Manual Honda Civic 96-00

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INTRODUCTION
How to Use This Manual
This manual contains information for the 1996- 2000 ClVlC. lt is

divided into 24 sections.The first page of each section is marked
with a black tab that lines up with its correspondingthumb index
tab on this page and the back cover. You can quicklYfind the first
page of each section without looking through a tull table ol con_
tents.The symbols printed at the top corner of each page can also
be used as a quick referencesystem.
Eachsectionincludesl
1. A table of contents,or an explodedview index showing:
. PartsdisassemblYsequence.
. Bolt torquesand thread sizes.
. Pagereferencesto descriptaons in text
2. Disassembly/assembly proceduresand tools.
3. Inspection.
4. Testing/troubleshooting.
5. Repair.
6. Adjustments.
Special Information
!@ Indicates a sttong possibility of sover. perconal iniurY

or loss ol lite if in3tructions are not follow€d.
GAUTION: Indicaiqs a possibility ot p€lsonal injury or 6quipm.nt

damage il instiuc'tions are not followod
t Noncal
i-. pu.po.. ot thes6 messages is to help provent demage lo lhe
vehicle, other property, or the €nvironment.
NOTE: Giveshelpfulinformation.
*Transaxle
ds
CAUTfON: Detaifed descriptions ol standard workshop p.oceduro3.
safoty principles and servico operations are not included. Pleaso
note that this manual contain3 wetnings and cautions against
some sp6cific sGrvic€ methods which could cause PERSONAL
INJURY, damage a vohicle or make il unsafe. Ploase undorstand
that these warnings cannot covsr all conceivable weys in which
service. whelher or not iocommgndod bY HONDA. mighi bo done,
or ol tho possiblG hazardou3 consgquonces of ev€aYconceivablg
way, nor could HONDA invqstigato all 3uch way3. AnYono using
sgrvice procedures or lools, whethei or nol rGcommendod bY
HONDA, must srtisty hifisetf thoroughlylhat nohher pefsonal sefety
nor vehiclc satsty will be reopardi2ed.
All intormationcontainedin this manual is basedon the latestprod

uct information available at the time oI printing We reserve the
right to make changes at any time without notice No part of this
publicationmay be reproduced,stored in retrievalsystem,or trans'
mitted, in any form by any means, electronic,mechanical,photo
copying, recording,or otherwise,without the prior written permis-
sion of the publisher.This includestext, figuresand tables.
FirstEdition8/99 1848Pages HONOAMOTORCO.,LTD.

SorvicoPublicationOffico
All Right Reserved
* El e c tri c a l 't
As sectionswith * includeSRScomponents;
sDecialprecautionsare lequiredwhen servlclng
* SR S SRS
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l l
GeneralInformation
Ghassis 1-2
andPaintCodes.......................
NumberLocations.........
ldentification 1-32
Warning/Caution LabelLocations.......1-33
Under-hood Emissions
ControlLabel.......... .......1-37
Lift and SupportPoints
1-41
LiftandSafetyStands.......................
FloorJack 1-42
.......................
Towing .........
1-43

Chassisand PaintGodes
U.S. 1996Model (2-doorHatchback)
Vehicleldentification Number
2 H GE J 63 2 * T H I 0 0 0 0 1
oa
D16Y7 1500001
Manufacturel, Make and EngineType
Type of Vehicle D 16Y7:1600SOHC16-vatves
2HG: HONDAOF CANADA SequentialMultiport
M F G . I, N C . Fuel-injected
Engine
HONDAPassenger SerialNumber
vehicle
Line,Bodyand EngineType
EJ6: CIVIC3-door/D16Y7
Body Type and TransmissionType
3: Hatchbaclds-speed
M an u aI
4: Hatchbacl(4'speed
Automatic
44RA: 4-speedAutomaticTransmission
Vehicle Grade
S40 : s-speedManualTransmission
2i CX
4i DX
6: DX
Ch€ckDigit
Model Year
T: 1996
FactoryCode
H: Alliston Plant, Ontario, Canada
Destinations
Serial Numbel GY,16P
NH-503P
NH.583M
Midori GreenPearl
GranadaBlackPearl
New VogueSjlver lvletallic
O '
R-97 RomaRed
VehicleldentificationNumber
and FederalMotor Vehicle
Safety Standard Certification Paint Code
COLOR
GY.l6P
o e
1-2
U.S. 1996Model (4-doorSedanl
O O
' ]500001
1 H GE J 6 5 2* T L 0 0 0 0 0 1 D16Y7-
D16Y7:1600SOHC16-valves Sequential
1 H G :H O N D AO FA M E R I C A Engine
MultiportFuel-injected
t\4FG., lNC. Dl6Y8: 1600SOHCVTEC16-valves Sequential
HONDAPassenger vehicle Engine
2HG: HONDAOF CANADA
M F G . I, N C . , l6Yg 1500001-
U . S . A : D 1 6 Y 7D
HONDAPassenger vehicle
Line, Body and EnginsType
EJ6: CIVIC4'door/D'16Y7 I ransmlssron
EJ8: CIVIC4-door/D16Yo
Body Type and TransmissionTyPe
5: Sedan/5-speed Manual
TransmissionType
A4RA:4 speedAutomaticTransmission
S40 : s-soeedManualTransmission
A4RA(U.S.A.):
5000001-
S40{JAPAN): 1000001-
7: LX with IVC
CheckDigit
Model Year
O O T: 1996
L: EastLiberty,Ohio Plant,U.S.A. B-73M CycloneBlueMetallic

H: AllistonPlant,Ontario,Canada G-82P CypressGreenPearl
NH-538 FrostWhite
NH-503P GranadaBlackPearl
NH-583M New VogueSilverMetallic
Vehicleldentification Number R,95P lslandCoralPearl
Safety Standard Gertification Paint Code
COLOR
8.73M
l a
1-3
Chassisand Paint Codes
U.S. 1996Model (2-doorCoupe)
EngineNumber
o f
I H G E J 61 2 * T L 0 0 0 0 0 1 1300001
EngineType
D16Y5:1600SOHCWEC E 16-vatves
SequentialMultiport
Fuel-injected
Engine
D 16Y7:1600SOHC16-vatves
SequentialMultiport
Line. Body and Engine Type Fuel-injected
Engine
EJ6: CIVIC2-doorD16Y7 D16Y8:1600SOHCWEC 16-vatves
EJ7: ClVlC2-doorDl6Y5 SequentialMultiport
EJ8: ClVlC2-door/D16Y8 Fuel-injected
Engine
Body Type and TransmissionType SerialNumber
1:Coupe/s-speed JAPAN:Dl6Y5- 130000'1-
M an u aI U.S.A.: D16Y7,D16YB- 150000'1-
2: Coupe/4-speedAutomatic,CVT
4: DX with A'lC,HX with A,,/C,

EX
5: DX with ABS and A,/C,EX with ABS
CheckDigit
Model Year
T: 1996
A4RA | 4-speedAutomaticTransmission
oa
S 4 0 : s - s p e e dM a n u aT
l ransmission
L: EastLiberty,Ohio Ptant,U.S.A.
M4VA I ContinuouslyVariabte
Transmission (CVT)
A4RA: 5000001-
Vehicleldentification Number S40 : 1000001-
and FederalMotor Vehicle M4VA:1000001-
Safety Standard Certification
CypressGreenPearl
NH-538 FrostWhite
NH 583M New VogueSilverMetallic
R-81 M i l a n oR e d
R-95P lslandCoralPearl
Paint Code
COLOR
G.82P
O O
1-4
CANADA 1996Model (2-door Hatchback)
O O VehicleldentificationNumber
2 H GE J 6 3 2 * T H 0 0 0 0 0 1 D16Y7 -
Manulacturer,Make and
Type of Vehicle D16Y7:1600SOHC'16-valves
2HGr HONDAOF CANADA SequentialMultiPort
Engine
Fuel-injected
HONDAPassenger
vehicle
Line, Body and Engino Type
EJ6: ClvlC3-door/D16Y7
Body Type and TransmissionTyPe
3: Hatchbacld5-speed
M a n u aI
4: Hatchbacld4-speed
Automatic A4RA:4-sDeedAutomaticTransmission
VehicleGrade S40 : 5-sDeedManualTransmission
2,Cx
3:CX-G
CheckDigit
ModelYeal
T: 1996
FactoryCode
H: AllistonPlant,Ontario,Canada
selial Number
O O Vehicleldentification Number
GY-16P
NH-503P
NH-583M
Midori GreenPearl
GranadaBlackPearl
New VogueSilverMetallic
and CanadianMotor Vehicle R-97 RomaRed
Paint Code
COLOR
GY.l6P
0 0
1-5
Chassisand PaintCodes
CANADA1996Model (4-doorSedanl
Vehicleldentification Number EngineNumber !)

lHG 53 * T 800001
r-' D 1 6 Y 7 170000'l
-[
Manufacturer,
Tvpe oI Vehicle
Make and
I H G : H O N D AO FA M E R T C A
EngineType
D16Y7r1600SOHC'16-vatves
I
SequentialN4ultiport
M F G , I, N C . Fuel-injected
Engine
HONDAPassenger SerialNumber
vehicle
Line, Body and EngineType
EJ6: CIVIC4-door/Dt 6y7
Body Type and TransmissionType TransmissionNumber
5: Sedan/5-speed Manual
6: Sedan/4-speed A4RA 5000001
Automatlc
Vehicle Grade
Transmission Type
A4RA:4 speedAutomaticTransmission
T t
3: LX
S 4 0 : s - s p e e dM a n u aT
l ransmission
4: LX with ABS
SerialNumber
5: LX with ABS and A,/C
A4RA:5000001-
6: EX
S40 : 1000001-
7: EX with ABS
CheckDigit
Model Year
Tr 1996
FactoryCode
L: EastLiberty,Ohio Plant,U.S.A.
SerialNumber B 73M
G-82P
NH-503P
C y c l o n eB l u eM e t a l l i c
CypressGreenPearl
GranadaBlackPearl
O '
NH,538 FrostWhite
Vehicleldentification Number NH.583M N e wV o g u eS i l v e rM e t a l l i c
and CanadianMotor Vehicle
Paint Code
COLOR
8.73M
1-6
CANADA1996Model (2-doorCouPe)
O O EngineNumber
1 H GE J 6 1 2 . T L 0 0 0 0 0 1
D16Y7:1600SOHCl6-valves
SequentialMultiPort
Engine
Fuel-injected
D16Y8:1600SOHCVlEC 16-valves
SequentialMultiPort
Engine
Fuel-injected
Line, Body and EngineTYPe
EJ6: ClVlC2-door/D16Y7 SerialNumber
EJ8: ClVlC2'door/D16Y8
Body Type and TransmissionTYPe
A4RA- 5000001
Vehicle Glade
2: DX, Si 44RA:4-speedAutomaticTransmission
3: Si with ABS S40 : 5-speedManualTransmission
5: DX with ABS
CheckDigit
Model Yeal
T: 1996
O ' L: EastLiberty,Ohio Plant,U S.A.
G-82P CypressGreenPearl
Vehicleldentification Number NH-503P GranadaBlackPearl
NH-538 FrostWhite
and GanadianMotor Vehicle
NH 583M New VogueSilverMetallic
Safety StandardCertification M i l a n oR e d
R-81
R 95P lslandCoralPearl
Paint Code
COLOR
NH-538
O O
1-7
VehicleldentificationNumber O O
2 H G E J 63 2 * V H 1 0 0 0 0 1
Manufac-turer,Make and
Type of Vehicle
D16Y7:1600SOHC16-vatves
2HG: HONDAOF CANADA
SequentialMultiport
M F G . I, N C .
Fuel-iniected
Engine
HONDAPassenger
vehicle
Lins, Eody and EngineType
EJ6: ClvtC3-door/D16y7
Body Typo and TransmissionType
Manual
4: Hatchbaclv4-speed
Automatic
Vehicl€ Grade A4RA:4-speedAutomaticTransmission
2: CX B4RAt4-speedAutomaticTransmisston
4: DX S40 : s-speedManualTransmission
CheckDigit
Model Year 44RA:6000001-
V: 1997 B4RA:6000001-
FactoryCode S40 : 1000001-
Destinations
Serial Numbel
NH,5O3P
O O
VehicleldentificationNumber GranadaBlackPearl
and FederalMotor Vehicle NH-583N4 New VogueSilverMetallic
PB-74P DarkAmethystPearl
Salety Standard Certification
R-97 RomaRed
Paint Code
COLOR
NH-583M
O O
1-8
U.S. 1997Model (4-doorSedanl
0 0 Vehicleldentification Number
J-tH M E J 65 2 * V S 0 0 0 0 0 1 D 1 6 Y 7 2300001
Makeand
Manulaqturer.
Typeof Vehicle
Engine
MultiportFuel-iniected
HONDAMOTORCO.,
D16Y8:1600SOHCWEC Sequentral
16-valves
LTD.
Engine
MultiPortFuel-injected
HONDAPassenger
vehicle
HONDAOFAMERICA JAPAN:D16Y7,D16Y8- 2300001-
M F G . I, N C , U.S.A.: D16Y7,D16Y8- 2500001-
HONDAPassenger
vehicle
HONDAOFCANADA Number
Transmission
M F G . I, N C ,
HONDAPassenger A4RA- 6000001
vehicle
Line, Body and Engine TYPe TransmissionTYpe
EJ6: ClVlC4-door/D16Y7 A4RA: 4-speedAutomaticTransmission
EJ8: ClVlC4-door/D16Y8 B4RA: 4-speedAutomaticTransmission
Eody Type and TransmissionTYPe M4RA:4-speedAutomaticTransmissron
5: Sedan/S-sPeed Manual S4O : s-speedManualTransmission
6: Sedan/4-speed SerialNumber
Automattc A4RA(U.S.A.): 6000001^
Vehicle Grade B4RA(U.S.A.): 6000001"
t o 2i DX
4: EX
7: LX with A/C
M4RA(JAPAN):2000001-
S40{JAPAN) : 1000001-
CheckDigit
Model Yeal
V: 1997
FactoryCode
L: EastLibeny,Ohio Plant,U S.A B 73M CycloneBlueMetallic
Japan
S: SuzukaPlant,Mie Prefecture, CypressGreenPearl
G-82P
H: AllistonPlant,Ontario,Canada NH,538 FrostWhite
SerialNumbel NH-503P GranadaBlackPearl
NH.583M New VogueSilverMetallic
R-96P lnzaRed
and FederalMotor Vehicle Paint Code
COLOR
8.73M
O O
1-9
EngineNumber
O O
D16Y5- 2300001
EngineTyp6
D16Y5:1600SOHCVTEC-E16 vatves
SequentialMultiport
Fuel-injected
Engine
D16Y7:1600SOHC16-valves
SequentialMultiport
Lino. Eody and Engine Typ6
Fuel-injected
Engine
EJ6: ClVlC2-door/D16y7 Dl6Y8r1600SOHCVTEC16 vatves
EJ7: ClVlC2-door/Dl6Yb SequentialMultiport
EJ8: ClVlC2-door/D16y8 Fuel-injected
Engine
Body Type and TransmissionType SerialNumber
JAPAN:D16Y5 2300001-
U.S.A.: Dl6Y7, Dl6Y8- 2500001-
Check Digit
Model Yeal
V: 1997
A4RA: 4 speedAutomaticTransmission
84RA: 4-speedAutomaticTransmissron
S40 :s-speedManualTransmission
M4VA:ContinuouslyVariable
Transmission(CVT)
eo
VehicleldentificationNumber A4RA: 6000001-
and FederalMotor Vehicle B 4 R A :6 0 0 0 0 0 1 -
Safety Standard Certification S40 : 1000001-
M4VA:2000001-
G.82P CypressGreenPearl
NH,538 FrostWhite
R-8r M i l a n oR e d
PaintCode
COLOR
G.82P
lo
1 - 10
CANADA1997Model (2-doorHatchbackl
eo VehicleldentificationNumber
2 H G E J 63 2 * V H 0 0 0 0 0 1
-[
Manufacturer,Make and ] '1600SOHC16-valves

D16Y7:
Type oI Vehicle
SequentialMultiPon
2HG: HONDAOF CANADA
Engine
Fuel-iniected
M F G . I, N C .
HONDAPassenger
vehicle
EJ6: ClVlC3-door/D16Y7
3: Hatchbacld5-sPeed
lvlanual
4: HatchbaclV4-speed
Automatic A4RA:4-speedAutomaticTransmission
VehicleGrade B4RA:4-speedAutomaticTransmission
2i CX S 4 O : s - s p e e dM a n u a l T r a n s m i s s i o n
3: CX-G
CheckDigit A4RA:6000001-
Model Yeal 84RA;6000001-
V: 1997 S40 :1000001'
FactoryCode
Selial Number
ao VehicleldentificationNumbel NH-503P GranadaBlackPearl

and CanadianMotor Vehicle NH.583M
PB.14P DarkAmethystPearl
Safety Standard Certification RomaRed
R-97
PaintCode
COLOR
NH.5O3P
e o
1-11
Chassisand Paint Godes
CANADA1997Modet(4-doorSedan)
]l
l H G E J 65 3 * V L 8 0 0 o o l
D16Y7 2750001
1600SOHC16-vatves
SequentialMultiport
Fuel-injected
Engine

EJ6: ClvtC4-door/D16y7
Body Typ€ and TransmissionType
5; Sedan/5-speedManual
,A4RA:4-speedAutomaticTransmission
B4RA:4 speedAutomaticTransmission
4: LX with ABS S40 :s-speedManualTransmission
5; LX with ABS and A,/C
7: EX with ABS 44RA:6000001-
8: EX with ABS and Ay'C B4RA:6000001-
Ch.ck Digit S40 :1000001-
Model Year
V: '1997
B-73M CycloneBlueMetallic
0 0
CypressGreenPearl
VehicleldentificationNumber NH-503P GranadaBlackPearl
NH-538 FrostWhite
and CanadianMotor Vehicle NH-583M New VogueSilverMetallic
Paint Code
COLOR
B.73M
ea
1-12
E-
CANADA1997Model (2-doorCouPel
ao EngineNumber
D16Y7 2750001
1 H GE J 6 1 2 * V L 8 0 0 0 0 1
Engins Typs
SequentialMultiPort
1 H G : H O N D AO FA M E R I C A
Engine
Fuel-injected
D16Y8:l600 SOHCVTEC16-valves
SequentialMultiPort
Engine
Fuel-iniected
EJ6: ClvlC2-door/D16Y7 SerialNumber
Body Type and Tr8nsmissionTYP8
A4RA- 6000001
Vehicle Grado
2 : D X ,S i A4RA:4-speedAutomaticTransmission
3: Si with ABS B4RA:4-speedAutomaticTransmission
5: DX with ABS S4O : s-speedManualTransmission
6: DX with ABS and l'lc
7: Siwith ABS and A,/C A4RA:6000001-
CheckDigit B4RA:6000001*
Model Ysar S40 :1000001-
0 0 V:1997
G-82P CypressGreenPearl
Vehicle ldentification Number NH-503P GranadaBlackPearl
and CanadianMotor Vehicle NH-538 FrostWhite
PaintCode
COLOR
NH-538
a o
1-13
Ghassisand PaintGodes
Vehicleldenti{icationNumber 0 a
2 H G E J 63 2 . W H 1 0 0 0 0 1
Manufactursr,Mak€ and
Type of Vehicle D16Y7:'1600SOHCl6-valves
2HG: HONDAOF CANADA
SequentialMultiport
MFG.,INC. Fuel-injected
Engine
HONDAPassenger
vehicle
Lin€, Body and Engine Type
EJ6: ClvlC3-door/D16y7
Manual
4: Hatchbacl/4-speed
Automatic
B4RA:4-speedAutomaticTransmission
Vehicle Grade
S40 : s-speedManualTransmission
2i CX
4: DX
CheckDigit
Model Year
W: 1998
FactoryCode
HrAllistonPlant,Ontario,Canada
Deslinations
Serial Numbet
NH-592P
NH-583M
PB,74P
FlamencoBlackPearl
DarkAmethystPearl
0 0
R-97 RomaRed
PaintCode
COLOR
NH.583M
ao
1-14
U.S. 1998Model (4'doorSedan)
eo VehicleldentificationNumber EngineNumber
D 1 6 Y 7 3300001
J H M E J 65 2 * W S O O O O O 1
Manufacturer,Make and EngineType

Type of Vehicle
Engine
MultiportFuel'injected
J H M : H O N D AM O T O RC O .
D l6Y8: 1600SOHCVTEC16-valves Sequential
LTD.
Passenger Multiport Engine
Fuel-injected
HONDA
vehicle Serial Number
HONDAOFAMERICA JAPAN:D16Y7.D16Y8- 3300001-
M F G . I, N C . U.S.A : D16Y7,D16Y8- 3500001^
HONDAPassenger
vehicle
HONDAOF CANADA
M F G , I, N C ,
HONDAPassenger B4RA 700000' I
vehicle
Line, Body and Engine TYPe
EJ6: ClVlC4-door/D16Y7 84RA: 4-speedAutomaticTransmission
EJ8: ClVlC4-door/D16Y8 M4RA:4-speedAutomaticTransmission
Body Type and TransmissionTYPe S4O :s-speedManualTransmission
5: Sedan/5-sPeed Manual
6r Sedan/4-speed B4RA(U.S.A.): 7000001-
Automatic M4RA(JAPAN):3000001"
S40(JAPAN) : 1000001-
ro
vehicle Grade
2i DX
4: EX
7: LX with IVC
Check Digit
Model Yeal
W: 1998 CycloneBlueMetallic
B-73M
FactoryCode G 82P CypressGreenPearl
L: EastLiberty,Ohio Plant,U S.A NH-578 TaffetaWhite
S: SuzukaPlant,Mie Prefecture,Japan FlamencoBlackPearl
NH-592P
H: AllistonPlant.Ontario,Canada NH-583M New VogueSilverMetallic
SerialNumber R-96P lnzaRedPearl
000001:JAPAN,U.S.A.
500001:CANADA
PaintCode
VehicleldentificationNumber COLOR
Sa{ety Standard Certification
B-73M
e o
1-15
Ghassisand Paint Codes
U.S. 1998Model (2,doorCoupel
l H G E J 61 2 * W L 0 0 0 0 0 1
EngineNumber
ea
D16Y5 3300001
EngineType
D16Y5:1600SOHCWEC-El6,vatves
SequentialMultiport
Fuel-injected
Engine
SequentialMultiport
Line, Body and Enginc Type
Fuel-in.iected
Engine
EJ6: ClVlC2-door/D16y7
Dl6Y8: 1600SOHCWEC 16-vatves
EJ7: ClVtC2-door/D16ys
SequentialMultiport
Fuel-injected
Engine
Serial Number
JAPAN:D16Y5- 3300OOt-
U.S.A.: D16Y7,D'16y8- 3500001-
5: EX with ABS and IVC

ChockDigir
Model Year
W: 1998
84RA: 4-speedAutomaticTransmissron
L: EastLiberty,Ohio ptant.U.S.A. S40 :s-speedManualTransmission
M4VA:ContinuouslyVariable
Transmission(CVT) 0 a
B4RA:7000001-
Vehicleldentification Number S40 :1000001-
and FederalMotor Vehicle M4VA:4000001-
CypressGreenPearl
NH-592P FlamencoBlackPearl
NH-578 TaffetaWhite
NH-583M New VogueSilverMetaltic
R-81 MilanoRed
PaintCode
COLOR
G.82P
aa
1-16
CANADA 1998Model (2-door Hatchback)
trO VehicleldentificationNumber
2 H G E J 63 2 + W H 0 0 0 0 0 1
Manulacturet, Make and

1600SOHC16-valves
Type of Vehicle
2HG: HONDAOF CANADA SequentiallvlultiPort
Fuel-injecteEdn g i n e
HONDAPassenger
vehicle
Line,Body and EngineTYPe
M a nu a l
Automatic B4RA:4-speedAutomaticTransmission
Vehicle Grade S40 :s-speedManualTransmission
2t CX
3:CXG 84RA:7000001-
CheckDigit S40 :1000001'
Model Year
W: 1998
FactoryCode
SerialNumber
VehicleldentificationNumber PB-74P DarkAmethystPearl
BomaRed
and CanadianMotor Vehicle R-97
Safety StandardCertification
Paint Code
COLOR
NH.592P
1-17
VehicleldentificationNumber A O
2HG .I H 900001
Manufacturer,Make and
Type of Vehicte
I D16Y7:1600SOHC16-valves
2HG: HONDAOF CANADA
] SequentialMultiport
M F G , I, N C .
Fuel-injected
Engine
HONDApassenger
l
vehicle
3 7 5 0 0 0 1 -U: . S . A .
JHM: HONDA|\4OTOR CO., I 370000'l-:JAPAN
r_rD
HONDApassenger
]
I
vehicte I
5: Sedan/5speedManual
6: Sedan/4-speed
Automatic
VehicleGrade
0: EX
3: LX
4: LX WithABS B4RA{U.S.A,): 700000.1-
5: LX with ABS and A"/C M4RA(JAPAN): 3000001-
7: EX with ABS S40(JAPAN) : 'tOO0OO1-
8: EX with ABS and A"/C
CheckDigit
Model Year
W: 1998
0 0
FastoryCode
H :A l l i s t o nPlant,Ontario,Canada
B-73M CycloneBluef\4etallic
S : S u z u k aPlant,N4iePrefecture,Japan
SerialNumber CypressGreenPearl
NH-592P FlamencoBlackpearl
800001^:JAPAN
NH-578 TaffetaWhite
900001-:CANADA
VehicleldentificationNumber Paint Code

SafetyStandardCertification COLOR
8.73M
ao
1-18
CANADA1998Model (2-doorCouPe)
aa Vehicleldentification Numbel EngineNumber
D16Y7
1 H GE J 61 2 * W
EngineType
D'16Y7:1600SOHC16-valves
1 H G : H O N D AO FA M E R I C A SequentiallvlultiPort
M F G , I, N C , FueliniectedEngine
HONDAPassenger D16Y8:1600SOHCVTEC16-valves
vehicle SequentialMultiPon
Engine
Fuel-iniected
Line, Body and Engine TYPe
EJ6: CIVIC2 door/D16Y7 Serial Numbel
EJ8: CIVIC2 dootD16Y8 D16Y7:375000'l'
Body Type and TransmissionTYPe D16Y8:3780001-
Vehicle Grade
2: DX, Si
3: Si with ABS
5: DX with ABS B4RA:4-speedAutomaticTransmissron
6: DX with ABS and A,/C S40 : s-speedManualTransmission
7: Si with ABS and A,/C
CheckDigit 84RA:7000001-
ModelYear S40 :1000001-
tio W:1998
L: EasrLiberty,Ohio Plant,U.SA.
G-82P Cypress Green Pearl

Vehicleldentification Number NH-592P Flamenco Black Pearl
and CanadianMotor Vehicle NH-578 Taffeta White
N e w V o g u e S i l v e rM e t a l l i c
safety StandardCertification NH-583M
R,81 MilanoRed
Paint Code
COLOR
NH-578
t a
1-19
U.S. 1999Model (2-doorHatchbackl
2HGEJ632*XH100001
aa
Manufacturer,
Makeand T
Typeof Vehicte
D'16Y7:
1600SOHCl6-vatves
2HG: HONDAOF CANADA
SequentialMultipon
M F G .t.N C . I Fuel-injected
Engine
HONDApassenger I
vehicle
Line,Body and EngineType - _ r
EJ6: CIVIC3-door/Dt6y7
3: Hatchback/b-speed
M an u aI
4: Hatchbacl/4-speed
Automatic
Vehicle Grade 84RA:4-speedAutomaticTransmission
2: CX S40 : s-speedManualTransmission
4: DX
Check Digit B4RA:8000001-
Model Year S40 | 1000001-
X: 1999
FactoryCode
Destinations
1a
Serial Numbel
NH.592P FlamencoBIackPearl
VehicleldentificationNumber PB-14P DarkAmethystPearl
and FederalMotor Vehicle R-97 RomaRed
PaintCode
COLOR
NH-583M
a a
1-20
U.S. 1999Model (4'doorSedan)
ro Vehicleldentification Number
-f
J H ME J 6 5 2 * X S 0 0 0 0 0 1
Manufacturel,Make and EngineType

Sequential
1600SOHC16-valves
D,]6Y7:
Type ol vehicle
Engine
1 H G : H O N D AO FA M E R I C A
D16Y8:
HONDAPassenger
vehicle
HONDAOF CANADA U.S.A : D16Y7.D16Y8- 4500001-
M F G . I, N C .
HONDAPassenger
vehicle
HONDAMOTORCO.,
LTD.
HONDAPassenger
vehicle
Line. Body and EngineTYPe B4RA: 4-speedAutomaticTransmission
EJ6: CIVIC4 door/D16Y7 S40 :s-speedManualTransmission
Body Type and TransmissionTYPe B4RA(U.S.A.): 8000001-
5: Sedan/S-speed Manual M4RA{JAPAN):4000001-
'1000001-
6: Sedan/4-speed S40(JAPAN) :
Automatic
ro
Vehicle Grade
'l: DX-V
2t DX
4: EX
7: LX BG.41P lcedTealPearl
Check Digit CloverGreenPearl
Model Year NH-578 TaffetaWhite
X: 1999 NH-592P FlamencoBlackPearl
FactoryCode NH.583M New VogueSilverMetallic
L: EastLiberty,Ohio Plant,U S.A R-96P lnzaRedPearl
S: SuzukaPlant,Mie Prefecture,Japan
Serial Numbel
Paint Code
U.S.A.
000001:JAPAN.
500001:CANADA COLOR
NH-s78
t a
1-21
VehicleldentificationNumber EngineNumber
aa
1 H GE J 61 2 * X L 0 0 0 0 0 1
Manutacturer,Make and
EngineType
Type of Vehicle
'1HG: 81642:'1600DOHCVTEC16 vatves
HONDAOF AMERTCA
SequentialMultiport
M F G . I, N C .
Fuel-injected
Engine
HONDAPassenger Dl6Y5: 1600SOHCWEC-E16 vatves
vehicle
SequentialMultipon
FuelinjectedEngine
D16Y7:1600SOHCt6-vatves
SequentialMultiport
Fuel,injected
Engine
EM1: CIVIC2-doorlB'1642
D16Y8:1600SOHCVTEC16-vatves
SequentialMultipon
1:Coupe/s-speed
Fuel-injected
Engine
Manual Serial Numbel
2: Coupe/4-speed
Automatic,
CVT JAPAN:816A2,Dl6Y5 - 4300001-
VehicleGrade
U.S.A.: D16Y7,D16Y8- 4SO000t-
2: DX, HX
4: EX
5: EX WithABS,Si
CheckDigit
Model Year
X:1999
FactoryCode
SerialNumber
B4RA : 4-speedAutomaticTransmission
S40,S4C:5-speedManuatTransmission
ta
M4VA : ContinuouslyVariable
(CVT)
Transmission
and FederalMotor Vehicle B4RA : 8000001-
Safety Standard Certification S 4 0 ,S 4 C : 1 0 0 0 0 0 1 -
M4VA : 5000001-
B-95P ElectronBluePearl
G-95P CloverGreenPearl
NH-578 TaffetaWhite
R-97 RomaRed
PaintCode
COLOR
NH.592P
ea
1-22
CANADA1999Model (2-doorHatchback)
Vehicleldentification Number E n g r n eN u
-rl
2 H GE J 6 3 2 * X H 0 0 0 0 0 1

Type of Vehicl€ D16Y7:1600SOHC16-valves
2HG: HONDAOF CANADA SequentialMultiport
lNC.
l\4FG., Engine
Fuel-injected
HONDAPassenger
vehicle
Line,Bodyand EngineType
3r Hatchbaclds speed B4RA 8000001
M an u aI T t
4r Hatchbacld4-speed TransmissionType
Automatic B4RA:4-speedAutomaticTransmission
VehicleGrade S40 : s-speedManualTransmission
2: CX SerialNumber
3: DX 84RA:800000'l-
CheckDigit S40 :1000001-
Model Year
X: 1999
FactoryCode
Serial Number
ro Vehicleldentification Number
NH-592P
NH-583M
PB.74P
R,97
FlamencoBlackPearl
DarkAmethystPearl
RomaRed
PaintCode
COLOR
NH.592P
t a
1-23
Ghassisand Paint Codes
J H ME J 6 5 3 * X S 8 O O O O 1
eo
D16Y7 4700001
Manufaclurer,Make and EngineType

Type ot Vehicle D 16Y7:1 600SOHC16-valves Sequential
JHM: HONDAMOTORCO., MultiportFuel-injected
Engine
LTD.
HONDAPassenger JAPAN:D16Y7- 4700001-
vehicle - 4750001-
U.S.A : D'16Y7
2HG: HONDAOF CANADA
M F G . I, N C .
HONDAPassenger
vehicle
5: Sedan/s-speed Manual B4RA: 4-speedAutomaticTransmission
6: Sedan/4-speed M4RA:4-speedAutomaticTransmission
Automatic S40 rs-speedManualTransmission
VehicleGrade
0:EX B4RA(U.S.A.): 8000001-
3: LX M4RA(JAPAN);400000'l-
4: LX with ABS S40(JAPAN) : 1000001-
5: LX with ABS and lVC
7: EX with ABS
8: EX with ABS and Ay'C
Ch6ckDigit
Model Year
X: 1999
BG.41P lcedTealPearl
ro
FactoryCode
S: SuzukaPlant,Mie Prefecture,
Japan G-95P CloverGreenPearl
H: AllistonPlant,Ontario,Canada NH-578 TaffetaWhite
SerialNumber NH-592P FlamencoBlackPearl
800001:JAPAN NH-583M New VogueSilverMetallic
900001:CANADA R-97 RomaRed
PaintGode
COLOR
BG.41P
ta
1-24
CANADA1999Model (2-doorCouPel
VehicleldentificationNumber EngineNumber
1 H GE J 61 2 * X L 8 0 0 0 0 1 D 1 6 Y 7 4750001

Type of Vehicle 816,42:1 600DOHCVTEC16-valves
l H G r H O N D AO FA M E R I C A I SequentialMultiport
M F G , I, N C . FuelinjectedEngine
HONDAPassenger D16Y7:1600SOHC16'valves
vehicle SequentialMultiPort
Line. Body and EngineTyPe - i Engine
Fuel-injected
EJ6: ClVlC2-door/D16Y7 D16Y8:1600SOHCVTECl6-valves
EJ8: ClVlC2-door/D16Y8 SequentialMultiPort
EMlr CIVIC2'doorlB'16,42 Engine
Fuel'injected
Body Type and TransmissionTYPe SerialNumber
1:Coupe/s-speed 8 1 6 4 21: 7 0 0 0 0 1 -
M a nu a l D16Y7: 4750001-
2: Coupe/4-speed D16Y8: 4780001'
Automatic
Vehicle Grade
2: DX,Si TransmissionNumber
4 :S i R
5: SiRwith ABS B4RA
6: DX with ABS and IVC T
7: Si with ABS and A,,/C Type
Transmission
CheckDigit B4RA : 4-soeedAutomaticTransmission
Model Year S40.S4C:5-sgeedManualTransmission
X:1999 SerialNumber
FactoryCode B4RA : 8000001-
L: EastLiberty,Ohio Plant,U.S.A. S40,S4C:1000001-
SerialNumbel
C ol o r
Safety Standard Certification B.95P ElectronBluePearl
G-95P CloverGreenPearl
NH-592P o l a c kP e a r l
F l a m e n cB
NH 578 TaffetaWhite
NH-583M N e wV o g u eS i l v e rM e t a l l i c
R97 R o m aR e d
PaintCode
COLOR
NH-592P
t o
1-25
U.S.2000Model (2-doorHatchback)
VehicleldentificationNumber 0 0
2 H G E J 6 3 2 *H 1 0 0 0 0 1 5500001
D16Y7 -[
Type of Vehicle Dl6Y7: 1600SOHCI6-valvesSequenlal
2HG: HONDAOF CANADA MultiportFuel-injected
Engine
M F G , I, N C .
HONDAPassenger
Vehicle
Body Type and T.ansmissionType
3: Hatchbaclds-speed Manual
4: Hatchbacld4-speed Automatic
Vohicle Grade
84RA:4 speedAutomaticTransmissron
2: CX
S40 :s-speedManualTransmissiorr
4: DX
Check Digit
84RA:900000'l-
Model Yeal
S40 | 100000'l-
Y: 2000
FastoryCode
H: AllistonPlant,Ontario.Canada
SerialNumber
to
NH-578 TaffetaWhite
VehicleldentificationNumbeI NH.583M New VogueSilverlr4etallic
and FederalMotor Vehicle NH-592P FlamencoBlackPearl
Safety Standard Certification R-97 RomaRed
PaintCode
COLOR
NH.583M
ro
1-26
U.S.2000Model {4-doorSedan)
t VehicleldentificationNumber EngineNumber
J H ME J 6 5 2 * Y S 0 0 0 0 0 1 Dl6Y7, 5300001
Manufacturer,Makg and EngineType

Type of Vehicle D16Y7:1600SOHC16-valves Sequential
JHM: HONDAMOTORCO., Engine
MultiportFuel-iniected
LTD. D16Y8:1600SOHCVTEC16-valves
HONDAPassenger SequentialMultiportFuel-iniected
Vehicle Engine
HONDAOFAMERICA Sorial Numbsr
MFG.,INC. Japan:5300001-
HONDAPassenger U.S.A.r5500001-
Vehicle
2 H G : HONDAOF CANADA
IVIFG.,
INC,
HONDAPassenger
Vehicle
EJ8: ClVlC4-door/D16Y8 S4RA : 4-sDeedAutomaticTransmission
Body Type and TransmissionTyPe B4RA : 4-speedAutomaticTransmission
5: Sedan/5-speed Manual S40,S4C : s-speedManualTransmission
6: Sedan/4-speed Automatic
Vshicle Grade S4RA{Japan)
2: DX B4RA(U.S.A.)
4: EX S40,S4C(Japan)
7: LX
CheckDigit
Model Year
Y: 2000
FactoryCode
S: SuzukaPlant,Mie Pretecture,Japan
L: EastLiberty,Ohio Plant,U.S.A. BG-41P lcedTealPearl
H: AllistonPlant,Ontario,Canada G.95P CloverGreenPearl
NH-578 TaffetaWhite
Serial Number
JapanU , .S.A.:000001- NH-592P FlamencoBlackPearl
500001- YR.525M TitaniumMetallic
Canada:
RP.32P VintagePlum Pearl
VehicleldentificationNumber Paint Code

Safety Standard Certification COLOR
NH-578
t o
1-27
U.S.2000Model (2-doorCoupe)
l H GE J 61 2* Y 1 0 0 0 0 0 1
EngineNumber ta
D16Y5- 5300001
Manufacturer.Make and EnginoType
Type ol Vehicle Bl642; 1600DOHCWEC '16-vatves
'1HG:
HONDAOF AMERICA SequentialMultiportFuel-injected
t\4FG.,
tNC. Engine
HONDAPassenger D'I6Y5:1600SOHCWEC-E16.vatves
Vehicle SequentialMultiportFuel-injected
Line,Body and EngineType Engine
EJ6: ClvlC2-door/Dt6Y7 D16Y7:1600SOHC16-valves Sequenlal
EJ7: ClVlC2,door/D16y5 MultiportFuel-injected
Engine
EJ8: ClVlC2-door/D16Y8 D16Y8:1600SOHCWEC 16-vatves
EM1: CIVIC2-doorlB1642 SequentialMultipon Fuel-injected
Body Type and TransmissionType Engine
1: Coupe/s-speed
Manual Serial Number
2: Coupe/4-speed
Automatic,CVT 81642,D16Y5:5300001-
Vehicle Grade Dl6Y7,Dl6Y8:5500001-
2: DX, HX
4: EX
5: EX with ABS,Si
CheckDigit
Model Year
Y: 2000
FactoryCode
Serial Number B4RA : 4-speedAutomaticTransmission
S40,S4C:5-speedManualTransmissron
M4VA :ContinuouslyVariable
(CVT)
Transmission
to
and FederalMotor Vehicle B4RA : 9000001*
Safety Standard Certification S40.S4C:1000001-
M4VA :6000001-
B-95P ElectronBluePearl
CloverGreenPearl
NH-578 TaffetaWhite
PaintCode
COLOR
NH.592P
to
1-28
CANADA2000 Model (2-door Hatchbackl
ro Vehicle ldentification Number
D16Y7 -
2 H GE J 6 3 2 * Y H 0 0 0 0 0 1
Manufaqturor,Make and
Type of Vehicle D16Y7:1600SOHC16-valves Sequential
2HG: HONDAOF CANADA Engine
Number
Se1i8l
HONDAPassenger
Vehicle
EJ6: ClVlC3-door/Dl6Yt
3: HatchbacUs-sDeed Manual
4; Hatchbacld4-speedAutomatic
Vehicle Glade B4RA:4-speedAutomaticTransmission
2t CX S40 : s-speedManualTransmission
3: OX
5r SE 84RA:9000001-
CheckDigit S40 :1000001-
Model Yoal
Y: 2000
FactoryCode
H: AllistonPlant.Ontario,Canada
Serial Numb€r
NH.592P FlamencoBlackPearl
VehicleldentificationNumber R-97 RomaRed
and CanadianMotor Vehicle RP-32P VintagePlum Pearl
Paint Code
COLOR
NH.592P
1-29
J H M E J 65 2 * Y S 8 0 0 0 0 1
ro
D16Y7
Manufaqturer, Makg and EngineType

Type ot Vehicle D't6Y7| 1600SOHC16-valves Sequential
JHM: HONDAMOTORCO., MultiportFuel-injected
Engine
LTD.
HONDAPassenger J a p a n5
: 700001-
Vehicle U.S.A.:5750001-
2HG: HONDAOF CANADA
M F G . I, N C .
HONDAPassenger
Vehicle Transmission
Number
Body Type and TransmissionTyp€
--t
S4RA- 5000001
5: Sedan/s-speed Manual TransmissionType

6: Sedan/4-speed Automatic 54RA: 4-speedAutomaticTransmissron
Vehicle Grade B4RA: 4-speedAutomaticTransmissron
0: EX S 4 0 : s - s p e e dM a n u aT
l ransmission
1: LX-V SerialNumber
2: LX-Vwith ABS 54RAlJapan): 500000'1-
3: LX B4RA(U.S.A,);900000
1-
4: LX with ABS S40(Japan) : '1000001,
5: LX with ABS and ly'C
7: EX with ABS
8; EX with ABS and A,,/C
Check Digit
Model Y€ar
Paint Code
Paint Code
ro
Y: 2000 G-95P CloverGreenPearl
Fac'tory
Code NH,583M New VogueSilverMetallic
S: SuzukaPlant,Mie Prefecture,
Japan NH.592P FlamencoBlackPearl
H: AllistonPlant,Ontario,Canada YR-525M TitaniumMetallic
Serial Number RP.32P VintagePlum Pearl
Japan :800001-
Canada:900001-
PaintCode
COLOR
and CanadianMotor Vehicle NH.583M
ro
1-30
CANADA2000 Model (2-doorCoupel
l H G E J 6 ' l2 * Y 1 8 0 0 0 0 1 81642 5700001
Type of Vehicle 816A2:1600DOHCVTEC16-valves
1 H G : H O N D AO FA M E R I C A SequentialMultiportFuel-iniected
M F G , I, N C . Engine
'1600SOHC16-valves Sequential
HONDAPassenger Dl6Y7:
Vehicle Engine
Line, Body and EngineType D16Y8:1600SOHCWEC 16-valves
EJ6r ClVlC2-door/D16Y7 SequentialMultiponFuel-injected
EJ8: ClVlC2-door/D'16Y8 En gi n e
EM1: CIVIC2-door/B1642
Body Type and TransmissionType 81642:5700001-
1: Coupe/s-speed Manual D16Y7:575000'l-
2: Coupe/4-speed Automatic D16Y8:578000'l-
Vehicle Grade
2: DX,Si
4 :S i R
5: SiRwith ABS
6: DX with ABS and A,/C
7:DXG
Check Digit
Model Year B4RA :4-speedAutomaticTransmission
Y: 2000 S40,S4C:s-speedManualTransmissron
FactoryCode
L L: EastLibertv,Ohio Plant.U.S.A.
SerialNumber
B4RA :9000001-
S40,S4C:1000001-
8.95P ElectronBlue Pearl
G.95P CloverGreenPearl
NH.592P FlamencoBlackPearl
PaintCode
COLOR
NH-592P
ra
1-31
ldentification Number Locations
Vehicle ld6ntification
Numbsr(VlN)
t,
ta
Number
t a
1-32
Warning/CautionLabelLocations
'96 -99 model C: DRIVERMODULEOANGER

A: CABLEREELCAUTIONA:
DANGER
TO SERVICEMANUAL FOR DETAILEDINSTRUC. EXPLOSIVE/FLAMMABLE
TtoNs. CONTACTWITH ACIO.WATER OR HEAVY METALS SUCH
AS COPPER. I.EADOR MERCURYMAY PRODUCEHARMFUL
'00 model AND IRRITATINGGASESOR EXPLOSIVECOMPOUNDS,
STOBAGETEMPERATURES MUST NOT EXCEED2OO'F
I1(x}"CI.FOR PROPERHANDLING.STORAGEAND DISPOS.
AL PROCEDURES REFERTO SERVICEMANUAL. SRS SUP.
ALLATIONOF THE SRS CAELEREELIS CRITICALTO
PLEMENT.
THE PROPEROPERATIONOF THE SRSSYSTEM.REFERTO
POTSON
T H E S E R V I C E M A N U A L D E T A I L E DI N S T A L L A T I O N
CONTAINSPOISONOUSSODIUM AZIOEAND POTASSIUM
INSTRUCTIONS.
NITRATE.
FIRSTAID:
Br oRIVERMODULEWARNING IF CONTENTSARE SWALLOWED,INDUCEVOMITING,FOB
EYECONTACT.FLUSHEYESWTTHWATERFOR15 MINUTES.
WARNING IF GASES{FNOMACIOORWATEBCONTACTIAREINHALED,
THE AIRBAG INFLATORIS EXPLOSIVEAND, IF ACCIOEN- SEEKFRESHAIR. IN EVERYCASE,GET PBOMPTMEDICAL
TALLYDEPLOYEO, CAN SERIOUSLY HURTOR KILLYOU. ATTET,ITION.
. DO NOT USE ELECTRICAL TESTEoUIPMENToR PROB- KEEPOUT OF REACHOF CHILDREN.
ING OEVICES.
THEYCAN CAUSEACCIDENTAL DEPLOYMENT.
o N O S E R V I C E A B L EP A R T S l N S l D E . D O N O T
DISASSEMBLE.
. PLACEAIRBAGUPRIGHTWHENREMOVED.
. FOLLOWSERVICE MANUALNSTBUCTIONS CAFEFULLY.
(cont'd)
1-33
Warning/GautionLabelLocations
(cont'dl
to
-==-J
_) F
v7777m7na
ro
CANADAmod6l l'96 - gtt modell
D: DRIVERINFORMATION: U.S. model l'98, 39 model)
WARNING
ALWAYSWEARYOURSEATBELT OEATHOR SERIOUSINJURYCAN OCCUR.
. THIS CAR IS EOUIPPEDWITH A DRIVERAIRBAGAND A . CHILDREN 1 2 A N D U N O E RC A N B E K I L L E DB Y T H E
FRONTSEAT PASSENGER AIRBAG' AS A SUPPLEMEN- AIREAG.
TAL RESTRAINTSYSTEMISRSI. . THEBACKSEATIS THESAFESTPLACEFORCHILDREN.
. IT IS OESIGNEDTO SUPPLEMENT THESEATBELT, o N E V E RP U T A B E A R . F A C I N G C H I L DS E A T I N T H E
* Except CANADA CX FRONT.
. SIT AS FARBACKAS POSSIBLEFROMTHEAIRBAG.
. ALWAYSUSESEATBELTSAND CHILDRESTRAINTS.
E: SBSINFORMATION:U.S. model ('96.'97 model)
. THE SRSMUST BE INSPECTED TEN YEARSAFTERIT IS
INSTALLED,
CAUTION . T H E D A T E O F I N S T A L L A T I O NI S S H O W N O N T H E
TO AVOIDSERIOUSINJURY: DRIVER'SDOORJAMB.
. FORMAXIMUM SAFEW PROTECTION IN ALL TYPESOF
CBASHES,YOU MUST ALWAYS WEAR YOUR SAFETY
BELT. U.S. model ('00 modelI
. DO NOT INSTALLREARWARD-FACING CHILDSEATSlN
ANY FRONTPASSENGER SEATPOSITION. WARNING
. DO NOT SIT OR LEAN UNNECESSARILY CLOSETO THE DEATHOR SERIOUSINJURYCAN OCCUR,
AIRBAG. . CHILDREN12 AND UNDER CAN BE KILLEDBY THE
. DO NOT PLACEANY OBJECTSOVERTHE AIRBAGOR AIRBAG.
BETWEENTHEAIRSAGAND YOURSELF. . THEBACKSEATIS THESAFESTPLACEFORCHILOREN.
o SEE THE OWNER,S MANUAL FOB FURTHER . N E V E RP U T A R E A R - F A C I N G
C H I L DS E A T l N T H E
INFORMATION AND EXPLANATIONS. FRONT.
ro
. THESRS MUST BE INSPECTED TEN YEASSAFTERIT IS o SIT AS FARBACKAS POSSIBLEFROMTHEAIRBAG.
INSTALLED, o ALWAYSUSESEATBELTSAND CHILDRESTRAINTS.
. THE DATEOF INSTALI-ATION I S S H O W NO F T H E
DRIVER'SDOORJAMB.
1-34
Llo CANADAmodel ('00 model) MOOULEDANGER
I: FRONTSEATPASSENGER
CAUTION DANGER
TO AVOIDSERIOUSINJURYT EXPLOSIVE/FLAMMABLE
. FORMAXIMUM SAFETYPROTECTION lN ALL TYPESOF CONTACTWITH ACID, WATEROR HEAVY METALS SUCH
CRASHES,YOU MUST ALWAYS WEAR YOUR SAFETY AS COPPER, LEADOR MERCURYMAY PRODUCEHARM.
BELT. F U L A N D I R R I T A T I N GG A S E S O R E X P L O S I V EC O M -
. DO NOT INSTALLREARWARD-FACINGCHILDSEATSlN POUNDS,STORAGETEMPERATURES MUST NOT EXCEED
SEATPOSITION.
ANY FRONI PASSENGER 2OO'FI1OO"C}. FOR PROPERHANOLING,STORAGEAND
. DO NOT PLACEANY OBJECTSOVER THE AIRBAGOR DISPOSALPNOCEDURES REFERTO SERVICEMANUAL'
BETWEENTHEAIRBAGAND YOURSELF. SRSSUPPLEMENT.
. SEE THE OWNER'S MANUAL FOR FURTHER POISON
INFORMATION ANDEXPLANATIONS. CONTAINSPOISONOUSSODIUM AZIDEAND POTASSIUM
NITRATE.
ExceptCx tor passengerside FIRSTAID
'97 mod€l) IF CONTENTSARE SWALLOWEO,INDUCEVOMITING.FOR
F: ASSISTANTINFoRMATION:US MODEL('96. EYE CONTACT,FLUSH EYES WITH WATEB FOR 15 MIN-
UTES. IF GASESIFROM ACID OB WATER CONTACT)ABE
AIRBAGSEEOTHERSIDE, INHALED.SEEKFRESHAIR. IN EVERYCASE,GET PROMPT
MEDICALATTENTION.
KEEPOUT OF REACHOF CHILDREN,
U.S. model l'98 - 00 modell
WARNING
AIRBAGWARNING THE AIRBAG INFLATORIS EXPLOSIVEAND, IF ACCIDEN-
FLIPVISOROVER TALLYOEPLOYED, CAN SERIOUSLY HUBTOR KILLYOU.
. D O N O T U S E E L E C T R I C ATL E S T E O U I P M E N TO R
PROBINGDEVICES.
G: STEERINGCOLUMNNOTICE TH€YCAN CAUSEACCIDENTAL DEPLOYMENT'
. N O S E R V I C E A B L EP A B T S l N S l D E . o O N o T
NOTICE DISASSEMBLE.
TO PBEVENTSRS DAMAGE, REMOVESTEERINGWHEEL . PLACEAIRBAGUPRIGHTWHENREMOVED
Llo BEFOREREMOVINGSTEERINGSHAFT CONNECTING

BOLT.
ll: MONITORCAUTION
. FOLTOWSERVICE
Jr SRSWARNINGIHOOD)
MANUALINSTRUCTIONS CAREFULLY
SUPPLEMENTAL RESTRAINT SYSTEMISRS}

NOTICE THIS VEHICLEIS EOUIPPEDWITH DBIVERAND FRONT
. NO SERVICEABIfPABTSlNSlDE. SEATPASSENGER AIRBAGS'.
. REFERTO SERVICEMANUAL FORDETAILEDINSTRUC' ALL SRS ELECTRICAL WIRINGAND CONNECTORS ABE
TtoNs. 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.
WARNING
THE AIRBAGINFLATORIS EXPLOSIVEAND, IF ACCIDEN.
TALLY DEPLOYED,CAN SERIOUSLYHURT YOU. FOLLOW
SERVICEMANUAL INSTRUCTIONSCAFEFULLY'
' ExceotCANADACX
K: PASSENGER AIRBAGCAUTION
u.S. model l'98 - 00 model)
WARNING
CHILDREN CAN 8E KILLEDOR INJUREOBY PASSENGER
AIRBAG,
THE BACKSEAT IS THE SAFESTPLACEFORCHILDREN12
AND UNDER.MAKESUREALLCHILDREN USESEATBELTS
OR CHILDSEATS.
(cont'd)
1-35
Warning/CautionLabelLocations
(cont'd)
t,
191t7CANADAMod6l
t,
t,
1-36
Under-hoodEmissionsControl Label (1996,1997model)
EmissionGroupldentification Families
Engineand EvaPorative
Example: EngineFamily: T|I
V H Nl . 6 V J G K G K
Model Year TI
T: 1996
V: 1997
Manufacturer
H N :H o n d a
Displacem€nt
VACUUMHOSEROUTINGDIAGRAM
V: Light DutyVehicle/Passenger Car
Fuel Systsm and Number of valves
J: ElectronicSequentialMultiportInjection
(threeor more valvesper cylinder)
Fuel Type
G:Gasoline
Standard
F: 49 or 50 StatesTier 1
-VEHICLE K: 49 or 50 StatesTier 1
Ei/ISSION INFORMATION
CONTROL 1 : C a l i f o r n iTai e r 1
E \ G \ . r r M r r v t s N r s \ J L K 6 \ D s p - A ( . M5F9N0 ( - - , . O CIVIC fa:n
!APOF!]V4-AV.t' !-rirorrSrMAc \Y:/ 2: CaliforniaTLEV
IwcN02S{2)sFr 3: CaliforniaLEV
CATALYST
F l . t a r o s t q ! t M A \ u A t t o a a o o T o \ a -\ ' o F M ^ r o \ rt Tl 4; CaliforniaULEV
r . \ F J o ( O \ D' O \ S E \ G r \ lA I N O n M A - O o l q l l N C T M oU
E q lA lH i
a-LACCESSoT rS r-F\Eo0F C00ll\G-A\ 0( \-!-lJ Catalyst
TRANSM1SSION N NEUTFAI
NOOTHERAOJUSIMENTS NEEDEO. O8D IICERTIFIED E, F, G. H: ThreeWay Catalyst
IDLESPEEO OBD
ATDC K - T: OBDEquipped
NDr(Jl6CR.L1l
U S.EPAANDSTATE
r.r-i," Family:
Evaporative '|T
v HN1077BYMAc
THSVEHCLECONfOFMSTO
RECULAI
OFCALfORNIA
MOOETYEARNEWMOTORVEHCL'S
1997
ONSAPPLICA8IElO
ilil]]lrl Model Year
T:1996
4q!sq+HT-q4E!rL
Er!4#_"E!!ifl |
TIEB
l FULL
V:1997
N US€ l
.?2EAO2
11211 HONDA
MoTOR
C0, tTD
Manufacturel
H N :H o n d a
Storage System
50ST{50 States): 1:Canister
THISVEHICLE CONFORMSTO U.S,EPAAND STATEOF CanisterWorking Capacity (grams)
CALIFORNIA APPLICABLE
REGULATIONS TO 1996AND CanisterConfigulation
1997MODELYEARNEWMOTOR VEHICLES. A: PlasticHousing(ClosedBottom)
B: PlasticHousing(oPenBottom)
/$ST (49 States/Federall: Fuel Systsm
THISVEHICLE CONFORMS TO U.S.EPA REGULATIONS Y: FuelInjection
' 1 9 9 6A N D 1 9 9 7M O D E LY E A RN E W
A P P L I C A B LTEO Fuel Tank
MOTOBVEHICLES, M: Metal
Standard
CAL (Calitornis): A: CurrentEvap
THISVEHICLE CONFORMS TO U.S.EPAAND STATEOF E: EnhancedEvap
CALIFORNIA REGULATIONSAPPLICABLETO 1996AND Wild Card
,1997MODELYEARNEW PASSENGER CARSPROVIDED
THATTHISVEHICLE IS ONLYINTROOUCED INTOCOM-
MERCEFORSALEIN THESTATEOF CALIFORNIA.
1-37
Under-hoodEmissionsControl Label(lggg model)
EmissionGroup ldentification
Example:
Engineand EvaporativeFamilies
EngineFamily: H N X v 0 ' t . 6J L 2
rf
Model Year
W: 1998
oR3.'@M|LES|3,@|frlw!cs
Manufacturer
H N X :H o n d a
Type
V: Light DutyVehicle/Passenger
Car
VEHICLE
EI\4ISSION
CONTROL
INFORIVATION Displacement
rH SVEHCLECONFOFMS
STA1EOFCALIFORNIA
IO U S EPAAND
RE6ULAIIONS APPLICABLE
SequenceCharacters
IO 199AMODELYEARNEWTIEVPASSENGER
CA8SPFOVOEOTI]AI 'HIS VEI CLE S OILY
INIBODUCEDINTOCOMMEfiCE FORSALE N TNC EvaporativeFamily: W HNX E 0065A A D
VALVE
LASH
CATALYST
IWCINO?S]2)EGR6F/OBO] CEFT]F
ED
Model Year
W: 1998
T
1C0L0l EX 0 r51002mm
Manufacturel
NOOTHTR
AO.]USIMI\ISNI'TOEO
H N X :H o n d a
Type
I]ONDA
OE E :EVAP
MOTOB
CO.,ITD
CanisterWork C.pacity (glamsl
SequenceCharacters
50ST (50 Statosl:
THISVEHICLE CONFORMS TO U,S.EPAAND STATEOF
C A L I F O R N IR
A E G U L A T I O NASP P L I C A B LTEO 1 9 9 8
MODELYEARNEWMOTORVEHICLES,
ilgsT 149States/Federal):
THISVEHICLE CONFORMS TO U.S.EPAREGULATIONS
LO
APPLICABLE TO 1998MODELYEARNEWMOTORVEHI.
CLES.
CAL (California):
THISVEHICLE CONFORMS TO U.S.EPAAND STATEOF
C A L I F O R N IR
A E G U L A T I O NASP P L I C A B LTEO 1 9 9 8
M O D E LY E A R N E W P A S S E N G E C R A R SP R O V I D E D
THATTHISVEHICLE IS ONLYINTRODUCED INTOCOM.
MERCEFORSALEIN THESTATEOF CALIFORNIA.
ro
1-38
(1999modell Families
Engineand Evaporative
EmissionGroupldentification X HNX V 0 t . 6J F 1
EngineFamily:
Example:
Model Yeal
T rT T
X:1999
Manutacturer
H N X :H o n d a
r l
Tvpe
Car
V: Light DutyVehicle/Passenger
Disolacement
INFOEMATION
CONTROL
EMISSION
VEHICLE SequenceCharacters
IO U S E
13 S VEHCLECONFORMS
APPLCABLETOI999MOOELYEAR NEWPASSENCER FamilY:
Evaporative
++
_T
R 0090AAD
T_
ModelYear I
CATALYST X:1999
Manufacturer
l
IAIV€L{SH
COLD H N X :H o n d a
SPARTPLU6CAP
E v
Type
R: ORVR
@o CanisterWork CaPacitY(gramsl
MOTOECOLTD
HONDA SequenceCharacters
FEDERALTIER1:
THISVEHICLECONFORMS TO U.S,EPAREGULATIONS
TO '1999MODELYEARNEW PASSENGER
APPLICABLE
CARS.
CALIFORNIA+ NLEV{RESTRICTEDI TLEV:

THIS VEHICLECONFORIVIS TO CALIFORNIA REGULA-
TIONS APPLICABLE TO 1999 MODEL YEAR NEW TLEV
PASSENGER CARSAND TO U.S.EPA NLEVPROGRAM
REGULATIONS APPLICABLE TO 1999NEW TLEV PAS-
SENGER CARS.
THISVEHICLE MAY ONLYBE INTRODUCED INTOCOM-
MERCEFORSALEIN CALIFORNIA, A STATETHAT HAS
THE CALIFORNIASTANDARDSIN EFFECTTO WHICH
A , S T A T ET H A T
H A S B E E NC E R T I F I E D
T H I SV E H I C L E
HAS OPTEDINTOTHE NLEV PROGRAM, OR A STATE
CONTIGUOUS THERETO.
50 STATELEV+ CFFV+ NLEV {UNRESTRICTED}:

C O N F O R MT
T H I SV E H I C L E SO U . S .E P A N L E VA N D
CLEAN-FUEL V E H I C L A
E N D C A L I F O R N IR
AE G U L A '
T I O N SA P P L I C A B LT E O G A S O L I N EF U E L E D1 9 9 9
M O D E LY E A R N E W L E V I P A S S E N G E R CARS/LIGHT
DUW TRUCKS].
50 STATETLEV + NLEV (UNRESTRICTED):

THISVEHICLE CONFORMS TO U.S.EPANLEVREGULA'
TIONSAPPLICABLE TO 1999MODELYEARNEW TLEV
RA R SA N D C A L I F O R N IR
P A S S E N G EC AE G U L A T I O N S
APPLICABLE TO 1999 MODELYEAR NEW TLEV IPAS'
SENGERCARS/LIGHT DUW TRUCKS].
1-39
Under-hoodEmissionControl Label (2000model)
EmissionGroupldentification
Example:
Engineand Evaporative
EngineFamily:
Families
Y H N X V 0 1 , 6J F 1
ro
Model Yeal
Y; 2000
oRs'MM|LESt4,0oorml,wtscN
Manufaqturer
HNX:Honda
Type
V: Light DutyVehicle/passenger
Car
VEHICLE
EMISSION
CONTROL
INFOBI\4ATION Displacoment
T8ISVEHCLECONFOfiMS
TO U,S EPARECIJLATIONS
APPLICABLE
IO 'OOOMODELYEASNEWPASSENGER
SequenceCharaqtgrs
EvaporativeFamily: Y HNX R OO99

AAD
CATALYST Model Year
vAtw LcsH rN0.20:0
0?nn Y: 2000
lcorDr EX025:00?mh
SPAAKPIIJGCAP Manufaeturer
NOOTNERAD.IUSIMENIS
NE€OTO
HNX: Honda
Type
R: ORVR
(0. Lro
t0N0aM0T08
CanisterWork Capacity (grams)
SsquenceCharacters
FEDERALTIER1:
THISVEHICLECONFORMSTO U,S.EPA REGULATIONS
APPLICABLETO 2OOO
MODELYEARNEW PASSENGER
CARS.
CALIFORNIA+ NLEV (RESTR|CTEDt

T H I SV E H I C L E
TIONSAPPLICABLE
CONFORMS
TLEV:
T O C A L I F O R N IR
TO 2OOO
AE G U L A - LO
MODELYEARNEW TLEV
PASSENGER CARSAND TO U,S.EPA NLEVPROGRAM
REGULATIONS APPLICABLETO 2OOO NEW TLEV PAS-
SENGERCARS.
THISVEHICLE MAY ONLYBE INTRODUCED INTOCOM.
MERCEFORSALEIN CALIFORNIA. A STATETHATHAS
THE CALIFORNIASTANDARDSIN EFFECTTO WHICH
THIS VEHICLEHAS BEENCERTIFIED, A STATETHAT
HAS OPTEDINTOTHE NLEVPROGRAM,OR A STATE
CONTIGUOUS THERETO.
50 STATELEV + CFFV+ NLEV {UNRESTRTCTED):

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 VA N D
C L E A N . F U EVLE H I C L E A N D C A L I F O R N IRAE G U L A ,
T I O N SA P P L I C A B L T E O G A S O L I N EF U E L E D2 O O O
MODELYEARNEWLEVPASSENGER CARS.
E P A C E R T I F I C A T I OTNE S T F U E L :E P A U N L E A D E D
GASOLINE
50 STATETLEV+ NLEV (UNRESTRICTED}:

THISVEHICLE CONFORMS TO U.S.EPANLEVREGULA.
TIONSAPPLICABLE TO 2OOO MODELYEARNEW TLEV
P A S S E N G EC
RA R SA N D C A L I F O R N IR
AE G U L A T I O N S
APPLICABLE TO 2OOO MODELYEAR NEW TLEV PAS-
SENGERCARS.
L,
1-40
Lift and SupPort Points
Lift and SafetYStands
L,O t!ffi when heavv rear componentssuch as suspension'fuel tank' spare tire'
hatch' and trunk lid are to be
-aE rear
before hoisting. when substantial weight is lemoved from the
removed, place additional wetght Inihe luggage arga
vehicle to tip tolward on the hoisi
of the vehicls. the center of gravity may change and can cause the
NOTE:
assembly
. Sinceeachtire/wheel 30 lbs (14kg)'placingthefrontwheelsin the luggageareacan
weighsapproximately
assistwiththeweightdistribution
. Usethesamesupportpointsto supponthevehicleon safetystands'
1 . Placethe lift blocksas shown.
and rockthe vehicleto be sure it is firmly supported'

2 . Raisethe hoista lew inches(centrmeters)
3 . Raisethe hoistto full height,and inspectlift pointsfor solidsupport
REARSUPPORTPOINT
1-41
Lift and Support Points
FloorJack
1. Apply the parkingbrakeand blockthe wheetsthat
t,
are not being lifted. Always use safety stands whon working on or undel
any vehicle that is supported by only a iack.
When liftingthe rearof the vehicle,put the gearshift Never attempt to use a bumper jack for lifting or
lever in reverse(Automatictransmission/Cwin E supporting the vehicle.
position).
Raisethe vehicle high enough to insert the safety

stands.
4. Adjust and place the safety stands so the vehicle

will be approxlmatelylevel,then lower the vehicle
onto them.
FRONT:
Centerthe jacking
bracketin the middle
of the iack lift platform.
LIFT PLA
REAR:
Centerthe iack
bracketin the middle
of the jack lift ptatform.
LIFT PLATFORM
L,
1-42
Towing
lf the vehicleneedsto be towed,call a professional tow- Front:

ing service.Nevertow the vehiclebehindanothervehi
cle with iust 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 usest\ivopivoting

armsthat go underthe tires {frontor rear}and liftsthem
o f f t h e g r o u n d .T h e o t h e r t w o w h e e l s r e m a i no n t h e
ground.
Sling-type Equipment- The tow truck uses metal cables

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

be towed with the front wheelsoff the ground lf due to
d a m a g e ,t h e v e h i c l e m u s t b e t o w e d w i t h t h e f r o n t
wheelson the ground,do the following:
lvlanualTransmissionand CW
. Releasethe parkingbrake
. Shiftthe transmissionto neutral(CW to E position)'
AutomaticTransmission Rear:
. Release the Parkingbrake.
. Start the engine.
. Shiftto LDllposition,then E position.
. Turn oif the engine
CAUTION;
o lmploper towing preparation will damage ihe tfans-
mission. Follow the above procedute exaqtly lf you
cannot shift the tlansmission or start the engino
laulomatic transmissionl,yout vehicle must be trans-
ported on a flat-bed.
. lt is best to tow the vehicle no farther than 50 mil€s
(80 km), and ksop thE speedbelow 35 mph (55 km/hl
. Trying to lift 01 tow your vehicle by tho bump€F will
caus€setious damagg.Ths bumpers are not dEigned
to supportthe vshicle'sweigh. TOWINGHOOK
tJO
1-43
The Special Tools Section of this manual has
been omitted intentionally. Each section in the
manual that requires the use of special tools has
them listed separately for that section.

