft Assembly


1.

Removethe specialbolts and conicalspring washers.

SHIFTARMA

SHIFT
ARM
COVER

SPCCIALBOLT
8x1.0mm
29 N.m (3.0kgf.m,
22IbI.ftI

CONICALSPRING

SHIFTLEVER

SHIFTARM SHAFT

THRUSTWASHER

SHIFI ARM C
WASHER

8x1.0mft

29 N.m13.0kg{.m,
z2 tbt.ftl
R e m o v et h e s h i f t l e v e r , s h i f t a r m C , a n d t h r u s t
washerfrom the shift arm cover.

SPECIALBOLT
8x1.0mm
29 N.m {3.0kgf.m,22 lbtft}

Removethe oil seal.


NOTE: lnstallthe thrust washerwith the alloy surfacetoward shift arm cover.

13-18

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SPRING
WASHER

2.

Remove the interlock, shift arm A, and shift arm B


from the shift arm shaft.

3.

Installin the reverseorderof removal.

InsPection
Clearance
1.

Measurethe clearancebetweenthe shift arm A and


selectarm.
0.05- 0 25 mm (0.002- 0'01 inl
Standard:
ServiceLimit:0.5mm (0.02in)

3.

Measurethe clearancebetweenthe shift arm B and


shift arm c.
0.05- 0.25 mm (0.002- 0.01 inl
Standard:
SeryiceLimit:0,5mm (0.02inl
SHIFTARM C

SELECTARM

SHIFT ARM A

2.

SHIFTARM B

l f t h e c l e a r a n c ea r e m o r e t h a n t h e s e r v i c el i m i t ,
measurethe diameterof the selectarm pln

l f t h e c l e a r a n c ea r e m o r e t h a n t h e s e r v i c el i m i t ,
measurethe diameterof the shift arm C.

Standard:7.9- 8.0 mm (0.311- 0.315in)

Standard:12.9- 13.0mm (0 508- 0.512in)

SHIFTARM C

SELECT
ARM
lf the diameterof the selectarm pin is lessthan
the service limit, replacethe select arm wrtn a
new one.
lf the diameterof the selectarm pin is within the
servicelimit, replacethe shift arm A with a new
one.

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lf the diameterof the shift arm C is lessthan the


servicelimit, replacethe shift arm C with a new
one.
l f t h e d i a m e t e ro f r h e s h i f t a r m C i s w i t h i n t h e
servicelimit, replacethe shift arm B with a new
on e .

13-19

ReverseShift Holder
ClearanceInspection
1.

Measurethe clearancesbetweenthe reverseshift


holderand sth/reverse
shift DieceDin.
A: 0.05- 0.35mm (0.002- 0.014in)
8: 0.4 - 0.8 mm 10.02- 0.03 inl
ServiceLimit:A: 0.5 mm (0.02in)
B: 1.0mm 10.0,[
in]
Standard:

3.

Measure the clearancebetween the reverseidler


gearand reverseshift holder.
Standard: 0.5- 1.1mm {0.02- 0.0i1in}
ServiceLimit: 1.8mm (0.07in)
REVERSE
IDLER
GEAR

PIECEPIN

2.

l f t h e c l e a r a n c ea
s r e m o r e t h a n t h e s e r v i c el i m i t .
measurethe widths of the groove in the reverse
shift holder.
Standard:A: 7.05- 7.25 mm {0.278- 0.285inl
B: 7.4- 7.7 mm (0.29- 0.30inl

lf the clearanceis more than the servicelimit. measurethe width ot the reverseshift holder.
Standard:13.0- 13.3mm (0.512-0521inl

REVERSE
SHIFTHOLDER

lf the widths of the grooves are not within the


standard,replacethe reverseshift holderwith a
new one.
lf the widths of the groovesare within the standard, replacethe sth/reverseshift piece with a
new one.

13-20

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It the width is not within the standard,replace


the reverseshift holderwith a new one.
lf the width is within the standard,reolacethe
reverseidler gearwith a new one.

Shift ForkAssembly
Disassembly/ReassemblY
I

cleanall the pans in solvent,dry them, and apply lubricantto any contactparts
erior,o reassembling,

3RD/,|THSHIFTFoRK
1ST/2NDSHIFTFORK

5TH/REVERSE
SHIFTPIECE

PIN PUNCH,5.0 mm

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13-21

Shift ForkAssembly
ClearanceInspection
NOTE:The synchrosleeveand synchrohub should be
reolacedas a set.
1.

3.

Measurethe clearancebetweenthe shift fork and


the shift arm A.

Measurethe clearancebetweeneach shift fork and


its matchingsynchrosleeve.

Standard; 0.2- 0.5 mm (0.008-0.020


in)
ServiceLimit: 0.6 mm (0.02i1in)

Standard:
0.35- 0.65 mm 10.01/t- 0.026inl
ServiceLimit: 1,0 mm {0.039inl

sTH/REVERSE
SHIFTPIECE

ran,rru

lST/2ND
SI{IFTFORK

lf the clearanceexceedsthe servicelimit, measure


the width of the shift arm A.

SHIFTFORK

2.

lf the clearanceexceedsthe servicelimit. measure


the thicknessof the shiftfork fingers.

- 0.512inl
Standard:12.9- 13.0mm 10.508

Standard:
3rd/4th shift fork
1sv2ndshiftfork
5th shift fork

7 . 4- 7 . 6m m
(0.29- 0.30in)
6 . 2- 6 . 4m m
(0.24- 0.25in)

lf the thicknessof the shift fork finger is lessthan


the standard,replacethe shift fork with a new
one.
lf the thicknessof the shift fork tinger is within
the standard,replacethe synchrosleevewith a
new one.

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lf the width of the shift arm A is less than the


standard,reDlace
the shift arm A with a new one.
lf the width of the shift arm A is within the standard, replacethe shift fork or shift piecewith a
new ones.

MainshaftAssembly
lndex
Notethe Iollowingduringreassembly:
. The 3rd/4th,and 5th synchrohubs,and the ball bearingare installedwith a press.
. Installtheangularball bearingwith the thin-edgedouter racefacingthe stop ring
prior to reassembling,
clean all the parts in solvent,dry them, and apply lubricantto any contactsurfaces.The
hubs,however,shouldbe installedwith a pressbeforelubricatingthem'
5th
svnchro
3rd/4thand

SYNCHRORING
page l3 37
Inspection,

ANGULAREALLBEARING
Checkfor wear and operation.
Note the direction
of installation.

SYOPRING

SYNCHROHUB
page13-36
lnspection,
SYNCHROSLEEVE
page13 36
Inspection,

TAPERRING
BEARING
CheckIor wear and operataon.
COLLAR

SPRING

RING
page13-37
Inspection,

SYNCHRO

SYNCHROSPRING

Inspection,
page13-37

SYNCHROHUB
page13_36
Inspection,

3RDGEAR
Inspeclton,
page13 24,37

SYNCHROSLEEVE
page13 36
Inspection,
SPFING

BEARING

RING
page13_37
Inspection,

Checkfor wear
ano operalton.

GEAR
page13_25,
37
Inspection,
page13 26
Inspection,
COLLAR
page13-24,25
Inspection,
NEEDLEBEARING
Checkfor wear and operat,on.
GEAR
I n s p e c t i o n ,p a g e 1 3 2 4 , 3 7

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13-23

MainshaftAssembly
ClearanceInspection
NOTE; lf replacementis required,always replacethe
synchrosleeveand hub as a set.
L

Support the bearing inner race with a socket.and


Dushdown on the mainshaft.

2.

Measurethe clearancebetween2nd and 3rd oears.

4.

Measurethe clearancebetween 4th gear and the


spacercoIar,
Standard:
0.06- 0.21 mm {0.002- 0.008in)
ServicLimit: 0.3 mm {0.01inl

Siandard:
0.06- 0.21 mm 10.002- 0.008in)
ServicaLimit: 0.3 mm (0.01in)

lf the clearanceis more than the servicelimit, measure distance@ on the spacercollar,
Standard:
26.03- 26.08mm {1.025- 1.027inl
ServiceLimit: 26.01mm {1.02,[in]

o[-l:-g;;em

lf the clearanceis more than the servicelimit, measurethe thicknessof 3rd gear.
Standard: 34.92- 34.97mm {1.375- 1.377in)
ServiceLimit 34.8 mm (1.37in)
3RD GEAR

fp-rro.ERcoLLAR
6.

tf distance@ is lessthan the servicelimit, replace


the sDacercollarwith a new one.
lf distance@ is within the service limit. measure
the thicknessof 4th gear.
- L239 inl
Standard: 31.42- 31.'17mm 11.237
SarviccLimit:31.3mm {1.23in)

lf the thicknessof 3rd gear is lessthan the service limit, replace3rd gearwith a new one.
lf the thicknessof 3rd gear is within the service
limit, replacethe 3rd/4thsynchrohub with a new
one.

13-24

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lf the thickness of 4th gear is less than the service limit, replace 4th gear with a new one.
lf the thickness of 4th gear is within the service
limit, replace the 3rd/4th synchro hub with a new
one,

Disassembly
7.

Measurethe clearancebetweenthe spacer collar


and 5th gear.
0.06- 0.21 mm {0.002- 0.008in)
Standard:
ServiceLimit: 0.3 mm {0.01in)

1.

S u p p o r t5 t h g e a r o n s t e e l b l o c k s ,a n d p r e s st h e
mainshaftout of the 5th synchrohub, as shown.Do
not use a jaw-type puller, becauseit can damage
the gearteeth.
PRESS

MAINSHAFT

I
ACHMENT

SPACERCOLLAR

SOCKET

8.

5TH GEAR

lf the clearanceis more than the servicelimit, measuredistance@ on the spacercollar


26.03- 26.08mm 11.025- 1.027in)
Standard:
SrvicoLimit: 26.01mm (1.024in)
SPACER
COLLAR

In the same manneras above,supportthe 3rd gear


on steel blocks.and pressthe mainshaftout of the
3rd/4thsvnchrohub, as shown.
PRESS

5TH GEAR
SIDE

9.

lf distance@ is lessthan the servicelimit, replace


the spacercollarwith a new one.
lf distance@ is within the service limit, measure
the thicknessof sth gear.
Standard: 30.92- 30.97mm (1.217- 1.219in)
ServiceLimit:30.8mm (1.21in)

gt

r--\

,,srH GEAR

Fq

I- l.J'-----!--\--J

lf the thicknessof 5th gear is less than the service limit, replace5th gearwith a new one.
li the thicknessof sth gear is within the service
l i m i t , r e p l a c et h e s t h s y n c h r oh u b w i t h a n e w
one.

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BLOCKS

MainshaftAssembly
Inspection
1.

I n s p e c t h e g e a r s u r f a c ea n d b e a r i n gs u r f a c ef o r
wear and damage,then measurethe mainshaftat
pointsA, B, and C.
Standard:
A (Ballbearingsurface): 27.987- 28.000mm
1 1 . 1 0 1- 81 . 1 0 2 4i n l
B (Needlebearing surfacel:37.984- 38.000mm
- 1.4961inl
(1.4954
C {Baflbearingsurfacel: 27.977-27.990 mm
( 1 . 1 0 1-5 1 . 1 0 2 0
inl
ServiceLimit:A:27.94mm (1.100in)
B: 37.93mm (1.'193
inl
C: 27.94mm 11.100
inl

2.

Inspectfor runout.
Standard: 0.02mm (0.0008in) max.
ServiceLimit: 0.05 mm 10.002inl
N O T E : S u p p o r tt h e m a i n s h a f a
t t both ends
shown.

lf the runout is more than the servicelimit, reDlace


the mainshaftwith a new one.
I n s p e c t o i l p a s s a g e sI o r c l o g g i n g .

lf anv oart of the mainshaftis lessthan the service


limit. reolaceit with a new one.

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Reassembly
sequence.
NOTE:Referto page13-23for reassembly
1.

3.

I n s t a l lt h e a n g u l a rb a l l b e a r i n gu s i n g t h e s p e c i a l
tools and a oress.Notethe directionof installation.

Suppon 2nd gear on steel blocks as shown, then


i n s t a l lt h e 3 r d / 4 t hs y n c h r oh u b u s i n g t h e s p e c i a l
tools and a pressas shown.

PRESS

NOTE:After installing,inspectthe operationof the


3rd/ 4th synchrohub set.
PRESS

3RD/4TH
SYNCHROHUB

HANDLE
07749- 0010000

I
DRIVER,,l(} mm l.O.
07746 - 0030'100
ATTACHMENT,
/Vl x a7 mm

077a6- 0011x100

BALLBEARING
Notethe diredion
o{ installation.

2NO GEAR

2.

Installthe sth synchro hub using the specialtools


and a press.
PRESS

I
DRlvER,40mm l.D.
077{6 - 00301(x)

ATTACHMENT,
35 mm l.D.
077i16- lx)3ollx)

sTH SYNCHBOHUB

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13-27

CountershaftAssembly
Index
NOTE:The 3rd, 4th.and sth gearare installedwith a press.

Priorto reassembling,
cleanall the partsin solvent,dry them, and apply lubricantto any contactsurfaces.The 3rd,
4th,and sth gears,however.shouldbe installedwith a pressbeforelubricatingthem.

LOCKNUTReplace.
127-o-127N.m
113-0- 13kstmi
9.trbtft/
\94-0WASHER

IST/2ND SYNCHROHUB
page13 36
Inspection,
DAMPER
Checklor wear and
damage.

AEARING
Checkfor wear and ooeration.
BEARING
Checkfor wear and
operation.
GEAR

SPNING
4TH GEAR
DOUBI.f CONE
page13-37
Inspection,
3RD GEAR
1STGEAR
page13 29,37
Inspection,

BEARING
Checktor wear and operation.
THRUSTWASHER
page13-29
Inspection,

GEAR
page13-30,37
Inspection,
NEEDLEBEARING
Checkfor wear and oPeration
SPACER
page13-30
Selection,
DAMPER
C h e c kf o r w e a r a n d d a m a g e .

DOUBLECONE
page13-37
Inspection,

SPRING

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ClearanceInspection
NOTE: lf replacementus required,always replacethe
synchrosleeveand hub as a set.
1.

M e a s u r et h e c l e a r a n c eb e t w e e nt h e l s t o e a r a n d
thrustwasher.

3.

lf the thicknessis lessthan the standard,reDlacethe


thrust washer with a new one. lf the thicknessis
w i t h i n t h e s e r v i c el i m i t , m e a s u r et h e t h i c k n e s so f
t h e 1 s tg e a r .
Standard:26.95- 27.00mm (1.061- 1.063inl

Standard: 0.06- 0.18mm (0.@2- 0.007in)


ServicaLimit:0.23 mm {0.009in)

THRUST WASHER

2.

lf the thicknessof 1st gear is lessthan the standard,replace1stgearwith a new one.


lf the thicknessof lst gear is within the standard.
replace1sv2ndsynchrohub with a new one.

lf the clearanceis more than the servicelimit, measurethe thicknessof the thrustwasher.
Standsrd:1.95- 1.97mm (0.077- 0.078in)

{cont'd}

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13-29

CountershaftAssembly
Clearance
Inspection(cont'dl
4.

Measurethe clearancebetweenthe 2nd qear and


3rd gear.
Standard: 0.07- 0.1,1mm (0.003- 0.006inl
ServiceLimit:0.18mm (0.007inl

6.

lf the thicknessis lessthan the standard,reDlacethe


spacerwrln a new one.
lf the thicknessis within the standard,measurethe
thicknessof the 2nd gear.
Standald:28.92- 28.97mm (1.139- 1.141in)

FEET.ER
GAUGE

. -]

lf the thicknessof 2nd gear is lessthan the standard,replace2nd gearwith a new one.
lf the thicknessof lst gear is within the standard,
replace1sv2ndsynchrohub with a new one.

lf the clearanceis more than the servicelimit. measurethe thicknessof the spacer.
Standard:29.07- 29.09mm (l.14il- 1.145inl

13-30

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Disassembly
1.

S e c u r e l yc l a m p t h e c o u n t e r s h a f ta s s e m b l yi n a
benchvisewith wood blocks.

4.

Removethe Jrictiondamperfrom the spacerusinga


pressand a socket.
PRESS

CHISEL

SPRIiIGWASHEF
BETICH

vtsE

W(X)DBLOCKS

2.

FRICTIONDAMPER
Inspectlor wear and damage.

Raisethe locknuttab from the groove in the countershaft,then remove the locknut and the spring
washer.
Removethe ball bearingusinga pressas shown.

5.

S u p p o r t l s t g e a r o n s t e e l b l o c k s ,a n d p r e s st h e
out of 3rd gear.
countershaft
PRESS

3RD GEAR

1STGEAR

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13-31

CountershaftAssembly
Inspection
1.

I n s p e c t h e g e a r s u r f a c ea n d b e a r i n gs u r f a c eI o r
wear and damage,then measurethe countershaft
at pointsA, B, and C.
A: 36.000- 36.015mm
- f.ill79 inl
11.,1173
B: 36.98/t- 37.000mm
{r.4561- 1.4567inl
C: 24.987- 25.000mm
- 0.9843inl
{0.98:17
Limit:
Servics
A:35,95mm (1.'115
in)
B: 36.93mm (1.454in)
C: 24.94mm (0.982in)

2.

Inspectfor runout.
Standard:
0.02 mm 10.0008inl max.
ServiceLimit: 0.05 mm {0.002inl

Standa.d:

N O T E :S u p p o r tt h e c o u n t e r s h a fat t b o t h e n d s a s
shown.

Rotatetwo completerevolutions.

lf the runout exceedsthe servicelimit, reDlacethe


with a new one.
countershaft
lnspectfor wear and damage.

lf anv part of the countershaftis lessthan the service limit.reolaceit with a new one.

13-32

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Reassembly
Notetheseitemsduring reassembly:
. Pressthe 3rd, 4th, and sth gear on the countershaft
without lubrication.
. When installingthe 3rd, 4th. and sth gears,suppon
the shaft on steelblocksand installthe gearsusinga
press.
. Referto page 13-28for reassemblysequence.
1.

2.

Installthe doublecone synchro.

OUTER

Installthe thrustshim, needlebearing,1stgear,and


frictiondamper.
NOTE: Reassemblythe friction damper on the lst
gearbeforeinstallation.

----.-4O)
orn,leen
rnrcrroru
lST GEAR

NEEDLEBEARING

3.

Installthe 1sv2ndsynchrohub by align the friction


damperfingerswith 1svzndsynchrohub grooves.

THRUSTSHIM

lST/2ND

(cont'd)

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13-33

CountershaftAssembly
(cont'dl
Reassembly
4.

Reassembly
the frictiondamperon the spacerusing
the sDecialtoolsand a Dress.

6.

Supportthe countershafton a steel blockas shown


and install 3rd gear using the specialtools and a
press.
PRESS

PRESS

ATTACHMENT,
U2t 47 mfi
07716- 0010300

3ROGEAR
FRICTIONDAMPER
Inspectfor wear and
damage.

7.

lnstall4th gear usingthe specialtools and a press.

Install the 2nd gear by align the synchrocone the


fingers with 2nd gear grooves.

PRESS

ATTACHMENT,
35 mm LD.
07746- 0030,100
GROOVE

13-34

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Installsth gear usingthe specialtools and a press.

8.

PRESS

DRIVER,40 mm l.D.
07715- 0030300

DRIVER.40 mm LD.
07746- 0030100
ATTACHMENT,
30 mm LD.
077a6- 0030300

ATTACHMENT,
30 mm LD.
077,16- 0030300

10. Installthe ball bearingusingthe specialtools and a


press.
PRESS

I n s t a l lt h e n e e d l eb e a r i n gu s i n g t h e s p e c i a tl o o l s
and a press,then installthebearingouter race
PRESS

1 1 .S e c u r e l yc l a m p t h e c o u n t e r s h a f ta s s e m b l yi n
benchvisewith wood blocks.
LOCKNUT
Replace.

I
DRIVER.40 mm l.D.
077{6 - 0030100

ATTACHMENT,
30 mm l.D.
07746- 0030300

NEEDLE
BEASING

wooD slocKs
12. Installthe springwasher.
Installthe new locknutto the correcttorque, then
stakethe locknuttab into the groove.
Torque:127+ 0 + 127N.m 113- 0 +13 kgf.m,
94+0-94|bf.ft)

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13-35

SynchroSleeve,SynchroHub
Inspection
1.

Installation

Inspectgear teeth on all synchrohubs and synchro


s l e e v e sf o r r o u n d e d o f f c o r n e r s ,w h i c h i n d i c a t e

I n s t a l le a c h s y n c h r oh u b i n i t s m a t i n gs y n c h r o
sleeve,and checkfor freedomof movement.

When assemblingthe synchrosleeveand synchrohub,


b e s u r e t o m a t c h t h e t h r e e s e t s o f l o n g e rt e e t h ( ' 1 2 0
degreesapart)on the synchrosleevewith the three sets
of deepergroovesin the synchrohub. Do not installthe
synchrosleevewith its longerteeth in the lsv2nd synchro hub slotsbecauseit will damagethe springring.

N O T E :l f r e p l a c e m e ni ts r e q u i r e d a, l w a y sr e p l a c e
the synchrosleeveand synchrohub as a set.

SYNCHRO
SLEEVE

SYNCHRO

SYNCHBO
HUB
SYNCHBO
SI.EEVE

13-36

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LONGER?EETH

SynchroRing,Gear
Inspection
1.

SYNCHROSPRING

Inspectthe synchroring and gear.


Ar lnspectthe insideof the synchroring for wear.
B: lnspectthe synchro sleeveteeth and matching
teeth on the synchroring for wear (roundedof0.

SYNCHRO

CC

GOOOWORN
teeth
and matching
sleeve
Cr Inspectthe synchro
teethon the geartor wear (roundedoff).

,,\n

(-l
u
WORN
GOOO
D: Inspectthe gear hub thrustsurfacefor wear.
E: Inspectthe conesurfacelor wear and roughness.
F: Inspectthe teeth on all gearsfor unevenwear,
scoring,galling,and cracks.
2.

Coatthe cone surfaceof the gearwith oil, and place


the synchro ring on the matchinggear. Rotatethe
synchroring, makingsurethat it does not slip.
Measurethe clearancebetween the synchro ring
a n dg e a ra l l t h ew a y a r o u n d .
NOTE:Holdthe synchroring againstthe gearevenly while measuringthe clearance.
Synchro Ring-to-GearClearance
0.85- 1.10mm (0.033- 0.0,lil in)
Standard:
ServiceLimit: 0.,1mm 10.02inl
Double Cone Synchro-lo-GoarClearance
Standard:
@: {Outer Synchro Ring to Synchto Conel
0.5- 1.0mm (0.02- 0.04in)
): {synchro cone to Geal)
0.5- 1.0mm (0.02- 0.0i1inl
@: louter Synchro Ring to Gearl
0.95- 1.68mm (0.037- 0.056inl
ServiceLimit:
@: 0.3 mm (0.01inl
@: 0.3 mm {0.01in}
@: 0.6 mm {0.02in)

OUTERSYNCHRORING

lf the clearanceis lessthan the servicelimit, replace


the synchroring and synchrocone.

www.emanualpro.com

13-37

Differential
lndex

BacklashInspection

NOTE: lf the * mark parts were replaced,the tapered


roller bearing preloadmust be adjusted(see page 1341).

1.

*THRUSTSHIM
Adiustment,Page13'41

P l a c e t h e d i f f e r e n t i a l a s s e m b l yo n V - b l o c k sa n d
install both axles.

PINIONGEARS

+BEARINGOUTERRACE
page13 40
Beplacement,
Inspectfor wear and damage.
*TAPEREDROLLER
BEARING
pagel3-39
Replacement,
Inspectfor wear and damage.

1 0x 1 . 0m m
103N.m {10.5kgf m, 75.9lbf.ft}
Left-handthreads

CARRIER
page13 38
Backlash
inspection,
lnspectfor cracks.

V-BLOCK

FINALDRIVENGEAR
page13-39
Replacement,
Inspectfor wear and damage

TRANSFERDRIVENGEAR
page13-39
Replacement,
Inspect{or wear and damage.

,,4\

W-

*TAPEREDROLLERBEARING
page13'39
Beplacement,
Inspectfor wear and damage.
IEEARINGOUTERRACE
page13-40
Replacement,
Inspectfor wear and damage.
.75 mm SHIM

13-38

www.emanualpro.com

2.

Measurethe backlashot both piniongears.


Standard(Newl:0.05- 0.15mm (0.002- 0.006inl
lf the backlashis not within the standard,reolace
the differentialcarrier.

FinalDrivenGearRePlacement
L

Removethe bolts in a crisscrosspatternin several


steps,and removethe final drivengearfrom the differentialcarrier.
NOTE: The final driven gear bolts have left-hand
threads.

TaperedRollerBearing
Replacement
Notetheseitems:
. T h e t a p e r e dr o l l e r b e a r i n ga n d b e a r i n go u t e r r a c e
shouldbe replacedas a set.
. Inspectand adiustthe taperedroller bearingpreload
wheneverthe taperedrollerbearingis replaced'
. Checkthe taperedrollerbearingsfor wear and rough
rotation.lf the taperedrollerbearingsare OK, removal is not necessary.
1.

1 0x 1 . 0m m
103N.m (10.5kgf m,75.9lbf'ftl
Left'handthreads

Removethe taperedroller bearingsusing a bearing


pullerand a bearingseparatoras shown.

BEARING
BEARING
SEPAFATOB
{Commercially

FINALDRIVENGEAR
lnsoect{or weal and damage

TRANSFERORIVENGEAR
Inspectfor wear and damage.

Installnew taperedroller bearingsusingthe special


tool as shown.
N O T E :D r i v et h e t a p e r e dr o l l e r b e a r i n g so n u n t i l
they bottomagainstthe differentialcarrter.
PRESS

Installthe final driven gear by tighteningthe bolts


in a crisscrosspatternin severalsteps.

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IJ

ATTACHMENT,
,10x 50 mm
07LAD - PWs060l

13-39

Differential
BearingOuter RaceReplacement
Notetheseitems:
. The bearing outer race and tapered roller bearing
shouldbe replacedas a set.
. lnspectand adjustthe taperedroller bearingpreload
wheneverthe taperedrollerbearingis replaced.
'1.

2.

3.

Notetheseitemsduringbearingreplacement:
. Installthe bearingouter racesquarely.
. Check that there is no clearancebetween the
bearingouter race,thrust shim or 75 mm shim
and housing.

Removethe oil sealsfrom the transmissionhousing


and clutchhousing(seepagej3-43).
Drivethe bearingouter raceand thrust shim out of
the transmissionhousing, or remove the bearing
outer raceand 75 mm shim from the clutchhousing
b y h e a t i n gt h e c l u t c h h o u s i n gt o a b o u t 2 1 2 " F
(100"C)with a heat gun. Do not reuse the thrust
shim if the outer racewas drivenout.

Installthe thrust shim or 75 mm shim and the beari n g o u t e r r a c e i n t h e t r a n s m i s s i o nh o u s i n g a n d


clutchhousingusingthe specialtools.

TRANSMISSION
HOUSING:

HANDI-E
07749 - 00 xxto

TRANSMISSION
HOUSING:

ATTACHMENT,
62x68mm
077ir6- 0010500
ATTACHMENT
52x55mm
07746- 0010400

THRUSTSHIM

BEARING
OUTERRACE

BEARING
OUIER RACE

THRUSTSHIM

CLUTCH
HOUSING:

HANDLE
07749 - 001tXX)o

CLUTCH
HOUSING:

ATTACHMENT.
72xt5mm
07745 - 00106{x)

OUTERRACE
75 mm SHIM

4,

13-40

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lnstalltheoil seal(seepage13-43).

TaperedRollerBearingPreloadAdiustment
After installingthe thrust shim, installthe bearing
outer race in the transmissionhousing (see page
13-40).

the tapered
lf any oJthe itemslistedbelowwere replaced,
be
adjusted.
preload
must
rollerbearing
.
.
.
o
.
.

Transmissionhousing
Clutchhousing
carrier
Differential
Taperedrollerbearingand bearingouter race
Thrustshim
75mm sham

1.

Do not use more than one thrust shim to adjustthe


t a p e r e db e a r i n gp r e l o a d .F i r s tt r y t h e s a m e s i z e
thrust shim that was removed.There are no shims
usedon the clutchhousingside

W i t h t h e m a i n s h a f ta n d c o u n t e r s h a f tr e m o v e d ,
i n s t a l lt h e d i f f e r e n t i a al s s e m b l y ,a n d t o r q u e t h e
clutchhousingand transmissionhousing.
NOTE:lt is not necessaryto use sealingagent betweenthe housings.

R e m o v et h e b e a r i n go u t e r r a c e a n d t h r u s t s h i m
from the transmissionhousing(seepage 13-40)'
NOTE:
. Do not reusethe thrust shim if the bearingouter
racewas drivenout.
. Let the transmissioncool to room temperatureil
the bearingouter race was removedby heating
the clutchhousing.

2.

4.

TOBOUE;8 x 1.25mm: 27 N'm


(2.8kgf'm, 20 lbt'ftl
5.

Rotatethe differentialassemblyin both directions


to seatthe taperedrollerbearings.
Measurethe taperedroller bearingpreloadat normal room temperature.Measurethe startingtorque
of the differentialassemblyin both directionswith
the specialtool and a torquewrench.
STANDAFD:1.4- 2.5 N'm
{1/r- 26 kgf'cm, 12 - 23 lbf in)

THRUSTSHIM

/A

07HAJ- PK4020'1

(cont'd)

www.emanualpro.com

13-41

Differential
TaperedRollerBearingPreloadAdjustment(cont'd)
7.

lf the tapered roller bearing preload is not within


the standard,selectthe thrust shim which will give
the correcttaperedroller bearingpreloadfrom the
followingtable.
N O T E :C h a n g i n gt h e t h r u s t s h i m t o t h e n e x l s i z e
w i l l i n c r e a s eo r d e c r e a s et a p e r e d r o l l e r b e a r i n g
p r e l o a da b o u t 0 . 3 - 0 . 4 N . m ( 3 - 4 k g f . c m ,2 . 6 3.5 lbf.in).

9.

How to selectthe correctthrustshim:


- 1 ) C o m p a r et h e t a p e r e dr o l l e r b e a r i n gp r e l o a d
you get with the thrustshim that was removed,
w i t h t h e s p e c i f i e dp r e l o a do f 1 . 4 - 2 . 5 N . m
(14-- 26 kgfcm, 12-23lbtinl.
-2) lf your measuredtaperedrollerbearingpreload
is less than specified.subtractyours from the
specified,
l f y o u r s i s m o r e t h a n s p e c i f i e ds, u b t r a c tt h e
specifiedfrom your measurement.

THRUSTSHIM
Part Numbe.
41381- PX5 000

Thickness
1 . 9 0m m ( 0 . 0 7 4 i8n )

41382- PX5 000

41383-PX5-000

1 . 9 3m m { 0 . 0 7 6 i0n )
'1.96mm (0.0772
in)

41384-PX5-000

1 . 9 9m m ( 0 . 0 7 8 i3n )

41385-PX5-000

2 . 0 2m m ( 0 . 0 7 9 i5n )

41386-PXs-000

2.05mm (0.0807in)

41387-PXs-000

2 . 0 8m m ( 0 . 0 8 1 i9n )

41388-PX5-000

2 . 1 1m m ( 0 . 0 8 3 i1n )

41389-PX5-000

2 . 1 4m m ( 0 . 0 8 4 i3n )

41390-PXs-000

2.'17mm (0,0854in)

41391- PX5- 000

2.20mm (0.0866in)

4'1392-PX5-000

2.23mm (0.0878in)

41393-PX5-000

2.26mm (0.0890in)

41394-PX5-000

2.29mm (0.0902in)

4 1 3 9 5P
, X s- 0 0 0

2.32mm (0.09'13
in)

41396-PX5-000

2.35mm (0.0925in)

41397-PX5-000

2.38mm (0.0937in)

4' t398-PXs-000

2.41mm (0.0949in)

41399-PXs-000

2.44mm (0.0961in)

41400-PXs-000

2.47mm (0.0972in)

41873-P16-000

1 . 6 6m m ( 0 . 0 6 5 i4n )

AC

41874-Pl6-000
41875 P16- 000

1 . 6 9m m ( 0 , 0 6 6 i5n )
'1.72mm (0.0677
in)

AD

41876-P16-000

1 . 7 5m m ( 0 . 0 6 8 i9n )

AE

41877-P16-000

1 . 7 8m m ( 0 . 0 7 0 1i n )

AF

41878-P16-000
41879-P16-000

3)
1 . 8 1m m ( 0 . 0 7 ' 1i n
'1.84
mm (0.0724in)

41880-P16-000

1.87mm {0.0736in)

AB

AH
8.

Recheckthe taperedrollerbearingpreload.

13-42

www.emanualpro.com

For examplewith a 2.17 mm (0.0854in) thrust


shiml
2.5 N.m (26 kgf.cm,23lbiin)
@ specified
- you measure0.6 N.m (6 kgf.cm,5lbf.in)
1.9N.m(20kgicm, 18 tbt.in)tess
@ you measure3.3 N.m (34 kgf.cm,30lbf.in)
- specified
2.5 N.m (26 kgncm,23lbf.in)
0.8 N.m (8 kgf.cm,7lbt.in)more
E a c hs h i m s i z e u p o r d o w n f r o m s t a n d a r d
m a k e sa b o u t 0 . 3 - 0 . 4 N . . ( 3 - 4 k g f ' c m ,
2.6- 3.5 lbf.in)differencein taperedrollerbearingpreload.
I n e x a m p l e@ , y o u r m e a s u r e dt a p e r e dr o l l e r
b e a r i n gp r e l o a dw a s 1 . 9 N . m ( 2 0 k g f . c m ,
1 8 l b f . i n ) l e s s t h a n s t a n d a r ds o y o u n e e d a
thrust shim five sizesthickerthan standard{try
t h e 2 . 3 2 m m ( 0 . 0 9 1 3i n ) t h r u s r s h i m . a n d
recheck).
ln example@, your measurementwas 0,8 N.m
{8 kgf.cm,7 lbf.in)more than standard,so you
need a thrust shim two sizesthinner (try the
2.1'l mm {0.0831in) thrustshim,and recheck).

Oil Seal Replacement


Clutch Housing:

TransmissionHousing:
1.

Removethe oil sealfrom the transmissionhousing

1.

Removethe oil sealfrom the clutchhousing.

OIL SEAL

Replace.

lnstallthe new oil seal into the clutchhousingusing


the specialtools.
2.

lnstallthe new oil seal into the transmissionhousing usingthe specialtools.

NOTE:Installoil seal up to t0.5 mm (t0.02 in) from


transmissionhousingend surface

jn)
NOTE:Installoil sealup to i0.5 mm (10.02 from
transmissionhousingend surface.

CLUTCH
HOUSING

TRANSMISSION
HOUSING

PRESS

PRESS

HANOLE
- @1OCIO0
.--.'/'01119
DRIVERATTACHMENT

- PG4()r00

OIL SEAL
Replace.
PILOT,28x 30 mm
07JAO- PH80400

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HANDLE
07749 - tx)l(xxto
DRIVERATTACHMENT
OTJAD- PHM1Ol

PILOT,28 x 30 mm
07JAD - PH8oaU)

13-43

TransferAssembly
lllustrated Index

ea/
g B

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,AC

O TRANSFERHOUSING
@ O-RINGReplace.
O DAMPERHUB
G) NEEDLEBEARING
G) TRANSFERDRIVENGEAR
G) TRANSFERSHAFT
O TAPEREDROLLERBEARINGOUTERRACE
@ TAPEREDROLLERBEARING
) TRANSFERSHAFTCOLLAR
@ THRUSTSHIM,25 mm selectivepart
6D TRANSFERDRIVEGEAR(HYPOIDGEAR)
@ CONICALSPRINGWASHERRePlace
SHAFTLOCKNUT.22x 1.25mm Left-handthreads,replace'
GDTRANSFER
BEARING
ROLLER
TAPERED
E)
BEARINGOUTERRACE
ROLLER
TAPERED
@
@ THRUSTsHlM. 68 mm selectivepart
O o.RlNG Replace.
@ TRANSFERCOVERA
GDTRANSFERCOVERB
@ O-RINGReplace.
) TRANSFERDRIVENGEARSHAFT(HYPOIDGEAR}
@ THRUSTSHIM,35 mm SelectivePart
@ TAPEREDROLLERBEARING
@ TRANSFEBSPACEBRepIace.
@ TAPEREDROLLERBEARINGOUTERRACE
@ TAPEREDROLLERBEARINGOUTERRACE
@)TAPEREDROLLERBEARING
@ olL SEALReplace.
@ COMPANIONFLANGE
@ O-RINGReplace.
@ BACK-UPRING
@ coNtcAL SPRINGWASHEBReplace.
(o TRANSFERDRIVENGEARSHAFTLOCKNUT,22x 1.25mm Replace.

TOROUESPECIFICATIONS
Boh/Nut No.

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Torque Value

Size

6A
8C
22L

12 N.m (1.2kgf.m.8.7lbf.ft)
24 N.m {2.4kgf.m,17 lbf'ft)
118N.m (12.0kgf.m,86.8lbf'ftl

6x1.0mm
8 x 1 . 2 5m m
2 2 x 1, 2 5m m

22H

1 3 2- 2 1 6N . m( 1 3 . 5- 2 2 . 0k g f ' m ,
97.6- 159lbf.ft)

2 2 x 1. 2 5m m

Remarks

Transfershaftlocknut:
Lett-handthreads
Transferdriven gear shaft locknut
Tighteningtorque:dePendingon
TotalStartingTorquevaiue

13-45

TransferAssembly
Inspection
N O T E : T o p r e v e n t d a m a g e t o t h e t r a n s f e rh o u s i n g ,
always use soft jaws or equivalentmaterialsbetween
the transferhousingand the vise.

TransferGear lHypoid gearl Tooth Contaqt Inspction


5.

Transter Gaar (Hypoid goar) BacklsshMasurement


1.

Removetransfercover B, then apply PrussianBlue


to both sides of the translergear teeth lightly and
evenlv.

S e t a d i a l i n d i c a t o ro n t h e c o m p a n i o nf l a n g e a s
shown.

DIALINDICATOR

TRANSFERDRIVEGEAR
COMPANIONFLANGE

2.

Rotatethe companionflangein both directionsuntil


the transfergear rotatesone full tuln in both directions.

Measurethe transfergear backlash.


STANDARD:0.06- 0.16 mm {0.002- 0.006in}

7.

Checkthe transfer gear tooth contact pattern.

Total Sta.ting Torquo Msasuremont


3.

Rotatethe companionflange severaltimes to seat


the taperedrollerbearing.

4.

M e a s u r et h e s t a r t i n gt o r q u e ( c o m p a n i o nf l a n g e
side)usinga torquewrench.
STANDARD:
2.68- 3.47 N.m
{27.3- 35.4 kgf.cm.23.7- 30.7 tbt.in)
lf the measurementsor the tooth contact Dattern
are not within the standard.disassemblethe transfer assembly,replaceworn or damagedparts,and
reassembleit.

1 3 -4 6

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Disassembly
1.

3.

Removethe transfercoversA and B.

Hold the transfershaft with a 14 mm Allen wrench


clampedin a benchvise.

TRANSFER

TRANSFEF

Replace.

14 mm ALLENWRENCH

Loosenthe transter shaft locknut.The transfer shaft


locknuthaslett-handthreads.
Removethe transfershaft assembly,transferdrive
gear,25 mm thrust shim. transfershaft collar.and
taperedrollerbearingfrom the transferhousing.
TRANSFERSHAFT
ASSEMBLY

Cutthe locktabsofthe locknutusinga chisel.Keepa t l


of the chiseledparticlesout of the transferhousing

TAPEREDROLLER
BEARING
TRANSFERSHAFT
COLLAR

THRUSTSHIM,
25 mm
pan
Selective

TRANSFERDRIVE
GEAR

LOCKNUT

LOCKTAB

(cont'd)

www.emanualpro.com

13-47

TransferAssembly
Disassembly(cont'd)
Secure the transfer housing in a bench vise with
soft jaws.

9. Removethe transferdrivengear shaft,then remove


the transfer spacer from the transfer driven gear
shaft.

COMPANION
FLANGE
HOLDER
07RAA-

7.

TRANSFER
ORIVEN
GEARSHAFT

I n s t a l lt h e s p e c i a lt o o l o n t h e c o m p a n i o nf l a n g e ,
then loosenthe transferdrivengearshaft locknut.
Removethe transferdrivengear shaft locknut,conical spring washer, back-upring, O-ring,and compsnionflange.

Removethe oil seal and the taperedroller bearing


from the transferhousing,

OIL SEAL
Replace.

TAPEREOROLIIR
AEARING

TRANSFERHOUSING

TRANSFERDRIVEN
GEARSHAFTLOCKNUT
Reolace,

13-4 8

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Replacement

TransferDrivenGearShaft
BearingReplacement

NOTE:Coatall partswith MTFduring reassembly.

NOTE:Coatall partswith MTFduring reassembly.

TransferDriveGearBearing

1.

Removethe taperedrollerbearingfrom the transfer


drive gear usingthe specialtools and a press.

1.

Removethe taDeredrollerbearingfrom the transfer


drivengear shaftusinga pressand a collar.

ATTACHMENT,
37x/Omm
07746- 0010200

SEPARATOR,
BEARING
o - 1112"

GEAR

SEPARATOR,
BEARING
0 - 1112'
available)
lCommercially

{ C o m m e r c i a l l ya v a i l a b l e )

Installthe new taperedrollerbearingin the transfer


drive gear usingthe specialtools and a press

lnstallthe 35 mm thrust shim on the transterdriven


gear shaft.
Installthe new taperedrollerbearingon the transfer
drivengearshaftusingthe specialtoolsand a press.
NOTE:Use old transferspacerfor bearinginstallation, then discardit.
DRIVER40 mm l.D.
07746- 0030r00

ATTACHMENT,
40x50mm
07LAD - PW5lr601

www.emanualpro.com

13-49

TransferAssembly
TransferShaft Disassembly/
Reassembly
1.

Support the transfer driven gear on steel blocks,


then pressthe transfershaftout of damperhub,

TransferGoverA BearingOuter
RaceReplacement

NOTE:Coatall partswith MTFduring reassembly.


1.

Bemovethe taperedroller bearingouter racefrom


t r a n s f e rc o v e r A b y h e a t i n gt h e c o v e r t o a l m o s t
2 1 2 " F( 1 0 0 o Cu) s i n g a h e a t g u n . D o n o t h e a t t h e
coverover 212"F(100'C),

BEARINGOUTERRACE

2.

Installthe 68 mm thrustshim in transfercoverA.

Align the damper hub groovesand transferdriven


gear teeth,and reassemble
the damperhub. needle
bearing,and transferdrivengear.
Installthe transfershaftusinga press.

BEARINGOUTERRACE
TRANSFERCOVERA
ATTACXMCNT,
52x68mft
07746- tD,t0500

Install the tapered roller bearing outer race u sI n g


the special tools and a press.

13-50

www.emanualpro.com

TransferHousingBearingOuterRaceReplacement
NOTE:Coatall partswith MTFduring reassembly.
1.

Bealing Outer RaceLocations


and SpecialTool APP|ications

Removethe taperedroller bearingouter racefrom


the transferhousing.
HOUSING
TRANSFER
SectionalView

ATTACHMENT,
62x68mm
07746- 0010500

ATTACHMENT,
62x68mm
07?a6- 0010500
ATTACHMENT,
52x55mm
07715- 0010400

TBANSFERHOUSING

I n s t a l lt h e n e w t a p e r e dr o l l e r b e a r i n go u t e r r a c e
usingthe specialtools and a press

DRIVER
07749- 0o1(xD0

J
i=
\ l

TRANSFERHOUSING
DRIVERATTACHMENT

www.emanualpro.com

BEARINGOUTER
RACE

13-51

TransferAssembly
Reassembly
Notetheseitemsduring reassembly:
. While reassembling
the transferassembly:
- Checkand adjustthe transfergeartooth contact.
- Measureand adjustthe transfergear backlash.
- Checkand adjustthe taperedroller bearingstartIng rorque.
. Coatall partswith MTFduring reassembly.
. R e p l a c et h e t a p e r e dr o l l e rb e a r i n ga n d t h e b e a r i n g
outer raceas a set if eitherpart is replaced.
. Replacethe transferdrive gear and the transferdriven gear shaftas a set if eitherpart is replaced,

EXAMPLE:
C: EXISTING35 mm
THRUSTSHIM
Thicknoss:C=1.05mm

X: REPLACEMET{T35
mm
THRUSTSHIM
Thickness:X=??mm

Number: A=+2

Number: B-l

Outlineof Assembly
1.

Selectthe 35 mm thrustshim.
Performthis procedureif the transler driven gear
shaft or the tapered roller bearingon the transfer
drivengearshaft is replaced.

2.

Preassemble
the parts to checkand adjust transfer
gear backlashand transfergeartooth contact.

3.

Disassemblethe parts,then assemblethe transfer


drivengear shaftand its relatedparts.

4.

Measureand adjustthe staningtorque of the transfer drivengear shafttaperedrollerbearing.

5.

Assemblethe transfershaftand jts relatedparts.

6.

Measureand adjustthe total startingtorque.

35 mm Thrust Shim Seleqtion


1.

Selectthe 35 mm thrust shim if the transferdriven


gearshaftor the taperedrollerbearingon the transfer drivengear shaft is replaced.

A: EXISTINGTRANSFER
DRIVENGEARSHAFT

B: REPLACEMENT
TRANSFER
DRIVENGEAFSHAFT

'x- = A - B - .100 100


2 - 1
'100 100
= 0.02+ 0.01+ 1.05
-'1.08(mm)
S e l e c t3 5 m m t h r u s t s h i m t h i c k n e s so t ' 1 . 0 8m m
(0.043in). lf the taperedrollerbearingon the transfer
drivengear shaftis replaced.
M e a s u r et h e t h i c k n e s so f t h e r e p l a c e m e nbt e a r i n g
and the existingbearing,and calculatethe difference
of the bearingthickness.Adjust the thicknessof the
existing35 mm thrust shim by the amount of differencein bearingthickness.and selectthe replacement
35 mm thrustshim. Do not use more than one 35 mm
thrustshim to adjustthe transfergear backlash,
THRUSTSHIM.35 mm

C a l c u l a t teh e t h i c k n e s so f t h e 3 5 m m t h r u s ts h i m
usingthe formulabelow.

ronrvruu:fi--fr-+c=x
A: Numberon the existingtransferdrivengearshaft
B: Numberon the replacement
transferdriven gear
shaft
C: Thicknessofthe existing35 mm thrustshim
X : T h i c k n e s sn e e d e df o r t h e r e p l a c e m e n3t 5 m m
thrustshim

Shim No.

c
E
F
n

N O T E : T h e n u m b e r o n t h e t r a n s f e rd r i v e n g e a r
shaft is shown in 1/100mm.

13-52

www.emanualpro.com

Part Number
41361- PS3- 000
41362-PS3-000
41363-PS3-000
41364-PS3-000

Thickness
0.72 mm (0.028in)
0.75 mm (0.030in)

0.78 mm (0.031in)
0.81 mm (0.032in)
41365-PS3-000
0.84 mm (0.033in)
4 r 3 6 6 - P S 3 - 0 0 0 0.87 mm (0.034in)
41367-PS3-000
0.90 mm (0.035in)

4 1 3 6 8 - P S 3 - 0 0 0 0.93 mm (0.037in)
4 1 3 6 9 - P S 3 - 0 0 0 0.96 mm {0.038in)
4 1 3 7 0 - P S 3 - 0 0 0 0.99 mm (0.039in)
41371- PS3- 000

1.02mm (0.040in)

4 1 3 7 2 - P S 3 - 0 0 0 1 . 0 5m m ( 0 . 0 4 1i n )
4 1 3 7 3 - P S 3 - 0 0 0 1.08mm (0.043in)

41374-PS3-000

1 . 1 1m m ( 0 . 0 4 4i n )

TransterGear BacklashInspectionand TransferGear


Tooth Contaqt Inspection

5.

Installthe transferdriven gear shaft in the transfer


housing. Do not install the transfer spacer on the
transferdrivengear shaftin this step.

lnstallthe 35 mm thrust shim on the transferdriven


g e a r s h a f t ,t h e n i n s t a l lt h e t a p e r e dr o l l e r b e a r i n g
usingthe specialtools and a press.

2.

TRANSFER
HOUSING

NOTE:Use old lransferspacerfor bearinginstallation, then discardit.

6,
DRIVEN
TRANSFER
GARSHAFT

Installthecompanionflange.conicalspringwasher,
and locknut on the transfer driven gear shaft. Do
n o t i n s t a l lt h e O - r i n ga n d t h e b a c k - u pr i n g o n t h e
transfergearshaft in this step.
TRANSFERHOUSING

3.

Installthe bearingouter race,then the taperedbeari n g o n t h e c o m p a n i o nf l a n g e s i d e o t t h e t r a n s f e r


housing.

DRIVER
077/tg - 001qt00

OIL SEALDRIVER
ATTACHMENT
07JAD- PH80101
CONICALSPRING
WASHER
direction.

COMPANION
FLANGE

Replace.

TAPEREDROLLER
BEARING

I n s t a l lt h e n e w o i l s e a l o n t h e t r a n s f e r h o u s i n g
usingthe specialtools.

www.emanualpro.com

(cont'd)

13-53

TransferAssembly
(cont'd)
Reassembly
7.

S e c u r et h e t r a n s f e rh o u s i n gi n a b e n c hv i s e w i t h
soft jaws, then installthe specialtool on the companion flange. To preventdamageto the transfer
housing,alwaysuse soft jaws or equivalentmaterials betweenthe transferhousingand the vise.
COMPANION
FLANGE
HOLDER
07RAB- 0020000

9.

Installthe transfer shaft assembly in the transfer


h o u s i n g ,t h e n i n s t a l lt h e t a p e r e dr o l l e r b e a r i n g ,
t r a n s f e rs h a f t c o l l a r , 2 5m m t h r u s t s h i m , t r a n s f e r
drive gear, conical spring washer, and locknut on
the transfershaft.
NOTE:
. C o a t t h e t h r e a d so f t h e l o c k n u t ,a n d t h e s h a f t
with MTFbeforeinstallingthe locknut.
. Do not stakethe locknutin this step.
TRANSFERSHAFT
ASSEMBLY

TRANSFER

WRENCH

8.

T i g h t e nt h e l o c k n u tw h i l e m e a s u r i n gt h e s t a r t i n g
torque so the starting torque is within 0.98 - 1.39
N.m {10.0- 14.2kgf.cm.8.68- 12.3lbf.in).

THRUSTSHIM.
25 mm
Selectivepart
COLLAR

NOTE:
. C o a t t h e t h r e a d so f t h e l o c k n u t ,a n d t h e s h a f t
with MTFbeforeinstallingthe locknut.
. Do not stakethe locknutin this step.
STARTINGTOROUE:
0.98- 1.39N.m
(10.0- 14.2kgf.cm,8.68- 12.3lbf.in)

www.emanualpro.com

TRANSFERDRIVE
GEAR

Replace.

CONICALSPRING
WASHER
Replace.

Rotatethe companionflange severaltimes to seat


the taperedrollerbearing.

10. Hold the transfershaft with a 14 mm Allen wrench


clampedin a benchvise.
TOROUEWRENCH

'14.

Set a dial indicatoron the companionflange,then


measurethe transfergear backlash.
- 0.006in)
STANDARD:
0.06- 0.15mm 10.002
DIALINDICATOR

FLANGE
COMPANION

lil mm ALLENWRENCH

NOTE:
. The transfershaft locknuthasleft-handthreads,
. Do not stakethe locknutin this step.

l f t h e m e a s u r e m e n ti s n o t w i t h i n t h e s t a n d a r d ,
removethe transfershaft locknutand replacethe 25
m m t h r u s t s h i m . S e l e c ta n d i n s t a l la n e w 2 5 m m
Do not
thrust shim. then recheckthe measurement.
use more than one 25 mm thrust shim to adjustthe
transfergear backlash,

TOROUE:118 N.m (12.0kgf.m,86.8 lbf.ft)

THRUSTSHlM,25mm

1 1 .Tightenthe transfershaftlocknut.

Temporarilyinstallthe transfercover A without the


O-ring.

rl0ustNG

Shim No.

Thickness

29416-PlC-000

2
3

7
8

'10
11
TRANSFERCOVERA

Part Numbel

in
2 9 4 1 r- P 1 C- 0 0 0 1.70mm 10.067
'L73
mm (0.068in
29412-PlC-000
2 9 4 1 3 - P 1 C - 0 0 0 1.76mm (0.069in
2 9 4 1 4 - P l C - 0 0 0 1.79mm (0.070in
2 9 4 1 5 - P 1 C - 0 0 0 1.82mm (0.072in

12
13
l4
16
17

'18
19

1.85mm (0.073in
2 9 4 ' 1 7 - P r C - 0 0 0 1.88mm (0.074in
2 9 4 ' 1 8 - P 1 C - 0 0 01 . 9 1m m ( 0 . 0 7 5i n )

2 9 4 1 9 - P l C - 0 0 0 1.94mm (0.076in)
2 9 4 2 0 - P 1 C - 0 0 0 1.97mm 10.078in)
29421- P1C- 000 2.00mm (0.079in)
29422-P1C - 000 2.03mm (0.080in)
2 9 4 2 3 - P 1 C - 0 0 0 2.06mm (0.081in)
2 9 4 2 4 - P 1 C - 0 0 0 2.09 mm (0.082in)
29425-P'tC-000 2 . 1 2m m ( 0 . 0 8 3i n )
2 9 4 2 6 - P 1 C - 0 0 0 2 . 1 5m m ( 0 . 0 8 5i n )
29427-P1C-000
2 . 1 8m m { 0 . 0 8 6i n )
2 9 4 2 8 - P 1 C - 0 0 0 2.21 mm {0.087in)
2 9 4 2 9 - P 1 C - 0 0 0 2.24 mm 10.088in)

8xL25mm
24 N.m (2.4kgt.m. 17 lbnftl

(cont'd)

www.emanualpro.com

13-55

TransferAssembly
(cont'dl
Reassembly
16. Apply PrussianBlue to both sides of the transfer
gearteeth lightlyand evenly.

19. lf the transfergear tooth contactis incorrect,adjust


the transfergear tooth contactwith a 35 mm or 25
m m t h r u s ts h i m .
NOTE:
. To selecta 35 mm thrust shim, referto page '13.