Specifications
StandardsandServiceLimits "'.".'.""' 3-2

"...""' 3-20
ications,..'....,.'..'....
DesignSpecif
BodySpecifications "'."'." 3-23

Standardsand ServiceLimits
CylinderHead/ValveTrain (Dt6y5,
( u r b Y 5 , Dt6y7, -Section6 -
u l 6 Y 7 , D l 6 Y g e n lSines)
Compression 250rpm and wide openthroftle

kPa{kgf/cm,,psi)
MEASUREMENT
Nominal
STANDARD INFWT
L,
Minimum 930{9.5,135)
Maximumvariation 200 120 ?R\
Cylinderhead Warpage
Height 0.05{0.002)
92.95- 93.05{3.659 3.663)
Camshaft Endplay 0 . 0 5 , 0 . 1 5( 0 . 0 0 2 0 . 0 0 6 ) 0.5(0.02)
Camshaftto-holderoil clearance 0.050- 0.089(0.002_ o.oo4)
Totalrunout 0.15(0.006)
0 . 0 3( 0 . 0 0 1 ) m a x . 0.04(0.002)
Cam lobeheight D16y7 IN 35.299(1.38971
EX 31.241/.1.4678)
D16Y5 IN 38.427(1.5129)
Secondary 32.19311.2674l
EX 38.784(1.5269) =
D16Y8 IN Primary 36.778(1.4479)
Mid 38.274(1.5068)
Secondary 37.065 .4592)
EX 38.008(1.4964)
Valveclearanca
{Cold) IN 0.18- 0.2210.007 - 0.009)
EX 0.23 0.27(0.009 0.011)
ValvestemO.D. IN 5.48- 5.49(0.2157 0.2161) 5.45(0.2146)
EX 5.45- 5.46{0.2146 _ 0.2150} 5.42 tO.21341
Stem-toguideclearance IN 0.02- 0.05(0.001_ o.oo2) 0.08(0.003)
EX 0.05-008lono2-nnn?l 0 . 1 1( 0 . 0 0 4 )
Valveseat width IN 0.85- 1.15(0.033- 0.045) 1.6(0.063)
EX 1.25- 1.5510.049 - 0.061i 2.0(0.079)
Steminsta ed height IN 5 3 . 1 7- 5 3 . 6 4{ 2 . 0 9 _3 2 . 1 1 2 ) 53.a9\2.122|j
EX 53.17- 53.64(2.093_ 2.112) $.a9 Q.122)
Valvespring Freelengrh Dt6y7 57.9 (2.2a)
D16Y5 IN 56.5\2.221
Valveguide t.D.
D16Y8
EX
IN
EX
IN
EX
57.9 t2.29l
58.0 (2.2a)
58.7{2.31i
5 . 5 1- 5 . 5 3( 0 . 2 1 -7 0 . 2 1 8 )
5.51- 5.53(0.217_ 0.218)
5.55t0.219)
ra
I n s t a l l e dh e i g h t 5.5s{0.219)
IN 17.85- 18.35\0.103- 0.722)
EX 18.65 19.t5 (0.734_ 0.754)
Rockerarm Arm-toshaftclearance IN 0.017- 0.050(0.0007 0.0020) 0.08(0.003)
EX 0.018- 0.054(0.0007 - 0.0021) 0.08(0.003)
LO
3-2
U n i t o f i e n g t h :m m ( ! n )
CylinderHead/ValveTrain (816A2engine)- Section
MEASUREMENT STANDARD
INEW) SERVICELIMIT
2 5 0r p m ( m i n r i a n d Nominal
wide openthrottle Minimum 930(9.5,135)
kPa (kqf/cm' psi)
, Maximum variation 20012.0,zal
Endplay 0.05- 0.15(0.002- 0.006)

Camshaft-toholderoil clea€nce 0.050- 0.089(0.002- 0.004)
Totalrunout 0.0310.001)max.
Cam lobe height lN Primary 33.088(1.3027i
Mid 36.261{1.4278)
Secondary 3 4 . 9 7 (81 . 3 7 7 1 )
EX Primary 32.785{1.2907)
Mid 35.720(1.4063)
Secondary 34.691(1.3658)
Valveclearance I N 0.15- 0.19(0.006- 0.007)*
EX 0.17- 0.21(0.007- 0.008)*
ValvestemO.D. I N 5.475- 5.48510.2156 - 0.2159) u*u lo.r,ool
EX 5.450- 5.460(0.2146- 0.2150) 5.420(0.2134)
IN 0.025- 0.055(0.0010 0.0022) 0.08(0.003)
Stem-to-guideclearance
EX 0.050-0.080(0.0020- 0.0031) 0 . 1 1( 0 . 0 0 4 )
IN 1.25- 1.55{0.049- 0.061) 2.0(0.08)
width
EX r.25- 1.55(0.049- 0.061) 2.0(0.08)
IN 37.465- 37.935(1.4750 - 1.4935) 3 8 . 1 8 (51 . 5 0 3 3 )
Stem installedheight
EX 37.165- 37.635(1.4632 - 1.4817) 3 7 . 8 8 (51 . 4 9 1 5 )
free t*gth lN OUTER 4 0 . 9 2( 1 . 6 1 1 ) * '
4 0 . 9 1( 1 . 6 1 1 1 "
36.71(1.415)
4 1 . 9 6( 1 . 6 5 2 ) * r
4 r.94(1.651)*'
LD. lN 5.51- 5.53(0.217- 0.218)
EX 5.51- 5.53(0.217- 0.218i
Installedheight lN 12.55- 13.05(0.494 0.5' j4)
EX 12.55- 13.05(0.494- 0.514)
0.025- 0.052(0.00100.0020)
o.o2s- 0.052{0.00100.0020)
*: Measuringpoint betweencamshaftand rockerarm'
*1: NTHONH;TSUJOmanufactured vatvespring. *2: CHUOHATSUJOmanutactured
valvespnng.
3-3
EngineBlock {Dl6Y5,D16Y7,Dt6y8 enginesl- Section
,n7 _--
MEASUREMENT STANDAFOINEW}
Cylinderblock Warpageof decksurface
Borediameter
0.0710.003)
max.
75.00 75.02(2.953- 2.954)
SERVICE
0.10(0.004)
75.07(2.956)
LIMIT
L,
Boretaper
Reboringlimit 0.05(0.002)
Piston 0.5(0.02)
SkirtO.D. at 5 mm (0.2in) 74.9A0 74.990t2.9520 2.95241
from bottomof skin 74.970(2.9516)
Clearance in cylinder 0.010- 0.040(0.0004 0.0016)
Groovewidth {for ring) 0.05(0.002)
Top 1.020- 1.03010.0402 _ 0.0406) 1 . 0 5( 0 . 0 4 1 )
Second 1.220 1.230(0.0480 - 0.0484) 1.2510.049)
oil 2 . 8 0 5- 2 . 8 2 0{ 0 . 11 0 4_ 0 . 1 1t O ) 2.85(0.112)
Pistonring Ringto-grooveclearance Top 0.035- 0.060(0.0014 0.0024) 0 . 1 3{ 0 . 0 0 5 )
Second 0.030- 0.055{0.0012 0.0022)_ 0.13(0.005)
Ring end gap Top 0.15 0.30{0.006_ 0.012) 0.60(0.024)
Second 0 . 3 0- 0 . 4 5( 0 . 0 1 -2 0 . 0 1 8 ) 0.70(0.028)
oil 0.20- 0.7010.008 0.028)
Pistonpin o.D. 18.994- 19.000(0.7478 _ 0.7480)
ljqql) _
Pin-topistonclearance 0.010- 0 0?2 lo oona-n dnôl
Connecting Pin-torod interference
rod 0.014- 0.040(0.0006 _ 0.ool6)
Smallend borediameter 18.96- 18.98(0.746 0.747)
Largeend borediameterNominal 48.011.89)
Endplay installedon crankshaft 0.15- 0.30(0.006- 0.012)
Crankshaft
oroto.o',ur
M a i nj o u r n a l d i a m e t e r 54.976- s5.000(2.1644 - 2.1654)
R o di o u r n a l d i a m e t e r 44.91 6 - 45.0001'1.17 01 _ 1.71111
Taper 0.002510.0001) max. 0.005(0.0002)
Out of-round 0.0025(0.0001)max.
Endplay 0.005(0.0002)
0.10- 0.35(0.004 0.014) 0.4510.018)
Totalrunout 0.03(0.001)max.
Bea.ings 0.04(0.002)
Main bearingto-lournalo't clearance-
N o _l a n d5 j o u r n a l s 0.018- 0.036(0.0007 0.0014) 0.05(0.002)
_ N o .2 , 3 a n d4 j o u r n a t s 0.024 0.042(0.0009- 0.0017) 0.05{0.002)
Bodbearingto,journatoil ctearance 0.020- 0.038(0.0008
_ o.oo.t5) 0.05(0.002)
LO
LO
3-4
Unlt of length: rnm ( n)
EngineBlock (816A2engine)- Section7
STANOARD{NEW) LIMIT
SERVICE
MEASUREMENT
Cylinder block Warpageof decksurface 0.05(0.002) 0.08{0.03)
8 L 0 0 8 1 . 0 2( 3 . 1 8 9 3 . 1 9 0 ) 8 1 . 0 7( 3 . 1 9 2 )
Borediameter 0.05(0.002)
Boretaper 0 . 2 5( 0 . 0 1 )
Reboringlimit
80.980- 80.990(3.lUUz 3. rUubl du Y/u lJ. ro/o,
Piston Skin O D. At 15mm (0.6in)
{rom bottomof skirt I
0.010 0.040(o.ooo4- 0.0016' 0 05 r0 002) I
Clearancein cylinder
ToP I O3O 1.04010.0406- 0.04091 1 060{0 0417) |
Groovewidth (for ring) . 0.04881 1.26010.04961
Second 1.230- 1.?40{0.0484 1
oil '*: ?:::i?l:91'::ll:l
I::::::= l
u . u 4 5- u . u / u l u . u u r o
l
Piston ring R i n g - t o - g r o o v ec l e a r a n c e
Second 0.040- 0.065(0.0016 0.0026)*l 0.13(0.005)
0.045- 0.070(0.0018 0.0028)*' 0.1310.005)
Ring end gap Top 0.20- 0.35(0.008- 0.014)*1 0.60(0.024)
o.20- 0.30(0.008- 0.012)*' 0.60t0.024)
Second 0.40 0.55(0.016 0.022) 0.7010.028)
oil 0.20- 0.50(0.008- 0.020)*' 0.70(0.028)
0.20- 0.45(0.008- 0.018)"
- 0.8268)
,rr]q!4l
Piston pin o.D. 20.994- 21.000{0.8265
Pin to-pistonclearance 0.010- 0.022(0.0004 0.0009)
0.013- 0.032(0.0005 - 0.0013) -
Connectingrod Pin'torod interference - 0.8260)
Smallend borediameter 20.968 20.981(0.8255
Largeend borediameter Nominal
Endplayinstalledon crankshaft
o.o''r,
lliSlto?,o.oou o.rotoo'ut
Crankshaft Mainjournaldiameter - 2.1654)
No. 1, 2, 4 and 5 iournals 54.976 55.000(2.1644
No. 3 journal 54.970- 54.994(2.1642 2.1651)
44.976 - 1.1711|
- 45.00011.'1707
Rodjournaldiameter 0.010(0.0004)
Taper 0.005(0.0002)
max.
0.004(0.0002)
max. 0.006(0.0002)
Out of round 0 . 4 5( 0 . 0 1 8 )
Endplay 0.10 0.35(0.004- 0.014)
0.020(0.0008imax. 0.030(0.0012)
Totalrunout
Eearing Main bearingto_journal oil clearance
- 0.042(0.00090.0017)
0.024 0.06(0.002)
N o .1 ,2 , 4 a n d5 j o u r n a l s - 0.048 0.06(0.002)
N o .3 j o u r n a l o.o3o {0.00120.0019)
- 0.0020)
- 0.050(0.0013
0.032 0.06(0.002)
Bod bearing'toiournaloil clearance
*1: RIKENmanutactured
prstonrrng
*2:TEIKOKU PISTONRINGmanufactured pistonring
ginesl- Section 8
EngineLubri,cation(Dl6Y5,Dl5Y7' Dl6Y8 enginesl
STANOARD(NEW) S€RVICELIMIT
MEASUREMENT
Capacity | (USqt, lmp qt) D16Y74.3(4.5,3.8)Iorengineoverhaul
E n g i n eo i l
3.6(3.8,3.2)for oil change,includingfilter
3.3(3.5,2.9)for oil change,withoutfilter
D16Y5D16Y8 3 . 7( 3 . 9 , 3 . 3 ) f oern g i n eo v e r h a u l
3.3(3.5,2.9)for oil change,includingfilter
3.0{3.2,2.6}for oil change,withoutfilter
0.02- 0.14(O.OO1 - 0.006) 0.20{0 008)
O i lp u m p rotorradialclearance
lnner-to-outer - 0.007) (0
Pumphousingto_outerrotor radialclearance 0.10 0.18 (o.oo4 i 0.20 008)
o 03 !.08 (qool!.oo3l (0006) -
Pumohousrnq_to rotora)rialclearance _
R e l i e fv a l v e Pressuresettingwith oil temperature176'F(80'Ci
kPa(kgf/cm'PsiI
, at idle 7 0 ( 0 . 7 1, 0 )m i n .
at 3,000rpm 3 4 0( 3 . 5 , 5 0m) in
(cont'd)
3-5
EngineLubrication(B16A2engine)(cont,d)- Section8
MEASUREMENT
E n g i n eo i l Capacity f (uS qt, lmp qt)
STANDARD INFWI
4.8(5.1,4.2)for eng;neoverhaul
4.0(4.2,3.5)for oil change,;ncludin
g oilfilter
L,
3.7 (3.9.3 3)for dil .h,nde '^,irh^,,r
O i lp u m p Inner-toouterrotorradialclearance 0.04- 0.16{0.002- 0.006) 0.20(0.008)
Pumpbody-toouterrotorradialclearance 0 . 1 0- 0 . 1 9( 0 . 0 0 4 - 0 . 0 0 7 )
Pumpbody to-rotoraxialclearance 0.20{0.008)
0.02 0.0710.001 ,0.003) 0 15 {OOO6i
R e l i e fv a l v e Pressuresetting176"F(80.C)
kPa(kgflcm,,psi) at;dte 70 (0.7,10)min.
at 3,000rpm 340(3.5,50)min.
Cooling- Section 10
MEASUREMENT STANOARO{NEW)
Radrator Coolantcapacity t 1USqt, tmp qt) 81642engine
includingengine,heater,coolinglineand 5.0{5.3,4.4)for overhaul
reservotr 4.5(4.8,4.0)for cootantchange
D16Y5,D16Y7,D16Y8engines:
Beservoircapacity: M/T: 4.2(4.4,3.7)foroverhaul
0.4f {0.42US qt, 0.35lmp qt) 3.1(3.3,2.7)for coolantchange
A"/T:016Y7
4.1(4.3,3.6)for overhaul
3.0(3.2,2.6)for cootantchange
Dl6Y8
4.3{4.5,3.8)foroverhaul
3.2(3.3,2.8)for cootantchange
CW: 4.3(4.5,3.8)foroverhaul
3.2(3.3,2.8)forcootantchanqe
R a d i a t o rc a p Openingpressure kPa(kgl/cm,,psi) 9 3 1 2 3( 0 . 9 5 -1 . 2 51, 4 1 8 )
Thermostat Start to open .F (.C) 1 6 9- 1 7 6( 7 6 8 0 )
Fully open "F ('C) 194(90)
L.
Valve lift at fulty open 8 . 0( 0 . 3 1 ) m i n .
Cooling fan Thermoswilch 'ON" temperature F r.C, 196- 203191 95)
Thermoswitch "OFF' lemperature .F (
C) Subtract5 - 15{3 - 8) from actual,,ON,,temperature
L,
3-6
Unit of length: mm (in)
Fueland Emission - Section
MEASUREMENT STANOARO(NEW)
Fuelpaessure wilh fuel pressureregulatorvacuumhose

Pressure
regulator disconnected kPa(kgvcm' Psi)
,
D16Y5 260 310(2.7- 3.2,38 - 46)
D16Y7 260- 310(2.7- 3.2,38 - 46i
D16Y8 260- 310(2.7- 3.2,38 - 46)
81642 210- 320 Q.A- 3.3, 40 - 471
Capacity I (USgal,lmp gal) 4 5 { 1 1 . 99, . 9 )

Fueltank
En g i n e ldlespeed rpm M/T (neutral) I A/T or C\.T (lE or fd positioni
u.s.A. Canada U,S,A. Canada
016Y5 670 1 50 700t 50

D16Y7 6701 50 7 5 0 15 0 700I 50 750150
D16Y8 670150 7 5 0 15 0 7 0 0 15 0 750r 50
816A2 700t 50 7 5 0 15 0
ldleCO % 0.1max.
Clutch- Serr tion12

STANDARD{NEWI I SERVICELIMIT
MEASUREMENT
to floor 16s(6 1/2)
Clutchpedal Pedalheight
Stroke 130 140(5 1/8 5 1/2)
Pedalplay 12 -21 t1l2- 13/161
D i s e n g a g e m e n th e i g h t to floor 83 (3 1/4)
to carpet 44 (1 3/4)min. Reference
0.05(0.002) max. 0.15(0.006)
Flywheel Clutchsurfaceruoout
Rivetheaddepth 1 . 3 -1 . 9( 0 . 0-50 . 0 7 ) 0 . 2{ 0 . 0 1 )
Clutch disc - 0.36) 5.5(0.22)
Thickness 8.5- 9.1(0.33
0.03(0.001)max 0.15(0.006)
plate
Pressure Warpage 1.0(0.04)
Diaphragmspringfingersalignment 0.6(0.02)max
Lro
3-7
ManualTransmissionS40- Section 13
Mainshaft End play

MEASUREMENT
Capacity | (USqt, tmp qt)
STANDARDINEW}
' 1 . 9( 2 . 0 ,
1 . 7 ) f oo r verhaul
1 . 8( 1 . 9 1, . 6 )f o r o i t c h a n g e
SEBVICE
LIMIT
ro
0 . 1 1 0 . 1 8( 0 . 0 0_4 0 . 0 0 7 ) Adjust
Diameter of ball bearing contact area A 21.987- 22.000(0.8656 0.8661)
( T r a n s m i s s i o nh o u s i n g s i d e ) 2 1 . 9 3 (00 . 8 6 3 4 )
Diameterof 4th, 5th gear contact area B 26.980 26.993(1.0622
_ 1.0627)
Diameter of 3rd gear contact area C
26.930('1.0602i
33.984 34.000(1.3380 1.3386) 33.930(1.3358)
Diameterof ball bearing contact area D 25.917- 25.99011.02271.0232)
( C l u t c hh o u s i n g s i d e ) 25.92011.0205)
Bunout 0 . 0 2( 0 . 0 0 1m) a x . 0.05(0.002)
39.009 39.025(1.5358 1.5364) 39.07('r.538)
0.06 0.21(0.002 0.008) 0 . 3 3{ 0 . 0 1 3 )
0.06 0.19(0.002 0.007) 0 . 3 1( 0 . 0 1 2 )
30.22 30.21(1.190 1.192) 3 0 . 1 5( 1 . 1 8 7 )
3 0 . 1 2- 3 0 . 1 7( 1 . 1 8 6 1 . 1 8 8 ) 3 0 . 0 5( 1 . 1 8 3 )
37.00937.025 (1.4570
_ 1.4577) 3 7 . 0{71 . 4 5 9 )
0.06- 0.19(0.002
- 0.007) 0 . 3 1( 0 . 0 ' 1 2 )
28.42- 2a.4711.119,1.1211 2 8 . 3(51 . 1 1 6 )
Countershaft Diameterof needlebearingcontactareaA 3 0 . 0 0 03 - 0 . 0 1 {51 . 1 811- 1 . 1 8 1 7 ) 2 9 . 9 5 (01 . 1 7 9 1 )
Djameterof lst gear contact area g 3 5 . 9 8 -4 3 6 . 0 0 (01 . 4 1 6 71 . 4 1 7 3 ) 3 s . 9 3 r0. 4 1 4 6 )
Diameter of ball bearing contactarea C 24.980 24.993(0.9835 - 0.9840) 24.930(0.9815)
Runout 0 . 0 2( 0 . 0 0 1 ) m a x . 0.0s(0.002)
4 1 . 0 0-9 4 1 . 0 2 (5' t . 6 1 4 51 . 6 1 5 2 ) 41.0111.617J
E n d p l a y ( W h e n t i g h t e n e d b y t h e s p e c i f i e dt o r q u e )
0.03 0.10(0.001_ 0.004) 0.22(0.009)
Thickness
3 0 . 4 1 3 0 . 4 4( 1 . 1 9-7 1 1 9 8 ) 3 0 . 3 6( 1 . 1 9 5 )
44.009 - 44.025 (1.73261.7333) 44.0111.t35)
gear Endptay(Whentightenedby the specifiedtorque) 0.04- 0.12(0.002 - 0 005) 0.24(0.009)
3 1 . 9 13 1 . 9(61 . 2 5 61 . 2 5 8 ) 3 1 . 8 5( 1 . 2 s 4 )
t.D. 33.000- 33.010(1.2992 1.2996)
o .D . 3 3 . 0 4{ 1 . 3 0 1 )
38.989 39.00011.53s0_ 1.53s4) 38.93(1.533)
Length 32.03- 32.06tl.261 - 1.2621
Spacercollar
(Mainshaft4th
and 5th gear)
2 7 . 0 0 22 7 . 0 1(21 . 0 6 3_ 11 . 0 6 3 5 )
33.989 - 34.000 (1.3381 - 1.3386)
3 2 . 0 1( 1 . 2 6 0 )
2 7 . 0(61 . 0 6 5 )
33.93 (1.336)
LrO
3r.989- 32.000 (1.25941.2598) 3 r . 9 3{ 1 . 2 5 7 )
22.83 - 22.86 (0.8990.900) 22.81 (0.898)
23.53 23.56(0.926 - 0.928) 2 3 . 5(10 . 9 2 6 )
Beverserdlergear LD. r s . 0 1 6 1 5 . 0 4(30 . 5 9 1_20 . 5 9 2 2 ) 15.08(0.594)
G e a r t o r e v e r s eg e a r s h a f t c j e a r a n c e 0.032 0.077(0.0013 _ 0.0030) 0 . 1 4( 0 . 0 0 6 )
R i n g - t o g e a r c l e a r a n c e{ R i n g p u s h e d a g a i n s t g e a r ) 0 . 7 3- 1 . l 8( 0 0 2 9- 0 . 0 4 6 ) 0 . 4( 0 . 0 1 6 )
Forkfinger thickness lsv2nd/sth I 6.2- 6.410.244 - O.ZS2)
3rdl4th 7.4 i.6lO 2g1 O 2ggt
Fork to-synchrosleeveclearance 0.35- 0.65(0.014- 0.026)
Beverseshittfork Forkpawl groovewidth 1 2 . 7- 1 3 . 0( 0 . 5 0_ 0 . 5 1 )
Forkto-reverseidlergearclearance 0.5 1.t (0.020 0.043)
L groovewidth 7.05- 7.25tO.21A - 0.2851
Fork'to-5th/reverse shiftpiecepin clearance 0.05 0.35(0.002 0.014)
Shift arm A tnnerdiameterof shift arm C contactffi 13.05 13.13 (0.5140.517)
Shift arr14-go "L;L ".m C clearance 0.05- 0.23(0.002_ 0.009)
Innerdiameterof shiftarm B shaftcontactpoint 13.973- 14.000(0.5501 0.5512)
Shiftarm 8-to shaftclearance 0.013 0.070(0.0005 _ 0.0028)
Shiftarm B to-shiftpiececlearance 0.16(0.006)
0.2- 0.5{0.008 0.020) o.6210.02441
Diameterof shiftpiececontactpoint 1 2 . 9 1 3 . 0( 0 . 5 0 -8 0 . 5 1 2 ) 12.78(0.5031)
MBS Shiftprece Diameterof pin 6.9 7.1 \O.27 0 2A)
D i f f e r e n l i a lc a r r i e r Pinion shaft bore diameter 18.010 18.028(0.7091 _ 0.7098)
C a r r i e r - t op i n i o n s h a f t c l e a r a n c e 0.023 0.057(0.0009 - 0.0022)
D r i v e s h a f tb o r e d i a m e t e r
0.095(0.004)
26.025 26.04s{1.0246_1.0254)
C a r r i e r t o , d r i v e s h a f tc l e a r a n c e 0.045- 0.086(0.0018 0.0034) 0 . 1 4( 0 . 0 0 6 )
Backlash 0.05 0.15(0.002 0.006)
Piniongearborediameter 1 8 . 0 4-2 1 8 . 0 6(60 . 7 1 0_30 . 7 1 1 3 )
Piniongear-topinionshaftclearance 0.055- 0.095{0.0021 _ o.oo37)
0 0.110- 0.004) Adjust with shim
LO
3-8
U n i t o f l e n g t h :m m ( i n )
ManualTransmissionS4C- Section 13
M€ASUREMENT STANDARD{NEW) LIMIT
SERVICE
T r a n s m i s s i ooni l Capacity | (US qt, lmp qt) 2 . 3( 2 . 4 , 2 . 0f o) r o v e r h a u l

2 . 2( 2 . 3 1, . 9 ) f o or i lc h a n g e
Mainshaft Fnd plaV 0 . 1 1- 0 . 1 8( 0 . 0 0-4 0 . 0 0 7 ) Adtust
Diameterof ball bearingcontactareaC 21.917- 21.990 11.1015 - 1.10201 2 7 . 9 3 (01 . 0 9 9 6 )
(Clutchhousingside)
Diameterof 3rd gearcontactareaB 37.984 38.000(1.4954 1.4960) 37 930 (1.4933)
Diameterof ballbearingcontactarea'q 2 7 . 9 8-7 2 8 . 0 0 (01 . 1 0 1 81 . 1 0 2 4 ) 2 7 . 9 4 (01 . 1 0 0 0 )
( T r a n s m i s s ihoonu s i n gs i d e )
Runout 0 . 0 2( 0 . 0 0 1 ) m a x . 0.05(0.002)
Mainshaft 3rd and LD. 43.009- 43.025(1.6933 1.6939) 4 3 . 0 8( 1 . 6 9 6 )
4th gears Endplay 0.06- 0.21(0.002 0.008) 0 . 3( 0 . 0 1 )
Thickness 3rd 34.92- 34.91\1.315 1.311) 34.3(' t.350)
4th 31.42- 31.41(1.237 1.239) 31.3 11.232)
t.D. 43.00943.025 - 1.6939) 4 3 . 0(81 . 6 9 6 )
(1.6933
Endplay
- 0.008)
0.06 0.21(0.002 0 . 3( 0 . 0 1 )
Thickness - 31.41
31.42 \1.231 1.2391 31.311.232)
Diameterof ball bearingcontactareaA 24.980 24.993(0.9835 0.9840) 24.940(0.9818)
Diameterof lst gearcontactareaI 36.984 37.000(1.4561 - 1.4567) 36.930(1.4539)
33.000- 33.015(1.2992 - 1.2998) 3 2 . 9 5 (01 . 2 9 7 0 )
Diameterof needlebearingcontactareaC
Runout 0.02(0.0008) max. 0.05(0.002)
4 1 . 0 0-9 4 1 . 0 2 (51 . 6 1 4-51 . 6 1 5 2 ) 4 1 . 0 7( 1 . 6 1 7 )
0.045- 0.205(0.0018 0.0081) 0 . 2 5( 0 . 0 1 )
44.00944.025 {1.7326 - 1.7333) 4 4 . 0 7( 1 . 7 3 5 )
LD.
torque) - 0.006)
0.07 0.14(0.003 0.24(0.009)
Endplay{Whentightenedby the specified
- 28.97
28.92 -' j.1405)
(1.1386 2 8 . 8( 1 . 1 3 4 )
Thickness
LD. 36.521- 36.531(1.4378 1.4382) 3 6 . 5 4( 1 . 4 3 9 )
S p a c ecr o l l a r
(CoLrntershaft 2nd o.D. - 2 . 0 0 (01 . 6 5 3-11 . 6 5 3 5 )
4 1 . 9 8 94 4 1 . 9 3( 1 . 6 5 1 )
29.07- 29.0911.1444 - 1.1453)
gear) Length
S p a c e rc o l l a r LD. 31.0O2 31.01211.2205- 1.2209'l
- 3 1 . 0 6( 1 . 2 2 3 )
( M a i n s h a f t4 t h o.D. 36.989- 37.000{1.4563 - 1.4570) 3 6 . 9 4( 1 . 4 5 4 )
56.45- 56.551'2.2224 - 2.22641
and 5th gear) Lengtn
26.03- 26.0A11.025- 1.021|
(cont'd)
3-9
ManualTransmissionS4C(cont'd) - Section 13
Reverseidlergear
Synchroring
t.D.
MEASUREMENT
Gear-toreversegearshaftclearance
Ringto-gearclearance (Ringpushedagainstgear)
STANDARD(NEW)
20.016- 20.043(0.7880
0.036- 0.084{0.0014
-0.7891)
- 0.0033)
SERVICELIMIT
20.09(0.7909)
0.16(0.006)
ua
0.73- 1.18(0.029 0.046) 0 . 4( 0 . 0 1 6 )
Doublecone Clearance (Ringpushedagainstgead
Outersynchroring to gear 0.9s- 1.6810.037 - 0.066) 0.6(0.024)
Inner synchroring to-gear 0.5- 1.0(0.02- 0.04) 0 . 3{ 0 . 0 1 )
Outersynchroring-to-synchro cone 0.5 1.0(0.02- 0.04) 0 . 3( 0 . 0 1 )
Shiftfork Fork{ingerthickness 7 . 4- 7 . 6( 0 . 2 9 1 0
- .299i
Fork-tosynchrosleeveclearance 0.35- 0.65(0.015 0.026) 1.0(0.04)
Beverseshiftfork Forkpawl groovewidth 13.0- 13.310.512 - 0.524)
Fork-to-reverse idlergearclearance 0.5- 1.0(0.02- 0.04) 1 €{ 0 . 0 7 )
L-groovewidth At 5th gearside 7.4 t.1 10.29-O.30)
At reverseside 7.O5- 7.25 (0.21A- 0.2A5i'
Fork'to-5th/reverse shift piecepin clearance
At 5th gearside 0.4 0.9(0.02 0.04)
At reverseside 0.05 0.45(0.002- 0.018)
Shiftpiece Shiftpiece-to-shift arm clearance 0.1- 0.3(0.004- 0.012) 0.6(0.02)
Groovewidth of shiftarm contactarea 8 . 1 - 8 . 2( 0 . 3 1-9 0 . 3 2 3 i
Shilt'piece-to-shiftfork shaft clearance 0.2- 0.5 (0.008 0.020) 0.8(0.03)
Width of shift lork contactarea 11.9- 12.010.469 - 0.472)
Selectarm Selectarm-to-interlock clearance 0.05- 0.20(0.002- 0.008) 0.45(0.018)
Selectarm to-shimclearance 0.01- 0.210.0004 - 0.008)
Interlock Width of selectarm contactarea -
9.9 10.0 (0.390 0.394)
Changepiece Changepiece-to-shilt arm holderclearance 0.05- 0.35(0.002 - 0.014) 0.8{0.03)
Groovewidth ot shittarm holdercontactarea 1 2 . 0-51 2 . 1\50 . 4 7-40 . 4 7 a 1
Changepiece-toselectarm clearance 0.05- 0.25(0.002 - 0.010) 0.5(0.02)
Groovewidth of selectarm contactarea 12.05 - 12.t5 (0.474 - 0.478)
Final driven gear Backlash 0.090- 0.149(0.0035
- 0.0059)
.'1
0.200(0.008)
Differentialcarrier Pinionshattborediameter -
18.000 18.01610.7087- 0.7093)
Carrierto-pinionshaftclearance 0.013- 0.045{0.001 0.002) 0.10{0.004)
Driveshaft borediameter 24.000- 28.02111.1024 1.1032)
Carrier-todriveshaftclearance 0.020,0.062(0.0008- 0.0024) 0.12(0.005)
Carrier-to-int6rmediate shattclearance 0.05- 0.087{0.0020
- 0.0034) 0.14(0.006)
Differentialpinion Backlash 0.05-0.15(0.002 - 0.006)
gear Piniongearborediameter 1 8 . 0 4 21 8 . 0 6( 60 . 7 1-00 . 7 1 1 )
Piniongear-to-pinion shaftclearance 0.055 - 0.095(0.002 - 0.004) 0 . 1 5( 0 . 0 0 6 )
Setring to bearingouterrace 0 - 0.10(0 - 0.004) Adjust with shim
L,O
3-10
U n i t o f l e n g t h im m ( i n )
tssron- Section 14
AutomaticTf ansmtssron
MEASUREMENT STANOARD{NEWI LIMIT
SERVICE
Transmission Capacity f (US qt, lmp qti 5.9(6.2,5.2)Ioroverhaul

fluid 2.7(2.9,2.4)for fluid chanse
Hydraulic Linepressureat 2,000rpm in E or E position sgO g8ol85 SO,rzO rSO, r A o , e ' 0I 0 ,
1 s tc l u l c h p r e s s u r ea l 2 , O 0 O r p m i n D . p o s i t i o n
kPa 2nd clutchpressureat 2,000rpm in El position 800- 850(8.2-8.7, 120- 124) 7 6 0( 7 . 7 1, 1 0 )
(kgf/cm',psa) 8 1 0 - 8 6 0( 8 . 3- 8 . 8 ,1 1 8- 1 2 5 ) 7 6 0( 7 . 81, l 1 )
3rd and 4th clutchpressureat 2,000rpm in lFl posi-
tion
Stallspeedrpm (Checkwith vehicleon levelground) 2,100 28 1_ffi9
Clutch Clutchinitialclearance 1st,2nd 0.65, 0.85(0.026- 0.033)
3rd,4th 0.40- 0.60(0.016- 0.024)
Clutchreturnspringfree length
(A4RA,B4RATransmission) 1st 3 2 . 0( 1 . 2 6 ) 3 0 . 0( 1 . 1 8 )
2nd,3rd,4th 30.s(1.20i 28.5\1.12)
lst 31.1 11.221 2 9 . 1( 1 . 1 5 )
lM4RATransmission)
2nd,3rd,4th 3 0 . 5( 1 . 2 0 ) 28.511.121
1.88- 2.00{0.074- 0.079) Untilgroovesworn out
Clutchdiscthickness
Clutchplatethickness 1st 1 . 5 5- 1 . 6 5 1 0 . 0 -601. 0 6 5 ) Discoloration
2nd,3rd,4th 1.95- 2.05(0.077 0.081)
Ctrt"h ""d pl"t" thl"t** Mark1 2.05 2.10(0.081- 0.083) Discoloration
2.15- 2.20(0.085- 0.087)
(A4RA,B4RATransmission) Mark2
Mark3
Mark4
2.25- 2.30{0.089- 0.091i
2.35- 2.40(0.093- 0.094)
1
Mark5
Mark6
2.45- 2.50(0.096- 0.098)
2.55- 2.60(0.100- 0.102)
I
2.65- 2.70(0.104 0.106)
Mark7
M a r kI 2 . 7 5- 2 . 8 0( 0 . 1 0 8 0 . 1 1 0 ) I
MarkI 2 . 8 5 2 . 9 0( 0 . 1 1 -2 0 . 1 1 4 ) Discoloration
Clutch end plate thickness M"*l 2.3- 2.4{0.091 0.094) Discoloration

Mark2 2.4, 2.5{0.094- 0.098)
(M4RA Transmassioni
Mark3
Mark4
2.5 2.6(0.098- 0.102)
2.6- 2.7(0.102- 0.106)
1
Mark5 2 . 7, 2 . 8( 0 . 1 0 -6 0 . 1 1 0 ) I
Mark6 2 . 8- 2 . 91 0 . 1 1 00 . 1 1 4 )
Mark7 2 . 9- 3 . 0( 0 . 1 1 4 0- .118)
Mark8 3 . 0 , 3 . 1( 0 . 1 1 8 - 0 . 1 2 2 )
Mark9 3.1- 3.2\O.122-0.1261
Mark 10
M a r k1 1
3 . 2- 3 . 3{ 0 . 1 2 -6 0 . 1 3 0 }
2.0- 2.1(0.079- 0.083)
I
2.1- 2.2(0.083- 0.087)
M a r k1 2
M a r kl 3 2.2- 2.3(0.087- 0.091) L
M a r k1 4 3 . 3- 3 . 4( 0 . 1 3 0 0 . 1 3 4 )
M a r k1 5 3.4- 3.5(0.134- 0.138)
M a r k1 6 3.5- 3.6(0.138 0.142)
Mark17 3 . 6 3 . 7{ 0 . 1 4 2 0 - .146) I
Mark 18 3 . 7, 3 . 8 1 0 . 1 4-60 . 1 5 0 i Discoloration
(cont'd)
3-11
Automatic Transmission(cont'd)- Section l4
MEASUREMENT STANOARD{NEW) SERVICE
LIMIT
Diameterof needlebearingcontactarea
On mainshaftstatorshaftbearing 22.980 22.99310.9047 0.9052|j
On mainshaft2nd gear 3 5 . 9 7 5 3 5 . 9 9 (11 . 4 1 6-31 . 4 1 6 9 )
On mainshaft4th gearcollar 3 1 . 9 7 5 3 1 . 9 9 (11 . 2 5 8 9 _ , 1 . 2 5 9 5 )
On mainshaft1stgearcollar 30.975- 30.991t1.2195 1.22011
On countershaft (leftside) 3 6 . 0 0 4 3 6 . 0 1 (71 . 4 1 7-51 . 4 1 8 0 )
On countershaft 3rd gearcollar 3 5 . 9 8 03 5 . 9 9 6 ( 1 . 4 1 6-51 . 4 1 7 2 )
On countershaft 4th gear 2 7 . 9 8-0 2 7 . 9 9 (31 . 1 0 1-61 . 1 0 2 1 )
On countershaft reversegearcollar 3 1 . 9 7 5 3 1 . 9 9 (11 . 2 5 8-91 . 2 5 9 5 )
On countershaft 1stgearcollar 3 1 . 9 7 s 3 1 . 9 9 (11 . 2 5 8-91 . 2 5 9 5 )
On reverseidlergearshaft 13.990 - 14.000{0.5508 - 0.5512)
Insidediameterof needlebearingcontactarea
On mainshaft1stgear 3 5 . 0 0 0 , 3 s . 0 1( 61 . 3 7 8-01 . 3 7 8 6 )
On mainshaft2nd gear 4 1 . 0 0-0 4 1 . 0 1 16 1 . 6 1 4- 21 . 6 1 4 8 )
On mainshaft4th gear 38.000- 38.0'16 {1.4961 - 1.4967)
On countershaft 1stgear 38.000 38.016(1.4961 - 1.4967)
On countershaft 3rd gear 4 1 . 0 0 0 4 1 . 0 1 (61 . 6 1 4-21 . 6 1 4 8 )
On countershaft 4th gear 33.000- 33.016(1.2992 1.2998)
On countershaft reversegear 38.000- 38.016(1.4961 - 1.4967)
On reverseidlergear 18.007- 18.020(0.7089 - 0.7094)
On statorshaft(ATFpump sidei 29.OO0 -29.O1311.1417 - 1.14221
On statorshalt(statorside) 27.O00 27.02111.0630 - 1.0638)
Reverseidlergearshaftholderl.D. '14.416 - 14.434(0.5676 0.5683)
Endplay
Mainshaftlst gear 0.08 0.19(0.003- 0.007)
Mainshaft2nd gear 0.05- 0.13(0.002 0.005)
Mainshaft4th gear 0.075- 0.185(0.003 0.007)
Countershaft lst gear 0.1- 0.5{0.004- 0.020)
Countershaft3rd gear 0.05- 0.17{0.002- 0.007)
Countershaft4th gear 0.10- 0.18(0.004 0.007)
Reverseidlergear 0.05- 0.18(0.002 0.007)
Countershaftreversegear 0.10- 0.25(0.004 0.010)
Selecto.hub O.D. 51.87- 51.90{2.042 2.043)
Mainshaft4th gearcollarlength 45.00- 45.03(1.771- 1.773)
Marnshaft4th gearcollarIlangethickness 4.435- 4.525(0.1746 - 0.1781)
Mainshaftlst gearcollarlength 2 7 . 0 0 -2 7 . 1 5( 1 . 0 6-3 1 . 0 6 9 )
Countershaftdistancecollarlength 38.87- 38.90{1.530- 1.531)
38.92 38.95{1.532- 1.533)
3 8 . 9 7- 3 9 . 0 0( 1 . 5 3 4 , 1 . 5 3 5 i
39.02- 39.05(1.536- 1.537)
39.07- 39.10{1.538- 1.539)
3 9 . r 2- 3 9 . 1 5( 1 . 5 4 -0 1 . 5 4 1 )
3 9 . 1 7- 3 9 . 2 0( 1 . 5 4-2 1 . 5 4 3 )
39.22- 39.25(1.544- ' t.545)
39.27 39.30(1.546- 1.547)
Countershaft
3rd gearcollarlength ,96 97 models
21.15- 21.20(0.833- 0.835)
'98 -
00 modets 20.65 20.70(0.813- 0.825)
Countershaft
reversegearcollarlength 14.5 r4.6 {0.571- 0.575)
Countershaft
reversegearcollarflange
thackness 2.4- 2.610.094 0.102) Wear or damage
Countershaft
1stgearcollarlength 14.s- 14.6(0.571- 0.575)
Countershaft
lst gearcollarflangethickness 2.4 2.6(0.094- 0.102)
t a.\
L Downloaded from www.Manualslib.com manuals search engine

Un;t of length: mm {in)
Automatic Transmtsston Section 14
MEASUREMENT STANDARDINEW) LIMIT
SEBVICE
3.97 4.0010.156 - 0.157)
Transmission Mainshaft 2nd gear thrust washer thickness
4.02-
4 . 0 7-
4 . 1 2-
4.05(0.158 0.159)
4 . 1 0( 0 . 1 6-0 0 . 1 6 1 )
4 . 1 5( 0 . 1 6 2 0 . 1 6 3 )
1
4 . 1 7- 4 . 2 01 0 . 1 6-40 . 1 6 5 )
4.22-
4 . 2 7-
4.25(0.166- 0.167)
4 . 3 0( 0 . 1 6 8 - 0 . 1 6 9 )
I
4 . 3 2-
4.37-
4.42-
4 . 3 5( 0 . 1 7 0 0 . 1 7 1 )
4.4010.172
4.4510.114
- 0.173)
- 0.175l
+
Wearor damage
Thrustwasherthickness
Mainshaftball bearingleftside 2 . 9 5- 3 . 0 5{ 0 . 1 1 -6 0 . 1 2 0 ) Wearor damage
Mainshaftlst gear
'96 97 models
2.43
4 . 4 5-
2.50(0.096- 0.098)
4 . 5 0( 0 . 1 7-5 0 . 1 7 7 i
+
I
3rd gearsplinedwasher
Countershaft '98- 00 models 4.95- 5.00(0.195 0.197)
One-wayclutchcontactarea
Countershaft 1stgearLD. 83.339- 83.365(3.2810 3.2821) Wearor damage
66.685- 66.698(2.6254- 2.6259) Wearor darnage
ParkgearO.D.
Mainshaftfeed pipeA, O.D.(at 15 mm (0.59inlfrom 8.97- 8.98(0.353- 0.354) 8.95(0.352J
Mainshaft feedpipeB,O.D.(at30 mm {1.2in)from end) 5.97 5.9810.2350- 0.2354i 5 . 9 5( 0 . 2 3 4 )

Countershaft feedpipeO.D.lat 15 mm (0 59 in) from
- 0.3142)
7.97- 7.98(0.3138 7 . 9 5( 0 . 3 1 3 )
eno)
Mainshaftsealingringthickness 1.87- 1.97{0.074 0.078) 1 . 8 0( 0 . 0 7 1 )
1 2 9m m 1 1 . 1i n i a n d3 5 m m { 1 . 4i n ) )
Mainshaftbushingl.D.
- 0.2374)
6.0r8 - 6.030{0.2369 6.045(0.2380)
MainshaftbushingLD. 9.000- 9.01s10.3543-0.3549) 9.03(0.356)
8.000-8.022(0.3150 - 0.3158) 8.03{0.316)
Countershaft bushingLD.
Mainshaftsealingring goovewidth 2.025- 2.015l0.0197-0.0417) 2.08(0.082)
Seatingring conlact area l.D. 35.000 35.02511.37801.3782) 35.050(1.3799)
Regulator
valve body
ReverseshiftforkIingerthickness 5.90- 6.00(0.232- 0.236) 5.40(0.213)
Shifting device and
park brake control Parkbrakepawl or otherdefect
Parkgear lWear
14.000- 14.010(0.5512 - 0.5516)
Servobody Shift fork shaft bore LD.
Shiftfork shaftvalveborel.D. 37.000- 37.039(1.4567 - 1.4582) 3 7 . 0 4 (51 . 4 5 8 5 )
ATFpump gearsideclearance 0.03-0.05 {0.001- 0.002) 0.07(0.003)

ATFpump - 0.0052)
ATFpump gear-to-body clearance Drive 0.1050- 0.1325(0.0041
Daiven 0.0350- 0.0625(0.0014 - 0.0025)
- 14.034{0.5518
14.0' |6 - 0.5525i
ATFpump drivengearLD.
ATFpump drivengearshaftO.D 13.980 13.990(0.5504 0.5508)
Differential PinionshaftcontactareaLD. 18.010 18.028{0.7091 0.7098)
0.023- 0.057(0.0009 -0.0022) 0.1{0.004)
carrier Carrierto'pinionclearance
Driveshaftcontactare LD. 26.025* 26.04511.0246 1.0254)
0.045- 0.086(0.0018 - 0.0034) 0 . 1 2{ 0 . 0 0 5 )
clearance
Carrierto-driveshaft
Differential Backlash 0.05- 0.15{0.002- 0.006)
18.042- 18.066(0.7103 - 0.7113i
prnrongear t.D.
Pinion gear to-pinion shaft clearance 0.055- 0.095(0.0022 - 0.0037) ffi.oour
Set ring-to bearing outer race clearance 0 - 0.15(0 0.006) Adjust
(cont'd)
3-13
Automatic Transmission(cont'd) Section '14
STANDARD{NEW}
Springs Hegulator
MEASUREMENT
valvespringA
Wire Dia.
1 . 8{ 0 . 0 7 1 )
o.D.
14.7(0.584)
FreeLongth
87.8(3.457)
No. ol Coils UO
16.5
Regulato. valvespringB 1 . 8{ 0 . 0 7 1 ) 9.6 (0.381) 44.0i.732l' 11.0
Statorreactionspring 4.5\O.117) 3s.4(1.407) 3 0 . 3( 1 . 1 9 3 ) 1.9
Modulatorvalvespring 1 . 4( 0 . 0 5 5 ) 9.4(0.374) 35.0{1.378) 10.9
Torqueconvenercheckvalvespring 1.010.039) 8.4 (0.334) 3 3 . 8( 1 . 3 3 1 ) 4.2
Coolerreliefvalvespring 1.0(0.039) 8.4 (0.334) 3 3 . 8( 1 . 3 3 1 ) 4.2
Reliefvalvespring 1 . 1( 0 . 0 4 3 ) 8.6{0.342) 3 7 . 1( 1 . 4 6 1 ) 13.4
2nd oriticecontrolvalvespring 0.7 (0.028) 6.6(0.262) 34.8(1.370) 22.0
1-2shiftvalvespring 0.9 (0.035) 7.6 (0.302) 4 1 . 3( 1 . 6 2 6 ) 16.3
2-3shift valvespring 0.9(0.035) 7.6 (0.302) 57.0 (2.2441 26.8
3 4 shiftvalvespring 0.9(0.035) 7.6 (0.302) 51.0 \2.2441
'lst accumulator 26.a
spring 2.1(0.083) 16.0(0.636) 89.1{3.508) 16.2
4th accumulator springB 2.3 (0.091) 10.2lo.402l 5 1 . 6( 2 . 0 3 1 ) 13.8
4th accumulator springA 2.610.102) 17.0{0.676) 87.0(3.425) 14.2
2nd accumulator springA 2.4(0.094) 2 9 . 0( 1 . 1 5 2 ) 39.011.535) 2.9
3rd accumulator springA 2 . 8( 0 . ' 1 1 0 ) 1 7 . 5( 0 . 6 9 5 1 89.3(3.516) 15.6
2nd accumulator springB 1.6(0.063) 9.0 (0.358) 2 0 . 7( 0 . 8 1 5 ) 6.1
3rd acc!mulatorspringB 2.2(0.087) 3 1 . 0( 1 . 2 2 0 ) 3 5 . 11 1 . 3 8 2 ) 2.4
2nd accumulator springC 2.2 t0.041) 14.5{0.576) 68.012.6711 13.9
Lockup shiftvalvespring 0.9 (0.035) 7.6(0.302) 73.7 12.902) 32.0
Lockup timing valvespring 0.9(0.035) 8 . 1( 0 . 3 1 9 ) 80.7(3.177) 45.8
Lock-upcontrolvalvespring 0.7(0.028) 6.610.262) 38.0{1.496) 14.1
3 4 ofificecontrolvalvespring 0.7(0.028) 6.6(0.262) 37.5fi.476) 24.6
Servocontrolvalvespring 1.0(0.039) 8.1 (0.322) 52.1(2.051) 20.4
CPCvalvespring 0.6(0.024) 5.6 (0.2231 12.2(0.480)
CPBvalvespring 0.9{0.035) 8.110.322) 47.2{1.858} 18.3
4th exhaustvalvespring 0.9(0.035) 6.1 10.242) 36.4{1.433) 19.5
CVT Section 14
MEASUREMENT STANDARDINEWI SERVICELIMIT
Transmission Capacity f {USqt, lmp. qt) 6.4{6.8,5.6)for overhaul
fluid 3.9 (4.1,3.4)for fluid change
Hydraulic Forwardclutchpressureat 1,500rpm in E position 1.4- 1.15114.3 - 11.A,203 - 2531
pressure Reversebrakepressureat 1,500rpm in E position -
1.4 1.75(14.3 11.8,203 2531
Dr;vepulleypressureat 1,500rpm in E posrtron o . 2- 0 . 7 1 2 . 0
-7.1,28- 1011
1kgflcm,,psi)
Drivenpulleypressureat 1,500rpm in N position -
r . 5 2 . 31 1 5 .-3 2 3 . 52, 1 8- 3 3 4 )
pressureat 3,000rpm in E posrtron
Lubrication A b o v e0 . 2 1 2 , 3 0 )
Stallspeedfpm (Checkwith vehicleon levelground)
E position 2,500 - 2,650
2,350
E, E, El positions 3,000 - 3,r00
2,800
Clutch Clutchinitialclearance Forwardclutch 0.6- 0.8(0.024- 0.031)
Start clutch 0.5- 0.7(0.020 0.028)
Reversebrake 0.45- 0.75(0.018- 0.030)
Clutchreturnspringfree length Forwardclutch 3 0 . 5{ 1 . 2 0 1 ) ,*x.ar}
Start clutch 4 0 . 9( 1 . 6 1 0 ) 3 8 . 9( 1 . 5 3 1 )
Reversebrake 2 9 . 4( 1 . 1 5 7 ) 27.411.019l'
Clutchdiscthickness Forwardclutch 1.88- 2.00(0.074-0.079) Until groovesworn out
Startclutch 1.88 2.00(0.074- 0.079)
Reversebrake 1.94- 2.06(0.076- 0.081) Untilgroovesworn out
Clutchplatethickness Forwardclutch 1.95- 2.05(0.077-0.081) Discoloration
Start clutch 2.25 2.35(0.089- 0.093) Discoloration
Reversebrake 1.90- 2.00(0.075 0.079) Discoloration
3-14
L.
[Jnit of length: mm (in)
cw Section 14
MEASUBEMENT STANDARD{NEW} SERVICELIMIT
Forwardclutchend platethickness Mark 1 or 15 -

3.4 3.510.134 - 0.138) Discoloration
M a r k2 o r 1 6 3 . 5- 3 . 6( 0 . 1 3-8 0 . 1 4 2 )
M a r k3 o r 1 7 3 . 6- 3 . 7( 0 . 1 4-2 0 . 1 4 6 )
M a r k4 o r 1 8 3.7 3.8(0.146 0.150)
M a r k5 o r 1 9 3 . 8- 3 . 9( 0 . 1 5 -0 0 . 1 5 4 )
Mark6 or 20 3 . 9- 4 . 0( 0 . 1 5-4 0 . 1 5 7 i
Mark7 or 21 4 . 0- 4 . 1( 0 . 1 5-7 0 . 1 6 1 )
Mark8 or 22 4.1- 4.2(0.161- 0.165)
MarkI or 23 4.2- 4.3(0.165- 0.169)
Mark 10 or 24 4.3- 4.4(0.169- 0.173)
Mark11or 25 4 . 4- 4 . 51 0 . 1 7-30 . 1 7 7 i
Mark12or 26 4 . 5 4 . 6( 0 . 1 7 7 0 . 1 8 1 )
Matk 13ot 21 4.6- 4.7(0.181- 0.185) Discoloration
Reversebrakeend platethickness Mark 1 3.55- 3.65(0.140 0.144) Discoloration

3.75- 3.8510.148 - 0.152)
Mark2
Mark3
Mark4
\44rk 5
3.95- 4.05(0.156- 0.159i
4 . 1 5- 4 . 2 5( 0 . 1 6 3 0 . 1 6 7 )
4.35- 4.45(0.171- 0.175)
1
Mark6
Mark7
Mark8
4.55- 4.65(0.179- 0.183)
4.75- 4.85(0.187- 0.191)
4.95- 5.05(0.195- 0.199)
I
Discoloration
ATFpump ATFpump drive gear shaftO.D. 9.98 - 9.99(0.3929 0.3933) Wear or damaged
ATFpump drivengearshaftO.D. 9.98- 9.99{0.3929 - 0.3933) Wear or damaged
ATFpump body bushingl.D. Drivegearshaft 10.000- 10.015(0.3937 0.3943) Wear or damaged
Drivengearshaft 10.000- 10.015(0.3937 0.3943) Wear or damaged
ATFpump gearsideclearance 0.01s- 0.035(0.0006 0.0014)
ATF pump gear-to-bodyclearance Drive gear 0.035- 0.0505(0.0014-0.0020)
Drivengear 0.035- 0.0505(0.0014- 0.0020)
Transmission Diameterof needlebearingcontactarea
Inputshaft- flywheelside 19.987- 20.000(0.7869- 0.7874) Wear or damaged
Inputshaft forwardclutchside 19.987- 20.000(0.7869- 0.7874) Wear or damaged
Drivepulleyshaft- startclutchside 43.981- 43.991(1.7315- 1.7319) Wear or damaged
Drivepulleyshaft- flywheelside 24.007- 24.020(0.945- 0.946) Wear or damaged
Drivepulleyshaft- forwardclutchside 24.007- 24.020(0.945- 0.946) Wear or damaged
Thrustclearance
0.050- 0.110(0.0020- 0.0043)
Carrierand ring gear
0.000- 0.13010.000- 0.005)
Drivenpulleyshaftand startclutchhub
Inputshaftand ATFpump drivensprocket 0.370- 0.650(0.015- 0.026)
Secondary gearshaftand flywheelball bearing 0.00 0.15(0.00 0.006)
(cont'd)
3-15
CW {cont'd) Section 14
Transmission
(cont'd)
MEASUREMENT
T h r u s st h i m , 2 5x 3 1 m m t h i c k n e s s
STANDARD{NEW}
rlz-r-osr-o.o+o
oolrr
1 . 0 9- 1 . 1 2( 0 . 0 4 3 0 . 0 4 4 )
SERVICE LIMIT
I Wr"r - d-"-"g"d rl
ii
1 . 1 6 1 . 1 9( 0 . 0 4-6 0 . 0 4 7 )
1.23 1.26(0.048 0.050)
1 . 3 0- 1 . 3 3( 0 . 0 5 1 0 . 0 5 2 )
1.37- 1.40(0.054 0.055)
1.44- 1.47(0.057 0.058)
1 . 5 1 1 . 5 4( 0 . 0 5 9 0 . 0 6 1 )
1 . 5 8 1 . 6 1( 0 . 0 6-2 0 . 0 6 3 )
11
1.65- 1.68(0.065 0.066)
1.72 1.75{0.068 0.069)
1.79 1.a2t0.O10 - 0.012]}
1 . 0 5 5 1 . 0 8 5( 0 . 0 4 1 50 . 0 4 2 7 )
1 . 1 2 -5 1 . 1 5 5( 0 . 0 4 4 30 . 0 4 5 4 )
ir
1.195- ' I.225(0.0470 0.0482)
1.265 - 1 . 2 9 s( 0 . 0 4 9 80 . 0 5 1 0 )
1.335 1.365(0.0526 - 0.0537)
1.40s- 1.435(0.0553 - 0.0565)
r.475 1.505{0.0580 0.0593)
1.545 1.575(0.0608 0.0620)
1.615 1.645(0.0636 - 0.0648)
1 . 6 8 5 1 . 7 1 5 1 0 . 0 6- 603. 0 6 7 5 )
1.755- 1.785{0.0691 0.0703)
Cottersthickness 2 . 8 7- 2 . 9 0( 0 . 1 3- 0 . 1 1 4 ) Wear,or damaged
2 . 9 7- 3 . 0 0( 0 . 1 1 7 0 . 1 1 8 )
3.07-3.10 \0.121 0.122)
3 . 1 7- 3 . 2 0( 0 . 1 2 5 0 . 1 2 6 )
I
Wearor damaoed
ATFpump drivesprocketthrustshim,22 x 28 mm 1 . 1 2 1 . 1 5 1 0 . 0 -4 4 0.045) Wearor damaged
thickness 1.37 1.40(0.054- 0.055)
1.62- 1.65(0.064 0.065)
1 . 8 7- 1 . 9 0( 0 . 0 7 4 , 0 . 0 7 5 )
t
Secondary
thickness
gearshaftthrustshim,25 x 35 rnm
2.12 2.15(0.083- 0.08s)
2.37 2.40(0.093 0.094)
2 . 8 0- 2 . 8 5( 0 . 1 ' t-00 . 1 1 2 )
2 . 9 0 2 . 9 5( 0 . 1 1-4 0 . 1 1 6 )
3 . 0 0 3 . 0 5( 0 . 1 1-8 0 . 1 2 0 )
3 . 1 0- 3 . 1 51 0 . 1 2 20 . 1 2 4 )
3 . 2 0- 3 . 2 5( 0 . 1 2 6 0, .128i
{
Wear or damaged
Wearor damaged
w
3.30- 3.35(0.130 0.132)
3 . 4 0- 3 . 4 s1 0 . 1 3 40 . 1 3 6 )
3 . 5 0 3 . 5 5( 0 . 1 3-8 0 . 1 4 0 )
3 . 6 0 , 3 . 6 5( 0 . 1 4 2 0 . 1 4 4 )
3 . 7 0- 3 . 7 5( 0 . 1 4 6 0 . 1 4 8 )
3 . 8 0- 3 . 8 5 1 0 . 1 5 0 . 1 5 2 ) Wearor damaqed
Input shaft feed pipe O.D.
Drive pulley leed pipe 6.97- 6.98(0.274- 0.27s) 6.95(0.274)
Forward clutch feed pipe 1 1 . 4 -7 1 ' 1 . 4(80 . 4 5 1 60 . 4 5 2 0 ) (0.451)
11.45
Input shaft bushing t.D.
Drive pulley feed pipe bushing 7.O0O7.0t510.2156 - 0.2762]l 7.030(0.277)
Forward clutch feed pipe bushing 1 1 . 5 0 0 1 1 . 5 1(80 . 4 5 2 80 . 4 5 3 5 ) 1 1 . 5 3(30 . 4 s 4 )
Driven shaft feed pipe O.D.
Start clutch feed pipe (right side cover side) 6.97- 6.9A\0.214 0.275:l 6.95(0.274)
Driven pulley feed pipe 11.47- 1 1 . 4 8( 0 . 4 5 1_60 . 4 5 2 0 ) 1 1 . 4 5( 0 . 4 5 1 )
S t a n c l u t c h f e e d p i p e ( f t y w h e e th o u s i n g s i d e ) 8.97 8.9810.353 - 0.354) 8 95 (0.352)
Driven pulley shaft bushing LD.
Stan clutch feed pipe (right side cover sroer 7.000 7.015(0.2756 - 0.2762) t.030l0.2t7l
Drive pulley feed pipe 11.500- '11.518
(0.4528- 0.4535) 1 r . 5 3 3( 0 . 4 5 4 )
Start clutch feed pipe (flywheel housing side) 9.000 9.01510.354 - 0.355) 9.03(0.356)
Secondarydriven gear sealing ring groove width 2.50 2.65(0.098 0.104) 2.655(0.r05)
Start clutch end plate l.D. 88.900,88.935(3.500- 3.501) Wearor damaged
Input shaft sealing ring groove width 2.00 2.1010.079- 0.083) 2 . 1 0 5( 0 . 0 8 3 )
Dnve pullev shaft LD. at sealing ring
5*
Wearor damaqed
Shifting device Parkbrake cone
Wear or other defect
ano parK Parkbrake pawl
brakecontrol Parkgear
ro
3-16
U n i t o f l e n g t h :m m l i n )
cw Section14
MEASUREMENT STANDARD{NEW) SERVICELIMIT
Differential Pinion shaft contact area LD. 1 8 . 0 1 0 1 8 . 0 2 8 ' 0 . 7 0-901. 7 0 9 8 )