Do not use more than one 35 mm shim to adjust


the transfergeartooth contact.
. To selectthe 25 mm thrust shim, refer to page
13-55.
a Do not use more than one 25 mm shim to adjust
the transfergeartooth contact.

TRANSFERDRIVEGEAR

1 7 . Rotatethe companionflangein both directionsuntil


the transfergear rotatesone full turn in both directions.
1 8 . Checkthe transfergeartooth contactpattern.
CORREST
TOOTHCONTACT
PATTERN

INCORRECT
IOOTH CONTACTPATTERN

TOECONTACT

Toe Contact
U s e a t h i c k e r3 5 m m t h r u s t s h i m t o m o v e t h e
transferdriven gear shaft toward the transferdrive
gear. Becausethis movement causesthe transfer
gear backlashto change,move the transfer drive
gear away from the transfer driven gear shaft to
adjustthe transfergearbacklash
asiollows;
. I n c r e a s et h e t h i c k n e s so f t h e 2 5 m m t h r u s t
shim.
. R e d u c et h e t h i c k n e s so f t h e 6 8 m m t h r u s t
shim bv the amount of increasedthicknessof
the 25 mm thrustshim.
Heol Contact
Use a thinner 35 mm thrust shim to move the
transfer driven gear shaft away from the transfer
drive gear. Becausethis movement causesthe
transfer gear backlashto change,move the transfer drive gear toward the transferdriven gear shaft
to adjustthe transfergear backlashas follows:
. R e d u c et h e t h i c k n e s so f t h e 2 5 m m t h r u s t
s hi m .
a I n c r e a s et h e t h i c k n e s so f t h e 6 8 m m t h r u s t
shim by the amount of reducedthicknessof
t h e 2 5 m m t h r u s ts h i m .

HEELCONTACT

FLANKCONTACT

FACECONTACT

13-56

www.emanualpro.com

Flank Contact
Use a thinner thrust shim to move the transfer
drive gear toward the transferdriven gear shaft.
Flankcontactmust be adtustedwithin the limits
o f t h e t r a n s f e rg e a r b a c k l a s h l. f t h e b a c k l a s h
e x c e e d st h e l i m i t s , a d j u s t a s d e s c r i b e du n d e r
HeelContact.
FaceContsct
Use a thickerthrust shim to move the transfer
drive gear away from the transfer driven gear
shaft. Facecontactmust be adjustedwithin the
limits of the transjergear backlash.lf the backl a s h e x c e e d st h e l i m i t s , a d j u s t a s d e s c r i b e d
underToe Contact.

20. Removethe partson the transfershaft,and remove


the transfershattfrom the transferhousinq.
TRANSFERSHAFT

Removethe transterdrivengear shaftand the companionflange.


Installthe new transferspaceron the transferdriv e n g e a r s h a f t ,t h e n i n s t a l lt h e m i n t h e t r a n s f e r
housing.

TRANSFERDRIVEN
TRANSFERHOUSING GEARSHAFT

TRANSFERSPACER
Installin this direction.

TRANSFER

TAPEREDROLLER
BEARING
TRANSFERSHAFT
COLLAR
TMNSFER DRIVE
GEAR

THRUSTSHIM,25 mm
Selectivepart
CONICALSPRING
WASHER
Replace.

LOCKNUT
Replace.
Transter Driven Gear Shaft Starting Torque Inspection
and Adlustment
21. Securethe transfer housing in a bench vise with
soft iaws.
COMPANIONFLANGEHOLDER

25. Installthe companionflange,O-ring,back-upring,


conical spring washer and locknut on the transfer
drivengear shaft.
NOTE:
. Coatthe threadsof the locknut,O-ringand transfer shaftwith MTFbeforeinstallingthe locknut.
. Installthe conicalspring washer in the direction
shown.
TRANSFER
HOUSING

O.RING
COMPANION
FLANGE
CONICALSPRING
WASHER
Replace.
BACK.UP

22. I n s t a l lt h e s p e c i a lt o o l o n t h e c o m p a n i o nf l a n g ,

LOCKNUT
Replace.

then removethe transferdriven gear shaft locknut


and the conicalspringwasher.
(cont'd)

www.emanualpro.com

13-57

TransferAssembly
(cont'dl
Reassembly
26. Securethe transfer housing in a bench vise with
soft jaws.

28. Stakethe locknutinto the transferdriven oear shaft


u s i n ga 3 . 5m m p u n c h .

COMPANION
FLANGE
HOLDER
07RAB- 002tD00

0.7- 1.2mm
(0.03- 0.05 inl
PUNCH
3 . 0 - 3 . 5m m
- 0.1ainl
10.12

Point to be
staked.

29. Installthe transfer shaft assemblv in the transfer


h o u s i n g ,t h e n i n s t a l lt h e t a p e r e dr o l l e r b e a r i n g ,
transfer shaft collar, 25 mm thrust shim, transfer
drive gear,conicalspringwasher,and transfershaft
locknuton the transfershaft.
2 7 . I n s t a l lt h e s p e c i a lt o o l o n t h e c o m p a n i o nf l a n g e .
then tighten the transferdriven gear shaft locknut
while measuringthe startingtorque of the transfer
drivengearshaft.

NOTE:
. Coatthe threadsof the locknutand transfershaft
with MTFbeforeinstallingthe locknut.
. lnstallthe conicalspringwasher in the direction
snown.

STARTINGTOROUE:
0.98- 1.39N.m
{10.0- 1i1.2kgf.cm,8.68- 12.3lbf in}
TIGHTENINGTOROUE:
132- 216 N.m
(13.5- 22.0kgf.m,97.6- 159lbf.ft)
NOTE:
. R o t a t et h e c o m p a n i o nf l a n g e s e v e r a lt i m e s t o
seatthe taperedrollerbearing,then measurethe
startrngtorque.
. l f t h e s t a r t i n gt o r q u e e x c e e d s1 . 3 9 N . m ( 1 4 . 2
kgf.cm, 12.3 lbf.in), .eplacethe transfer spacer
a n d r e a s s e m b l et h e p a r t s . D o n o t a d j u s t t h e
torquewith the locknutloose.
. l f t h e t i g h t e n i n gt o r q u ee x c e e d s2 1 6 N . m ( 2 2 . 0
kgf.m,159 lbf'ft),replacethe transferspacerand
reassemble
the parts.
. W r i t e d o w n t h e m e a s u r e m e no
t f the starting
torque: it is used to measurethe total starting
torque.

TMNSFER SHAFT
ASSEMBLY

TRANSFERHOUSING

TAPEREDROLLER
BEARING
TRANSFERSHAFT
COLLAR
TRANSFERDRIVE
GEAR

THRUSTSHIM,25 mm
Selectivepart

CONICALSPRING
WASHEB
Replace.
LOCKNUT
Replace.

www.emanualpro.com

30. Hold the transfershaft with a 14 mm Allen wrench


clamDedin a benchvise.
NOTE:The locknuthas left-handthreads.

Totsl Starting Torquo Inspoctionand Adiustment


32. Temoorarilvinstalltransfercover A without the Oring.
TRANSFER
HOUSING

TOROUE:118N.m (12.0kgt'm,86.8lbf'ft)

TRANSFERCOVERA

l E
/Eh

v
14 mm ALLENWRENCH
5t.

/E\
\g

8 x 1.25 mm
24 N.m (2.4kg{ m, 17 lbtftl

Securethe transfer housing in a bench vise with


soft jaws. then rotatethe companionflange several
times to fit the taperedrollerbearing,

31. Stakethe locknuton the transfershaft using a 3.5


mm Dunch.

PUNCH
3.0- 3.5 mm
{0.12- 0.14inl

TOROUEWRNCH

34. Measurethe total startingtorque.


TOTALSTARNNGTOROUE:
- 21.2kgf.cm,15.0- 18.i1lbf inl
1.70- 2.08N.m 117.3
+ Transter Driven Gear Shaft Starting Torque Value
(wrot down in step 27).

(cont'd)

www.emanualpro.com

13-59

TransferAssembly
(cont'd)
Reassembly
3 5 . RemovetransfercoverA.

37. Selectthe 68 mm thrustshim.

36. lf the measurementis out of specification,remove


t h e 6 8 m m t h r u s t s h i m f r o m t r a n s f e rc o v e r A b y
h e a t i n gt h e c o v e rt o a l m o s t2 1 2 ' F( 1 0 0 ' C )u s i n ga
heat gun. Do not heat the cover higher than 212F
( 1 0 0 " C )L. e t t h e c o v e r c o o l t o r o o m t e m p e r a t u r e
beforeadjustingthe startingtorque.
go to
lI the measurementis within the specification,
step 40.

THRUSTSHIM,68 mm
Shim No.

Part Number

Thickne3s

zv

23914-P1C-020

zw

23975-P1C-020
23916 PlC -020
23917-P1C-O20

1.41mm (0.056in)
'1.44mm
in)
10.057
'1.47mm (0.058in)
1.50mm (0.059in)
1.53mm (0.060in)

zx
ZI

zz

23978-PlC-020
23941- PW5 000

1.56mm {0.061in)
1.59mm (0.063in)
2 3 9 4 3 - P W 5 - 0 0 0 't.62mm (0.064in)
23944 PW5- 000
1.65mm (0.065in)
2 3 9 4 5 - P W s - 0 0 0 1.68mm (0.066in)

23946-PW5-000

23947-PW5-000

23942-PWs-000

c
D

HEAT GUN

1.71mm 10.067
in)
'1.74mm
in)
10.069
23948-PWs-000
1.77mm (0.070in)
2 3 9 4 9 - P W s - 0 0 0 1.80mm (0.071in)
2 3 9 s 0 - P W 5 - 0 0 0 1.83mm (0.072in)
23951- PW5- 000
1.86mm (0.073in)

23952-PWs-000

COVERA

1.89mm {0.074in)

2 3 9 s 3 - P W s - 0 0 0 1.92mm {0.076ini
N

23954-PW5-000

23955-PW5-000
23956- PW5, 000

o
R

T
U

2.01mm (0.079in)

2 3 9 5 7 - P W s - 0 0 0 2.04mm (0.080in)
2 3 9 5 8 - P W s - 0 0 0 2.07mm (0.081in)
23959-PW5-000

BEARINGOUTERRACE

1.95mm (0.077in)
1.98mm (0.078in)

23960-PW5-000
23961- PW5- 000
23962-PW5-000

2.10mm (0.083in)
2.13mm (0.084in)
2.16mm (0.085in)
2.19mm (0.086n)

2 3 9 6 3 - P W s - 0 0 0 2.22 mm (0.087 n)
X

23964-PWs-000

2.25mm (0.089n)

2 3 9 6 5 , P W s - 0 0 0 2.28mm 10.090n )
23966-PW5-000

2.31mm {0.091in)

2 3 9 6 7 - P W s - 0 0 0 2.34mm (0.092in)
23968-PWs-000

AC
AD

2 3 9 6 9 - P W s - 0 0 0 2.40mm {0.094in}

M
BZ

cz

13-60

www.emanualpro.com

2.37mm (0.093in)

AB

23970-PW5-000
23941- PW8- 000
23942-PW8-000

DZ

23943-PW8-000
23944-PW8-000

EZ

23945-PW8-000

2.43mm (0.096in)
2.46mm {0.097'n}
2.49mm (0.098in)
2.52mm {0.099ini
2.55mm (0.100in)
2 . 5 8m m ( 0 . 1 0 i2n i

3 8 . I n s t a l lt h e 6 8 m m t h r u s t s h i m u s i n g t h e s p e c i a l
tools.

DRIVER
077 - 001(xno

4 0 . C o a t t h e n e w O - r i n g sw i t h M T F , i n s t a l lt h e m o n
transfercoversA and B, then installthe coverson
the transferhousing.

6x1.0mm
12 N.m 11.2kgf.m,
8.7 tbt.ft)

TRANSFERCOVERB

TRANSFER

THRUSTS1{IM,
68 mm
Selectivepart
BEARINGOUTERBACE
ATTACHMENT.
62x68mm
077a6 - (x)10500

O.RING
Replace.

O.BING
Replace.

39. After replacingthe 68 mm thrust shim, recheckand


m a k e s u r e t h e t o t a l s t a r t i n gt o r q u e i s w i t h i n t h e
soecification.

TRANSFER
COVERA

8 r 1.25mm
2,r N.m (2.4 kgl.m. 17 lbtft)

www.emanualpro.com

13-61

MainshaftBearing/OilSeal
Replacement
1.

Removethe ball bearingusingthe specialtool.

3.

Drivethe new oil seal in from the transmissionside


usingthe specialtools.

3/8" -16 SLIDEHAMMER


(Commercially
available)

ATTACHMENT,
12x 17 .nfi

07746- 0010300

- ,10mm
PULLER.25
07736- A01000A

Drivethe new bali bearingin from the transmission


side usingthe specialtools.
2.

Removethe oil sealfrom the clutchhousing.

ATTACHMENT.
62x68mm
07746- 0010500

BALLBEARING

13-62

www.emanualpro.com

GountershaftBearing
Replacement
1.

Removethe retainingplatefrom the clutchhousing.

Positionthe oil guide plate.


Drivethe needlebearingusingthe specialtools.

Replace.

CLUTCHHOUSING
HETAININGPLATE

Removethe needlebearingusing the specialtool,


then removethe oil guide plate.

3/8" -16 SLIDEHAMMER


(Commercially
available)

ATTACHMENT,
62x88mm
07746- 0t!105q)

NEEDII AEARING

CLUTCHTIOUSING

Installthe retainingplate,and stakethe bolt heads


into the groovein the retainingplate

^'

ADJUSTABI.fBEARING
PULLER,25- 40 mm
07736- A01(x)04

6x1.0mm
12 N.m (1.2 kgt m,8.7 lbtftl

NEEDLEBEARING

www.emanualpro.com

13-63

MainshaftThrustClearance
Adjustment
l.

Removethe 78 mm shim and oil guide plate from


the transmissionhousing.

5,

Measuredistance@ betweenthe end of the clutch


housingand bearinginner race.
NOTE:
. Usea straightedgeand depthgauge.
. Measureat three locationsand avoragethe readIngs.

78 mm SHIM

END ot CLUTCHHOUSING

BEARING

Installthe 3rd/4th synchro hub, spacer collar, sth


synchrohub, spacer,and ball bearingon the mainshaft.then installthe above assemblyin the transmissionhousing.
lnstallthewasheron the mainshaft.
4.

Measuredistance@ betweenthe end of the transmissionhousingand washer,

Selectthe proper 78 mm shim from the chan by


usingthe formulabelow.
Shim Slection Formula:

NOTE:
. Usea straightedgeand verniercaliper.
. Measureat three locationsand averagethe readIng.

you made in steps4 and 5:


Fromthe measurements
-1. Add distance@ (step5) to distance@ (step4).
-2. From this number. subtract0.93 (which is the
midpointof the flex rangeof the clutchhousing
bearingspringwasher).

ENDot
TRANSMISSION
MAINSHAFT

-3. Takethis number and compareit to the availableshim sizesin the chart.
WASHER

(Forexample)

3RD/4THSYNCHROHUB
SPACERCOLLAR
sTH SYNCHROHUB
SPACER
BALLBEARING

13-64

www.emanualpro.com

A: 2.39
+ Bi O.22

2.61
- 0.93

= 1.68

2.61

Try the 1.68mm (0.0661in) shim.

7,

78 mm SHIM

c
u
F
G
H

K
L
M
N

X
z
AB
AD
AE

AH
AI
AJ

AK

AN

Part Numbor
23941- P16- 000
23942-P16-000
23943-P16-000
23944-Pt6-000
23945-P16-000
2 3 9 4 6 -P 1 6- 0 0 0
23947-P16-000
23948-P16-000
23949-P16-000
23950-P16-000
23951- P16- 000
23952-Pl6-000
23953-P16-000
23954-P16-000
23955-P15-000
23956- P16- 000
23957-P16-000
2 3 9 5 8 -P 1 6- 0 0 0
23959-P16-000
23960-P16-000
23961- P16- 000
23962-P16-000
23963-P16-000
23964-P16-000
23965-P16-000
23966-Pl6-000
23967-Pl6-000
23968-P16-000
23969-Pl6-000
2 3 9 7 -0 P l 6 - 0 0 0
23971- P16- 000
23972-P16-000
23973-P16-000
23974-P16-000
23975-P16-000
23976-Pl6-000
23977-P16-000
23978-Pl6-000
23979-Pl6-000
23980-P16-000

Checkthe thrust clearancein the mannerdescribed


Delow.

Thickness
1.20mm (0.0472in)
1.23mm (0.0484in)
'1.26mm (0.0496in)

in)
1.29mm (0.0508
1.32mm (0.0520n )
1.35mm (0.0531n )
1.38mm {0.0543n )
1.41mm (0.0555n )
1.44mm (0.0567in)
1.47mm (0.0579in)

N O T E : M e a s u r e m e nst h o u l d b e m a d e a t n o r m a l
room temperature.
-1. Installthe 78 mm shim selectedand oil guide
platein the transmissionhousing.
78 mm SHIM
OIL GUIDEPLATE

1.50mm {0.0591in}

in)
1.53mm (0.0602
1.56mm (0.0614in)
1.59mm (0.0626in)

in)
1.62mm (0.0638
1.65mm (0.0650in)
1.68mm (0.066'tin)
1 . 7 1m m ( 0 . 0 6 7 i3n )

- 2 . I n s t a l lt h e s p r i n g w a s h e ra n d w a s h e ro n t h e

1.74mm {0.0685in)
1.77mm {0.0697inl

ball bearing.

in)
1.80mm (0.0709
in)
1.83mm (0.0720
'1.86mm (0.0732
in)

NOTE:
. Cleanthe spring washer,washerand thrust
shim thoroughlybeforeinstallation.
. Installthe spring washer,washerand thrust
shim properly.

1.89mm (0.0744in)
1.92mm (0.0756in)
1.95mm (0.0768in)

in)
1.98mm (0.0780
in)
2.01mm (0.0791
in)
2.04mm (0.0803
n)
2 . 0 7m m { 0 . 0 8 1i 5

2.10 mm {0.0827in}

in)
2.13mm (0.0839

WASHER

SPRTNG*ASHER

,-g

2.16 mm (0.0850in)

in)
2.19mm (0.0862
4 inl
2.22mm 10.087
in}
2.25mm {0.0886
2.28mm {0.0898
in)
in)
2.31mm (0.0909
2.34mm (0.0921
in)
2.37mm (0.0933
in)

Installthe mainshaftin the clutchhousing.


Placethe transmissionhousingover the mainshaftand onto the clutchhousing.
- 5 . Tightenthe clutch and transmissionhousings
with several8 mm bolts.
NOTE:lt is not necessaryto use sealingagent
betweenthe housings.
Tap the mainshaftwith a plastichammer.
(cont'd)

www.emanualpro.com

13-65

MainshaftThrustClearance
Adjustment(cont'dl
-7. Slidethe mainshaftbaseoverthe mainshaft.

-12. Turn the mainshaftholder bolt clockwise;stop


t u r n i n gw h e n t h e d i a l g a u g e h a s r e a c h e di t s
maximum movement,The readingon the dial
gaugeis the amountof mainshaftend play.
NOTE:Turningthe mainshaftholderbolt more
t h a n 6 0 d e g r e e sa f t e r t h e n e e d l eo f t h e d i a l
gaugestopsmoving may damagethe transmission.
MAGNETSTANDAASE
07979- PJ40001

DIALGAUGE

07GAJ- PG20130

-8. Attachthe mainshaftholderto the mainshaftas


follows:
NOTE:
. B a c k - o u t h e m a i n s h a f th o l d e r b o l t a n d
loosenthe two hex bolts.
. Fit the holderover the mainshaftso its lip is
towardsthe transmission.
. Align the mainshaftholder'slip around the
groove at the insideof the mainshaft
splines,then tightenthe hex bolts.
HOLDER
MAINSHAFT
BOLT

-13. lf the readingis within the standard,the clearancers correct.


l f t h e r e a d i n gi s n o t w i t h i n t h e s t a n d a r d ,
recheckthe shim thickness.
Standard:0.11- 0.18mm (0.00i1-0.007inl

t--E-H
lf\f,A\
l\.

xex

l"\y
I aors
t____=__)"n-____"8
\
MAINSHAFT
HOLDER
07GAJ- PG20110

MAINSHAFT
EASE
07GAJ- PG20130
-9. Seatthe mainshaftfully by tappingits end with
a plastichammer.
-10. Threadthe mainshaftholder bolt in until it just
c o n t a c t st h e w i d e s u r f a c eo f t h e m a i n s h a f t
base.
- 1 1 . Z e r oa d i a lg a u g eo n t h e e n d o f t h e m a i n s h a i t .

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MAINSHAFTHOLDER
07cru - PG20110

TransmissionAssembly
Reassembly
1.

Installthe differentialassemblyin the clutch housIng.

4.

ASSEMBLY
DIFFERENTIAL

'97 - 99 models: Installthe reverseidle gaar and


reverse gear shaft in the clutch
housing.
'00 model: Installthe coller,thrust washer,reverse
idler gear and the reversegear shaft in
the clutchhousing.

model

THRUSTWASHER

Installthe springwasherand washerwith the angle


againstthe clutchhousingas shown.

COLLER

Tape the mainshaft splines. insert the mainshaft


and countershaft into the shift forks, and install
them as an assemblv.

NOTE:Installthe reversegear shaft ('00 model) in


the directionshown.
5.

Installthe reverseshift holderin the clutch housing


with the sth/reverseshift piecepin positionedin the
slot of the reverseshift fork.

5x1.0mm
15 N'm 11.5kgt.m, 11 lbf.ftl

Tapethe mainshatt
splines.

REVERSE
SHIFTHOLDER

(cont'd)

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13-67

TransmissionAssembly
Reassembly(cont'dl
6.

Installthereverselockcam on the clutchhousing.


6x1.0mm
15 N.m (1.5kgf.m, 11 lbf.ftl

10. Apply liquid gasket (P/N 08718- 0001 or 087180003)to the selectspring bolt threads,then install
the selectspringbolt.
SELECTSPRINGBOLT
39 N.m la.o kgf'm,29lbtft)

LOCKCAM
REVERSE

7.

l n s t a ltl h e o i l s e a l .
HANDLE
07749- 001mO
ATTACHMENT,
32x35mm
07745- 0010100

'I1. I n s t a l tl h e o i l g u i d e M p l a t e . 7 8m m s h i m ,
and oil
guner platein the transmissionhousing.
N O T E : S e l e c tt h e 7 8 m m s h i m a c c o r d i n gt o t h e
measurements
madeon page13-64,

OIL SEAL
Replace.

Installthe selectlever,spring washer,and springs


on the selectarm.
SELECT
LEVER

SELECTBETURN
SPRING
5TH/REVERSE
SELECTRETURN

SPRINGPIN
Replace.

OIL GUIDEM PLATE

SELECT
ARM
9.

Installthe
s e l e ca
t r m a n ds p r i n gp i n .

13-68

www.emanualpro.com

12. Apply liquid gasketto the surfaceof the transmission housingas shown.

15. Lowerthe transmissionhousingwith the snap ring


pliers.and set the snap ring into the groove of the
countershaftbearing.

Notetheseitems:
. Use liquid gasket(P/N 08718- 0001 or 087180003).
. Removethe dirty fluid from the sealingsurface.
. Sealthe entirecircumterence
of the bolt holesto
preventfluid leakage.
. lf 20 minutes have passedafter applying liquid
gasket,reapplyit and assemblethe housings.
a Allow it to cure at least20 minutesafter assembly betorefillingthe transmissionwith MTF.

SNAPRINGPLIERS

DOWELPINS

r3. Installthe 14 x 20 mm dowel pins.


1 4 . Set the stopperring as shown. Placethe transmis-

sion housingover the clutchhousing,being careful


to line up the shafts.Be sure to align the stop ring
with the 5th shift fork fingertip.
TRANSMISSIONHOUSING

1 6 . Checkthat the snap ring is securelyseatedin the


grooveof the countershaftbearing.
DimensionA as installod:3.6 - 6.3 mm
(0.142- 0.2/8 in)
32 mm SEALINGBOLT
25 N m 12.5kgf.m, 18 lbf.ftl

SNAPRING

vk..*,
SHIFTFORK
Align point

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1 7 . A p p l y l i q u i d g a s k e t( P / N0 8 7 1 8- 0 0 0 1o r 0 8 7 1 80003)to the 32 mm sealingbolt threads,then install


(cont'd)
the 32 mm sealingbolt.

13-69

TransmissionAssembly
Reassembly
lcont'd)
18. Installtransmission
hanger,then tightenthe bolts in
a crisscrosspatternin severalstepsas shown.
8 x 1.25mm bolis: 27 N.m 12.8kgf.m,20 lbf'ft}

2 0 . I n s t a l lt h e s t e e l b a l l s ,s p r i n g s .w a s h e r s ,s e t b a l l
screws,back-uplight switch.
WASHER
Replace.
STEELBALL
D,5/16 in

TRANSMISSION
HANGER

SPRINGL.26.1mm 11.03inl

1 9 . Install flange bolt, w a s h e r s d


, rainplug.and filler
plug.
21. Installthevehiclespeedsensor(VSS).
FILLERPLUG
4,r N.m (a.5 kgl.m,33lbtftl

VEHICI."ESPEEDSENSOR

DRAINPLUG
39 N.m {4.0kg{.m,29lbtftl
WASHER
Replace.

13-70

www.emanualpro.com

8 x 1.25mm
22 N.m 12.2kgl.m, 16 lbt.ftl
WASHER

22. Turn the selectlever and shift arm shaft counterclockwise,then insertthe shift arm shaft.
EOLT
INTERLOCK
39 N.m (4.0kqt ft, 29 lbf ft)

26. Installthe shift arm coverassembly.

SELECTARM
SHIFTARM COVERASSEMBLY

-->.-

10 x 12 mft DOWELPIN
SHIFTARM A

I x 1.25mm
27 N m 12.8kgtm,20 lbf'ft)

SHIFTARM SHAFT

23. Align the shift arm A groove and selectarm finger


by turn the shift arm shaft and select lever clockwise.then installtheshift arm shaftassembly.
Apply liquid gasket (P/N 08718- 0001 or 08718
bolt'
interlock
to the threads,then installthe
OO03)

t1

Installthe transferassemblY.
N O T E : L u b r i c a t eM T F t o t h e O - r i n g a n d c o n t a c t
areas.

Apply liquid gasketto the surfaceof the shift arm


coveras snown.
Notetheseitems:
. Use liquid gasket(P/N 08718- 0001 or 087180003).
. Removethe dirtv oilfrom the sealingsurface.
of the bolt holesto
. Sealthe entirecircumference
preventoil leakage.
. lf 20 minutes have passedafter applying liquid
gasket.reapplyit and assemblethe housings.
a Allow it to cure at least20 minutesafter assembly betorefillingthe transmissionwith MTF.

10x 1.25mm
44 N.m 14.5kgf.m,33 lbl.ftl

www.emanualpro.com

13-71

TransmissionAssembly
Installation
1.

Checkthat the dowel pins are installedin the clutch


housing.

5.

P l a c et h e t r a n s m i s s i o no n t h e t r a n s m i s s i o nj a c k ,
and raiseit to the enginelevel.

Apply greaseto the releasefork and releasebearing.

6.

Installthe transmissionmountingboltsand the rear


enginemountingbolts.

{P/N 08798- 90021

{P/N 08798- 9002)


0.{ - 1.0g
{0.0'l- 0.04ozl

TRANSMISSION
MOUNTINGEOLT
12x 1.25mn
64 N.m {6.5
47 tbt.ft)

REARENGINEMOUNNNG BOLTS
Replace.
Itl x 1.5mm
8:l N.m 18.5kgt m, 61 lbf.ft)

RELEASE
BEARING

(P/N 087989002)

7.
RELEASE
FORK
BOOT

(P/N08798- 9002)
'1.0
- 1.6g {0.0,10.06o2l
?

Installthe releasebearing,releasefork, and release


fork boot to the clutchhousing.
Installthe startermotor and hoseclamp.
HOSE

10x 1.25mm
4{ N'm (4.5 kgf.m,
32 tbf.ftl

13-72

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Risethe transmission,then installthe transmission


mount bracketand transmissionmount.
T o r q u et h e m o u n t i n g b o l t s a n d n u t s i n t h e
sequenceshown.
. Checkthat the bushingare not twistedor offset.
O . @ : 1 2x 1 . 2 5m m
64 N.m (6.5 kgf.m, 47 lbf'ft)
Temporarytightening
O:
1 2x 1 . 2 5m m
@:
74 N.m (7.5kgf'm,54lbf.ft)

8.

Installtheright front mounvbracket.


12 x 1.25mm
64 N.m (6.5 kgf'm,
47 tbf.ftl
Replace.

10. Pourtransmissionfluid of 1 literfrom the driveshaft


insertedhole.
11. lnstallthe intermediateshaft {seesection18).While
installingthe intermediateshaft in the differential.
be sure not to allow dust and other foreignparticles
to enterthe transmission.

RIGHTFRONT
MOUNT/BBACKET

10r 1.25mm
39 ttm 14.0kgf.m,
29 tbt ftl

SETRING
Replace.

10 x 1.25mm
4,aN.m (4.5kgf m,
33 tbf ftl
Install the clutch housing cover and rear engine
stiffener.

SHAFT
INTERMEOIATE

1 2 . l n s t a l l t h e d r i v e s h a f t s( s e e s e c t i o n 1 8 ) . W h i l e
in the differential,be sure
installingthe driveshaft(s)
not to allow dust and otherforeignpaniclesto enter
the transmission.
DRIVESHAFT

6xl0mm
12 N.m 11.2kgt.m.
8.7 tbf.ft)

HOUSING
'12x 1.25mm
29 N.m 13.0kgf.m.22 lbf'ft)

8 x 1.25mm
24 N.m {2.5 kgf'm'
18 tbl.ft)

SET RING
Replace.

10 x 'l .25 mm
44 N.m {4.5kgf m,33 lbf ftl

(cont'd)

www.emanualpro.com

13-73

TransmissionAssembly
Installation(cont'dl
13. Installthe balljoints onto the lower arms.

Installthe exhaustpipe A, then connectthe heated


oxygensensor(HO2S)connector.

DAMPERPINCHBOLT
10 x 1.25mm
43 N.m {a.a kgf.m,
32 rbfft)

GASKETS
Replace.

HO2SCONNECTOR

SELF.LOCKINGNUT
'12x 1.25|nm
6il N'm 16.5kgtin, 47 lbtftl
Reolace.

Replace.

10 x 1.25mm
5,1N.m15.5kgtm.
() tbt fil
Replace.

12x 1.25mm
,19- 59 N.m
(5.0- 6.0kgi.m,36 - lbfttl

SELF.LOCKING
8 x 1.25rr|ln
22 N.m (2.2 tgf.m, 16 lbl.ftl
Replac6.

NUT
SELF.LOCKING
8 x 1.25mm
16 N.rn 11.6kg{.m,
12lbtfr)
Replace.

GASKET
Replace.

1 4 . Installthe right damperfork bolt.


1 5 . Installthe propellershaft to the transferassembly
by aligningthe referencemarks.

'17.

Installthe guard bar and the splash shield.

REFERENCEMARKS

E x 1.25mr'|

32 N.m 13.3kst m, 2a lbf.ftl

SPLASHSHIEI.I)
I x 1.25mm
24 N.m l2.a kgf.m.
17 tbtft)

GUARDBAR

6x1.0mm
9.8 N.m (1.0 kgf.m,7.2 lbf.ft)

PROPELI"ER
SHAFT

13-74

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TRANSFER

1 8 . Refillthe transmissionfluid (seepage 13-3)

21, Installthe cablebracketfrom the clutchhousing.

1 9 . Installthe four uppertransmissionmountingbolts.

8 x 1.25mm
27 N.m (2.8 kgt'm. 20 lbtftl

COTTERPIN

Rplace.
STEEL
WASHER
COTTENPIN
Replace.

STEEL
WASHER
PLASTIC
WASHER

12 x 1.25mm
6it N.m 16.5kgf m,
il7 lbf.ftl

20. Connectthe vehiclespeedsensor(VSS)connector.

SELECT
CABLE

22. lnstallthe shift cableand selectcableto the levers,


then installplasticwashers,steelwashers,and cotter prns,
)a

------------,-

Connectthe back-up light switch connector.and


installthe wire harnessclamP.
6x1.0mm
9.8N.m{1.0kgf.m,

VSS CONNECTOR

HARNESSCLAMP

(cont'd)

www.emanualpro.com

13-75

TransmissionAssembly
(cont'dl
Installation
24. Connectthe startercablesand transmissionground
caore.

26. Turn the breathercap so that the "F" mark pointsat


the right side of the vehicleas shown.

6x1.0mm
9.8 N.m (1.0kg{.m,
7.2 tbt.ttl

TRANSMISSION
GROUND
CABLE

Apply greaseto the push rod on the slavecylinder,


then installthe slavecylinderand clutchhosebracket,

2 7 . I n s t a l lt h e i n t a k ea i r d u c t a n d a i r c l e a n e rh o u s i n g
(seesection5),

NOTE:Use only SuperHigh Temp Urea Grease


{P/N08798- 9002).

28. Connectthe positive(+) cablefirst. then the negative (-) cableto the battery.

8 x 1.25mm
22 N.m 12.2kgi-m,
16 tbr.f0

CI-UTCHHOSE
BRACKET

29. Checkthe levelof the transmissionf luid.


30. Checkthe clutchoperation.
31. Shift the transmissionand checkfor smooth operation.
32. Checkthe front wheelalignment(seesectionl8).

6x1.0mm
9.8 N.m {1.0kgf.m,
7.2 rbf.ftt

_G1

(P/N 08798- 9002)

13-76

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GearshiftMechanism
Overhaul
Notetheseitemsl
. InsDectrubberpartsfor wear and damagewhen disassembling'
. Checkthat the new cotterpin is seatedfirmly.
. Be carelulnot to damagethe guide pipe when removingthe cables'

CHANGELEVERKNOS
8 N.m (0.8kgl.m, 5.8 lbf.ft)

COTTEFPIN

CABLE
SELECT
PLATES
Replace.

WASHEB
(PlN

I
I

curur
I

\ \"1I a,I
?-@ -.4'

-(
I

Guidepipe in the

\
GUIDEPIPES

DOOI,

SHIFTCABLE
PLASTICWASHER
6 x 'l.0mm
9.8 N.m {1.0 kgf.m, 7.2 lbf.ftl

(stLlcoNE
GREASEI
LEVERASSEMBLY
8 x 1.25mm
13 N.m 11.3kgt'm,9.4lbfft)
FLOATING
COLLAR

www.emanualpro.com

13-77

AutomaticTransmission
14'2
.
S p e c i a lT o o l s
Oescription
. .... 143
G e n e r aO
l peration
'14_6
.
. ..
Power Flow
.
.
.
1
4
_15
.
.
.
.
.
.
S
y
s
t
e
m
E l e c t r o n iC
control
.. 14 24
H y d r a u l i cC o n t r o l
..
.. . 14_29
H y d r a u l i cF l o w . . . . - . . . . . . . . . . . .
.'t4'39
..
Lock'upSyslem
Electrical System
14 45
ComponenlLocdlrons
P C M C i r c u i l D r a g r a m( A / T C o n t r o l S v s t e m )
'97
.14-46
- . ...
M o d e l . . . . . . . . . . . . . . . . . . . . . ... . .
' 9 8 M o d e .l . . . . . . . . . . . . .. . . . . . .
.1450
.. ..
'99 00Models.... ....
1452
.
.
.
P C M T e r m i n a l V o l t a g e / M e a s u r i n gC o n d i t i o n s
..14'48
......
A"/T
C o n t r oSl y s t e m - ' 9 7 M o d e l
14 54
00 Models . . .. . .
A , / TC o n t r o l S y s t e m - ' 9 8
... - 14_56
.....
T r o u b l e s h o o t i nPgr o c e d u r e s. .
Svmotom to comoonent Charl
14 60
.
E i e c t r , c aS
l yslem -'97 Model .
14_62
E l e c t r i c aS
l y s t e m - ' 9 8 - O OM o d e l s . . . . .
E l e c t r i c aTl r o u b l e s h o o t i n g( ' 9 7 M o d e l )
T r o u b l e s h o o t i nFgl o w a h a r t s. . . . . . . . . . . . . . 1 4 _ 6 4
E l e c t r i c aT
l r o u b l e s h o o t i n g( ' 9 8 - 0 0 M o d e l s )
T r o u b l e s h o o t i nFql o w c l t " n " . . . . . . . . . - . . 1 4 - 9 3
ElectricalTroublesliooting('99 00Models)
T r o u b l e s h o o t i n oF l o w c h a r t
14 131
O / D O F F I n d i c a t o rL i g h t D o e s N o t C o m e O n
O / D O F F I n d i c a t o rL i a h t O n C o n s t a n t l Y . . . . 1 ! - 1 3 2
O / D O F F I n d i c a t o rL i g h t D o e s N o t C o m e O n
EvenThough O/D Switch ls Pressed . .... - 14_133
L o c k u p C o n t r o l S o l e n o i dV a l v e A , / BA s s e m b l y
. .14-135
Test....................-.........
.ll_135
.
Replacement
S h i f r C o n t r o l S o l e n o i dV a l v e A y ' BA s s e m b l ,
. .. 14-136
T e s t. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. .14'136
Replacement..............L i n e a rS o l e n o i dA s s e m b l Y
T e s t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. . . . .. .. .. .. . . . . .. . . .1 4 _ 1 3 7
14138
..
.
Replacement
M a r n s h a f t l c o u n t e r s h a fSl p e e d S e n s o r s
14_138
...-...
Replacement
A/T Gear Position Switch
. .. 14-139
T e s t. . . . . . . . . . . . . . . . . . . . . . . . . . - . . .
. . . . . . . . . . . .1. .4. .- .1. 4 0
Replacement
A/T Gear Position l n d i c a t o r
'97 ..
9 8 M o d e l s . . . . . . . . . . . . . . . _ . . . . . . .t.4. .1. .4. 2
Input Test'99 0 0 M o d e l s . . . . . . . . . . . . . . . . . . . . . . . .1. .4. -. 1. .4. .3. .
Input Test
I n t e r l o c kS y s t e m
I n t e r l o cC
k o n t r o l U n i tl n p u t T e s t .- . . . . . - . . . . . . . - 1 4 1 4 4
* K e y I n t e r l o c kS o l e n o i dT e s t . - . . . . . - . . . . . . . . 1 4 _ 1 4 6
* S h i f t L o c k S o l e n o i dT e s t . . . . . . . . . . . . . . -. ..-... . . . . . . . 1 4 1 4 7
* S h i f t L o c k S o l e n o i d R e p l a c e m e n t . . . . .. . . . . . 1 4 1 4 8
* park pin Switch Test
. . . . . . . .1. 4 1 1 9
' Park Pin Switch Replacement
- '97 - 98 Models
. . . . . . .1 4 - 1 5 0
* Park Pin Swirch/Over Drive (O/Di Switch
'99-00Models
14_151
. ..
Replacemenl
o v e r - D r i v e ( O / D )S w i t c h { ' 9 9 0 0 [ 4 o d e l s ]
.......14-152
Test........_.....................
Hydr.ulic System
Symptom to-Component Chart
H y d r a u l i cS y s t e m . . . . . . . . . . . . . . .
14 157
R o a d T e s t . . . . . . . . . . . . . -. . . . . . . .

StallSpeed
T e s t. . . . . _ . . . . . . . . . . . . . . . . . . . . . . . .
FluidLevel
Checking

. . . . .1
. .4 - 1 5 9
. . . . . . _ . . . . . . . . . . .1. .4. '.1. .6. 0.

Transmigrion

www.emanualpro.com

14 164
I n s p e c l r o n. . . . ..,. . . . . . . . . .
T r a n s f e rA s s e m b l y
14-165
Remova1,.,,,..............,
14,167
l n s t a l l a l i o n. . . . . . . . . . . . .
Transmission
14-169
Removal ...,
l l l u s t r a t e dI n d e x ( 4 W D )
14'174
.
End Cover/Transmissio
... .. . . .... .. 14-176
T r a n s m i s s i oH
n o u s i n g. . . .
T o r q u e C o n v e r t e rH o u s i n g l y ' a l v eB o d y . . - . . . - . 1 4 1 7 8
lllustrated lndex (2WD)
. . . . . . .1 4 1 8 0
End Cover/Transmissio
T r a n s m i s s i oH
n ousing . . ... . .. .... ... 14'182
14-184
T o r q u eC o n v e n e rH o u s i n g / r ' a l vBeo d y . . . . . . End Covef
. . . . . .1. 4 ' 1 8 6
R e m o v a t. . . . . . . . . . . . . . . . . . . . . .
T r a n s m i s s i o nH o u s i n g
..
14_188
R e m o v a l. . . . . . . . . . . . . . . . . . . . . .
Torque Convener HousingA/alve BodY
. - . . . .1. 4 - 1 9 0
R e m o v a t. . . . . . . . . . . . . . . . - . . . . .

ValveEody
n e p a i r. . . . . . . . . . . . . . . . . . . . . . ........... ... .. . . - . . . . . . 1 4 1 9 2
.. 1{_193
A s s e m b l .y. . . . . . . . . . . . . . . . . . .
ValveCaps
D e s c i i p t i o n . . . . - . . . . . . . . . . . . . . . . . . . . .. .. .. .. . . 1 4 1 9 4
. . 1 4 1' 9 5
...................
tnspeition
ValveBody
N4ain
- ...... .. 14_196
Disassembly/lnspection/Reassemblv
ValveBodY
Secondarv
14 198
.. .
Disassemblv4nspectron/ReassemblY
Reoulator
ValveBodv
. 14199
bisassembtv,lnspiction/Reassemblv
ServoEodv
....14'200
...
Disassembly/lnspection/Reassembly
Lock'uoValveBodY
. 14_201
....
Dis;ssembly/lnspection/Reassembly
Mainshaft
.. .. .. ..14'202
Disassembly/lnspection/Reassembly
..11_203
I n s p e c t i o.n. . . - . . . . . . . . . . . . . .
SealingRings
...... ..... . 14'204
Reilaceient
Countershaft
.. . . . . . 11-205
Disassembly/lnspection/Reassembly
D i s a s s e m b l y / R e a s s e. .m.b. .|.y. . . . . . . . . . . . . 1 4 _ 2 0 6
1 42 0 7
.... .
I n s p e d r o .n. . . . . . . . . . . . . . .
Onewav Clutch
11_209
Disassembly/lnspection/ReassemblY...
Sub-shaft
... . .. . 14-210
Disassembly/lnspection/Reassembly
o i s a s s e m b l y / R e 6 s s e.m b. l.y. . . - . . . . . . . . . . 1 4 - 2 1 1
Bearings
Sub-shaft
.......14'212
Replacement
Clutch
. . .14-213
Index..........
llfustrated
.... .. .....14-216
Disassembly
.... . .. .. . 14'218
Reassembfy
Differential
14-222
"
llfustratedIndex
. ..... .14'223
Inspection
Backlash
.. 11-223
BearingRepiacement
.. .. . . . .. ..11-2?4
CarrierReplacement
Differe-ntial
. .. 14'225
OifSealReplacement.
lnspection. . - .. ... . - ....... .. 11'226
SideClearance
HousingBearings
Transmission
Eearings
MainshaJVCountershaft
.......14221
Repfacement
. . . . . . . . . ..11'224
Sub'siraltEearingReplacement
HousingBearings
ToroueConverter
.. l4229
.
MainshattEearing/OilSe6lReplacement
Bfet a ; i n R
g e p l a c e m e n t..... . . . . . 1 4 - 2 3 0
Countersha
ControlLeverAssembly
. . . . . . . .1. .4 - 2 3 0
R 6 p l a c e m e n t. . . . . . , . ,
R e v e r s el d l e r G e a r

...............
1 n s t a 1 | a t.i .o. n
ParkStop
Inspeclion/Adjustmenl
TransferAssemblY
lllustrated lndex

.........
Disessembly
T r a n s f e rD r i v e G e a r B e a r i n g
Replacement
T r a n s { e rD r i v e n G e s f S h a f t B e a r i n g
Replacement
T r a n s f e rH o u s i n g R o l l e r B e a r i n g
Replacement
T r a n s f e rC o v r A B e a r i n gO u t e r R a c e
Replacement
T r a n s f e r H o u s i n g B e a r i n gO u t e r R a c e
R e p l a c e m e n t. . . . . . - . . , , , , , . . . . .

1 42 3 1
11-231
.......14.232
...........
14-235
11-237
11-237
14-238
$-234

11-239
14-240
Reassemblv
Transmassaon
...-.. .... .14250
Beassembly
C o n v e r i e r / D rPi vl a
e t e. . - . . . . . . . . . . . . . . . . 1 4 _ 2 5 8
Torque
Transmission
.......14'259
..................
lnstatlation
. . ......11-261
C o o l eFr l u s h i n g
ATFCoolerHoses
.......14-266
Connection..................
I Shift Lever
. .. 14'261
Removal/lnstallation
- '97 - 98 Models . . 14_264
Disassemblv/Reassemblv
-'99 00 Models.
14-269
Disassembli/Reassemblv
(O/D)SwitchWire
Over'Orive
C l e a r a n c e A d j u s t m -e n.t... . . . . . . . . 1 4 ' 2 7 0
... .14'271
D e t e nSt p r i n R
g e p l s c e m e. n .t - . .
*ShiftCable
14'272
.......
Adiustment
. 11'273
Repfacement..............

Ref.No.
^

Tool Number

Description

Oty I

BackprobeSet
lVT Oil PressureGaugeSetw/Panel
A,/TLow PressureGaugew/Panel
AdjustableBearingPuller,25 - 40 mm

2
1
'l

@
@
@
@

07GAB- PF50101
or
07GAB- PF50100
07GAE- PG40200
or
_ PG4O2OA
OTGAE
07HAC- PK40102
07JAB- 001020A
07JAD- PH80101
07LAD- PW50601
07LAE- PX40100
OTMAJ- PY4O114
07MAJ- PY40120
07PAZ- 0010100
07RAB- TB4010Aor
07RAB.TB40lOB
07sAz - 001000A
07406- 0020400
07406- 0070300
07736- 4010008or
07736- A010004
07746- 0010100
07746- 0010200
07746- 0010400
07746- 0010500

Anachment,32 x 35 mm
Attachment,37 x 40 mm
Attachment.52 x 55 mm
Attachment.62 x 68 mm

I
1
1
1

@
@
@
@

07746077460774607749-

Attachment,72 x 75 mm
Driver40 mm l.D.
Attachment,35 mm LD.
Driver

1
1
1
I

07947- SD90200

tl)

@
*rar

@
@

,-o
@

@
@
@
@
@
.--@

0010600
0030100
0030400
0010000

MainshaftHolder

PagoReferonc
14-181, 254

ClutchSpringCompressorBoltAssembly

14-216,219

HousingPuller
HolderHandle
Oil SealDriverAftachment
Attachment,40 x 50 mm
ClutchSpringCompressorAttachment
Ay'TPressureHose,2210mm
IVT PressureHoseAdapter
SCSServiceConnector
CompanionFlangeHolder

1
1
1
,l

14-189
't4-236,242,245,246
't 4-225,
241
14-237
14-216,2't9
14-161
1 4 -1 6 1
14-57
14-236,242,245,246

1
I

SealDriverAftachment
lf the top arm is too short,replaceit with 07SAC- pOZ01OO1.
07HAE- PL50101may be usedto substituteone of thesetools.
Must be usedwith commerciallyavailable3/8"-16slide hammer.

14-58,157
14-161
14-161
'14-229,230
14-211,
2't2
14-231
14-239
14-212,227, 228,229,230, 238,
14-239,249
14-221,229
't 4-207
, 223,226, 237, 241
14-237,241
1+21 1, 2't2, 225,227, 228, 229,
14-230,237, 238, 239,24't, 249
't4-225

E----G

tvj
@@@@@

14-2

www.emanualpro.com

\r'

@)

Description
GeneralOperation
controlledunit which provides4
The Automatictransmissionis a 3-elementtorqueconverterand triple-shaftelectronically
positioned
with
the
engine'
in
line
is
The
unit
speedsforwardand 1 reversespeed
('97- 00)' and the front-wheel
Thereare two tvoes of automatictransmissionon CR-V;the four-wheeldrive (4WD)model
drive (2WD)model ('98- 00).
Toroue Converter,Gars,and Clutches
The torqueconverterconsistsof a pump.turbine.and statorassemblyin a singleunit.The torqueconverteris connectedto
Thesepartsturn togetheras a unit as the engineturns.Aroundthe outsideof the torqueconverteris
the enginecrankshatt.
a ring gearwhich mesheswith the starterpinionwhen the engineis started.The torqueconverterassemblyservesas a flywheelwhile transmittingpowerto the transmissionmainshaft.
The mainshaftis in line with
and the sub-shaft.
The transmissionhasthree parallelshafts:the mainshaft.the countershaft,
reverseand 1st
gears
lor
3rd,2nd,4th.
and
4th
clutches,
1st,
2nd.
and
the
includes
The
mainshaft
crankshaft.
the engine
the 3rd
gear).
includes
The countershaft
(3rdgear is integralwith the mainshaft,while reversegear is integralwith the 4th
at
its cencountershaft
gears
locked
to
the
be
4th
can
clutchand gearsfor 3rd,2nd,4th, reverse,1st,and park.Reverseand
the
lst-hold
includes
The
sub-shaft
is
moved.
way
the
selector
which
ter, providing4th gear or reverse,dependingon
clutchand gearsfor lst and 4th.
Whencertaincombinations
and sub-shaft.
The gearson the mainshaftare in constantmeshwith thoseon the countershaft
to provideE, D!, tr, tr,
of gearsare engagedby the ctutches,power is transmittedfrom the mainshaftto the countershaft
('99
position
models)'
00
and E position('97 98 models).and E. E, E, and E
Electlonic Control
The electroniccontrot system consistsof the PowenrainControl Module (PCM),sensors,a linear solenoid,and four
controlledfor comfortabledrivingunderall conditions.The PCMis
solenoidvalves.Shiftingand lock-upare electronically
panel
side.
on the passenger's
locatedbelowthe dashboard,underthe kick
HydraulicControl
The valve bodiesincludethe main valve body, the secondaryvalve body, the regulatorvalve body, the servo body, and
the lock up valve body.They are boltedto the torque converterhousing.The main valvebody containsthe manualvalve,
the 1-2 shift valve,the 2nd orificecontrolvalve.the CPB{ClutchPressureBack-up)valve,the modulatorvalve,the servo
controlvalve.the reliefvalve,and ATF pump gears.The secondaryvalve body containsthe 2-3 shift valve,the 3-4 shift
valve,the 3,4 orificecontrolvalve.the 4th exhaustvalveand the CPC(ClutchPressureControl)valve.The regulatorvalve
bodv containsthe pressureregulatorvalve,the torque convertercheckvalve,the coolerreliefvalve,and the lock-upcontrol valve.The servo body containsthe servovalvewhich is integratedwith the reverseshift tork, and the accumulators
The lock-upvalve body containsthe lock-upshift valveand the lock-uptiming valve.The linearsolenoidand the shift control solenoidvalveAy'Bare boltedto the outsideof the transmissionhousing,and the lock-upcontrolsolenoidvalveAy'Bis
boltedto the outsideof the torque converterhousing.Fluid trom the regulatorpassesthrough the manualvalve to the
feed pipesor internalhydrauliccircuit
variouscontrolvalves.The clutchesreceivefluid from their respective
ShiftControl Mechanism
input from varioussensorslocatedthroughoutthe vehicledetermineswhich shift controlsolenoidvalvethe PCMwill actipressurizes
vate.Activatinga shift controlsolenoidvalvechangesmodulatorpressure,causinga shiftvalveto move.This
A
and B are
valves
gear.
solenoid
The
shift
control
a lineto one of the clutches.engagingthat clutchand its corresponding
controlledby the PCM.
Lock-up Mechanism
('97- 98
tn E! position(,97- 98 modets)and in E position('99 - O0models),in 3rd and 4th, and in Delpositionin 3rd
('99
pressurized
models),
00
(by
in
3rd
(O/D)
pressing
O/D
switchl
rhe
is OFF
models)and in El positionwith Over,Drive
fluid is drainedfrom the back of the torque converterthrough a fluid passage,causingthe lock-uppiston to be held
againstthe torque convertercover,As this takesplace,the mainshaftrotatesat the same speedas the enginecrankshaft.
Togetherwith hydrauliccontrol,the PcM optimizesthe timing of the lock-upmechanismThe lock-upvalvescontrolthe
range of lock-upaccordingto lock-upcontrol solenoidvalves A and B, and the linear solenoid.When lock-upcontrol
solenoidvalvesA and B activate,the modulatorpressurechanges.The lock-upcontrol solenoidvalvesA and B and the
linearsolenoidare controlledby the PCM.
{cont'd)

www.emanualpro.com

14-3

Description
GeneralOperation(cont'dl
Gsar Selection
'97 - 98 Models
The shift lever has sevenpositions;El PARK,ts REVERSE,
N NEUTRAL,Ell 1st through 4th ranges,lpq 1stth.ough 3rd
ranges,P 2nd gear,and [ 1stgear
'99 - 00 Models
,lst through
The shitt lever has six positions;El PARK,E REVERSE,
4th ranges,and 1st through 3rd
E NEUTRAL.E
(whenOver-Drive(O/D)is OFF)ranges.@ 2nd gear,and E 1stgear.
Position

Description

tll PARK
t!!l l|EvEn>E

Reverse;reverseselectorengagedwith countershaftreversegear and 4th clutch locked.

E NEUTRAL

Allclutches released.

('97- sB)
Ell DRrvE
('ss- oo)
E DRrvE
(1stthrough
4th)

Generaldriving;startsoff in 1st,shifts automaticallyto 2nd, 3rd, then 4th, dependingon vehiclespeed


and throftle position.Downshiftsthrough 3rd,2nd, and lst on decelerationto stop.
The lock-upmechanismoperates;n3rd and 4th gear.

E DRrvE
{'97- s8)
with overO DRTVE
Drive(O/D)
isOFF
('99- 00)

used for rapid ccelerationat highway speeds and general driving; stans off in 1st, shifts automaticallyto
2nd_then
3rd, dejending on vehiclespeedand throttleposition.Downshiftsthroughlower gearson decelerationto stop.The lock-upmechanismcomesinto operationin 3rd gear.

E SECOND

Driving in 2nd_gear;stays in 2nd gear,does not shift up and down. For engine brakingor bettertrac_
tion startingoff on loose or slipperysurfaces.