C a r r i e r - t op i n i o n c l e a r a n c e 0.023 0.057(0.0009 - 0.0022) 0.1(0 004)
Drive shaft contact area l.D. 26.025- 26.045(.0246 1 0254\
Carrierto driveshaftclearance 0.045 0.086(0.0018 - 0.0034) 0.12(0.005)
Backlash -
0 0 5 0 . 1 5i 0 0 0 2 0 . 0 0 6 )
Dtri"*"t"|p'.b"
gear LD. 1 80 4 2 1 8 . 0 6{60 . 7 1 0 30 . 7 "l 3 )
Pinion gear to-pinion shafl clearance 0.055- 0.095(0.0022 - 0.0037) 0.15{0.006)
0 0.15 (0 - 0.006) Adjlrst
S"t rrg-t" b""il"s ) u t e r r a c e c l e a r a n c e
MEASUBEMENT WireDia O.D. FreeLength No. of Coils
I
Springs PHregulatorvalvespring 1 2 (0 047) 9.0{0.354) 2 6 . 7( 1 . 0 5 1 ) r0.0
PHcontrolvalvespring 1 7 {0.067) 13.4(0.528) 3 9 . 4( 1 . 5 5 1 ) 8.1
PL regulatorvalvespring 0 9 (0.035) 1.2lO.2A3\ 1 4 . 6( 0 . 5 7 5 ) 1.2
PH'PLcontrolvalvespring 1 0 (0 039) 10.0(0.394) 3 1 . 4( 1 . 2 3 6 ) 8.6
c r u t l hr e d u c ' n vs d r v es p n n s 1 6 . 8( 0 . 6 6 1 ) 44.4\1.14al 8.0
]I : 1(u
9 9]:l 13.4(0.528) 5 1 . 6( 2 . 0 3 1 )
LLbrication valvespring b ubJr
Shittvalvespring 1 4 (0.055) 8.2 (0.323) 3 4 . 1( 1 . 3 4 3 ) 13.0
Shiftcontrolvalvespring 1 0 (0.039) 1.4 t0.2911 1 9 . 3( 0 . 7 6 0 ) 1.5
Stan clutchcontrolvalvespring 0.4(0 016) 4 . 1( 0 . 1 6 1 ) 1 2 . 1( 0 . 4 7 6 ) 6.8
Pitotregulatorvalvespring 0.6(0 024) 5.7 t0.224) 9 . 5( 0 . 3 7 4 ) 5.0
Startclutchvalveaccumulator spring 1 2 \0 O47) 8.3{0.327) 2 9 . 8( 1 . 1 7 3 ) 12.3
Reversecontrolvalvespring 1 2 (0.047) 9.4 (0.370) 3 1 . 4( 1 . 2 3 6 ) 11.0
Shiftinhibitorvalvespring 1 3 (0 051) 1 3 . 2( 0 . 5 2 0 ) 4 8 . 3( 1 . 9 0 2 ) 10.6
Steering Section 17
{NEWI
Steeringwheel Playat steeringwheel circumference 0 - 1 0( 0 0 . 4 )
S t a r t i n g l o a d a t s t e e r i n gw h e e l c i r c u m f e r e n c e
N (ksf, lbf)
Manual steering 1 5( 1 . 5 , 3 . 3 )
Power steering Engine running 2 9( 3 . 0 , 6 . 6 )
Gearbox Angleof rackguidescrewloosened M/S 20!5"
from lockedposition P/S 20'Max
Preloadat piniongearshaftN m (kglcm,lbfin) M/S 0 . 5- 1 . 7( 5- 1 7 , 4 . 3- 1 4 . 8 i
0 . 6 1 . 2( 6- 1 2 ,5 . 2 0- 1 0 . 4 2 )
P u m p p r e s s u r ew i t h v a l v e c l o s e d 6,400- 7,400{65- 75,920- 1,070)
( o i l t e m p . / s p e e d :4 0 ' C ( 1 0 5 " F )m i n . / i d l e
Do not run for more than 5 seconds).
kPa (kgtcm?,psi)
Power steering Recommended powersteeringfluid HONDAPowerSteeringFluid
fluid Fluidcapacity | {US qt, lmp q0 0.85(0.90,0.75) at disassembly
Reservoir 0 . 4{ 0 . 4 2 . 0 . 3 5 }
Powersteering with 98 N (10kgf,22lbf)
Deflection
belt* betweenpulleys'99 modell81642EngineTypeonly 7.5 11.0{0.30- 0.43)withusedbelt
5.0 7.0(0.20 0.28)with new belt
'96 '99 models:OtherEngineTYPes 10.5- 14.010.41
- 0.55)with usedbelt
7.5 10.010.300.39)with new belt
ron.ionffi
N (kgf,lbf) '99 model: 81642EngineTvpeonly 390 540{40 55,88 '120)wrth usedbek
'96 -'99 models:OtherEngineTYPes 340- 490(35- 50,77 - 110)with usedbelt
'99 modelr 81642EngineTYPeonlY 740 880(75- 90, 170- 200)with new belt
'96 '99 models:OtherEngineTYPes 640 7 8 0( 6 5- 8 0 ,1 4 3 - 1 7 6 ) w i t hn e w b e l t
M / S : [ , 4 a n u a ls t e e r i n g , P / S l P o w e r s t e e r i n g
*: When using a ne; bett,adjust dellection or tension to new values. Run the engine for 5 minutes then turn it off-
R e a d j u s tt h e d e f l e c t i o n o r t e n s i o n t o u s e d b e l t v a l u e s .
3-17
Suspension- Section 18
MEASUREMENT STANOAROINEW} SERVICELIMIT
Camber Front 0 " 0 0 ' 11 "
algnmenl Rear -1.11'
Caster Front 1'40'I 1"
Totaltoe Front I n ' 1 . 0 12 . 0{ 1 / 1 6t 1 / ' 1 6 )
Bear I n 2 . 0l j B( 1 / 1 6 11 / 1 6 )
Frontwheelturningangle Inwardwheel 39.50'
Outwardwheel 33'10'(Reference)
B i mr u n o u t A l u m i n u mw h e e l Axial 0 0.7(0- 0.03) 2.0(0.08)
Badial 0- 0 . 7( 0- 0.03) 1 . 51 0 . 0 6 )
Steelwheel Axial 0- 1 . 0( 0 0.04) 2.0{0.0B)
R a d l Ia 0- 1 . 0( 0 0.04) 1.5(0.06)
Wheel bearing Endplay Front 0 0.0s(0 - 0.002)
Rear 0 0.05(0 0.002)
Brakes- Section 19
MEASUREMENT STANDAROINEWI SERVICELIMIT
Parklngbrake Playin strokeat 196N (20kgf,44 lbfi leverforce To be lockedwhen pulled
6 - I notches
Footbrake Pedalheight(withfloor mat removed) M/T 156.5 {6.16)
peoal A/'T, CVT 161(6 5/16)
Freeplay 1 5(1/16-3/16)
Mastercvlinder Pistonto pushrodclearance 0 - 0.4(0 0.02)
Discbrake Discthickness Front 20.9- 21.8(0.82- 0.86) 19.0(0.75)
Rear 8.9- 9.1(0.350- 0.358) 8 . 0( 0 . 3 1 )
Discrunout Front 0 . 1 0( 0 . 0 0 4 )
Rear 0.10(0.004)
Discparallelism Frontand rear 0.015(0.0006)
Padthackness Front 9.5 10.5*' 1.6(0.06)
8.5- 9.5*' 1 . 6( 0 . 0 6 )
Rear 7 . 0 8 . 0( 0 . 2 8 - 0 . 3 r ) 'r.6(0.06)
Rearbrake LD. 200 17.a7l 201 \7.911
drum Liningthickness 4 . 0( 0 . 1 6 ) 2.0{0.08}
*1. 5410Stampedon the caliperbody.
*2. 2056Stampedon the caliperbody.
Air Conditioning- Section22

MEASUREMENT STANDARDINEWI
Lubricanttype:SP 10 (P/N38897- Pl3 - A01AHor 3889I - P13 A0li lForrefrigerant: (R,134a))
HFC-134a
Conditioning Lubricantcapacity Condenser | 20\2t30.11
mf (floz, lmp oz) Evaporator I 45(12/3,1.6)
SANDEN Lineor hose 1 0( 1 / 3 , 0 . 4 )
Receiver 1 0t 1 / 3 , 0 . 4 )
NIPPONDENSO Lubricanttype:ND'O|L8(P/N38899- PR7- 003)(ForRef.igerant:HFC,134a (R-134a))
Lubricantcapacity Condenser 25 (s/60.9)
mf (floz, lmp oz) Evaporator 6 0 ( 2 , 2 . 1 1
Lineor hose 1 0( 1 / 3 , 0 . 4 )
Receiver 1 0( 1 / 3 . 0 . 4 )
Compressor Lubricanttype:SP-10
SANDEN Lubricantcapacity ml lfl oz,lmp oz) 130 150(4 1/3 4.6,5.0- 5.3)
Fieldcoil resistance at 68'F(20"C) O
Pulley-to-pressure plateclearance 0.5r 0.1510.020 t 0.006)
NIPPONDENSO Lubricanttype:ND-OlL8{P/N38899- PR7,003 or P/N38899 pR7- AO1)(ForRefrigerant: HFC134a{R,134a))
L u b r i c a nc ta p a c i t y m { ( f l o z ,l r n p o z ) | 1 4 O ( 4 . 7 , 4 . -91J5 S { 5 . 2 . 5 . 4 )
S t a t o r c o i l r e s i s t a n c ea t 2 0 ' C ( 6 8 . F ) 0 3.4- 3.8
P u l l e y - t o - p r e s s u r ep l a t e c l e a r a n c e 0 . 5 1 0 . 1 5( 0 . 0 2 1 0 . 0 0 6 )
Compressor Deffection with 98 N (1Okgl.22lbll 7.5- 9.5(0.30 0.37)with usedbelt
belt* betweenpulleys 5.0- 6.5(0.20- 0.26)withnew belt
Belttension N (kgf,lbf) 340 490i35 50,77 - 110)with usedbell
Measuredwith belttensiongauge 690- 830(70- 85, 150 190)with new belt
*: When using a new belt,adjust deflectionor tension to new
values.Run the engine for 5 minutes then turn it of{.
R e a d j u s td e f l e c t i o n o r t e n s i o n t o u s e d b e l t v a l u e s .
3-18
U n i t o f e n g l h :m m { n )
Electrical Section 23
{NEW}
lgnitioncoil Ratedvoltage V 12
at 68'F(20'C) o
Primarywindingresistance
HITACHI 0.45 0.55
TEC 0.63 0.11
Secondary windingresastance at 68'F120"C) kO
HITACHI 22.4- 33.6
TEC 12.A- 19.2
lgnitionwire Resistance at 68'F(20'C) kf) 25 max.
F i r i n go r d e r 1-3-4 2
Sparkplug Type Seesection23
Gap 1.13,(o.o€-3*.)
l g n i t i o nt i m i n g At idle
' B T D Cl R e d )
Alternator belt+ 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 ) 8.0- 10.5{0.31- 0.41}with usedbelt

between pulleys 6.0- 8.5{0.26- 0.33)withnew belt
Belttension N (kgf,lbf) 340- 490(35- 50,77 110)with usedbelt
Measuredwith belttensiongauge 5 4 0- 7 4 0( 5 5- 7 5 ,1 2 1 . 1 6 5 ) w h hn e w b e r t
STANDARDINEWI SERVICELIMIT
Outputl3.5 V at hot A 75
(MITSUBISHI) (rotor)at 68'F(20"C) kO 3.4-3.8 -
Coalresistance I
S l i pr i n sO . D . Z2.j \0.A9) 22.2\0.47)
Brushlength 19.0(0.75) 5.0(0.20)
Brushspringtension g (oz) 3 4 0 4 2 0( 1 2 . 0 1 4 . 8 )
'13.5V at hot A 80
Alternator Output
(DENSOi Coil resistance (rotor)at 68'F (20'C) k0 2.2- 3.0
S l i pr i n gO . D . 14.4(0.57) | 14.0(0.55)
Erushlength 10.5(0.41) 1.5(0.06)
Brushspringtension g (oz) 3 3 0{ 1 1 . 6 )
Starter Tvpe Gearreduction
(MITSUEA Commutatormicadepth 0.4- 0.5(0.016- 0.020) 0.15(0.006)
1 . 0k w Commutatorrunout o o.o2(o - 0.000e) | o.o5(o.oo2)
1.2kW) CommutatorO.D. 2 8 . 0 - 2 8 . 1( 1 . 1 0 2 1 . 1 0 6 ) | 27.5(1.083)
Brushlength 1 5 . 8- 1 6 . 21 0 . 6-2 0 . 6 4 ) 1 1 . 0( 0 . 4 3 )
Brushspringtension(new) 15.7- 11.1
N (ksf,lbf) {1.60- 1.80,3.5- 4.0i
*: When usinga new belt,adjustdeflectionor tensionto new values.Runthe enginefor 5 minutesthen turn it off
Readiustdeflectionor tensionto usedbeltvalues
3-19
DesignSpecifications
ITEM METRIC ENGLISH NOTE

DII/IENSIONS OverallLength
2 door Coupe/4door Sedan (,96 98) 4,445mm 1 7 5 . 0i n
('99,' 00) 4,450mm 115.2in
2 door Hatchback (,96,,97) 4 , 1 7 0m m 164.2in
('98- 00) 4 , 1 8 0m m 1 6 4 . 6i n
Overallwidth 1 , 7 0 5m m 6 7 . 1i n
Overallheight 2 doorCoupe/2doorHatchback 1,375 mm 5 4 . 1i n
4-doorSedan 1,390mm 5 4 . 7i n
Wheelbase 2,620mm 1 0 3 . 1i n
I Track FronvRear 1,475/1,415 mm 58.1/58.1
GroundClearance 1 5 0m m 5.9in
SeatiogCapacity
WEIGHT(USA) GrossVehicleWeightRaring(GVWR)
2 door Coupe HX M/T,DX M/T 3,290tbs
HX CVI ('96) 3,320tbs
HX CVT('97,'98) 3,330tbs
HX CVT('99} 3,360rbs
DX A,/T(96 98, 3,290rbs
DX A"/T('99,'00) 3 , 3 1 0t b s
EX 3,440tbs
Si 3,480tbs
2 door Hatchbacl CX.DX r'96, 97, 3,285tbs
cx, DX ('98) 3,290tbs
cx (,99,,00) 3,290tbs
DXM/Ti'99,00i 3,290tbs
DX A/T ( 99, 00, 3,330lbs
4 door Sedan DX, LX,DX-V 3,330tbs
EX 3,460tbs
WEIGHT(CANADA) GrossVehicleWeightBating(GVWR)
2-doorCoupe DX ('96) 1,500ks
DX ('97 00) 1,510 kg
DX-G 1 , 5 1 0k g
si 1,96) 1,560kg
si ('97- 00) 1,570kg
siR 1,590ks
2 door Hatchback CX,CX,G('96) 1,495 kg
cx,cx,G1,97) 1,505kg
cx-G(,98) 1 , 5 1 0k s
cx ('98 00) 1 , 5 1 0k s
DX M/T, SE M/I 1,510 kg
DX A,/T,SE A,/T 1,530kg
4 door Sedan LX,LX V 1,510 kg
EX M/I 1 , 5 1 0k s
EX A/T 1,540ks
ENGINE Type Water-cooled, 4-strokeSOHC*1, SOHC * 1 :D 1 6 Y 7
VTEC"',SOHCWEC.E'3,DOHCVTEC{ *': D16Y8
gasolineengine *3:D16Y5
CylinderArrangement Inline4 cylinder,transverse *': 816A2
Boreand Stroke D16Y5,D16Y7,Dt6y8 75.0x 90.0mm 2.95x 3.54in
B1642 8 1 . 0x 7 7 . 4m m 3 . 1 9x 3 . 0 5i n
Displacement D16Y5,D16Y7,Dl6Y8 1,590cm3 97.0cu-in
81642 1,595cm3 97.3cu in
Compression Ratio D16Y5,D16y7 9.4
D16Y8 9.6
816A2 10.2
ValveTrain Beltdriven,4 valveper cylinder
LubricationSystem Forcedand wet sump,trochoidpump
Oil PumpDisplacement
at 6,800enginerprn
D16Y5,D,l6Y7,D16Y8 33.4f (35.3US qt, 29.4lmp qt)/minute
81642 43.8| (46.3US qt, 38.6lmp qt)/minute
WaterPumpDisplacement
at 6,000enginerpm 016Y5,D16Y7,D16y8 125{ {132US qt, 110lmp qt}/minute
816A2 140f {148US qt, 123lmp qt}/minute
FuelRequired D16Y5,D16Y7,D16y8 UNLEADED gasolinewith 86 Pump
OctaneNumberor higher
816A2 PremiumUNLEADED gasoline91 Pump
OctaneNumberor higher
STARTEB Type/Make Gearreduction/MITSUBA
NormalOutput 1.0kw, 1.2kw
NominalVohage 12V
HourRating 30 seconds
Directionof Rotation Clockwiseas viewedfrom gearend
5-Z.V
Downloaded from www.Manualslib.com manuals search engine -

trEM I merntc ENGLISH NorEs
SfAnff n i*nt-i- W"'gf,t MllSUBAr.u,l.z kw r'4 rg
CLUTCH ClutchType M/T Singleplatedry, diaphragmspring
Torqueconverter
CVT Multi plateswet sanP,hYdraulic
ClutchFacingArea M/T 160cm, 2 5s q i n
TRANSMISSION TransmissionType M/T Synchronized5-speedforward,1 reverse
Arr 4 speedautomatic,1 reverse
CW Non stagespeedforward,1 reverse
PrimaryReduction Direct1 : 1
Manualtransmission Enginetype
D16Y5 | D16Y7 D16Y8 I 81642
3.230 *1:2 door
GearRatio 1st 3.250 3.250 3.250
2nd 1.182 1.182 1.909 2.105 Hatch back
1.250 1.458 + 2 r2 - d o o r C o u p e ,
3rd 1.112 1.112
4th 0.909 0.909 0.909 1.107 and 4 door
5th 0.702 0.702 0.102 0.875 Sedan
Reverse 3.153 3.153 3.153 3.000
FinalReduction Gearratio 1 4.250 |
3.122 13.122"11.053" 4.266
GeartYPe S i n g l eh e l i c a l g e a r
Automatictransmission Enginetype
D16Y7 | D16Y8
'lst 2.600 2.122
GearRatio
2nd 1.468
3rd 0.926 0.975
4th 0.638 0.638
Reverse 1.954 1.954
FinalReduction Gearratio 1.351 4.357
GeartYPe
cw
GearRatio Low - O.D. 2.466 0.449
Reverse 2.466
SecondaryReductionGearRatio 1.333
FinalReductionGearRatio 4.357
AIR CoolingCapacity 3,530Kcal/h 14,000BTU/h
CONDITIONING Compressor Type/Make Scroll/SANDEN
No. of CYlinders
CaPacitY 85.7 m//rev 5.22cu inkev
Max.Speed 10,000rpm
LubricantCaPacitY 1 3 0m f 41l3tloz. sP,10
| 4.6imp oz
Compressor Type/Manufacturer Swash-plate/DENso
No. of Cylinder 10
Capacity 155.3mf /rev 9.4cu_in/rev
Max.Speed 76,000rpm
LubricantCaPacitY 140mf | 4 2l3fl oz,
I 4 9 l m po z
LubricantTYPe ND'OIL8
Condenser Type Corrugatedfin
Evaporator TyPe fin

Corrugated
Elower TyPe fan
Sirocco
Motor Input 200w112v
SPeedControl 4 speed variable
Max.CaPacity 460 m3/h 16,200 cu ft/h
Temperature Control
Compressor
Clutch TyPe Dry,singleplate,PolY-V'belt
drive
PowerConsumPtion 40 W max./12V at 68'F(20'C)
Refrigerant TyPe HFC134a(R'134a)
ouantity 650 gos | 22.9 isoz
( c o n t ' )d
4 .\t
J-Z I

DesignSpecifications
(cont'd)
ITEM METRIC ENGLISH NOTE
STEERING Tvpe P/s Powerassisted, rackand pinion
SYSTEM M/S R a c ka n dp i n i o n
OverallRatio p/S 1l.1
M/S 20.3
Turns,Lock-toLock p/S 3.6
M/S 4..1
SteeringWheelDia. 380 mm 15.0in
SUSPENSION TYPe Frontand Rear Independent doublewishbone,coil spring
Frontand Rear Telescopic,hydraulicnitrogengas-filled
WHEEL Camber Front 0.00,
ALIGN|\t4ENT Rear - 't'
Caster F.ont 1.40'
TotalToe Front ln 1 mm ln 1/16
Rear In 2 mm In 1/16
EBAKESYSTEM Type Front Powerassistedselfadjustingventilateddisc
Rear Powerassisted selfadiustjngsoliddisc
Powerassistedsell adjustingdr!m
PadSurfaceArea Front 37.5cm' x 4 5.8sq in x 4 5410stampedon
the caliperbody
44.1ctn,x4 6.84sq-inxa 2056stampedon
]
the caliperbody
Rear 67.2cmzx 4 | to.+ sq in ' I Drum
21.2cm, x 4 3.3 sq in x 4 Disc
ParkingBrake Type Mechanicalactuating,reartwo wheel
brakes
TIRE Sizeand Pressure Seelire intormationlabel
WASHER Capacity 2door Coupe/4,door
Sedan 2.5f (2.6LJSqt, 2.2 lmp qt) USAmodel
4 . 5| ( 4 . 8U S q t , 4 . 0 l m pq t ) Canadamodel
2,doorHatchback 2.51 (2.6US qt, 2.2lmp qt) DX
4.5f (4.8US qt, 4.0lmp qt) ExceptDX
ELECTRICAL Baftery 12V 38 AH/5HR
Starter 12V 1.0kW, 1.2kW
Alternator 1 2 V 7 5A , 8 0A
Fuses In UnderdashFuse/Felay
Box 7.5A, t0 A, 15A, 20 A
In Under-hoodFuse/Belay
8ox 7.5A, 10A, 15A, 20 A, 30 A, 40A, 80 A
In UnderhoodABS FLrse/Relay
Box 7 . 54 . 2 0 A , 4 0A
Headlights 12V_60/55W
FrontTurn Signal/Parking
Lights 12V-2115W
RearTurn SignalLaghts 1 2 V- 2 1 W
Brake/Taillights 1 2 V- 2 1 / 5 W
InnerTaillights*, 12V-5W
HighMount BrakeLight 1 2V 1 8W * " 2 1W + " * 3
Backup Lights 12V 21W
LicensePlateLights 12v-5w
CeilingLight l2V-8W(Withmoonroofl
12V - 5W (Withoutmoonroof)
TrunkLights
GaugeLights 12V-1.4W,3W
IndicatorLights ' t 2v 1 . 1 2 W 1 . . 4W
llluminationand PilotLights 1 2 v - 0 . 8 4 w ,1 . 4W
HeaterControlPanelLights 1 2 V 1 . 4W
P/S:PowerSteering M/S:ManualSteering
*l: 2-doorCoupe *2: 2door Hatchback *3: 4-doorSedan
*4: USA (HAM),Canada(HCM)produced *5: Japanproduced
L'
3-22
Body Specifications
2-doorCoupe: U n i t :m m ( i n )
lt t9) gtt't

Body Specifications(cont'd)
2-door Hatchback: Unit:mm (in)

Lif
(t t9] gre'r
3-24
Un i t :m m ( i n )
4-doorSedan:
(r'tsl 06€'l
3-25
Maintenance
LubricationPoints .""."".' 4'2
MaintenanceSchedulefor 1996Model
Normal Gonditions '.""" 4-4
SevereConditions ."""" 4-6
Normal Conditions ."""' 4-8
SevereConditions ....""' 4-10
Normal Conditions """" 4'12
SevereConditions ."""" 4-14
Normal Conditions ."""' 4'16
SevereConditions ."""" 4'18
Normal Conditions ."""' 4-2O
SevereConditions "'.""' 4-22

I LubricationPoints
For the detailsof lubricationpointsand types of lubricantsto be

applied,referto the lllustratedIndexand variouswork
procedures(suchas Assembly/Reassembly, Replacement,Overhaul.Installation,etc.)containedin eachsection.
No. LUBRICATIONPOINTS LUBRICANT
I Engine
"Energy
Conserving"gradeoil,
The oil containermay also displaythe Apl Certificationmark
shownbelow.Makesureit says,,ForGasoline Engines.,,
SAEViscosity:Seechart below,
Transmission Manual GenuineHondaMTF*1
Automatic GenuineHondaPremiumFormula
AutomaticTransmission Fluid(ATF)*,
CVT GenuineHondaCVTFluid*3
3 BrakeLine GenuineHondaDOT3BrakeFluid*a
4 ClL,tci t""e GenuineHondaDOT3BrakeFluid*a
I Powersteeringgearbox Steering greaseP/N 08733- BO70E
Shift leverpivots(manualtransmission) Greasewith molybdenumdisulfide
-:7 Releasefork (manualtrancmi<si^nl SuperHighTemp Ureacrease(p/N08798- 9OO2)
ti Steeringboots
9 Tailgatehingesand latches(2-doorHatchbackl
1 0 Steeringballjoints
'l'l Multi-purpose grease
Shift lever(automatictransmission) i
Pedallinkage I
l3 Brakemastercylinderpushrod
1 4 Trunkhingesand latch(4-doorSedanand 2-door I
Coupe)
Door hingesupperand lower HondaWhite LithiumGrease
Door openingdetents
't7
Hood hingeand hood latch
-
1 8 F U eTt t e r t t d
1 9 Clutchmastercylinderpushrod
20 Throttlecableend and throttlelinkage Multi-purposegrease
2 1 Rearbrakeshoe linkages
22 Steeringwheel(backside)
23 Caliper pistonseal,dust seal,
caliperpin. piston Siliconegrease
Throttlecableend (dashboardlower panel)
E Power steering system (for cars with p/S)
- Air conditioningcompressor @
ComDressor
oil:
SANDEN:SPlo P/N38897- p13-A01AH or 38899- p13_ A01
{ForRefrigerant:
HFC-134a(R-134a))
API SERVICELABEL CERTIFICATION
SEAL Recommended
EngineOil
ffi
NorE: The itemsm arked* 1,*2, +3,*4 and +5 on abovechan are described
*1: Always use GenuineHonda
Engineoil viscosityfor
ambrenttemperatureranges
as folows:
Manual TransmissionFluid (MTF).Using motor oil can causestiffer shifting
does not containthe properadditives.
*2: Always use GenuineHondapremium
FormulaAutomaticTransmissionFluid(ATF).Usinga non-HondaATF can
becauseit
affect
shift quality.
+3:UseGenuineHondacVTfluid
only usingotherfluidcanaffecttransmissionoperationand may reducetransmission
*4: Alwaysuse GenuineHonda life.
DoT3 BrakeFluid.Usinga non-Hondabrakefluid can causecorrosionand
of the svstem. dec.easethe life
*5: AlwaysuseGenuineHonda
PowersteeringFluid.using any othertype of powersteeringfluid or automatrc
fluid can causeincreasedwear and poor steeringin cold weather. transmission
4-2
NOTE:Lubricateall hinges,latchesand locksoncea year'
ln corrosiveareas,more frequentlubricationis necessary'
We recommendHondaWhite LithiumGrease'
4-3
MaintenanceSchedulefor 1g96Model
NormalConditions
+
6
a - . 8 _
f O J
- i
g .S 1:*
;: ii! 6!4
9 c ;
-d
o : : - 9 ..: = FrliF
.s- > -;[ ; (Ja
E
aol 5c, c r l = E i F = . 1: : !
,.9-- c< co E E do!6: d:
6 E d (9 - --_ d
6 d i : i ' r o I
e 3
trii;i 9 5 o e +- q )
; 6 = @ F =tr =tr t l f l t E- 9 E
! o ' i :
f ;: -'
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4-23
Engine
EngineRemoval/lnstallation 5-1
................
GylinderHead/Valve 6-1
Train ...................
EngineBfock.......... ...........7-1
EngineLubrication 8-1
...........
IntakeManifold/ExhaustSystem........ 9'1
Cooling 10-1
.........

Eng ine Removal/lnstallation
Removal "..'.'5'2
lnstaflation '.' 5-12 lgr"

EngineRemovaUlnstallation
Removal
(
@@
. Make sure
5. Removethe batteryand batterybase.
iacks and salety stands are placedploperly
and hoist brackets are attached to the correct posi-
tions on the engine. 8 x 1 . 2 5m m
24 N.m (2.4kgf.m, 17 lbf ftl
. Make sure the vehicle will not roll off stands and fall
while you are working underit.
CAUTION:
. Use fender covers to avoid damaging painted sur-
face.
. Unplug the wilin9 connectorscaretully while holding
the conngstor portion to avoid damage,
. Mark all wiring and hososto avoid misconnoction.
Also, be sure that they do not contact other wiring or
hosesor interferewith other parts,
1. Securethe hood as open as possible.
Disconnectthe batterynegativeterminalfirst. then

the positiveterminal.Removethe battery.
Removethe strut brace(B'16A2

engine).
8 x 1.25 mm
24 N.m {2.4kgl.m, 17 lbf.ft} STRUTBRACE
Disconnect
the connectorsfrom the ECM/pCM.
7. Disconnect
the main wire harnessconnector.
MAIN WIRE HARNESS

CONNECTOR
Disconnectthe batterycablesfrom the under-hood

fuse/relaybox and batterypositiveterminal.
BATTERYCABLES
UNDER.HOOD
FUSE/RELAY
BOX
ECM/PCM
5-2
8. Removethe intakeair duct and air cleanerhousing. 016Y5,Dl6Y& 815A2engin€sl
D16Y, ongino: a. D i s c o n n e c t h e I A T s e n s o r c o n n e c t o r ,t h e n
removethe intake8ir duct and air cleanerhous-
a. Removethe resonatorand intakeair duct. Ing.
6x1.0mm 6x1.0mm INTAKE AIR

9.8 N.m (1.0kgt m, 7.2 lbf.tt) 9.8 N m {1.0kgtm, 7.2 lbl'ft) DUCT
INTAKE AIR
AIR CITANER IAT SENSOR

HOUSING CONNECTOR
Disconnectthe intake air tempsrature (lAT) sen-
sor connector,then r€movethg air cleanerhous- 9. Disconnectthe engine wire harnessconnectoron
Ing. the left sideof the enginecompartment.
6x1.0mm
AIR CI."EANER 9.EN.m (1.0kgtm, t.2lbtft,
HOUSING
IAT SENSOR
CONNECTOR
(cont'd)
5-3
EngineRemoval/lnstallation
Removal(cont'dl
10. Relievefuel pressure(seesectionl1). 12. Removethe brakeboostervacuumhose,fuel return
hoseand vacuumhose.
!@ Do not smokewhile working on the fuel
system, Keep open flame or spark away from the D16Y7engine:
wolk area.Drainfuel only inlo an approvedcontainer.
1 1 . R e m o v et h e e v a p o r a t i v e m i s s i o n( E V A P c) o n t r o l VACUUMHOSE
canisterhoseand fuel feed hose.
D16Y7engine:
BANJOBOLT
33 N m ( 3.itlgt m, 25 lbt.ft)
FUEI-FEEDHOSE Dl6Y5, D16Y8,Bl642 enginos:
BRAKEBOOSTER
VACUUMHOSE
D16Y5,D16Y8,Bt642 engines:
5-4
13. Removethe throftlecableby looseningthe locknut, the connectorsfrom the PCM.
1 4 , Disconnect
then slip the cable end out of the acceleratorlink-
age. R e m o v et h e g r o m m e t a n d w i r e h a r n e s sc l a m p s ,
then pull out the ECM/PCMconnectors
NOTE;
. Takecare not to bend the cablewhen removing
it. Always replaceany kinkedcable with a new 6x1.0mm
one.
. Adjustthe throttlecablewhen installing(seesec-
t i o n 11 ) .
D16Y7engine:
LOCKNUT
16. Removethe mountingboltand lockbolt,then remove

the power steering(P/S)pump belt and pump
the P/Shoses.
NOTE:Do not disconnect
816A2engine:
D16Y5,D16Y8,B16A2engines: Removethe adjustingbolt and mountingboits,

then removethe P/Spump belt and pump
AOJUSTING
LOCKNUT
(cont'd)
5-5
EngineRemoval/lnstailation
Removal(cont'dl
(
Dl6Y5. DrGYr, D16Y8enginas: '18.
Removethe ransmission ground cable and hose
ct8mo.
-1. Removethe mounting bolt and lock
bolt, then
removethe P/Spump beltand pump.
6 x '1.0mm
HOSECLAMP
MOUNTING BOLT
8 x 1.25mm
24N.m{2.4kgl.m,17tbf.ftl
LOCKBOLT
8 x 1.25mm
24 N.m 12.4kgf.m, 17 lbf.ftl
1 9 . R e m o v et h e c l u t c h s l a v e c y l i n d e ra n d l i n e / h o s e
assembty(M/T).
17. Loosenthe idler pulleycenternut and adjusting NOTE:

bolt, then remove the air conditioning (A[/C) . Do not disconnectthepipe/hoseassembly.
compressorbelt. . Do not operatethe clutch pedal once the slave
cylind€r has been removed.
IDI.IR PULLEYCENTER o Takecarenot to bendthe line.
NUT
10 x 1.25mm
a,l N.m {,1.5kgt.m, 33 lbf.ft) 6x1,0mm 8x1.2Smm
11N.m{1.1kgt.m, 2a N.mt2.4kgf.m,
I tbf.ftl 17tbf.ftl
8 x 1.25mm
2a N'm {2,4 kgt m,
17 tbt.ftl
5-6
and splashshield.
24. Removethe front tires/wheels
20. Removethe shiftcable(CVT)
LOCKNUT
CLIP WASHER 29 N.m {3.0 kgf m,22lbf'ft}
Pt-Aslc
6 . 0mm
u x 1l.u mm SHIELD
9.8Nm(10 kqt'm,
7.2lbf.ftl
SHIFTCABLE
25. Drain the engine coolant (see page 10-7).Loosen
2 1 . D i s c o n n e c t h e P o w e r s t e e r i n g p r e s s u r e( P S P ) the drain plug in the radiator.
switch connector, and r e m o v et h e w i r e h a r n e s s
cramp. 26. Drainthe transmissionfluid Reinstallthedrainplug
l l usinga new washer(seesection13,14).
I 27. Drainthe engineoil. Reinstallthe drain bolt usinga

new washer(seepage8-6).
28. Removethe shift rod and extension rod (M/T)
SHIFTROD
ER
EXTENSION
ROD
caP.
theradiator
Remove
8 x 1.25mm
't6lbtft)
usa carewhen l€movingthe tadiator 22 N.m t2.2 kgf'm,
!!!@
Ap to avoidscaldingby hot coolantor steam'
(cont'd)
Raisethe hoist to full height.

Removal(cont'dl
{
29. Removethe Ay'Ccompressor. 31. RemoveexhaustpipeA.
NOTE:Do not disconnectthe Ay'Choses. Dl6Y5. D16Y7engines:
8 x 1.25mm
22 N.m12.2ksl.m.16tbI.fr)
Replace.
8x 1.25mm A/C
A/C COMPRESSOR
COMPRESSOR
24 N.m(2.{ kgf.m,t7 tbtft}
SELF.LOCKING
8 x 1.25mm
16 N.m (1.6kgtm,
12tbt.ftl
30. Removethe shift cable(IVT). Replace. SELF.LOCKING NUT
10x 1.25mm
33 N.m {3.4kgt.m,
NOTE: 25 lbr'frl
. Takecare not to bend the cablewhen removing Replace.
it. Always replaceany kinkedcable with a new
one.
. Adjust the shift cable when installing(see sec_
D16Y8 ongin6;
tion14).
8 x 1.25mm
22 N.m (2.2kgf.m. 16 tbf.ftl
8 x 1.25
mm Replace.
22 N.m(2.2kgf.m,16lbf.frl
GASKET
Replace.
SELF.LOCKING NUT
8 x 1.25mm
16 N.m 11.6kgf.m,12 lbtft)
Replace.
SELF-LOCKING NUT
LOCKWASHER l 0 x 1 . 2 5m m
Beplace. 6x1.0mm
14 N.m (1.4kgf.m, tO tbtft) 54 N.m (5.5kgf.m, 40 lbf.ft)
Replace.
5-8
Downloaded from www.Manualslib.com manuals search engine t
81642 engine: 35. Lowerthe hoist.
HO2SCONNECTOR
36. Remove the upper and lower radiator hoses and
8 x 1.25mm ,&
22N,n 122 kdl'rn, 16rbt.ftl
heaterhoses,
Replace. GASKETS
Replace.
UPPER
RADIATORHOSE
Replace.
SELF.LOCKING
8 x 1.25mm
16 N.m t1.6 kg{ m, 12 lbl'ft)
Replace.
PIPEA 10 x 1.25 mm
s4 N.m {5.5 kgf m, 40 lbf'ftl
RePlace'
32. Removethe damperforks (seesection18).
D i s c o n n e ctth e s u s p e n s i o nl o w e r a r m b a l l j o i n t s
(seesection18).
34. Removethe driveshafts.
CAUTION:
o Do not pull on th€ drivoshaft. the CV ioint may 37. Removsthe ATF cooler hoses,then plug the ATF
com9 apart. cooler hosesand PiPes(A,/T)
o Use care whgn prying out the assombly.
Pull it straight to avoid damaging the differential
oil seal or intermediate shaft dust seal.
N o T E : C o a t a l l p r e c i s i o n - f i n i s h esdu r f a c e sw i t h
cleanengineoil. Tie plasticbagsover the driveshaft
enos.
!^.
HOSES
(cont'd)

Removal(cont'd)
38. Attachthe chainhoistto the engine.
HOISTINGBRACKET
Installon the cylinderhead
witha8x1.25mmbolt.
5-10
39. Removethe left and rightfront mount and bracket' 41. Removethe uPPsrbracket.
UPPER
4 2 . R e m o v et h e t r a n s m i s s i o nm o u n t b r a c k e t ,t h e n
removethe transmissionmount.
TRANSMISSION
MOUNT/BRACKET
40. Removethe rearmount bracket.
Checkthat the engine/transmissionis completely

free of vacuum hoses,fuel and coolant hosesand
electricalwiring.
150mm
44. Slowlyraisethe engineapproximately
(6 in)'
Checkonceagain that all hosesand wiresare discon-
nectedfrom the engine^ransmission
45. Raisethe engineall the way, and removeit from the

car.
5-11
Installation
Brackei Bolts Torque Specifications:
Dl5Y5,Dl6Y7,Dl6Y8 €nginss 10x 1.25mm

44 N.m {4.5 kgt m, 10 x 1.25mm
33 tbr.ftl 54 N.m {5.5kgf.m,
40 rbf.ftl
D16Y5,D16Y8engines(M/Tl:
10x 1.25mm
REARSTIFFENER 44 N.m 14.5kgf.m,
33 tbf.frt
8 x 1.25mm
2/t N.m 12.4kgf.m, 17 tbf.ftl
1 0x 1 . 2 5m m
ALTERNATOF 44 N.m {4.5kg'f.m,
EXCEPTD16Y5, Dl6Yg engines lM/T)j BRACKET 33 tbtftl
STIFFENER
Tightenthe boltson the stiffener
in the numberedsequenceas shown
li) o). O8x1.25mm
24 N.m {2.4kg{.m,
17 tbr.ftt
10x 1.25mm
14 N.m 14.5kgt m,
l3l 10x 1.25mm 33 tbf.ft)
44 N.m {1.5kgt.m,
33 tbt.ft) 8 x 1.25mm
24 N.m (2.4 kgf.m,
17 tbf.ft)
o16Ys,D16Y8
enginoslM/T):
FRONT
STIFFENER
10 x 1.25mm
4,4N.m {4.5kg{.m.
8 x 1.25mm 10x 1.25mm 33 tbf.ftl
2{ N.m (2.t kgtm, 14 N.m (4.5kgf.m,
17 rbtft) 33 lbf.ftl
5-12
816A2engine
P/S PUMP
BRACKET
REAR
STIFFENER
SIDEENGINE
MOUNT BRACKET
t0 x 1.25mm
ia{ N.m (i1.5kgt rn,
33 lbt.tr)
1 2x 1 . 2 5n m
8 x 1.25mm
57 N.m {5.8 kgf,m,
24 N.m (2.4 kgl.m,
12 tbl.ttl
t 17lbf.ft) 10x 1.25mm
54 N m {5.5 kgf m, a0 lbl ft}
10x 1.25mm
4a N,m (4.5kgf.m,
FRONT 33 tbf.ftt
STIFFENER
A/C COMPBESSOR
BRACKET
'12x 1.25mm
57 N.m {5.8 kgt'm,
8 x 1.25mm
42 tbt.ft)
24 N.m {2.4kgf.m,
ALTERNATOR
17 tbtft)
BRACKET
'10x 1.25mm
,14N.m {,1.5kgt.m,
33 rbf.ft)
(cont'd)
5-13
Engine Removal/lnstallation
Installation(cont'd)
Engino Inst!llation:
Installthe engine in the reverseorder of removal.

Beinstallthe mount bolts/nutsin the followingsequence.
Failureto follow these proceduresmay cause excessive
nois€and vibration,and reducebushinglife.
l, Install the transmissionmount and bracket,then

tightenthe boltson the frame side,
NOTE; Do not tighten the bolts/nutson the trans_

missionside.
CW;
10x 1.25mm
38 N.m {3.9 kgt m. 28 lbt.ftl
I
I
2, Installthe upper bracket,then tighten the nuts in

the numberedssquenceshown (O _ @).
O t2 x 1.25mm
74 N.m17.5kgf.m,
O t2 x t.2smm
74N.m17.5
rbrft)
kgtm,
l
a
5-14
3. Installthe rear mount bracket,then tightenthe bolts 4. Tighten the bolvnuts on the transmissionmount
in the numberedsequenceshown (O - @). bracketin the numbe.edsequenceshown (O - O).
CVT:
O 12 x 1.25mm @ t2 x t.2smm
59 N.m (6.0 kgl'm, 7,1N.m(7.5kg{m, 54 lbfftl
ilil lbf ftl
Replace.
12x 1.25mm
59 N.m 16.0kgf'm,
|:r tbf.tt)
Replace.
O 12 x 1.25mm
59 N'm {6.0 kgf'm,
/€ lbf.ftl
Replace.
ExceptCVT:
, @ 1 4x ' 1 . 5m m O 12r 1.25mm

/ 8:t N.m {8.5 kgf.m, 59 N m 16.0kgt m, 12 x 1,25mm
61 rbr.fr) (} tbf.ftt fl N.m 16.5kgt.m,
/
\ Replace. Replace. 47 tbf.ftl
Tightenthe boltson the rightfront mounvbracketin

the numberedsequenceshown(O - @).
GW:
O to x 1.25mm
Olax1.5mm 54 N.m{5.5kgl.m.
83 N.m 18.5kgf.m, /|{}lbf.ftl
61 tbf.ftl
Replace.
10 x 1.25mm
L 4,1N.m {4.5kgf.m. 33 lbf.ftl

(cont'd)
5-15
ExceptCVT:
7. Performthe following:
. Cleanthe areaswhere the driveshaft(s) and the

intermediateshaft contactthe transmission(dif_
ferential)thoroughlywith solvent or carburetor
cteaner,and dry with compressedair.
. Checkthat the set rings on the ends of the drive_
shaftand intermediate shaftclickinto place.
CAUTION: Use new set rings,
. Adjustthe shift cable(seesection14).
. Adjustthe throttlecable(seesection11).
. Adjustthe cruisecontrolcable(seesection23).
. Refillthe enginewith engineoil (seepage8-6).
. Refillthe transmissionwith fluid (seesection13,
14).
. Refillthe radiatorwith enginecoolant(seepage
10-7).
. Bleedair from the coolingsystemwith the heater
valveopen (seepagej0-7).
12 x 1.25mm . Cleanthe batterypostsand cableterminalswith
64 N.m (6.5kgd.m, sandpaper,assemblethem, then apply greaseto
preventcorrosaon.
. Inspectfor fuel leakage(seesectionj l).
After assemblingthe fuel line,turn on l) the igni_
tion switch(do not operatethe starter)so that the
fuel pump runs for approximatelytwo seconds
Tightenthe bolts/nuton the left front mount in the and the fuel line pressurizes. Repeatthis opera_
numberedsequenceshown {O - @). taontwo or three times,then checkfor fuel leak_
age at any point in the fuel line,
( t 1 2 x 1 . 2 5m m
8 3 N ' m ( 8 . 5k g f . m , 6 1t b t . t r l
O 1 2 r 1 . 2 5m m
59 N.m 16.0kgt.m,
/+4 N.m 14.5 kgf.m, 43 tbt.rtl
Seplace.
33 lbt.trl \
5-16
Mount and Brackst Bohs/Nuts Torque Value Spocitications:
A: '10x 1.25mm
64 N.m {6.5 kgl'm, 47 lbf'ft}
B : 1 0i 1 . 2 5m m
44 N.m {4.5kgim,33 lbtft)
C : 1 2x 1 . 2 5m m REARMOUNT
83 N.m 18.5kgt'm, 61 lbf'ft)
D : 1 2x 1 . 2 5m m
59 N.m (6.0ks{ m, 43 lb{ft)
Replace.
SIDEENGINE
MOUNT

CylinderHead/ValveTrain
Dl6Y5,D16Y7,Dl6Y8engines
SpecialTools .............
G2 Cylinder Head
VTECControl System 6-23
lllustratedIndex ...............................
TroubleshootingFlowchart .........."6-3 Removal 6-27
.................
VTEGSolenoidValve Warpage 6-40
................
Inspection ............"
6-6 lnstallation .............
6-45
VTECRocker Arms Rocker Arms
Manuallnspection Removal 6-30
.................
(D16Y5engine).............................
6-7 Disassembly/Reassambly 6-31
...............
Manual Inspection RockerArms and Lost Motion Assemblies
(D16Ygenginel................'............
6-7 Inspection (D16Y5,D16Yg
Inspection Using Special Tools enginesl "..........'5-34
6-8
{D16Y5engine}.....................""'... Rocker Arms and Shafts
Inspection Using SpecialTools 6-35
GlearanceInspection.......................
(D16Y8engine).........................'.'.
6-10
Camshaft
Valve Clearance
Inspection 6-36
..............
Adiustment ..."".....6-12
Valves, Valve Springs and Valve Seals
Valve Seals
Removal ........"".....
6-38
Replacement(Cylinderhead removal
6-1tl
not requiredl................................ Valve Guides
6-39
Valve Movement ..............................
CrankshaftPulleyand PulleYBolt
."......&16 Replacement .........6-41
Replacement
Reaming .......'......'.'
6-43
Timing Selt
6-17
lllustratedIndex ............................... Valve Seats
6-18
.............. Reconditioning .'....6'40
Inspection
TensionAdjustment ........................6-1I Valves
6-19
......,,......... lnstallation .............
6-tt3
Removal
lnstallation .............
6-20 Camshaft/RockerArms and
CrankshaftSpeedFluctuation(CKF)Sensor Camshaft Seal/Pulley
.........6'22 lnstallation .............
6-44
Repfacement

SpecialTools
\ (
Ref.No. I Tool Number
o OTHAH_ PJTOlOB ValveGuideReamer,5.5 mm 6-43

0 7 J A A- 0 0 1 0 1 0 A Socket,17 mm 6-16
o 07JAB- 0010204 H o l d e rH a n d l e o- to
@ OTLAJ_ PR3O2OB Air Stopper 6-8,10
07NAB- 0010404 HolderAttachment.50 mm 6-16
@ 07NAJ- P07010A PressureGaugeAdapter 6-4
o 01406 - 0020201 A/f PressureHose 6-4
or@-1 OTMAJ- PY4O'114 A/T PressureHose,2,210mm 6-4
andO-2 07MAJ- PY40120 Ay'TPressureAdapter 6-4
@ 07406- 0070300 A,/TLow PressureGaugeWPanel 6-4
o 0 7 7 4 2- 0 0 1 0 1 0 0 ValveGuideDriver,5.5 mm 6-4't,42
-rE=-!fT----F
o @
@
@
g-A\
o El
O-r
A-2 @
ril
6l
a
6-2
VTECControlSystem
Flowchart
Troubleshooting
code(Drc)Pr25e:
rrouble A probrem
inthevrEcPressure circuit
switch or
tFtrsrl #ilH:::lj1t:"J:T,?ffnostic
Reterto page 1 l-38 th rough 11-55beforetroubleshooting.
The MIL has been reoortedon.

DTCP1259is sto.ed.
Checkthe VTECCont.olSyst6m:
1. Do the enginecontrolmodule
(ECM)/powertraincontrol mod * Road Test:
ule lPCM)ResetProcedure(see A c c e l e r a t ei n 1 s t g e a r t o a n e n g i n es p e e do v e r 3 , 0 0 0r p m
section11). (D16Y5engine)or 6,000rpm (D'16Y8 engine).
2. Stan the engine. Holdthat enginespeedfor at leasttwo seconds.
3. Warm up the engineto normal It DTCP1259is not repeatedduringthe first road test, repeat
operatingtemperature(cool- thistesttwo moretames.
ing fan comeson).
4. Do the BoadTest.* Intermittont tailura, 3y3t.m is OK
at thia time.
Check for ooor connoctionr o.
ls OTCP1259indicated?
loose wirea at VTEC oiassurc
lwitch, VTECsolonoid valvo .nd VTECPRESSURE
SWITCH2P
ECM/PCM, CONNECTOR
Test rhe VTECPrensureSwitch:

1. Turnthe ignitionswitchOFF.
2. Disconnectthe VTECPressure
switch2Pconnector.
3. Checkfor continuitybetween
VTECpressureswitch2P con-
nectorterminalNo. 1 and No.
2.
Terminalsideof
maleterminals
ls there continuity? Replacethe VTECpreasure3witch.
VTM
(BLu/BLK)
l1
f;-) |
I
Te3t the VTEC Pressure Switch I
Y
Wire:
1. Turnthe ignitionswitchON lll).
2. Measurethe voltagebetween
V T E C p r e s su r e s w i t c h 2 P
c o n n e c t o rN o . l a n d b o d y
ground.
I
Wire sid6 ol female
rermtnats
In3poct for en opon or shod to
ground in thG wi.. bctwoon tho
VTEC pro$ur6 switch rnd ECM/
ls there batteryvoltage? PCM l'96 - 9a: C15,'99- 00: C101.
lf tha wiro i3 OK,3ubrtitute a
known-good ECM/PCM and
recheck.
{Topage6'4i

I
VTECControl System
TroubleshootingFlowchart(cont'd)
: (
VTECPRESSURE
SwlTCH2P
(From page 6-3) CONNECTOR
Test the VTEC Pr6suro Switch t

Wiro: I
Nleasurevoltage acrossthe VTEC t
pressureswitch2P connector.
:
. Rcpai. opon in tho wire Wire side of female t

(€rmrnats
brtw.en VTECpr6.urc switch
ls there bafteryvoltage? andG101.
. lf th. wir6 b OK, sub.thuto a
lnown-good ECM/PCM !nd
racheck.
I
VTECSOLENOIDVALVE lP
CONNECTOR
Te3tthe VTECSolonoidV.lve:
1. Turnthe ignitionswitchOFF. Ir----'t I
2. Disconnect the VTECsolenoid
valve1Pconnector.
3. Checkfor continuity between
'll '- ff---r
'1
t h e V T E Cs o l e n o i dv a l v e 1 P I
connectorterminalNo. 1 and
bodyground. I-L
ls there 14- 30 0?
Terminalsideof
maleterminal
I
A/T LOWPRESSURE
w/PAt{EL
Te3ttho WEC SolonoidVatvo: 07406-0070300
'1. Remove
the VTEC pressure
swatchand installthe special
tool as shown, then reinstall
the VTECpressureswitch.
2. Reconnoctthe VTECsolenoid
valve 1P connectorand VTEC
pressureswitch 2P connector.
3, Connectthe tachometer(see
section11).
4. Stanthe engine. A/T PRESSURE I{OSE
5 , W a r m u p e n g i n et o n o r m a l 07406- 0020201
operatingtemperature(cool, ot
ing fan comeson). A/T PRESSURE HOSE.
6. Checkoil pressureat engine 2,210mm
speeds D16Y5engine: 1,000 N O T E : K e e p m e a s u r i n gt i m e a s s h o r t a s 07MAJ - PY&llA and
and 3.000rpm, D16Y8engine: possiblebecauseengineis runningwith no PRESSURE GAUGE A/T PRESSURE ADAPTER
1,000,3,000 and 5,000rpm. load(lessthan one minute). ADAPTER 07MAJ - PY,()120
07NAJ - P07010A
ls pressurebelow 49 kPa In.poct the VTEC aolonoid vllvo

(0.5kgflcm,,7 psi)? ls.c p.g. &6).
(To page6-5)
6-4
VTECSOLENOIDVALVE
(Frompage6'4)
1P CONNECTOR
Terminalsideof
Testthe VTECSolenoidValve: maleterminal
2. Disconnect the wEC solenoid
valve 1Pconnector.
3 . A t t a c h t h e b a t t e r yp o s i t a v e
terminalto the VTECsolenoid
valveterminal.
4 . S t a r t t h e e n g i n ea n d c h e c k
t h e o i l p r e s s u r ea t e n g i n e
speedof 5,000rpm.
ls the pressureabove390kPa Inspect lhe VTEC solonoid valve

(4.0kgtcm' ,57psi)? lseep6gem). C {31P}
ECM/PCMCONNECTOR
'99 - 00:
'96 - 98:
VTM
Testthe VTECPressureSwitch:
With the battery positiveterminal
connectedto the VTECsolenoid
valve, measurevoltagebetween
the ECM/PCM connectorterminal
' 9 6 - 9 8 : C l 5 , ' 9 9 - 0 0 : C 1 0a n d
bodyground.
'99 - 00:
ls there batteryvoltage above ECM/PCMCONNECTOR
VTECSOLENOID
5,000rpm? VALVE B {25Pt
1PCONNECTOR
'96 - 98:
VTECSOLENOID ECM/PCMCONNECTOR
VALVE A {32P1
CONNECTOR
T6st the VTEC Solenoid Valve VTS
wire:
{GRN/YEL)
2. Checkfor continuitybetween wire sideo{ female
t h e V T E Cs o l e n o i dv a l v e 1 P terminals
c o n n e c t o rt e r m i n a la n d t h e
ECM/PCMconnectorterminal
'96 - 98: A8, '99 00r B'12. wire sideoI temale
terminals
Repair open in the wire between
the ECM/PCM ('96 - 98: A8, '99 -
0o: 8l2l and VTEC solenoid v.lv6
connoc{or.
Test the VTEC Solenoid Valve
Check for continuity between the

V T E Cs o l e n o i d v a l v e 1 P c o n n e c t o r
t e r m i n a l€ n d b o d y g r o u n d .
ReDair 3hort in the wire between

the ECM/FCM ('96 - 98: A.8,'99 -
ls therecontinuity?
0O:Bl2l and VTECaolenoidvalve
connectot,
Substitute a known-good ECM/

PCM and recheck. lf symptom/
indication goes away, replace
the original ECM/PCM.