E FIRST

Driving in 1st gear;stays in 1st gear,does not shift up. For engine braking.

(1stthrough3rd)

Startingis possibleonly in @ and @ positions.usinga slide-type.neutral-safety


switch.
Automatic Transaxle(A/T) Gear Position Indicator
This indicatorin the instrumentpanelshowswhich gear has beenselected.
Transler Mochanism {4WD}
The transfermechanismconsistsof the transfershaftdrivegear.the transfershaft.the transferdrivegear,the transferdriven gear shaft,and the companionflange,The transfermechanismassemblyis on the rearside ot the transmission.
beside
the differential.
The transfershaftdrivegearon the final drivengeardrivesthe transfershaftdrivenqear.poweris transmitted to the reardifferentialvia the transfershaftand the Drooellershaft.
Clutches
The four-speedautomatictransmissionuses hydraulically-actuated
clutchesto engageor disengagethe transmissiongears.
When the hydraulicpressureis introducedinto the clutch drum, the clutch piston moves.This pressesthe friction discs and
steel platestogether,lockingthem so they don't slip. Power is then transmiftedthrough the engagedclutch pack to its hu$
mountedgear.When hydraulicpressureis bled from the clutchpack,the piston releasesthe friction discsand steelplates,and
they are free to slide pasteachother.This allowsthe gearto spin independentlyon its shaft,transmittingno power.
lst Clutch
The 1stclutchengages/disengages
lst gear,and is locatedat the end ofthe mainshaft,just behindthe end cover.
The 1stclutchis suppliedhydraulicpressureby its ATFfeed pipewithin the mainshaft.
lst-hold Clutch
The 1st-holdclutchengages/disengages
1st-holdor E position,and is locatedat the middleof the sub-shaft.The 1st-hold
clutchis suppliedhydraulicpressureby its ATF feed pipewithin the sub-shaft.
2nd Clutch
The znd ciutchengages/disengages
2nd gear,and is locatedat the middleof the mainshaft.The 2nd clutchis joined backto-backto the 4th clutch.The 2nd clutchis suppliedhydraulicpressurethroughthe mainshaftby a circuitconnectedto the
internalhydrauliccircuit.

14-4

www.emanualpro.com

3rd Clutch
oppositethe end cover.The 3rd
3rd gear,and is locatedat the end of the countershaft,
The 3rd clutchengages/disengages
clutchis suppliedhydraulicpressureby its ATFfeed pipewithin the countershaft.
ilth Clutch
4th gear,as well as reversegear,and is locatedat the middleof the mainshaft.The 4th
The 4th clutchengages/disengages
joined
clutch.The 4th clutchis suppliedhydraulicpressureby its ATFfeed pipewithin the
to
the
2nd
back-to-back
clutchis
mainshaft.
One-way Clutch
The one-wayclutchis positionedbetweenthe parkgear and the countershaft1stgear,with the parkgear splinedto the countershaft.The countershaft1st gear providesthe outer race surface,and the park gear providesthe inner racesurface The
one,way clutch locks up when power is transmittedfrom the mainshaftlst gear to the countershaft1st gear. The 1st
pt, E, or E position The one-way
clutchand gearsremainengagedin the 1st,2nd, 3rd, and 4th gear rangesin the lo],
in
the
or E position'
applied
are
[d,
E,
or
4th
clutches/gears
lor,
clutchdisengageswhen the 2nd, 3rd,
the locking"speedrange" of the
gears
over-ride
on
the
countershaft
of
the
rotational
speed
increased
because
the
This is
one-wavclutch.The one-wavclutchfree-wheelswhen the lst clutchis engaged
2NOCLUTCH

lST.HOLD
CLUTCH

4TH CLUTCH

1STCLUTCH

MAINSHAFT
3RDCLUTCH

COUNTERSHAFT

TRANSFER
SHAFTDRIVE
GEAR
ONE.WAYCLUTCH
TRANSFER
ASSEMBLY

OUTSIDEOF ONE.WAY
CLUTCH
INSIDEOF ONE.WAY
CLUTCH
Splined with countershaft

N O T E :T h e i l l u s t r a t i o ns h o w s t h e 4 W D
a u t o m a t i ct r a n s m i s s i o n{ s e c t i o n avl i e w )
t h e 2 W D t r a n s m i s s i o nd o e s n o t h a v e a
transferassemblyand transfershaft drive
gear on the differentialassembly.
www.emanualpro.com

LOCKINGCONDITION

The sprags engage/


disengage outside
and inside of the

OVER.RIOING
LOCKINGSPEEDCONOITION

14-5,

Description
PowerFlow

*N
E
E
N
1ST

Fi

2ND

or

3RD

4TH

tr

TOROUE

1ST.

1STGEAR 2ND GEAR 3RDGEAR

4TH
REVERSE PARK
coNHOLD
1ST
2ND
3RD
GEAR
VERTER CLUTCH CLUTCH CLUTCH CLUTCH GEAR CLUTCH

o
o
o
o
o
o
o

o*,
o*,

o
o

o*1

o*1

'tsT

o"

2ND
OverDrive
(o/D) 3RD
is OFF

o*1

o*r

o
o

o*r

or

tr
tr

o
o
o

O: Operates,
x: Doesn'toperate.
* 1:Althoughthe 1stclutchengages,drivingpower
is not transmittedas the one_wayclutchslips.
*2: The one-wayclutchengageswhen accelerating.
and slipswhen deceleraung.
NOTE:p! and Ipj positionsare on the '97 - '98 models;El positionis on the ,99- OOmodels.

14-6

www.emanualpro.com

E Po3ition
Hydraulicpressureis not appliedto the clutches.Poweris not transmittedto the countershaft.
The countershaft
is lockedby the parkpawl interlockingthe parkgear,
E Position
Enginepower transmittedfrom the torque converterdrivesthe mainshaft.but hydraulicpressureis not appliedto the
The countershaft4th gear is engagedwith the reverseselectorhub
clutches.Poweris not transmittedto the countershaft.
and the countershaftby the reverseselector,when the shift lever is shiftedin E positionfrom E or E position.The
countershaftreversegear is engagedwhen shiftedfrom E position.
NOTE;The illustrationshows the 4WD automatictransmission;oower flow of the 2WD automatictransmissionis identical to the 4WD exceDtfor oarts relatedto the transfer assemblv.

PARKGEAR

SELECTOR

COUNTERSHAFT
REVEBSEGEAR

(cont'd)

www.emanualpro.com

14-7

Description
Power Flow (cont'dl
E Position
In E position,hydraulicpressureis appliedto the lst clutchand the lst-holdclutch.
The powerflow when accelerating
is as follows:
1. Hydraulicpressureis appliedto the lst clutchon the mainshaft,and power is transmittedvia the 1stclutchto the mainshaft 1stgear.
Hydraulicpressureis also appliedto the lst-hold clutchon the sub-shaft.Powertransmittedto the mainshaft1st gear
is conveyedvia the countershaft1st gear to the one-wayclutch,and via the sub-shaft1st gear to the 1st-holdclutch.
The one-wayclutchis usedto drivethe countershaft,
and the 1st-holdclutchdrivesthe countershaft
via the 4th gears.
Poweris transmittedto the final drive gear,which drivesthe final drivengear,and the transfershaftdrive gear (4WD),
4. The transfershaftdrive geardrivesthe transfershaftand the transferdrivengearshaft(4WD).

NOTE;The illustrationshowsthe 4WDautomatictransmissjon;


powerflow ot the 2WDautomatictransmissionis identical to the 4WDexceptfor partsrelatedto the transferassembly.
TOROUE
CONVERTER

SUB.SHAFT4TH GEAR

SU8-SHAFT1STGEAR

lST.HOLDCLUTCH
SUB.SHAFT

1STGEAR

lST CLUTCH

COUNTERSHAFT

ONE.WAYCLUTCH
FINALDRIVE
GEAR
PARKGEAB

COUNTERSHAFT
4TH GEAR
FINALDRIVENGEAR
TRANSFERSHAFTORIVEGEAR{4WD}
TRANSFERSHAFT{4WD}

14-8

www.emanualpro.com

TRANSFERDRIVENGEARSHAFT{4WD)

E Position
is as follows:
The powerflow when decelerating
trom the road surfacegoesthroughthe tront wheels(and rearwheels:4WD)to the final drive gear.
L Rollingresistance
then to the sub-shaftlst gearvia the 4th gear.and 1st-holdclutchwhich is appliedduringdeceleration.
2 . The one-wayclutchis free becausethe applicationof torque is reversed.
J.

The counterforceconveyedto the countershaft4th gear turns the sub-shaft4th gear via the mainshaft4th gear.Since
hydraulicpressureis also appliedto the 1st clutch.counterforceis also transmittedto the mainshaft.As a result,
enginebrakingcan be obtainedwith'lst gear.
powerflow of the 2WDautomatictransmissionis identiNOTE:The illustrationshowsthe 4WDautomatictransmission;
cal to the 4WD excepttor parts relatedto the transfer assembly.
lST.HOLDCLUTCH
SUB.SHAFT1STGEAR
TOROUECONVERTER

SUB.SHAFT
{TH GEAR
MAINSHAFT
lST GEAR

lST CLUTCH
MAINSHAFT

COUNTERSHAFT

FINALDRIVEGEAR
HUB
SELECTOR
REVERSE

SELECTOR
REVERSE
COUNTERSHAFT
IITHGEAR
FINALORIVENGEAR
TRANSFERSHAFTDRIVEGEAR{4WDI
TRANSFEBSHAFT{{WD)

{cont'd}

TRANSFERDRIVENGEARSHAFT{,lWDl
www.emanualpro.com

14-9

Description
PowerFlow lcont'd)
lst Gear(8. E or E positionl
In E, E, or D position,
the optimumgearis selected
from 1st,2nd,3rd,and4thgears,according
to conditions
suchas
the balancebetweenthrottle opening (engineload) and vehicle speed.
1. Hydraulicpressureis appliedto the 1st clutch,which rotatestogetherwith the mainshaft,and the mainshaft1st gear
rotates.
2. Poweris transmittedto the countershaft1stgear.which drivesthe countershaft
via the one-wayclutch.
3. Poweris transmittedto the final drive gear.whichdrivesthe final drivengearand the transfershaftdrive gear (4WD).
4. The transfershaftdrive geardrivesthe transfershaftand the transferdrivengearshaft(4WD).
NOTE:
o In @, @, @, or E position.hydraulicpressureis not appliedto the 1st-holdclutch.
. The illustrationshowsthe 4WD automatictransmission;power flow of the 2WD automatictransmissionis identical
to the 4WD exceptfor parts relatedto the transfer assembly.
CONVERTER

MAIiISHAFT
1ST

CLUTCH

MAINSHAFT

COUNTERSHAFT
FINALOBIVEGEAR
ONE.WAYCLUTCH

PARKGEAR

FINALDRIVENGEAR
TRANSFERSHAFTDRIVEGEAR{4WD}

14-10

www.emanualpro.com

2nd cesr (8, E. E, or E positionl


1. Hydraulicpressureis appliedto the 2nd clutch,which rotatestogetherwith the mainshaft,and the mainshaft2nd gear
rotales.
2. Power is transmitted to the countershaft2nd gear, which drives the countershaft
3. power is transmittedto the final drive gear,which drivesthefinald rivengearand the transfershaftdrive gear (4WD)
4. The transfershaftdrive gear drivesthe transfershaftand the transferdrivengearshaft(4WD).
NOTE:
. Hvdraulicpressureis also appliedto the 1stclutch,but sincethe rotationspeedof 2nd gear exceedsthat of lst gear.
powerfrom 1stgear is cut off at the one-wayclutch.
. The illustrationshowsthe 4WD automatictransmission;power flow of the 2WD automatictransmissionis identical
to the 4WD exceptfor parts relatedto the transfer assembly.
CLUICH

TOROUE

COUNTERSHAFT

FINALORIVEGEAR

2NO GEAR

FINALDRIVENGEAF
TRANSFERSHAFTDBIVEGEAR{4WD}
TRANSFERSHAFT{4WDI

(cont'd)

TMNSFER DRIVENGEARSHAFT(4WD)
www.emanualpro.com

14-11

Description
PowerFlow (cont'd)
3rd Gear {8. @, or @ position)
1. Hydraulicpressureis appliedto the 3rd clutch.Powerfrom the mainshaft3rd gear is transmittedto the countershaft
3rd gear.
2. Poweris transmiftedto the final d rive gear,wh ich d rivesthe f inal drivengearand the transfershaftdrive gear(4WD).
3, The transfershaftdrive geardrivesthe transtershaftand the transferdrivengearshaft (4WD).
NOTE:
. Hydraulicpressureis also appliedto the 1stclutch,but sincethe rotationspeedof 3rd gear exceedsthat of 1stgear,
powerfrom lst gear is cut off at the one-wayclutch.
. The illustrationshowsthe 4WD automatictransmission;Dowerflow of the 2WD automatictransmissionis identical
to the 4WDexceptfor partsrelatedto the transferassembly.
CONVERTEF
MAINSHAFT3RDGEAR

COUNTERSHAFT

COUNTERSHAFT
3ROGEAR
3RDCLUTCH
DRIVENGEAR
SHAFTDRIVEGEAR(4WO)
TRANSFERSHAFT(,lwDl
TRANSFERORIVENGEANSHAFT(4WD)

14-12

www.emanualpro.com

4th Goar (E or D positionl


1. Hydraulicpressureis appliedto the 4th clutch,which rotatestogetherwith the mainshaft,and the mainshaft4th gear
rotates,
2. Poweris transmittedto the countershaft4th gear,which drivesthe countershaft.
3. Poweris transmiftedto the f inal d rive gear,which drivesthe finaI drivengearand the transfershaftdrive gear (4WD).
4. The transfershaftdrive gear drivesthe transfershaftand the transferdrivengearshaft {4WD).
NOTE:
. Hydraulicpressureis also appliedto the 1stclutch,but sincethe rotationspeedof 4th gear exceedsthat of 1stgear,
powerfrom 1stgear is cut off at the one-wayclutch,
. The illustrationshowsthe 4WOautomatictransmission;power flow of the 2WD automatictransmissionis identical
to the 4WD except for parts relatedto the transfer assembly.
ilTH GEAR

TOROUE
CONVERTER
.TH CLUTCH

COU'{TERSHAFT

HUB
SELECTOR
REVERSE

REVERSE
SELECTOR

FINALDRIVENGEAR
TRANSFEBSHAFT DRIVEGEAB I'WD)
TNANSFERSHAFTI4WDI

{cont'd)

TMNSFER DRIVENGEARSHAFT(4WDI
www.emanualpro.com

14-13

Description
PowerFlow (cont'dl
E position
1. Hydraulicpressureis switched by the manual valve to the servo valve, which movss the reverseshift fork to the
reverseposition,The reverseshift fork engageswith the reverseselector,the reverseselectorhub, and the countershaft reversegear.
2. Hydraulicpressureis also appliedto the 4th clutch. Power is transmittedfrom the mainshaftreversegear via the
reverseidler gear to the countershaftreversegear.
3. Rotationaldirectionofthe countershaftreversegear ischangedviathe reverseidlergear.
4. Poweris transmittedto the final drivegear,whichdrivesthefinald rivengear and the transfershaftdrive gesr (4WD).
5. The transfershaftdrive geardrivesthe transfershaftand the transferdrivengearshaft (4WD).
NOTE:The illustrationshows the 4WD automatic.transmission;
power flow of the 2wD automatictransmissionis identical
to the 4WD exceptfor partsrelatedto the transferassembly.
REVERSE
MAINSHAFT

TOROUECONVERTER

COUNTERSHAFT
REVERSE
IDLER
GEAR

FINALORIVE

COUNTERSHAFT
REVERSE
GEAR

REVERSESEITCTOR
HUB
REVERSESELECTOR
FINALOBIVENGEAR

REVEBSC
SHIFT
FORK

TRANSFERSHAFTDRIVEGEAR
{4WD)
TRANSFERSHAFT{4WD)
TRANSFERDRIVENGEARSHAFTI4WD}

14-14

www.emanualpro.com

SERVOVAI-VE

ElectronicControlSystem
The electroniccontrolsvstemconsistsof a PowertrainControlModule(PCM),sensors,a linearsolenoid,and four solenoid
valves.Shiftingand lock-upare electronically
controlledfor comfortabledriving under all conditions.The PCMis located
side.
belowthe dashboard,underthe kickpanelon the passenger's
'97 - 98 Modls

Throttl Poshion Sensor


Signal

VehicleSp.ed Sensor
Signal
PGM.FI
Control Sy3t6m

EnginoCoolantTampereture
SonsorSignrl

ServiceCheckconnector

A/T Control Sy3tem


INTERLOCK
CONTROLUNIT

Shift Control
Solenoidvalve A

Shift Cont.ol

Shift Control
SolenoidValve B

N
Linear Solenoid

Dr
Ds
Lock-upControl

Lock-upConirol
Sol6noidvalvo B

M.inshaft SpoedSensor
Signel

-D! Indicator Light

Selt-Oiagnosbsignel

Lock-upControl
SolenoidValve A

Il -

Sell-Diagnosis
Function

CountrahaftSpeed
sensorSignel

{cont'd)

www.emanualpro.com

14-15

Description
ElectronicGontrolSystem(cont'd)
'99 - 00 Models

PCM
Throttle Position Sensor
Signel

VehicleSpeedSensor
Signal
PGM.FI
Control System

EnginCoolsnt Tomperature
Sen30rSignal

Service Chck Connectol

A/T Control Svstem


INTERLOCK
CONTROLUNIT

Shift Conlrol
SolenoidValve A

Shift Control

Shift Control
SolenoidValve B

N
Linear Solenoid

D
2
Lock-upControl

Lock-upControl
SolenoidValve B

Over-Drive
Switch Signal

Mainshaft SpeedSensor
Signal

E Indicator Light

Selt-OiagnosisSignd

Lock-upControl
Solenoidvalve A

Self-Diagnosis
Func{ion

CountershaftSpeed
SensorSigntl

O/D OFF
Indicetor Light

14-16

www.emanualpro.com

Shift Control
The PCMdetermineswhich gear should be selectedby varioussignalssent from sensors,and actuatesthe shift control
solenoidvalvesA and B to controlshifting.Also.a GradeLogicControlSystemhas beenadoptedto controlshiftingin E
anOE ('gZ- gg),and E ('99- 00) positionwhile the vehicleis ascendingor descendinga slope,or reducingspeeo.
Position

E, E, Or

E
E orE

tr

Gear

Shift Control Solenoid


Valve A

Shift Control Solonoid


Valve B

'Ist

OFF

ON

2nd

ON

ON

3rd

ON

OFF

4th

OFF

OFF

2nd

ON

ON

1st

OFF

ON

Reverse
ON
E*See page 14-37for reverseinhibitorcontroldescription.

OFF

Lock-upControl
From sensor input signals,the PCM determineswhether to turn the lock-upON or OFF,and activateslock-upcontrol
solenoidvalveA and/orB accordingly.Lock-updoes not occur until the engineis warm. The combinationof driving signalsto lock-upcontrolsolenoidvalvesA and B and the linearsolenoidpressureis shown in the table below.
Lock-upControl
Solonoid Valve A

Lock-upControl
Solenoid Valve B

LinearSolenoid
Pressuro

LOCK-Up
\Jrr

OFF

OFF

High

Lock-up,Half

ON

Dutyoperation
OFF- ON

Lock-up,Full

ON

ON

Hish

Lock-up
duringdeceleration

ON

Dutyoperation
OFF- ON

Low

Lock-upConditions

(cont'd)

www.emanualpro.com

14-17

Description
ElectronicControlSystem(cont'dl
Grade Logic Control System
How it works:
The PCMcomparesactualdrivingconditionswith memorizeddrivingconditions,basedon the inputfrom the vehiclespeed
sensor,the throttlepositionsensor,the barometricpressuresensor('98model).the enginecoolanttemperaturesensor,the
brakeswitch signal,and the shift lever positionsignal,to controlshiftingwhile the vehicleis ascendingor descendinga
slope,or reducingspeed.

SIGNALSDETECTED

Judgemont ot Controlling Aroa


Driving Rcsisl.nce

.
.
.
.

14-14

www.emanualpro.com

Normal Modo {Flrt ro.d mode}


AscendingMode
DeacendingMode
DecelerationMode

AscendingControl {37 Modol}


When the PCMdeterminesthat the vehicleis climbinga hill in E] and E positions,the systemextendsthe engagement
area of 2nd gar and 3rd gear to preventthe transmissionfrom frequentlyshifting between2nd and 3rd gears,and
between 3rd and 4th gears,so the vehicle can run smooth and have more power when needed.
NOTE:
. Shift schedulesstored in ths PCM between 2nd and 3rd gears, and between 3rd and 4th gears. enable the PCM'sfuzzy
logicto automaticallyselectthe most suitablegearaccordingto the magnitudeof 8 gradient.
t Fuzzylogic is a form of artificialintslligencethat lets computersrespondto changingconditionsmuch like a human
mind would.
2ND- 3RD

ASCENoINGMODE:UFhift Sch.dulc

3RD - tlTH

. FLATROADMODE

-----------. : GRADUAL
ASCENDING
MODE
o 5 l )

- - - - - : STEEPASCENDING
MODE
SHIFTINGCHARACTERISTICS
FN1NS : 2ND-3RD
CONTROLAREA

SHIFTINGCHARACTER|SnCS
7,.,.7a | 3RD-aTH
CONTROLAREA

62 mph
1100km/h)

Vehicle .o..d

AscondingConirol ('98 - 00 Mod.ls)


When the PCMdeterminesthat the vohicleis climbinga hill in E] and E positions('98 model),and in E] position('9900 models),the system extendsthe engagementsrea of 2nd gear and 3rd gear to prevent the transmissionfrom frequently shifting between 2nd and 3rd gears, and between 3rd and 4th gears, so the vehicle can run smooth and have more
power when needed.
NOTE: Shift schedulssstored in the PCM between2nd and 3rd gears, and between3rd and 4th gears,enable to selsct the
most suitablegear accordingto th6 magnitudeof a gradint.
2ND + 3RD 3RD+ 4TH

ASCENDINGMODE:Up.hift Sch.dul.

8 5 0
: 2ND-3RDSXImNG CHARACTERISTICS
GoNTRoLAREA
VVVVVZ:IRD-ITHSHIFnNGCHARACTERISTICS
cot{TRoL AREA
NN
-

6:l mph
11fl)km/hl

Vahicl. sDctd

(cont'd)

www.emanualpro.com

14-19

Description
ElectronicControlSystem(cont'd)
DescendingControl
When the PCMdeterminesthat the vehicleis going down a hill in E and @ positions('97- 98 models).and in @ position {'99 - 00 models),the shitt-upspeedfrom 3rd to 4th gear and from 2nd to 3rd (whenthe throttleis closed)becomes
fasterthan the set speedfor flat road drivingto widen the 3rd gear and 2nd gear drivingareas.This, in combinationwith
engine brakingfrom the decelerationlock-up,achievessmooth drivingwhen the vehicleis descending.Thereare three
descendingmodeswith different3rd gear drivingareasand 2nd geardrivingareasaccordingto the magnitudeof a gradient storedin the PCM.When the vehicleis in 4th gear,and you are decelerating
when you are applyingthe brakeson a
steep hill, the transmissionwill downshiftto 3rd gear,When you accelerate,
the transmissionwill then returnto higher
gear.
2ND - 3RD

3RD- 4TH

DESCENDING
MODE:Downshift Schodule

: FLATROADMODE

----'-----' I GRADUALDESCENDING
MODE
o 5 0

- - - - - : MEDIUMOESCNOING
MODE
.

62mph
km/hl
1100

... : STEEPDESCENDING
MODE

Vehiclesped

DecelerationControl
When the vehiclegoes arounda corner,and needsto deceleratefirst and then accelerate,
the PCMsetsthe datafor deceleration
control to reducethe number of times the transmissionshifts.When the vehicle is deceleratingfrom speedsabove 27 mph
(4i| km,ih),the PCMshiftsthe transmissionfrom 4th to 2nd earlierthan normalto cope with upcomingacceleration,

14-20

www.emanualpro.com

CircuitDiagramand TerminalLocationsr9TModel
IGNITIONSWITCH

LOC( UPCONTROL

LOCK UPCONTROL
B
SOLEITOIDVALVE

sf Frc0|lltF0L
SOLENOIDVALVE
A

sHrFr
c0r{TnoL

VALVEB
SOLEI{OID

UNEASSOLINOID

www.emanualpro.com

14-21

Description
ElectronicControl System (cont'd)
CircuitDiagramand TerminalLocationsrgS
Model

GNTIONSWITCN

LOCK-UPCONIFOL
SOLEIIO
D VALVEA

LOCK-UPCONTSOL
SOLEI.IO
0 vALvEB

SBIFICONTROL
A
SOLEIDVALVE

SHFTCONTFOL
SOLEiDIDVALVE8

LINAASOLiDID
GNIION
SWTCH
tGr

14-22

www.emanualpro.com

Circuil Diagram and Terminal Locations-'gg- 00 Models

GN'IONSWITCN

pG2

LOC(UPC,ONTROL
SOLEIDD VALVEA

IGPI
IGP2

vcc2

LOCK.UPCON'IFO!
SOLENOIOVALVE
B

SNIFTCONTAOT
VALVEA
SOLNOID

SH]FTCONTROL

vArvE
B
solEtiroro

L NEAFSOLEI{OIO

rGNloNSWrlCH
GI

PCM Connclor Tehrial Loaabm

www.emanualpro.com

14-23

Description
HydraulicControl
The hydrauliccontrolsystemis controlledby the ATF pump,valves,accumulators,
and electronically
controlledsolenoids.
The ATF pump is driven by splineson the end of the torqueconverterwhich is aftachedto the engine.Fluidfrom the ATF
pump flows throughthe regulatorvalveto maintainspecifiedpressure,throughthe main valve body,to the manualvalve,
directingpressureto each clutch.The valve body includesthe main valve body, the regulatorvalve body, the lock-up
valve body,the secondaryvalve body,the servo body,the linearsolenoid,the shift controlsolenoidvalveAy'Bassembly,
a n d t h e l o c k - u pc o n t r o ls o l e n o i dv a l v e A / B a s s e m b l yT. h e s h i f t c o n t r o ls o l e n o i dv a l v eA , / Ba s s e m b l ya n d t h e l i n e a r
solenoidare boltedon the outsideof the transmissionhousing.The lock-upcontrolsolenoidvalveA,/Bassemblyis bolted
on the outsideof the torqueconverterhousing.
SHIFTCONTROL
SOLENOIDVALVEA/B
ASSEMBLY

LINEAR

REGULATOR
VALVEBOOY

VALVE
SECONDARY
BODY

VALVEBODY

SOLENOIDVALVEA/B
ASSEMELY

14-24

www.emanualpro.com

ATF PUMPGEARS

Main Valve Sody


The main valve body housesthe manualvalve,the 1-2shift valve.the 2nd orificecontrolvalve.the CPBvalve,the modulator valve.the servo controlvalve.and the reliefvalve.The primaryfunctionsof the main valve body are to switchfluid
pressureon and off, and to controlthe hydraulicpressuregoing to the hydrauliccontrolsystem.
CP8 VALVE

2ND ORIFICE
CONTROL
VALVE

MODULATORVALVE
1-2 SHIFTVALVE

RELIEFVALVE

MANUAL VALVE

MAIN VALVE
BOOY

SERVOCONTROIVALVE

Secondaryvalve Body
The secondaryvalve body is locatedon the main valvebody,The secondaryvalvebody housesthe 2-3 shift valve,the 3-4
shiftvalve,the 3-4 orificecontrolvalve,the 4th exhaustvalve,and the CPCvalve'
3.' SHIFTVALVE

2.3 SHIFTVALVE

.TH EXHAUSTVALVE

CPCVAL

3naORIFICECONTROL
VALVE

VALVE

(cont'd)

www.emanualpro.com

14-25

Description
HydraulicControl(cont'd)
RegulatorValve Body
The regulatorvalve body is locatedon the main valve body.The regulatorvalve body consistsof the regulatorvatve,the
torqueconvertercheckvalve.the coolerreliefvalve,and the lock-upcontrolvalve.

COOLERRELIEFVALVE

Lock-upValve Body
The lock-upvalvebody,with lock-upshift valveand lock-uptiming valve,is locatedon the regulatorvalvebody.

LOCK.UPSHIFTVALVE

NMINGVALVE

14-26

www.emanualpro.com

RegulatorValve
The regulatorvalve maintainsconstanthydraulicpressurefrom the ATF pump to the hydraullccontrolsystem,while also
furnishingfluid to the lubricatingsystemand torque converter.Fluid from the ATF pump flows through B and B'. Fluid
enteringfrom B flows throughthe valveorificeto the A cavity.This pressureof the A cavitypushesthe regulatorvalveto
the right side. and this movementof the regulatorvalve uncoversthe fluid port to the torque converterand the relief
valve. The fluid flows out to the torque converterand the relief valve, and the regulatorvalve moves to the left side.
Accordingto the levelof the hydraulicpressurethrough B, the positionof the regulatorvalvechangesand the amountof
fluid from B,throughthe torqueconverteralsochanges.This operationis continued,maintainingthe line pressure.
"|eft" or "right" indicatesdirectionon the illustrationbelow.
NOTE;When used,
ENGINERUNNING

ENGINENOT RUNNING

To TOROUECONVERTER Lubtication
STATORSHAFTABM

Stator ReactionHydraulic PressursControl


in hydraulicpressureaccordingto torqueare performedby the regulatorvalve usingstatortorque reaction.The
Increases
statorshaft is splinedto the stator in the torque converter,and its arm end contactsthe regulatorspring cap When the
or climbing(TorqueConverterRange),statortorque reactionactson the statorshaft,and the stator
vehicleis accelerating
pushes
springcap in the directionof the arrow in proportionto the reaction.The statorreactionspring
regulator
the
arm
and the regulatorvalve movesto increasethe line pressure.Line pressurereachesits maximum when the
compresses,
statortorque reactionreachesits maximum.
TOROUECONVERTER
VALVE
REGULATON

STATORREACTION

TOR SPRINGCAP

STATON

www.emanualpro.com

STA

SHAFT

ATOF SHAFTARM

(cont'd)

14-27

Description
HydraulicControl(cont'd)
Servo Body
The servo body is locatedon the secondaryvalve body.The servobody containsthe servovalve(whichis integratedwith
the reverseshiftfork),and the accumulators.

2ND ACCUMULATOR

3RDSUB
ACCUMULATOR

SERVOBODY

1STACCUMULATOR

SERVOVALVE/SHIFT
FORKSHAFT

14-28

www.emanualpro.com

HydraulicFlow
GeneralChart of Hydraulic Pressure
RegulatorValve -a
ATFpump -

ModulatorPressureClutchPressure
ToroueConverterPressure
Pressure
LUbrication
LinePressure

|
LL

5
-

LinearSolenoid

Distribution ol Hydraulic Pressure


. RegulatorValve
-"- TorqueConverterPressure
LLubricationPressure
I
To regulateLinePressure
.

ManualValve

To selectLinePressure -

ModulatorValve

ModulatorPressure --

.
.
.

--1-2ShiftValve
2-3 ShiftValve -t-I
3-4 Shift Valve

ClutchPressure

't'
2
3
3'
3"

MODULATE
(SHIFT
SOLENOIO
CONTROL
MODULATE
VALVEA)
(SHIFT
SOLENOID
CONTROL
MODULATE
VALVEB)
(LOCK.UP
SOLENOID
CONTROL
IVODULATE
VALVEA)
(LOCK-UP
SOLENOID
CONTROL
MODUTATE
VALVEB)
(LOCK-UP
SOLENOID
CONTROL
MODULATE
VALVEB)

91

92

TOROUECONVERTER

93

ATF COOLER

94

TOROUECONVERTER

95

LUBRICATION

LIN E

97

LINE/CPC
LINE
1STCLUTCH

99

LINE
LINE
LINE
LINE
LINE
LINE
LINE
LINE
LINE
LINE

6D'
7

8
I
10

PORTNO,
15

17
18
20
20A
30
40
41

90

5
6A

---- ShiftControlSolenoidValves
Lock-upControlSolenoidvalves
fL
LinearSolenoid

OFPRESSURE
DESCRIPTION
CLUTCH
lST-HOLD
CLUTCH
1ST-HOLD
CLUTCH
1ST-HOLD
1ST-HOLDCLUTCH
2ND CLUTCH
2ND ACCUMULATOR
3RDCLUTCH
4TH CLUTCH
4THCLUTCH
SOLENOID
LINEAR
TOROUECONVERTER
TOROUECONVERTER

OFPRESSURE
DESCRIPTION

PORTNO,
1

ClutchPressure

TOROUECONVERTER

TOROUECONVERTER
SUCTION
DRAIN

HIX

HIGHPOSITIONDRAIN

{cont'd)

www.emanualpro.com

14-29

Description
HydraulicFlow (cont'dl
lll Position
As the engine turns, the ATF pump starts to operate.Automatictransmissionfluid (ATF)is drawn from (99) and dischargedinto (1).Then,ATF flowing from the ATF pump becomesline pressure('l). Line pressure(1) js regulatedby the
regulatorvalve.Torqueconverterinlet pressure{92)enters(94)of the torqueconveTter
throughthe lock-upshift valveand
dischargesinto (90) The torque convertercheckvalve preventstorque converterpressurefrom rising.Underthis condition, hydraulicpressureis not appliedto the clutches.
NOTE;
. When used."|eft" o. "right" indicatesdirectionon the hvdrauliccircutt.
. The hydrauliccircuitshowsthe '97 - 98 models{7 positions};the '99 - 00 models(6 positions)is similar.

'lF'.j.l

14-30

www.emanualpro.com

B Position
pressure(1) changesto line pressure(4) and
Line pressure{1) flows to the manualvalve and the modulatorvalve,Line
pressure
at the modulatorvalve Modulatorpres1st-holdclutchpressureat the manualvalve,and changesto modulator
shift
controlsolenoidvalveA is turned oFF
because
sure {6)flows to the left ends of the 1-2shift valve and 3-4 shift valve
Line pressure(4) becomes1st clutch
side.
right
to
the
moved
are
by the PcM. The 1-2 shift valve and the 3-4 shift valve
1st clutchis engaged lstpressure(10)at the 1-2 shift valve.1st clutchpressure(10)is appliedto the 1st clutch,and the
Poweris transmitted
valve
shift
1-2
hold clutchpressure(18)flows to the lst-hol; clutchvia the 3-4 shift valve and the
throughthe 1st-holdclutch.
only duringdeceleration
NOTE:
"right" indicatesdirectionon the hydrauliccircuit'
. When used,"left" or
'99 - O0models(6 positions)is similar'
. The hvdrauliccircuitshowsthe'97 - 98 models(7 positions);the

(cont'd)

www.emanualpro.com

14-31

Description
HydraulicFlow (cont'dl
l?JPosition
Line pressure{1) flows to the manualvalve and the modulatorvalve.Line pressure(1} changesto line pressure(4) at the
manualvalve,and changesto modulatorpressureat the modulatorvalve.But modulatorpressure{6} does not flow to
eachshift valvebecauseshift controlsolenoidvalvesA and B are turnedON by the PCM.Linepressure(4) passesthrough
the CPBvalveand the CPCvalve,and changesto line pressure(5),then flows to the 'l-2shift valve.Line pressure(5)from
the 1-2shift valvechangesto 2nd clutchpressure(20)at the 2-3 shift valve.The 2nd clutchpressure(20)is appliedto the
2nd clutch,and the 2nd clutchis engaged,Line pressure(4)passesthroughthe 1-2shiftvalveand the orifice,and changes
to lst clutchpressure.The 1stclutchpressure{10)also flows to the 1stclutch.However,no power is transmittedbecause
of the one-wayclutch.
NOTE:
. When used,"left" or "right" indicatesdirectionon the hvdrauliccircuit.
. The hydrauliccircuitshowsthe '97 - 98 models(7 positions);the '99 - OOmodels(6 positions)issimilar.

14-32

www.emanualpro.com

E] or E Position ('97 - 98 Models), and D Position ('99 - 00 Modelsl


1.

lst Gear
Fluidflow throughthe torque convertercircuitis the same as in E] position.Line pressureflows to the manualvalve
pressure
and the modulatorvalve.Line pressurechangesto modulatorpressure(6) at the modulatorvalveand to line
3-4
shift
valve
and
the
1-2
shift
valve
(6)
of
the
left
end
pressure
flows
to
the
{4) at the manual valve. Modulator
is
moved
to
valve
The
1-2
shift
PcM.
oN
by
the
B
is
turned
and
is
turned
oFF
valve
A
solenoid
becauseshift control
'lst clutchpressure(10}at the 1-2shift valveand the orifice The 1stclutch
the right side.Line pressure{4)changesto
the vehiclewill move as the enginepower is transpressure(10)is appliedto the 1stclutchand the 1st accumulator;
mitted.
NOTE:
. When used,"left" or "right" indicatesdirectionon the hydrauliccircuit.
'97 - 98 models(7 positions);
the '99 - 00 models{6 positions)issimilar.
. The hvdraulic circuitshowsth e

(cont'dl

www.emanualpro.com

14-33

Description
HydraulicFlow (cont'dl
2nd Gsar
As the speed of the vehiclereachesthe prescribedvalue.shift control solenoidvalve A is turned ON by the pCM.
Modulatorpressure(6A) in the left end of the 1-2shift valveis releasedby turning shift controlsolenoidvalveA ON.
The 1-2shift valve is movedto the left side and uncoversthe port to allow line pressure(5)to the 2-3 shift vatve.Line
pressure(5) changesto 2nd clutch pressure(20)at the 2-3 shift valve,The 2nd clutch pressure
{20)is applidto the
2nd clutch.and the 2nd clutchis engaged.
Fluidflows by way of:
- LinePressure(4)+ CPBValve- Line Pressure(5)* 1-2ShiftValveLinepressure(S)* 2-3 ShiftValve
- 2nd ClutchPressure(20)- 2nd Clutch
The hydraulicpressurealsoflows to the lst clutch.However,no power is transmittedbecauseof the one-wav
ctutch.
NOTE:
. When used,"|eft" or "right" indicatesdirectionon the hydrauliccircurr_
' The hydrauliccircuitshowsthe'97 - 98 models(7 positions);the '99 - 00 models(6 positions)
is similar,

14-34

www.emanualpro.com

3.

3rd Gear
As the speedof the vehiclereachesthe prescribedvalue.shift control solenoidvalve B is turned OFF by the PCM.
Shift controlsolenoidvalveA remainsON. Modulatorpressure(6)flows to the right end of the 1-2shift valveand the
(68) The 2-3 shift
left end of the 2-3 shift valve.The 2-3 shift valve is movedto the right side by modulatorpressure
2-3 shift valve
as
the
(5)
shift
valve
the
3-4
and
uncovers
prsssure
2nd
clutch.
to
the
valvecoversthe port to stop line
(30)
The
3rd clutch
valve.
pressure
3-4
shift
(5)
at
the
pressure
3rd
clutch
becomes
side,
Line
is moved to the right
pressure(30)is appliedto the 3rd clutch,and the 3rd clutchis engaged.
Fluidflows by way of:
- Line pressure(4)- CPBValve- LinePressure(5)* 1-2Shift Vaiv- LinePressure(5)* 2-3 ShiftValve
- Line Pressure(5)* 3-4 ShiftValve- 3rd ClutchPressure(30)* 3rd Clutch
The hvdraulicDressurealsoflows to the 1stclutch.However,no power is trsnsmittedbecauseof the one-wayclutch.
NOTE:
. When used,"|eft" or "right" indicatesdirectionon ths hydrauliccircuit.
. The hvdrauliccircuitshowsthe '97 - 98 models(7 positions);the'99 - 00 models(6 positions)is similar.

(cont'd)

www.emanualpro.com

14-35

Description
HydraulicFlow (cont'd)
4th Gear llQ! or E Posirion)
As the speedof the vehiclereaches the prescribedvalue.shift controlsolenoidvalve A is turned OFF by the pCM,
Shift controlsolenoidvalve B remainsOFF.Modulatorpressure(6)flows to the left end of the 1-2shift valveand the
left end of the 3-4 shift valve.Modulatorpressure(64) in the left end of the 1-2shift valveequalsmodulatorpressure
(68)in the right end of the 1-2shift valve.The 1-2shift valveremainsat left side by the tensionof the valvespring.
The 3-4 shiftvalve is movedto the right side by modulatorpressure(6A).The 3-4 shift valvecoversthe pon to the 3rd
clutch and uncoversthe port to the 4th clutchas this valve is moved to the right side,The 4th clutch pressure(41)
from the 3-4 shift valve becomes4th clutchpressure(40)at the manualvalve.The 4th clutchpressure(40)is applied
to the 4th clutch,and the 4th clutchis engaged.
Fluidflows by way of:
- Linepressure(4)+ CPBValve- Line Pressure(5)+ l-2 ShiftValve- LinePressure * 2-3
{5)
Shift Valve
- LinePressure(5)+ 3-4 ShiftValve- 4th ClutchPressure(41)+ ManualValve- 4th ClutchPressure(40)
+ 4th Clutch
The hydraulicpressurealsoflows to the lst clutch.However,no power is transmittedbecauseof the one-wavclutch.
NOTE:
. When used,"lelt" or " tight" indicatesdirectionon the hydrauliccircuit.
. The hydraulic circuitshowsthe '97 - 98 models(7 positions);the '99 - 0Omodels(6 oositions)issimilar.

14-36

www.emanualpro.com

E Position
(3)
Fluidflow throughthe torque convertercircuitis the same as in N position.Line pressure(1)changesto line pressure
(3')
servo
and
flows
to
the
pressure
1-2
shift
valve
(3)
at
the
and flows to the 1-2shift valve.Line pressure changesto line
(3")
vaive.The servovalveis movedto the right side (Reverserangeposition)and uncoversthe port to allow line pressure
valve
and
manual
valve
to
the
(3')
through
the
servo
valve
flows
pressure
1-2
shift
from
the
Line
manual
valve.
to the
changesto 4th clutchpressure(40).The 4th clutchpressure(40)is appliedto the 4th clutch,and the 4th clutchis engaged.
RverseInhibitor Control
Whenthe @ positionis selectedwhile the vehicleis movingforwardat speedsover 6 mph (10 km/h),the PCMoutputsthe
1stspeedsignalto shiftcontrolsolenoidvalvesA and B; shift controlsolenoidvalveA is turnedOFF,shift controlsolenoid
(3')
valve B is turned ON. The 1-2 shift valve is moved to the right side and coversthe port to stop line pressure to the
(40}
to
the 4th
pressure
is
not
applied
4th
clutch
and
valve,
pressure
to
the
servo
servo valve. Line
{3') is not applied
power
direction.
the
reverse
not
transmitted
to
is
clutch,as a result,
NOTE:
. When used,"lelt" ot " right" indicatesdirectionon the hydrauliccircuit.
'97 - 98 models(7 positions);the '99 - 00 models(6 positions)is similar'
. The hvdrauliccircuitshowsthe

(cont'd)

www.emanualpro.com

14-37

Description
HydraulicFlow (cont'dl
E Position
Fluidflow throughthe torqueconvertercircuitis the same as in fl position.Linepressure( 1)changesto line pressure(3)
and flows to the 1-2shift valve.Line pressure(3) changesto line pressure{3') at the 1-2shift valveand flows to the servo
valve.The servovalveis movedto the right side (Reverserangeposition)and uncoversthe port to allow line pressure(3")
to the manualvalveas in E position.Linepressure(3") from the servovalveis interceptedby the manualvalve.Hydraulic
pressureis not suppliedto the clutches,and power is not transmitted.
NOTE:
. When used,"left" or "right" indicatesdirectionon the hydrauliccircuit.
. The hydrauliccircuitshowsthe '97 - 98 models(7 positions);the '99 - 00 models(6 positions)issimilar.

14-38

www.emanualpro.com

Lock-upSystem
In E position('97- 98 models)and in E position('99OOmodels)(3rdand 4th),and E position('97- 98 models) and in E positionwith Over-Drive(O/D)is OFF(by
pressingthe O/Dswitch)('99- 00 models)(3rd),pressurizedfluid is drainedfrom the backof the torque converter througha fluid passage,causingthe lock-uppistonto
be held againstthe torqueconvertercover,As this takes
Dlace,the mainshaftrotatesat the same speed as th8
engine crankshaft.Togetherwith the hydrauliccontrol,
the PCM optimizesthe timing of the lock-up system.
Under certaincondltions.the lock-upclutch is applid
in 3rd and 4th gear.
duringdeceleration,

CONVERTER
TOROUE

LOCK.UPCONTROL
' VALVE

LOCK.UPCONTROL
SOLENOIDVALVE
A

The lock-upsystemcontrolsthe rangeof lock-upsccording to lock-upcontrol solenoidvalvesA and B, and ths


linearsolenoid.When lock-upcontrol solenoidvalvesA
and B activate.modulator pressurechanges.Lock-up
controlsolenoidvalvesA and B are mountedon the outs i d e o f t h e t o r q u e c o n v e r t e rh o u s i n g ,a n d t h e l i n e a r
solenoidis mountedon the transmissionhousing.They
are controlledbv the PCM.
The table belowshowsthe lock-upconditionsfor lock-up
controlsolenoidvalvesand linearsolenoidpressure.
Lock-upConirol
Solenoid valve

Linaal
Solenoid
Prgssuls

OFF

OFF

High

Lock-up,Half

ON

Dutyoperation
OFF- ON

Low

MAINSHAFT

Lock-up,Full

ON

ON

High

COUNTERSHAFT

Lock-up
during
deceleration

ON

Duty operation
OFF- ON

Lock-up
Conditions

A
Lock-upOFF
MODULATOR
Pf,ESSURE
RELIEFVALVE

LOCK'UPTIMING
VALVE
SUB.SHAFT

LINEARSOLENOIDPRESSURE
COOLERRELIEFVALVE

ATF PUMP
ATF COOLER

ATF STRAINER

(cont'd)

www.emanualpro.com

14-39

Description
Lock-upSystem(cont'dl
Lock-upClutch
L

Ooeration(clutchon)
With the lock-upclutch on, the fluid in the chamber betweenthe torque convenercover and the lock-uDoiston is drained
off, and the converterfluid exertspressurethrough the piston againstthe torque convertercover,As a result,the convener turbine is lockedto the convertercover.This bipassesthe converter,placingthe vehiclein directdrive.
LOCK,UPPISTON

The power flows by way of:


Engine

IOROUE
COVER

Drive plate
Torque convertercover
I
Lock-uppiston

t
Damperspring
{
Turbine
Mainshaft

MAIf{SHAFT

Operation(clutchoff)
With the lock-upclutch off, the fluid flows in the reverseof "clutch on." As a result,the lock-uppiston moves away from
the convertercover,and the torque converterlock-upis released.

TOROUE

Engine
COVER
I
Driveplate
{
Torqueconvertercover
{
Pump
I
Turbine
{
Mainshaft

{(1
\\
n1

Jtl
ort

MAII{SHAFT

14-40

www.emanualpro.com

To ATF cooler
INLET

No Lock-up
.
.
.

TOROUECONVERTER

Lock-upControlSolenoidValveA: OFF
Lock-upControlSolenoidValveB: OFF
High
LinearSolenoidPressure:

The pressurized
fluid regulatedby the modulatorworks
on both endsof the lock-upshift valve.Underthis condition, the pressuresworking on both ends of the lock-up
s h i f t v a l v e a r e e q u a l . a n d t h e l o c k - u ps h i f t v a l v e i s
m o v e d t o t h e r i g h t s i d e b y t h e t e n s i o no f t h e v a l v e
spring. Fluid trom the ATF pump will flow through the
left side of the lock-upclutchto the torqueconverter;the
lock-upclutchis OFF.
"|eft" and "right" indicatesdirection
NOTE:When usd,
on the hydrauliccircuit.

LOCK.UPCONTROL
SOI-ENOIDVALVE

MOOULATOR
PRESSURE
MAINSHAFT
RELIEFVALVE

COUNTERSHAFT

TIMING
LOCK-UP
VALVE

LINEARSOLENOIDPRESSURE

i COOLERRELIEFVALVE

ATFPUMP
ATF COOLER

ATF STRAINER

(cont'd)

www.emanualpro.com

14-41

Description
Lock-upSystem(cont'dl
HalfLock-up
a Lock-upControlSolenoidValveA: ON
a Lock-upControlSolenoidValveB: DutyOperation

OFF- ON
LinearSolenoidPressure:
Low

TOFOUECONVERTER

L(rcK.UPCONTROL
SOLENOID
VALVE
A

RELIEFVALVE

MODULATOR
PNESSURE
MAINSHAFT

The PCMswitchessolenoidvalveA on to releasemodulator pressurein the left cavityof the lock-upshift valve.
Modulator pressure in the right cavity of the lock-up
shift valve overcomesthe spring force,and the lock-up
shiftvalveis movedto the left side.
Line pressureis then separatedinto the two passagesto
the torque converter;torque converterinner pressure
entersinto right side to engagethe lock-upclutch,and
torque convener back Dressureenters into left side to
disengagethe lock-upclutch.
Back pressure(F2) is regulatedby the lock-upcontrol
valve,whereasthe positionof the lock-uptiming valve
is determinedby linearsolenoidpressureand tensionof
the valvespring.Also the positionof the lock-upcontrol
valve is determinedby the back pressureof the lock-up
control valve.torque converterpressure(regulatedby
the torque convertercheckvalve),and modulatorpressure (determinedby the lock-upcontrol solenoidvalve
B). The PCM switcheslock-upcontrol solenoidvalve B
on and off rapidly(duty operation),undercertajnconditions,to regulatebackpressur(F2)and lockthe torque
convertef.
NOTE:When used,"left" and "right" indicatesdirection
on the hvdrauliccircuit.

COUNIERSHAFT

L(rcK-UP
TIMING
VALVE

LINEARSOLENOIDPRESSURE

COOLERRELIEFVALVE

ATFPUMP
ATFCOOLER

14-42

www.emanualpro.com

ATF STRAINER

FullLock-up
.
.
.

TOROUECONVEFTER

LOCK-UPCONTROL
SOLENOIDVALVE

Lock-upControlSolenoidValveA: ON
Lock-upControlSolenoidValveB: ON
LinearSolenoidPressure:High

W h e n t h e v e h i c l e s p e e d f u r t h e r i n c r e a s e s l,i n e a r
solenoidpressureincreasesto high in accordancewith
the linearsolenoidwhich is controlledby the PCM.
T h e l o c k u p t i m i n g v a l v e o v e r c o m e st h e s p r i n gf o r c e
and moves to the left side. Also, this valve closesthe
fluid port leadingto the left side of the lock-upcontrol
valve.
Underthis condition,modulatorpressurein the left side
of the lock-upcontrol valve had alreadybeen released
by the lock-upcontrolsolenoidvalve B; the lock-upcontrol valve is moved to the left side. As this takes place,
torqueconverterbackpressureis releasedfully, causing
the lock-upclutchto be engagedfully.
NOTE:When used."left" and "right" indicatesdirection
on the hydrauliccircuit.

MODULATOR
PRESSURE
MAINSHAFT
RELIEF
VALVE

COUNTERSHAFT

TIMING
LOCK.UP
VALVE
SUB-SHAFT

+
BELIEF
VALVE
COOLER

LINEARSOLENOIOPRESSURE

ATFPUMP
ATF COOLER

ATF STRAINER

(cont'd)

www.emanualpro.com

14-43

Description
Lock-up System (cont'dl
DecelelationLock-up
a Lock-upControlSolenoidValveA: ON
a Lock-upControlSolenoidValveB; DutyOperation

OFF- ON
LinearSolenoidPressure:
Low
The PCM switchessolenoidvalve B on and off rapidly
u n d e r c e r t a i nc o n d i t i o n sT
. h e s l i g h t l o c k - u pa n d h a l f
lock-upregionsare maintainedto lock the torque convener propeny.
TOROUECONVERTER

NOTE:When used,"left" and "right" indicatesdirection


on the hydrauliccircuit.

MOOULATOR
PRESSURE
MAINSHAFT
RELIEFVALVE
COUNTERSHAFT
LOCK.UPTIMING
VALVE
SUB.SHAFT

LINEARSOLENOIDPRESSURE

COOLERRELIEFVALVE

ATFPUMP
ATF COOLER

www.emanualpro.com

14-44

ATF STBAINER

ComponentLocations

CONTBOLUN]T

POWERTRAIN
CONTROL
MODULE{PCMI

ASSEMBLY

COUNTERSHAFT
SPEEDSENSOR

AUTOMAIIC TRANSAXI.E
(A/T} GEAR POSITION

swtTcH
\
SHIFTCONTROL
SOLEM)IDVALVE
ASSEMBLY

www.emanualpro.com

SPEEDSCNSOR

14-45

PCMCircuitDiagram(A/T ControlSystem)
'97 Model
FUSAFELAY
BOX
UNDER.I]OOD
EATTEFY

_YEL_
IGNITON
SWITCH

UNDEF
OASN
FUSAFELAYSOX

T-l ,

-T Tl

t_
-:
G101

oowEa-qar.
MooLrE
cor.lForpcMr

*1F

ATP
NP

&

r*--'l_____O_=_
IO!
lrNo

,ATP
lR

. A T D, A - P , A - P , A - P
101 103 12 ll

UNDER
DASN
M 25(7.54)

'Fr-r.04
_a TMEALOC(
BrKru-<< calTFoL

P- r.-or..u
L
P_ *+rr
F- onmrx

f-"".>

CFUISE
CONTFOL
UNIT

pw

F_
P_ eLu
F-- enN

I l,[-l; ,
III

Ar'TGEAR
POS]TION

swtcN

14-46

www.emanualpro.com

["'"]

INTEFLOC(
CONIFOL
UNIT
KEYLCICI(
ACCPUSNSWSOLEIJOIO IGI

SHIFILOCX
SOLEIOD

PPNSW

LI]

ATPF

GND

]'
I

YEI]BLK

-[I
l

YEITILX

t,

I
l-f?
POSrn0N
PPOsITION

SEr!5OR

II

ENGINE
CooL,ANT
TEMPERATURE
SENSOF

tr h.
nf

I1",, II r
I

l"

8nN

II

H
I

SEFVICECHECK
CONNECTON

BLX

{
G101

www.emanualpro.com

PGMTerminal Voltage/MeasuringConditions
A/T ControlSystem-'97 Model
The PCMterminalvoltageand measuringconditionsare shownfor the connectorterminalsthat are relatedto the Ay'Tcontrol system.The other PCMterminalvoltageand measuringconditionsare describedin section11.