VTECSolenoidValve
Inspection (
1. D i s c o n n e ct th e 1 P c o n n e c t o frr o m t h e V T E Cs o l e - 4. lf the filter is not clogged,push the VTECsolenoid
noid valve. valvewith your fingerand checkits movement.
Measureresistancebetweenthe terminaland body . lf the VTECsolenoidvalve is normal.checkthe

ground. enganeoil pressure.
I
l4 - 30 O
Resistance:
6x1.0mm
12 N.m {1.2kgt.m,8.7lbf.ft)
lf the resistanceis within specifications, removethe . (

\
V T E Cs o l e n o i dv a l v e a s s e m b l yf r o m t h e c y l i n d e r
I
head,and checkthe VTECsolenoidvalve filter for
cloggrng.
. lf there is clogging,replacethe engine oil filter

a n dt h e e n g i n eo i l .
VTECSOLENOID
VAI-VEASSEMBLY
6x1.0mm
12 N.m 11.2kgf.m,8.7lbtft)
..
6-6
VTECRockerArms
(D16Y5engine)
ManualInspection ManualInspection(D16YB
engine)
1 . Setthe No. 1 pistonat TDC. 1. Setthe No. 1 pistonat TDC.
2. Removethe cylinderheadcover. Removethe cylinderheadcover.
NOTE:Referto page 6-46when installingthe cylin- NOTE:Reterto page6-46when installingthe cylin-

der headcover. der headcover.
'l Pushthe intakemid rockerarm on the No. 1 cylin-

3. Move the intakesecondaryrockerarm on the No.
c y l i n d em
r anually. d e rm a n u a l l y .
4. Checkthat the intakesecondaryrockerarm moves 4. Checkthat the intakemid rockerarm movesindepen-

independentlyof the primaryintakerockerarm, dently of the primary and secondaryintakerocker
arms.
MID ROCKER
ARM
SECoNDARY PRIMARYROCKERARM
Pt
ROCKERARM
. P u s ha n d p u l l .
C h e c k t h e i n t a k e s e c o n d a r y r o c k e ra r m o f e a c h
c y l i n d e ra t T D C . 5, Checkthe intakemid rockerarm of eachcylinderat
TDC,
a lf the intakesecondaryrockerarm doesnot move,
removethe primaryand secondaryintakerocker l f t h e i n t a k em i d r o c k e ra r m d o e s n o t m o v e .
armsas an assemblyand checkthat the pistonsin remove the mid, primary and secondaryintake
t h e s e c o n d a r ya n d p r i m a r yr o c k e ra r m s m o v e rockerarmsas an assemblyand checkthatthe pis-
smoothly. t o n s i n t h e m i d a n d p r i m a r yr o c k e ra r m s m o v e
a lf any rockerarm needsreplacing,replacethe pri- smoothly.
mary and secondaryrockerarmsas an assembly. l f a n y r o c k e ra r m n e e d sr e p l a c i n gr,e p l a c et h e
primary,mid, and secondaryrockerarms as an
assemory.
6-7
VTECRockerArms
Inspection (Dl6Y5enginel
Using SpecialTools
(
CAUTION: 3, Removethe sealing bolt from the inspectionhole
. Before using th6 Valve Inspection Tool, make 3ure and connectthe an air pressureregulatorwith a 0 -
that ths air pressuregaugo on the air comptsssor 100psi gauge.
indicatesover iloo kPa 14kgf/cmr, 57 psi).
. Inspecl th6 valv€ clearancebeforo rocker atm insDec"
10x 1.0mm
tion, SEALING BOLT
Coverthe timing belt with a shop towel to protect tho 20N.m{2.0kgj'm.14lblft}
belt.
Check ths intakg primaty rocker arm of each cylindqr at
TDC.
'1.
Removethe cylinderheadcover.
NOTE:Referto page6-46when installingthe cylin-

der headcover.
Plugthe reliefholewith the specialtool.

l
l'
'10x 1.0mm (Commercially
;NSp€CTTONHOLE
ADAPTER available)
P u l l t h de i a a
l nd
YY turnto adlust,
Loosenthe regulatorvalve on the valve inspection

tool and applythe specifiedair pressure.
OTLAJ- PR3O2OB SpocifiedAir Pressurei

250 kPa {2.5 kg,t/cm,,36 psi}
o-at
5. With the specifiedair pressureappli€d,push up the 6. Stop applyingair pressureand push up the timing
timing plate;the synchronizingpiston will pop out plate;the synchronizingpistonwill snap backto its
and engagethe intakesecondaryrockerarm. originalposition.
Visuallycheckthe engagementof the synchronizing Visuallycheckthe disengagementof the synchro-
prston. nizingpistons.
NOTE; NOTE:
The synchronizing pistoncan be seen in the gap . When the timing plate is pushedup, it releases
betweenthe secondaryand primaryrockerarms, the timing piston,lettingthe returnspring move
With the timing plate engagedin the groove on the synchronizingpistonto its originalposition.
t h e t i m i n g p i s t o n ,t h e p i s t o n i s l o c k e d i n t h e
oushedout Dosition. 7. Replacethe intake rocker arms as an assemblyif
either does not work correctly,
TIMIT{GPLATE
TIMIiIG TIMINGPLATE
PLATE
SPRIT{C
oll PASSAGE--!
PRIMARYROCKER SECOI{DARY
ARM ROCKERARM
TIMII{GSPRII{G RETURI{SPRING
PRIMARYROCKERARM
SECODARY TIMI G PISTOI{
ARM
ROCKER
Removethe spscialtools.
AIR PRESSURE After inspection,checkthat the malfunctionindicator

lamp (MlLl doesnot comeon.
GROOVE
TIMINGSPRING
6-9
VTECRockerArms
InspectionUsing SpecialTools(D16Y8enginel
CAUTION: 3. Removethe sealing bolt from the inspectionhole
o Before using the Valve Inspection Tool. mak6 sure anclconnectan air pressureregulatorwith a 0 - 100
that the air pressuregauge on the air comprsssor psi gauge.
indicatesovor 400 kPa {4 kgf/cm,, 57 psil.
. Inspectth6 valve clearancobefore rockar arm inspec-
tion.
l 0 x 1 . 0m m
. Cov€r th€ timing belt with a shop towel to protect SEALINGEOLT
the bolt. 20 N.m (2.0 kgf.m, 14 lbf.ft)
. Checktho intake prima.y rockff arm of each cylindel
at TDC.
1 . Removethe cylinderheadcover.
NOTE: Referto page6-46when installingthe cylinder

neaocover,
Plugthe reliefhole with the specialtool.
(
AIR PRESSURE
REGULATOR
{Commercially
available)
. P u l l t h ed i a l a n d
turn to adjust,
OTLAJ- PR3O2OB
I,^ A IA
o- tu
4. Loosenthe regulatorvalve on the valve inspection 1. Removethe specialtools.
tool and applythe specifiedair pressure.
8. U s e a 1 0 m m d i a m e t e rr o d t o d e p r e s se a c h l o s t
SpecifiedAir Pressure: motionassemblythroughits full movement.
250 kPa {2.5 kgf/cm', 36 psil Replaceany lost motion assemblythat does move
smoothly.
PRIMARY
ROCKER MID ROCKER SECONDARY
ARM ARM ROCKERARM
SYNCHRONIZING
SYNCHRONIZING
PISTON
A PISTON
B
5. Make sure that the intake primary and secondary

rockerarmsare mechanically connectedby the piston
and that the mid rockerarm does not move when
oushedmanuallY.
ASSEMBLY
9. After inspection,checkthat the MIL does not come

on.
SECONDARY
ROCKERARM
lf any intake mid rockerarm moves independentlyof
t the primary and secondaryrocker arms, replacethe

rockerarms as a set.
6-11
Valve Clearance
Adjustment
NOTE: 5. Loosenthe locknut,and turn the adjustmentscrew
. Valves should be adjusted only when the cylindsr until the feeler gauge slides back and forth with a
headtemperatureis lessthan 100"F(38"C). sliOhtamountof drag,
. After adjusting,retorquethe crankshaftpulley bolt
(seepage6-16). D16Y7engin.:
1, Removethe cylinderheadcover. CAUTION: Do not oyertighlen the locknuts; tho

rockor arms are made of aluminum.
NOTE; Referto pagee46 when installingthe cytinder
headcover. INTAKE
endEXHAUST
VALVE
LOCKNUTS
18 N.m (1.8kgI.m, 13 tbl.ftl
2. Removethe uppercover (seepage6-19).
3. Set the No. 1 pistonat TDC.The "UP" mark on the

c a m - s h a f tp u l l e y s h o u l d b e a t t o p , a n d t h e T D C
marksshouldalignwith the cylinderheadsurface.
"UP"MARK
TDCMARKS
tr
Dl6Y5, Dl6Y8 engin€3:
INTAKE.nd EXHAUSTVALVE
LOCKNUTS
20 N.m 12.0kstm, 14lbtft)
4. Adjustvalveson No, 1 cylinder. Adiusting screw locations:

IMTAKE
Intako: 0.18- 0.22 mm {0.007- 0.009in}
o.4 1{o.3 No.2
Exhaust:0.23- 0.27mm (0.009- 0.011inl
(
No.4 nb.3 No.2 No. 1
EXHAUST
6- 12
' 1 8 0 'c o u n t e r c l o c k w i s teo
6. Tightenthe locknut,and checkthe clearanceagain. 8. R o t a t et h e c r a n k s h a f t
Repeatthe adjustmentif necessary. b r i n g N o . 4 p i s t o nt o T D C .B o t hT D C g r o o v e sa r e
o n c ea g a i nv i s i b l eA. d j u s tv a l v e so n N o .4 c y l i n d e r .
GAUGE
-UP'MARK
7. Rotatethe crankshaft180' counterclockwise (cam- Rotatethe crankshaft180'counterclockwise to bring

shaft oullevturns 90'1.The
"UP" mark shouldbe on No. 2 piston to TDC.The "UP" mark should be on
the exhaustside.Adjustvalveson No. 3 cylinder. the intakeside.Adjustvalveson No. 2 cylinder.
"UP- MARK
6-13
Valve Seals
(Cylinderheadremovalnot requiredl
Replacement
N O T E :C y l i n d e rh e a d r e m o v a li s n o t r e q u i r e di n t h i s Intake Valve Seals:
procedure.
6. Selectthe 7/8 in diametershort compressorattach-
The procedureshown below applieswhen using the in- ment,and fastenthe attachmentto the No. 4 holeof
c a r v a l v e s p r i n g c o m p r e s s o r( S n a p - o nY A 8 8 4 Sw i t h the leve.arm with the speedpin supplied.
Y48845- 2 A7/8" attachment).
7. lnsertan air adapto.into the sparkplug hole.pump
!@@ Alway wear approved eye protection when air into the cylinderto keepthe valve closedwhile
using ihe in-cai valve spring compressor. compressingspringsand removingthe valve keep
ers.
1. Turn the crankshaftso that the No. I and the No. 4
pistonsare at top deadcenter(TDC). 8. 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
2. Removethe cylinderheadcoverand the rockerarm neao.
assembly.
OIL PASSAGES
NOTE:
. R e f e rt o p a g e 6 - 3 0 f o r r o c k e r a r m a s s e m b l y
removat.
. W h e n r e m o v i n g o r i n s t a l l i n gt h e r o c k e r a r m ,
assembly,do not remove the camshaft holder I
b o l t s .T h e b o l t s w i l l k e e pt h e h o l d e r s ,s p r i n g s
and rockerarms on the shaft.
. Referto page 6-46 when installingthe cylinder
headcover.
3 . Removethe fuel injectorsand the wire harness.
4. Usingthe 8 mm bolts suppliedwith the tool. mount

t h e t w o u p r i g h t st o t h e c y l i n d e rh e a d a t t h e e n d
c a m s h a f th o l d e r s .T h e u p r i g h t sf i t o v e r t h e c a m -
shaftas shown.
i
OILPASSAGES
Positionthe lever arm underthe crossshaft so the

lever is perpendicularto the shaft and the compres-
sor attachmentrests on top of the retainerfor the
spring being compressed.Use the front position
slot on the leveras shown.
IN-CARSPRINGCOMPRESSOR
lnsert the cross shaft through the top hole of the

two uprights.
SLOT
6 - 14
10. Using a downward motion on the lever arm, com- 1 6 . Using a downward motion on the lever arm, com-
.pressthe valvespringand removethe keepersfrom pressthe valvespringand removethe keepersfrom
t h e v a l v e s t e m . S l o w l y r e l e a s ep r e s s u r eo n t h e t h e v a l v e s t e m . S l o w l y r e l e a s ep r e s s u r eo n t h e
spring. spnng.
't7. Removethe valveseals{seepage6-38),

11. Removethe valveseals(seepage6-38).
'18. Installthe valveseals(seepage6-43).
12. Installthe valveseals{seepage6-43).
13. Installthe springs,the retainersand the keepersin 1 9 . Installthe springs,the retainersand the keepersin
reverseorderof removal. reverseorderof removal.
ExhaustValvs Sesls: 20. Repeatsteps6 to 19 on the othercylinders.
'14.
Selectthe 7/8 in. diametershort compressorattach-
ment,and fastenthe attachmentto the No. 2 hole of
the leverarm with the speedpin supplied.
Positionthe lever arm under the cross shaft so the

leveris perpendicular to the shaftand the compres-
sor attachmentrests on top of the retainerfor the
s p r i n g b e i n g c o m p r e s s e dU. s e t h e f r o n t p o s i t i o n
slot on the leveras shown.
IN-CARSPRINGCOMPRESSOR
7/8 in SHORTATTACHMENT
6-15
CrankshaftPulleyand Pulley Bolt
Replacement
W h e n i n s t a l l i n ga n d t i g h t e n i n gt h e p u l l e y .f o l l o w t h e '1.
Tightenthe pulleybolt to the specifiedtorque.
procedurebelow,
Torque: 20 N.m {2.0 kgf.m, 14 lbf'ft}
C l e a n ,r e m o v e a n y o i l , a n d l u b r i c a t ep o i n t s s h o w n
below. Use I felt tip pen to mark the pulley bolt head and
O: Clean washer.
x: Bemoveany oil
a: Lubricate
CRANKSHAFT MARKING
TIMINGBELT
GUIOEPLATE
Crankhaft pulley bolt size and torque value:

14 x 1.25mm
20 N.m {2.0 kgl.m, 14 lbf.ft) + 90' EMBOSSINGMARKS
\ I
NOTE:Do not usean impactwrenchwhen installing.
3. Tightenthe pulleybolt an additional90".

HOI.I'ERHANDTI
07JAB- 001020A
HOLDERATTACHMENT.50 mm EMBOSSINGMABK MARKING
07NAB - ootoilllA
S(rc(ET,17mm
07JAA-lxtl010Aor
{Co.nm.rci.lly.v.il.bl.}
MARKING
6-16
Timing Belt
Illustratedlndex
NOTE:
. Referto page6-20for how to positionthe crankshaftand pulleybeforeinstallingthe belt.
. Markthe directionof rotationon the belt beforeremoving.
a Do not usethe uppercoverand lower coverfor storingremoveditems,
. Cleanthe uppercoverand lowercoverbeforeinstalling.
. Replacethe camshaftsealsand crankshaftseals if there is oil leakage.
. Referto page6-16beforeinstallingthe timing belt.
CYLINDER HEAD
COVER
Relerto page6-46
wheninstalling.
HEAD COVEBGASKET
Replacowhen l6akin9,
domagedor deteriorated.
Apply liquid gasketat
th€ lour cornersof the
tecessos.
TIMINGBELT I x 1.25mm
Inspection, page6-18 3t N.m {3.8 kgf'm, 27 lbfftl
d Adjustment,page6-18 Applyengineoilto the bolt
Removal,page6-19 thleads.
@ Installation.page 6-20
SPEEDFI.UCTUATION
CRANKSHAFT
lcr(FlsENsoR
Page6-22
Replacement,
COVEB
UPPER
6x1.0mm
9.8 N'm 11.0kgt m,
7.2 tbf.ft)
NUBBERSEALS
Replacewhen damaged
or deledorated.
LOWERCOVER
FUBBER
PLUG
CRANKSHAFTPULLEY
page6'16
Replacement,
PULLEYBOLT
lnstallwith lil x 1.25mm
surfacefacingin. 20 N.m 12.0kgt.m,
14 lbt'ft) + 90"
Replacement, page6'16
Do not us6 an impact
wrenchwhen installing.
TIMINGBELT
DRIVEPULLEY
\.-,o
page6_16
Replacement, x 1.0mm
BOLT o-RING 6 x 1 . 0 m m 9.EN'm (1.0 kgt.m,
10 x 1,25mm Reolace.t2 N.m 11.2kgf'm, ?.2 tbf.ftl
14 N.m {,1.5kgt m, 33 lbt ftl 8.7 tbt f0
6-17
Timing Belt
Inspection TensionAdjustment
1. Removethe cylinderheadcover. CAUTION:lt*ays aa;j"t the timing bett rension with
the enginecold.
. R e f e tr o p a g e6 4 6 w h e n i n s t a l l i n g .
NOTE:
2. Removethe uppercover(seepage6 19). . The tensioneris spring loadedto applytensionto the
belt automaticallyafter makingthe following adjust
3. I n s p e ctth e t i m i n gb e l tf o r c r a c k sa n d o i l o r c o o l a n t ment.
soakrng. . Always rotatethe crankshaftcounterclockwise when
v i e w e d f r o m t h e p u l l e ys i d e . R o t a t i n gi t c l o c k w i s e
NOTE: m a y r e s u l ti n i m p r o p e ra d j u s t m e not f t h e b e l t t e n -
. Replacethe belt if oil or coolantsoaKeo. sion.
. Removeany oil or solventthat gets on the belt. . lnspectthe timing belt beforeadjustingthe belt ten-
ston.
1. Removethe cylinderheadcover.
. Referto page6,46when installing.
2. Removethe uppercover(seepage6,'19).
3. Rotatethe crankshaftfive or six revolutionsto set

the belt.
4. Setthe No. 'l pistonat TDC(seepage6-21).
5. Loosenthe adjustingbolt 180'.
\ I
ADJUSTINGBOLT
44 N.m {4.5kgt m,
33 rbf.ft)
Rotatepulley
and inspectbelt.
After inspecting,retorquethe crankshaftpullevbolt

{seepage6- 16).
Rotatethe crankshaftcounterclockwise
three teeth
on the camshaftpulley.
7 . Tightenthe adjustingbolt.
8 . After inspecting,retorquethe crankshaftpulleybolt

(seepage6-16).
o- I6
Removal
NOTE: 5. Removethe dipstick,then removethe upper cover
. Replacethe timing belt at 105,000miles (168.000 km) and idler PulleYbracket
accordingto the maintenance schedule (normal con-
ditions/severe conditions). NOTE: Do not use the upper cover to store removed
lf the vehicleis regularlydrivenin one or more of the items.
followlngconditions,replacethe timing belt at 60.000
miles(U.S.A.)100,000km {Canada).
. I n v e r yh i g ht e m p e r a t u r e( so v e r1 1 0 ' F . 4 3 ' C ) 6x1.0mm
. In very low temperatures(under-20'F, -29"C)' 9.8 N.m 11.0kgf.m,
7.2
! Turn the crankshaftpulley so the No. 1 piston is at
top dead center(TDC)beforeremovingthe belt (see
page6'21).
. Inspectthe water pump before installingthe timing
belt {seePage10-14).
1. Removethe splashshield(seepage5-7).
2. Loosenthe mountingbolt and lockbolt.then remove

the powersteering(P/S)pump beltand pump
I x 1.25mm
IDLER
24 N.m (2.4kgl.m, 17 lbf'ft)
MOUNTINGBOLT BRACKET
8 x 1.25mm
2il N m 12.4kgl m, 17 lbf'ft)
6. Removethe upperbracket{seepage6-29)
NOTE:
. Usea jackto supportthe enginebeforethe upper
bracketis removed
. Make sure to place a cushion between the oil
pan and the jack.
1. Removethe crankshaftpulley(seepage6-16).
P/S PUMP
BELT
.'. Removethe lowercoverand dipsticktube
NOTE; Do not use the lower cover to store removed

I x 1.25mm items.
24 N m (2.4kgfm, 17lbtft)
DIPSTICKTUBE
3. L o o s e nt h e i d l e r p u l l e yc e n t e rn u t a n d a d j u s t i n g LOWER
bolt, then remove the air conditioning(AVC)com-
pressorbelt (seePage5-6).
Loosenthe mountingnut and lockbolt,then remove

the alternatorbelt.
ALTERNATOR LOCKBOLT
BELT I x 1.25mm
24 N.m 12.4kgf.m,
r? tbI.ft)
6x1.0mm
9.8 N.m (1.0kgf m,
7.2 rbt.ft)
Replace. (cont'd)
MOUNTING NUT
1 0 x 1 . 2 5m m
44 N.m 14.5kgl m,
33 rb{ ft)
6-19
Timing Belt
Removal (cont'd) lnstallation
9. Removethe CKFsensorfrom the oI pump. Installthe timing belt in the reverseorderof removal;
Only key pointsare describedhere.
l. set rhe timing belt drive pulleyso that the No. 1 pis-
ton asat top deadcenter(TDC),Align the grooveon
the timing belt drive pulleyto the pointeron the oil
pump.
TDC MARK POINTER
I
12 N.m 11.2kgt.m,
t
8.7 rbf.ftl
TIMING BELT
10. Loosenthe adjustingbott lgO.. Push the tensioner
t o r e m o v e t e n s i o n f r o m t h e t i m i n g b el t . t h e n
retightenthe adjustingbolt. 2.
DBIVEPULLEY
Clean.
S e t t h e c a m s h a f tp u l l e y t o T D C .A l i g n t h e T D C
I
marks on the camshaftpulleyto the cylinderhead
surface.
AD.'USNNG BOLT
4{ N.m 14.5kgt m,
33 tbtftl
1 1 . R e m o v et h e t i m i n gb e l t .
6-20
3. Installthe timing belttightlyin the sequenceshown' 9. Checkthat the crankshaftpulleyand camshaftpul-
ley are both at TDC.
OTiming beltdrive pullev(crankshaft) )@Adjusting
pulley-towater pump pulleyJ@Camshattpulley'
CRANKSHAFTPULLEY:
NOTE: Make sure the timing belt drive pulley and
camshaftPulleYare at TDC
(wHrTE)
CAMSHAFTPULLEY:
"UP" MARK
Loosenand retightenthe adiustingbolt to tension
the timing belt.
lnstallthe lowercoverand uppercover.
N O T E :C l e a nt h e u p p e r a n d l o w e r c o v e r sb e f o r e
installation.
lnstallthe crankshaftpulley,then tightenthe pulley

bolt (seepage&16)
7. Rotatethe crankshaftpulley about five or six turns

so that the timing belt positions TDC MARK
counterclockwise
on the Pulleys.
8. Adjustthe timing belttension(seepage6-18). lf the camshaftand crankshaftpulleysare not posi-

tioned at TDC, remove the timing belt and adjust
the positionfollowingthe procedureon page 6-20'
Then reinstallthe timing belt.
adjustthe tensionof eachbelt

1 1 . After installation,
. See section23 for alternatorbelt tensionadjust-

ment.
a See section22 tot NC compressorbelt tension
adjustment.
. See section17 for P/Spump belt tensionadjust
L ment,
6-21
CrankshaftSpeed Fluctuation(CKF)Sensor
Replacement
1 . Removethe cylinderheadcover.
NOTE:Referto page6-46when installing.
2. Removethe crankshaftpulley(seepage6_16),
3 . R e m o v et h e u p p e r c o v e r a n d d i p s t i c k / t u b e{ s e e
p a g e6 - 1 9 ) .
4. Removethe lower cover and idler pulley bracket

(seepage6-19).
5. Disconnectthe CKFsensorconnector,then remove

the CKFsensor.
CKFSENSOR
CONNECTOR
: (
I
6x1.0mm
'12N.m
{1.2kgt.m,
8.7 tbf.ft)
6. InstalltheCKFsensorin reverseorderof removal.
6-22
GylinderHead
lllustratedIndex
CAUTION:
(38'C)beforeremovingthe cylinder
. To avoid damage,wait until the enginecoolanttemperatuledrops below 100"F
head.
. When handlinga metal gasket,take carenot to fold it or damagethe contactsurface'
NOTErUsenew O-ringsand gasketswhen reassembling'
6x1.0mm
9.8 N.m 11.0kgf.m,7.2lbfft)
WASHER Applysoapsudsto threadsand cylinderhead
Replace when damaged contactsurfacewhen replacingthe rubber
or deteriorated. seal,then temoveany soapsudsafterinstall
ing rubberseal.
CYLINDER HEAD
RUBBERSEAL
COVER
Referto page6 46, when Replacewhen damaged
or deteriorated.
installingcylinderheadcover.
CYLINDERHEADBOI-T
10 x 1.25mm
67 N.m 16.8kgf m, a9 lbt'ft)
Tightening,Page6-46
HEADCOVEBGASKET Applyengineoilto the threads.
Replace when leaking,
damagedor deteriorated.
Apply liquidgasketat
the four cornersol the
recesses,
DISTRIBUTOR
Seesection23.
O.RING
Replace. CYLINDERHEAD
8 x 1.25 mm
GASKET
24 N.m (2.4kgf.m, Replace.
17 tbt.ft)
8 x 1.25mm
24 N.m {2.4kgf m, 17 lbf ftl
t PINS (cont'd)
6-23
CylinderHead
lllustratedIndex(cont'dl
-/) (
- _.
"or to reassembring,
creanat thepartsin sorvent,
drythemandappryrubricant
E to anvcontactoarts.
D16Y7 engine:
8 x 1.25mm
20 N.m (2.0kgt.m, 14 tbt.ftl
ROCK€RARM Applyengineoil to the
ASSEMBLY
Removal,page6 30
Inspection,
page6-35 6x1.0mm
12 N.m (1.2kst.m, 8.7 tbf.ft)
Applyengineoit to the
threads.
VALVEKEEPERS
CAMSHAFT
nspectron,
page6-36 SPRINGRETAINER
H
B INTAKEVALVE
OILCONTROL SPRING
ORIFICE
INTAKEVALVESEAL
Clean.
Replace.
VALVESPRING
O-RING
SEAT
Replace.
VALVEKEEPERS
INTAKEVALVE
GUIDE
:a
ti
\
SPRING
RETAINER
EXHAUSTVAL
SPRING
EXHAUST
VALVE
SEAL
8 x 1.25mm
VALVESPRING 37 N m (3.8kgt m,
SEAT 27 tbtftl
A p p l ye n g i n eo i l t o
the threads.
EXHAUSTVALVE
GUIDE
rnspectron,
page6,39
Beplacement,page6 4l
Aeaming,page6-43
Removal,page6,27
VALVE Warpage,page6 40
INTAKEVALVE Valveseatreconditioning,
page6-40 t
Removal,page6-38
lnstallation,
page6-43 Installation,
page6-45
t
t
c - A
9-2.+
L
D16Y5 engine:
I x 1.25mm
20 N.m (2,0 kgf m, 14 lbf ft)
Applyengineoilto the
threads.
ROCKEBARM
ASSEMBLY 6x1.0mm
Femoval,page6-30 12 N.m 11.2kgf m, 8.7 lbf'ftl
Apply engineoilto the
Page6-34
Inspection,
threads.
CAMSHAFT
page6-36
Inspection, VALVEKCEPERS
6x1.0mm
12 N,m 11.2
SPRINGRETAINER
8.7 tbf.ft)
INTAKE VALVE
WEC SOLENOID
VALVE
B SPRING
INTAKEVALVESEAL
Replace.
VALVESPRING
SEAT
INTAKE VALVE
GUIDE
VTECSOLENOID
VALVE FILTER CAMSHAFT
Replace. PUL|'IY
OIL CONTROL
ORIFICE
Clean.
VALVE
SPRINGRETAINEB
EXHAUSTV VE
SPRING 8 x 1.25mm
EXHAUSTVALVE 37 N.m 13.8kgf.m,
SEAL 27 tbf.frl
t"o'""".uoau, Apply engineoilto
Replace.
SEAT the lhreads.
GUIDE
page6-39
Inspection,
Replacement,Page6-41
Reaming,page6-43
EXHAUST OIL SEAL
VALVE Replace.
INTAKEVALVE HEAD
Removal, page 6 38 Removal,page6-27
I n s t a l l a l i o n ,P a g e 6 4 3 Warpage,Page6 40
Valveseatreconditioning'
page6-40
page6_45
lnstallation,
(cont'd)
6-25
CylinderHead
-vp
e,.io"o reassembring,
creanat the partsin sorvent,dry them and appryrubricantto
any contactparts.
D16Y8engine:
LOSTMOTION 20 N.m 12.0kgl.m, 14 tbf.ft)

LOSTMOTION ASSEMBLY Applyengineoit to the
ASSEMgLY HOLDER threads.
6x1.0mm
\ 12 N.m (1.2kgt.m,8.7lbf.ftl
Apply engineoil to the
ROCKERARM threads,
ASSEMBLY \
Removal,page6 30
Inspection,
page6-34
si l 9l l
CAMSHAFT
5xl.0mm Inspection,
page6-36
12 N.m {1.2
8.7 tbf.ft)
VALVEKEEPERS
SPRINGRETAINER
INTAKEVALVE
INTAKEVALVESEAL
VTECSOLENOID Replace.
VALVEFILTEB
Replace.
VALVESPRING
SEAT
INTAKEVAI.VE
I
GUIOE I
OILCONTROL
ORIFICE
Clean.
VALVEKEEPERS CAMSHAFT
PULLEY
SPRINGRET
EXHAUSTVALVE
SPRING
@
EXHAUSTVALVE
SEAL VALVESPRING
Replace. SEAT
EXHAUSTVALVE O.RING
8 x 1.25mm
GUIDE Replace.
37 N.m 13.8kgt m,
Inspection,
page6 39
27 tbfitl
Replacement,page6 41 A p p l ye n g i n eo i l t o
Reaming,page6 43
the threads.
OIL SEAL
Beplace.
INTAKEVALVE EXHAUST CYLINDERHEAD

Bemoval,page6 38 VALVE Removal,page6 27
Installation,
page6 43 Warpage,page6-40
Valveseatreconditioning,
page6 40
Installation,
page6-45

Removal
Engineremovalis not requiredfor this procedure 8. Removethe throttlecableby looseningthe locknut,
then slip the cableend out of the throttlelinkage
!!!s@ Make sure iacks and salety stands are
propetty
ta"eata"ea and hoist brackets are attached to the NOTE:
f
correct positions on the engine. . Takecarenot to bendthe cablewhen removingit
Alwaysreplaceany kinkedcablewith a new one
CAUTION: . Adjustthe throttlecablewhen installing(seesec-
. Use tender covels to avoid damaging painted sul- t i o n 11 ) .
faces.
o T o a v o i d d a m a g e ,u n p l u g t h e w i l i n g c o n n e c t o r s D16Y7engine:
carefully while holding the connector portion to
avoiddamage. LOCKNUT
. To avoid damagingthe cylinderhead,wait until the
e n g i n e c o o l a n t t e m p e r a t u r ed r o p s b e l o w 1 0 0 " F
{38"C}before loossning the tetaining bolts.
NOTE:
o M a r k a l l w i r i n g a n d h o s e st o a v o i d m i s c o n n e c t l o n
Also, be surethat they do not contactother wiring or
hoses,or interferewith other parts.
. Inspectthe timing belt before removingthe cylinder
he a d .
. T u r n t h ec r a n k s h apf tul l e ys o t h a tt h e N o . l p i s t o n i s a t
top deadcenter(seePage6-21)
'1. Disconnect
the negativeterminalfrom the battery'
CABLE
2. D r a i nt h e e n g i n ec o o l a n (t s e ep a g e ' 1 0 - 7 ) .
a Removethe radiatorcapto speeddraining.

Dl6Y5, Dl6Y8 engines:
3. Removethe intakeair duct and air cleanerhousing
(seepage5 3).
THFOTTLE
4. 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 CABLE
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 (seepage5'5).
L o o s e nt h e i d l e r p u l l e y c e n t e rn u t a n d a d j u s t i n g
bolt' then removethe air conditioning(A'lc)com-
pressorbelt (seePage5-6).
6. L o o s e nt h e m o u n t i n g n u t a n d l o c k b o l t . t h e n
removethe alternatorbelt (seepage6-19).
1. Removethe P/Spump bracket(seepage5-12).
(cont'd)
6-27
CylinderHead
Removal (cont'd)
(
9. Relievefuel pressure(seesection11),
1 1. Removethe brakeboostervacuumhose.fuel return
hoseand vacuumhose(seepageS_4).
E@E Do not smokewhile working on tho fuel
system. Ke6p opgn flame or gpark away from lhe 12. Removethe water bypasshose and positivecrank_
work area, Drain fuel only into an app.oved containgr.
caseventilation(pCV)hose.
10. Removethe evaporativeemission (EVAP)control
016V7engine:
canisterhose,fuel feed hoseand breatherhose.
D16Y7engine: WATEREYPASS
BANJOBOLT
33 N.m{3.4kgtm,
25 tbf.ftt
BREATHER
HOSE
\ a
PCVHOSE
D16Y5, D16Y8 engines:
D15Y5, Dl6YB engines:
BANJOAOLT
33 N.m (3.4kgf.rn, PCVHOSE
25 tbf.ftt
EVAP CONTROL
CANISTERHOSE
6 -28
13. Remove the upper radiator hose' heater hose and
1 5 . Removethe spark plug caps and distributorfrom
water bYPasshose
the cylinderhead.
Removethe uPPerbracket.
WATER
EYPASS NOTE:
HOSE . U s e a j a c k t o s u p p o r tt h e e n g i n e b e f o r et h e
UPPER
RADIATOR upperbracketis removed.
HOSE . Make sure to place a cushion between the oil
pan and the jack.
12 x 1.25mm
74 N.m {7.5 kgf m.
sil lbl.ftl
UPPER
BRACKET
HEATER
HOSE
1 4 . Remove the engine wire harnessconnectorsand

wire harness clamps from the cylinder head and the
intake manifold.
o Fourfuel injectorconnectors '17. Removethe cylinderheadcover'

. Engine coolant temperature(ECT)sensor con-
nector
a ECTswitch connector
ECTgaugesendingunit connector
a Throttlepositionsensorconnector CYLINDER
a Manitold absolute pressure(MAP) sensor con- HEADCOVER
nector
Primary heatedoxygen sensor (primary HO2S)
connector
S e c o n d a r yh e a t e do x y g e n s e n s o r ( s e c o n d a r y
HO2S)connector(D16Y7engine)
Exhaustgas recirculation(EGR)valve lift sensor
connector(D16Y5engine)
. VTECsolenoid valve connector(Dl6Y5, D16Y8
engrnes)
. VTECpressureswitch connector(D16Y5.D16Y8
engrnes,
. ldle air control(lAC)valveconnector
(cont'd)
6-29
Cylinder Head RockerArms
Removal(cont'd) Removal
(
\
1 8 . Removethe timing belt {seepage6-19). 1. Loosenthe adjustingscrews.
1 9 . Removethe camshaftpulleyand backcover,
ADJUSTINGSCREWS
CAMSHAFT
PULLEY
Cleanwhen installing.
8 x 1.25mm
6x1.0mm 37 N.m (3.8 kgf.m,
21 tbtlrl
Applyengineoilto the
bolt threads.
2. Unscrew the camshaft holder bolts, then,remove
Removethe exhaustmanifold{seepages9-6and 9_7). the rockerarm assembly.
2 1 . Removethe intakemanifold(seepages9-2thru 4). NOTE:
a Unscrewthe camshaftholderboltstwo turns at a
22. Removethe cylinder head bolts, then remove the t,me, in a crisscrosspattern,to preventdamao_
cylinderhead. ing the valvesor rockerarm assembly.
. When removingthe rockerarm assembly,do not
CAUTION:To pr€vent warpage, unsclew lhe bohs removethe camshaftholder bolts.The bolts will
in sequonce1/3 turn at a time; rgpeat tho sequence keep the camshaftholders,the springs and the
until all bolts are loosened. rockerarms on the shaft.
CYLINDERHEADBOLTSLOOSENINGSEOUENGE: CAMSHAFTHOLDERBOLTSLOOSENING
SEOUENCE:
6-30
Disassembly/Reassembly
NOTE:
. ldentifypartsas they are removedto ensurereinstallation in originallocations'
. lnsDectrockershafts and rocker arms (see page 6-35).
. Rockerarms must be installedin the same positionif reused.
. h e b o l t s w i l lk e e p t h e
r r m a s s e m b l y , d o n orte m o v et h e c a m s h a fht o l d e rb o l t s T
. w h e n r e m o v i n go r i n s t a l l i n g t h reo c k e a
holders,springsand rockerarms on the shaft.
-Zl
contactpoints.
prio, ,o reassemblinq, - cleanall the pans in solvent,dry them and apply lubricantto any
| TNTAKE RocKER RocKER
TNTAKE
D16Y7engine: ARM B ARM A
14places) (4 placesl
INTAXEROCKER
"8" is stamped
Lefter
on rockerarm. I
I
I
ROCKERSHAFT
COLLAR
14plac.3l
B A \ ' A
fift L$\ft
:l o ol ) l[ * o :
l .
I Jol----t
| | ruo.z cltusxerr 1i
No.3CAMSHAFT
T-* l=Bl-* d
I
,", 'l l=^ ^l
qJ?[l'-qJ'Ll EI
[ilH
l"\
9
' I ^ B A
ROCKERSHAFT
SPRING
{4 places)
t (cont'd)
6-31
RockerArms
(cont'dl
(
\
NOTE:
. ldentifypans as they are removedto ensurereinstallation
in originallocations.
. Inspectrockershaftsand rockerarms (seepage6-34).
. Rockerarms must be installedin the samepositionif reused.
t when removingor installingthe rockerarmassembly,do not remove
the camshaftholderbolts.The boltswill keepthe
holders,springsand rockerarms on the shaft.
erior to reassembring,
creana the partsin sorvent,dry them and appryrubricantto any contactpoints.
I
II{TAKEROCKERSHAFT
D16Y5engine:
ROCKER
ARMS
TIMINGPLATE RUBBER
BANO
-]-
-P'g,rp \ ra
t+.t't ll
\--,?|, -
\2i
No. 4 CAMSHAFT
HOLDER
No. 3 CAMSHAFI
HOLDER
No.2
HOLDER
I
No.5 CAMSHAFT
HOLDER
_ l
l
l
!-r I
?h'ffi*ffi'
EXHAUSTROCKER
ARM B /^ - --
{,1plac€s) IOCKERSHAFT
EXHAUSTROCKEESHAFT
Letter "8" is stamped Letter "A" is slamped
6-32
D16Y8engine:
INTAKESOCKERSHAFT
ROCKER
SI{AFT
ROCKERARMS
COLLAR BAND
NUBBER COLLAR
No. 4 CAMSHAFT No. 3 CAMSHAFT No. 2 CAMSHAFT No. 'l CAMSHAFT

HOLOER HOLDER HOLDER HOLDER
No. 5 CAMSHAFT
HOLDER
SHAFT
R(rcKER
SPRING
ARMB
EXHAUSTROCKERSHAFT
Letter
"B"
is stamped Letter"A" is stamped
6-33
RockerArms and Lost Motion Assemblies
(D16Y5,
Inspection Dt6Y8enginesl (
\
N O T E rW h e n r e a s s e m b l i n gt h e p r i m a r y r o c k e ra r m , DI6YSengine:
c a r e f u l l ya p p l y a i r p r e s s u r et o t h e o i l p a s s a g eo f t h e
rockerarm. NOTE:Set the timing plate and returnspring as shown
oerow.
1. Inspectthe rockerarm piston.push it manually.
- lf it does not move smoothly,replacethe rocker
a r ma s s e m b t y .
Dl6Y5 engine: RETURN
ROCKERARM
TIMINGPISTON
TIMINGSPRING
SYNCHRONTZING
PISTON
CAMSHAFTHOLDER
SECONDARY
ROCKERARM
Dl6Yg engine:
2. Removethe lost motion assemblyfrom the holder

and inspectit. Test it by pushingthe plungerwith
\ a
your finger.
- l f t h e l o s t m o t i o n a s s e m b l yp l u n g e rd o e s
not
move smoothly,replaceit.
MID ROCKERARM Pu3h

LOSTMOTION
I
ASSEMBLY
PRIMARYROCKER
SYNCHRONIZING
PISTON A
NOTE:
. Apply oil to the pistonswhen reassembling.
o Bundlethe rockerarms with a rubberbandto prevent
them from separating.
6-34
RockerArms and Shafts
ClearanceInspection
Measureboth the intakerockershaftand exhaustrocker 3. M e a s u r et h e i n s i d ed i a m e t e or f t h e r o c k e ra r m a n d
shaft. checkfor an out of-roundcondition.
1. Measurethe diameterof the shaft at the first rocker RockelArm-to-ShaftClearance

locatron. Standard(Newl:
lntake: 0.017- 0.050mm
{0.0007- 0.0020inl
Exhaust: 0.018- 0.054mm
(0 0007- 0 0021 in)
ServiceLimit:0.08mm {0.003inl
2. Zerothe gaugeto the shaftdiameter'
Repeatthesemeasurements on all the rockers.

- lf the clearance
is overthe servicelimit,replacethe
rockershaftand all overtolerancerockerarms.
6-35
Gamshaft
Inspection (
\
NOTE: 2. Seatthe camshaftby pushingit toward the rear of
. Do not rotatethe camshaftduringinspection. the cylinderhead.
. Removethe rockerarms and rockershafts.
3, Zerothe dial indicatoragainstthe end ofthe camshaft.
1. Put the camshaftand the camshaftholderson the Push the camshaft back and fonh, and read the end
cylinderhead.then tightenthe boltsto the specified ptav.
toroue.
Camshaft End Play:
Spocifiedtorqu€: Standard{New):0.05- 0.15mm
8 mm bolts; 20 N.m (2.0kgf.m t4 lbf.ft) 10.002- 0.006inl
Apply engin6 oil to tho throads, SorviceLimit 0.5 mm (0.02in,
6 mm bohs: t2 N.m (1.2 kgf'm 8.7 tbf.ft)
Apply oogine oil to the thleads.
6 mm bolts: @, @ @, @
Removethe bolts,then removethe camshafthold-

ers from the cylinderhead.
- Liftthe camshaftout of the cylinderhead,wipe it
clean, then inspect the liit ramps, Replacethe
c a m s h a f ti f a n y l o b e s a r e p i t t e d . s c o r e d ,o r
excessively worn,
- Cleanthe camshaftbearingsurfacesin the cylin-
der head,then setthe camshaftbackin place.
- Placea plastigagestrip acrosseachIournal.
5. Installthe camshaftholders,and tightenthe boltsto

the soecifiedtoroue.
\,l
6-36
E
6, Removethe camshaft holders. then measurethe 8. Checkthe cam lobe heightwear.
widest ponion of the plastigageon eachjournal.
Cam lobe heightstandard(New)
U n i tm m ( i n )
Camshaft-to-HolderOil Clearance:
Standard lNew):0.050- 0.08!tmm INTAKE EXHAUST
{0.002- 0.004in} O16Y/engine 35.299(1.3897) 37.281(1.4678)
ServiceLimit : 0.15 mm {0.006in)
D16Y5 PRI 38.427 11.51291
38.784(1.5269)
engrne SEC 3 2 . 1 9 3( 1 . 2 6 7 4 )
PRI 36.77811.44791
D l6Y8 38.008(1.4964)
MID 38.274(1.5068)
engrne
sEu 37.065(1.4592)
PRI;Primarycam lobe,SEC:Secondarycam lobe
MtD:Mid cam lobe.T/B:Timing belt
lN: Intake,EX:Exhaust
PRI sEc MIDSEC
-7. oil clearanceis out ot tol-

lf the camshaft-to-holder
erance: a* rN Ex
- 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 ,
t/g rts
- D16Y5engine - Dl6YE ongine
you must replacethe cylinderhead.
- lf the camshafthas not beenreplaced,first check
the total runout with the camshaftsupportedon
V-blocks.
CamshaftTotal Runout:
Standard (New): 0.03 mm (0.001inl max.
ServiceLimit: 0.04 mm {0.(X)2in)
Checkthis area{or wear.
Rotatecamshatt
while measuring.
- lf the total runout of the camshaftis within toler-

ance,replacethe cylinderhead.
- lf the total runout is out of tolerance,replacethe
L camshaftand recheckthe camshaft-to-holder oil
clearance.lf the oil clearanceis still out of toler-
ance.replacethe cylinderhead.
6-37
Valves,Valve Springs and Valve Seals
Removal (
N O T E : l d e n t i f yv a l v e sa n d v a l v e s p r i n g sa s t h e y a r e 3. Install the valve guide seal remover.
removedso that each item can be reinstalledin its orioi-
nal oosition.
SEAL REMOVER vat vF GI
VALVE nF !SEALREMOVER
GUIDE
'1.
Using an appropriate-sized socketand plasticmal- LISLEP/N 57900or KD3350
let. lightlytap the valve retainerto loosenthe valve
keepersbeforeinstallingthe valve spring compres-
sor.
PLASTICMALLET
SOCKET I
4. Removethe valveseal.
Installthe spring compressor.Compressthe spring
and removethe valvekeeper.
VALVE SPRII{GCOMPRESSOR
Snlp-onCF711or KD-383
whh #32 JAWS
6-38
Valve Guides
ValveMovement
Measurethe guide-to-stemclearancewith a dial indi-
cator while rockingthe stem in the directionof normal
thrust (wobblemethod).
lniake Valve Stem-to-GuideClearance:

St8ndardlNew): 0.04- 0.10mm
10.002- 0.004in)
ServiceLimit: 0.16 mm 10.006in)
ExhaustValvs Stem-to-GuideGlearance:
Standard{New}: 0.10- 0.16mm
10.004- 0.006in)
SorviceLimit 0.22 mm (0.009in)
Valveextended10 mm out from seat.
lntake Valve Dimensions

A StandsrdlNewl: 29.9- 30.1mm
1 1 . 1-8 1 . 1 9i n l
B Standard (New): 117.42- 117.72mm
(4.523- 4.635inl
C Standald{Newl: 5.'18- 5.49 mm
{0.2r57- 0.2r61in)
C ServiceLimit: 5.,[5mm (0.21,16in]
D Standard (New): 0.85- 1.15mm O
(0.033- 0.0'15in) /'-_)
D ServiceLimit: 0.65mm (0.026in)
ExhaustValve Dimensions . l f t h e m e a s u r e m e net x c e e d st h e s e r v i c el i m i t ,

A StandardlNew): 25.9- 26.1mm recheckusinga new valve.
(1.02- 1.03in) . lf the measurementis now within the service
B Standard {Newl: 114.60- 114.90mm limit, reassembleusinga new valve.
11.512- 4.521in1 . l f t h e m e a s u r e m e n st t i l l e x c e e d st h e l i m i t ,
C Standard {New): 5.i[5 - 5.46 mm recheckusing the alternatemethod below, then
10.21lt6 - 0.2150inl
replacethe valveand guide,if necessary.
C ServiceLimit: 5.,12mm 10.213'lin)
D Standard {New): 1.05- 1.35mm NOTE: An alternatemethod of checkingguide to
{0.041- 0.053in) stem clearanceis to subtractthe O.D. of the valve
D ServiceLimit: 0.95mm {0.037in} stem, measuredwith a micrometer,from the l.D.of
the valve guide, measuredwith an inside
micrometeror ball gauge.Takethe measurements
i n t h r e e p l a c e sa l o n g t h e v a l v e s t e m a n d t h r e e
places inside the valve guide. The differencebe-
t w e e n t h e l a r g e s t g u i d e m e a s u r e m e n ta n d t h e
smalleststem measurementshould not exceedthe
servicelimit.
lntake Valve Stgm-to-Guidgclearance:

Standard {Newl: 0.02- 0.05 mm
{0.001- 0.002in)
Ssrvico Limit 0.08 mm (0.003in)
ExhaustValvo Stem-to-GuideClearance:
Standard {New): 0.05- 0.OBmm
{0.002- 0.003in)
S€rviceLimit 0.11 mm (o'Ooilin)
6-39
Cylinder Head Valve Seats
Warpage Reconditioning
N O T E : l f t h e c a m s h a f t - t o - h o l d eori l c l e a r a n c e s( s e e '1. Renew
the valve seatsin the cylinderhead using a
page6-36)are not within specification, the cylinderhead valveseatcutter.
cannotbe resurfaced.
NOTE: lf the guides are worn (see page 6-39).
lf the camshaft-to-holderoil clearancesare within sDeci, r e p l a c et h e m ( s e e p a g e 6 - 4 1 )b e l o r e c u t t i n g t h e
fications,checkthe cylinderheadlor warpage. valveseats.
lf warpageis lessthan 0.05mm (0.002in), cylin- VALVESEAT

der headresurfacingis not required. CUTTER
lf warpage is between 0.05 mm (0.002in) and (Commercially
available)
0.2 mm {0.008in), resurfacethe cylinderhead.
M a x i m u m r e s u r f a c el i m i t i s 0 , 2 m m ( 0 . 0 0 8i n )
basedon a heightof 93 mm (3.66in).
2. C a r e f u l l yc u t a 4 5 ' s e a t , r e m o v i n g o n l y e n o u g h
materialto ensurea smoothand concentricseat.
? Bevelthe upperedge of the seatwith the 30. cutter

and the lower edge of the seat with the 60' cutter.
Checkthe width of the seatand adjustaccordingly.
4. Makeone more very light passwith the 45"cutterto

removeany possibleburrs causedby the other cut-
Iers.
Valve Seat Width:

Standard (N€w):
Intake: 0.85- 1.15mm 10.033 - 0.045in)
Exhaust: 1.25- 1.55mm {0.049- 0.061in}
SorviceLimit:
Measurealongedges,and threeways acrosscenter. Intake: 1.6mm (0.063inl
Exhausl: 2.0 mm (0.079in)
Seat Width
Cylinder Head Height:

Standard{Newl: 92.95- 93.05mm
{3.659- 3.66:}in) 5. After resurfacing the seat, inspect for even valve
s e a t i n g r A p p l y P r u s s i a nB l u e c o m p o u n d t o t h e
valve face, and insert the valve in its original loca-
tion in the head, then liit and snap it closed against \
the seat several times.
6-40
ValveGuides
Replacement
1 . As illustratedbelow, use a commercially-available
air-impactvalve guide driver attachmentmodified
to fit the diameterof the valveguides.In most cases.
the same procedurecan be done using the special
VALVE tool and a conventionalhammer.
SEAT VALVEGUIDEDRIVER
lCommerciallv
available)
PFUSSIANBTUECOMPOUNO 5.3 mm
The actual valve seatingsurface.as shown by the

bluecomDound,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'
87 mm +- 57 mft tr-r
'10.8mm
t3.43in) | 1224 inl
cutter to restoreseat width, (0.42 inl
. lf it is too low (closerto the vslve edge), you
must make a second cut with the 30" cutter to or
move it uD,then one more cut with the 45'cutter VALVEGUIDEDRIVER,5.5 mm
to restoreseat width. 07742- 0010100
Selectthe properreplacement guides.and chill them

NOTE:The final cut shouldalwaysbe madewith
in the freezersectionof a refrigeratorfor about an
the 45" cutter.
nour.
7. lnsertthe intakeand exhaustvalvesin the headand
measurethe valvestem installedheight. Use a hot plate or oven to evenlyheat the cylinder
headto 300"F(150'C).Monitorthe temperaturewith
Intake. Exhau3tSiem Installsd Height: a cookingthermometer.
Standard (New): 53.17- 53.6,4mm
- 2.112in)
12.093
SorviceLimit: 53.89mm (2.122in)
8. lf the valve stem installed height is over the service

limit. reDlacethe valve and recheck.lf its still over
t h e s e r v i c el i m i t , r e p l a c et h e c y l i n d e r h e a d ;t h e
valveseat in the headis too deep.
VALVESTEM
INSTALLEDHEIGHT
CAUTION:
. Do not use a torch; it may warp the head.
Do not got the head hottel than 300"F (150"C1;
excessiveheat may loosen thg valve seats.
To avoid burns. use heayy gloves whon handling
the heated cylinder h€ad.
\-
{cont'd)
6-41
Valve Guides
Replacement(cont'd)
Workingfrom the camshaftside,use the driver and 7. Apply a thin coat of cleanengineoil to the outside
I
a n a i r h a m m e tr o d r i v et h e g u i d ea b o u t2 m m ( 0 . 1i n ) of the new valve guide. Installthe guide from the
towardsthe combustionchamber.This will knockoff camshaftside of the head; use the specialtool to
some of the carbonand makeremovaleasier. drivethe guide in to the specifiedinsralledheight.lf
you haveall 16 guidesto do, you may haveto reheat
CAUTION: thehead.
. Always wear satety gogglesor a face shield when
driving valve guides.
. Hold the air hammer directly in line with the
valve guide to prevent damaging the driver.
Turn the headover, and drive the guide out toward

the camshaftside of the head.
VALVEGUIOE
DRIVER,5.5mm
07742- 0010100
ll
VALVE GUIOEORIVER,
5.5 mm Valve Guide lnstalled Height:
07742 - 001 01 00
Intake: 17.85- 18.35mm (0.703- 0.722inl
Exhausi:18.65- 19.15mm (0.734- 0.754in)
VALVEGUIDE
It a valve guide still won't move, drill it out with a

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

could damagethe cylinder head it the guide breaks.
6. Removethe new guidesfrom the freezer,one at a

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

to removeany cuttingresidue. changeable.
WHITE BLACK
5. Checkthe clearancewith a valve(seepage6-391. SPRING SPRING
Verifythat the valve slidesin the valve guide with-
out exertingPressure.
T u r nr e a m e irn
clockwisedireclion
o nl y .
INTAKEVALVESEAL EXHAUST
VALVESEAL
REAMER VALVEGUIDESEAL
INSTALLER
K D 2 8 9 9 ( C o m m e r c i a l l ya v a i l a b l e )
NOTE: Use small lD end of
o a)
o ,
o
o
REAMER,5.5 mm
O7HAH.PJ'O'IOB
I (cont'd)
6-43
Camshaft/RockerArms and
Valves CamshaftSeal/Pulley
Installation(cont'd) Installation
4. I n s t a l lt h e v a l v e s p r i n g a n d v a l v e r e t a i n e r .t h e n CAUTION:
installthe valve spring compressor.Compressthe . Make sure that all tockers are in alignment with their
springand installthevalvekeepers. valvgs when torquing the rocket assemblybolts,
. Valve locknuls should be loosened and adiusting
NOTE:Placethe end of the valvespringwith close- screws backed off bofore installation.
ly wound coilstoward the cylinderhead. . To prevont tho rocker arm a$smbly from coming
apad, l6av€the camshaft holder bohs in the holdeB.
1. After wiping down the camshaft,camshaftseal and

j o u r n a l si n t h e c y l i n d e rh e a d ,l u b r i c a t eb o t h s u r -
facesand installthe camshaft.
2. Cleanand installthe oil control orificewith a new

O-ring.
OIL CONTROLORIFICE
available)
lCornmercially
Snap-onCFrll or KD- 3tX'
with #32JAWS
Lightlytap the end of eachvalve stem two or three

times with a plasticmalletto ensureproperseating
of the valveand valvekeepers.
NOTE:Tap the valvestem only along its axisso you

do not bendthe stem.
CAMSHAFTSEAL
Sealhousingsurfaceshouldbe dry.
Applya lightcoat of oil to camshaft
a n d i n n e rl i p o f s e a l .
3. Turn the camshaft until its keyway is facing up (No.

piston TDC).
' 6-44
CylinderHead
lnstallation
4. Apply liquidgasket(PartNo. 08718- 0001or 08718- lnstallthecylinderheadin the reverseorderof removal:
0003)to the head mating surfacesof the No. 1 and
No.5 camshaftholders. NOTE:
- Apply liquidgasketto the shadedareas . Alwaysuse a new headgasket.
. C y l i n d e rh e a d a n d c y l i n d e rb l o c ks u r f a c em u s t b e
clean.
. "UP" markon the camshaftpulleyshouldbe at the top
. Turn the crankshaftso the No. 1 pistonis at TDC(see
page6-20).
. Cleanthe oil controlorificebeforeinstalling.
a Do not use the upper cover and lower cover to store
removeorlems.
Cleanthe upper cover and lower cover beforeinstal-
taUon.
1. Cylinderheaddowel pins must be aligned.
CYUNOERHEAD
Set the rockerarm assemblYin place and loosely
installthebolts.
- Makesurethat the rockerarms are properlyposi-
tionedon the valvestems.
Tighteneachbolttwo turnsat a time in the sequence

shown belowto ensurethat the rockersdo not bind
on the valves.
Specitiedtorquo:
8 mm bolts: 20 N.m (2.0 kgt'm, l/t lbf'ft)
Apply engine oil to the threads.
6 mm bolts: 12 N.m {1.2 kgif'm,8.7 lbf'ft)
Apply engine oil to the thresds.
6 mm bolts:O, @. @, @
PINS
7. Installthe backcover.then installthe camshaftpul-

! (cont'd)
6-45
Cylinder Head
Installation(cont'dl (
Positionthe camshaftcorrectly(seepage6-20). 7 . Installthetiming belt (seepage6-20).
Tightenthe cylinderhead bolts sequentiallyin four 8 . Adjustthe valveclearance(seepageel2),

steps.
9. Installthe head cover gasketin the groove of the
rsr st.p: O - @ 20 N.m (2.0 kgf.m, 14 lbf'ft| c y l i n d e r h e a d c o v e r , S e a t t h e r e c e s s e sf o r t h e
2nd srep: O - @ 49 N.m (5.0kgf.m, 36 tbtft) camshaftfirst, then work it into the groove around
3rd stop; O - @ 67 N.m {6.8 kgf.m, /r9 lbl'ft} the outsideedges.
4th st6p: O, O 67 N.m 16.8kgf.m, 49 tbf.ftl
NOTE:
NOTE: . B e f o r ei n s t a l l i n gt h e h e a d c o v e r g a s k e t ,t h o r -
. W e r e c o m m e n du s i n g a b e a m - t y p et o r q u e oughlycleanthe sealand the groove.
wrench, When using a preset-typetorque wrench. . When installing,make sure the head cover gas-
be sure to tighten slowly and not to overtighten. k e t i s s e a t e d s e c u r e l yi n t h e c o r n e r s o f t h e
. If a bolt makesanynoisewhileyouaretorquingit, recesses wathno gap.
loosenthe bolt, and retightenit from the 1ststep, COBNERS OF
THERECESS
CYLINDERHEADBOLTSTOROUESEOUENCE:
I
CORNERS
OF
THEREcEss covEB
1 0 . Apply liquid gasketto the head cover gasketat the
four cornersof the recesses.
NOTE:
. Use liquid gasket,Pan No. 08718- 0001or 08718
- 0003.
. Checkthat the matingsurfacesare cleanand dry
beforeapplyingliquidgasket.
4. Installthe intakemanifoldand tightenthe nuts in a . Do not installthe parts if five minutesor more
crisscrosspatternin two or three steps,beginning h a v e e l a p s e ds i n c e a p p l y i n gl i q u i d g a s k e t .
with the innernuts (seepages9-2thru 9-4). Instead,reapplyliquid gasketafter removingold
residue.
. Alwaysusea new intakemanifoldgasket. . After assembly,wait at least 30 minutes before
fillingthe enginewith oil.
Installthe exhaustmanifoldand tightenthe nuts in
a crisscrosspatternin two or threesteps,beginning
with the inner nut {seepages9-6 and g-7).
. Always usea new exhaustmanifoldgasket.
I n s t a l lt h e e x h a u s tm a n i f o l d b r a c k e t .l n s t a l l t h e
\-
exhaustpipe A and the bracket,then installthe cover.
6-46
1 1 . W h e n i n s t a l l i n gt h e c y l i n d e rh e a d c o v e r ,h o l d t h e 12. Tightenthe nuts in two or thre€ steps.In the final
headcovergasketin the grooveby placingyour fin- step,tighten all bolts, in sequence,to 9 8 N'm (1.0
gers on the camshaft holder contacting surfaces kgf.m,7.2 lbf.ft).
(top of the semicircles)
Setthe sparkplug sealon the sparkplug tube. NOTE: After assemblv, wait at least 30 minutes
O n c e t h e c y l i n d e rh e a d c o v e r i s o n t h e c y l i n d e r beforefillingthe enginewith oil
head,slidethe cover slightlybackand forth to seat
the headcovergasket.
NOTE:
. Before installingthe cylinder head cover, clean
t h e c y l i n d e r h e a d c o n t a c t i n gs u r f a c e sw i t h a
shop towel.
. Do not touch the parts where liquid gasketwas
aDolied.
. T a k ec a r e n o t t o d a m a g et h e s p a r k p l u g s e a l s
when installingthe cylinderheadcover,
. Visuallycheckthe sparkplug sealsfor damage.
. Replaceany washerthat is damagedor deterio-
rated.
6x1.0mm
9.8 N.m 11.0ksf.m,7.2lbfftl
1? After installation,check that all tubes, hosss and
connectorsare installedcorrectlY
\g-----*o""t'
Ptl
vE eE
\_
6-47
GylinderHead/ValveTrain
816A2 engine
6'50 RockerArms
VTECContlol System
6-51
TroubfeshootingFlowchart ............ Disassembly/Reassembly ...............6'72
VTECSolenoid Valve Rocker Arms and Lost Motion Assemblies
Inspection ...""'......5-54 Inspection .........""'6-73
VTEC RockerArms Rocker Arms and Shafts
6-54
ManualInspection........................... Clearance 6-74
Inspection..'..."'..............
InspectionUsing SpecialTools .....'6-55 Camshafts
ValveClearance
.^ Adiustment .........."
6-57 SpringsandValveSeals
Valves'Valve
. t PulleyandPulleyBolt
Crankshaft Removal """"""""' 6-77
Replacement ..".....6-59 ValveSeats
Timing Belt Reconditioning ......6'78
CylinderHead lnstallation 6-82

'............

SpecialTools
(
\
Ref.No. I Tool Number Description Oty PageRelerence

q o T H A HP J 7 0 1 0 B V a l v eG u i d eR e a m e r , 5 .m
5m 1 6-81
g 07JAA-001020A Socket,19 mm I
I 1 659
g I 07JAB-0010204 H o l d e rH a n d l e 1 6-59
I 07JAB- 0010404 PulleyHolderAttachment.50 mm 1 6-5s
g 07LAJ- PR3020A Air Stopper ]
1 I 6-55
|6) 07MAA- PR70100 TappetAdjuster 1 6-57
g I ozvu,r - enu orzo TappetLocknutWrench 1 6-57
g 07MAF- PR9010A ValveSpringCompressorAttachmentExtension 1
g 0 7 7 4-2 0 0 1 0 1 0 0 ValveGuideDriver,5.5 mm J 6-77
1 6-80,81
(!D I 0 7 7 5 7 - P J 1 0 1 0 4 ValveSpringCompressorAttachment 1 6-71
t a;
aL) 'n
-=<-,,LE;;
(D
\- a
6- 50
VTECControl SYstem
TroubleshootingFlowchart
problemin the WEC PressureSwitchcircuitor
The scantool indicatesDiagnosticTroubleCode{DTC)Pl259:A
VTECSolenoidValvecircuit
Referto page 1'l-38through 11 55 beforetroubleshooting
The MIL has beenteported on.

DTCP1259is siored.
Checkthe VTECControl SYsiem:

1. Do the enginecontrolmodule * Road Test:
( E C M) R e s e tP r o c e d u r e( s e e
Acceleratein 1stgearto an enginespeedover 6,000rp '
section11).
2. Startthe engine Holdthat enginespeedfor at leasttwoseconos'
3. Warm uP the engineto normal lf the DTC P1259is not repeatedduring the first road test'
operatingtemPerature(cool repeatthis testtwo moretimes
ing fan comeson).
4. Do the RoadTest.* lntermittent failure, sYstemis OK
at this time.
Check for Poor connectlons or
ls DTCP1259indicated? loose wires at VTEC Pressure
swilch. VTECaolenoid valvo and SWITCH2P
VTECPRESSURE
ECM. CONNECTOR
Test the VTECPressureSwitch:

2. Disconnect the VTECPressure
switch2P connector.
VTECpressureswitch2P con
n e c t o rt e l m i n a l N o 1 a n d
No.2.
T e r m i n a l s i d eo f
male termtnals
Reolacethe VTECPre3sureswitch.
WM
/1 IBLU/BLKI
/ 1 Y------r
t--------- l I
\1-/ |
I
Test the VTEC Pressure Switch
Wire:
1. Turnthe ignitionswitchON (ll).
I
2. N4easure the voltagebetween I
1
V T E C p r e s su r e s w i t c h 2 P
c o n n e c t o rN o . 1 a n d b o d y
ground, Wiresideof female
terminals
Inspectlor an open or short to

ground in the wire between the
VTEC orassure swilch and ECM
{c101.
lf the wire i3 OK, substitute a
YES known-good ECMand recheck.
{To page6 52)
(cont'd)
6-51
VTECControl System
TroubleshootingFlowchart(cont,d)
(
(Frompage6-5ll VTECPRESSURE
SWITCH2P
CONNECTOR
Test tha VTEC P.es3uro Switch

Wi.e:
Measurevoltage acrossthe VTEC
pressureswitch2P connector.
Wiresideof temale
Ropairopon in the wiro batwoen terminals
ls there batteryvoltage? VIEC pr...urc switch and Glot .
lf the wiro is OK, 3ubltitutr a
known-good ECMand rochack.
VTECSOLENOID
VALVElP
CONNECTOF
Ir------rI
Test the VTECSolenoidV.tve:
1. Turnthe ignitionswitchOFF. lLl.ll-r
valve1Pconnector. I
I
t h e V T E Cs o l e n o i dv a l v e 1 P
connectorterminalNo, I and
It
bodyground.
Terminalsideof
I
maleterminal
ls there14- 30 O?
OIL PRESSURE GAUGE

(Comm.rciallyavail.bte)
GAUGEJOINT ADAPTER
Te3tthe VTECSotonoidVatve: SNAP.ONMT26.17
'1. Remove
the VTEC pressure 10 x 1.0ftm
switch and installthe special . Usenew washerwhen
tool as shown. then reinstall installingthe sealingbott.
the VTECpressureswitch.
2. Reconnectthe VTECsolenoid
valve 1P connectorand VTEC
pressureswitch2P connector,
3. Connectthe tachometer(see
sectio1 nl).
4. Startthe engine.
5 . W a r m u p e n g i n et o n o r m a l
operatrngtemperature(cool-
ing fan comeson).
6. Checkoil pressureat engine N O T E : K e e p m e a s u r i n gt i m e a s s h o r r a s
s p e e do f 1 , 0 0 0 , 3 , 0 0 0
and possiblebecauseengineis runningwitn no
5,000rpm. loadllessthan one minute).
ls pressurebelow 49 kPa Inipoct thg VTEC aolenoid valve

(0.5kgflcm,,7psi)?
l3ee P8go6-54).
(To page 6-53)
6-52
Downloaded from www.Manualslib.com manuals search engine I
VTECSOLENOIDVALVE
(Frompage6-52) 1PCONNECTOR
Terminal side of
male terminal
Test the VTECSolenoid Valve:
1. Turnthe ignitionswitchOFF
valve 1Pconnector,
3 . A t t a c h t h e b a t t e r YP o s r t r v e
terminalto the VTECsolenoid
valveterminal.
4 . S t a r t t h e e n g i n ea n d c h e c k
t h e o i l P r e s s u r ea t e n g i n e
speedol5,000rPm
ls the pressureabove390 kPa lrcoect the VTEC solenoid valve

(4.0kgt/cm?,57 Psi)? (seepageS54)
C (31PI
ECMCONNECTOR
WM
Testthe VTECPressureSwitch:
With the battery Positiveterminal
connectedto the VTECsolenoid
valve,measurevoltagebetween
the ECMconnectorterminalC10
and bodyground.
ls there battery voltage above

5 , 0 0 0r p m ?
VIECSOLENOID ECMCONNECTOR
VALVE B l2sP)
1PCONNECIOR
Test the VTEC Solenoid Valve

Wire:
2. Checkfor continuitvbetween
t h e V T E Cs o l e n o i dv a l v e 1 P
c o nn e c t o rt e r m i n a la n d t h e
ECMconnector terminal812 Wire sideot female
termrnals
Repairopen in the wire between
the ECMlB12| and VTECaolenoid
VTECSOLENOIDVALVE
1P CONNECTOR
Test lhe VTEC Solenoid Valve

Wire: I'ft
Checkfor continuitybetweenthe
VTECsolenoidvalve'lPconnector
terminalandbodyground. I
Repair short in the wiro b€'tween
the ECM( 812)and VTECaolenoid
I
Wire sideof female
termanal
Substitute a known'good ECM

and recheck. lI sYmptom/indica'
tion goes away. repleca the origi-
nal ECM.
6-53
VTECSolenoid Valve VTECRockerArms
Inspection
1 . R e m o v et h e V T E Cs o l e n o i dv a l v e a s s e m b l yf r o m
t h e c y l i n d e rh e a d .a n d c h e c kt h e V T E Cs o l e n o i d
ManualInspection
1. Set the No. 1 pistonat TDC.
\ a
valvefilter for clogging. 2. Removethe ignitionwire coverand the wires.
. lf thereis clogging,replacethe engineoilfilter and 3. Removethe ignitionclampswhile pullingup on the
engineoil. Iock.
6xl.0mm
9.8 N.m (1.0kgl.m,7.2tbtftl
IGNITION
WIRECOVER
IGNITION
WIRE
SOLENOID
6x1.0mm
12N.m(1.2kgf.m,B,7tbf.ftl
I
lf the filter is not clogged.push the VTECsolenoid
valvewith your fingerand checkits movemenr.
. lf the VTECsolenoidvalve is normal,checkthe

engineoil pressure.
6x1.0mm
12 N.m (1.2kgtm,8.7 lbt.ft)
LOCK
6 -54
L-
InspectionUsingSPecialTools
Removethe cylinderheadcover. CAUTION:
. B€fore using tho Yalvo inspeciion tool, mako suro
NOTE:Referto page6-88when installingthe cylin- that ths air pre3sure gauge on the air comprossor
der head cover. indicatos ovor /rco kPa (,1kgf/cm', 57 psi)
. In3poct ths valve closranca bafore rock$ arm impoc'
Pushthe mid rockerarm on the No. 1 cylinderman- tion.
. Cover the timing beh whh I shop towel to prcvenl
ually.
gstting oil on the bolt'
. Chock ths mid rocker arm of each cylindll at TDC'
Checkthat the mid rockerarm movesindependently
of the primary and secondaryrockerarms.
1. Removethe cYlinderhead cover.
NOTE: Rsfer to page 6-86 when installing the cylin-

der headcover.
2. Plug the relief hole with the special tool (Air Stop-
per).
OTLA'- PRSO2OA
3. Removethe bolt and washer from the inspection

hole and connoct the an air pressureregulator with
a 0 - 100psi gauge.
AIF STOPPEB TNSPECTIONHOIE

7. Checkthe mid rockerarm ot eachcylinderat TDC' OTLA' - PR3O2OA
. lf the mid rockerarm does not move, removs the t0 x 1.0mrn

mid, primary and secondaryrockerarms as an 20 N.m{2.0kgfm,
14tbt'fr)
assemblyand checkthat the pistonsin the mid
and primaryrockerarms move smoothly.
. lf any rocker arm needs replacing,replacethe
primary.mid, and secondaryrockerarms as an
assembly.
AIRPRESSURE
REGULATOR
BEGULATORVALVE avril.bl.l
{Cornm.rcirlly
. Pullthe leverand
turn to adjust. {cont'd}
6-55
VTECRockerArms
InspectionUsingSpecialTools(cont,dl
4. L o o s e nt h e v a l v e o n t h e r e g u l a t o ra n d a p p l y t h e
I
specifiedair pressure.
SpecifiedAir Pressuro:
250 kPa {2.5 kgtlcm,, 36 psil
- 490 kPa {5.0 kgtcm,, 7t psil
Make sure that the primary and secondaryrocker

a r m s a r e m e c h a n i c a l l cy o n n e c t e db y t h e p i s t o n s
and that the mid rocker arms do no. move wnen
pushedmanually.
SECONDARY
ROCKER
ARM
. lf any mid rocker arm moves independentlyof

the primaryand secondaryrockerarms, replace
ll
the rockerarms as a set.
Removethe tools.
7. Checkthe operationof the lost motion assemblyby

p u s h i n go n t h e m i d r o c k e ra r m . T h e l o s t m o t i o n
a s s e m b l ys h o u l d c o m p r e s sf u l l y a n d o p e r a t e
smoothlythroughits full stroke.Replacethe assem_
bly if it does not work smoothly.
After inspection.check that the Malfunction Indi_

catorLamp{MlL)does not come on.
;l
6-56
ValveGlearance
Adjustment
Adjustvalveson No. 1 cylinder.
NOTE:
. Valves should be adjusted only when the cylinder lntako: 0.15- 0.19 mm {0'006- 0.007in)
ExhaGt 0.17- 0.21 mm {0'007- 0 008 inl
head temperaturs is lessthan 100'F (38'C)'
. After adjusting,retorquethe crankshaftpulleybolt to
4. Loosenthe locknut, and turn the adjusting screw
177N.m (18.0kgf'm,130lbt'ft)
until the feeler gauge slides back and forth with a
slightamountof drag.
1. Removethe cylinderheadcover'
NOTE:Referto pageG86 when installingthe cylin-

TAPPETADJUSTER
der headcover. WFENCHSET
"UP" mark on the pullsy 07MM - PR70110
2. Set No. 1 pi$on at TDC.The
should be at the top, and TDC grooves on the pulley
should align with the pointer on the backcover' TDC
grooves{white paint) on the crankshaftpulley should
align with the pointeron the timing belt lower cover'
Number I Pistonat TDC:
TAPPETLOCKNUT
WRENCH
07MAA - PR70120
LOCKNUT
20 N.m {2.0 kgf'm, lil lbt'ftl
Adiusting sclaw location:
(cont'd)
6-57
Valve Clearance
Adjustment{cont'd)
5. Tightenthe locknutand recheckclearance. 7. R o t a t et h e c r a n k s h a f t' 1 8 0 .c o u n t e r c l o c k w i s teo
I
Repeatadjustmentif necessary. bring No. 4 piston to TDC.The ,,Up,.mark should
be pointing straightdown. Adjust valves on No. 4
cylinder.
FE€LER
GAUGE
Number 4 piston at TDC:
R o t a t et h e c r a n k s h a f t1 8 0 . c o u n t e r c l o c k w i s e
(camshaftpulleyturns 90'). The "Up" mark should
8, R o t a t et h e c r a n k s h a f t1 8 0 . c o u n t e r c l o c k w i s teo
bring No. 2 pistonto TDC.The "Up., marksshould
L I
be on the exhaustside.Adjustvalveson No. 3 cylin- be on the intakeside.Adjust valveson No. 2 cylin_
der. der.
Number 3 piston at TDC: Number 2 piston at TDC:
"UP-
MARKS
I
6- 58
CrankshaftPulleYand PulleYBolt
Replacement
When installingand tighteningthe pulley,follow the procedurebelow'
Clean,removeany oil, and lubricatepointsshown below

a: Clean
x : BemoveanYoll
a: Lubricate
CRANKSHAFT
PULLEYBOLT
XXX
X X X X X
x x X X
I i XXXXX
x
BELT
WASHER TIMII GUIOEPLATE
GUID
Crankshaftpulley bolt size and torque value:

1 4 x 1 . 2 5m m
177 N.m t18.0kgtm, 130 lbf'ftl
NOTE:Do not usean impactwrenchwhen installing'
PULLEYHOLO€RATTACHMENT,
50 mm
07JAB- 0O10,OA
6-59
Timing Belt
lllustratedIndex
NOTE:
I
. Referto page6-59for positioningcrankshaftand pulleybeforeinstalling
belt.
. Markthe directionof rotationon the belt beforeremovino.
a Do not usethe middlecoverand lowercoverfor storingr'emoveditems.
. Cleanthe middlecoverand lowercoverbeforeinstallation.
WASHER
Replace when damaged
or deteriorated. CAPNUT
x 1,0mm
9.8 N.m lr.0 kgf.m,7.2lbtftl
CYLINDER
HEADCOVER
Referto page6-86
when installing.
HEADCOVERGASKET
Replacewhen leaking,
damagedor deteriorated.
Apply liquidgasketat
- -o the four cornersol the

recesses,
TIMINGBELT
page6-61
Inspection,
Adjustment,page6-61
Replacement,page 6-62
MIDDTECOVER
I
6 x 1.0mrn
9.8 N.m {1.0 kgf.m,
7.2 tbt-ltl
8 x 1.25mm
N.m {5.7 kgt.m,
6 x '1.0mm 41tbtfr)
9.8 N.m {1.0kgf.m, 7.2 lbt.ftl
6x1.0mm
N.m 11.0kgf.m,
7.2 tbt.ft'l
l0 x 1.25mm
5a N.m {5.5 kgl.m,
40 tbt ftt
Installwithconcave LOWER
surtacefacing out. COVER
TIMINGBELT Removeany oil and clean. PULLEYBOLT
DRIVEPULLEY 14x 1.25mm
Replacement,
page6-59 CRANKSHAFTPULLEY 177 N.m {18.0kgf.m. 130tbt.ft}
page6-59 Beplacement,
Replacement, page6-59
Do not usean impact
wrenchwhen installing.
6- 60
Inspection TensionAdiustment
'L Removethe cylinderheadcover. CAUTION: Always adiust timing belt tension with the
engine cold.
NOTE:Referto page6-86when installingthe cylin-
der headcover. NOTE:
. The tensioneris spring-loadedto apply proper ten
after makingthe follow-
sion to the belt automatically
Inspectthe timing belt for cracksand oil or coolant
soakrng. ing adjustment.
. Always rotatethe crankshaftcounterclockwise when
viewed from the pulley side. Rotating it clockw'se
NOTE:
. Replacethe belt if oil or coolant soaked. may result in improper adjustmentof the belt ten-
. Removeany oil or solventthat gets on the belt' sion.
1, Removethe cylinderheadcover.
NOTE;Referto page6-86when installingthe cylin-

lnspectthrs area der headcover.
2. Setthe No. 1 pistonat TDC(seepage6-64)
3. Rotatethe crankshaftlive or six revolutionsto set

the belt.
4. Setthe No. 1 Pistonat TDC
ADJUSTINGBOLT
54 N.m
(5.5kgt.m, a0 lbtftl
I
Rotate PUlleY
and inspect belt-
5. Loosenthe adjustingbolt 180'.
three teeth
Rotatethe crankshaftcounterclockwise
on the camshaftPulleY.
7. Tightenthe adjustingbolt.
After inspecting,retorquethe crankshaftpulley bolt
to 177N.m (18.0kgf'm,130lbf'ft) 8. After adjusting,retorquethe crankshaftpulley bolt
to 177N.m (18.0kgf'm,130lbnft)
6-61
Timing Belt
Removal
NOTE:
. Replacethe timing belt at 105,000mites(168,000
4. Loosenthe mountingnut and lockbolt,then remove
\ a
km) the alternatorbelt.
accordingto the maintenanceschedule(normalcon-
ditions/severe conditions).
lf the vehicleis regularlydrivenin one or more of the LOCKBOLT
8 x 1.25mm
followingconditions,replacethe timing beltat 60,OOO
24 N.m {2.4 kgt.m.
miles(U.S.A.)100,000km {Canada). 17 rb{.ftl
. In very high temperatures(over 110"F,43"C).
. In very low temperatures(under-20.F, 29.C).
. Turn the crankshaftpulley so the No. 1 piston is at
top dead center(TDC)beforeremovingthe belt (see
page6-57).
. Inspectthe water pump before installingthe timing
belt {seepage 10-14).
1. Removethe splashshield(seepage5-9).
Removethe adjustingbolt and mountingbolts,then

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.
MOUNTING
10x 1.25mm
44 N.m (4.5kgf.m. BELT
33 rbf.ftt
5. Removethe upperbracket(seepage6-69).
NOTE:
. Use a jack to support the engine before removing
'-f
the upper bracket.
o Placea cushionbetweenthe oil pan and the jack.
Removethe P/Spump lower bracket
8xL25mm
24 N m {2.{kgf.m,17lbf.ft) HEATSHIELD
8 x 1.25mm
24 N.m 12.,1
kgf.m,
Loosenthe idler pulley bracketbolt and adjustingbolt, 17 tbf.ftl
then removethe air conditioning(A,/C)compressor
belt aDJUsnNG
P/S PUMP LOWERARACKET

IOLERPULLEYBRACKET l 0 x 1 . 2 5m m
EOLT 44 N.m 14.5kgt.m, 33 lbf.ft)
10x 1.25mm
44 N.m 14.5kgf.m, 33 bnft)
6-62
lnstallation
7 . Removethe crankshaftpulley(seepage6-59). Installthe timing belt in the reverseorderof removal;
Only key pointsare describedhere.
8 . Removethe cylinderheadcover'
1. Set the timing beltdrive pulleyso that the No. 1 pis'
NOTE:Referto page6-86when installingthe cylin- ton is at top deadcenter(TDC).Align the grooveon
der headcover. the timing belt drive pulleyto the V pointeron the
oil pumP.
9 . Removethe middlecoverand lower cover.
NOTE:Do not use the middle and lower coversfor POINTER

storingremoveditems.
MIDDLE COVER
LOWERCOVER
9.8N.mlt.o kgfm,
7.2lw'ftl
set the camshaftpulleysso that the No. 1 piston is at
1 0 . Loosenthe adjustingbolt 180'. Pushthe tensioner TDC.
t o r e m o v e t e n s i o nf r o m t h e t i m i n g b e l t , t h e n Align the TDC marks on the intakeand exhaustcam-
retightenthe adjustingbolt. shaft pulleys.
N.m (5.5kgt'm,
TDC MARK
(cont'd)
11. Remove the timing belt.
6-63
TimingBelt
lnstallation(cont'dl
3. Installthe timing belttightlyin the sequenceshown. 9. Checkthat the crankshaftpulley and camshaftpul-
a
@ T i m i n g b e l t d r i v e p u l l e y ( c r a n k s h a f t )+ @ leys are both at TDC.
Adjusting pulley* @ Water pump pu ey + @ Intake
camshaftpulley+ @ Exhaustcamshaftpulley, CRANKSHAFT
PULLEY
NOTE: Make sure the timing belt drive pulley and

camshaftpullevsare at TDC,
CAMSHAFT
PULLEY:
"UP" MARKS
'l
Loosenand retightenthe adjustingbolt to tension
the timing belt.
Installthe lower coverand middlecover.
NOTE: Cleanthe middle and lower covers before

installing.
Installthe crankshaftpulley,then tighten the pulley 1 0 . lf the camshaftand crankshaftpulleysare not posi-
bolt (seepage459). tioned at TDC, remove the timing belt, adjust the
positionfollowingthe procedureon page&63, then
7. Rotate the crankshaft pulley about five or six turns reinstallthe timing belt.
counterclockwiseso that the timing belt positionson
the pulleys. 1 1 . After installation,
adjustthe tensionof eachbelt.
Adjustthe timing belttension(seepageA611. . See section 23 for alternator belt tension adjust-
ment.
. See section22lor NC compressorbelt tension
adiustment,
. See section 17 for P/S pump belt tension adjust-
ment.
6-64
CylinderHead
lllustratedIndex
CAUTION:
(38"C1bofote
. To avoid damaging the cylinder head, wait until the engine coolant tempsraturo drops below 100"F
removing it,
gasket.
. when handling a metal gasket,take caro not to fold the gaskot or damagethe contact surfaceof the
NOTE:Use new O-ringsand gasketswhen reassembling.
8 x 1,25 mm 6x1.0mm
27 N.m P.E kgl m. 9.8 N.m (1.0 kgf'm,
20 tbf.fo 7.2rbnftl 6 x l,omm
Applyengineoil to ft)
9.8N'mtl.0 kgt'm,7.2lbf
the threads.
cr.rMp.S IGNMON
WIRECOVER
CAMSHAFT \ A
"o''*t*'; wes@ CYLINOERHEAD
fi % COVER
Referto page 6-86
CYLINDERHEAO when installing
PLUG
Replace.
)@
DISTRIBUTOR
8 x 1,25mm HEADCOVERGASKET
Replace when leaking,damaged
24 N.m {2.4 kgf'm,
1? tbf.ftl OIL SEAL or deteriorated.
Replace. Apply liquidgasketat the
cornersof the recesses,Page6-86
RUBBER SEAL
Replacewhendamaged
EXHAUST or detedorated.
10 x 1.25mm
56 N.m (5.7 kgf m,
,r1 lbl.ft)
(cont'd)
6-65
CylinderHead
CYLINDERHEAD
BOLTS
1 1x 1 . 5m m INTAKEVALVESPRINGINNER
83 N.m {8.5kg{.m,61
Applyengineoil
to threads. VALVEKEEPERS
SPRINGRETAINER
INTAKEVAI.VESPRINGOUTER
valvEKEEPEBS\:""j"*' VALVESEAL
Replace.
SPRINGSEAT
VALVEGUIDE
SPRINGRETAINER
EXHAUSTVALVE INTAKEVALVE
SPRING
VALVESEAL
Replace.
VALVE
LOSTMOTION
t il
ASSEMBLY
ROCKERSHAFT
EXHAUSTVAL
SEALINGAOLTS.20mm
64 N.m (6.5kgt.m, 47 tbf.ft)
HEAOOIL CONTROL
ORIFICE
C l e an .
a
6-66
Removal
Engineremovalis not requiredfor this procedure. 6. Loosenthe idler pulley bracketbolt and adjusting
b o l t , t h e n r e m o v et h e a i r c o n d i t i o n i n g( A / C )c o m -
!@@ Make surejacks and safetystandsare placed pressorbelt.
properly and hoist brackels are attachedto correst posi-
tion on the engine,
CAUTION: ADJUSTING
o Use fender covers to avoid damaging painted sur-
faces.
T o a v o i d d a m a g e ,u n p l u g t h e w i l i n g c o n n e c t o r s
carelully while holding the connector portion.
To avoid damaging the cylinder head, wait until the
engine coolant temperature drops below 100"F{38'Cl
before looseningthe retaining bolt.
NOTE:
. Unspecifieditemsare common.
. Markall wiring and hosesto avoid misconnection.
AIso,be surethat they do not contactother wiring or
hosesor interferewith other parts.
o Inspectthe timing belt beforeremovingthe cylinder
ne a o . IDLERPULLEYBRACKET
. Turn the crankshaftpulleyso that the No. 1 piston is BOLT
10x 1.25mm
at top deadcenter(seepage6-64). 44N.m{4.5kg,l.m,
33 lbt.ft}
1. the negativeterminalfrom the battery.

Disconnect
2. Drainthe enginecoolant{seepage 10-7).
. Removethe radiatorcapto speeddraining. 7. Loosenthe mountingnut and lockbolt,then remove

the alternatorbelt.
3. Removethe strut brace(seepage5-2).
4. R e m o v et 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 h
r ousing LOCKBOLT
(seepage5-3). 8 x 1.25mm
24 N.m {2.4 kgf.m,
17 tbtftl
Removethe adjustingbolt and mountingbolt, then
removethe powersteering(P/S)pump beltand pump
(seepage5 5).
ALTERNATOR
10 x 1.25mm BELT
,l,l N.m {4.5 kgf.m,
33 tbf.ft,
\
(cont'd)
6-67
Cylinder Head
Removal(cont'd)
8. Removethe P/Spump lower bracket. 11. Removethe brakeboostervacuumhose,fuel return
hoseand vacuumhose(seepage5 4).
8 x 1.25mm
T SHIELD
24 N.m 12.4kgf.m,
17 tbtftl 12. Removethe water bypasshoseand positivecrankcase
ventilation(PCV)hose.
PCVHOSE
P/S PUMPLOWER
BRACKET
10x 1.25mm WATERBYPASS WATEREYPASS
44N.m{4.5kgf.m, HOSE HOSE
33 tbf.frl
1a Removethe throttlecableand throttlecontrolcable
9 . Relievefuel pressure(seesectionl1). by looseningthe locknut,then slip the cableend out
of the throftlelinkage.
@ Do not smok6 while working on fuel
system, keep open flam€ or spark away lrom work NOTE;
ar€a,Drainfuelonly into an approvedcortain€r. . Takecare not to bend the cableswhen removing
them.Alwaysreplaceany kinkedcablewith a new
1 0 . Removethe evaporativeemission (EVAP)control one.
canisterhose,fuel feed hoseand breatherhose. . Adjustthe throttlecablewhen installing(seesec-
tionI I ),
. Adjust the throttle control cablewhen installing
BANJOBOLT (seesection14).
33 N.m(3.4kgl.m.25lbf.ftl
WASHERS
BREATHER
HOSE
CONTROL
CABLE
\.
6 -68
14. Removethe upper radiatorhose, heater hose and 1 6 . Removethe spark plug caps and distributorform
water bvpasshose. the cylinderhead.
1 7 . Removethe upperbracket.
WATERBYPASS HEATER
NOTE:
. Use a jack to supportthe engine before removing
the upp€r bracketis removed.
. Placea cushionbetweenthe oil panandthejack.
12x 1.25fin
74N.m17.5 kgtm,
UPPERBRACKET
HOSE
1 5 . Removethe enginewire harnessconnectors andwlre

harnessclampsfrom the cylinderheadand the intake
manifold.
Fourfuel injectorconnector
a Enginecoolanttemperature(ECT)sensorconnec-
tor 18. Removethe cylinderheadcover.
a ECTgaugesendingunit connector
ECTswitchconnector
ldle air control(lAC)valveconnector
a Manifold absolutepressure(MAP) sensor connec-
tor
a Throttlepositionsensorconnector
a Primary Heatedoxygen sensor (PrimaryHO2S)
connecror
VTECsolenoidvalveconnector
\
{cont'd)
6-69
CylinderHead
Removal(cont'dl
1 9 . Removethe timing belt {seepage6-62). 24. Removethe camshaftholderplates,camshafthold-
ers and camshafts.
20. Removethe backcoverand camshaftpulleys.
CYLINDERHEAD CAMSHAFT
PLUG HOLDERPLATE
Replace.
t
BACKCOVER
\ 1
\ €
\ i
CAMSIIAFTS-
b4
56 N.m (5.7kgf m,
6xl.0mm 41 tbt.f0
9.8 N,m (1.0kgf.m, 7.2 lbf.ft)
Removethe cylinder head bolts, then remove the

21, Removethe exhaustmanifold(seepage9-8). c y l i n d e hr e a d .
22. Removethe intakemanifold(seepageg-5). CAUTION: To prevsnt warpage. unscrew the bolts

in sequonc€1/3 turn at a tim€; lepeat lh6 sequence
23. Loosenthe adjustingscrews. until all bolts aro loosened.
CYLINDERHEADBOLTSLOOSENINGSEOUENCE:
INTAKE
No.4 No.3 No.2 N o .1
6-70
RockerArms
Removal
'1. Holdthe rockerarmstogetherwith a rubberbandto 3. S c r e w 1 2 m m b o l t s i n t o t h e r o c k e ra r m s h a f t s .
preventthem from separating. Removeeach rocker arm set while slowly pulling
out the intakeand exhaustrockerarm shafts.
RUEBERBAND
12 mm BOLTS
2. Removethe intakeand exhaustrockershaftoil con-

trol orifices,then removethe VTECsolenoidvalve
and the sealingbolts.
ROCKERARM SHAFTS
NOTE:The shapesofthe intakeand exhaustoil con-
trol orificesare different,ldentifythe parts as they
are removedto ensurereinstallation in the original
locauons.
INTAKE ROCKER
EXHAUSTROCKER ORIFIGE
SHAFTORIFICE Clean.
Clean.
O.RING
O.RING Replace.
R e p l a c e ._ (lX
-dJ'v-l-<
r -Y^\ / /. I
6-71
RockerArms
CAUTION: After installing the rocker shaft oritice, make suro thot the orifics is correctly installed in the hole of rocker
a
shaft by trying to turn the rocker shaft. ll the orifice is in place, it should not turn.
NOTE:
. ldentifypartsas they are removedto ensurereinstallation
in originallocations.
. Inspectrockershaftsand rockerarms(seepage6-73).
o Rockerarms must be installedin the samepositionif reused.
. Cleanthe rockershaftorificeswhen installino.
erior.to ,"installing,cleanarrthe partsin sorvent,dry them, and appryrubricantto any contactsurfaces.

I
INTAKEROCKERARM ASSEMBLIES
CYLTNDERNUMBER
y'///
SEALINGBOLTS20 mm
64 N m {6.5kg{.m,/t7 lbf.ftl
k
r ROCKEN

RockerArms and Lost Motion Assemblies
Inspection
NOTE:When reassembling the primaryrockerarm,care- 2. Removethe lost motion assemblyfrom the cylinder
fully apply air pressureto the oil passageof the rocker head and inspectit. Test it by pushingthe plunger
arm. with your finger,
- l f t h e l o s t m o t i o n a s s e m b l yd o e s n o t m o v e
smoothly,replaceit.
PRIMARYROCKERARM
MID ROCKERARM
Push
I LOSTMOTIONASSEMBLY
PISTONS
1. Inspecteachrockerarm piston.Pushit manually
- lf it does not move smoothly. replacethe rocker

arm assemDly.
PRIMARY
SECONDARY
Check prstonmovement
NOTE:
. Apply oilto the pistonswhen reassembling.
. Bundle the rocker arms with a rubber band to
\
keepthem togetheras a set.
6-73
RockerArms and Shafts
ClearanceInspection
Measureboth the intakerockershaft and exhaustrocker 3. Measurethe insidediameterof eachrockerarm and
shaft. checkfor out-of-roundcondition
1. Measurediameterof shaft at the first rockerloca- RockerArm-to-Shaft Clearance:

tron. Intakeand Exhaust
Standard{Newl:0.025- 0.052mm
{0.0010- 0.0020in)
ServiceLimit: 0.08 mm {0.003in)
Surlaceshor/ldbe smooth.
Inspectrockerarm
facefor wear.
2. Zerogaugeto shaftdiameter.
Repeatfor all rockers.
- lf over limit, replacerockershaft and all overtol-
erancerockerarms.
NOTE:lf any rockerarm needsreplacement, replace

MICROMETER
all three rockerarms in that set {primary,mid, and
seconoary).
6-74
Camshafts
Inspection
NOTE:
. Do not rotatethe camshaftduringinspection.
. Removgthe rockerarms and rockershafts.
'L Putthe camshaftsand camshaftholderson the cylin-

der head.and then tightenthe boltsto the specified
torque.
SpecifiedTorque:
O -@: 8 mm botts27 N.m {2.8kgf.m,20lbt'ft)
Apply engineoil to the threads,
O - @: 6 mm bolts 9.8 N.m (1.0 kgf m, 7.2 lbf'ft)
o o o o o oo
4. Removethe bolts.then removethe camshafthold-

ers from the cylinderhead.
- Lift the camshaftout of the cylinderhead,wipe

c l e a n ,t h e n i n s p e c t h e l i f t r a m p s .R e p l a c et h e
camshaftif lobes are pitted, scored,or excessively
- Cleanthe camshaftbearingsurfacesin the cylin

o o o o o der head,then setthe camshaftbackin place,
- Inserta plastigagestrip acrosseachiournal.
Put the camshafton the cylinderhead.then install

the camshaftholders,and then tighten the bolts to
the specifiedtorque as shown in the left column on
this page.
R e m o v et h e c a m s h a f th o l d e r s ,t h e n m e a s u r et h e
widestportionof the plastigageon eachjournal.
Camshaft-to-Hold€1Oil Clearsnce:
Seatthe camshaftby pushingit toward the distribu- Standard {Newl: 0.050- 0.089mm
tor end of the cylinderhead. {0.002- 0.004inl
S6rviceLimit: 0.15 mm 10,006inl
Zerothe dial indicatoragainstthe end of the distrib-
utor drive. then push the camshaftback and fonh PLASTIGAGE
STRIP
and readthe end play.
CamshaftEnd Play:
Standard{New}:0.05- 0.15mm
{0.002- 0.006inl
Servicelimil: 0.5 mm (0.02in)
\- (cont'd)
6-75
Gamshafts
Inspection(cont'dl
7. lf the camshaft-to-holder
oil clearanceis out of tol- 8. Checkthe cam lobe height.
erance:
Cam lobe height standard (New):
- And the camshafthas alreadybeenreplaced, you
must replacethe cylinderhead. INTAKE EXHAUST
- lf the camshafthas not been replaced,first check
33.088mm 32.785mm
the total runoutwith the camshaftsupportedon PRIMARY
{1.3027in) (1.2907inl
V-blocks.
36.267mm 35.720mm
MID
CamshaftTotal Runout: (1.4278in) {1.4063in)
Standard(New):0.03mm {0.001in} max. 34.978mm 3i1.691mm
ServiceLimit: 0.04 mm (0.002inl SECONDARY
( 1 . 3 7 7i1n l (1.3658in)
I
Check thrs area lor wear.
- lf the total runout of the camshaftis within toler, Cam Position

- lf the total runout is out of tolerance.replacethe
INTAKE EXHAUST
camshaftand recheckthe camshaftto,holderoil
clearance.lf the oil clearanceis still out of toler- MID SEC MID PRI
TIB
T/B: TIMINGBELT
PRI: PRIMARY
MID: MID

Valves,Valve Springs and Valve Seals
Removal
NOTE: ldentify valves and valve springs as they are 3. Installthe valve guide seal remover.
removedso that eachitem can be reinstalledin its origi-
VALVEGUIDESEALREMOVER
nal Dosition. COMMERCIALLY AVAILABLE
()R KD3350
Ltst-EP/N 571100
l. Using an appropriate-sized socketand plasticmal-
let, lightlytap the valve to loosenthe valve
retainer
keeoers.
PLASTIC
4. Removethe valveguideseal.
Installthe valve spring compressor.Compressthe

spring and removethe vSlvekeepers. Valve Dimensions
VALVESPRING VALVESPRING
COMPRESSOR COMPRESSOR ATTACHMENT
ATTACHMENT EXTENSION
07757- PJ1010A OTMAF- PRgOIOA
lntake Valvo
A Standsrd {Newl; 32.90- 33.10mm (1.295- 1.303in}
B St ndard {New}: 101.00- 101.30mm (3.976- 3'988 in}
C Stsndard (Nowl: 5./t5 - 5.,185mm (0.2156- 0.2159in)
C ServicoLimit 5.445{0.21/l| in)
D Siandard (N!w): 1.05- 1.35mm (0.041- O.05ilinl
D S€.vice Limit: 0.85 mm {0.033inl
ExhaustValve
A StandardlNewli 27.90- 28.10mm (1.098- 1.106in)
B Stlndard {Nowl: 100.m - 1qr,90 mm {3.961- 3.972in)
- 0.2150in)
C Stsndard {Now}: 5.450- 5.,[60mm {0.21,16
C ServiceLimit 5.42010.213,0inl
I D Standard {New): 1.65- 1.95mm (0.065- 0.077in)
COMPRESSOR D SorvicoLimit: l.ils mm 10.057inl
Sn.p-onCFr1l
6-77
Valve Seats
Reconditioning
1. Renewthe valve seats in the cylinder head with a 5. After resufacingthe seat. inspect for even valve
valveseatcutter. s e a t i n g :A p p l y P r u s s i a nB l u e C o m p o u n dt o t h e
valve face, and insertthe valve in its originalloca-
NOTE:lf any guidesare worn (seepage6-79), t i o n i n t h e h e a d .t h e n l i f t i t a n d s n a p i t c l o s e d
r e p l a c et h e m ( s e e p a g e 6 - 8 0 )b e f o r ec u t t i n g t h e againstthe seatseveraltimes.
valveseats,
PRUSSIANBLUECOMPOUND
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
restoreseatwidth.
. lf it is too low (closerto the valve edge),you must
make a second cut with the 30. cutter to move it
up. then one more cut with the 45. cutterto restore
seatwidth.
NOTE:The final cut should always be made with

the 45"cutter, (
Carefullycut a 45oseat, removing only enough mate- 7. Insenthe intakeand exhaustvalvesin the headand
rial to ensurea smooth and concentricseat. measurevalvestem installedheioht.
Bevel the upper edge of the seat with the 30" cutter Intaka Valve Stem Installed Height:
and the lower edge of the seat with the 60. cutter. Standsrd lNaw): 37.465- 37.935mm
Checkwidth of seatand adjustaccordingly, (1./P50- r.4935inl
SorviceLimit: 38.185mm 0.5033 in)
Makeone more very light passwith the 45"cutterto
removeany possibleburrs causedbv the other cut- Exhau3tValv€ Stem Installed Height:
ters. Standard (New): 37.165- 37.6i|5mm
- 1.i1817
(1.46:t2 inl
Valve Seat Width: ServicoLimit 37.885(1.4915inl
Standard(Newl: 1.25- 1.55mm {0.0't9- 0.061in)
ServiceLimii: 2.0 mm 10,08inl
SearWidrh
lf valve stem installedheight is over the servicelimit,

replacethe valve and recheck.lf it is still over the ser-
vice limit,replacethe cylinderhead;the valveseatin
the h6ad is too deep.
6-78
CylinderHead Valve Guides
Warpage ValveMovement
NOTE:lf camshaft-to-holder oil clearances(seepage 475) Measurethe guide-to-stem clearancewith a dial indica-
the headcannotbe resurfaced.
are not within specification, t o r w h i l e r o c k i n gt h e s t e m i n t h e d i r e c t i o no f n o r m a l
thrust (wobblemethod).
are within specifica-
oil clearances
lf camshaft-to-holder
tions,checkthe headfor warPage. lntake Valve Stem-to-GuideCl6arance:
Standard(Newl:0.05- 0.11mm
. lf warpage is less than 0.05 mm (0.002in) cylinder (0.0020- 0.0043inl
headresurfacingis not required. ServiceLimit: 0.15 mm {0.0059inl
. lf warpageis between0.05mm (0.002in) and 0 2 mm
(0.008in), resurfacecylinderhead ExhaustValve Stem-to-GuideClealance:
. Maximum resurfacelimit is 0.2 mm (0.008in) based StandardlNewl: 0.10- 0.16mm
o n a h e i g h to f 1 4 2m m ( 5 . 5 9i n ) . (0.0039- 0.0063inl
ServiceLimit: 0.24 {0.0094in)
EDGE
STRAIGHT
PRECISION
Valveextended10 mm out from seat.
lf the measurementexceedsthe service limit, recheck

usinga new valve.
lf the measurementis now within the servicelimit.
reassembleusingthe new valve
lf the measurementstill exceedsthe limit. recheckusing
the alternatemethod below.then replacethe valve and
guide,if necessary.
NOTE:An alternatemethod of checkingguide to stem

clearanceis to subtractthe o.D. of the valve stem, mea-
Measurealongedges,and threeways acrosscenter' sured with a micrometer,from the l.D. of the valve guide,
measuredwith an insidemicrometeror ball gauge.
Takethe measurementsin three placesalong the valve
stem and three placesinsidethe valveguide.
The differencebetweenthe largestguide measurement
and the smalleststem measurementshould not exceed
the servicelimit.
lntake Valv€ Stem-to-GuideClsarance:

Standard lNswl: 0.025- 0.055mm
10.0010- 0.0022inl
service Limit: 0.08 mm (0.003in)
ExhaustValve Stem-to Guide Cl€arance:
Standard {Newl: 0.050- 0.080mm
Cylinder Head Height: {0.0020- 0.0031inl
StandardlNewl: 1i11.95 - 142.05mm ServiceLimit 0.ll mm (0.004in)
15.589- 5.593in)
6-79
t
Valve Guides
Replacement
1. As illustratedbelow, use a commerciallvavailable Workingfrom the camshaftside,use the driverand
air-impactvalve guide driver attachmentmodified an air hammerto drivethe guideabout2 mm (0.1in)
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 .l n m o s t towardsthe combustionchamber.This will knockoff
cases,the same procedurecan be done using the someofthe carbonand makeremovaleasier.
sDecialtool and a conventionalhammer.
CAUTION:
. Always wsar safety gogglesor a faceshield whsn
COMMERCIALLYAVAILABLE driving valve guides.
VALVEGUIDEDRIVER . Hold the air hammer dir€ctly in line with the
valve guide to prevont damaging thg dtiver.
Turn the head over and drive the guide out toward
the camshaftsideof the head.
rE-
87mm -L- sz mm t t
inl I
(3.43 tz.zrint 10.8mm
10.42inl
ol
VALVEGUIOEDRIVER,
5.5mm
077,P- 0010100
S e l e c tt h e p r o p e r r e p l a c e m e n g
t uidesand chill
t h e m i n t h e f r e e z e rs e c t i o no f a r e f r i g e r a t o rf o r
aboutan hour.
Use a hot plate or oven to evenlyheat the cylinder

headto 300"F(150"C). Monitorthe temperaturewith
a cookingthermometer.
VALVEGUIOEDRIVER,
5.5mm
077{2- 0010100
-:^-,65i^q
NNSp-<
lf a valve guide still won't move. drill it out with a
CAUTION: 8.0 mm (5/16in) bit,then try again.
. Do not use a torch; it may warp tho head.
. Do not get tho head hotter than 300"F {150"C}; CAUTION: Drill guides only in extreme cases; you
excesgiveheat may loosenthg valve seats. could damagothe cylinder head if ths guide br6aks.
. To avoid burns. use haaw gloves whon handling
the heatod cylinder head. Removethe new guide(s)from the freezer,one at a
time, as vou needthem.
6-80
Reaming
7. Apply a thin coat of cleanengineoil to the outside NOTE:For new valveguidesonlY.
of the new valve guide. Installthe guide from the
camshaftside of the head; use the specialtool to 1. Coatboth reamerand valveguidewith cuftingoil.
drive the guide in to the specifiedinstalledheight.lf
you haveall l6 guidesto do, you may haveto reheat 2. Rotatethe reamer clockwisethe full length of the
thehead, valveguide bore.
C o n t i n u et o r o t a t e t h e r e a m e r c l o c k w i s ew h i l e
removingit from the bore
VALVEGUIDEDRIVER,
5.5mm Thoroughlywash the guide in detergentand water
- (x)l01(x)
077i12
to removeany cuttingresidue.
Checkclearancewith a valvelsee page6-73)
. V e r i f y t h a t t h e v a l v e s l i d e s i n t h e i n t a k ea n d
exhaustvalveguideswithout exertlngpressure.
REAMERHANDLE
Turn r6amerin
tr clockwisedirection
A\
Valve Guide Installed Hoight:

lntake: 12.55- 13.05mm {0.,194- 0.514in)
Exhaust:12.55- 13.05mm 10.494 - 0.51'lin)
a
VALVEGUIDE
VALVEGUIOEREAMER.5.5 mm
OTHAH- PJTO1IIB
6-81
Valves
Installation
(
1. Coatthe valve stemswith oil. lnsertthe valvesinto 4. l n s t a l lt h e v a l v e s p r i n g a n d v a l v e r e t a i n e r ,t h e n
the valveguides. installthe valve spring compressor.Compressthe
spring,and installthe valvekeepers.
NOTE: Checkthat the valves move up and down
smoothly. NOTE:Placethe end of the valvespringwith closely
wound coilstowardthe cylinderhead.
2. Installthespringseatson the cylinderhead.
VALVESpRtNG VALVESPRTNG
COMpRESSOR COMPRESSORATTACHMENT
Installthe valvesealsusingthe specialtool. ATTACHMENT EXTENSTON
0775?_ pJlOl0A o?MAF- PR9010A
NOTE:Exhaustand intakevalvesealsare not inter-
changeable.
WHITE BRACK
SPRING SPRING
VALVEGUIDESEALINSTALLER
KD-28)g(Commercially
available)
NOTE:UsesmalllD
end of tool,
VALVESPRINGCOMPRESSOR
5.
lCommercially available)
Snap-onCF711or KD-3tXl
with #32JAWS
Lightly tap the end of each valve stem two or three
I
times with the wooden handle of a hammer to ensure
proper seating of the valve and valve keepers.
NOTE: Tap the valve stem only along its axis so

you do not bend the stem.
VALVESEAL
Replace.
VALVEGUIDESEALtNsTALLER
KD-2899
NOTE:UsesmalllD
end of tool

RockerArms
lnstallation
1. l n s t a l l t h e r o c k e r a r m s i n t h e r e v e r s eo r d e r o f 4. Cleanand installthe rockershaft orificeswith new
removal: O - r i n g s .l f t h e h o l e s i n t h e r o c k e ra r m s h a f t a n d
. Valveadjustinglocknutsshouldbe loosenedand cylinderheadare not in line with each other,screw
the adiustingscrew, backedoff before installa- a 12 mm bolt into the rockerarm shaft and rotate
tron. the shaft.
. The componentparts must be reinstalledin the
originallocations. NOTE: The shapesof the rockershaft orificestor
the intake and exhaust are different.The orific'
2. lnstallthe lost motion assemblies. must be installedin the properlocations.
3 . l n s t a l lt h e r o c k e ra r m s w h i l e i n s e r t i n gt h e r o c k e r
arm shaft into the cylinderhead
INTAKEROCKER
SHAFTORIFICE
NOTE:Removethe rubberband after installingthe Clean
ROCKER
EXHAUST
rockerarms. SHAFTORIFICE
O.RING
12 mm BOLT
6-83
I
Cylinder Head
Installation
lnstallthe cylinderheadin the reverseorderof removal: 2, Tightenthe cylinderhead bolts in two steps.In the
first step, tighten all bolts in sequenceto about 29
NOTE: N.m (3.0 kgf.m, 22 tbf.ftl. ln the final step, tighten in
. Alwaysusea new headand manifoldgasket. the samesequenceto 83 N.m (8.Skgf.m,6t lbf.ft).
. The cylinderheadgasketis a metal gasket,Takecare
not to bend it. NOTE:
. Rotatethe crankshaft, setthe No. 1 pistonat TDC(see . Apply clean engine oil to the bolt threads and
page6-63). underthe bolt head.
. D o n o t u s e t h e m i d d l ec o v e r a n d l o w e r c o v e rf o r . W e r e c o m m e n d u s i n g a b e a m - t y p et o r q u e
storangremoveditems. wrench. When using a preset-typetorque wrench,
. Cleanthe middlecoverand lowercover beforeinstal_ be sure to tighten slowly and not to overtighten.
lation. . lf a bolt makesany noisewhile you are torquing it,
o Replaceany washersthat are damagedor deteriorated. loosenthe bolt, and retightenit from the 1ststep.
1. Installthe cylinderheadgasket,dowel pins and the CYLINDERHEADBOLTTOROUESEOUENCE

headoil controlorificeon the cylinderhead.
NOTE:Cleanthe oil controlorificewhen installing. 1 1 x1 . 5m m

83 N.m18.5kgf.m,61 tbf.ftl
DOWELPIN
Installthe intakemanifoldand tightenthe nuts in a

cflsscrosspatternin two or three steps,beginning
with the innernuts.
. Alwaysusea new intakemanifoldgasket.
4. Install the exhaust manifold and tighten the new

self-lockingnuts in a crisscrosspattern in two or
threesteps.beginningwith the innernuts.
. Alwaysusea new exhaustmanifoldgasket.
6-84
5. lnstallthe camshaftsand camshaftoil seals. 7- lnstall the camshaftholders and camshaft holder
plaIe.
NOTE: NOTE:The arrowsmarkedon the camshaftholders
. lnstallthecamshaftswith the keywayfacingup. shouldpointto the timing belt.
. lnstallthe oil sealwiththespring sidefacingin. CAMSHAFT
. The oil sealhousingsurfaceshouldbe dry'
. Set the O-ringand dowel pin in the oil passage
of the No, 3 camshaftholder'
CAMSHAFT
OIL SEAL
Replace.
Tighteneach bolt two turns at a time in the sequence

shown below.
NOTE:Wipe off the excessliquid gasketfrom the No.
1 and No. 5 camshaftholderswith a shop towel
(D - @: 8 x 1.25mm 27 N.|n (2.8ksf'm, 20 lbf'ft)
Apply ongine oil to the throads.
O O: 6 x 1.0 mm 9.8 N'm (1.0 kgfrm,7.2 lbf'ft)
-
-
Apply liquid gasket (P/N 08718- 0001 or 08718 INTAKE
0OO3) to the head mating surfacesof the No. 1 and ( Do o o oo o
N o . 5 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.
NOTE:Cleanand dry the cylinderhead mating sur-

facesbeforeapplyingliquidgasket.
- Apply liquidgasketto the shadedareas'
@ o 0 o o o o
EXHAUST
lnstallthe backcoverand camshaftpulleys.
{cont'd)
6-85
CylinderHead
Installation(cont'dl (
\
1 0 . 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 14. Apply liquid gasketto the headcover gasketat the
cylinder head upper surface,then installthe cylin, eight cornersof the recesses.
der headplug in the cylinderhead.
NOTE:
. Use liquidgasket,PartNo. 08718- 0001or 08718
- 0003.
beforeapplyingliquidgasket
. Do not installthe parts if five minutes or more
h a v e e l a p s e ds i n c e a p p l y i n g t i q u i d g a s k e t .
Instead,reapplyliquid gasketafter removingold
restdue.
. After assembly.wait at least 30 minutesbefore
f i l l i n gt h e e n g i n ew i t h o i l .
CYLINDEB
HEAD
PLUG
Replace.
1 1 . Installthe timing belt (seepage6-63).
1' Adjustthe valveclearance(seepage6-61).
1 3 . Installthe head cover gasketin the groove of the

c y l i n d e r h e a d c o v e r . S e a t t h e r e c e s s e sf o r t h e
camshaftfirst, then work it into the groove around
the outsideedges,
NOTE:
. Beforeinstallingthe headcovergasket,thorough-
ly cleanthe head cover gasketand the groove.
. When installing,makesurethe headcovergasket
is seatedsecurelyin the cornersof the recesses
wrrn no gap.
HEADCOVEB
6-86
15. When installingthe cylinder head cover, hold the 16. Tightenthe nuts in two or three steps.In the final
headcovergasketin the grooveby placingyour fin- step, tighten all nuts, in sequence,to 9 8 N'm {1 0
gers on the camshaft holder contacting surfaces kgf.m,7.2 lbf.ft).
(toDof the semicircles).
NOTE: After assembly,wait at least 30 minutes
O n c e t h e c y l i n d e rh e a d c o v e r i s o n t h e c y l i n d e r
head,slidethe cover slightlybackand forth to seat beforefillingthe enginewith oil.
the headcovergasket.
NOTE:
. Be{oreinstallingthe cylinder head cover, clean
the cvlinder head contacting surfaces using a
shoPtowel.
. Oo not touch the parts where liquid gasket was
applied.
. Replaceany washertaht is damagedor deter'o-
rated.
1 7 . After installing,checkthat all tubes' hosesand con-

nectorsare installedcorrectly.
6-A7
EngineBlock
SpeciafTools 7-2
..........." CylinderBlock
7-3
lllustlatedIndex ...................."..'.......... lnspec'tion ..............7-16
Flywheeland Drive Plate BoreHoning ..........7-17
Repfacement """'.' 7-7 PistonPins
ConnectingRod and Crankshaft Removal ...,...........'.7-17
End Play ..........."....7-8 lnstallation .............7-18
Main Bearings Inspection .'............7-19
Clearance 7-9
............... ConnectingRods
Selection ................7-10 Selection ................7-18
ConnectingRod Bearings Piston Rings
clearance 7-11
....'.......... EndGap ..........".."'7'2O
Selection 7-11
................ Repfacement .........7-2O
Pistonsand Crankshaft Ring-to-GrooveClearance 7 -21
...........'.'.
Removaf 7 -12
................. Afignment .......""'..7'21
Crankshaft CrankshaftOil Seal
Inspection ."".........7-14 fnstaffation .............7-22
Pistons Crankshaft
Inspection ......"'.....7-15 fnstaffation ..-.-..'.".'7'23
fnstaffation .............7-23 Oil Pan
lnstallation .............7-26
Oil Seals
fnstaffation ....""""' 7-29
r - f

SpecialTools
Ref. No. I Tool Numbel

o 07LAB- PV00100 R i n gG e a rH o l d e r 1-7
07749- 0010000 Driver 7-22,29
aal 07947- SB00200 SealDriver 7.29
@ 07948- SB00'101 DriverAttachment 7-22,29
07973- PE00200 P i l o tC o l l a r 7-17,18
07973- PE00310 PistonPin DriverShaft ' 7- 1 7 ,
1a
o 07973- PE00320 PistonPin DriverHead 7 - 1 1 ,1 A
@ 07973- PE00400 PistonPin BaseInsert 7- 1 7 ,1 8
6' 07973- S800100 PistonBaseHead 1 - 1 7 1, 8
@ 07973- 6s70500 PistonBase 7-17,18
o 07973- 6570600 PistonBaseSpring 7-17,18
Y(\!
a.:
ai
C
a
Eg
o t0 arll
\ a
7-2
lllustrated Index
runricateatt internalpartswith engineoil during reassembly'

I
NOTE:
pumpcasebeforeinstallingthem'
o Apply liquidgaskettothe matingsurfacesofthe right sidecoverand oil
o
. U s el i q u i dg a s k e tp, a r tN o 0 8 7 1 8 - 0 0 0 1 r 0 8 7 1 8 - 0 0 0 3 '
pan
. Cleanthe oil pan gasketmatingsurfacesbetoreinstallingthe oil
81642 engine: OILPAN 6 r 1 . Om m

Reterto page7 27 12 N.m t1.2 kgl'm, 8 7 lbf'lt)
DRAIN BOLT when installing.
44 N,m {4.5 kgf'm,33 lbt'ft)
6 x 1.0 mm OIL PAN GASKET

' 1 1N . m ( 1 . 1 k g I ' m ,
I tbl.ft)
BUFFLEPLA
6 x 1.0 mm
1 1 N . m ( 1. 1 k g f . m ,
12 x 1.0mm 8 tbI.fr)
103 N.m {10.5kgf'm,
76 tbr.ft) GASKET
FLYWHEEL Replace.
(M/TI
1 1 x 1 . 5m m
76 N.m (7.9 kgf'm, 56 lbf'ft)
FLYWHEELCOVER Apply engineoil to the bolt
IM/T) threads.
12 x 1.0mm NOTE:After torqurng
74 N.m (7.5
kof.m, 54 lbf'ft)
1^
d#* each cap, turn crankshaft
to check for binding.
MAIN EEARINGCAP
c{Eb
\%^ t*^ MAIN BEARINGS
*o"rr^--(Wffi Selection,page 7_10

NOTE:New main bearingsmusl
be selectedbY matchingcrank
and block identificationmarkrngs
oa*,trto2,.w
Check for cracks DRIVE PLATE CRANKSHAFT
COVER(AiT) Page7'23
Installation,
6x1.0mm
11 N.m {1.1 k g f ' m , I l b f ' f t }
OIL JET BOLT
16 N.m 11.6 kgf'm, 12 lbl'ft)
OIL JET
Page8_10
Inspection,
CRANKSHAFT OIL SEAL DOWEL PIN
OILPUMP
Installation, Overhaul,page8-'l1
pagesl22andl 29
Removal/lnspection,
Replace- page8-13.
Apply liquidgasket
RIGHTSIDECOVER to matingsurlace.
Apply liquidgasket
to mating surface.
8 x 1.25mm
THRUSTWASHERS 24 N.m {2.4 kgf.m, 17 lbf'ft)
Groovedsidesface outward
NOTE:Thrusr washer thickness
is tixed and must not be changed
by grindingor shimming SEAL
CRANKSHAFT
O-RING 11 N.m {1.1 kgf'm, l n s t a l l a t i o n ,p a g e s 7 ' 2 9 a n d I 1 4
Replace a lbt.ltl Heplace. (cont'd)

lllustrated Index
(cont'dl
, (
Luoricateatt internalpartswith engineoil during reassembly.
I
NOTE:
' Apply liquidgasketto the matingsurfacesofthe rightside
coverandoil pumpcasebeforeinstallingthem.
. Use liquidgasket,part No. 08718- 0001or 087,18
_ OOO3. I
. Cleanthe oil pan gasketmatingsurfacesbeforeinstallingit.
I
D16Y7engine: 6 x 1.0mm
DRAIN BOLT 12 N.m (1.2kgt.m.
44 N.m {4.5 kgt.m.33 tbt.ttl 8.7 tbf.tr)
FLYWHEEL
COVER
OIL PAN GASKET IM/T)
6 x 1 . 0m m Replace.
12 N.m ('l .2 kgt.m, 8.7 tbt.trl WASHER
Replace.
1 2 x ' 1 . 0m m
OIL PAN 1 1 8N . m
Referto page7-27
{12.0 kgt.m, 87 tbf.tr}
Apply liquidgaskerto
these points.
1 1x 1 . 5m m
51 N.m
15.2kgl.m,38lbtftl
Applyengineoilto the bolt
threads.
NOTE:Aftertorquing
each cap, turn the crankshaft
to checkfor binding.
MAIN BEARINGCAP
MAIN BEARINGS
Selection, page7-10
NOTE:New main bearingsmust
be selectedby matchingcrank
and blockidentification markings. Check for cracks.
CRANKSHAFT
Installation,
page7 23
6 r 1.0mm
1 1 N . m { 1 . 1 ksI.m, 8 lbt.ft) CRANKSHAFT OIL SEAL
Installation,
OILSCREEN pages1 22 a^d 7-29
6 x 1.0 mm
1 1 N . m 1 1 . 1kgt.m, 8 lbf.trl \:eprace'
6 x 1 . Om m
11 N.m {1.1kgt.m,
GASKET 8 rbt.frl
Replace.
OILPUMP
Overhaul,page8-12 RIGHTSIDECOVER
Bemoval/lnspection, DOWEL PIN Apply liquidgasker
page8-13 1o matrngsurface,
WASHERS
Grooved sides face outward.
NOTE: Thrust washer thickness
CRANKSHAFT
SEAL is fixed and must not be changed
pages --.S)
z.2e BREATHING PORTCOVER by grinding or shimming.
l.j"Ji:l"^ MOUNT BOLTS
Replace. 6 x 1.0mm
6 x 1.0 mm DOWELPIN
1 1 N . m { 1 . 1 k g t . m ,8 t b f . f r }
1 1 N . m{ 1 . 1 Apply liquidgaskerto
8 tbt.fr) the boh threads.
7-4
D16Y5,D16Y8engines:
OIL PAN
WASHER Apply liquidgasketto Referto page7-25
DRAIN BOLT Replace. these points. when installing.
39 N.m 14.0 kgt'm,
FLYWHEELCOVER
29 lbl.tt) (M/T}
\
\^
q%
P 12 x 1.0mm
6 x 1 . 0m m 1 1 8N . m
I
t 2 N . m 1 1 . 2k g f ' m , (12.0 kgt.m, 87 lbt'ft)
8.7 lbl.ftl
1 1x 1 . 5m m
51 N.m
(5.2kgf'm, 38 lbf ftl (M/TI
FLYWHEEL
Applyengineoiltothe bolt
threads.
NOTE:Aftertorquing OII PAN GASKET
eachcap,turn crankshaft Replace.
to checkfor binding.
DRIVEPLATECOVER
MAIN {A/T or CVT)
BEARING
12 r 1.0mm
74 N.m
MAIN BEARINGS 17.5 kgl.m, 54 lbf'ft)
page7-10
Selection,
NOTE:New main bearingsmust
be selectedby matchingcrank --------*-i6{\ DBIVEPLATE{A/T or CVTI
"nJ lr."i io"irriti"",ion-markings. Checkfor cracks
CRANKSHAFT
page7-23 6 x 1 . Om m
Installation,
11 N.m {1.1kgl'm,
8 tbl.ftl
6 r 1.0mm OIL SEAL
11 N.m (1 1 kgf'm, I lbf'ttl CRANKSHAFT
lnstallation, '1
pages7'?1 and '28
Replace.
OIL SCREEN
RIGHTSIDECOVER
GASKET
Apply liquid gasket
Replace.
to mating surface.
OIL PUMP
Overhaul,page8_12 DOWEL PIN
Removal/lnspection,
page8-13
Apply liquidgasket WASHEFS
to mating surface. Groovedsidestace outward
NOTE:Thrust washerthickness
is fixed and must not be changed
bV grindingor shimming.
CRANKSHAFT SEAL OOWELPIN BREATHINGPORT COVER

pages7 29 MOUNT BOLTS
Installation,
O.RING 6 x 1 . Om m
and 8-14
Replace. 11 f{..n (1.1 kgf'm, 8 lbf'fl)
Replace.
Apply liquidgasketto
6 x 1.0 mm
the bolt threads.
11 N.m (1 1 kgl'm,
8 tbr.ftl
\ (cont'd)
7-5
lllustrated Index
(cont'd)
NOTE:New rod bearingsmust be selectedby matchingconnectingrod
assemblyand crankshaftidentificationmarkings
( s e ep a g e7 , 1 1 ) .
Lubricateall internalpartswith engineoil during PISTONINSTALLATION

DIRECTION:
reassembtv.
EXHAUST
4\/=\6\z\
\e/!rqrf/
INTAKE
PISTONRINGS
Replacement.page7-20
Measurement, pages7 20 andj-21
Alignment,page7-21
PISTONPIN
Removal,page7,17
Installation,
page7-18 PISTON
Inspection,page7,19 Inspectron, page7-15
NOTE:Betoreremovingthe piston,inspectthe
top of the cylinderborefor carbonbuild-upor
ridge.Bemoveridgeif necessary, page7-13
CONNECTING ROD
Endplay,page7-8 ENGINEBLOCK
page7,18
Selection, Cylinderboreinspection,
page7-16
Warpageinspection,page7,'16
Cylinderbore honing,page7,17
CONNECTING
ROD
BEARINGS
C l e a r a n c e ,p a g e 7 1 1
S e l e c t i o n ,p a g e 7 - 1 1
Inspecttop of eachcylinderbore
for carbonbuild-upor ridge
before removing piston.
Removeridgeif necessary, page7-13
CONNECTING RODCAPNUT
816A2€ngin6:
CONNECTING RODBEARINGCAP
page7-23 9 x 0.75mm
Installation,
{0 N.m (4.1 kgt m, 30 tbf.ftl
NOTE:lnstallcapsso the
D16Y5,Dl6Y7. D16Y8engines:
bearing recessis on the
8 x 0.75mm
samesideas the recess
3l N.m {3.2kg{.m,
in the rod.
23 tbt.fr)
Applyengineoilto
the bolt threads.
NOTE:Aftertorquingeachbearing
cap, rotate crankshaftto
checkfor binding.
7-6
Flywheel and Drive Plate
Replacement
ManualTransmission: Automatic Transmission:
816A2engine: Removethe six drive platebolts,then separatethe drive
olatefrom the crankshaft tighten
flange.Atter installation,
Removethe eight flywheel bolts,then separatethe fly-
w h e e l f r o m t h e c r a n k s h a f ft l a n g e .A f t e r i n s t a l l a t i o n ' the bolts in a crisscrossPattern.
tiohtenthe bolts in the sequenceshown
RINGGEARHOLDER"-i
OTLAB PVOOlOO
rurS;u'.\
$..3s' 12 x 1.0mm
74 N.m
t7.5 kgl.m, 54 lbl'ltl
RINGGEAB 1 2 x 1 . 0m m
Inspectring gear 103 N.m
teeth lor wear or (10.5 kgf.m, 76 lbf.tt)
damage.
Removethe six flywheel bolts,then separatethe flywheel
tightenthe
from the crankshaftflange.After installation,
bolts in a crisscrossPattern.
RINGGEAR
Inspectring gear 1 2 x 1 . om m
wear or
teetn lor wea(
teeth / 11 8 N , m
danase. (12.0kgI.m,87 lbf.ftl
\ ,///.'
7-7
ConnectingRod and Crankshaft
EndPlay
\
Connecling Bod End Play: Pushthe crankshaftfirmly away from the dial indicator,
Standard(Newl:0.15- 0.30mm and zerothe dial againstthe end of the crankshaft.
- 0.012inl Then
10.006 pull the crankshaftfirmly backtoward the indicator;dial
ServiceLimit: 0.40mm (0.016inl readingshouldnot exceedservicelimtr.
a lf out-of-tolerance.installa new connectingrod. GrankshaftEnd Play:

a lf still out-of-tolerance,replacethe crankshaft(see
Standard (Newl: 0.10- 0.35 mm
pages7-12and 7-23). (0.00,f- 0.01,tinl
Servic€Limit 0.it5 mm (0.018in)
. lf end play is excessive,inspectthe thrust washers

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

changedeitherby grindingor shimmrng.
Thrust washersare installedwith groovedsidesfacing
outward.
7-8
Main Bearings
Glearance
1 . T o c h e c k m a i n b e a r i n g - t o - j o u r n aoli l c l e a r a n c e .
removethe main capsand bearinghalves.
C l e a ne a c h m a i n j o u r n a l a n d b e a r i n gh a l f w i t h a
cleanshop towel.
Placeone strip of plastigageacrosseach main jour-

n al .
NOTE:lf the engineis still in the car when you bolt

the main cap down to checkclearance,the weight
of the crankshaftand flvwheelwill flaftenthe plasti-
gage further than just the torque on the cap bolt.
and give you an incorrectreading.For an accurate
r e a d i n g ,s u p p o r tt h e c r a n kw i t h a j a c k u n d e r t h e
c o u n t e r w e i g h t as n d c h e c ko n l y o n e b e a r i n ga t a lf the plastigagemeasurestoo wide or too narrow,
time, (removethe engineif it's still in the car),removethe
crankshaft,and removethe upper half of the bear-
4. R e i n s t a ltlh e b e a r i n g sa n d c a p s ,t h e n t o r q u e t h e ing. Installa new. completebearingwith the same
bolts. color code {selectthe color as shown on the next
page),and rechsckthe clearance.
lst step: 25 N'm (2.5kgl'm. 18 lbf'ft)
FinalsteD: CAUTION: Do nol fil€, shim, or scrapethe bearings
B16A2engine: or tho cap3to adiust cleatanc€.
76 N.m (7.8 kgf.m, 56 lbf'ft)
D16Y5,Dl6Y7, D16Y8engines: 7. lf the plastigageshows the clearanceis still incor-
51 N.m (5.2kgf'm, 38 lbf'ft) rect,try the next largeror smallerbearing(thecolor
listedaboveor belowthat one),and checkagain
NOTE:Do not rotatethe crankshaftduring inspec-
tron. NOTE: lf the proper clearancecannot be obtained
by usingthe appropriatelargeror smallerbearings,
Removethe cap and bearingagain,and measurethe replacethe crankshaftand start over.
widestpartot the plastigage.
Main Boaring-toJournal Oil Clearance:

816A2 engine:
Standald {New}:
No. l, 2, 4, 5 Journals:
O.O2,l- 0.042mm 10'00(B- 0.0017in)
No. 3 Journals:
0.030- 0.048mm {0'0012- 0'0019in)
ServicoLimit: 0.06 mm {0.002in,
Dl6Y5, Dl6\rr, Dl6Y8 engines:

Standard (Nsw):
No. 1,5 Journals:
0.018- 0.035mm {0.0007- 0'001'[ in)
No. 2. 3, 4 Journals:
0.02,1- 0.0,(2mm {0'0009- 0.0017in}
ServiceLimit: 0.05 mm (0.002in)
7-9
Main Bearing
Selection
CAUTION: lf the codes are indecipherablebecauseof an D16Y5,D16Y7,D16Y8engines:
accumulationof dirt and dust, do not scrub them with a Lettershave beenstampedon the end of the blockas a
wire brush or scraper.Clean them only with solvent ol codefor the sizeof eachof the 5 mainjournalbores.
deiergent. Use them, and the numbersstampedon the crankshaft
(codesfor main journalsize),to choosethe correctbear-
Crankshaft Bore Code Location Ings.
81642engine:
Lettershave beenstampedon the end of the blockas a
codefor the sizeof eachof the 5 mainjournalbores.
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
beaflngs.
Main Journal Code Location(Numbers)
Main JournalCode Locations {Nombers or Barc)
Bearing ldentification
Color code Ldrger crank bore
on the
Eearing ldentification
C o l o rc o d e r s
edge of B c D
the bearing-
on lhe edgeof Larger crank bore Smaller bea ng {th'cker)
the bear ng.
a c
-----------""'
D
lr-l Red Pink Green
Smallerbeanngtlhrcker)
tt +#, t ll Pink
Green
Green
Brown
Brown
Black
f l 4 't t l Green Brown Black Elue
f '-
Smaller Smaller
maan
9""1 B':"" Black bearing
Alack Alue
journal {thicker)
\ I
7-10
ConnectingRod Bearings
Clearance Selection
'1. Removethe connectingrod cap and bearinghalf CAUTION: lf the codes are indecipherable because of
an accumulationof dirt and dust, do not sclub them
C l e a nt h e c r a n k s h a frto d i o u r n a la n d b e a r i n gh a l f with a wile brush or scraper.Cleanthem only with sol-
with a cleanshop towel. vent or detergent,
Placeplastigageacrossthe rod journal. ConnectingRod Code Location
4. the bearinghalfandcap,andtorquethe nuts.