PCMTerminalLocations

A {32P}Connector

B (25P1Connectol

C {31PIConnector

D {16P}Connector

PCMCONNECTOR
A {32P}
Torminal Numbcr

Signsl

A9

LG1

G r o u n d( G 1 0 1 )

A10

PG1

G r o u n d{ G 1 0 1 )

At1

IGPl

Power supply system


With ignitionswitchON (ll):Batteryvoltage
(under-hoodFuse44 via main relav) With ignitionswitchOFF:0 V

422

Description

MeasuringConditions/TerminalVohage

Ground
Ground

424

IGP2

Power supply system


With ignitionswitchON (ll):Batteryvoltage
(under-hood
Fuse44via main relav) With ignitionswitchOFF:0 V

FCM CONNECTORB (25P)

Description

Terminal Number

Signal

B1

LSM

Linearsolenoidpowersupply
negativeelectrode

lgnitionswitchON (ll):Pulsingsigna

82

LSP

Linearsolenoidpower supply
positive electrode

lgnitionswitchON (lll: Pulsingsigna

B3

SHA

Shift controlsolenoidvalveA
control

In @, @ position,in 2nd and 3rd gear in E,


E position:Batteryvoltage
In 1stgear in E. F! position,in 4th gear in E
position:0 V

B4

LCB

Lock-upcontrolsolenoidvalve B
control

With full lock-up:Batteryvoltage


With half lock-up:Pulsingsignal
With no lock-up:0 V

B5

LCA

Lock-upcontrolsolenoidvalveA
control

When lock-upis ON: Bafteryvoltage


With no lock-up:0 V

86 to 87
B8
89 to 810

14-48

www.emanualpro.com

Measuring Conditions/TerminalVohage

Not used

ATPD3

,VT gear position switch E position signalinput


Not used

In E position:0V
In otherthan E position:Batteryvoltage

PCMCONNECTORB (25P)lcont'd)
Signal

811

SHB

Shift controlsolenoidvalveB
control

812

ILU

lnterlockcontrol

B13

D 4I N D

D4 Indicatorlight control

814

NMSG

Mainshaftspeedsensorground

815

NM

Mainshaftspeedsensorsignal
InpuI

Dependingon enginespeed:Pulsingsignal
When engineis stopped:0 V

816

ATP R

Ay'Tgear position switch E


positionsignalinput

I n E p o s i t i o nO; V
In otherthan E position:Batteryvoltage

817

ATP2

Ay'Tgear position switch E position signalinput

InEposition:0V
In otherthan E position:Batteryvoltage

B18

ATP 1

A/T gear positionswitchEl posit i o n s i g n a il n p u t

InEposition:0V
In otherthan E position:Batteryvoltage

NCSG

Countershaft
speedsensorground

NC

Countershaft
speedsensorsignal
Inpur

Dependingon vehiclespeed:Pulsingsignal
when vehicleis stooped:0 V

824

ATP D4

A/T gear position switch iql position signalinput

I n E p o s i t i o n0: V
In other than lgalposition: Bafteryvoltage

825

ATP NP

Ay'Tgear positionswitchE and


N positionsignalsinput

0V
In E andE positions:
V
Inotherthan
@ andffi positions:5

8 1 9t o 8 2 1

B22

Description

voltage
MeasuringConditions/Terminal

TerminalNumbel

In E, E position,in 1stand 2nd gear in -q,


Er position:Batteryvoltage
In B position,in 3rd gear in qd, q:l,inatn
gear in D. position:0 V
When ignitionswitchis ON (ll),brakepedal
deDressed
and accelerator
oedalreleased:0V
When ignitionswitchis first turnedON (ll):6 V
or more for tlvo seconds
In lDllposition:6V or more

Not used

PCMCONNECTOR
C {31PI
TerminalNumber

c10

Signal

Description

Measuring Conditions/TerminalVoltage

SCS

Servicechecksignal

With ignitionswitchON (ll) and servicecheck


connectoropen: 5 V
With ignitionswitchON (ll) and servicecheck
connectorconnectedwith specialtool: 0 V

VBU

Back-uppower system
(under-hoodFuse47)

Alwaysbatteryvoltage

PCM CONNECTORD II6PI


Terminal Number

Signal

STOPSW

www.emanualpro.com

Description
Brakeswitchsignalinput

Measuring Conditions/TerminalVoltage
BrakepedalpressedrBatteryvoltage
Brakepedalreleased:0 V

14-49

PCMCircuitDiagram(A/T GontrolSystem)
'98 Model
FUSAFELAY
sox
UNOEF-HOOO

_YEL_

rGD2

I ocr

ATP
NP

I oG2

IDl
lrND

,ATP
lR

I CAs

, A T P, A - P , A T P, A _ P
lD4 lD3 12 ll

PNK BLU

rronr

F_

GFNTBLX

*,',,,)83Hf'L

f-'r'------}-'er'
F_

cRN_______]_f-

F_

gnN

PN(

*'-> 3111"?"

1*[-l

l
l
,I I

sr{rTat

14-50

I SIOPSW

09 lD0 lDl,llDl5

UNOEF-DASH
FUSE/BELAYBOX

www.emanualpro.com

| V8 S0.

Gro]

NIEFIOCX
T
CONTAOLI]N
KEYLOCX
ACCPUSN
SW SOLEIOLO 6]

SHFILOCK
SOLENO1O

PPINSW

ILU

l ' l ' I'

YEUBLX

WNI/8LI< V

ATPP

GNO

II '
I

BLl(BLU

It_

___L

T-T
l
l

YEL]BLK

PosrTroN

VI

PPOSITON

WHTELK

l , l

,T

q**
IH
lF I
l:$"."
-T-

SPEED
SENSOR

I s"'nLocr erx

tJFj

gLUA|/H'I

lS0LEN00 |
4
vrL

__t

;,

,l

Tl'

BLU/YELGFNAiI/N]

COTJNIEFSHAfI
SPEEDSENSOA

LNEAFSOLEID

l*

BFN

-T-

--l

t*l
I
t ? t L

SERVCECHECX
CONNECTOF

I SNFTCONTFOL
I SOLENOIDVALVE

AssEM4Y

I
I-:

BLK

I
BqNLK

I
Gr01

www.emanualpro.com

PCMCircuitDiagram(A/T ControlSystem)
'99- 00 Models
IJNOER'HOOD
FUSE/FELAY
EoX
EATTERY

-]-

8LKryEL

l .

]T

BLX,'YEL

AIP,O,0,ATP,ArPlO/D
04 t5w t2
tr
tN0

D 9 1 0 0 | 0 r 4| D r t I B t g

IJNOER
DASII
FUS'/FELAYBOX

GAUGEASSEMELY
LTGRN
BLKtsLU

Fffi[t**
L'om
{--1
sr&BrLr
l-

F-lwr-i
FED

|--FED----.1

YEL
8LU
|-BFN-LI BLU

f-

Lr sLrJ-l

,-rI ,

G401

)
{
:-\
G4o1
POS]IION
!r'TGEAF

www.emanualpro.com

14-52

NIEFLOCX
UNIT
CONTROL

.'1"
.l'
I
XEYLOCX
ACCP1JSHSW
SOLENOID 61

SHFILOCX
SOLENO
D

PPNSW

YEU8L(

T--[T

?
I

YEUBLK

t,

rt--r

| tr-r I

t9il
LJA
LOCK
1SNTFl
D
SOTENO
L
YEL

LL]

A'PP

GND

l6
I

SLTBL!

Posti0N

SPEEO
SENSOn

YL
I

iJrl
I

(PCM)
POWEFTFALN
CONTROL
MODIJLE

0rr

012

i"']*

lDro

BFN

BLU/IEL

8FN

BLI]IEL

I t
-tl
Trt

SERVCE
CHECK
CONNECIOF

f7

nx^*
ltfJ: I o
coNNEcroR

LOC(,I]PCON'IBOL
SOLENOIDVALVE

BLK

G10r

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PCMTerminalVoltage/MeasuringConditions
A/T ControlSystem-'98 - 00 Models
The PCMterminalvoltageand measuringconditionsare shownfor the connectorterminalsthat are relatedto the A"/Tcontrol system.The other PCMterminalvoltageand measuringconditionsare describedin section11.
FCM ConnectorTerminalLocalions

NOTE:819 and C3terminals


are appliedto'99 - 00 models.

o (16Pt

T6rminal Number

Signal

A5

CRS

Downshiftsignalinput from
cruisecontrolunit

Whencruisecontrolis used;Pulsingsignal

A10

scs

Timing and adjustmentservice


checksignal(5 V from PCM)

With ignitionswitchON (ll)and servicecheck


connectoropen:5 V
With ignitionswitchON (ll) and servicecheck
connectorjumpedwith specialtool: 0 V

A14
('98 model)

D4 IND

D4 indicatorlight control
{Voltagefrom PCMturns D4 light

When ignitionswitchis firstturnedON (ll):


Batteryvoltage for two seconds
In E position: Batteryvoltage

Description

oN)
A14
('99- 00 models)

D IND

D indicatorlight control
(Voltagefrom PCMturns D light

oN)
428

ILU

A.32

STOPSW

MeasuringConditions/TerminalVoltage

When ignitionswitchis firstturnedON (ll):


Bafteryvoltage for two seconds
ln E position:Batteryvoltage

Interlockcontrol
(Voltagefrom PCM)

When ignitionswitchON {ll),brakepedal


pedalreleased:
depressed,
and accelerator
Batteryvoltage

Brakeswitchsignalinput

Brakepedalpressed;Batteryvoltage
Brakepedalreleased:0 V

FCM CONNECTORB I25P}


Terminal Number

Signal

B1

IGPl

Powersupplycircuitfrom main
relayvia under-hoodFuse44

82

PG1

G r o u n d( G 1 0 1 )

B8

LSM

Linearsolenoidpower supply
negativeelectrode

IGP2

Powersupplycircuitfrom main
relay

PG2

G r o u n d( G 1 0 1 )

810
B17
819
('99- 00 models)

O/DIND

s20

MeasuringConditions/TerminalVoltage
With ignitionswitchON {ll):Batteryvoltage
With ignitionswitchOFF:0 V

With ignitionswitchON (ll):Bafteryvoltage


With ignitionswitchOFF:0 V

Linearsolenoidpower supply
positiveelectrode

With ignitionswitchON (ll):Pulsingsignal

Over-Drive(O/D)OFFindicator
light control

When ignitionswitchis first turnedON (ll):


0 V for two seconds
O/DOFFindicatorlight ON:0 V
O/DOFFindicatorlight OFF:Batteryvoltage

G r o u n d( G 1 0 1 )

B21

VBU

Back-uppowersupply
(under-hoodFuse47)

B22

LG2

G r o u n d( G 1 0 1 )

14-54

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Description

Always battery voltage

PCMCONNECTORD (16P)
Signal

D1

LCA

Lock-upcontrolsolenoidvalveA
control

Duringlock-upconditions:Bafteryvoltage
Duringno lock-upcondition:0 V

D2

SHB

ShiftcontrolsolenoidvalveB
control

Batteryvoltagein followingpositions:
. E, E and positions
. E, -ql, and E positionsin lst and 2nd gear
0 V in followingpositions:
. E, E;, and E positionsin 3rd gear
. E and E positionsin 4th gear
. E, El, and El positions

D3

LCB

Lock-upcontrolsolenoidvalveB
control

Duringfull lock-upconditions:Batteryvoltage
Duringhalf lock-upconditions;Pulsingsignal

D4

Not used
Powersupplyfor solenoidvalves
(Under-hoodFuse15)

With ignitionswitchON (ll);Batteryvoltage


With ignitionswitchOFF:0 V

ATP R

Ay'Tgear position switch


B positioninput

In E position:OV
In otherthan E position:Bafteryvoltage

SHA

Shift controlsolenoidvalveA
control

Batteryvoltagein followingpositions:
. E position
. E, E, and E positionsin 2nd and 3rd gear
. E position
0 V in followingpositions:
. E position
. E. E, and E positionsin lst gear
. Erl and E positionsin 4th gear
.EandEpositions

ATPD3

Ay'Tgear position switch


E positioninput

In E position:
0V
voltage
Baftery
In otherthanE position:

O/DSW

Over-Drive(O/D)switch signal
input

When Over-Drive{O/D)is OFF(O/DOFF


indicatorlight is ON):0 V
When Over-Drive{O/D)is ON {O/DOFF
indicatorlight is oFF):Batteryvoltage

D9

ATP D4

A/f gear position switch


E positioninput

I n E p o s i t i o n0: V
In otherthan E position:5 V

D10

NC

Countershaft
sDeedsensorinout

Dependingon vehiclespeed:Pulsingsignal
when vehicleis stopped:Approx.0 V

Dl1

NM

Mainshaftspeedsensorinput

Dependingon vehiclespeed:Pulsingsignal
When engineis stopped:Approx.0 V

D12

NMSG

Mainshaftspeedsensorground

D13

ATP NP

A,/Tgear position switch E and


El positionsinput

I n E a n d E p o s i t i o n s 0: V
In otherthan E and m position:5 V

D14

AlP 2

I n E p o s i t i o n0 ;V
Battery
voltage
In otherthanE position:

D15

ATP 1

A/T gear position switch


El positioninput
A,/Tgear position switch
E positioninput

D16

NCSG

D5

VB SOL

D6
D7

D8
{'98model}
D8
('99- 00 models)

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Description

Measuring Conditions/TerminalVoltage

Terminal Numbor

InEposition:0V
ln otherthan El position:Batteryvoltage

Countershaft
speedsensor
grouno

14-55

TroubleshootingProcedures

Checkingths DiagnosticTrouble Code (DTC)


with an O8D ll Scan tool or Honda PGM Tsster
Whenthe PCMsensesan abnormalityin the input or outputsystems,the El ('97- 98) or E ('99- O0)indicatorlight in the
gaugeassmblywill blink.When the 16PData Link Connector(DLC){locatedunderthe dash on the passenger'sside) is
connectedto the OBD ll ScanTool or Honda PGM Testeras shown, the scan tool or testerwill indicatethe Diagnostic
TroubleCode(DTC)when the ignitionswitchis turnedON(ll).

DATA LINKCONNECTOR
{16PI

[ -=.r,
ili

,i

/i,
v,.,
i

HONDAPGMTESTER
ol
OBDII SCANTOOL

lf the E or E indicatorlight or the MIL has been reportedon, or if a driveabilityproblemis suspected,


follow this procedure:
1.

2.
3.
4.

5.
6.
7.

8.

Connectthe OBD ll ScanTool (conformingto SAEJ1978)or HondaPGMTesterto the 16PDLC.(Seethe OBD ll Scan
Tool or HondaPGMTesteruser'smanualfor specificinstructions.lf you are usingthe HondaPGMTester,makesure
it is set to the SAE DTCWpe).
Turn the ignitionswitchON (ll),and observethe DTCon the screen
Recordallfuel and emissionDTCS,
A,,/T
DTCS,and freezedata.
lf there is a fuel and emissionsDTC,first checkthe fuel and emissionssystemas indicatedby the DTC(exceptfor DTC
P0700).DTCP0700meansthere is one or more Ay'TDTC,and no Droblemswere detectedin the fuel and emissions
circuitof the PCM.
Wire down the radio station presets.
Resetthe memorywith the PGMTestero. by removingthe BACKUP fuse in the under-hoodfuse/relaybox for more
than 10seconds.
Drive the vehicle for several minutes at speeds over 30 mph (50 km/hr), and then recheckfor DTCS.lf the A/T DTC
returns,9o to the Symptom-toComponentCharton pages14-60and 14-61for the '97 models,and pages14-62and
14-63for '98 - 00 models.lf the OTCdoes not return,there was an intermittentproblemwithin the circuit.Makesure
all pinsand terminalsin the circuitare tight, and then go to step8.
Resetthe radioDresetstations,and setthe clock.

1 4 -5 6

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Checkingthe DiagnosticTrouble Code IDTCI


with the ServicCheckConnestoland SpecialTool
('97- 98) or E (gS - OO)indicatorlight in the
when the PcM sensesan abnormalityin the input or outputsystems'the E
gaugeassemblymay blink.
the specialtool
When the ServiceCheckConnector(2P)(locatedunderthe dash on the passengerside)is connectedwith
is turned ON
(DTC)
switch
the
ignition
when
Trouble
Code
as shown,the E or E indicatorlight will blinkthe Diagnostic
{ ).
(2P)to the specialtool
when the E or E indicatorlight has beenreponedon, connectthe servicecheckconnector
light'
Thenturn ON (ll)the ignitionswitchand observethe E or E indicator

.AUGE
AssEMaLY

'99 - O0models

$1,"^f:tT"'ff,

SCSSERVICECONNECTOR
07PAz- (x!l0100

'97 - 98 models

long and short


codes 1 through9 are indicatedby individualshort blinks.codes 1o and aboveare indicatedby a seriesof
After detercode.
the
to
determine
together
blinks
short
long
and
Add
the
blinks.
blinks.one long blink equals1o short
'97 model,
for
the
pages
and
14-61
14-60
on
chart
symptom-to-component
system
electrical
refer
to
the
code,
miningthe
'98- 00 models.
and pages14-62and 14-63tor the

Short blinl lonc.)

Sr. DTC1

S.. DTC2
Long blink

Shori blink! {fiv. timt

Sc. DTC 15

(cont'd)

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14-57

TroubleshootingProcedures
(cont'dl
L

Removethe kickpanelon the passenger's


side (seesection2O),

2.

Removethe PCM,and turn it over.

KICK PANEL

Inspectthe circuiton the PCMaccordingto the troubleshooting


flowchartwith the specialtools and a digitalmultimeter.
How to Use the BackplobeSet
Connectthe backprobeadaptersto the stackingpatchcords,and connectthe cordsto a multimeter.Usingthe wire
insulationas a guide for the contouredtip of the backprobeadapter,gentlyslidethe tip into the connectorfrom the
wire side until it comesin contactwith the terminalend of the wire.

BACKPROBE

EACKPROBE
SET
07sAz- 001000a
{tworequired)

DIGITALMULTIMETER
(Commercially.v.ilablel
KS-AHM-32-003
ot oquivalont

14-58

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PCMResetProcedure
'1. Turn the ignitionswitchoff
2.

Removethe BACKUP fuse (7.5A) from the under-hoodfuse/relaybox for 10 secondsto resetthe PCM.
NOTE:
. Disconnecting
the BACKUp fuse also cancelsthe radio presetstationsand clock setting Make note of the radio
presetsbeforeremovingthe fuse so you can resetthem
. The PCMmemorvcan also be clearedby usingthe OBD ll ScanTool or HondaPGMTester'
BACKUP IRADIO}{7.5AI FUSE

UNDER.HOOD
BOX
FUSE/RELAY
Final Proceduro
This proceduremust be done after any troubleshooting.
1. Turn the ignitionswitchOFF.
2.

Resetthe PCM.

3.

the OBD ll ScanTool or HondaPGMTesterfrom the DataLinkConnector(16P),or removethe specialtool


Disconnect
from the ServiceCheckConnector(2P).

4.

Turnthe ignitionswitchON (ll),and set the radio presetsand clocksetting'

5,

To verifythat the problemis repaired.test-drivethe vehiclefor severalminutesat speedsover 30 mph

www.emanualpro.com

(48 km/h).

14-59

Symptom-to-Component
Chart
ElectricalSystem-'97

Model

DTC*

E Indicatol
Light

MIL

P1753
(1)

Blinks

ON

Lock up controlsolenoidvalveA

(seepage 14-64)

P1758
\21

Bl i n k s

ON

Lock-upcontrolsolenoidvalve B

(seepage14-66)

P1 7 0 5
(5)

Blinks

ON

A,/Tgear positionswitch(shortto ground)

(seepage14-68)

P1706
(6)

OFF

ON

A,/Tgear positionswitch{open)

(seepage14-70)

P0753
\11

Bl i n k s

ON

Shift controlsolenoidvalveA

(seepage 14-72)

P0758
(8)

Blinks

ON

Shift controlsolenoidvalveB

(seepage14-74)

P0720
(9)

Blinks

ON

Countershaft
speedsensor

{seepage14-76)

P0715
(15)

Bl i n k s

ON

Mainshaftspeedsensor

(seepage l4-78)

P1768
(1 6 )

Blinks

ON

Linearsolenoid

(seepage 14-80)

P0740
{40)

OFF

ON

Lock-upcontrolsystem

(seepage14-82)

P0730
(41)

OFF

ON

Shift controlsystem

(seepage 14-84)

Detection ltem

DTC*:The DTc in parentheses


is the codethe loaindicatorrightindicateswhen the DataLink
Connectoris connectedto the HondapGM Tester.

14-60

www.emanualpro.com

Page

NOTE:When the OBD ll ScanTool or HondaPGMTesterindicateDTC(s)for the automatictransmissioncontrolsystem'


code P07oomeansa detectionof some automatictransmisthe scantool or testerindicatescode P0700simultaneously.
sion problemin the PGM-Flcontrolsystem
lf the self-diagnostic
E indicatorlight does not blink,performan inspectionaccordingto the table below.
Symptom
E indicatorlight is on constantly(not blinking)wheneverthe ignition
switchis ON (ll).
E indicatorlight does not come on for two secondsafterignition
switchis first turnedON (ll).
Shift levercannotbe movedfrom @ positionwith the brakepedal
Dressed,
lgnitionkey cannotbe movedfrom ACC(l) positionto LOCK{0) posi
tion with the shift leverin E position.

Inspection

Ref.page
14-86
't 4-41

Checkshift locksystem

14-89

CheckkeYinterlocksystem

14-91

NOTE: lf a customer describesthe symptom for code P1706(6), it will be necessaryto recreatethe symptom by test-driving, then recheckthe OTC.

www.emanualpro.com

14-61

Symptom-to-Component
Chart
ElectricalSystem-'98 - 00 Models
Et Indicatol
Lighr (98)
E Indicator
Light ('99 - 00)

MIL

P1753
(1)

Blinks

ON

Lock-upcontrolsolenoidvalveA

{seepage14-93)

P1758
(21

Blinks

ON

Lock-upcontrolsolenoidvalveB

(seepage 14-96)

P1705
(5)

Blinks

ON

A,/Tgear positionswitch(shonto grounol

(seepage14-99)

P1706
(6)

OFF

ON

A,/Tgear positionswitch(open)

(seepage 14-103)

P0753
(71

Blinks

ON

ShiftcontrolsolenoidvalveA

(seepage14-106)

P0758
(8)

Blinks

ON

Shift controlsolenoidvalveB

(seepage14-109)

P0720
(9)

Blinks

ON

Countershaft
speedsensor

{ s e ep a g e1 4 - 1 1 2 )

P0715
{15)

Blinks

ON

Mainshaftspeedsensor

( s e ep a g e1 4 - 1 1 4 )

P1768
(16)

Blinks

ON

Linearsolenoid

( s e ep a g e1 4 - 1 1 7 )

POl40
(40)

OFF

ON

Lock-upcontrol system

(seepage 14-119)

P0730
(41)

OFF

ON

Shiftcontrolsystem

( s e ep a g e1 4 - 1 2 1 )

DTC*

Detestion ltom

Page

DTC*;The DTCin the parentheses


is the codethe E or E indicatorlight indicateswhen the DataLink
Connectoris connectedto the HondapGM Tester.

14-62

www.emanualpro.com

for the automatictransmissioncontrolsystem,


NOTE:When the OBD ll ScanTool or HondaPGMTesterindicateDTC(S)
means
a detectionof some automatictransmisP0700
Code
P0700
simultaneously.
code
indicates
the scantool or tester
sion problemin the PGM-Flcontrolsystem.
lf the self-diagnostic
E or E indicatorlight does not blink,performan inspectionaccordingto the table below.
Symptom
E or E indicatorlight does not come on for two secondsafterignition
switchis first turnedON (ll).
E or E] indicatorlight is on constantly(not blinking)wheneverthe
ignitionswitchis oN {ll).
Shift levercannotbe movedfrom E positionwith the brakepedal
presseo.
lgnitionkey cannotbe movedfrom ACC(l) positionto LOCK(0)position with the shift leverin E position.

Inspection

14-123
14-125
Checkshift locksystem

14-'t26

Checkkey interlocksystem

14-129

O/DOFFindicatorlight does not come on for two secondsafter ignition


switchis first turnedON (ll).('99- 00 models)
The O/DOFFindicatorlight is on constantlywheneverthe ignition
switchis ON (ll).('99- 00 models)
The O/DOFFindicatorlight does not come on eventhoughthe OverDrive(O/Dlswitchis pressedin E position.('99- 00 models)

Ref.page

14-131
14-132
CheckOver-Drive{O/D}
switchcircuit

14-133

(6), it will be necessaryto recreatethe symptom by test-drivNOTE: lf a customer describesthe symptom for code P17OO
ing.then recheckthe DTC.

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14-63

ElectricalTroubleshooting('97 Model)
TroubleshootingFlowchart- Lock-upControlSolenoidValveA
. OBD ll ScanTool indicatesCode
P1753.
. S e l f - d i a g n o s i si @ i n d i c a t o r
light blinksonce.

PossibleCause
. Disconnectedlock-up control
solenoid valve A/B assembly
. Short or open in lock-up control
solenoidvalveA wire
. Faulty lock-up control solenoid

Checkand recordthe freezedata


rn caseit is neededlaterfor problem verification.
lf the Honda PGM
Tester is available:

P e r f o r mt h e l o c k , u p c o n t r o l
s o l e n o i dv a l v eA t e s t u s i n gt h e
HondaPGMTester.

Did the solenoid pass the test?

The solenoidis OK at this time.


Verify that all connectors in the
circuil are making good contact,

NO

PCMCONNECTORS
Checkfor a Short to Power:
r. I urn rne tgntUonswttchut-f.
2. Disconnecr
the A (32P)and B
( 25 P ) c o n n e c t o r sf r o m t h e
PCM.
3. Turnthe ignitionswitchON (ll).
4. Measurethe voltagebetween
t h e 8 5 a n d A 9 o r A 2 2t e r m i
nals.
Wiresideof femaleterminals

ls there voltage?

Repairshort to power in the wire


between the 85 terminal and the
lock-upcontrol solenoidvalveA.

Measure Lock-upControl Solenoid Valve A Resistance:


1. Turnthe ignitionswitchOFF.
2. Measure the resistance
betweenthe 85 and A9 or A22

ls the resistance
12 25 ()?

To page14 65

14-64

www.emanualpro.com

Checkfor loose terminal fit in the


PCM connectors, ll necessary,
substitulea known-goodsolenoid
valve assembly or PCM and
recheck,

From page 14-64

PCMCONNECTORS
Check Lock-up Control Sol6noid
Valve A tor a Short Circuit:
1 . D i s c o n n e ct ht e 2 P c o n n e c t o r
from the lock-upcontrolsole
noidvalve4!/Bassembly.
2. Checkfor continuitybetween
the 85 andA9 or A22termi
nals.
Wiresideof femaleterminals

Reprir short to ground in the wire


between the 85 terrninal and the
lock-uDcontiol solenoidvalveA.

LOCK.UPCONTROLSOLENOID
VALVEA/B ASSEMBLYCONNECTOR

----E-

MeasuroLock-upControl Solenoid Valve A Resistanceat the


solenoid valve Connector:
Measurethe resistancebetween
the No. 2 terminalof the connector and body ground.

lFr]
.=-A LcA IYELI
(nJ
Y

Terminalsideof maleterminals

12- 25 O?
ls the resistance

Check for open in the wire


belwen the 85 teiminal and the
lock-uocontrol solenoidvalve A

Replacethe lock-np control solenoid valve A/B assembly.