Reinstall Numbershave been stampedon the side of each con
necting rod as a code for the size of the big end Use
Torque them, and the lettersstampedon the crankshaft(codes
Bl6A2 engine: for rod journalsize),to choosethe correctbearlngs
40 N.m (4.1 kgl.m, 30 lbf'ft)
Dr6Y5,D16Y7,D16Y8enginss: Half of number ls
31 N'm (3.2 kgf.m, 23 lbf ftl stampedon bearing
cap and the other
half is stampedon
NOTE| Do not rotatethe crankshaftduring inspection.
rod.
Removethe rod cap and bearinghalf and measure

the widest part of the plastigage.
ConnectingRod Bearing-to.JournalOil Glearance:

816A2engine:
Standard lNewl: 0.032- 0.050mm
10.0013- 0.0020in)
ServiceLimit: 0.06mm 10.002 inl
Standard lNew): 0.020- 0.038mm
(0.0008- 0.0015in)
ServiceLimit 0.05 mm 10.002inl ConnectingRod Journal Code Locations(Lettels)
PLASTIGAGESTRIP
lf the plastigagemeasurestoo wide or too narrow'
removethe upper half of the bearing,installa new,
completebearingwith the same color code (select Bearing ldentilication
t h e c o l o r a s s h o w n i n t h e r i g h t c o l u m n ) ,a n d
Color code is on the Largerbrg end bore
recheckthe clearance. edge of
the bearing. 1 2 3 4
CAUTION: Do not lile, shim, or scrapethe bearings
or the caps to adiust clgarance. lfA--;T] | ---------------- Smallerbearing{thrcker)
7. lf the plastigageshows the clearanceis still incorrect.

l l e " ' tl t; Red Pink Green
l l c o r l l ll l
try the next largeror smallerbearing(thecolor listed I lD;;ilril | Pink Green
aboveor belowthat one),andcheckclearance again. l - l Green Erown Black
Smaller Smaller Green Brown Black Blue
rod bearlng
NOTE: lf the Droperclearancecannot be obtained journal (thicker)
by usingthe appropriatelargeror smallerbearings,
\ replacethe crankshaftand startover.
7-11
Pistonsand Crankshaft
Removal
\
1. Removethe oil pan assembly. 3. Removethe oil screen.
2. Removethe right sidecover. 4. R€movethe oil pump.
816A2 engine 816A2engin€
OIL SCREEN
OILPUMP
D16Y5,Dl6Y7,D16Y8ongines D16Y5,D1oyr, D16Y8engin.s
RIGHT SIDE
O-RING
Replace.
5, Remove the baffle plate (816A2 engine).
7-12
q
6. Removethe boltsand the bearingcaps. Removethe upperbearinghalvesfrom the connect-
ing rods and set them aside with their respective
CAUTION: To prevenl warpago unscrow lhe bolts caos.
in s€quence1/3 turn at a tims, r€paat the soquence
until all bolts ar€ loo3ened. 1 0 . Reinstallthe main caps and bearingson the engine
in proper order,
MAIN BEARINGCAPBOLTSLOOSENINGSEOUENCE
1 1 . lf you can feel ridgeof metalor hard carbonaround
t h e t o p o f e a c h c y l i n d e r ,r e m o v ei t w i t h a r i d g e
reamer.Follow the reamer manufacturer'sinstruc-
I|ons.
CAUTION; lf the ridge is not removed, it may dam-

age tho pistons as they are pushod out.
RIOGEREAMER
S:_]ILOJLOAO
7. Removethe rod caps/bearings and main capvbear-

ings.Keepall caps/bearing
in order.
12. Use the wooden handle of a hammer to drive the
Lift the crankshaftout of the engine,being careful pastonsout.
not to damagejournals.
1 3 . Reinstallthe connectingrod bearingsand capsafter

removingeachpiston/connecting rod assembly.
CRANKSHAFT
1 4 . Mark each piston/connecting
rod assemblywith its
cylindernumberto avoid mixup on reassembly.
NOTE:The existingnumber on the connectingrod

does not indicateits positionin the engine,it indi-
catesthe rod bore size.
7-13
Crankshaft
Inspection
. Cleanthe crankshaftoil passageswith pipe cleaners Out-of-Roundand Tapet
or a suitablebrush.
. Measureout-of-roundat the middle of each rod
. Checkthe keywayand threads. and main journalin two places.
Alignment a The differencebetweenmeasurementson each

journalmust not be morethan the servicelimit.
. M e a s u r er u n o u t o n a l l m a i n j o u r n a l st o m a k e
surethe crankis not bent. Joulnal Out-of-Round:
81642engine:
. The differencebetweenmeasurementson each Standard (New): 0.0004mm {0.0002in) max.
journalmust not be more than the servicelimit. ServiceLimit: 0.006mm {0.0002in)
Dr6Y5, Dl6Y7, D16Y8engines:
CrankshaftTotal IndicatedRunout: Standard (Newl: 0.0025mm (0.0001inl max.
ServiceLimh: 0.005mm (0.0002inl
Bl6A2 engine:
Standard (Newl: 0.020mm {0.0008in} max.
ServiceLimit: 0.030mm {0.0012inl
Standsrd{New):0.03mm (0.001in} max.
ServiceLimit; 0.0i1mm 10.002in)
round at middle.
Support with lathe

type tool or V blocks.
. Measuretaper at the edgesof eachrod and main
journal.
. The differencebetweenmeasurementson each

journalmust not be more than the servicelimit.
JournalTaDer:
B16A2ongine:
Standard lNewl: 0.005mm (0.0002inl max.
ServiceLimit: 0.010mm (0.00i1inl
D16Y5,D16Y7,Dl6YBengines:
Standard (New): 0.0025mm {0.0001in) max.
ServiceLimit: 0.005mm (0.0002in)
7-14
Pistons
Inspection
1 . Checkthe pistonfor distortionor cracks, 3. Calculatethe differencebetweenthe cylinder bore
diameter(seepage7-16)and the pistondiameter.
N O T E :l f a c y l i n d e ri s b o r e d .a n o v e r s i z e dp i s t o n
must be used. Piston-to-CylinderClsarance
StandardlNewl: 0.010- 0.0,10mm
Measurethe piston diameterat a distanceA from (0.0004 - 0.0016inl
bottom of the skirt. ServicoLimit: 0.05 mm {0.002in}
816A2engino:
A: 15 mm 10.6in)
A: 5 mm (0.2inl
Piston Diameter:
816A2engine:
Standard lNewl: 80.980- 80.990mm
13.1882 - 3.1886in)
Standard {New): 7,f.980- 7i1.990mm
|.2.9520- 2.9521in!
ServiceLimit: 74.970mm {2.9516inl
lf the clearanceis near or exceedsthe servicelimit,
inspectthe piston and cylinderblockfor excessive
wear.
SKIRTDIAMETER
OversizoPiston Diametor
816A2ongine:
0.25t81.23- 81.21mm (3.1980- 3.1984inl
D16Y5.D16Y7,D16Y8engines:
O.25t75.23- 75.21mm (2.9618- 2.9622in)
0.50:75.i18- 75.49mm {2.9716- 2.9720in}
7 - 15
Cylinder Block
Inspection
'L
X andy at three
Measurewearand taperin directions lf the measurementsin any cylinderare beyond
levelsin eachcvlinderas shown. the OversizeBore ServiceLimit, replacethe block.
lf the block is to be rebored.refer to piston Clear-

anceInspection(seepage7-15)after reboring.
NOTE:Scoredor scratchedcylinderboresmust be
honed.
ReboringLimit:
Bl642 enginc:
0.25mm (0.01in)
Dl6Y5,D16Y7,D16Y8engin€s:
0.50 mm (0.02in)
Checkthe top of the blockfor warpage,

Measurealong the edges and acrossthe centeras
shown.
SURFACES
TO BEMEASUREO
Cylinder Boro Size

816A2engine:
Standard(Newl:81.00- 81.02mm EngineBlockWarpage:
{3.1t|:l- 3.190int Bl6A2 engine:
ServiceLimit: 81.07mm {3.192in) Standard (Now):0.05 mm {0.002inl max.
D16Y5,D16Y7,D16Y8engines: ServiceLimh: 0.08 mm (0.003in)
Standard lNew): 75.00- 75.02mm DtOYs,D16Y7,D16Y8€nginas:
(2.9s3- 2.954in) Standard (N€w):0.07 mm l0.OO3inl max.
SarviceLimit: 75.07mm (2.956in) ServicaLimit; 0.10 mm {0.00itin)
Oversize PRECISION
STRAIGHTEDGE
816A2 engiDe:
0.25t41.25- A1.27mm {3.199- 3.200in)
D16Y5,D16Y7,D16Y8Engines:
0.25t75.25-15.27 mm (2.9626- 2.963,0in)
0.50:75.50- 75.52mm 12.9721-2.9i32 inl
Bore TaDet
Limit: (Differencebetween first and third measure"
ment) 0.05 mm (0.002inl
7-16
Cylinder Block PistonPins
BoreHoning Removal
1. Measurecylinderboresas shownon page7-16.lf the l. Assemble the special tool as shown.
block is to be reused,hone the cylindersand remea-
surethe bores. PISTONBASEHEAD
07973 - SBtx)too
Honecylinderboreswith honingoil 8nd a fine (400 f t
grit) stone in a 60 degreecross-hatchpattern.
PISTONPINBASE
NOTE: INSERT
. Use only a rigid hone with 400grit or finer stone 01973- PE00'0)
suchas Sunnen,Ammco,or equivalent.
. Do not usestoneslhat are worn or broken.
rg\g
W h e n h o n i n g i s c o m p l e t e ,t h o r o u g h l yc l e a n t h e
lj*N*,""
engine blockof all metal particles.Wash the cylin-
der bores with hot soapYwater, then dry and oil 2. Assembleand adjust the length of the piston p t n
immediatelyto preventrusting. driverand shaftto 53 mm (2.1inl as shown.
PISTONPINDRIVERHEAD
NOTE: Never use solvent.it will only redistributethe 07973- PE00320
grit on the cylinderwalls. Proat
lf scoring or scratchesare still presentin cylinder 0

bores after honing to the servicelimit, reborethe
cylinderblock.
PISTON PIN
NOTE:Some light verticalscoringand scratchingis DRIVERSHAFT
acceptableif it is not deep enough to catch your fin- 0t973 - PEqr310
gernailand does not run the full lengthof the bore.
PILOTCOLLAR
CYLINOESBLOCK 07973 - PE00200
CYLINDER Emboss6dmark facing up
NOTEi Us6 a hydraulic press.

When pressingthe pin in or out.
make sure that the recesssd
NOTE: portion of the piston aligns
. After honing,cleanthe cylinderthoroughlywith with the lips on the collar.
soapy warer.
. Onlv a scoredor scratchedcylinderbore must be 3. Placethe piston on the sp€cialtool and press the
noneo. pin out with the specialtools and a hydraulicpress.
7-17
ConnectingRods PistonPins
Selection Installation
, (
Eachrod fallsinto one of four toleranceranges{fromOto 1. Usea hydraulicpressfor installation.
+ 0.024mm (0 to + 0.0009in), in 0.006mm (0.0002in)
increments) dependingon the sizeof its big end bore.lt,s . Whenpressingthe pin in or out, be sureyou posi
then stampedwith a number{1, 2,3, or 4) indicatingthe tion the recessed
flat on the pistonagainstthe lugs
range. on the baseattachment.
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 l , 2 , 3 , o r 4 i n a n y
engrne. 816A2engine D16Y5,D16Y7,O16Y8engines
The arrowmustfacethe
NormalEoreSize:48.0mm (1.89in) timing beltsideo{ the
engineand the connecting
rod oil holemustfacethe
NOTE: rearof the engine.
o Referencenumbersare for big end bore sizeand do
NOTindicatethe positionof the rod in the engine.
. Inspectconnectingrod for cracksand heatdamage.
The arrow must face the

timing belt side of the
e n gI n e .
CONNECTING ROD AORE
REFERENCE NUMBER
Half of numberis stampedon
bearingcap, the other half on
connectrngrod. The markmustface
the timing beltside
o f t h ee n g i n e .
PISTONPIN DRIVERHEAD a
Adjustthe lengthof the
pistonpin driverto
53 mm (2.094n)
PISTONPINDRIVERSHAFT
07973-PEOo3r0
P,"roNPrN
il--Z PILOTCOLLAR
07973-PE00200
PISTONPINBASE INSERT
07973 PEO0400
PISTONEASE HEAO
07973-5800100
7-18
lnspection
1. Measurethe diameterof the pistonpin. 3. Measurethe pistonpin-to-piston
clearance.
Piston Pin Diametel: NOTE:Checkthe pistonfor distortionor cracks.

B16A2engine:
Standard{New):20.994- 21.000mm lf the pistonpin clearanceis greaterthan 0.024mm
(0.8265- 0.8268in) ( 0 . 0 0 0 9j n ) , r e m e a s u r eu s i n g a n o v e r s i z e dp i s t o n
Oversize: 20.997- 21.003 pin.
10.8267- 0.8269inl
D16Y5,Dl6Y7,Dl6YBengines: Piston Pin-to-PistonClearance:
StandardlNewl: 18.99,1-19.000mm Standard(New):0.010- 0.022mm
(0.7478- 0.7480inl (0.0004- 0.0009in)
Oversize: 18.997- 19.003
{0.7479- 0.7481in)
pistonpins are overslze.

NOTE;All replacement
4. Checkthe differencebetweenthe pistonpin diame-

ter and the connectingrod smallend diameter'
Piston Pin-to-ConnestingRod Interterence:

816A2engine:
Standard(New):0.013- 0.032mm
(0.0005- 0.0013in)
2. Zerothe dial indicatorto the pistonpin diameter' D16Y5,D16Y7,Dl6YBengines:
SiandardlNewl; 0.014- 0.040mm
- 0.0016
10.0006 inl
7-19
PistonRings
EndGap Replacement
1 . Using a piston, push a new ring into the cylinder 1. Usinga ring expander.removethe old pistonrings.
bore 15- 20 mm (0.6- 0.8 in) from the bottom.
Cleanall ring groovesthoroughly.
Measurethe pistonring end-gapwith a feelergauge:
NOTE:
. lf the gap is too small,checkto see if you have . U s e a s q u a r e d - o fbf r o k e nr i n g o r r i n g g r o o v e
the properringsfor your engine. cleanerwith bladeto fit pistongrooves.
. lf the gap is too large.recheckthe cylinderbore o Top ring grooveis 1.0mm (0.039in)wide.
diameteragainstthe wear limits on page7-16, . Secondring grooveis 1.2mm (0.047in) wide.
lf the bore is over the servicelimit, the cvlinder . Oil ring grooveis 2,8 mm (0.11in) wide.
blockmust be rebored. . Filedown the bladeif necessary.
Pkton Ring End-cap: CAUTION: Do noi use a wire blush to clean ring
Top Ring lands. or cut ring lands deepol with cleaning tool.
81642 engino
Siandtrd (New): 0.20- 0.35 mm NOTE:lfthe pistonis to be separatedfrom the con-
{0.008- 0.01,1in) nectingrod, do not installnew ringsyet.
ServiceLimit: 0.60 mm l0-02i1inl
D16Y5.Dl6Y7, D16Y8enginos 3. Installnew rings in the proper sequenceand posi-
Standard lNewl: 0.15- 0.30 mm taon(seepage7-22).
{0.006- 0.012in)
Ssrvic€ Limit 0.60 mm {0.024inl NOTE:Do not reuseold pistonrings.
Socond Ring
816A2 ongina
Standard (Nowl: 0.40- 0.55 mm
10.016- 0.022inl (Commercially
available)
ServiceLimit: 0.70 mm (0.028inl
D16Y5,D16Y7,Dt6Y8 engines
Standard (New): 0.30- 0.ia5mm
{0.012- 0.018in)
SorviceLimit 0.70 mm 10.028inl
Oil Ring
81642 ongine
Standard {Now): 0.20- 0.50 mm
(0.008- 0.020inl
SorvicoLimit: 0.70 mm (0.028in)
Dl6Y5. Dl6Y7, D16Y8€nginos
Standard (Nowli 0.20- 0.70 mm
(0.008- 0.028inl
ServicaLimit: 0.80 mm 10.031in)
7-20
Clearance
Ring-to-Groove Alignment
After installing a new set of rings, measure ring-to- 1. Installtheringsas shown.
grooveclearances:
NOTE: The manufacturingmarks must be facing
Top Ring Clearance upward.
Standard (New):
B16A2angine: TOP RING(Chrome)
0.045- 0.070mm (0.0018- 0.(X128 in)
Dl6Y5, Dt6Y7, Dl6Y8 engin€s:
0.035- 0.060mm {0.0014- 0.002'lin)
service Limit: 0.13 mm (o.fixi in)
SecondRing Clearance
Standard lNow):
B16A2engine:
0.0/t0- 0.065mm (0.0016- 0.0026in)
Dl6Y5, D16Y7,D16Y8onginos:
0.030- 0.055mm (0.(X)12- 0.0022in)
Sewica Limh: 0.13 mm (0.005io)
SECONDRING(Darkl
Piston Ring Dimsnsions:
t----T f
l B
t---f_-L
A
Top Ring (Standard) U n i tm m ( i n )

B
Bl642 engine 3 . 1( 0 . 1 2 ) 1.0(0.04)
D16Y5,D16Y7,
2 . 6( 0 . 1 0 ) 1.0(0.04)
D16Y8engines
SecondRing(Standard) U n i tm m ( i n )
B
816A2engine 3 . 3( 0 . 1 3 ) 1.2(0.05)
D16Y5,D16Y/.
3 . 0( 0 . 1 2 ) 1.2{0.05t
D16Y8engines
.,o (cont'd)
7-21
PistonRings CrankshaftOil Seal
Alignment(cont'dl Installation , (
The sealsurfaceon the blockshouldbe dry.

MARK Apply a light coat of oil to the c.ankshaftand to
t h el i po f t h es e a l .
TOP RING ---.>
1. Drivethe crankshaftoil seal squarelyinto the right
sidecover usingthe specialtools.
SECONDRING>
HANDLEDRIVER
,a-) 07749 0010000
/\_4
o,.rô( qffi<--sPACER
\Z-.
v
Rotatethe rings in their groovesto makesure they
do not bind.
Positionthe ring end gapsas shown:
seal with the

pan number side
facing out.
DO NOTpositionany ring gap
SECONDRINGGAP
at pistonthrustsurfaces.
C o n f i r m t h a t t h e c l e a r a n c ei s e q u a l a l l t h e w a y \
aroundwith a feelergauge.
- 0.8 mm (0.02- 0.03inl

Clearance:0.5
Approx.90
TOP RINGGAP
DO NOTpositionany ring gap

in linewith the pistonpin hole. OIL RINGGAP
NOTE:Referto page 8-14 for installationof the oil

pumo sidecrankshaftoil seal.
7-22
Pistons Grankshaft
lnstallation lnstallation
B e f o r ei n s t a l l i n gt h e p i s t o n s ,a p p l y a c o a t o f Beforeinstallingthe crankshaft,apply a coat of
e n g i n eo i l t o t h e r i n g g r o o v e sa n d c y l i n d e r engineoil to the main bearingsand rod bearings.
bores.
1. Insertthe bearinghalvesinto the cylinderblockand
1. lf the crankshaftis alreadyinstalled: connectingrods.
. Setthe crankshaftto BDCfor eachcylinder. 2 . Holdthe crankshaftso the rod journalsfor cylinders
. Removethe connectingrod caps,and slip short No.2 and No. 3 are straightdown.
sectionsof rubber hose over the threadedends 3 . Lowerthe crankshaftinto the block,seatingthe rod
of the connectingrod bolts. journalsinto connectingrods No. 2 and No. 3, and
. lnstallthe ring compressor.checkthat the bear- installthe rod capsand nutsfinger-tight.
ing is securelyin place,then positionthe piston
in the cylinder,and tap it in using the wooden
h a n d l eo f a h a m m e r .
o Stop after the ring compressorpops free, and
checkthe connectingrod-to-crank journal align-
ment beforepushingthe pistoninto place
. Apply engine oil to the bolt threads.Installthe
rod capswith bearings,and torquethe nuts to:
815A2engine:
40 N.m {,1.1kgf.m, 30 lbf'ft| Groovedsidesface
D16Y5,D16Y7,D16Y8engines: oulward.
31 N.m (3.2kgf'm,23lbf'ft) Botatethe crankshaftclockwise,seat journals into
connectingrods No, 1 and No.4, and installthe rod
2. lf the crankshaftis not installed: capsand nutsfinger-tight.
. Removethe rod capsand bearings, installthe ring
compressor, then positionthe pistonin the cylin- NOTE:Installcaps so the bearingrecessis on the
der, and tap it in using the wooden handleof a sameside as the recessin the rod.
hammer.
. Positionall Distonsat top deadcenter. 5. Checkrod bearingclearancewith plastigage(see
The arrcw must face p a g e7 - 1 1 )t,h e n t o r q u et h e c a p n u t sA. p p l y e n g i n e
the tamingbelt side oil to the bolt threads.
of the engine.
Torque:
816A2 sngine:
/l{, N.m {a.l kgf.m, 30 lbf'ftl
CONNECTINGROO
OILHOLElD16Y5,D16Y7,D16YBongines) D16Y5,D16Y7,Dl6Y8 engines:
31 N.m (3.2 kgf.m, 23 lbf'ft|
NOTE: Referencenumbers on connectingrod are

for big-endbore toleranceand do not indicatethe
positionof pistonin the engine.
RUBBER
NOTE:Maintaindownwardforce on the ring com-
pressorto preventthe rings from expandingbefore
enteringthe cylinderbore.
,lll
Lineup the markswhen

i n s t a l l i n gt h e c o n n e c t r n g r o d
cap.
6. Installthe thrust washerson the No. 4 journal.Oil

the thrustwashersurfaces, (cont'd)
7-23
Crankshaft
7. I n s t a l l t h em a i nb e a r i n gc a p s . NOTE:
Checkclearancewith plastigage(seepage7-9),then . Useliquidgasket,part No.08718- 0001or08718-
tightenthe bearingcap boltsin 2 steps. 0003.
. Checkthat the mating surfacesare cleanand dry
First step: 25 N.m {2.5 kgf.m, 18 lbf.ft) beforeapptyingliquidgasket.
Secondstop: . Apply liquidgasketevenly,beingcarefulto cover
B1642engine: all the matingsurface.
76 N.m {7.8 kgf.m, 56 lbf.ft) . To preventoil leakage,apply liquidgasketto the
D16Y5,D16Y7,D16Y8engines: innerthreadsof the bolt holes.
51 N.m (5.2 kgf.m, 38 lbf.ft) . Do not installthe parts if five minutes or more
haveelapsedsinceapplyingthe liquidgasket.
NOTE: Coat the thrust washer surfacesand bolt Insteadreapplyliquid gasketafter removingthe
threadswith oil. old residue.
. After assembly,wait at least30 minutesbefore
MAIN BEARING
CAPBOLTSTIGHTENING
SEOUENCE f i l l i n gt h e e n g i n ew i t h o i l .
o o c o o
L Apply liquid gasketto the block mating surfaceof
the right side cover,then install it on the cylinder
block.
Bl6A2 engine;
:V fr\-/.---\-/.-
CAUTION:Whenever any crankshaft or connecting

rod bearing is replaced,it is necGssaryafter reassom- Apply tiquid gaslet along
bly to run the engine at idling spe6d until it reaches the broken line.
normal operating temperature,than continue to run
it for approximately15 minutos. D16Y5,D16Y7,D16Y8engines:
RIGHTSIDECOVER
7-24
81642ongin€: 9. Apply liquid gasketto the oil pump mating surtace
of the block,then installthe oil pump on the cylin-
der block.
RIGHTSIDE
Apply greaseto the lips of the oil seals.
Thgn, align the inner rotor with the crankshaftand
i n s t a l lt h e o i l p u m p . W h e n t h e p u m p i s i n p l a c e ,
clean any excessgreaseoff the crankshaft.Check
that the oil seallips are not distorted.
B16A2ongino:
DOWELPINS
D16Y5,Dl6fr, Dl6Y8 engines: Apply liquidgasketalong

the brokenline,
Dl6Y5,Dl6Y7,Dt6Y8ongino3:
Apply liquid gasket

alongthe broken
6 x 1.0 mm
1 1 N . m { 1 . 1 k9l.m,
a rbf.ft)
OIL PUMP }{OUSING
OOWEL PIN
{cont'd)
7-25
Crankshaft Oil Pan
(cont'd)
Installation Installation
NOTE: D16Y5,Dl6Yg engines:
. Apply a light coat of oil to the crankshaftand io
t h e l i po f s e a l . 1. I n s t a ltlh e o i l p a ng a s k eot n t h e o i l p a n .
. U s e n e w O - r i n g sa n d a p p l y o i l w h e n i n s t a l l i n g
them.
1 0 . l n s t a l l t h eo i l s c r e e n . OIL PAN
816A2engine:
6 x 1 . Om m
l l N ' m ( 1. 1 k g l . m ,
8 tbt.Irl
,.//
{ / cor*rt
(..ao Replace.
t(^^ 1 1 N . m 1 1. 1 k g f . m ,
OIL PAN
tbt4tl ,/
a lbl'ltl
.rB / GASKET
*P/ Replace.
& ^/t
O.RING
Replace.
24 N.m (2.4kgf.m,
I
OtL PutitP '17
lbl.fr)
D16Y5, D16Y7, D16Y8 engines:
6x1.0mm
1 1 N . m { 1 . 1k g f . m ,
8 tbt.rr)
6 x 1.0mm
1 1 N . m { 1. 1 k g f . m ,
a lbf.fr) I
OIL SCREEN
I
DOWELPIN
/
rl l Te
OIL PUMP
6 x 1.0mm
11 N.m
l l.1 kgf'm, a lbf.frl
7-26
2. Apply liquid gasketto the blockmating surfacesof 816A2, D16Y7engines:
the oil pan,then installit. Apply liquid gasketto the
t n t h e o i l p u m p a n d r i g h ts i d e
1 . A p p l y l i q u i dg a s k e o
shadedareas.
NOTEI covermatingareasas shown below.
. U s e l i q u i d g a s k e tp a r t N o . 0 8 71 8 - 0 0 0 1 o r
08718- 0003. NOTE:
. Checkthat the matingsurfacesare cleanand dry . U s e l i q u i d g a s k e t ,p a r t N o . 0 8 7 1 8- 0 0 0 1o r
beforeapPlyingliquidgasket. 08718- 0003.
. Apply liquid gasketas an even bead, centered . Checkthat the matingsurfacesare cleanand dry
betweenthe edgesol the matingsurface' beforeapplyingliquidgasket
. To preventleakageof oil, apply liquid gasketto . Apply liquid gasket as an even bead, centered
the innerthreadsof the bolt holes betweenthe edgesol the matingsurface'
. Do not installthe parts if five minutes or more . To preventoil leakage,apply liquid gasketto the
haveelapsedsinceapplyingthe liquidgasket innerthreadsof the bolt holes
. Do not install the parts if five minutes or more
lnstead,reapplyliquid gasketafter removingthe
old residue haveelapsedsinceapplyingthe liquidgasket
. After assembly,wait at least 30 minutes before Instead,reapplyliquid gasketafter removingthe
f i l l i n gt h e e n g i n ew i t h o i l . old residue.
. Aftel assembly,wait at least30 minutes before
filling the enginewith oil.
CYLINDER
ELOCK
Apply liquid gasket
to these pornts-
OIL PAN
3. T i g h t e nn u t s f i n g e r - t i g h ta t s i x p o i n t s a s s h o w n
below.
Apply liquid gasket

to these pornts.
4. Tighten all bolts and nuts, startingfrom nut @, clock-

wisein threesteps.
NOTE:Excessive tighteningcan causedistortionof
the oil pan gasket and oil leakage.
I (cont'd)
Torque:12 N'm {1.2kgt'm,8.7lbf'ft|
7 -27
Oil Pan
lnstallation(cont'dl
\
Installthe oil pan gasketand oil pan 3, Tightenthe bolts and nuts finger tight at six points
as shown below.
NOTE:
a Usea new oil pan gasket.
. I n s t a l lt h e o i l p a n n o m o r e t h a n f i v e m i n u t e s
afterapplyingliquidgasket.
816A2 engine:
4. T i g h t e na l l b o l t s a n d n u t s , s t a r t i n gf r o m n u t O .
clockwise in threesteps.
OIL PAN NOTE:Excessive tighteningcan causedistortionof

GASKET the oil pan gasketand oil leakage.
R€place.
Torque: 12 N.m {1.2 kgf.m, 8.7 lbf.ft)
Apply liquid
gasKet to
these points.
OIL PAN
Apply liquid gasker GASKET
to these points. Beplace.
7-28
Oil Seals
lnstallation
NOTE: 2. Measurethe flvwheel-endsealthicknessand the oil
. Engineremovalis not required. sealhousingdepth.Usingthe specialtool. drive the
. The crankshaftoil sealhousingshouldbe dry. flywheel-endseal into the rear cover to the point
Apply a light coat of greaseto the crankshaftand to where the clearancebetweenthe bottom of the oil
-
the lips of the seals. sealand the right side cover is 0.5- 0.8 mm (0.02
0.03in) (seepage 7-23).
1. U s i n gt h e s p e c i atl o o l , d r i v e i n t h e t i m i n g p u l l e y -
e n d s e a l u n t i l t h e d r i v e r b o t t o m sa g a i n s tt h e o i l NOTE:Align the hole in the driver attachmentwith
pump. the Dinon the crankshaft.
When the seal is in place,clean any excessgrease
off the crankshaftand checkthat the oil seal lip is
not distorted.
DRIVER
07749-0010000
DRIVERATTACHMENT
07947 -S800200 0794a-s800101
lnstallseal with the lnslall seal with the
part numbersade part number side
facing out. facing out.
7 -29
EngineLubrication
SpecialTools .......... "'.""".8'2
lllustratedIndex........... .'..'8-3
EngineOil
Inspection 8-6
.....'......"....."'.
8-7
Replacement........'......".'.'..."...."......"
OilFilter
8-8
Rep1acement...............".'...'..'.....'.'...".
Oil Pressure
Testing '.....'8-9
OilJet (B16A2 engine)
Inspection ...'.'......"...."'..8-10
OilPump
overhaul.'... 8-11
.....'...'..'."""'
Removal/lnspection/lnstallation ..'....8-13

SpecialTools
Ref. No. I Toot Number
07746- 0010400 Attachment,52 x 55 mm

07749- 0010000 Driver
0 7 9 1 2- 6 1 1 0 0 0 1 Oil FilterWrench
o 6\ ,6
\ ll
\ a
8-2
lllustrated Index
NOTE: CAUTION: Do not overiighten the drain bolt.

. Usenew O-ringswhen reassembling
. Apply oil to O-ringsbeforeinstallation
. Use liquid gasket,Part No 08718- 0001or 08718- 6x1.0mm
0003. 12 N.m (1.2kqtm,8.7 lbl.ftl
. Cleanthe oil pan gasketmating surlacesbefore install-
Ing. WASHER
RePlace'
B1642 engine:
DRAINBOLT
44 N.m (4.5kgl'm,33 lbt'ft)
Do not overtrghten. OIL PAN
Relerto page 7'27
when installing.
OIL PAN
GASKET
6x1.0mm Replace-
OIL BREATHER
CHAMEER 11 N.m (1.1kgtm,
8 6x1.0mm
11 N'm (1.1 kgl.m,8 lbf.ft)
otL
SCREEN
GASKET
Replace.
BAFFLEPLATE
OIL JET BOLT

16 N'm 11.6kgf.m, 12lbt'ttl
€!
fl OIL JET
[50 page8-10
Inspection,
8x1+5mm
24 N.d\l2.il kgf.ft,
t7 tbtft)
Replace.
OIL FILTER
R e p l a c e m e n l ,p a g e 8 - 8
Replace.
6x1.0mm
SWITCH
ENGINEOIL PRESSURE 11 N.m 11.1kgt m,
8 tbt.frl
PipeTaper)28 Threads/inch Clean

Overhaul.page8'11
Useproperliquidsealant. Removal/lnspection,Page8-13
Apply liquidgasketto (cont,d)
matingsurfaceof engineblock
8-3
lllustrated Index
(cont'dl
NOTE: CAUTION: Do not overtighten the drain bolt.
. Usenew O-ringswhen reassembling.
. Apply oil to O-ringsbeforeinstaltal|on. ENGINEOILPBESSURE SWITCH
. Use liquid gasket,Part No. 08718 0001 or 0e719 18 N.m (1.8kgtm, 13 tbt.trl
1/8in. BSPT(British
0003. StandardPipeTaper)
. Cleanthe oil pan gasketmatingsurfacesbeforeinstall_ 28 threads/inch.
Use
ing. properliquidsealant.
. Apply liquid gasketto the recessesof the oil pan gas
ket (seepage7-27).
D16Y7€ngine:
OILPUMP
Overhaul,page8-12 O-BING OILBREATHER
Inspection,page8 13 Replace. CHAMBER
Apply liquidgasker
to the matingsurface 6x1.0mm
of the block. '11N.m 1.1ksnm,
{
8 tbtft)
DOWELPIN
ll
6x1.0mm
1l N.m {1.1kgf-m,
8 tbf.ftl
OIL PAN
GASKET
Bepiace.
OIL PAN
R e f e rt o p a g e 7 - 2 7
when installing.
6x1.0mm 6 x 1 . 0m m
1 1N m ( 1 . 1k g t . m , A p p l y l i q u i d g a s k e t t o l2 N.m {1.2kgtm, 8.7tbf.ft)
8 tbl.ftl
DRAINBOLT
44 N.m {4.5kgtm, 33 tbf.ft}
Do not ovenighten.
a
8-4
NOTE: CAUTION: Do not overtightsn the drain bolt.
. Use new O-ringswhen reassembling.
. Apply oil to O-ringsbeforeinstallation.
-
. Use liquid gasket,Part No 08718- 0001 or 08718
0003. ENGINEOIL PRESSURE SWITCH
18 N,m l'1.8kgf.m, 13 lbf.ftl
. Cleanthe oil pan gasketmatingsurfacesbeforeinstall- 1/8in. ESPT(British
Ing. StandardPipeTaper)
28 Threads/inch. use
D16Y5,D16Y8engines: properliquidsealant.
O.RING O-RING
Replace.
OIL BREATHER
CHAMBER
OILPUMP
Overhaul,Page8 12
Inspection,Page8 13 OOWELPIN
Apply liquidgasket
to the matingsurface
of the block.
6x1.0mm
11 N.m {1.1kgf.m,
I tbt'ftl
FILTER
page8_8
Replacement,
6 x ' 1 . 0m m
11 N.m ('1.1|
8 tbf.ft)
BAFFL€PLATE
GASKET
Replace. OILPAN
GASKET
Feplace.
6x1.0mm 6x1.0mm
11N.m 11.1kgl.m, 11 N.m 11.1kg{'m, OIL PAN
8 tbf.ftl 8 rbf.ftl Relerto page7 26
when installing.
\3
BOLT
39 N.m (4.0kgf.m.29lbtftl
Do not overtighten.
6x1.0mm
\ 12 N.m {1.2kg{.m,8.7lbf ftl
8-5
EngineOil
Inspection Replacement
1 . Parkthe vehicle on level ground, and turn off
the CAUTION:Removothe drain boli carefully while
engine.Allow the oil a few minutes to drain back lho
engine is hot; the hot oil may causoscalding.
into the oil pan so the dipstickwill show the actual
level. :1. Warm up the engine.
Make certainthat the oil level indicatedon the dip_

2. Drainthe engineoil.
stick is betweenthe upper and lower marks.
81642,D16Y7engin€s:
lf the level has dropped close to the lower mark.
add oil until it reachesthe uppermark.
CAUTION: lmert thc dipstick car€fully to avoid b€nd_

ing it.
Bl6A2 angin.:
,,7.fp--)*,".
rowrn-u l
DRAINBOLT
{rl N.m (4.5 kgf.m,33 tbt ft}
Do not overtighten.
D16Y5, Dl6Y8 6ngin93:
WASHER
D16Y5,D16Y7,Dt6y8 ongines:
DRAINBOLT
39 N.m 14.0kgfm, 29 tbf,f0
uo not overtighten.
8-6
3. Reinstallthe drain bolt with a new washer.and rbfill
the enginewith the recommendedoil.
"Energy
Requirement API ServiceGrade:Use an
Conserving"SJ gradeoil or an
"EnergyConservingll" SH gradeoil,
SAE5W - 30 preferred
You canalsousean oil that bearsthe
APICERTIFICATION mark.
Capacity [atolz engine:
3.7f (3.9US qt,3.3 lmp qtl
MARK
API CERTIFICATION
I at oil change.
qtl
J 4.0r 9.2 US qt, 3.5 lmp
at oil change, including filter'
I
( 5 . 1U s q t , 4 . 2l m p q t )
| 4 . 8f
after engine overhaul
I
I Dl6Y7 engine:
3.6f (3.8US qt, 3.2 lmP qt)
filter.
I at change.including
3.3 f (3.5US qt,2.9 lmP qtl
I
filter.
I at change,without
4 . 3f ( 4 . 5u s q t , 3 . 8l m p q t l
I
I afterengineoverhaul.
J D16Y5,D16Y8engines:
L 3.3{ {3.5US qt,2.9 lmp qt} API SERVICELABEL
filter.
I at change,including
3.01 ( 3 . 2U S q t , 2 . 6 l m pq t )
I at change, withoutfilter.
3.7{ (3.9US qt,3.3 lmp qt}
- '1.€fter
engineoverhaul.
Run the engine tor more than three minutes,then
Change Every7,500miles(12,000km) or
checkfor oii leakage
12months(NormalConditions).
Every3,750miles(6,000kml or
6 months (SevereConditions).
NOTE:Under normalconditions,the oil filter should be

replacedat every other oil change Under severecondi-
tions,the oilfilter shouldbe replacedat eachoil change'
The numbersin the middle of the API Servicelabeltell
you the oil's SAE viscosityor weight Selectthe oil for
vour car accordingto this chart:
Ambient Temoerature
30 20 -10 0 10 20 30 4OoC
A n o i l w i t h a v i s c o s i t y o f 5 W - 3 0 i s p r e f e r r e df o r
improvedtuel economyand year-roundprotectionin the
car.You may usea 10W- 30 oil if the climatein your area
is limitedto the temperaturerangeshownon the chart'
8-7
Oil Filter
Replacement
Installthe oil filter by hand.

After the engine has been run, the exhaust pipe will
be hot; be careful when working around ihe exhaust
Afterthe rubbersealseats,tightenthe oil filterclock_
pipe.
wise with the oil filterwrench.
Be careful when loosening the drain bolt whils the
engine is hot. Burns can resuh becausethe oil tem-
Tighten: 7/8 tu.n clockwise.
peratu16is very high.
Tightening tolque: 22 N.m (2.2kgt.m, 16lbf.ft)
l. Removethe oil filter with the oil filter wrencn.
Inspectthe threadsand rubbersealon the new filter.

Wipe off the seat on the engineblock,then apply a
lightcoatof oil to the new filter,srubberseal.
NOTE: Use onty fitters with a built-in bypasssys,

tem.
Applyoil to rubberseal
beforeinstalling.
OIL FILTERWRENCH
07912- 6110001
I n s p e c tt h r e a d s a n d
rubber seal surface.
8-8
Oil Pressure
Testing
Usethis procedureto tightenthe filter if eight num- lf the oil pressurewarningIight stayson with the engine
bers(1 to 8) are printedon the surfaceof the filter. running,checkthe engineoil level.It the oil level is cor-
rect:
1) Makea markon the oil filterbaseunderthe num-
ber that shows at the bottom of the filter when 1. Connecta tachometer'
the rubbersealis seated.
2. Removethe engineoil pressureswitch,and installan
2l Tightenthe filter by turning it clockwiseseven oalpressuregauge.
numbersfrom the markedpoint. For example,if a
markis madeunderthe number2 when the rub
SWITCH
OtLPRESSURE
ENGINE
ber seal is seated,the filter should be tightened
MOUNTINGHOLE
untilthe number1 comesup to the markedpoint'
7/8 turn
MARK
Numberwhen rubDer Numberaftertightening.

sealis seated
ADAPTER OIL PRESSUREGAUGE

Numberwhen rubber 5 7 8 (1/8\28. BSPTI (Commerciallv
available)
sealis seated {CommerciallYavailablei
Numberaftertightening 8 1 5 1
Startthe engine.Shut it off immediatelyif the gauge

CAUTION:Using any procedureother than those
registersno oil pr€ssure.Repairthe problembefore
shown could rosult in serious engins damage due
continuing.
to oil leakage
fill the enginewith oil up to the spec- Allow the engineto reachoperatingtemperature(tan
5. Afterinstallation. The pressureshouldbe;
comeson at leasttlivice).
ified level,run the enginefor more than three minutes,
then checkfor oil leakage
EngineOil Temperature:176"F(80"C1
EngineOil Pressulo:
At ldle: 69 kPa (0.7 kgf/Gm'.10 Psi)
minimum
At 3.000rpm: 3/UtkPa (3.5 kgt/cm', 50 psi)
minimum
. replace
lf the oil Dressureis within specifications,
the oil pressureswitch and recheck.
. lf the oil pressureis NOT within specifications,
inspectthe oil pump (seepage8-10).
8-9
OilJet (B1642engine)
Inspection
1 . Removethe oil jet (seepage 8-3) and inspectit as
follows.
M a k es u r et h a t a 1 . 1m m ( 0 . 0 4i n ) d i a m e t e dr r i l l
will go throughthe nozztehole (j.2 mm (0.05in)
diameter).
Insertthe other end of the same 1.1mm (0.04in)
d r i l l i n t o r h e o i l i n t a k e( i . 2 m m ( 0 . 0 5i n ) d i a m e _
ter).
M a k e s u r e t h e c h e c kb a l l m o v e ss m o o t h l ya n d
hasa strokeof approximately4.0 mm (0.16in).
Checkthe oil jet operationwith an air nozzle.lt
shouldtake at least200 kPa (2.0kgf/cm,,28 psi)
to unseatthe checkball.
NOTE: Replacethe oil jet assemblyif the nozzle

rs damagedor bent.
1.2 mm (0.05inl
CHECKBALL
SPRING
1 6 N . m1 1 . 6k g f , m ,t 2 t b f . f i l
Mounting torque is critical.Be very precisewhen

installing.
Torque:16 N.m (1.6kgt.m,12 tbt.ft)
8-10
Oil Pump
Overhaul
NOTE:
. Use new O ringswhen reassembllng.
. Apply oil to O-ringsbeforeinstallation.
-
. Useliquidgasket,PartNo. 08718- 0001or 08718 0003
. The rotorsmust be installedto the samedirectionin order'
o After reassembly, checkthat the rolors move without binding'
B15A2engine:
6x1.0mm
7 N.m (0.7 kgf m, 5 lbf ft)
OUTERROTOR
page8-13
Inspection,
INNERROTOR
page8-13
O-RING
Replace.
OOWEL
PIN
6x1.0mm
1 1 N . m( 1 . 1kgf.m,
8 tbtfrl
8 x 1.25mm
PUMPHOUSING 24 N,m {2.i1kgl.m.
Inspection,page8-13 RELIEFVALVE 17 tbf.ft)
Applyliquidgasket Valve mlst slide freeiy
to the matingsurfaceof in housingbore.
the cylinderblock Replaceif scored. OIL SEAL
when installing. Replace.
p a g e8 - 1 4
lnstallation,
SEALINGBOLT SPRING
39 N.m l4Okgt'm,
29 tbt frl
\ (cont'd)
8-11
O il Pu mp
Overhaul(cont'dl
(
NOIE:
. U s en e w O r i n g sw h e n r e a s s e m b l i n g .
. Apply oil to O rings beforeinstalraUon.
. U s el i q u i dg a s k e tP, a r rN o .0 8 7 1 8- 0 0 0 1o r 0 8 7 1 8 _ 0 0 0 3 .
. The rotorsmust be installedto the samedirection.
. After reassembly, checkthat the rotorsmove without binding.
6x1.0mm
7 N.m (0.7kgI.m, 5 lbf ftl
PUMP HOUSING
I n s p e c t i o n ,p a g e 8 1 3
Apply liquid gasket
to mating surfaceof
INNERROTOR
the cylinder biock
Inspectron,
page8 13
when installing.
DOWELPIN
PUMPCOVEB
O-RING
_.feor,""
\
6x1.0mm OIL SEAL R E L I E FV A L V E
[".?li;:;"".
*,",,.rg
""rc
11 N.m {1.1kgf.m,8lbl.ft) Valve must slide freely
i n h o u s i n gb o r e .
R e p l a c ei f s c o r e d
@.-*or"."
9''ggttt*
8 -12
Removal/lnspection/lnstallation
1. D r a i nt h e e n g i n eo i l . 1 0 . R e m o v et h e s c r e w sf r o m t h e p u m p h o u s i n g t, h e n
separatethe housingand cover'
2 . Turn the crankshaftand align the white groove on 1 1 . Checkthe inner-to-outerrotor radial clearanceon
the crankshaftpulleywith the pointeron the lower the pump rotor.lf the inner-toouter rotor clearance
cover. 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.
3. Removethe cylinderheadcoverand uppercover'
lnner Rotor-to-OuterRotor RadialClearance
4. Removethe power steeringpump belt, air condi- Standard{New}:815A2engine0.04- 0.16mm
tioner beit and the alternatorbelt (0 002 - 0'006 in)
D16Y5,D16Y7,D16Y8engines
0.02- 0.14mm 10.001 - 0.006in)
5. Removethe crankshaftpulleyand removethe lower
cover. ServiceLimit: 0.20 mm (0 008 inl
ROTOR
OUTER
6. Removethe timing belt.
1. Removethe drive pulley.
8. Removethe oil pan and oil screen.
O.RING
OOWELPIN Replace
INNERROTOR
' t 2 . Checkthe housing-to-rotoraxial clearanceon the
pump rotor. lf the housing-torotor axial clearance
exceedsthe servicelimit, replacethe set of inner
and outer rotorsand/orthe pump housing
Housing-to-RotorAxial Clearance
Standard (N€w): 816A2 engine 0.02- 0.07 mm
(0.001- 0.003inl
OILSCREEN D16Y5,D16Y7,D16Y8engines
0.03- 0.08mm (0.001- 0.003inl
S€rviceLimit: 0.15mm 10.006 in)
9. Removethe oil PumP.
! ' a (cont'd)
8-13
Oil Pump
RemovaUlnspection/lnstallation
(cont'dl
13. Checkthe housing-to-outer rotor radialclearance. 17. Reassemblethe oil pump, applyingthread lock to
l f t h e h o u s i n g - t o - o u t erro t o r r a d i a l c l e a r a n c e the pump housingscrews.
exceedsthe service limit, replacethe set of inner
and outer rotorsand/orthe pump housing. 18. Checkthat the oil pump turnsfreely.
Housing-to-OuterRotor Badial Clearanco: 19. Apply a light coatof oilto the seallip.
Standard{Newl:816A2sngine0.10- 0.19mm
(0.004- 0.007in) 20. Installthe two dowel pins and new O-ringon the oil
D16y5,Di6y7, Dt6y8 engines pump.
0.10- 0.18mm {0.00it_ 0.007in)
ServiceLimit: 0.20 mm (0.008in) 21. Apply liquidgasketto the cylinderblockmatingsur_
faceof the oil pump.
NOTE:
. Use liquidgasket,PartNo.08718- oOOjor 08718
- 0003.
beforeapplyingliquidgaskel
. Apply liquidgasketevenly,in a narrowbeadcen-
teredon the matingsurface.
o To preventleakageof oil, apply liquid gasketto
the innerthreadsof the bolt holes.
. Do not installthe parts if five mtnuresor 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 removingthe
old residue.
. After assembly,wait at least30 minutesbefore
fillingthe enginewith oil.
\
1 4 . lnspectboth rotors and pump housingfor scoring 81642engine:

or otherdamage.Replacepartsif necessary.
1 5 . Removethe old oil sealfromthe oil pump.
1 6 . Usingthe specialtool, gentlytap in the new oil seal

untilthe driverbottomsagainstthe pump.
NOTE:The oil seal alone can be replacedwithout

removingthe oil pump.
alongthe brokenline.
DRIVERATT
52x55mm PUMP HOUSING
077a6- 0010ao0
8-14
22. Installtheoil pump on the cylinderblock. lnstallthe oil screen.
Apply greaseto the lip ot the oil pump seal.
Then.installthe oil pump onto the crankshaft. Installthe oil pan (seepages7-26or 7-27).
Whenthe pump is in place,cleanany excessgrease
off the crankshaftand checkthat the oil seal lip is NOTE:Cleanthe oil pan gasketmatingsurfaces.
not distorted.
81642engine:
8 x 1.25mm 6x1.Omm
24 N.m (2.i4kg[.m, 11 N.m {1.1 kg{.m,
17 tbl.trl 8 rbt ft)
O.RI G
Replace.
DOWELPINS
GASKET
Replace.
OIL SCREEN
6x1.0mm
rl N.m {1.1kgf'm,
I tbf.ftl
D16Y5, D16Y7. D16Y8 enginos:
6x1.0mm
1 1 N ' m( 1 . 1k g fm '
OOWELPIN
DOW€LPIN
GASKET
Replace.
O.RING
Replace.
6x1.0mm
'11N'm {1 1 kgf'm,
6 x 1.0 mm
11 N.m (1.1kgf.m, I lbf ftl
8 lbf.ft)
! o
8-15
lntakeManifold/ExhaustSystem
lntakeManifold
Replacement 9-2
....................................... L_s
ExhaustManifold
Rep|acement 9-6
....................................".
ExhaustPipeand Muffler
Replacement 9-9
...............................'.'."..
ThreeWay CatalyticConverter{TWCI
Inspection 9-12
.................."'.
HeatedOxygenSensor(HO2SI
Rep|acement 9-12
...........................'.."....."
r fo

IntakeManifold
Replacement
NOTE:Usenew O-ringsand gasketswhen reassemblinq.
CAUTION:
. Checktor folds or scratchoson the surfaceof tbe gasket.
. Replacewith a now gasket if damaged.
D16Y7engine:
8 x 1.25mm
22 N.m 12.2kgtm, 16 tbtftl
INTAKEMANIFOLD
Replaceif crackedor
if mating surfacesare
damaged.
8 x 1.25mm
23 N.m {2,3 kgt m.
17 rbf.ftl
INTAKEMANIFOLD
BRACKET
8 x 1.25mm
24 N.m {2.4kgf.m, 17 tbf.ftl
9-2
D16Y5engine:
6x1.0mm
12 N'm (1.2kgl.m,8.? lbf'ft)
EGRCHAMBER
INIAKE MANIFOLD
Replaceif crackedor 8 x 1.25mm
if mating surfacesare 21 N m (2.1kgf.m,
damageo, 15 tbtft)
EXHAUSTGAS
INTAKEAIB CONTROL RECIRCULATION
(IAC)VALVE(M/TI (EGRIVALVE
8 x'1,25mm
22 N.m (2.2kst m, 16lblftl
8 r 1.25mm
2a N.m (2.4kgt m,
17 rbt.ft) INTAKEMANIFOLD
BRACKET 8 x 1,25mm
22 N.n 12.2kol'm,
16tbftr)
8 x 1.25mm
23 N.m 12.3kgf'm,
17 tbt fr)
I (cont'd)
9-3
lntake Manifold
Replacement(cont'dl
NOTE:Usenew O,ringsand gasketswhen reassembling.
CAUTION:
. Checklor folds or scratcheson the surfaceof the gasket.
. Replacewith a new gasket il damaged.
D16Y8engine:
INTAKEMANIFOLD
Replaceif crackedor
if matingsurfacesare
oamageo,
INTAKEAIR CONTROL
{ract vAt_vE {M/Tl
GASKET
Replace.
THROTTLE
BODY
8 x 1.25mm
24 N.m {2.{ kgtm. 8 x 1.25mm
17 tbtftt INTAKEMANIFOLD 22 N.rn |.2.2kgl.rn,
BRACKET 16 tbtft)
9-4
816A2engine:
INTAKEMANIFOLD
Replaceif crackedor
if matingsurfacesare
oamageo,
t_-l
n ""\--
UH
8 x 1.25mm
22 N.rA 12.2kgl.trr,
E
16 tbtftt
VlCd>-^
M\G
INTAKEAIR CONTROL
IIACIVALVE
MANIFOLD Al N-m 12.2kgt.m,
BRACKET 8 x 1.25mm 16 tbt.ftl
8 x 1.25mm
23 N.m {2.3 kg{.m,
24 N.m 12.4kgf.m,
17 tbt.ftl
17 tbtftl
yo
9-5
ExhaustManifold
Replacement
NOTE:Use new gasketsand self-locking
nutswhen reassembling.
CAUTION:
. Checkfor folds or scratch€son the surfaceof the gasket.
. Replacewith a new gasket it damaged.
D16Y5.D16Y7engines:
PRIMARYHEATED
OXYGENSENSOR
IPRIMAFYHO2SI
I x 1.25mm 44 N.m {4.5kgf m, 33 lbtft)
24 N.m {2.4kgt.m, 17 tbtft} Replacement, page9-12
GASKET
Replace.
I x 1.25mm
31 N.m (3.2kgf.m,
23 tbf.ft)
Beplace.
WAY CATALYTIC
CONVERTER {TWCI
page9'12
lnspection,
MANIFOLD SECONDARYHEATED
BRACKET OXYGENSENSOR
6x1.0mm (SECONDARY HO2S}
11 N.m {1.1kgt m,8 lbf.ft) 44 N.m 14.5kgf.m,33 lbf.ft)
9- 6
D15Y8engine:
8 x 1.25mm
2,1N.m (2.akgf'm, GASKET
17 tbf.ftl Replace.
8 x 1.25mm
31 N.m 13.2kgf'm,
23 lbf.ftl
Replace.
PRIMARYHO2S
44 N.m (4.5kgf.m,33 lbtft)
EXHAUSTMANIFOLD
BRACKET
10 x 1.25rnm
/r4 N.m {4.5kgf.m,33 lbf.ft)
v (cont'd)
9-7
ExhaustManifold
(cont'dl
Replacement
NOTE:Usenew gasketsand self-lockingnutswhen reassembljng.
CAUTION:
. Checkfor folds or scratcheson the surfaceot the gask€t.
. R€placewith a new gaskot if damagod,
B16A2engine:
GASKET
Replace.
10 x 1.25mm
44 N.m {4.4kgt.m,
SELF.LOCKING NUT 33 tbl.ft)
8 x 1.25 mm
31 N.m (3.2 kg{.m,23 lbf.ft) EXHAUSTMANIFOLD
Replace- BRACKET
10x 1.25mm
4{ N.m (4.5 kgf.m.33 tbt.fil
9-8
Exhaust Pipe and Muffler
Replacement
nutswhen reassembling
D16Y5,D16Y7engines:
PIPE
EXHAUST TIP
MUFFLER
/
O
6x1.0mm
9.8 N.m 11.0kgt m, 7.2 lbf'ftl
HEATSHIELO
oP---------------- 8 x 1.25mm
22 N.m 12.2kg .m,
16 tbf.f
Replace.
Tighlenthe boltsin
steps,alternating
6x1.0mm sideto-side.
9.8 N.m tl.0 kgf'm,7.2lbf'ft)
EXHAUSTPIPEB
8 x 1.25mm
22 N.m 12.2kgl'm, 16lbl'ttl
Replace.
Tighten the bolts in steps,
alternatingside-to-side
----------"+@
neOlace. GASKET
Replace.
SELF-LOCKING NUT
8 x 1.25mm
SELF.LOCKING NUT
16 N.m 11.6kgt m, 12 lbt'ftl
10 x 1.25mm Replace.
33 N.m (3.4ksd.m,
25 lbf.frl
Replace.
\ (cont'd)
9-9
ExhaustPipe and Muffler
Replacement{cont'dl
nuts when reassembling.
D16Y8engine:
MUFFLER
d'*'ou"'"'""'
6x1.0mm
9.8N.m (1.0ksf m,7.2lbf ft)
8 x 1.25mm
22 N.rn 12.2kgl.m,
16 tbt.ft)
Replace.
Tightenthe boltsin
steps,alternatrng
side-to-side.
HEATSHIELD
6x1.0mm
9.8 N.m (1.0kgl m, 7.2 lbf.ft)
SELF.LOCKING NUT
10 x 1.25mm
EXHAUSTPIPE 33 N.m {3.4kgf.m,
25 tbtftl
Replace.
SECONDARY HO25
44 N.m {4.5kgl.m, 33 lbtftl
TWC
page9-12
inspection,
GASKETS
Replace.
I x 1 - 2 5m m
EXHAUSTPIPEA 22 N m (2.2 kgf.m. 16 lbfft)
Tighten the bolts in steps,

a l t e r n a t i n gs i d e ' t o s a d e .
e) GASKET
SELF-LOCKING NUT Heplace.
1 0x 1 . 2 5m m
54 N.m {5.5kgl.m, 40 lbtft} 1 6 N . m { 1 . 6k g l . m , 1 2 l b f . f t }
Replace. Replace-
9-10
816A2 engino:
_.,. EXHAUSTPIPE
MUFFLER tlP
-/-
GASKET
g
Replace.
\6r1.omm
9.8N m 11.0kgf'm,7.2lbl'ttl
8 x 1.25mm
2. N'm 12.2kgl-m,
t6 tbtf0
Replace.
Tighten the bolts in
steps,alternatrng
6x1,0mm side-to-side.
9,8 N.m 11.0
7.2lbl4rl
SELF-LOCKING NUT
l0 x 1.25mm
3:t N.m {3.4 kgf m,24lbf'ftl
PRIMARYIIEATED ReDlace.
OXYGENSENSOR
{PRIMARYHO2S)
ll N.m (4.5kgl.m,
33 tbt f0 SECONDARY HEATED
Replacement, OXYGENSENSOR
{SECONDARY HO2SI
lrt N.m 14.5kgf.m,
33 rbl.ft)
GASKET
R€place.
twc
GASKEIS page9-12
Inspection,
Replace.
8x1.25mm
22 N.m {2.2 kgt m, 16 lbf.ftl
Replsce.
NUT
SELF.L(rcKNG Tight6n the bolts in st6ps,
10x 1.25mm 8 x 1.25mm alternatingside-to-side.
Replaca.
5,r N.m 15.5kgf.m, ,|{} lbf.ft) 16 N.m 11.6kgt.m,
ReDlace. 12 rbf.ft)
F€pl8ce.
9-11
TWC HO2S
l. Usinga flashlight,makea visualcheckfor plugging, PrimaryHO2S:
meltingand crackingof the catalyst.
1. Removethe primaryHO2S.
D16Y5,D16Y7engines:
D16Y5,D15Y7engines:
a. D i s c o n n e ct ht e p r i m a r yH O 2 Sc o n n e c t o rt ,h e n
removethe cover.
a 8 x ' 1 . 2m
5m
24 N.m{2.4kgl.m,
A
PRIMARYH02S
CONNECTOR
816A2,D16Y8engines:
FLASHLIGI{T
b. Removethe primaryHO2S.
-\
6{
-)\
lT | \l,l(
I bK/l
l llw. (
/\\
PBIMARYHO2S
44 N m (4.5kgf.m,33 tbI.ft)
9 - 12
Bt6A2, Dl6Y8 engines: Secondsry H02S:
a. Disconnectthe primary HO2Sconnectorthen 1. Removethe secondaryHO2S

removethe primaryHO2S.
Dl6Y5, Dt6Y7 engines:
816A2engine
a. D i s c o n n e c t h e s e c o n d a r yH O 2 Sc o n n e c t o r .
then remove the secondaryHO2S'
02 SENSOR
PRIMARY
H02S CONNECTOR
D16Y8engine
816A2, Dt6Y8 ongin6s:
a. Removethe grommet,and pull out the secondary

HO2Sconnector,then disconnectthe secondary
HO25connector'
H()2S
SECONOARY
CONNECTOR
PRIMARYHO2S
44 N.m {4.5kgt'm.33 lbf'ft)
2. Installthe primary HO2Sin reverseorder of removal'

L {cont'd)
9-13
HO2S
(cont'd)
Replacement
b, Removethe secondarvHO2S.
w a
02 SENSORWRENCH
SECONOARY HO2S
4,r N.m (4.5kgf.m, 33 tbf.ft)
I n s t a l lt h e s e c o n d a r yH O 2 S i n r e v e r s eo r d e r o f
removat.
9 - 14
Cooling
fllustratedIndex."..."... ""' 10-2

Radiator
Replacement .'....'...."..." 10-6
EngineCoolantRefillingand
Bleeding 10-7
CapTesting 10-9
Testing 10-9
Thermostat
Replacement .............'.... 10-10
Testing 10-10
EngineGoolantTemPerature
(ECT)Switch
Testing """ 10-11
WaterPumP
Index ......'...
fffustrated " 10-12
Inspection ' 10'14
Replacement 10-14
..'..'...."...'.'....'..'.....'."""

lllustrated Index
@@ system is under high pressure when the CAUTION:lf any engine coolant spills on painted por-
engine is hot. To avoid dangsr of rsleasing scalding tions of the body, rinse it off immediately.
engine coolant, removo the cap only when the engine is
coot. NOTE:
. Checkall cooling systemhosesfor damage,leaksor
Total Cooling System Capacityflncluding heater and deterioration
and replaceif necessary.
foservoir (0.4f (0.42US qt, 0.35 tmp qt)ll: . Checkall hoseclampsand retightenif necessary.
. Usenew O-ringswhen reassembling.
Mt-|- 4 . 2 f ( 4 . 4U S q t , 3 . 7 t m p q t ) * j
5.0 / (5.3 U$ q1, 4.4 16p q11*z
4 . 1f ( 4 . 3U S q t , 3 . 6l m p q 0 * 3
4.31 (4.5US qt, 3.8 tmp qt)*a
CVT 4 . 3f ( 4 . 5U S q t , 3 . 8I m p q t )
*1i D16Y5,D16Y7,D16Y8engines
*2: 81642engine RADIATORCAP
*3: D16Y7engine test,page'108
Pressure
6x1.0mm
* 4 : D 1 6 Y 8e n g i n e 9.8 N.m {1.0kgtm,
RAOIATOR 7.2 tbt.ltl
Enginecoolantrefillingand bleeding,
p a g e1 07
UPPERBRACKET
Leaktest,page10-9
AND CUSHION
UPPER Inspectsolderedjointsand
RADIATOR seamsfor leaks,
HOSE Blow out dirt Irom between
core fins with compressed air. COOLANT
l f i n s e c t s ,e t c , , a r e c l o g g i n g RESERVOIR
r a d i a t o r ,w a s h t h e m o f f w i t h
5x0.8mm r o w p r e s s u r ew a t e r .
A: ,1.4N.m {0.45kgf.m, 3.3 tbtftl
g: 5.4N.m (0.55kgtm.4.0 tbf.ft)
iil
6x1.0mm
7.2 N.m (0.73kgt.m,
5.3 tbtftl
LOWER
LOWEB CUSHION
O-RING RADIATOR
DRAIN Replace. HOSE
BADIATOR PLUG
RADIATORFAN FAN
FAN MOTOR SHROUD Referto section14
when installing.
Ar TOYORADIATOR
manufacturedradiator
B: NIPPONDENSO
manufacfared
raoraror
10-2
Engine HoseConnections:
D15Y7engine:
IAC VALVE
WATEFBYPASS
THERMOSTAT
HOUSING
lv
CONNECTING
PIPE
HEATER VALVE
HOSES
{cont'd)
10-3
lllustrated Index
(cont'd)
EngineHoseConnections:
D16Y5,D16Y8engines:
IACVALVE
{A/T)
Replace.
WATERBYPASS
HOSE
IAC VALVE
(M/TI
THERMOSTAT
HOUSING
O.RING
Replace.
\
\
\
\
h
CONNECTING
PIPE
HEATER
VALVE
HEATER
HOS€S
1 0- 4
Engine Hose Conneqtions:
81642engine:
THERMOSTAT
HOUSING
CONNECTING
PIPE
O-RING
Replace.
WATERBYPASS
HOSE
ENGINEOILCOOLER
HEATER
VALVE
HEATER
HOSES
10-5
Radiator
Replacement
1 . Drainthe enginecoolant. 5. Removethe fan shroud assembliesand other parts
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. Installthe radiatorin the reverseorderof removal:
3. Disconnectthe fan motor connector. NOTE:

. Setthe upperand lower cushionssecurely.
Removethe radiatorupper bracket,then pull up the . F i l l t h e r a d i a t o rw i t h e n g i n ec o o l a n ta n d b l e e d
raotator, the air.
6x1.0mm
RADIA CAP Y|lT,PS:|"
AND CUSHION
i.i ru-ii brgr.-,
7.2tbr.ftl
ATF COOLER
HOSES(A/T)
Referto section1 4
when installing.
UPPERRAOIATORHOSE
6x1.0mm
7.2 N.m (0.73kgf.m.
,iiiiii
5.3 tbf.ft)
RESEBVOIR
TANK
I
RADIATOR
RAOIATORFAN/SHROUD
ASSEMBLY LOWERCUSHION
DRAINPLUG
O-RING
Replace.
LOWER RAOIATOR HOSE
ATFCOOLER
PIPES{A/T)
10-6
EngineCoolantRefillingand Bleeding
B1642 engin€:
CAUTION:when pouring engine coolant, be sure to
shut the relay box lid and not to lst coolant spill on the
eleqtricalparts or the paint. lf any coolant spills, rinse it WASHER
off immediately. Replace.
1. Slide the heatertemperaturecontrol leverto maxl-

mum heat. Make sure the engine and radiatorare
cool to the touch.
Removethe radiatorcaP.
Loosenthe drain plug,and drainthe coolant'
DRAINPLUG
DRAINBOLT
78N m (80 kgfm' 58lbfft)
Apply liquid gasketto the drain bolt threads,then

reinstallthe bolt with a new washer and tighten 't
securely.
6. Tightenthe radiatordrain plug securely

tl
1. Remove,drain and reinstallthe reservoir'Fill the
tank halfwayto the MAX mark with water, then up
to the MAX mark with antitreeze.
Removethe drain bolt from the cylinderblock'
D16Y5.D16Y7,Dl6Yg sngines:
0d
78 N.m {8.0kgl m.58lbt'ft) MAX MARK
I ro (cont'd)
10-7
Radiator
EngineCoolantRefiltingand Bleeding(cont,dl
8. 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 o u a l 9. Pourcoolantinto the radiatorup to the baseof the
\.- I
amountof water in a cleancontainer. filler neck.and installthe radiatorcap looselv.
NOTE:
o Useonly genuineHondaantifreeze/coolant.
. For best corrosion protection.the coolant con_
c e n t r a t i o nm u s t b e m a i n t a i n e dy e a r _ r o u n da t
50% minimum.Coolantconcentrations lessthan
50% may not provide sufficient protection
againstcorrosionor freezing.
. C o o l a n tc o n c e n t r a t i o n gs r e a t e rt h a n 6 0 0 1w0i l l
i m p a i r c o o l i n g e f f i c i e n c ya n d a r e n o t r e c o m _
mended.
CAUTION:
. Do not mix difforont brands ofar ilreeze/coolants.
. Do not use additional rust inhibiiors or anti_rust
produqt3; they may not be compatible with the
coolant.
Engine Coolent Refi Capacity Iincluding reservoir

{0.4f 10.42US qr, 0.35 lmp qt),I;
M/r 3.8f {4.0US qt, 3.3 lmp qt)*1 1 0 . Startthe engineand let it run until it warms up (the
4.5/ (4.8US qt. 4.0 tmp qt)*, radiatorfan comeson at leasttwicer.
Att 3 . 7 , ( 3 . 9U S q r , 3 . 3t m p q t ) . 3
3 . 9/ ( 4 . 1U S q t , 3 . 4 l m pq t ) * . 1 1 .Turn off the engine.Checkthe level in the radiator.
CW 3 . 9/ ( 4 . 1U S q t , 3 . 4t m pq t l add coolantif needed.
*1: D16Y5,D16Y/,O16Y8
engines Put the radiatorcap on tightly,then run the engine
*2: 81642engine
againand checkfor leaks.
*3; Dl6Y7 engine
*4: Dl6Y8 engine
10-8
CapTesting Testing
1. Removethe radiatorcap, wet its seal with engine L Wait until the engineis cool, then carefullyremove
coolant,then installit on the pressuretester' t h e r a d i a t o rc a p a n d f i l l t h e r a d i a t o rw i t h e n g i n e
coolantto the top of the tiller neck
PR€SSURE
RADIATOR TESTER Attachthe pressuretesterto the radiatorand apply
'123kPa(0.95- 1.25kgflcm' ,14 -
(CommerciallY
available) a pressureof 93 -
1 8p s i l .
RAOIATOR
ADAPTOR
(for 32 mm neck,low Profile)
PRESSURE
RADIATOR
TESTER
available)
lCommerciallY
ADAPTOR
(for32mm neck'lowPro{ile)
- 'l 25 kgflcm''
Apply a pressureof 93 - 123kPa (0.95
-
1 4 1 8p s i ) .
Checkfor a drop in Pressure.
lf the pressuredrops,replacethe cap
Inspectfor enginecoolantleaksand a drop In pres-

sure.
Removethe testerand reinstallthe radiatorcap
NOTE: Checkfor engine oil in the coolant and/or

coolantin the engineoil.
t 10-9
Thermostat
Replacement
NOTE:Usea new O-ringwhen reassemblinq.
THERMOSTAT
Install
withpinup.
THERMOSTAT
THERMOSTAT
HOUSING
ENGINECOOLANT
TEMPERATURE
{ECT)
swtTcH
24 N.m {2.4kgf.m, t7 tbf.ft) 6x1.0mm
12 N.m {1.2kgf.m,8.7tbf.frl
10-10
EGTSwitch
Testing Testing
Romovingthe EcT swhch while lhs engine
Replacethe thermostatif it is openat room temperature' !!@
i!-ot can causethe coolant to sPrayout, seriouslyscald-
To test a closedthermostat: ing you. Always lst th€ ongine and rediator cool down
before removing ihe ECTswitch.
1, Suspendthe thermostatin a containerof water as
shown. NOTE:Bleedair from the coolingsystemafter installing
the ECTswitch (see Page10-7)
1. Removethe ECTswitchfrom the thermostathous-

THEBMOMETER ing (seePage'10-10).
2. Suspendthe ECTswitch in a containerof water as

shown.
THERMOSTAT
-f Heat the water, and checkthe temperaturewith a

thermometer.Checkthe temperatureat which the
thermostatfirst opens,and at which it is fully open
Heat the water, and checkthe temperaturewith a
CAUTION: Do not let the thermometer touch the
thermometer.
bottom of the hot Gonlainel.
CAUTION: Do not let the thermomoter touch tho
Measure lift height of the thermostat when fully
bottom of the hot container'
open.
4. Measurethe resistancebetweenthe A and B termi-
STANDARDTHERMOSTAT
above 8.0 mm (0.31inl nalsaccordingto the table.
Lift height
Starts opsning: 169' - 176'F (76' - 80'Cl Terminal
Fully open: 194'F {90"C1
Oo"rffi
196' - 203"F o- -o
ON (91"- 95'C)
swlTcH 5" - 15'F{3" - 8'C)
OFF lower than the temPera-
ture when t goeson
! ' o
1 0 - 11
Water Pump
lllustratedIndex
NOTE:
. Use new O-ringswhen reassembrrng.
. Use liquidgasket,PartNo. 08718- 0OOlor 087t8 _ 0003.
O16Y5,D16Y7,D16Y8engines:
ECTGAUGE
SENDINGUNIT 6 x 1 . 0m m
9 N.m {0.9 kgI.m, 9.8N.m {1.0kgf.m,
7 tbnftl 7.2 tbt.ft'|
Apply liquidgasket
to the threads.
ENGINECOOLANT
TEMPERATURE(ECT)
O.RING
SENSOR
Replace.
1E N.m (1,8 kgf.m, WATEROUTLET
13 rbttt) COVER
Apply liquidgasket
to matingsurface.
ECTSW1TCH
24 N.m 12.4kgf.m,
17 rbf.ftl
6xl.0mm
12 N.m {1.2kgf.m,
8.7 tbf.ft)
6x1.0mm
'12N.m
{1.2 kgt m,
8.7 lbt fr)
10 x 1.25mm
itl N.m 14.5kgt m,
33 rbf.ftl
O.RING
Replace.
1 0- 1 2
815A2 engine:
WATEROUTLET
COVER
Apply liquidgasket
to matingsurface.
6x1.0mm
9.8 N.m {1.0 kgl'm,
7,2 tbl.ftt
ECTGAUGE
SENDINGUNIT
9 N.m (0,9 kgf.m,
7 rbf.ft)
Apply liquidgasket
to the threads.
r
ENGINE
COOLANT
SENSOR
(ECT)
TEMPERATURE
18 N.m {1.8 kgf.m,

13 tbtftl
6x1.0mm
12 N.m (1,2kgdm,
8.7 tbf.ftl
16@
aY@
t"
S X 1.0 Mrf WATENPUMP
pase10'1'r
\lo iiil:i'iij rnr.., Inspection,

8.7 tbf.ftl
10-13
Water Pump
't. Remove
the timing belt (seesection6). 1. Removethe timing belt (seesection6).
2. T u r n t h e w a t e r p u m p p u l l e yc o u n t e r c l o c k w i s e . Removethe water pump by removingfive bolts.

Checkthat it tarnsfreely.
NOTE:Inspect,repairand cleanthe O-ringgroove
Checkfor signsof sealleakage. and matingsurfacewith the cylinderblock.
NOTE:A smallamountof "weeping,,fromthe bleed D16Y5,D16Y7,D16Y8engines:

h o l ei s n o r m a l .
Dl6Y5, Dl6Y7,D16Y8engines:
BLEED
HOLE
6x1.0mm
12N.m{1.2kgf.m, l0 x 1.25mm
8.7lbt.ft) {4 N.m14.5kg{.m.
33 tbt.ft)
Bl642 engine:
WATER
PUMP
BLEEDHOLE
B16A2engine:
BLEEDHOLE
d
orp,
I @;2
O.RING
6x1.0mm Replace.
12 N.m 11.2kg{.m,
8.7 tbf.ft)
3. Installthewaterpumpin the reverse

orderof removal.
NOTE:
o KeeptheO-ringin position
wheninstalling.
BLEEDHOLE . Clean the spilled engine coolant.
10-14
Fuel and Emrsslons
SoecialToofs .....,...."..,.11-2 ldle Control System

Component Locations SystemDoscriplion ............ 11-190
l n d e x. . . . . . . . . . . . . . . . . . . . . , . . . . . . .1. .1 - 3 Troubleshooting Flowcharts
Svstem Description ldle ControlSystem ......11-192
VacuumConnections ................,,..,.. ......... 11-12 ldle Air Control Va1ve .................................... I 1-19i1
ElectricalConnections...............,.,.,... .......11-29 StarterSwitch Signal .................................... 11'202
S y s t e mC o n n e c t o r .s. . . . . . . , . , . , . . . . . . . . . . . . . .1.1. .-.5. .1. . . . . . Air ConditioningSignal ................................. 11'201
Troubleshooting Ahernator FR Signal .................................... . 11-208
T r o u b l e s h o o t i nPgr o c e d u r e s . . . . . . . . . . . . . . . . .1 1 - 8 1 B r a k e S w i t c S
h i g n a l. . . . . . . . . . . . . . . . . . . . . . . . . . f. .1.". 2
. .1. .0. . .
EngineControlModule/Powertrain Power Sleering ProssureSwitch Signal ......11-212
ControlModuleTerminal A/T GearPositionSignal............................... 11-216
Afiangement ....,.,..... 11-88 ClutchSwiich Signal ................................-.... 11-214
DiagnosticTroubleCodeChart .................,., 11.97 ldteSpeedSetting. .............11-220
How to ReadFlowcharts.,.......................... . 11-103
Fuel Supply System
PGM-FlSystem FuelLines .,...................,.,.,.,11-221
! SystemDescription ......11-10,1 FuefTube/Ouick-Connect Fittings..........,.,........ 11-227
TroubleshootingFlowcharts SystemDescription ....'.... 11-230
EngineControlModule/Powertrain FuelPressure .......,.,,........... 11-230
Contlol Module ........11-107
Fueffniectors ......................11-232
ManitoldAbsolutePressureSensor.....'.. ... 11-115 Fu€fPressureRegulator.....,.......................'...,. 11-231
fntakeAir TemperatuieSensor ...... . ., . 11'121
FuefFifter ............................11-235
EngineCoolantTemperatuae Sensol.........,11-128 . . . . . . . . . . . . . ' . . . . .1. .1' .-.2. .3 6
F u e lP u m p
ThrottlePositionSensor ...................,........... 11-132
PGM-FI Main Relay .............11'237
PrimaryHeatedOrygen Sensor(Sensor1l ... 11-139 ....,...'.'.' 11'211
FuelTank ................
SecondaryHeatedOxygen Sensor
( S e n s o2r 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1. .1. -. 1 5 3
..............
HeatedOxygenSensorHeater ...................,. 11-157 IntakeAir System
......11-164 SystemDescription ....-.-.....11-243
FuelSupplySystem
. . . . . . ..,. 1 1 - 1 6 6 Air Cfeaner ...........,......."". .11-211
R a n d o mM i s l i r e
Throttle Cable .....................11-211
MisfireDetectedin One Cylindsr ................. 11-167
. , . , . . . . . . . .1. 1. .-. 1 7 0 ThrottfeBody ........ ..'.... . .,.11-211
K n o c kS e n s o r
11'172 Fuel IniestionAir ControlSystem ,.,.,....-........... 11-250
CKP/TDC/CYP Sensor...................................
VehicleSpeedSensor...........,......,...,.,........... 1t-176
BarometricPressureSensor ...............,......... I 1-178 Emission Control System
System Description .-..........11-252
E l e c t r i c aLlo a dD e t e c t o r , . , , . . . . . . . . . . . . . . . . .1. .1. -. .1.7. .9. . .
. . . . . . . . . . . . . . 1. .1. .
- .
1 . 8 3 Taifpip€ Emission ...............11-252
C K FS e n s o r
I 1-188 ThreeWay CatafyticConvert€r............,.,,.,.,.,.... 11-252
ECM/PCMInternalCircuit .............................
I 1-189 Exhaust Gas Racirculaiion System ...,.,,,,.,.,.,.,,. 11'254
A/T Signal{TMA/TMBI..................................
PositiveCrankcas€Ventilation System .... . . .. 11-266
EvaoorativeEmissionControls..................,,..,.,. 11-267

SpecialTools
SpecialTools
\- a
R€f. No. I Tool Number Dsscription Oty I Pagr Reference
O A973X_041_ XXXXX 0 - 30 in.H9
VacuumPump/Gauge, I 11-251,256, 257,
273,274, 283,284,
286, 288,289, 291,
294,296,297
@ 07JAZ- 0010008 Vacuum/PressureGauge,0 - 4 in.Hg I 11-294,295
/n 07PAZ - 0010100 SCSServiceConnector 1 11-81
@ 07sAz- 001000A BackprobeSet 2 11-83
@ 07406- 0040001 FuelPressureGauge 1 1't-230,231,234
@ 07406- 0040304 FuelPressureAdapter,6x 15 mm I 11-230
ta
1n
\Y
11-2
GomponentLocations
lndex
D16Y5engine:
THROTTLEPOSITIONITP) MANIFOLDABSOLUTE
SENSOR PRESSURE IMAPI SENSOR
page11-132
Troubleshooting, page1'l-115
Troubleshooting,
EXHAUSTGAS RECIRCULATION IDLEAIRCONTROL(IAC)VALVE

IEGRIVALVEand EXHAUSTGAS {M/T)
RECIRCULATION IEGRIVALVE page11-194
Troubleshooting,
LIFTSENSOR
page'l1-254
Troubleshooting, EXHAUSTGAS RECIRCULATION
{EGRICONTROLSOLENOID
VALVE ICW)
INTAKEAIR TEMPERATUR€ page11-254
Troubleshooting.
{IATISENSOR
Troubleshooting, EVAPORATIVE EMISSION
IEVAPIPUNGECONTROL
ELECTRICALLOAD SOLENOIDVALVE
DETECTOR IELD)(USA mod6l) Troubfeshooting,Page11'211, 243
page11 179
Troubleshooting,
POWERSTEERINGPRESSURE
CRANKSHAFT (PSP)SWITCH(USAI
POS|TTON/ Page11-212
Troubleshooting,
TOPDEADCENTER/
CYLINDER KNoCK SENSoR(Ks)
POS|T|ON (cwl
ICKP/TDC/CYP} SENSOR Page11'170
Troubleshooting,
(Builtintothe distributor)
T r o u b l e s h o o t i n g ,P a g e 11 ' 1 7 2
FLUCTUATION (CKF}SENSOR
VEHICLESPEEDSENSOR Page11-183
Troubleshooting,
Page11-176
Troubleshooting,
ENGINECOOLANT IDT.E CONTROLIIACIVALVE

TEMPERATURE {cw)
IECT)SENSOR Page11 198
Troubleshooting,
Page11 128
Troubleshooting,
WAY CATALYTIC
CONVERTER
ITWCI
Troubleshooting,Page 11-252
PRIMARYTIEATED
SENSOR{PNIMARY HO2SI
tsENsoR1t {M/Tl
Page'l1-146
Troubleshooting,
PRIMARYHEATEDOXYGEN
SENSOR(PRIMARYHO2SI
1l{cw}
tsENsoR SECONDARY HEATEDOXYGEN
Page11-139
Troubleshooting, SENSOR{SECONDARY HO2S)
{SENSOR2)
page11 153
Troubleshooting,
L (cont'd)
11 - 3
Component Locations
Index(cont'd)
THROTTLEPOSITION{TPI
D16Y8enginc: SENSOR
page11-132 MANIFOLOABSOLUTE
Troubleshooting,
INTAKEAIR TEMPERATURE PRESSURE{MAPI SENSOR
page11-115
Troubleshooting,
IIATISENSOR
Troubleshooting,
page11,124 IDI.EAIR CONTROLIIACIVALVE
lMtfl
ELECTRICAL LOAD Troubleshooting,
page11-194
DETECTOR IELDI{USAI
Troubleshooting, page11-179 EVAPORATIVE EMISSION
IEVAPIPURGECONTROL
SOLENOIOVALVE
CRANKSHAFT Troubleshooting,page 11 271. 283
POSTTTON/
TOPDEADCENTER/ POWERSTEERINGPRESSURE
CYLINDER (PSPISWTTCH|USA)
POStTtON Troubleshooting,page11-212
{CKP/TI'C/CYPISENSOR
(Builtinto the distributor)
KNOCKSENSORIKSI
Troubleshooting. page11-172 page11 170
Troubleshooting,
CRANKSHAFT SPEED
FLUCTUANONICKFISENSOR
Troubleshooting,
page11,183
IDI.E CONTROL{IACIVALVE
{A/T)
ENGINECOOLANT Troubleshooting,page11 198
TEMPERATURE PRIMARYHEATEDOXYGENSENSOR
{ECTISENSOR {PRIMARYHO2S}(SENSOR1l {'96 - 98 modolsl
page11128 Troubleshooting,
Troubleshooting, page11-139
'96 - 98 modols: '9!t -

00 modols:
THREEWAYCATALYNC THREEWAYCATALYNC
CONVERTERITWCI CONVERTER ITWCI
page11-252
Troubl6shooting, page11-252
Troubleshooting.
SECONDARY HEATEDOXYGEN SECONDARY HEATEDOXYGEN PRIMARYHEATEOOXYGENSENSOR

SENSOn SENSOB IPRIMARYHO2SIISENSOR1I
(SECONDARY HO2SI(SENSOR2I ISECONDARY HO2S}ISENSOR2I page11-141
Troubleshooting,
page11-153
Troubloshooting,
11-4
D16Y7engine:
THROTTLEPOSITIONITPI MANIFOLDABSOLUTE
SENSOR PRESSURE (MAPI SENSOR
Page11-115
Troubleshooting, r1-132 Troubleshooting,
SENSOR
SPEED (VSSI INTAKEAIRTEMPERATURE
VEHICLE
Troubleshooting, 11-176 IIATISENSOR
Page page11124
Troubleshooting,
LOAO
ELECTRICAL
DETECTOR(ELD)IUSA} POWERSTEERll\lG PRESSURE
Page11'179
Troubleshooting, {PSP'SWTTCH{USA)
Page11 212
Troubleshooting,
CRANKSHAFT
POSTTTON/
TOPDEADCENTER/
CYLINDER IDLEAIR CONTROL(IAC)VALVE
POSITION page11-198
Troubleshooting,
{CKP/TDC/CYPI SENSOR
(Builtintothe distributorl l
't
Troubleshooting, Page 1-172
/i
CRANKSHAFTSPEED
FLUCTUATIONICKFISENSOR
Page11-183
Troubleshooting,
PRIMARYHEATEDOXYGEN
ENGINECOOLANT
SENSOR(PRIMARVHO2S)
TEMPERATURE
(ECTISENSOR {SENSOR1l
page11'139
Troubleshooting,
page11 128
Troubleshooting,
EVAPOBATIVE EMISSION THNEEWAY CATALYTIC
(EVAPIPURGECONTROL SECONDARY HEATEDOXYGEN CONVERTERITWCI
SOLENOIDVALVE SENSOR(SECONDARY HO2S) page11-252
Troubleshooting,
Troubfeshooting,page11 271, 283 (SENSOR2l
Page11-153
Troubleshooting,
(cont'd)
, l . l -r,
tr
| |

Component Locations
Index(cont'dl MANIFOLOAESOLUTE
PRESSURE IMAPI SENSOR
INTAKEAIR TEMPERATURE page11-119
Troubleshooting. IOLEAIR CONTROL{IAC)VALVE
Bl6A2 engine: {IAT}SENSOR page11,196
Troubleshooting,
Troubleshooting,
page1'1-125
THROTTLEPOSITIONITPI
ELECTRICAL LOAD
SENSOR
DETECTOR IELDI(USA) page11-134
Troubleshooting,
POWERSTEERINGPRESSURE
CRANKSHAfi {PSPISWTTCH (USA)
POStTtON/ page11-214
Troubleshooting,
TOP DEADCENTER/
CYLINDER
POStTtON
{CKP/TDC/CYPI SENSOR
(Bualtintothe distributor)
Troubleshooting,
page11-174
VEHICLESPEEDSENSOR{VSS}
Troubleshooting,
page11-177 CRANKSHAFT SPEED
ENGINE FLUCTUATION (CKFISENSOR
TEMPERATURE Troubleshooting,
page11-t85
IECTISENSOR
Troubleshooting,
pageI 1-128
THREEWAY CATALYTIC
CONVERTER ITWC)
Troubleshooting,
page11,252
S€CONOARY HEATEDOXYGEN
sf rlsoR PRIMARYHEATEDOXYGENSENSOR
sfCoNDARY HO2SI{SENSOR2) IPRIMARYHO2S)ISENSOR1I
: ? s h o o t r n pg a, g e1 1 1 5 5 Troubleshooting,
page11-141
1 1- 6
CLUTCHSWITCHlDl6Y5 ongino
M,/TI
page11-218
Troubleshooting,
Sell-diagnosticProcedures.
p a g e1 18 1
'96 - 98 modsls: '9!, - 0o modol3:

PGM.FIMAIN RELAY
RslayTesting,page11-237
page11-238
Troubleshooting,
PGM.FIMAIN RELAY
RelayTesting,pagel1 237
pago1'! 238
Troubleshooting,
ENGINECONTROLMODU1T
SERVICE CONNECTOR (ECM}/POWERTRAIN
l2Pl CONTROLMODULEIPCMI
Self-diagnosticProcedures, page11 111
Troubleshooting,
CHECKCONNECTOR ENGINCCONTROLMOOUI.T
SERVICE
page11-81
tzPl (FCMI/POWERTRATN
I Self-diagnostic Procedures,
page11-81
CONTROLMODULEIPCMI {cont'd)
page11-107
Troubleshooting,
11-7
ComponentLocations
Index (cont'dl
'96 D16Y8engine(coupel,
'97 D16Y7engine(coupe:KL model,
sedan:KL (LXl model),
'97 D16Y8engine(coupe:
all models,sedan:KL modell,'98-allmodels:
FUEI-VAPORPIPE FUELGAUGESENDINGUNIT FUELPUMP
FUEL FEEDPIPE Testing,seesection23 Testing,page11 236
FUELFILTER Replacement,page11 236
Replacement,
FUELFILL
€VAPOFATIVEEMISSION CAP
(EVAPICONTROLCANISTER
VENTSHUTVALVE
page l1'283
Troubleshooting,
EVAPORATIVE EMISSION
IEVAPICONTROLCANISTER
page11 283
Troubleshooting,
FUELTANK
pageI l-241
Replacement,
IEVAP)BYPASSSOLENOID
VALVE
page11-283
Troubleshooting,
FUELINJECTORS EVAPORATIVE EMISSION
page11-232
Replacement, (EVAPITWOWAYVALVE
page11294
Testing,
TANK PRESSURE
FUEL SENSOR
REGULATOR T r o u b l e s h o o t i n g ,p a g e 1 1 - 2 7 5
Testing,page 11-234 FUEL
R e p l a c e m e n t ,p a g e 1 1 - 2 3 4 FITTINGS
page11-227
Precautions,
page11 227
Disconnection,
page11-228
Connection,
'96 Dt6Y5engine,'96D16Y7engin€,'96
D16Y8engine(sedanl,
'97 D16Y5engine,'97 Dl6Y7 engins (coupe:
l(A, KC models,
sedan:KA, KC, KL (DXl models, hatchback:all models),
'97 Dl6Y8 engine (sedan:KA, KC modelsl:
FUEL VAPORPIPE
FUEL FEEDPIPE
FUELFILTER FUELPUMP
Replacement,
page11-235 Testing,page11-236
Replacement,page11-236
IEVAPICONTROLCANISTER
page11-271
Troubleshootiog,
FUELTANK
page11 241
Beplacement,
TIVEEMISSION
{EVAP)TWO WAY VALVE
Testing,page11-294
TUBE/OUICK.CONNECT
FITTINGS
FUELPRESSURE page11-227
Precautions,
REGULATOR page11'227
Disconnection,
Testing, page 11'234
FUEL RETURNPIPE page11-228
Connection,
Beplacement, p a g e 11 234
11-8
'99 - 00 models:
IEVAP}PURGECONTROL
SOLENOIDVALVE FUELGAUGESENDING UNIT
page11'288
Troubleshooting, Testing,seesection23
ONBOARDREFUELING VAPOR
FUELVAPORPIPE R€COVERY IORVRI
VENT SHUTVALVE
FUEL FEEDPIPE
Test,page11 296
FUELFILTER FUEI-PUMP
page11-235
Beplacement, page11236
Testing,
page11-236
Replacement,
EVAPORATIVEEMISSION
{EVAP)CONTROLCANISTER FUELFILL
VENT SHUTVALVE CAP
T r o u b l e s h o o t i n g ,P a g e 11 _ 2 8 8
{EVAPICONTROL
page11_288
Troubleshooting,
{EVAP)BYPASSSOLENOID
FUEL VALVE
PULSATIONDAMPEB page11-288
Troubleshooting,
FUEL FUELTANK PRESSURE

RAIL SENSOB
Page11'274
Troubleshooting,
FUELINJECTORS IEVAPITWO WAY VALVE
page11'232
Replacement, Testing,page11 295
FUELPRESSURE
REGULATOR
Testing,page11-234
page11 234 FUEL RETURNPIPE FUELTUBE/OUICK.CONNECT
Replacement,
FITTINGS
page1l-227
Precautions,
R e p l a c e m e n t ,p a g e 11 - 2 4 1 page11 227
Disconnection,
page11-228
Connection,
I (cont'd)
11 - 9
Component Locations
Index(cont'd)
D16Y5,D16Y8ongine:
THROTTLEBODY(TBI
page11-247
Inspection, THROTTLECABLE
AIR CLEANERIACLI Removal,page11-248 page 11-244
lnspection/Adjustment.
page11-244
Replacement, Disassembly,page11 249 page 11245
Installation,
RESONATOR
AIR {FIA}CONTROL POSITIVECRANKCASE
VAIVE VENTILATIONIPCV)VALVE
{'99 modeli page11-266
Inspection,
D16Y86ngin6)
Testing,page11,250
D16Y76ngin€:
THROTTLECABIT
fnspection/Adjustment.
page11,244
AIR CLEANERIACLI page11-245
Installation,
page11,244
Replacement,
RESONATOR POSITIVECRANKCASE .iBoov ffet

VENTILATIONIPCVIVALVE page11 247
Inspection,
page11-266
Inspection, Removal,page11,248
Disassembly,page11-249
11 - 1 0
816A2 engine:
THROTTLEBODY{T8)
page11-247
Inspection.
Removal,page1'1-248
Disassembly,page11-249
THROTTLECABLE
AIR CLEANER(ACLI lnspection/Adiustment,page 11-244
Page11-244
lnstallation,
POSITIVECRANKCASE
VENTILATIONIPCVIVALVE
page11-266
Inspection,
\-
11-11
System Description
VacuumConnections
D16Y5engin6('96- 97 modelsl:
To EVAPORATIVEEMISSION MANIFOLD
(EVAPI ABSOLUTE
TWO WAY VALVE PRESSUREIMAPI
SENSOR
EXHAUSTGAS BECIRCULATION
(EGR)VALVEend EXHAUSTGAS
RECIRCULATIONIEGR)VALVE
LIFTSENSOR EXHAUSTGAS RECIRCULATION
(EGR)CONTROLSOLENOID
\ VALVE {CVT}
.'.-' \
\
I
I
\ )
Qo
€VAPORATIVE
EMISSIONIEVAPI
PURGECONTROLSOLENOID
VALVE
Qo
FRONTOF VEHICLE
To CRUISE
CONTROL
DIAPHRAGM
(wathcruisecontrol)
FUELPRESSURE
REGULATOR
O: VacuumhoseNo.
11-12
D16Y5enginel'98 - 00 models):
EVAPORATIVEEMISSION{EVAPI
CONTROLCANISTER
VENT SHUTVALVE
To EVAPORATIVE EMISSION
tEVAPITHREEWAY VALVE{98 model)
To EVAPORATIVE EMISSION To EVAPORATIVEEMISSION
IEVAP'CONTBOLCANISTER l'99 - 00 modelsl {EVAP)
FILTER1'99- 00 modelsl TWO WAY VALVE
EXHAUSTGAS RECIRCULATION
(EGRIVALVEand EXHAUSTGAS
RECIRCULATIONIEGRIVALVE
LIFTSENSOR
tcwl
..,.-----.-(CWontyl EXHAUSTGAS RECIRCULATION

IEGR}CONTROLSOLENOIO
VALVEICVTI
EVAPORATIVE
EMISSION{EVAP)
,t'ffi,
PURGECONTROL
CANISTER
ig
MANIFOLD
ABSOLUTE
PRESSURE{MAPI
SENSOR
To CRUISE
EVAPORATIVE
EMISSION{EVAP)
Qo CONTROL
DIAPHRAGM
(withcruisecontrol)
VALVE FRONTOF VEHICLE
FUELPRESSURE
REGULATOR
o: VacuumhoseNo.
L (cont'd)
11 - 1 3
System Description
VacuumConnections
{cont'd}
Dl6Y8 enginel'96 - 98 models):
EVAPORATIVE EMISSION(EVAPI
CONTROLCANISTER
VENT SHUTVALVE
{'96coupe,'97coupe:all models,
'97 sedan:KL model. 'g8-modelsl
To EVAPOBATIVE EMISSION
IEVAPITHREEWAY VALVE
'97 coupe:all models. To EVAPORATIVE
EMISSION
{'96 coupe,
'97 sedan:KL model. 'g8-models) {EVAP)
TWOWAYVALVE
EVAPORATIVE
EMISSION{EVAPI
PUBGECONTROL
CANISTER
{'96coupe,'97coupe:all models,
sed6n:KL model)
FUELPRESSURE
REGULATOR MANIFOLDABSOLUTE
PRESSURE(MAP)SENSOR
EVAPORATIVE
{EVAPIPUBGE
EMISSION
I
CONTROLCANISIER
'97 sodan:
l'96 sadan, XA,
KC mod6l3l
EVAPORATIVE
EMISSION{EVAPI To CRUISE
PURGECONTROLSOLENOID CONTROL
VALVE DIAPHRAGM
{withcruisecontrol)
FRONTOF VEHICLE
11-14
Dl6Y8 ongino ('99 - 00 modols):
(EVAP}
EMISSION
€VAPORATIVE
CONTROL
CANISTER
VENTSHUTVALVE
EMISSION
To EVAPORATIVE
{EVAPICONTROLCANISTER (EVAPI
FILTER
TWOWAYVALVE
EVAPORATIVE
EMISSION
IEVAPI
PURGECONTNOL
CANISTER
To CRUISE
CONTROL
DIAPHRAGM
(with cruise control)
FRONTOF VEHICI-E
REGULATOR
{cont'd)
11 - 1 5
System Description
(cont'dl
VacuumConnections
D16Y7engine('96models,'97coupe:KA. Kc models,'97 sedan:KA, Kc, KL lDx) models,'97hatchback:all modelsl:
FUEL
EVAPORATIVE PRESSURE
EMISSION(EVAPI REGULATOR
PURGECONTROL
To EVAPORATIVE
MANIFOLDABSOTUTE
EMISSION{EVAP} (MAP)
PRESSURE
TWO WAY VALVE
To CRUISE
CONTROL
DIAPHRAGM
lwith cruise
EVAPORATIVE
(EVAPI
EMISSION
PURGECONTROL
CANISTER
FRONTOF
VEHICLE
11-16
model):
Dl6YTengine('97coupe:KL model,'97sedan:KL ILX)model,'98model"gg model"oo
{EVAP}THREEWAY VALVE
l'97 coupe:KL model, EVAPORATIVEEMISSION{EVAP)
'97 sedan:KL (LX) model, CONTROLCANISTER
'98 modell VENT SHUTVALVE
To EVAPORATIVE EMISSION EMISSION
To EVAPORATIVE
EVAPORATIVEEMISSION(EVAP) {EVAP)CONTROLCANISTER IEVAPI
CONTROLCANISTER FILTER('99- 0Omodels) TWO WAY VALVE
VENT SHUTVALVE
PURGEJOINT
EVAPORATIVE
EMISSION{EVAP}
PURGECONTROL FUELPRESSURE
CANISTER REGULATOR
_.\,,..,_..-.
{'97coupe: KL model, MANIFOLDABSOLUTE

'97 sedan:KL (LX) model.
'98 model) PRESSURE{MAP)SENSOR
To CRUISE
CONTROL
DIAPHRAGM
lwith cruisecontrol)
EVAPORATIVE
(EVAP}
EMISSION
VALVE
gtt
FRONTOF VEHICLE
(cont'd)
11-17
System Description
VacuumGonnections(cont'd)
B16A2engine:
EMISSION(EVAPI
EVAPORATIVE
CONTROL
CANISTER
VENTSHUTVALVE
To EVAPORATIVE
EMISSION
(EVAPICONTROLCANISTER To EVAPOBATTVE
EM|SS|ON
FILTER (EVAPI
TWOWAYVALVE
EVAPORATIVE
EMISSIONIEVAPI
PUBGECONTROLSOLENOID
VALVE
MANIFOI.D
ABSOLUIE
PRESSURE(MAPISENSOR
EVAPORATIVE
EMISSION{EVAPI
PURGECONTROL
CANISTER
2
VEHICLE
To CRUISE
CONTROL
DIAPHRAGM
(withcruisecontrol)
FUELPRESSURE
REGULATOR
11 - 1 8
Dl6Y5 engine ('96 - 97 modelsl:
:li Vacuum hose No

*: CVTonly
o PRIMARY1'HEATEDOXYGENSENSOR{PRIMARYHO2S, {DFUELTANK EVAPORATIVEEMISSTON{EVAP)VALVE

SENSOR o AIR CLEANER
(D RESONATOR
SECONDARY HEATEDOXYGENSENSOR(SECONDARY
IPCVIVALVE
@ POSITIVECRANKCASEVENTIL/ATION
HO2S.SENSOR2l
,6i MANIFOLDABSOLUTEPRESSURE {MAP)SENSOR @ EXHAUSTGAS RECIRCULATIONIEGR)CONTROL
(ECTISENSOR SOLENOIDVALVE
@ ENGINECOOLANTTEMPERATURE (EGRIVALVE
INTAKEAIR TEMPERATURE IIAT) SENSOR @ EXHAUSTGAS RECIRCULATION
IEGRIVALVELIFT
@ EXHAUSTGAS RECTRCULATION
KNOCKSENSOR(KS)
SENSOR
o CRANKSHAFT SPEEDFLUCTUATTON
(IAC}VALVE
(CKF}SENSOR
EMISSIONIEVAPIPURGECONTROL
@ EVAPORATIVE
@ IOLEAIR CONTROL
SOLENOIDVALVE
€) THROTTLEBODY(TBI EMISSION{EVAP}CONTROLCANISTER
@ FUELINJECTOR @ EVAPORATIVE
EMISSION{EVAP}TWO WAY VALVE
o FUELPULSATIONDAMPER @ EVAPORATIVE
@ THREEWAY CATALYTICCONVERTER(TWCI
FUELFILTER
@ FUELPRESSURE REGULATOR
(il FUELPUMPIFPI
! ' a (i' FUELTANK

(cont'd)
11 - 1 9
System Description
VacuumConnections
(cont'd)
D16Y5engine('98modet):
-: VacuumhoseNo,
*: CW only
il) PRIMAFYHEATEDOXYGENSENSORIPRIMARYHO2S. (9 POSITIVECRANKCASE

SENSOR VENTILATION{PCV}VALVE
1) ?!J EXHAUSTGAS BECIRCULATION (EGR}CONTROL
O SECoNDARYHEATEooxYGEN sENsoR {sEcoNDARY SOLENOIOVALVE
HO2S.SENSOB2) '1 ExHAUSTGAs RECIRCULATIoN
iq] MANIFOLDABSOLUTEPRESSURE (MAPISENSOR IEGRIVALVE
22 EXHAUSTGAS RECIRCULATION {EGR}VALVELIFI
O ENGINECOOLANTTEMPERATURE IECT)SENSOR SENSOR
5 INTAKEAIR TEMPERATURE {IATISENSOR €J EvApoRATtvE EMtsstoN {EvAp} puRGEcoNTRoL
! KNOCKSENSOR tKSl SOLENOIDVALVE
O CRANKSHAFT SPEEDFLUCTUATIoN{cKF)sENsoF q4 PURGEJOINT
O IDLEAIR coNTRoL {IAc) vALvE @ EVAPoRATIVEEMIssIoN {EVAP)coNTRoL CANISTER
99 THROTTLEBODYITBI @ EVAPORATIVE EMISSIONIEVAP}BYPASSSOLENOID
@ FUELINJECToR VALVE
O FUELPULSATIONDAMPER ?? EVAPORATIVE EMISSION{EVAP)THREEWAY VALVE
@ FUELF -TER ITIIEVAPORATIVEEMISSIONIEVAP}CONTROLCANISTER
@ FUELPRESSURE REGULAToR VENT SHUTVALVE
[4 FUELPUMPIFPI
(9 FUELTANK O FUELTANK PRESSURE sENsoR
(D FUELTANK EVAPoRATIVEEMIssIoN QlI EVAPORATIVEEMISSION{EVAP}TWOWAY VALVE
IEVAPIVALVE 8' THREEWAY CATALYTICCONVERTER {TWCI
O' AIR CLEANER
(D RESoNAToR
11-20
D16Y5engine('99- 00 modelsl:
(PBIMARYHO2S, @ EXHAUSTGAS RECIRCULATION IEGR}CONTROL

O) PRIMARYHEATEDOXYGENSENSOR SOLENOIDVALVE
SENSOR 1) (EGR)VAI-VE
HEATEOOXYGENSENSOR{SECONDARY 6 EXHAUSTGAS RECTRCULATION
O SECONDARY rf exxlust cls nectRcuLATloN IEGR)vALvE LIFT
HO2S.SENSOR2)
IMAPI SENSOR SENSOR
6] MANIFOLDABSOLUTEPRESSURE EMISSION(EVAPIPURGECONTNOL
rO CruCIruCCOOUruT TEMPERATURE IECTISENSOR @ EVAPORATIVE
0AT) SENSOR SOLENOIDVALVE
o rrurlxe ln ETUpERATURE O} PURGEJOINT
.d KNOCKSENSOR(KS} io :vaponanveeutssloN(EVAP)
coNTRoLcANlsrER
O CN,NruXSXITT SP:ED FLUCTUATION (CKFISENSOR
soL-eNolD
tEvAPlBYPASS
d rvlponlrtve EmtsstoN
0Ac)valvE
@ rou an corurnoL VALVE
O THROTTLEBODY(TB) EMISSION{EVAP)CONIROLCANISTER
6 EVAPORATIVE
@ FUELINJECTOR FILTER
E) FUELPULSATIONOAMPER EMISSION(EVAPICONTROLCANISTER
@ EVAPORATIVE
t? FUELFILTER VENTSHUTVALVE
G) FUELPRESSURE REGULATOR SENSOR
OA FUELTANK PRESSURE
OI FUELPUMP(FP) 6 :vlponlnvg er,/tlssloN tEvAPl TWO WAY VALVE
Gi FUELTANK {onvRlVENT
6 oNgoanonerueltNcvAPoRREcovERY
G) AIR CLEANER SHUTVALVE
fi? RESONATOR (ORVRIVAPOR
VAPORRECOVERY
(PCV)VALVE €!) ONBOARDREFUELING
Gl posmvr cnglrcAsE VENTILATION VALVE
RECIBCULATION
(TWCI
@ THREEWAY CATALYTICCONVERTER
L (cont'd)
11-21
System Description
VacuumConnections
(cont'd)
D16Y8engine ('96 sedan, '97 sedan:KA, KC modelsl:
{M/T}
i @ l
: F @ i
HiiFl
(A/T)
I ENGINE I
I coor-rruri
i@ i+i
l/A.
(Or)l
nfi |
/U[ |
\)l#t,/ ,6
0) PRIMARYHEATEDOXYGENSENSOR(PRIMARYHO2S. @ FUELPRESSURE REGULATOR

SENSOR
t; @ FUELPUMP{FPI
SECONOARY HEATEDOXYGENSENSOR{SECONDARY
HO2S,SENSOR2l
@ FUELTANK
-l
(9 FUELTANK EVAPORATIVEEMISSIONIEVAP}VALVE
MANIFOLDABSOLUTEPRESSUBE {MAPI SENSOR @ AIR CLEANER
@ ENGINECOOLANTTEMPERATURE {ECTISENSOR @ RESONATOR
INTAKEAIR TEMPERATUFE IIATI SENSOR @ POSITIVECRANKCASEVENTILATION{PCV}VALVE
!o, KNOCKSENSORIKSI (D EVAPORATIVEEMISSIONIEVAP)PURGECONTROL
(t CRANKSHAFTSPEEDFLUCTUATION{CKFISENSOR SOLENOIDVALVE
IDLEAIR CONTROLIIACIVALVE
@ EVAPORATIVE
EMISSIONIEVAPICONTROLCANISTER
@ THROTTLEEODY(T8) A) EVAFORATIVEEMISSIONIEVAP}TWO WAY VALVE
@ FUELINJECTOR @ THREEWAY CATALYTICCONVERTER
(TWC'
@ FUELFILTER
11- 2 2
D16Y8engine l'96 coupe.'97 coup6: all models.'97 sodan: KL modol.'98 modell:
PRIMARYHEATEOOXYGENSENSORIPRIMARYHO2S, @ AIR CLEANER

SENSOR 1) o RESONATOR
? SECONDARY HEATEDOXYGENSENSORISECONDARY @ POSITIVECRANKCASEVENTILATION(PCV)VALVE
@ EVAPORATIVEEMISSIONIEVAPIPURGECONTROL
HO2S.SENSOR2l
3- MANIFOLDABSOLUTEPRESSURE IMAPI SENSOR SOLENOIDVALVE
IECTISENSOR EMISSION{EVAPICONTROLCANISIER
@ EVAPORATIVE
ENGINECOOLANTTEMPERATURE
a INTAKEAIR TEMPERATURE(IATISENSOR
VALVE
EMISSIONIEVAPIBYPASSSOLENOIO
@ EVAPORATIVE
6 KNOCKSENSOR{KS)
7. CRANKSHAFT SPEEDFLUCTUATION ICKFISENSOR EMISSION{EVAPITHREEWAY VALVE
@ EVAPORATIVE
a IOLEAIR CONTROL{IAC)VALVE EMISSIONIEVAPICONTROLCANISTER
@ EVAPORATIVE
VENT SHUTVALVE
9 THROTTLEBODYITBI
,! FUELINJECTOR @ FUELTANK PRESSUFESENSOR
@ EVAPORATIVEEMISSIONIEVAP)TWO WAY VALVE
FUELFILTER
1? FUELPRESSURE REGULATOR @ THREEWAY CATALYTICCONVERTER ITWCI
! FUELPUMPIFPI
1 { FUELTANK
r 5 FUELTANK EVAPORATIVE EMISSIONIEVAP)VALVE
(cont'd)
11-23
System Description
VacuumConnections
(cont'dl
D16Y8enginel'99 - 00 modetsl:
--j
I
IMTTI^
n 14[l(2i)
-fr l-
1ry|
'- -
*o'*-
COOLANT
]L
n
r l
*
ii8'x'",
(]-i PAIMARYHEATEOOXYGENSENSOR{PRIMARYHO2S,
.19)EVAPORATIVE
EMIssIoN {EVAP)PURGEcoNTBoL
SENSOR1) SOLENOIDVALVE
..2rSECONOARY HEATEOOXycEN SENSOBISECONDARY €g PURGEJorNT
HO2S,SENSOR2l tj EVApoRATtvEEMtsstoN {Evap} coNTRoL cANtsTER
i3) MANIFOLDABSOLUTEPBESSURE {MAPI SENSOR C4 EVAPONANVEEMISSION(EVAP)BYPASSSOLENOID
O ENGINEcooLANT TEMPERATURE (ECTIsENsoR VALVE
(5) INTAKEAIR TEMPERATURE {IAT}sENsoR ?3 EVAPORATIVEEMISSION{EVAP}CONTROLCANISTER
G] KNOCKSENSORIKSI FILTER
?r CRANKSHAFT SPEEoFLUCTUATTON {CKF)SENSOR A4 EVAPoBATIVEEMIssIoN (EVAP)coNTRoL CANISTER
.O IDLEAIR coNTRoL {IAc)vALvE VENT SHUTVALVE
i-9]THROTTLEBOOY{TB) C! FUELTANK PRESSURE
(O FUELINJECToR sENsoR
EO EVAPOBATIVE EMISSION(EVAP)TWO WAY VALVE
I]'i FUELFILTER e? oNBoARD REFUELtiIGvApoR REcovERy {oRvR} VENT
.O FUELPRESSURE REGULAToR SHUTVALVE
[t FUELPUMP{FPl @ oNBoARD REFUELTNG vapoR REcovERy (oRvR) vapoR
.D FUELTANK RECIRCULATIONVALVE
il' AIR CLEANER iP THREEWAY CATAI.YTIC CONVEBTER {TWCI
TD RESONATOR
O FUELTNJEC oN AtR tFtA)coNTRoL vAt_vE
.19POSITIVECRANKCASE VENTILATION{PCVIVALVE
11-24
DI6YTengine('96mode|.,97coupe:KA,Kcmode|s,,97sedan:KA,KC,KL{Dx}modets,'gThatchback:a||models}:
COOLANT
FUELPUMP IFPI
l) PRIMARYHEATEDOXYGENSENSOR(PRIMARYHOzS,
SENSOR 1) [3) FUELTANK
EMISSION(EVAPIVALVE
@ FUELTANK EVAPORATIVE
SECONDARY HEATEDOXYGENSENSOR{SECONDARY
HOzS,SENSOR2) aoAIR CLEANER
r.-.
MANIFOLDAESOI-UTEPRESSURE IMAP)SENSOR (oRESONATOR
.t) ENGINECOOLANTTEMPERATURE IECT)SENSOR a POSITIVECRANKCASE IPCVIVALVE
VENTILTATION
EMISSION(EVAP}PURGECONTROL
INTAKEAIR TEMPERATURE(IAT}SENSOR @ EVAPORATIVE
CRANKSHAFT SPEEDFLUCTUATION (CKF)SENSOR SOLENOIDVALVE
EMISSION(EVAP)CONTROLCANISTER
(0 EVAPORATIVE
a:!)IDLEAIR CONTROL(IACIVALVE EMISSIONIEVAPITWO WAY VALVE
o BOOY(TB) @)EVAPORATIVE
-o THROTTLE THREEWAY CATALYTICCONVERTER (TWCI
FUELINJECTOR
aroFUELFILTER
a1tFUELPRESSUREREGULATOR
|- (cont'd)
11-25
System Description
VacuumConnections(cont'd)
Dl6Y7 angin6 ('97 coup.: KL mod€l, sedan: KL (LX) model,,9g
modet):
i1] PRIMARYHEATEDOXYGENSENSOR(PRIMARYHO2S, (tORESONATOR

SENSOR1) l? PoSITIVEcRANKcAsE VENTILATIoNIPcv}VALVE
E) SECONDARY HEATEDOXYGENSENSOR{SECONDARY IA EVAPORANVEEMISSIONTEVAPIPURGECONTROL
HO2S,SENSOR2l
SOLENOIDVALVE
€l MANTFOLD ABSOT_UTE
PRESSUnEtMAp) SENSOR 19 EVAPORATIVE
€r ENGINECOOLANTTEMPERATURE EMISSIONIEVAPICONTROLCANISTER
|ECT)SENSOR E EVAPORATIVE EMISSION(EVAPIBYPASSSOLENOID
€] INTAKEAIR TEMPERATUREIIAT}SENSOR VALVE
6 CRANKSHAFT SPEEDFLUCTUATION ICKFISENSOR
17 IOLEAIR CONTROLIIACIVALVE €' EVAPoRATIVEEMIssIoN IEVAPITHREEwAY vALvE
@ THRoTTLEBoDY {TBI Q' EVAPORATIVE EMISSIONIEVAPICONTROLCANISTER
VENTSHUTVALVE
O FUELINJEGToR
(9 FUE|-FTLTEF @ FUELTANK PRESSURE sENsoR
{?1!EVAPORANVEEMISSIONIEVAPITWO WAY VALVE
O FUELPRESSURE REGULAToR
@ FUELPUMP{FPI ?5 THREEWAY CATALYTICCONVERTER ITWC'
(D FUELTANK
@ FIFL TANK EVAPoRATIVEEMIssIoN {EVAPIVALVE
(, AIR CLEANER
11-26
Dl6Y7 engins ('99 - 00 modelsl:
VENTILATION(PCV)VALVE
6d POSITIVECRANKCASE
a PRIMARY1)HEATEDOXYGENSENSOR{PRIMARYHO2S, coNTRoL
PURGE
6 rvapoamve eutssloNtEvAP)
SENSOR SOLENOIDVALVE
6t sENsoRISECoNDARY
iiconoanv neareooxYGEN COPURGEJOINT
HO2S,9ENSOR2) 6 evlponnnve eutssloN(EvAPl cANlsrER
coNTRoL
MANIFOLDABSOLUTEPRESSURE (MAP)SENSOR
(ECT}SENSOR i evlponnnve eussloN {EVAP} solrNolD
BYPASS
@ ENGINE COOLANT TEMPERATURE
(IATISENSOR VALVE
!., INTAKEAIR TEMPERATURE EMISSION(EVAPICONTROLCANISTEN
CRANKSHAFT SPEEDFLUCTUATION ICKFISENSOR 6) EVAPORATIVE
FILTER
o IOLEAIR CONTROL(IAC}VALVE
@ EVAPORATIVE EMISSTON(EVAP)CONTROLCANISTER
@ THROTTLEBODY (TBl VENT SHUI VALVE
ao FUELINJECTOR SENSON
A FUELTANK PRESSURE
@ FUELFILTER rwo wAYvALvE
d rvlpoamve emtsstoNtEvAPl
@ FUELPRESSURE REGULATOR vAPoRREcovERYloRvnlvENT
6 orueonnonerueLING
FUELPUMP (FP) SHUTVALVE
(} FUELTANK {ORVR)VAPOR
€) ongolno neruellNc VAPORRECOVERY
@ AIR CLEANER RECIRCULATIONVALVE
@ RESONATOR €) THREEWAY CATALYTICCONVERTER
(TWC)
(cont'd)
11-27
I
System Description
VacuumConnections(cont'd)
816A2engine:
(' PRIMARYHEATEDOXYGENSENSORIPRIMARYHO2S.
SENSOR1l
@ EvApoRATtvE EMtsstoNtEvAp)puRGEcoNTRoL
SOLENOIDVALVE
.?) SECONDARY HEATEDOXYGENSENSOR{SECONDARY
HO2S,SENSOR2) @ PURGE JoINT
€t EvApoRATtvEEMtsstoN(EVAptcoNTRoLcaNtsTER
13] MANIFOLDABSoLUTEPRESSURE (MAP)sENsoB
QAEVAPORATIVE EMISSION(EVAP)BYPASSSOLENOID
i' ENGINECOOLANTTEMPERATURE IECT)SENSOR VALVE
O INTAKEAIR TEMPERATURE ITATISENSOR @ EVApoRATtvE EMtsstoNlEvAplcoNTRoLcaNtsrER
i6l KNOCKSENSOR{KS} FILTER
O oRANKSHAFTSPEEDFLUCTUATIoN{cKF}sENsoR @ EvApoRATtvE EMtsstoN{EvAptcoNrRoL cANtsrER
@ IDLEAIR coNTRoL (IAc} VALVE VENTSHUTVALVE
€) THRoTTLEBoDy trB| @ FUELTANKPRESSURE
(D FUELINJECToR sENsoR
GI EVAPORATIVE EMISSION(EVAP}
TWOWAYVALVE
O FUELPULSATIoNDAMPER
@ ONBOARD REFUETING VAPORRECOVERY {ORVR}VENT
[D FUELFILTER SHUTVALVE
@ FUELPRESSURE REGULAToR
@ oNBoAnDREFUELING vApoRREcovERy(oRvRlvApoR
!I FUELPUMPIFP)
f,' FUELTANK .(c} RECIRCULATION
VALVE
(iD ArRCLEANER THREEWAYCATALYTIC CONVERTER {TWCI
t' RESONAToR
'.1]iPOSITIVEcRANKcAsE VENTILATIoN{Pcv} VALVE
11-28
ElectricalGonnections('96- 98 Models,'99- 00 Dl6Y5 enginewith M/T)
To A/C PlEStUnC 6wrctt
clEc{
.2.Arr pt6rt, DraYt.nlh.t
I .a: AfI Drar, .ndn

arr .nd Drart .nsrF
=.5 Er..d afr.nd Dla\t 6eh.
r?, cvt (D,t6ys ddn.tDd Oiew d!lh.
.8:'S6 Dr6Y3 dsin. td|p.), '97 Dl6Y8 {tin. o [rnEnoRUGtlTlt.s Ar
No, 13l{ Et tU[9 ll5 Al
{cou9.; .ll Dod.b..r!.t: lG nod.ll, sa Or6Y5 mdn',
o HoRxtr5 AF
No. ri Al'ltElATOll gt l€Ntol lt,5 Al
o rcr l|o Ar t{o. 3l EtAatEn gc at lt.5 al
'10: MfI lD1aV5.ncir.l r: h tL o.d..{ood io/t l.v bor
rrt. Exc.orM/I (D15Y5.ntin.l
r12: O16Y5.Ol6Ya.ncln.
(cont'd)
rt5. i9? Ot0\., ssid l6up.; (L mod.l,..d..:
Kl ttxl mod.ll, 9a Dl6rr.ndn.
11-29
System Description
ElectricalConnections('96- 98 Models,,99- 00 D16Y5enginewith M/Tl (
(cont'd)
SENSOF
PRESSURE
SENSOE
EGR
UFT
s E N s o R* 3
c-rrusren
vemsrurvtvrlf;
EGR
uF solENotovALvE*3
wec soLeton vltve'!2
SENSOR
SPEED
sENsoR'2
COUNTEFSHAFI
s P E E Ds E N s o R * 2
soeeloto vltve l*2
ToI|{TEFLOCK
CONTBOLUNIT
*l: t SA model
*2: A/T(DI6W,oi6y8 engine)
*3:CVT(DI6Y5 6ngine)
1.4: A"/Tand Dl6Y7engine
*5; ExceptA/Tand Dl6Y7engine
ECM/PCMA(32P) ECM/PCi/lBEsP) *6: A/T(O16YO engin6)
*7:CW(DI6y5 ongine)and D16y8engino
*8;'96 Ol6Y8sngine(coupe),,97 D16y5
ongine(coup€:all modol!,sedan: KL
modoD,'98 Dl6Y5engine,'98 ot6Y8
en9ne
ECM/PCMD(16P) *9:D16Y5engin.
*10: |!UT(D16Y5 engine)
*ll : ExceptiUT(Dl6Y5engine)
*12: D16y5,016yoengino
*13:DI6YO engine
TERMINALLOCATIONS *14:Dl6Y7engine
*15:'97D16Y7 engine[coupe:KL modet,
ssdan: KL(LX)modetl,'9gDt6y7engine
11 - 3 0
l- SEiV|qE CHECK
@NI\IECIOR
[*-
I
l-.i-*.,*,.
@NI\ECIOR
r-Bu(
f-*
ceor (cont'd)
11-31
System Description
ElectricalConnections('96- 98 Models,,99- 00 Dl6y5 enginewith M/T)
(cont'd)
ptozs'"
pozslttc*rr
Ho2s(sENsoFl)
c125
WHT,'RED'l
s02sHTc
-BLK/WHT
*12
aLKlyeL!
wrlaeo!{-L wrzneo.=r.:
GFN/BLr-I FcFN,wHrJ
alvwrr'Ll -ff
ar-x,rvnr,
Ho2s (sENsoR2)
f--fi"-r".^'--]
I
LraeL*ro ;lcnr-caz fi crls*'u
\
pozsntc*lu
H O 2 S( S E N S O R '
:soL*3 c142
ecRcortnoL*3
SOLENOID
VALVE
c14o
BLU/ALK
VT€C PRESSURE
12: A/T (Ol6Y7, Dl6Y8

enginel
'3: CvT
lDt6Y5 engane)
ia: A/T and Dl6Y7 enqine
15: Erc.pt A/T.nd Dr6Y7
engine
'6:A/T (O16Y8.ngine)
i7: CVI
{Dl6Y5 Gosin.) .nd D16yo snqine
r8:'96 DI6YB .ngi.. ,97
lcoup.), Dt6yl
ensio. (coups: lll mod6ts, s.d6n. KL
dod6ll,'98 D16y5 6ngine.,9a D16y8
o n g i n e , ' 9 9- 0 0 O t 6 Y 5 ( M / T l o n o i n e
'9: Dl6Y5 ongine
'10: M/T
lO16Y5engine)
'l r: Ex@pt M/T (Dt6y5
engine)
r'12:Ot6Y5, Ol6Y8.ngine
'15r'97 D16Y7.ngine
{coupe: Kt- model, sedan:
(L (l-Ximod.l), '98 Dl6y7 angins
11-32
PSPSWITCHI
c1t7
/YEL Jlr.^r'\-r I
atu/wHT =..'-_ wHr---] FaMrr=ll
L_id-ll
8r-x,--L- |
IT GRN/WI{T
CAI\IISTERVENT
tr--+r
-*' I
=
calT
_ 66s' fr:-l
- -
l-BL!(--- lf.a I
CLUTCHSWTCH'X
_-o_
ctor
I (cont'd)
11 - 3 3
System Description
ElectricalConnestions{'96- gBModels,,99- 00 Dl6yS enginewith M/T)
(cont'dl
s€N90fi
I
rDc
I
rDic M
RET' sEt\tsoi
ct(P P
I
I
CXPM cxP
YEUGifl
CIG M
FIF']EE
TTiT
8At{/ aR / !R|{/ AAX/
lhx/
ALJ(I
A&
L:] l'l
12:A/t tD16Yt,Dt0Y8.ncin.t r10: M/I {D16Y5.nsin.}