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14-65

ElectricalTroubleshooting('97Model)
TroubleshootingFlowchart- Lock-upControlSolenoidValveB
. OBOll ScanTool indicatesCode
P1758.
. Self-diagnosispr- indicatorlight
blink3twice.

Check and record the {reeze data


jn case it is needed later for prob,

PossibleCauso
. Disconnoctedlock-up control
solnoid valve A/B assembly
. Short or opn in lock-upcontrol
3olenoidvrlve B wi.e
. Faulty lock-up control solenoid
valve B

lem verification.

Did the code return?

The system is OK at this time.


Verify thet dll connectors in the
circuit are makinggood contact.

PCMCONNECTORS

Checktor a Short to Powerl


1. Turnthe ignitionswitchOFF.
2. Disconnect
the A (32P)and B
( 2 5 P )c o n n e c t o r sf r o m t h e
PCM.
3. Turnthe ignitionswitchON {ll).
4. Measurethe voltagebetween
the 84 and Ag ot A22 tetmi
nals,

Wire sideof femaleterminals


Repairshort to power in tho wire
bstween the 84 terminal and the
lock-upcontrol rolenoid valve B.

MeasureLock-upControl Solenoid Valve B Resistance:


1. Turnthe ignitionswitchOFF.
2. Measure the resistance
b e t w e e nt h e 8 4 a n d A g o r
A22terminals.

l s t h e r e s i s t a n c e1 2 2 5 O ?

To page14-67

14-66

www.emanualpro.com

Checktor looseterminal tit in the


PCM connectors, It necessary,
subslitute a known-good solenoid valve assemblyo. PCM and
rechck.

Frompage14 66

Check Lock-up Control Solenoid


Valve B lor a Short Circuit:
1. Disconnectthe 2P connector
from the lock-upcontrolsole
noid valveA/8 assembly.
2. Checkfor continuitybetween
the 84 and A9 or A22 lermi_
nals-

PCMCONNECTORS

Wiresideof femaleterminals

Repairshort to ground in the wire


between the 84 lerminal and the
lock-upconlrol solenoidvalve B.

LOCK-UPCONTROLSOLENOID
VAI-VEA/B ASSEMBLYCONNECTOR
Me6aureLock-upControl Sole_
noid Valve B Resistanceat the
SolenoidValve Connector:
Measurethe resistancebetween
the No. 1 terminalof the connector and body ground.

12- 25 0?
ls the resistance

LC B (GRN/BLK)

Check lor open in the wire


bctween the 84 terminal and the
lock-upcontrol solenoidvolva B.

Replacethe lock-up conttol solenoid valve A/B ass6mbly.

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14-67

ElectricalTroubleshooting{'97Model}
TroubfeshootingFlowchart- AIT GearPositionSwitch (Short)
. OBOll ScanTool indicatsCode
P1705.
' Selt-diagnosisp1- indicatortight
blinb Iive times.

Checkand record the freeze data


in caseit is neededlaterfor problem verification.

Po$ible Cause
' Short in A/T gear position switch
. Faulty A/T gear position switch
NOTE:Code P1705(5) is causedwhen
t h e P C M r e c e i v e st w o g e a r p o s i t i o n
anputsat the sametime.

Observethe A/T Gar Po3ition


Indicator:
1. Turnthe ignitionswitchON lll).
2. Observethe A./Tgear position
i n d i c a t o r ,a n d s h i l t t o e a c h
positionseparately.

Doesany indicatorstayon
when the shift leveris not in
that position?

The system is OK .t this time.


Ch6ck ihe wii6 harnessfor dam490,

Do allgear positionindicators
go out?

PCMCONNECTORS

MeasureATP R Voltago:
1. Shittto all positionsotherthan

tr.

2. lMeasure
the voltagebetween
the 816 and Ag or A22 terminals.

Check tor 3hort in the wire


betwaenthe 816torminal and tho
A/T gear pGilion switch or A/T
gsar posiiion indicator. ff wire is
OK, checkfor 10036torminal flt in
lhe PICMconnectoB. It necessary,
substitute a known-9ood PCM
and recheck.

Wire sideof femaleterminals

MeasureATP NP Voltage:
1. Shiftto all positionsotherthan

NorE.
2. Measurethe vohagebetween
lhe 825 and Ag or A22 terminals.

ls there battery vohage?

To page14-69

14-6 8

www.emanualpro.com

Chock for ahort in the wire


betwentho 825 torminal end the
A/T 96.r pGition indicstor, or a
sho.t in tha wiro! btween the
A/T gear po3ition indicator and
the A/T gar position lwitch. lf
wircs ar OK, ch6ck for loos terminal fit in the PCMconnectors.It
nece3sary,substitute a knowngood PCMand recheck.

ATP NP {LT GRNI

Frompage14-68

MeasureATP D4 Voltage:
1. Shiftto all positionsotherthan

Eil

2. [/leasurethe voltage between


the 824 and Ag or A22 terminals.

ls thereapprox.5 V?

MasureATP D3 Voltage:
L Shiftto all positionsotherthan

Check tor short in the wire


betweenthe 824 terminal and the
A/T geai position indicator. or a
3hort in the wir6s between the
A/T gear position indicttor and
the A/T gear position switch. lf
wires are OK, checklor loose ter'
minal fit in the PCMconneclo.s.lf
necessary,substitute a known'
good PrCMand recheck.

Wire side of female terminals

tr.

2. Measurethe voltagebetween
the 88 and A9 or A22 termi
nats.

ls there bafteryvoltage?

Check for short in the wi.e


between the 88 torminal and the
A/T gear position switch or A/T
gear position indicator. lf wire i3
OK,checklor looseterminaltit in
the PCM connectors. lf necessarY,3ubslitute a known'good
PCMand recheck.

MeasurATP 2 Vohage:
1. Shiftto all positionsotherthan
l;
2. Measurethe voltagebetween
the 817 and Ag or A22 termi'
nals.
Check for short in the wire
bstwen the 817 terminal and the
A/T gear posilion switch or A/T
gear position indicator. lf wire is
OK, checklor looseterminal fit in
th6 PCM connctoF. lf necssaty,
substitute a known-good PCM
and recheck.
Mersure ATP 1 Volt.ge:
1. Shiftto all positionsotherthan

El.

2. Measurethe voltagebetween
t h e 8 1 8 t e r m i n a la n d A 9 o r
A22terminals.

ls there batteryvoltage?

Check lor short in the wire


betw.en the 818 torminal and
the A/T gear position switch or
A/T gear position indicator. lI
wiro is OK. check for loose terminal fii in the PCM connectorc. lf
necessary.substitute a known'
good PCMand recheck.

Checkfor loose terminalfit in the


PCM connectors, lf neces3aty,
substitute e known-good PCM
end rocheck.

www.emanualpro.com

14-69

ElectricalTroubleshooting('97Model)
TroubleshootingFlowchart- A/T GearpositionSwitch (Openl
. OBD ll ScanTool indicat6 Code
P1706.
. Setf-diagnGb Dl indicatortight
blinks six tim$.

Po$iblo C.u3e
. DisconnectedA/T gear position
switch connectol
. Open in A/T goar position switch
. Faulty A/T goar position switch

Checkand recordthe freezedata


in caseit is neededlaterfor problem verilication.

Test the A,/Tgear position switch


{ s e ep a g e1 4 1 3 9 ) .

Measu.eATP R Voltage:
'1. Turnthe ignition
switchON (ll).
2. Shiftto E position.
3. Measurethe voltagebetween
the 816 and Ag or A22 terminals.

Repeir opn in the wire botween


the 816trminaland the A/T g.r
po3itionswitch.

Wire sideot temaleterminals

MeasureATP NP Voltage:
1. Shiftto E or E position.
2. Measurethe voltagebetween
the 825 and A9 or A22 termin al s ,
ATP NP ILT GRNI
Repai. open in th6 wir6 bctwoan
the 825 terminal and tho A/T gear
polition indicltor or tho A/T gea.
Doshionswhch.

MoasureATP 04 Voltage:
1. Shiftto E position.
2. Measurethe voltage between
the 824 and A9 or A22 terminars,

Ropai. opcn in tho wiro betwoen


the B24torminal .nd the A/T gcar
Dosition switch.

To page14-71

14-70

www.emanualpro.com

Frompage14-70
FCM CONNECTORS

MeasureATP D3 Vohag:
1. Shiftto E position.
2. Nleasurethe voltagebetween
the 88 and Ag or A22 termi
nals,
Wire sideof femaleterminals

Repairopen in the wirg bstween


the 88 tolminal and tho A/l gear
oo3ition 3witch.

MsasureATP2Volttg6:
'1. Shiftto position.
E
2. Measurethe voltage between
the 817 and A9 or A22 termi'
nals.

Repairopen in lhe wire between


the 817 terminaland tho A/T
gear position switch.

MoasureATP1Voltage:
1. Shiftto A position.
2. Measurethe voltagebetween
the 818 and Ag or A22 terminats,

Rpairopon in the wiro between


the 818 terminll and the A/T
goar poshion switch.

Checktor looso terminal fit in the


PCM connectors. lf necossarY,
substitute a known-good PCM
and rechock.

www.emanualpro.com

ElectricalTroubleshooting('97 Model)
TroubleshootingFlowchart- Shift ControlSolenoidValveA
. OBD ll ScanTool indicatesCode
P0753.
. Self-diagnoskE indicator light
blinks seventims.

PossibleCauso
. Disconnectedshift control solenoid
valve A/8 a$embly connector
. Short or open in shift control solenoid valve A wire
shift controlsolenoidvalveA

Checkand record the freezedata


in caseit is neededlaterfor prob
lem verification.
lf the Honda PGM
Tester is available:

I
Performthe shiftcontrolsolenoid
v a l v eA t e s t u s i n gt h e H o n d a
PGMTester.

Did the solenoidpassthe test?

The solnoid is OK at this time.


Verify that all connectors in the
circuit are making good contact.

PCMCONNECTORS
Checktor a Short to Power:
1. Turnthe ignitionswitchOFF.
2. Disconnect
the A (32P)and B
( 25 P ) c o n n e c t o r sf r o m t h e
PCM.
3. Turnthe ignitionswitchON lll).
4. Measurethe voltagebetween
the 83 and Ag or A22terminals.

Wire sideof femaletermin6ls


Repairshort to power in the wire
between the 83 terminal and the
shift control solenoid valve A.

Measure Shift Control Solenoid


Valve A Resistanco:
1. Turn the ignitionswitchOFF.
2, Measure the resistance
betweenthe 83 and A9 or A22
termrnals,

ls the resistance
12 25 {)?

To page l4-73

www.emanualpro.com

14-72

Checktor loose terminal tit in the


PCM connectors, lf necessaay,
subslituie e known-good solenoid valve assemblvor PCM and
rechck.

Frompage14-72

C h e c kS h i f t C o n o l S o l e n o i d
Valve A for a Short Circuit:
1. Disconnectthe 2P connector
from the shiftcontrolsolenoid
valve Ay'Bassembly.
2. Checkfor continuitybetween
the 83 andA9 orA22terminals.

Wire sideof femaleterminals

Repai.short to ground in the wire


belwen th6 83 terminal and the
shift cont.ol solenoidvalveA.

SHIFTCONTROLSOI.ENOID
VALVEA/B ASSEMALYCONNEC1OR
MeasureShift Control Solenoid
Valv6 A Resistanceat the Solenoid
Valve Connector:
Measurethe resistancebetween
the No. 1 terminalof the connec
tor and bodyground.

lffil
SHA IBLU/YELIl-(o)
T
I

Terminalsideof maleterminals

ls the resistance
12- 25 0?

Check lor ooen in the wire


between the 83 terminal and the
shift control solnoidvalve A.

Replace the shift control solenoid


valve A/B assemblv.

www.emanualpro.com

14-73

ElectricalTroubleshooting('97Model)
TroubleshootingFlowchart- Shift ControlSolenoidValveB
. OBOll ScanToot indicrt8 Codo
P0758.
. Setf-diagnGisE indicatorlight
blinks oight tim93.

Po33iblaCrusa
. Disconnec{edshift cont.ol solenoid
valve A/B dssomblyconnector
. Short or open in shift conlrol solenoid valvg B wire
' Faultvshift comrol 3olenoidvalvo B

Checkand rcord the lreere data


in case it is neededlater for prob
lem verilication.
lf the HondaPGM
Tsteris available:
Test solenoid valve B with the
Honda PGM Tester in the FLrnc
tion test mode.

Did the solenoidDassthe test?

The 3olonoid is OK at this time.


Verifv that all connoctors in the
circuit are making good contlct.

PCMCONNECTORS
Chocktor a Sho.t to Power:
1. Turnthe ignitionswitchOFF.
2. Disconnect
the A (32P)and B
{25P)connectorsIrom the PCM.
3. Turnthe ignitionswitchON (ll).
4. Measurothe voltage botveen
the 811 and Ag or A22 terminats.

Wiresideot femaleterminals
R.p.ir 3hort to power in the wire
botwon the 811 iormin.l and
tho shift control sol.noid valve B.

M.6sure Shift Control Solonoid


Valve B Reaistanco:
1. Turnthe ignitionswitchOFF.
2. Measure the rsistance
b e t w e e nt h e 8 1 1 a n d A 9 o r
A22terminals.

ls the resistance
12- 25 O?

To page14-75

www.emanualpro.com

14-74

Checl lor loosc terminal fil in the


PCM connactors. It nocessarv,
substitute a known-good aolenoid vllvo asssmbly or PCM and
r6chsck,

Frompage14-74
PCMCONNECTORS
C h e c kS h i f t C o n t r o l S o l e n o i d
Valvo B tor a Short Circuil:
1. Disconnectthe 2P connector
from the shift control solenoid
valvey'y'8assembly.
2. Checkfor continuitybetween
the 811 and Ag or A22 terminals,
Wire side of female terminals

Ropairshort to ground in the wire


b64wntho 811 torminal and lhg
shift control solenoidvalvo B.
SHIFTCONTROLSOLENOID
VALVE A/B ASSEi'BLY CONNECTOR

Meesure Shift Control Solenoid


Valve B Rosistanceat lh Solenoid Vrlve Connector:
Measurethe resistancebetween
the No. 2 terminalol the connec
tor and bodyground.

ti;Tll
I sH B |GRN/W{T|

oY
I

Terminalsideof maleterminals

ls the resistance
12- 25 O?

Check tor open in the wire


bdtweonthe 811 torminal and the
shift control solnoidvalv6 B.

Reolacethe shift control solenoid


valve A/B asJembly,

www.emanualpro.com

14-75

ElectricalTroubleshooting('97 Model)
TroubleshootingFlowchart- CountershaftSpeedSensor
. OBO ll Scan Tool indicatesCode
m720.
' solt-diagnosis iD!' indicator light
blink3 nine tim6s.

PossibleCause
. Looseor faulty connectionbetween
ih PCMand vehicleharness
. Disconnected countershaft spoed
sensorconneclor
. Short or open in countershaftspeed
. FaultycounteBhaft speedlensor

Checkand recordthe freezedata


in case it is neededlater for prob
lem verification.
lf the Honda PGM
Tester is available:

I
Connectthe Honda PGM Tester,
a n d t e s t - d r i v et h e v e h i c l ew i t h
the tester in Data Link or snap'
Shot mode,Makesure the countershaftspeed sensor readsthe
sameas the vehiclespeedsensor
lVSS).
The countershaftsooed sensor is
OK sr this time. Veritv that all
c o n n e c l o a si n t h e c i r c u i t a r e
making good contacl.

C h e c kt h e c o u n t e r s h a f ts p e e d
sensor installation,and check it
for damage.

ls the countershaft
speedsensor installedproperly,and not
damaged?

neinstall or roDlacoand recheck.


SPEEDSENSOR
COUNTERSHAFT
CONNECTOR

MeasuroCountoBhaftSpeedSensor Relbtance at the Sensor Connector:


1. Disconnectthe 2P connector
from the countershaftspeed
sensorconnector.
2. Measurethe resistance
of the
countershaft
speedsensor.

ll-'T,ll
-rT
ral

YL__lI

Terminalsideof maleterminals
ls the resistance400- 600 o?

To page14-77

www.emanualpro.com

14-76

B I25PI
PCMCONNECTOR

Chck CounteGh!ft Spocd Sonsoi


for a Short Cirruit:
1 . D i s c o n n e ctth e B 1 2 5 P c) o n '
nectorlrom the PCM.
2. Checkfor continuity botween
the body ground and the B23
t e r m i n a la n d 8 2 2 t e r mi n aI
individually.
Repair short in tho wirgs btwoen
tho 823 ,nd 822 te.minals and
thc countaBhaft spd senso..

Wire sideof lemaleterminals

Mersuro Countorrhrtt Spoed Sonsor qrcuit tor an Open:


'1.Connect the countershaft
speedsensor2Pconnector,
2, Measure the resistance
betweenthe 823 and 822 ter
mrnals.

ls the resistance400- 600 0?

Rapair loor t.rminll or opon in


tho wircs betwoon tho 823 .nd
822 terminrl! .nd th. countaF
shaft specd san3or.

Checkfor loo3eterminsl fit in the


PCM connecto13.It necess!ry,
sub3titulg s known-good PCM
and rochock.

www.emanualpro.com

14-77

ElectricalTroubleshooting{'97Model)
TroubleshootingFlowchart- MainshaftSpeedSensor
. OBD ll Scan Tool indic.t6 Code
m715.
. Self-diagnosisE indic.tor light
indicatagCode 15.

Po$ible Cau3o
. Disconnocted mainshaft speod sensot connectot
. Short or open in mainsh.ft sp6ed
' Faulty meinshaftspoedsensor

Checkand record the freeze data


in case it is neededlater {or prob,
lem verification.

N O T E : C o d e P 0 7 1 5 1 1 5o)n t h e P C M
doesn'talwaysmeanthere'san electrical
problemin the mainshaftor counlersharl
speedsensorcircuit;code P0715(15)
may
problemin the
also indicatea mechanical
transmission.
Checkthe freezedata with
a Honda PGM Tester. lf the mainshaft
speed sensor rpm was 0, proceedwith
this troubleshooting.
lf not, the probable
problomwithinthe
causeis a mechanical
transmission,

Checkthe mainshaftand countershaft speed sensor installation,


and checkthesensorsfor damage.

Are the mainshaftand countershaft speedsensorsinstalled


properly,and not damaged?

Reingtallor reolaceand recheck.

MAINSHAFTSPEEO
SENSORCONNECTOR
_ E _

MeaaureMaiNhatt SpoedSen3or
R6sist!nce at the Sensor Connecaor:
1. Disconnectthe 2P connector
from the mainshaftspeedsensor connector.
2. lreasurethe resistance
of the
mainshaftspeedsensor.

ItiT,ll
-F=r

9t
LJ

Terminalsideof maleterminals

ls the resistance
400- 600O?
B {25P'
PCMCONNECTOR

Check MainahaftSpeed Sensor


tor a Short Circuit:
1. Disconnect
the B (25P)connector lrom the PCM.
2. Checkfor continuitybetlveen
bodygroundand 815terminal
and the 814 terminalindividu-

Wire side of female terminals

ReDairshort in the wir6 bt\ reen


the 815 and 814 torminals and
the mainsh!ft sped sensor.

To pagel4-79

14-78

www.emanualpro.com

Frompage14'78
PCMCONNECTOR
B {25P}

MoasuroMrin3haft SpoedSanlor
Resktanco:
1. Connectthe mainshaftspeed
sensor2P connector,
2, Measure the resistance
betweenthe 815 and 814 terminals,
Wir sideof femaleterminals

ls the resistance400- 600 O?

Run the Electricrl Troubloshooting


Flowchs tor codo m72O l9l.
Chockfor loo3etorminal fh in the
PCM conn6cto.s. It necessarY,
substitute a known-good PCM
and rochgck.
MAINSHAFTSPEEDSENSOR
CONNECTOR

CheckNM Wiro Continuity:


1. Disconnectthe 2P connector
from the mainshaftspeedsensor connector.
2. Checkfor continuitybetween
t h e 8 1 5t e r m i n a l a ntdh e N o . 2
terminal of the mainshaft
speeosensorconneoor.

Ropairopen in the wir6 betwon


the 815 terminal and the mainshaft sDood$nsoa.

CheckNMSG Wire Continuity:


Checkfor continuity between the
814 terminaland the No. 1 terminal of the mainshaftspeedsensor
connector.

Rpai. opon in the wi.o between


the Bltl terminal and tho main'
3haft sDedsensoa,

Ch.ck lor loos. t6rminallit in the


PCM connecto13,lf neca3sary,
substitute a known-good PCM
and rochock.

www.emanualpro.com

14-79

ElectricalTroubleshooting('97Modell
TroubleshootingFlowchart- LinearSolenoid
. OBD ll Scan Tool indicatesCode
P1768.
. S.lt-diagnosis E indicator light
indicat* Code 16.

PossibleCaus
. Disconnoctedlinear solenoid con. Short or oDen in linear solenoid
. Fsultv linear solenoid

Checkand record the freezedata


in case it is neededlater for prob
lem verification.

LINEARSOLENOIDCONNECTOR
t-TTI t]]lt

t-T
lI ?rr l
Mssurc Linear Solanoid Re3istance ei th SolonoidConnoctor:
1. Disconnectthe 2P connector
from the linear solenoidconnector,
2, Measurethe resistance
ol the
linearsolenoid.

at
l

L_l
Terminalsideot maleterminals

ls the resistance
about5.0O?
B I25PI
PCMCONNECTOR
LSM {WHTI

LSP{RED)

CheckLinearSolenoid{or a Short
Cileuit:
1. Disconnect
the B (25P)connec
tor from the PCM.
2. Checkfor continuitybetween
t h e b o d y g r o u n da n d t h e B 1
terminaland 82 terminalindi
vidually.
Wiresideof lemaleterminals
Rooairshort in the wires between
the Bl end 82 terminek .nd the
linearsolenoid.

To page14-81

www.emanualpro.com

ChckGround Lin:
1 . D i s c o n n e ct th e A ( 3 2 P )c o n nectorfrom the PCM.
2. Checklor continuitybetween
t e r m i n a l sA g a n d A 1 0 a n d
b e t w e e nt e r m i n a l sA 2 2 a n d
A.23.

PGl IBLKI

PG2(ALKI

Wiresideof temaleterminals
Repair loose terminal or opon in
th wires between terminals A9,
A10,A22 and A23 and g.ound,and
repairpoor ground lG101,G4011.

Measure Linear Solenoid R*istance:


1. Connectthe linearsolenoid2P
connector.
2. Measure the resistance
betweenthe 81 and 82 termi
nals,

ls the resistance
about5.00?

Ropair loos terminal or op6n in


the wiles between th 81 and 82
l6rminals and the linear solenoid.

Chocklor loose tarminalfit in the


PCM connectors. lf necosaarv,
subsiituto a known-good PCM
and recheck.

www.emanualpro.com

14-81

ElectricalTroubleshooting('97Model)
TroubleshootingFlowchart- Lock-upControlSystem
. OBD ll ScanTool indicrt6 Cod6
P0740.
. Self-diagno3bE indicatorlight
indicatos Codc 40.

PossibloCause
Faulty Lock-upcontrol sy3t6m

Checkand recordthe freezedata


in caseit is neededlaterlor problem verification

Checktor Another Code:


C h e c kw h e t h e rt h e O B D l l s c a n
t o o l o r t h e E i n d i c a t o rl i g h t
indicatesanothercode.

Doesthe OBDll scantool or


the E indicatorlight indicate
anothercode?

Perlorm the Troubleshooting


Flowchart lor th indicatd
Codo{s).Rochecktor code P0740
{ilol after troubl$hooting.
NOTE:Do not continuewith this troubleshootinguntil the causesof any other
DTCShave beencorrected.

Tesl Line Pressure:


M e a s u r et h e l i n e p r e s s u r e( s e e
p a g e1 4 - 1 6a1n d 1 4 - 1 6 2 ) .

ls the line pressurewithinthe


servicelimit?

* Even if yotl cannot reproducecode P0740.test the line pressure,test the clutch
pressures,
replacethe lock-upcontrolsolenoidvalveassembly
and i{ necessary,

R6pairtho hydraulicaystm as
necessary{seepage 14-162}.

Test lst, 2nd, 3rd, and 4th Clutch


Pressure:
Measurethe 1st,2nd,3rd,and 4th
clutch pressure(seepage 14161
thru 14''163).

ls eachclutchpressurewithin
the servicelimit?

To page14-83

1 4-82

www.emanualpro.com

Repairthe hydraulicsystem ds
necessary {see pago 14-152rnd
14-163).

From page14 82

R e p l a c et h e L o c k - u p C o n t r o l
S o l e n o i dV a l v e A s s e m b l ya n d
Recheck:
1 . R e p l a c et h e l o c k - u pc o n t r o l
solenoidvalve A/B assembly
(seepage14-'135).
2 . T u r n t h e i g n i t i o ns w i t c hO F F
and reset the PCM by removing the BACKuP (7.5A) fuse
in the under-hoodfuse/relay
box for morethan 10seconds.
3. lJsingthe scantool, checkto
be surethatthe enginecoolant
is 176"F180'C)or
temperature
above,
4 . D r i v et h e v e h i c l ea t 5 5 m p h
(88 km/h)constantlyfor more
tnan one mrnute.
5. Recheck
for code P0740(40).

Doesthe OBDll scantool indicate


codePO74O
or doesthe El indica
tor light indicatecode40?

The svstem is OK ai this time.

R e p l a c et h e L i n e a r S o l n o i d
A$embly and Recheck:
' 1 . B e p l a c et h e l i n e a r s o l e n o i d
assembly{seepage14-138).
2. Turn the ignition switch OFF
and resetthe PCMmemory by
removingthe BACKUP (7.5A)
fuse in the underhood fuse/
r e l a yb o x f o r m o r e t h a n 1 0
seconds.
3. Usingthe scantool, checkto
be surethatthe enginecoolant
temperature
is 176"F(80'C)or
above.
4. Drivethe vehicleat 55 mph (88
km/h)constantlyfor more than
oneminute,
5. Recheck
for codeP0740{40).

Does the OBD ll scan tool


i n d i c a t e c o d e P 0 7 4 0o r d o e s
the E indicator light indi
cate code 40?

Replacethe transmission and


torque convertorassembly.

www.emanualpro.com

The svsteo is OK at this tim.

ElectricalTroubleshooting('97Model)
TroubleshootingFlowchart- Shift ControlSystem
. OBD ll ScanTool indicatesCode
P0730.
. S e l t - d i a g n o s i sE , l i n d i c a t o r
light indicatesCode41.

PossibleCause
F""lty "t lft ".tttr"l "y"t..

Check and record the freeze data


in case it is needed later for problem verification.

Checktor Another Code:


C h e c kw h e t h e rt h e O B D l l s c a n
t o o l o r t h e P l l i n d i c a t o rl i g h t
indicatesanothercode,

Doesthe OBDll scantool or


the E indicatorlight indicateanothercode?

Test lst. 2nd, 3rd. and 4th Clutch


Pressure:
M e a s u r et h e 1 s t ,2 n d , 3 r d , a n d
4th clutchpressure(seepage 141 6 1t h r u 1 4 - 1 6 3 ) .

ls eachclutchpressurewithin
the servicelimit?

To page 14-85

w