13: C1/t lDtOYSssin.t 11r: Exc.pt M/T {D16V5.nsin.l
'4 A/T .I(| Di6Y7 .nsi.. '12: Or6Y5,Dl6Ya.ngin.
r5: Erc.tr A/r ..d Dl6Y7 .nsin.
t6: AIt lDl6Y8 .ngin.l
i7:CvI lO16Y5..!ln.) ..d Dt6Y8.neln. .i5:3', O16Vt.ngin. lcoup.: X! mod.l,..d.n:
13: s6 Dt6Y6 ftsi..lco!p.I. 9t Dr6Y8.nqin. (L lLXl mod.ll, 93 ol6Yt.nsin.
lcolF:.rl mo.Llr..d.n: (L no.t.l),,s Di6Y5.nsin..
'98 DI6YB.ncin.,'99 -0o
O't6Y5(M/Tt.nsin.
1 1-3 4
LCB'
NCSC'
L (cont'd)
11 - 3 5
System Description
ElectricalConnections('96- 98 Models,'99- 00 Dl6Y5 enginewith M/Tl
(cont'dl
Cl3i C,ta6 cart c5o2

t--l c5t2
GA|l/OfiN o",.uonr.
l| FSIX' {
| FYEI l
g. l
Orl0 C50il c5t0
GRN/BIXI. GRN/aaX: r
dYEr.
I
LT GRflr- LrGiN'
-
-
8r"K/8ru 8rK/8ru
LT
T -
BEo - -J
f"* I
f r GRN-_'-
8ru'--1
".*,".u---f
REo--__-
- Etur
YEri
-
Gur{-------
Brur- -
l
L ArGEAR ?O6frO Swlrcs
IYTENLOC|(
CO TROT UMI
FronIAD|AtOh FAx
- RElAv EqtswIrEH
T'
BLu/REo,- B!u/FEo,-----l ro a/c swrrcH
l f
t_.1
ct3t c&t6
12:A/l (Dr5Y7,Dl6Y8.nglnel ,10: M/T {D16Y5..sin.l

r3: CyI lOl5Y5..sinel .11: Erc.pt M/l lOr5Y5.nginel
'.: A/T.nd Dr6Y7.nsin. '12: Ol6Y5,DlSYa.ngin.
15:Erc.pt A/T .nd D16Y7.ngin6
'5r A/i {Dl6Ya.ngin€l
17:CVT (D16Y5.noin.) rnd O16Ya.ngine '15: 97 Dl5Y7.ngin. {coup.:Klmod.l, $d.n:
'8r'96 015Y3.ngin. lcoup.), 9t O16Yasngin. (l lLXlmod.ll, 9A DIOYT.nsin.
(coop.r.llnod.l.,..d.n:KLmod.l), 98ol6Y5o.gins,
'94 Di6YA
.ngin., '99 - 0OD15Y5lM/Tl 6ngin.
11 - 3 6
UGIfI &AMRY
o5A) 60a)
ct31
WH'/ALU -wHT/gtU
-BLVRED A//C CIUICH
c354
- GRN/REO
f"*
u o€R.HOOD
BOX
FUSE/REIAY
-l
*t*'fi -*r
F*n*Aros^
I lsrc |
8ru/wHr-.1
f*-__l
YEUGRN |i il?-\.p--lI
I
a I ncB lll
I F I J EPLI I / | P III
lt n * l ll l
".-;"{
BtK,$rtf
n
l5-,- i I
l
'*+ t I Na15 | |
l arlnrl Ton l Ll
I sPsE*soaoia l l
l<\-,o lil
I NczsMErER I
I 05$ |
F-l
uN0€n-oAsH
FTJSE/FEIAYBOX
(cont'd)
11-37
System Description
ElectricalConnections('96- 98 Models,'99 - 00 Dl6Y5 enginewith M/Tl
(cont'dl
atu
EVA? EVPASS
F]I " l
Tf
R€D/ AED
c13r c4a6
o.3a
GRII _ lr- tr---------------
-
t |
I|
- ll rcrr I
1 | { |
J tt t
II
GRt{n'Y}rP-___-.l
]-t r
) caQ
Lll lrl
--
I lJ/c
.t
i - l
l ol25
Srli$},€
'AAXE SWIICH
19: Dl6Y5.ngin6
'2: A/T {Dl6Y7,016Y8.ngin.) rl0: M/T {Dl6Y5.ngin!)
,3: CW {Dl6Y5.nsin.l il1: Exc.pt M/r
14:A/T rnd DIGYTlnginc {Dr6Y5 angin€l
'12: Dl6Y5, 016Y8.ngin.
'5: Ex6pt A/T.nd O'l6Y7.ngin€ '13: O l6Y8 angin.
'6r A/T (Ol6Ygcnsin.) '1a: Ol6Y?.ngin.
rtrCvI lol6Y5 .ngin€) .nd Ol6Y8€ngin. '15:'97 Dl6Y7..qin. (coup€: Kl dod.t, sd.n:
18:'96O16Y8.ngin. lcoup.l, '97 Dl6Y8.nein.
Kl (Lx) mod.l), 98 D16Y7 6ngin.
{coop.:.ll mod.l., t d.nr KL mod.t,,'98 Dr6Y5.ngin6,
'98 Dr
6YE.nein., '!Xl- 0OO16Y5{M/T).ngin.
11-38
ElectricalConnestions('99- 00 ModelsexceptDl6Y5 enginewith M/Tl
-:
T
)
I
FUEI II{JECIOBS
L ChUISECOXTnOI UNII
lo CO|IPi€33OR CUrrcH BEI Y
lo A/c PRESSUiEalYrc|l
To FAoIAIOR FAI REL Y EcT3wllcll
SENSOF
FIJSES:
(DIN1ERIOR UGHTO5A)'
@ BACKUPO5A*
@HonN(15A).
(DSATTERY OOA* @ No.25MEIERCrsA)
@ rcl (104* @ ib. 15ALTERNATOR SPSEI{SOR OJA)
@FrvM(r5A* O ib. 3l STARTER SIGML (75A)
(lEA)
@No.I3FUELPLMP ': h lhc ud.rhood lu..//rcbY box
(cont'd)
11-39
System Description
ElectricalConnections('99- 00 ModelsexceptDl6Y5 enginewith M/Tl
(cont'd) L
T:I 0
1 EVAPPURGECONTROL
c26 ECT SoLENOtOVAIVE
ECTSENSOR
EVAPCOI{TROLCANISIER
c25 tAT
D IATSENSOR
ta-t EVAPBYPASSSOI.ENOID
VALVE
"Eso! 87
HO2S
(sENSoFt )w cl Po2s{tc
c16PHO2S
vlsBr2
EGFcoNTRoLsolENorovaLvE'"
VTECSOLEr{O|D
VATVE
H02S
iSENSOR2) ,w A23 SHO2S
VTECPFESSUFESWITCH
-t BRAKE SWITCH
,.1 f
sEt{soR
I c7 sG1
--t
SENSOB
(Bulnl o F
@E
GAUGE
lfil /V\ |
_r*
* lassEMBL
l - I
I
I D5VBSOL o4tNDA14 l-
I N DTI
SPEEOSENSOR
NC DTO
SPEEDSENSOR
tr L S +B l 7
UNEARSOLENOID
VALVE
T'I AT?04 LS- a3
Pr.l
03alP03 LCA 01
LOCI P CONTBOISOIENOiDVALVE
B
LCB 03
IOI{IROLSOLENOID
VAIV€ A
SHIFI COTITROL
SOLENOID
VALVEB
SHE D2
To IIIT!FLOCKCONTROLUNIT
POStTtON
,'-J
t----
I
-.._.._.._.._l
11-40
-'
DRIVEPULLEY
SPEEDSENSOR
GAUGE
ASSEMALY ORIVENPULLEY
SPEEDSENSOR
SECONOARY
GEABSHAFT
SPEEDSENSOR
SOLENOID
To INTERLOCK CONIBOL UNIT
*l : USAmodel
*2: a/T(D16Y/,D16Y8engine)
,.3: CW(016Y5engine)
*4: A/T and D16Wengine
*5: ExceptA/Tand Dl5Y7engine
*6: Cw(Dl6Y5 engine),Dl5Y8engineand 816A2engine
EcM/PcMA(32P) EcM/PcMB(25P)
7 I I 10 11
t4 16 1 7 1 8 1 9 2012122 23 24
ECM/PCMC(31P) ECM/PCMD(I6P)
I (cont'd)
TERMINALLOCATIONS
11-41
System Description
ElectricalConnections('99- 00 ModelsexceptD16Y5enginewith M/Tl
(cont'dl \
UFTSENSOR
sEnucEcSEcK
CONNEC'OR
ABS CONTROL
UNIT
_r"*
CONI{ECTOR
- BLX
"to'
aLul-_--r ".* ft *31ou..."
"on"t"to"
I
I
lll*,
1 1-4 2
llo2s (sENsoR
t
SECONOARY
HO2S(SENSOR
2)
I- wrrzneo'f15151
-]
FCA ,a[HT f- I
FELWWHI.- FFi/v\^- I
F ETJVWrfT'--I l+ |
HO2S(gENSOR2)
\-
11-43
System Description
ElectricalGonnections('99- 00 ModelsexceptDl6yS enginewith M/T)
(cont'd)
Fl
TI
| "u,
LB|.X'--Jf-ll
cad__J
PsPswrcH'
q30 h/wFDl
t-l + l
1"" vss
VTEC
soLEt{oto
VALVE
clia
----J----]
BLTC.YEL
neozvef--l neo,"yrr.'--{l- ---5 |
EVAP PUBGE
CONTROL
SOLENOIDVALVE
clat
EVAP CONTROL
CANISTEFVENT
SHUI VALVE
l,,"
I
11-4 4
-E--l
| ^ qYP I
I Y $rsoi I
- I
l
I /.JrDc I
I Y SEr$OiI
t
Il
f--Av) o' I
sEr,rsoi
I I
I
|f-------l I
' cM
ll | |
_L:_---J
DIgIRIBUTOR
tr:-l
til t E l-- FI CKFSENSOR
|- TI I
EiN/
ELxl
I AFN/
BRN/ ar-xl
ELxt
BFN/ EFN/
ar-xl aLKl
BRN/
B!K'
J- ;q ,l o l
I*l L P I
I (cont'd)
11-45,
System Description
(cont'd)
cl09
racvP*{
- BLK/eLu
-l
qt
pl
--
SOLENOID
VALVE
MAINSHAFT
SPEEOSENSOR
clla
COUN'IERSHAFTSPEED
SENSOR
c121
t t I I
UNEAR
SOL€NOIDVALVE
1 1-4 6
iFx/'ORN"f
' - LI
I
YEL
Lll
c!o4 crro
qF /ELKT
lrcnf
RED
GiN
aLuT
At c€AR PO3tllOl{ SWlrCH
wnnrd#"Si"*fi[*
"
BLU
GR+ 35111'o,-
u",,
F 'h MDIA'ORFAr{FELAY'
CnXr#
BLI,IREO+ ToA/CSwlICH
I (cont'dl
11-47
System Description
(cont'dl
DRIVEPULIEYSPEEOSENSOF
SECONDAFYGEAF
SHAFTSPEEOSENSOR
PNK/BLK
YE!'
SCLSM
PNK/BIU
INHSOL
cnvauC
c131 CrKa
GFN/Brf I f cnvsuC
L_
,T GEAF POSII|ON SWITCH
11-48
;:l
A/CO-UfAl
ELD''
BLtCWlfi -
BLK
T
UNDER-HOOD
BOX
FUSE/RELAY
YEVGRI{
*tT
sLrc\t/trt
1
BLvwHr
1
c501
r.. -{
UNDER-DASH
FUg€/FELAY AOX
(cont'd)
11-49
System Description
ElectricalConnections('gg- 00 ModelsexceptDl6y5 enginewith M/Tl
(cont'd)
Elt^-l
'tF'tF q23
r_ c446
I L - l l-- ,.,-,.u
vever-u
t | l
L-- cnrzer-rc-{f cnnzar-x,
CsO5 -r-\
- YELI6RN f/ \
I t P I
BLK __1\
'- \'----l /
I
Ft,EL PUMP
YEL/GRN - YEL/GRN
YEVELU - YEVBLU
lr cat' _ LT GRN2
qar/auC - qaN/eud
BLVWHf - BLK/WiT
BLIII - BLul
EVAPBYPASS
SOLENOID
VALVE
ft ti-l
I lJ/c
T__l I
T
t.] I c425__
LwHr GRN {-l
I _cnnzwm'_{h\_, I
aBAKEStlflTCB
*l : USAmod6l
*2: A/T(Di6W,Dt6Y8engine)
*3: CW(DI6Y5engino)
*4: A,rTe16 915y7"nn,n"
*5: ExceB AfTand Dl6Y7engine
,16:Cyr(DI6Y5€n9ine),D16y8engineand B,tOA2
engins
*7: Dl5Y8,816A2engine
11 - 5 0
SystemConnectors[FuelPumpl
'95 - 98 models, '99 - 00 Dl6Y5 engine with M/T:
c792*r,.'5 c793|.,.s
*1r USA mod€l

c565 c7931...15 '2: A/T {O16Y7,D16Y8 ensine}
13: CVT {O16Y5ensin€l
*4: A/T ind D16Y7 .ngane
E ffi ffi *5: ExceFt A/T end D16Y7 engine

'6: A/T lDl6Y8 enginel
*7: CvT (Dl6Y5 enginoland 016Yg engine
'8: ,96 Dl6YB engine {coupe),'97 Dl6Y8 sngine
{coupe: sll models, s€d.nr KL modell,
' 9 8 D l 5 Y 5 . n g i n e , ' 9 8 D 1 6 Y 7e n g i n e ,
'99 - OODl6Y5 (M/Tl engine
r9: D16Y5 ongine
t 1 0 : M / T { D 1 5 Y 5e n s i n e l
r 1 t : E x c e D tM / T ( D 1 6 Y 5e n g i n e )
t l 2 : D 1 6 Y 5 ,D l 6 Y g e n g i n e
*13:Dl6Y8 engine
r14: D16Y7 engine
*15:'97 Dl6Y7 ensine {coupe: KL model, sodan:
KL (LX) modeu,'98 Dt6Y7 engine
them (for example'YEUBLK1

NOTE:. Differentwireswith the samecolor have beengivena numbersuffixto distinguish
and YEVBLK'are not the samel.
. O: Relatedto Fueland EmissionsSystem'
. - Connectorwith maleterminals(double outline):View f rom terminal side
- Connectorwith femaleterminals(singleoutline):View from wire side
11 - 5 1
System Description
SystemConnectorsIEngineCompartment]
'96 - '98 Dl6Y5,
Dl6Y8 engin€, '99 - O0Dt6y5 engine wirh M/f:
I
:
ir
I
11-52
Cl0,r c105 c106
c102
:lo. {C.nadal
r'Trtt l'lrl
lrl.l
r'fr] Etr ffi
_-l
l6lwtr,eED' -l
E|BFIvBLK
l6lga-tnEcl--l
l6mrrrnru I
ElilrwA----l
lTltHtBtu__l
Bffiffi
c109.. c113*1 c114

c107 c108
ffi ffi r'frtr fr

-l
16lonl
l@LYEUBLK' I
bfgl-rcgtu'---l
ffiffi
c1a2.r
fr
,D GRN/BLK' (9 LT GRN?
BLU]
3
8
(for 6xample,YEUBLK1
NOTE:. Differentwireswith the samecolor have beengivena numbersuffixto distinguishthem
and YEUBLK' arenot the same).
. O: Relatedto Fueland EmissionsSyst€m'
. - Connectorwith maleterminals(doubleoutline):View from terminalside
- Connectorwith femaleterminals(singleoutline):View trom wire side
(cont'd)
11-53
System Description
SystemGonnectors[EngineCompartmentl(cont,d)
36 - 98 Dl6Y5, Dl6Y8 engine, ,99 - O0Dt6y5 engine with M/T:
t
I
I
C1,&r.3
II
c139r"
c120
c354r1
c122
G101
11-54
cl11 c112 c1t5 cl16 c1t7
fr r'ffi]
f'TBLir-l
lO BLX,YEI I
l6lEtu^tHr__-l
c125
c120 c122 c123 c121*'
c118"
ffi ffi ffi ffi

o 16lwrrin+o' t
trl-clrl---] i YEUGFN
liSlcFN/BLK I
BLU5 REO!
latlIBLU, I 16T8LK^'Er--l
8L(,
YEL' 9 8tu -.,IBaK,r/Hr. I
5 10 BLK/YEL
c13!,.f c1a0rt c141*'
c126*' c127*' c128.'
ffi fr ffi E fr ___l:t_

l-lrl
l6lgrf,---_-l I' LTGRNA/VHT

I
fOTwHn-_-l IFFEc'--__l 1618r-uf/EL-_]
-l tdl cnN/YEt--l
IOIREB I f€,]-BLK,rEf-__l
lOlREo. I ftlwHn-'_l 161-cfl,avHr
:.trn -c,1* cl45rrc c351

.EL Ft_
t-El-r
l 1 I 2 'l u
3l
l l-,T,ITd
[tT,l.l l.l t_-Ttli I
v
Ii wHl/8tK I 16lvvrrr/BtK---.l
lETcRNiBLF--l l g l c n N / B r KI ,
ET-YtrrrruBiu-__-l lO YEvBru I
16rlsrK' -- I
ET- -_l
f+plr-,
q]54't
r,f,"|
I i IBLK4/VHT I
lOlsLK I
IO LGRN/REDI
them (for example,YEUBLK'
NOTE:. Differentwireswith the samecolor havebeengivena numbersuffixto distinguish
and YEUBLICare not the same).
. O: Belatedto Fueland EmissionsSystem'
- Connectorwith femaleterminals(singleoutlins):View from wire side {cont'd}
11 - 5 5
System Description
SystemConnectorslEngineCompartmentl{cont,dl
\
36 - 98 D15Y7€ngine:
'l
\,
11 - 5 6
c1o4 c104 c105
c101 c102 '1 lcanadal
f,ftl ffi r'ftl ffi

l3l.l
f BLI(YEL 6 WHT/BLU I. WHT/FED. I

BLK' YEVGflN | ? lEFN/8LK' I
3 YEVBED I BLU f3TBr--/BEo-l
'4. B R N / 8 L K ' BLK,A/VHT
.alY E U B L K i l 0 BLKYEL
c112
c107 c108
c106
ffi EE ffi ffi
c113*!
r=1
, ' l \
\2
li G R N -. -l I
ftELiJ o GRNELKI o
ELUT
3 1
I
givena numbersuffixto distinguishthem {for example.YEUBLKl

NOTE:o Differentwireswith the samecorornavebeen
and YEUBLK'are not the same).
O: Relatedto Fueland EmissionsSystem
(cont'd)
a - Connector with maleterminals(doubleoutline):View from terminalside
- Connectorwith femaleterminals (single View
outline): from wire side
11-57
System Description
SystemConnectorsIEngineCompartment](cont,d)
\
'96 - 98 Dl6Y7
.ngin.:
11 - 5 8
c109 c114
r'ff;t ffi
Flo-'u I
l! veugLx' I
ftFwatu;'--l
c123
cl17 cl18 {A/T}
r'ftr Flrl
ffi
I O I G F N '- I t YEUGNN lolFED/wHr I
fdl'.,c---_l o BEF fd-cRN/8tK'_]l
l? BLKtEt I 16lBarr-- l 8LU5
@ CRN: BIK3
b]-Br.-^^,Hr-_-l YELl 9 BLU
5 10 8LX]"/E!
cl28lA/T) c141r16
cl24 (A/Tl c125 cl26 (A/Tl c121 |AFI
fr ffi fr ffi Fl,l ffi

l3l.l
-l lO LTGBN,.VVHT
I
lTlzRN,tsril
---l I lTltHr/R$' fol;nrr-_-l 16lwHr--l IC ISLU/YEL I
loiiED/vEr--l lOlREo. I lOlREp I I

161-Grr.,*1/Hl 161-BIK/YEL-_--l
l6l-YtL,
bfBaK/vEL- l
f!]BLX,1,,iHT'-l
Gt54*,
F1Eh
l'l3LlJ
-_l
l6ElKl,,/Hr-l
I6TBLK
R/E D
IO LGRN I
them (for example,YEUBLK1

NOTE:o Differentwireswith the samecolorhavebeengivena numbersuffixto distinguish
O: Relatedto Fueland EmissionsSystem.
L a - Connectorwith maleterminals(doubleoutline):View from terminalside
11 - 5 9
System Description I
SystemGonnectorslDashand Floor]
'96 -
98 modols, 'gtl - 00 Dl6yS engine with M/T:
11-60
crlo tA/Tl
6 t 7
v
8 l s l r o' t l 12
!t
tffii ffi
lEr.r.r,ll
l1 lslx,^/tl' I lllrlnEo' I
ll lsl'(^,!Hr l?IBLX I
I BLX
13 wHT,aLK-]l I
FF* 5
BLU
l-r-lw'r/cFNl'l
'sdurnyAlrm sFr.m
c125 a:2'
w l--r;-l
l! LcFN,.,vH?| L]-]llg!N ,-l
lalwHrresN I ll lcRY I
lrl- | l(JcRN^nH PI
--.1
hl- - - l6ltHrGFN
22
csto |ArIl
BLK
YEL
suffix to distinguishthem (Jorexample,YEUBLKT

NOTE: o Differentwires with the same color have been given a number
and YEUBLK'are not the same)
a o: Relatedto Fueland EmissionsSystem'
side (cont'd)
a - Connectorwith maleterminals(doubleoutline):View from terminal
11-61
System Description
SystemConnectorslDashand Floorl(contd) (
'96 - 98 models,'99 -
00 Dl6Y5 engine with M/T:
c432*13
1 1-6 2
(O16Y5,
Dl6Y8.nlin.3l lOl6Y?.ngir.l
ct33.r tFcM-B) C134{EC[r,l/FCMal

c t32 {ECt/r/pcM-a)
2 6 E 9 l0 tl
12 t 3 l/a 'ts t 6 1 7 1E l 9 20 24
25 21 2a 29 30
cr35lEcM/PCM-D) ca3l c{t3
ffi f'Tfl'n 9
l.
r o l r t 12 t 3
7
@
--- I-IBLffiHJ-Il]l
Tttr-Ei ll ltlcRr'r/wlr -l
FltEtstK l-''lwHtREcp--l
liELx/wNr'
FfwNr/RED''_l
lTltHr/BL( l
l!
2
12 1 3
a l 5 8 9 t0
1 7 t8 l9 ffi FIrt
Irli I
tilwHT,"Ed-l
| . lcFMMr I
11 BLX^VHT'I
11 B!x.^rHr I
(for example,YEUBLKT
NOTE:e Differentwireswith the samecolor have beengivena numbersuffixto distinguishthem
O: Relatedto Fueland EmissionsSystem
- Connectorwith maleterminals(doubleoutline):View from terminalside
11-63
System Description
SystemConnectorsIEngineCompaftment]
'99 - 00 D16Y5
ICVT),D16Y8engine:
cl14 C142'3
*1: USA model

'2: A/T {D16Y7,O16Y8engine)
*3: CVTlD16Y5engine)
*4:A/T and D16Y7engine
*5: ExceptA/T and D16Y7engine
*6: CVT {D16Y5engine).
O16YBengin€and
816A2 engine
*7: D'|6Y8,81642 engine
11- 6 4
c101 c'r02 c'r04
_"1on {Canada)
r'fil--dl ffi
l3 {l
lrl2 3l ffiffi
_-l
lElwHr/FED"- lSltHr/REo" ll
lttl-R^r/BLr- Fl xrvef
lSfBruritnEp- F]-wHrr+r/BLU I
c108 c109*. cl13*, C11,t
'-l-t_,
l 1 l 23 l
A
\^y
r-E--r
1 1 2 l
---l
lglE* |6IcFN;--l
FIBLr l
I€ IYEVBLKI I
|5lBwBuJ-u--l
c137r' c138'5 c112" c302
c e ffi ffi
NOTE:. Differentwireswith the samecolor havebeengivena numbersuffixto distinguishthem (for example,YEUBLK1

and YEUBLK' arenot the same)
. O: Relatedto Fueland EmissionsSystem.
(cont'd)
11 - 6 5
System Description
SystemConneetorsIEngineCompartment](cont'd)
'9!l - 00 Dl6Y5
{CvT}, Dl6Y8 onginol
v
C14,0*3
c139
cl20
c1{{}
c122
11 - 6 6
c112 cl17
t1l2l l1 2l3l
1 8 BLK |6l;LKr-----l
o YEUELKI BLK' lOlELK,^/EL ll I
YEVBLK] BLKI I tlsLU^/vHl
YEUBLKI ELKI
o YEUELKI 0, ALKI
o YEVBLK' (9 B L K '
YEVBLKI BLKJ
c118*' c120r3 c122 c123 121+'
a l1 2l
F-i
l1 2l
l1 2l l 1 l 2 l 3 l 1 l
ffil
l5l6l7lEl v m
--l
J. YEUGFN o IoFED //Hr--l FiiTwHr. l6TE"^r"". 1
BLU' a REDl 1olcnlriBirc I l€ cnN,,srr,I ItT"Eu I
.11 ALKI lt|sLKrElllll
o YEL' lolTlx,wH-r'
5 t 0 8LK/YEL
c125 c126r' C.127.' c128r' c140 Clitl
rffil
trtr f f i f f i f f i A
w fr
--.l
Iij wHri FEDi_l ffi;F---- FlREo,-___l El;*lvr.l l6EnNta, 16lBLLliBLa--l
--_l l6lir cFlr/wnT
I]l I
I a IGFN/BLK, I l,IRFD' I lr lwHr' I l e r l c R N / w H r Ir I6ELK' ITIBL/./YEL
I9 BLK,ryEL I
l6ELK,wHr I
c143*3 c144*3 c145'3 c145.3 c147r3
ffi _,q.
/-----f
,---t
11 2l
t./t2ts al
lffi fr
lr t2 3J l5lcl7l8l
\-/
it] GRN/BLK] l6FEDl.ryxF_l
-
ldElK îHrr_l I J IWHr/BLK I l(1-]l68N, I
trlwirmEp,I |-|cFN,RLr<,--1
I l6tFtj--reDtsLu] o @ PNI(BLK fdvi Hr. l
GRN/YEL3
FIYEUR.I (, (9 PNVBLU
c351 c352 C35/a'1
1l5l Lr/H-1-_r
/it El
f,ftf
toltrl l5l0
GRN 6 BLX'EL 16l BLK/wHr
I-l I
2 1 16lgl(
3 WHT/BLK o 16lGBNinEol
i, 9
o aL&a€D
Differentwireswith the samecolor havebeengivena numbersuffixto distinguishthem (for example,YEUBLKT

o: Relatedto Fueland EmissionsSystem
- Connectorwith femaleterminals(singleoutline):View from wire side (cont'd)
11-67
System Description
SystemConnectorslEngineCompartmentl(cont'dl
\
'99 - 00 D16Y7engine:
I a
11 - 6 8
c101 c102 c104*, C1oia c10s
{Canade)
f'tr] rftr r'ffi-a ffi

EE
c107 c10B c112

c106
ffi ffi ffi ffi
c113r' c3o2
a tu
(for example,YEUBLK'
NOTE: . Differentwires with the same color have been given a number suftix to distinguishthem
and YEUBLK'are not the samel.
a O: Relatedto Fu€land EmissionsSystem.
a - Connectorwith maleterminals(doubleoutline):View from terminalside (cont'd)
- Connectorwith femaleterminals(singleoutline):View from wir€ side
11-69
System Description
SystemConnectors[Engine Compartmentl(cont,d]
'99 - 0OD16Y7
€ngin€:
1 1-7 0
c109 cl10 c11a c115 cl16
r'ft] @
_-l o 8TK?YEL .!l GBN/8TKI

flofr-N 2 BLICYEL o GffN/8TK1
ItIYEUBLK, I
BLK/YEL @ GNN/aLK?
IEIBLvBLU' I BLfiEL o GRN/BLK
(t BLK/YEI 12
BLKJ^/EL !3 GRN/BLX'
8LK/YEL GRN/BLK'
c11EtA/Tl cl20 c123

clr7
F1ftr l-l,l
. . + ,
l+'.1'+:l
1
ffi
@fBLK-_-l lOlGBN, I
I a BLKTYEL-l I f6lBr-r,--l
|ol-Balro/Hl
c121lAtfl c125 c126lA/Tl c12t l[lTl c128(A/Tl c141
l-lrl rfrr
Etr
fr ffi
_El-
I ' l, l ffi
_l
IOIBLUryEI' -lI 16TLr cRN^/v-H;l
I I t lwHriREo'
M c n N / B L K ' __-l _-l I EIwHI-__-lI EIWHF 161-BrxtEL-__l
f4tEr-- ItrIRED/YEL,-l l€)lFEp5 l(?lREp, I 161-crNalrHr'
blBLK Ea
ftl BLK^tHi'l
c352 (xlsarr
c351
Ftr.T
-___-l
l6ELffiHr-]
tr18!(
lglcRN/REp I
(for example,YEUBLKl
NOTE:. Differentwireswith the samecolor haveb6engivena numbersuffixto distinguishthem
and YEUBLK' are not the same).
a O: Relatedto Fueland EmissionsSystem.
a - Connectorwith maleterminals(doubleoutlinel:View from terminalside (cont'd)
- Connectorwith femaleterminals(singleoutlin€):View from wire side
11-71
System Description
SystemConnectors[EngineCompartment](cont'dl
816A2engins:
11-72
c101 c102 c104 C10,1 c105
(Canadal
F1+..r
l 1 2 3 l l 1 2 l
l-f.l
Irlz 3l ffi
--.l -l
.1' BLKYEL 6 WHT/BLU ffl'wHnr€D" 16lwHrsEo.
e BLKI 1 YEUGRN ItrERlxBLa__l I2 BLK/YEL I
3 YEUREO 8 lo."llBurntotl-l ftlwHri BLUIl'l
9 BLKryVFT
5 l YEUBLKI 10 BLK,ryEL
c106 c107 c108 cl t3 C11il
ffi ffi ffi

D ffi
c123 c137
ffi
l3 4l
a
BLK^/EL :d) GBN/BLK'
2 BLK/YEL GRN/8LK'
3 BLK,YEL GRN/BLK'
rlj GRN/BLK'
ELKTYEL 12
BLI(YEL rt GFN/BLK'
!l
c138 c302
A
v
tu
FTBtKiBLtr__l
lZTYEuBLKi l
NOTE:o Differentwireswith the samecolor havebeengivena numbersuffixto distinguishthem (for example,YEUBLKl

a O: Relatedto Fueland EmissionsSvstem.
- Connectorwith maleterminals(doubleoutline):View from terminalside (cont'd)
11-73
System Description
SystemConnectors[EngineGompartmentl(cont'd]
81642 enginoi
v
11-7 4
c112 cl17 c122
ffi r'trTl A
,g
16lBLK,-__-l l-iln'eo*r,vHr__-l
lO BLX,\,E[ | l[lcRNiBLitl]l
16l Btu/wil-
Cliro C1'11
_-l
l6l-ciN/YEL'
o ffi
c'54*1
f r lz l s l
fflErKwH---l
lOlBLr -lI
f6lGrrunEp
NOTE:. Differentwireswith the samecolor havebeengivena numbersuffixto distinguishthem (for example,YEUBLK1

O: Relatedto Fueland EmissionsSystem,
11-75
System Description
SystemConnectors[Dashand Floor]
('99 - fil models except D16Y5engine with M/Tl
a
L a
L a
11-76
v1 s
8 l 7 l 6 l et 0r l ! 2 1 t 2 13 t5
14
5 i! a L (
LTATU
1 2 a
9 t0 l 2 13111/ l6 1 7 1 8
E t0 t 1 ,/ ./ie / 1Al,/ 20
!t
t1t
' S€cuitAr.h Sysi.m
cL5 elz5
lwithod cruir. cort?oll {with crui* codrol)
2 3 I 7 a 9
;--F--
t r t 2 l r'ffitr 1 0 1 1 12 t3 /lr5l/ 18 t9
w 1 3 r l
12
--l
l-T -
l . - I lElwHT"cRN I
YEL
c510ta/T)
YEL 3LK YEL

.! D
2 f,ED/BLK
t!
(for example,YEUBLKl
NOTE: o Differentwires with the same cotor have been given a number suffix to distinguishthem
a O; Relatedto Fueland EmissionsSystem
t-
a - Connectorwith maleterminals(doubleoutline):View from terminalside (cont'd)
11-77
System Description
SystemConnectorslDashand Floor](cont'dl
('99 - 00 mod€ls oxc€pt Dl6Y5 ongine with M/T)
11-78
c130 ct3r
I 10 1 l z 3 l t / X 6 1 7 8 9 t o
l 1 12 13 1,4 t 5 t a 1 1 t 8 t 9
cr34 tEcM/PCM-C) cr35 lPCM-Dr: cr35lPcl|.D,€
ca32
't/ 3l-1. 5 1 lrl2l 2 at6 I E e t|0
l r 2 3 . 1 'lt
/ t g to 12 l 3 111'12
It I t It[l
-_-l
Ill lll*
IiGTNiBN tn Bs I
l5l-wxr,nol]l
l:a BLXvHI I
c,|52tEcM/PCM-Al c1a
lr 2l
f.fil
,bl onrrwlrl.l
ftlBLrwHri- l]-l
Flirx,lvHJ
NOTE;. Differentwireswith the samecolor havebeengivena numbersuffixto distinguishthem (for example,YEUBLK1

and YEUBLK,are not the samel.
a O: Relatedto Fueland EmissionsSvstem.
\- - Connectorwith maleterminals(doubleoutline):View from terminalside
11-79
SystemDescriptions
SystemConnectorslFuelPump] (
\
('9!,- 00 models 6xcept Dl6Y5 ongino with M/T)
I
c565 c568 c792 c793
E ffi fr
NOTE: o Differentwireswith the samecolor havebeengivena numbersuffixto distinguishthem (for example,YEUBLKI

and YEVBLK,are not the same).
a O: Relatedto Fueland EmissionsSystem.
a - Connectorwith maleterminals(doubleoutline):View from terminalside
- Connectorwith femaleterminals(singleoutline):View from
wire side
11 - 8 0
Troubleshooting
TroubleshootingProcedures
How To BeginTroubleshooting
problem,usethe appropr'-
When the MalfunctionIndicatorLamp (MlL)has beenreportedon, or there is a driveability
ate orocedurebelowto diagnoseand repairthe problem'
A. Whenthe MIL hascome on:
,1.connectthe HondaPGMTesteror an oBD ll scantool to the 16PData Link connector(DLC)locatednearthe left

kickpanel.
2. Turn the ignitionswitchON (ll) MALFUNCTION

INDICATOR
3. Checkthe DTCand note it. Also checkand note LAMP
the freezetramedata
Referto the DiagnosticTroubleCode Chart and
begintroubleshooting.
NOTE:
.SeetheoBD||scantoolorHondaPGMTesteruser,smanua|sforspecificoperatinginstructions..
.Thescantoo|oltestercanreadtheDiagnosticTroub|ecodes(DTc},freezeframedata,currentdata,andoth
EngineControlModule(ECM)/Powertrain ControlModule(PCM)data'
oFreezeframedataindicatestheengineconditionswhenthefirstma|function,misfireorfue|trimma|functio
was detected.lt can be usefulinformationwhen troubleshooting'
problem,referto the SymptomCharton page 11-84'

B. Whenthe MIL hasnot come on , out thereis a d riveability
c.DTcswi|lbeindicatedbytheb|inkingoftheMa|function|ndicatorLamp(M|L)withthescsserviceconnectorco
nected.
shown (The 2P ServiceCheckConnectoris
Connectthe SCS serviceconnectorto ServiceCheckConnectoras
|ocatedunderthedashonthepassenger,ssideofthevehic|e')TurntheignitionswitchoN{||)'
OBOll SCANTOOLol
HONOAPGM TESTER
scs sERvlcE (cont'd)

SERVICECHECK 07PAZ- (x)l0100
CONNECTOR I2P)
DATA LINKCONNECTOR
Il6PI
11-81
Troubleshooting
TroubleshootingProcedures(cont,dl
ll, EngineControlModule(ECM)/powertrain
ControlModule(pCM)Resetprocedure
NoTE: Resettingthe EcM/PcM will erase any stored DTcs and any
freezedata. lt will also restart all readinesscode
monitors.
Eitherof the followingactionswill resetthe ECM/PCM.
. Usethe OBDll scantool or HondapGM Testerto clearthe EClM,s/pCM,s

memory.
NorE: see the oBD ll scantool or HondaPGMTesteruser'smanuals
for specificoperatinginstructions.
' Turn the ignition switch oFF. Removethe BACKuP (7.5A) fuse from
the under-hoodfuse/relaybox for 10 sec-
onds.
NorE: Bemovingthe BACKuP (7 5 A) fuse cancelsthe clockand the

radio presets.Make note of the customer,s
presetsso you can resetthen
lll. FinalProcedure(thisproceduremust be done afterany troubleshoottng)
1. Removethe SCSServiceConnectorif it is connected.
NoTE: If the Scs serviceconnectoris connectedand there are no DTcs

storedin the EcMipcM,the MtL will stay
on when the ignitionswitchis turnedON 0l).
2. Do the ECM/PCMResetprocedure.
1-82
checksat the ECM/PCMconnectors,removethe right
lf the inspectionfor a particularcode requiresvoltageor resistance
kick panel.Pull the carpetback to exposethe ECM/PCM. Remove the ABS control unit if so equipped.unbolt the EcM/
as describedbelow
PCM bolt. Turn the ignition switch oFF, and connectthe backprobesets and a digital multimeter
listedon the followingpages'
checkthe systemaccordingto the proceduredescribedfor the appropriatecode(s)
The illustration
shows '96 - '98 models.
KICK PANEL
How to Use lhe BackprobeSets
to a multimeter.using the wire insula-

connectthe backprobeadaptersto the stackingpatchcords,and connectthe cords
gently
adapter. slide the tip into the connectorfrom the wire side
tion as a guide for the contouredtrp of the backprobe
until it comesin contact with terminalend of the wire'
BackProbe
BACKPROEE SET
07SAZ- 001000A
lTwo
DIGITALMULTIMETER
(Commerciallyavail.bleI or
Ks - AHM - 32 - oo3 (cont'd)
11 - 8 3
Troubleshooting
TroubleshootingProcedures(cont,dl
CAUTION:
\ I
. Punqturingihe insulation on a wirs can causepoor or intermiftent electricar
connections.
I Bring the test€r probe into contacl with the terminatlrom the terminal
side of wire harnesgconncctors in the gngin€
compartment. For temale connectors,iust touch lightly with the tester probe and
do not inse.t the probe.
RUBBERSEAL TESTERPROBE
TERMINAL
Symptom Chart
Listedbeloware symptomsand probablecausesfor problemsthat Do NoT causethe Malfunction
indicatorLamp(MlL)to
L
c o m eo n . l f t h e M I Lw a s r e p o r t e do n , g o t o p a g e1 1 _ 8 1 .
Troubleshooteachprobabrecausein the orderristed(from reftto right)untirthe symptom
is eriminated.
The probablecauseand troubleshooting pagereferencecan be found berow.
*: '99 - 00 models
SYMPTOM PROBABLECAUSE
Enginewill not start 4 , 2 , 3 ,5 , 2 0 ,1 4 ,1
Hardstarting 2, 4, 11, 16,13,'t9
Coldfast idle too low ?, s^6. 16
Cold fast idle too high 1,8,10.9
ldle speedfluctuates 7 , 8 ,1 0 . 9
Misfireor rough running Troubleshoot for misfireon pagesl1-166,167
LOW power 2,9, 10,12, 11, 16,'t8,20
E"g|* "t"lb 2,4,11,7,20,8,5,15
Difficultto refuel* 't9,
21
Fueloverflowsduring refueling* 1r,,1
OtherProbableCausesfor an enginethat will not start:

- Compression - Startingsystem
- lntakeair leakage - Overheating
- Enginelockedup - Battery
- Timing belt
11-84
ProbableCauseList lFor th€ DTCChart, see page 11-971 *: '99 - 00 models
ProbableGause Page System
1 11 - 1 0 7 ControlModule(l'uM)
EngineControlModule(ECM)/Powertrain
2 11-230,231
't't-237 PGM-Flmain relay
3
Section23 l^îti^n cwetam
Fosltlonsensorclrculr'Lr\Fselrsor
CrankshaftPosition/fopDeadCenter/Cylinder
5 1' 1-172,183
circuit
't1-124 IntakeAir Temperature(lAT)sensorcircuit
7 11 - 1 9 4 ldle Air Control(lAC)Valve
I 11-220- 223 ldle speedadjustment
11-241 ThrottlebodY
'10 11-244 Throftlecable
11 11-115 ManifoldAbsolutePressure(MAP)sensor
12 11-132 ThroftlePosition(TP)sensor
't1-178 Barometricpressure(BARO)senso'
13
switchsignal
14 Section14.11-218 Mf g"a, po"itionsignal(seepage11-216)or clutch
15 11-210 Brakeswitchsignal
't1-244 Air Cleaner
16
lntakeair pipe
18 11-252 Three Way CatalyticConverter(TWC)
19 11-261 Evaporativeemission(EVAP)control
20 fuel
Contaminated
21* 11-296 ORVRvent shut valvs
(cont'd)
11-85
Troubleshooting
(cont,dl
(
ECM/PCMData
By connectingthe OBD ll scantool or the HondapGM Testerto the l6p data link connector(DLC),
variousdata can be
retrievedfrom the EcM/PcM.The itemsIistedin the table belowconformto the sAE recommendedpractice.
The HondaPGMTesteralso readsdata beyondthat recommendedbv SAE.
understandingthis datawil help to find the causesof intermittentfairuresor engineprobrems,
NOTE:
' The "operatingvalues" given below are approximatevaluesand may
be differentdependingon the environmentand
t h e i n d i v i d u avle h i c l e .
. Unlessnotedotherwise,"at idle speed,,meansidlingwith the enginecompletely
warmed up, Ay'Tin position@ or E],
M/T in neutral,and the Ay'Cand all accessories
turnedoff.
Data Description Operating Value FreezeData

Diagnostic lf the ECM/PCMdetectsa problem,it will storeit as a lf no problemis detected,
TroubleCode code consistingof one letterand four numbers. there is no output.
(DTC) Dependingon the problem,an SAE-defined code (poxxx) YES
or a Honda-defined code (Plxxx)will be outDutto the
rester.
EngineSpeed The ECM/PCM computesenginespeedfrom the signals Nearlythe sameas
sent from the Crankshaft Positionsensor. tachometerindication.
This data is usedfor determiningthe time and amountof YES
fuel injection,
VehicleSpeed The ECM/PCMconvertspulsesignalsfrom the Vehicle Nearlythe sameas
SpeedSensor(VSS)into speeddata. speedometerindication YES
Manifold The absolutepressurecausedin the intakemanifoldbv With enginestopped:
Absolute engineload and speed. Nearlythe sameas atmo-
Pressure{MAP) spheflcpressure
At idle speed: YES
24 - 31 kPa(180- 280
m m H g ,7 . 1- 1 1 . 0i n H g )
E n g i n eC o o l a n t The ECTsensorconvertscoolanttemperatureinto volt_ With cold engine:
Temperature age and signalsthe ECM/PCM. The sensoris a thermistor Sameas ambienttemper,
(ECT) whose internalresistance changeswith coolanttemDera_ atureand IAT YES
ture.The ECM/PCMusesthe voltagesignalsfrom the With enginewarmed up:
ECTsensorto determinethe amountof iniectedfuel. 176- 194.F(80- 90.C)
HeatedOxygen The HeatedOxygen Sensor detectsthe oxygen content 0 . 0- 1 . 2 5V
Sensor{HO2S) in the exhaustgasand sendsvoltagesignalsto the At idle speed:
(Primary, ECI\4/PCM. Basedon thesesignats,the ECM/pCMcon_ about0.1- 0.9V
S e n s o r1 ) trols the airlfuelratio.Whenthe oxygencontentis high
(Secondary (thatis, when the ratiois leanerthan the stoichiometric NO
Sensor2) ratio),the voltagesignalis lower. ( S e n s o1r )
Whenthe oxygencontentis low (thatis, when the ratio
is richerthan the stoichiometricratio),the voltagesignal
is higher.
11 - 8 6
Descriotion Operating Value F eeza Data
Data
"open" or "closed"' At idle speed:closed
HO2S Loopstatusis indicatedas
Feedback Closed:Basedon the HO2Soutput,the ECM/PCMdeter-
Loop Status minesthe airlfuelratioand controlsthe amountof inject-
YES
ed fuel.
Open:lgnoringHO2Soutput,the ECM/PCMrefersto sig-
nalsfrom the TP,MAP,and ECTsensorsto controlthe
amountof injectedfuel.
The air/fuel ratio correction coefficientfor correctingthe ! 20%
ShortTerm
FuelTrim amountot injectedfuel when H02Sfeedbackis in the
closedloop status When the signalfrom the HO2Sis
weak,shortterm fuel trim gets higher,and the ECM/PCM
increases the amountof injectedfuel The airlfuelratio YES
graduallygets richer,causinga higherHO2Soutput
Consequently, the shortterm fuel trim is lowered,and
the ECMiPCMreducesthe amountof injectedfuel
This cvclekeepsthe airlfuelratiocloseto the stoichio-
metricratiowhen in closedloop status'
Longterm fuel trim is computedfrom shon term fuel ! 20%
LongTerm
trim and indicates changes occurring in the fuel supply
FuelTrim
svstemover a long Period YES
lf long term fuel trim is higherthan 1.00,the amountof
injecGd fuel must be increased.lf it is lower than 1 00'
the amountof injectedfuel must be reduced'
The IAT sensorconvertsintakeair temperatureinto volt- With cold engine:
lntakeAir
age and signalsthe ECM/PCM. When intakeair tempera- Sameas ambienttemPer' YES
Temperature
ture is low, the internalresistanceof the sensor atureand ECT
{IAT)
increases. and the voltaqesignalis higher'
Basedon the accelerator pedalposition,the open'ng At idle speed: YES
Throttle
angleof the throttlevalve is indicated approx.10 %
Position
lgnitiontiming is the ignitionadvanceangleset by the At idle speed:12'i 2'
lgnition (81642engine:16"t 2")
Timing gCV/eCV.tn" gCU/PCMmatchesignitiontiming to the NO
drivingconditions. BTDCwith the SCSser-
vice connectorconnected.
CLVis the engineloadcalculatedfrom the MAP data' At idle speed:

Calculated
15-35% YES
LoadValue
At 2.500rpm with no load:
{CLV)
12 - 30%
r o
11-87
Troubleshooting
Engine/P_o,weft
rain ControlModuleTerminal Arrangement
('96- 98 Models,'99- 00 Dl6ySenginewith M/T) -
ECM/PCMCONNECTOR
A I32PI
1 2 1 5 6 7 I 10 l1
I N J 6 INJ3 INJ2 I N J l LG1 PGl IGPl
1 2 13 11 1 5 1 6 1 7 1 8 1 9 20 22 21
ACV PCS FLR acc MIL ALTC tcM PG2 IGP2
27 2A 25 30
VSVSLU
A (32P)
ECM/PCMCONNECTOR Wire side of female terminals
NOTE:Standardbatteryvoltaget s 1 2
Sign.l
1 YEL l N J 4 ( N o . 4 F U E LI N J E C I O B ) D ves No 4 ruel injector. W i l h e n g i n er u n n i n q :d d l y c o n i r o t e d
2 BLU l N J 3 l N o . 3 F U E LT N J E C T O B J D r i v e sN o . 3 l u e I n t e c l o r .
3 8ED I N J 2 ( N O ,2 F U E I I N J E C T O N ) Drives No. 2 iuel njector.
88N l N J l ( N o . 1 F U E LI N J E C T O B ) Dives No. 1 ruelinjector.
SO2SIITC(SECONDAFYHEATED Orives secondary heated oxyqen sensor With ignilion switch ON (lll: batery vo lage
5 OXYGENSENSOFHEATEFCON
W i t h f ! l l y w a r m e d u p e n g i n er u n n i n q : d L t vc o n t r o l e d
TFOL)
PO2SHTC(PRIMAFYHEATEO Drives prihary healed oxygen sensor
6 BLXAVHT W i t h i g n i t i o ns w i t c hO N l t t ) : b a n e r y v o t t a s e
O X Y G E NS E N S O RH E A T E R w l h r d l l y w d r m e d u p c n g n e , L n n r r dq u r y , o r l . o t r e d
CONTROL)
ESOL (EGF CONTRO! D r i v e sE G F c o n l r o l s o l e n od v a t v e . Wilh EGRoperating during drving wiih fu|y warmed
FED{ SOIENOIO VALVE)
up engrne:duty controtted
W i l h E G F n o l o p e f a t i n g : OV
E.EGR W i t h E G F o p e r a t i n gd u . i n g d r i v o g w i l h i u t y w a r m e d
u p e n 9 i n e :d u t y c o n t . o l t e d .
With EGR not ooeralino; o V
WS (VTECSOLENOTD
VALVE) Drives VTECsolenoid va ve
8*r/ GFN/YEL W i l h e n g n e a t o w e n g i n es p e e d : OV
Wirh engine at h gh enqine speedr banery vohaae
9 BflN/BLK L G 1 ( L O G I CG R O U N D ) G r o ! n d l o r t h e € C M / P C Mc o n l r o t c r c u i t . L e s s l h a n1 . 0V a t a t t i m e s
t0 ALK P G 1I P O W E FG F O U N D ) G r o u n di o r r h e E C M / P C Mp o w e r . t c u f .
11 IGPTiPOWEFSOUFCE) Power source forthe Ec[,l/PcM conlro
YEVBLK Wilh ignition swirch ON (tt): battery voltage
With gntron switch OFF:0 V
BLVBLU IACV(IDLEAIN CONTROLVALVE)
W i l h e n g i n er ! n n n g : d l t y c o n t r o e d
o8N I A C VN l I D L EA I 8 C O N T F O L Drivesthe IAC valve {negalive side).
13,.
VALVE NEGATIVESIOE)
IACV P (IDLEAI8 CQNTROL Orives IAC vaive (posilive side).
BLVBLU
VALVE POSITIVESIDE)
PCS (EVAPPURGECONTFOT Drives EVAP pu.ge controtsolenoid vatve. W i l h e n g i o er u n n i n g ,e n g i n €c o o t a n ib e t o w 1 5 4 , F
FEO/YEL SOIENOIOVALVE) '68'Cr bancry vohaSe w'ln ens nc runn,.o. eng,rc
FL8 (FUELPU[4P FELAY) O r i v e sf u e l p u m p r e l a y .

GRN/YEL 0 V {or two secoros ahe' tJ n ng 'onir or \wnch ON ,,,,,
I7 BLI(REO ACC (A,/CCLUTCHRELAY) Drives A/C clutch relay. W i r h c o m p r e s s oO r Nr0 V

Wilh compressof OFF:banery votrage
18 MIL (I\,lALFUNCTION
INDICATOF
GFN/ONN W i t h M I L l L r n e dO N : 0 V
With illl turned OFF: banery volaqe
19', AITC {AITERNAIOR CONIROL) se.ds ahernator controt signat. Wirh fully warmed.up engine ru.ntng: battery votlas€
During drivins wnh smatl eteclricattoad: O V
I C M ( I G N I ' T I OC
NO N T R O L
w i t h i g n l t l o ns w i l c h O N ( t l ) : b 6 n € r yv o h a g e
20 YEVGRN MOOU!E) W i l h e n s i n er u n n i n s :a b o u l t 0 V ( d e p e n d i n go n
22 BRN/BLK L G 2( L O G I CG A O U N D ) Ground for the ECM,/PCM conrrot ci'cu L Lessthan 1.0V at a tt mes
23 BLK P G 2i P O W E AG R O U N D ) G r o ! n d l o r t h e E C M / P C Mp o w e r c i r c u i r .
24 YEUBLK lGP2 (POW€RSOUSCE) Power sou.ce lor the ECM/PCl, conrrol Wnh ignilion swilch ON {it):battery vohage
W i l h i g n i l i o ns w i t c hO F F : 0V
25*6 WHT/FED VSEFIREFEflENCEVOLTAGE) ProvrdesreferencevoIaOe to TCM. W i t h i g n i t i o ns w i t c hO N ( t t ) : a b o u 5
r V
W t h g n i t i o ns w l t c hO F F :O V
FANC {RAOIATORFAN Drives radialof fan ielay.
21'1 GFN With radialor fan f!nn nqr O V
CONTFOL) Wilh radiato.tan stopped: battery
BL! 2WBS (EVAPBYPASS Orives EVAP bypass sotenotd va !e. W i t h i g n i r i o ns w r r c hO N ( t t ) : b a r e r yv o r a s e
SOLENOIOVALVE]
LT GRNA/VHT VSV (EVAPCONTFOTCANISTEF Drives EVAP conlfot canisrer venl shul w n h i g n i r i o ns w ' t c hO N l r | l b a r e r y v o l a q e
VENT SHUT VAIVE)
WHT/NED S L U ( I N T E F L O CC
KO N T F O L Detects intenock conlrotLn t signal W h h i g n i t i o ns w i t c hO N ( t t ) a n db r a k ep e d a
UNIT) depf essed: battery vollage
'2: A./T(D16Y7,016Y8
engine) '10i i,4/T(D16V5engine)
13: CvT (D16Y5enoin€) r 1 1 E x . e p tM / l ( D 1 6 V 5
',4: A/T and D16y7 engine enqinel
r 1 2 : 0 1 6 Y 5 ,D 1 6 Y Be n q i n e
*5: ExceptA/T and D16Y7€nsine
'6r A/T (D16Y8ensine)
'7 Cw
'"'3:Bi..I?'Jt;".'e'.!ti.?i?l'""."T8"_";btfr
1D16Y5 e n g , n e la n d D 1 6 y 8e n s r n e r 1 5 : ' 9 7 0 1 6 Y 7e n g i n e
'98D16Y7 l c o u p e :K L m o d e t ,s e d a n :K L ( L X l m o d e t ) ,
"fl engine
11 - 8 8
B {25P)
PCMCONNECTOR
Wire sideof {emaleterminals
B (25P)',
FCM CONNECTOR NOTE:Standardbatteryvoltageis 12 v'
Terminal Wire Terminal Description Signal

numoer cotol name
SOLENOID Groundfor linearsolenoidvalve
Wii-ignnionswitctroN {ll}:pulses
LS_(LINEAR
1 VALVE- SIDE) -Drii6l
linear solenoidvalve With ignilionswitchuN (lll:pulses
LS+(LINEARSOLENOID
2 RED VALVE+ SIDE) -Drives
SHA{SHIFTCONTROL shift controlsolenoidvalveA With enginerunningin 2nd,3rdgears:
SOLENOID VALVEA) batteryvoltage
3 BLU/YEL With enginerunningin 1st,4thgears:
about0 V
Driveslock up controlsolenoid With lock-upONI batteryvoltage
LC B (LOCK'UP
CONTROL
4 GRN/BLK VALVEB} valveB. With lock-upOFF:0v
SOLENOID
Driveslockup controlsolenoid With lock-uPON: bafteryvoltage
LCA (LOCK.UPCONTROL
5 YEL VALVEA) With lock-upOFFi0 V
SOLENOID
ATPD3(NT GEARPOSI. DetectsPy'Tgear Positionswitch In [D31position: 0 V
8 PNK
TIONSWITCHi signal. ln ;y other position: battery voltage
SHB(SHIFTCONTROL DnGs shift conttolsolenoidvalveB With enginerunningin 1st,2nd:battery

VALVEB) vo|taqe
1l GRN^lr'HT SOLENOID
With;ngine runningin 3rd,4th:about0 V
-DlivEilite'lock
control,rnit. With ignition switch ON (ll) and brake
SLU (INTERLOCK
CON
12 WHT/RED TBOLUNIT) pedaldepressed:0 V
D4 IND(D4INDICATOR DrivesD4 indicatorlight. With Pll indicator lrghtturneo urr: oarterv

voltaoe
13 GRN/BLK LIGHT)
W i t h l d i n d i c a t o r l i g h t t u r n e d O F F :0 v
NMSG{MAINSHAFT GZiiI'for mainshaftspeedsensol

14 WHT SPEEDSENSOR GROUND)
SPEED Detectsmainshaftspeedsensor Withenginerunning:
Pulses
NM {MAINSHAFT
RED SENSOR) srgnal.
ATPR{M GEARPOSI DetectsM gear Positionswitch InE position:
0V
signal In any other position:batteryvoltage
TIONSWITCH)
ATP2{A/T GEARPOSI DetectsA/T gear Positionswitch I n E p o s i t i o n0:V
't1 BLU In any other position:batteryvoltage
TIONSWITCH) signal.
NCSG(COUNTERSHAFT Ground for countershaftspeed
22 GRN SPEEDSENSOR GROUND) sensor.
NC (COUNTERSHAFT Detectscountershaftspeedsensor Vvithignition switch ON (ll), and front
23 BLU SPEEDSENSOR) signal. wheels rotating: Pulses
ATPD4{M GEAFPOSI- DetectsM gearPositionswitch ln E position:0V

24 YEL TIONSWITCH) signal. In any otherposition:5 V
ATPNP(A"/TGEARPOSI Detects A/T gear Position switch I n E o r E p o s i t i o n :V
0
25 LT GRN TIONSWITCH) srgnal, In any other position:batteryvoltage
* 1 i U S Am o d e l *9: D16Y5engine
*2: A/T (D16Y7,Dl6Ygengine) *10:M/T (D16Y5engine)
*3: CVT(D16Y5engine) *11:ExceptM/T {D16YSengine}
*4: M and Dl6Y7engane *12i D16Y5,D16Y8engine
*5: ExceptA.rTand 016Y7engine * 13:D16Y8engine
*6: A,/T(D16Y8engine) *14:D16Y7engine
! a *7r CVT(D16Y5engine)and D16Y8engine

* 8 : ' 9 6 D 1 6 Y 8e n g i n e( c o u p e ) , ' 9 7D 1 6 Y 8e n g i n e ( c o u p e : a l l
*15:'97 Dl6YTengine(coupe:KL model,sedan:KL (LX)model)'
'98D16Y7
engine (cont,d)
m o d e l s ,s e d a n :K L m o d e l ) , ' 9 8D t 6 Y 5e n g i n e , ' 9 8 D 1 6 Y 8
engine,'99 00 Dl6Y51M/Tiengine
11-89
Troubleshooting
Engine/P_o_wgrtrain
ControlModuleTerminalArrangement
('96- 98 Models'99 - 00 Dt6y5 enginewith M/T) tc'oniOi
ECM/PCMCONNECTOR
C {31PI
1 2 a 5 7 I I 10
CKFPCXPP TDCP ACS sTsscs rMA v8u
12 13 1 4 t5 1 5 17 TE
ALTF vss
23 21 25 29 30
lP+ TMA
Wiresideof femaleterminals
ECM/PCMCONNECTOR
C (31PI
NOTE: Standard baftery voltage is 12 V
To.min!l Wira Torminal
number coloa name Do6criptlon Signal
1 BLU/RED CKFP(CKFSENSORP SIDE) DetectsCKFsensor. Withenginerunning:
pulses
2 BLU CKPP(CKPSENSOF PSIDE) DetectsCKPsensor. W i t h e n g i n e r u n n i n g :p u l s e s
3 GRN TDCP{TDCSENSOR PSIDE} DetectsTDC sensor, W i t h e n g i n er u n n i n g :p u t s e s
4 YEL CYPP(CYPSENSORP SIDE) DetectsCYPsensor. W i t h e n g i n e r u n n i n g :p u l s e s
5 BLU/FED ACS{Tr'CSWITCHSIGNAL) Detects,ay'Csw;tch signat. With Iy'C switch ONr 0 V
With Ay'Cswitch OFF:batrery vottage
6 BLU/ORN STS(STARTER
SWITCH Detects staner swilch signal, W i t h s t a n e rs w i t c h O N l t l t ) :b a t e r y v o h a g e
SIGNAL) With staner switch OFF:0 V
SCS(SERVICE
CHECK Detectsservicecheckconnectorsignal Withthe connectorconnected:
8RN SIGNAL) OV
{thesignalcausinga OTCindicationl with the connectordisconnected:
about5 v
or batteryvoltage
LT8LU K , L I N E( D L C ) S e n d sa n d r e c e i v e ss c a ni o o l s i g n a l , Wirh ignition switch ON { ): about 5 V
9+3 GRY D a t 6c o m m u n i c a t i o nw i t h T C M : E C M W i t h i g n i t i o ns w i t c h O N ( t t ) : p u t s e s
control ctat6output
VBU(VOLTAGE
BACKUP) Power source forthe ECM/PCM Battery voltage at all times
10 WHT/BLU control circuit. Power sourc€ lorthe
DTC memory
11 WHT/RED CKFM{CKFSENSORM Groundtor CKFsensorsignal.
SIDE)
12 CKPM(CKPSENSORM Groundfor CKPsensors;gnat.
SIDE)
TDCI\4(TDCSENSORM Groundfor TDCsensorsignal.
RED
SIDE)
CYPM (CKPSENSOB M Groond for CYP sensor signal.
14 BLK
SIDE}
15." BLU/BLK VTM (VTECPRESSURE OetsctsVTECpressureswitchsignal. Wrth engine at low enginespeed:0 V

swtTcH) Wth engineathigh enginespeed:tatteryvoltase
(P/SOILPRESSURE Detects PSPswitch signal.
PSPSW At idle with steering wheel in straight ahead
16 GRN
swtTcH) p o s i t i o n : 0V
At idle with stsering wheet at fult tock battery
voltage
'17 ALTF (ALTERNATORFR Detects ahernator FR signal.
WHT/RED With fullyw6rmed up engine running:0 V- bat-
SIGNAL) teryvohage (dependingon electricattoad)
18 BLUI/VHT VSS{VEHICLES P E E DS E N - OetectsVSS signal. W h h i g n i t j o ns w i t c h O N { t t )a n d f r o n t w h e e t s
SOR} rotating: cycles 0 V- 5 V
23+14 BLK lP+{HO2SPUtr4P
CELL+} ControlsHO2Spumpce . W i t h i g n i t i o ns w i t c h O N ( l l ) :a b o u r 0 . 5- 5 . 3V
24.10 RED rP-,vs- {Ho2scoMt oN) Referencevoltagesupply. W i t h f u l l y w a r m e d u p e n g i n ee t i d l e :
a b o u t 2 . 6 - 2 . 8V
25*ro VS+(VSCELLVOLTAGE) DetectsVS cell voltage. W i t h i g n i t i o ns w i t c h O N t ) : a b o u r 7 V
LTGRN*'
ATPNP(Ar'TGEARPOSI, Deteds Ay'Tg6srposhion switch signat. InE orE position:OV
29
TroN swrTcH) ln any otherposition:batteryvottage
RED{ro
CLSW(CLUTCH SWITCH} Detectsclutch switch signal, Wilh clutch pedal released: about 5 V
With clutch pedal deDressed: O V
30 TMB Data communication with TCM: W i t h i g n i t ; o ns w i t c h O N ( l t ) : p u t s e s
PNK4
E C M c o n t r o l d a t ai n p u t
'1: USA model 1 9 : D 1 6 Y 5e n g i n e
r 2 r A , . T( D 1 6 Y 7 O
, 1 6 Y 8e n s a n e ) '10: M/T (Dl6Y5engine)
* 3 : C V T( O 1 6 Y 5e n g i n e ) * 1 1 rE x c e p tM / T
*4: Ay'Tand O16Y7engine 1 1 6 Y 5e n g i n e )
* 1 2 : D 1 6 Y 5 ,D 1 6 Y 8e n g i n e
'5: Excepl A./T
snd Dl6Y7 engine *13:Dl6Y8 enqine
16: Ay'T(D16Y8ensine) * 1 4 : O 1 6 Y 7e n g i n e
{ 7 : C V T( D l 6 Y 5 e o s i n e )a n d i 1 5 : ' - 9 7O 1 6 Y 7e n g j n e ( c o u p e :
O 1 6 Y 8e n o i n e KL modet, sedan: KL (LX) modet),
"8: 96 Dl6Y8 engine(coupe),'97 '98D16Y7
D 1 6 y 8 e n g i n e ( c o u p e :a t l enqine
'99 - 00
:ed-9I t!!rnodelr,'98 D16y5ensine,,98D16y8e;sine.
D 1 6 Y 5l M / T ) e n s i n e
11 - 9 0
D I16P)
ECM/PCMCONNECTOR
Wire sideot femaleterminals
ECM/PCMCONNECTORD l16P) NOTE: Standardbattery voltage is 12 V
Te.minal Wire Terminal Dor.ription Signal

numb€r color n!me
POSITIONDetectsTP sensorsignal.
TPS(THROTTLE With throttle fully open: about 4.8 V
RED/BLK SENSOR} With throttlefully closedlabout0.5V
ECT{ENGINECOOLANT DetectsECTsensorsignal With ignitionswitchON{ll):about0.1- 4 8 v
REDA/VHT SENSOR (dependingon enginecoolantlemperature)
TEMPERATURE
ABSO'
MAP {MANIFOLD DetectsMAPsensorsignal. With ignitionswitchON(ll):about3 V
RED/GRN LUTEPRESSURESENSOR} At idle:about1.0V
3 on enginespeed)
{depending
VOLTAGE) Power sourcelor MAP sensor.
VCCl (SENSOR With ignitionswitchON (ll):about5 v
YEURED With ignitionswitchOFF:0 V
BKSW{BRAKESWITCHI Detectsbrakeswitch signal With brakepedal released:0 v
5 GRNMHT With brakepedaldepressed:bafteryvoltage
RED/BLU KS {KNOCKSENSOR} DetectsKS signal. With engineknocking:Pulses
6*?
PHO2S(PRIMARYHEAT- DetectsPrimaryheatedoxygen With throttle fullv openedfrom idle with
EDOXYGENSENSOR, sensor(sensor1l signal Iully warmodup engine:above0.6V
1 SENSOR 1) With throttle quickly closed:below 0.4 v
LABEL DetectsLABELresistance With enginer!nning:about0.3- 4.9V
IAT (INTAKE
AIRTEM- DetectsIAT sensorsignal. With ignitionswitch ON (ll):about 0 1 -
8 RED//EL PERATURE SENSOR) 4.8V {dependingon intakeair temperature)
EGRLiEGRVALVELIFT DetectsEGRvalve lift sensorsignal At idlewithoutvacuum:about'12 V
9*l WHT/BLK With27 kPa(2OO mmHg,8in. Hg):about4 3 V
SENSOR)
VCC2(SENSOR VOLTAGE) Providessensorvoltage, With ignitionswitchON(ll):about5 V
10 YEUBLU With ignitionswitchOFF:0V
GRN/BLK SG2(SENSOR
GROUND} Sensorground. Lessthan 1.0V at alltimes
11
GRN,4/1r'HT SG1(SENSOR
GROUND) Ground for MAP sensor. Lessthan 1.0V at alltimes
12
(SECONDARY
SHO25G Ground for secondaryheatedoxy-
GRN/BLK*1?HEATED SEN'
OXYGEN gen sensor(sensor2).
2 GROUND)
SOR,SENSOR
SH02S(SECONDARY Detectssecondaryheatedoxygen With throftle fully openedlrom idle with
14 WHT/RED HEATEDOXYGENSEN' sensor(sensor2) signal. fully warmedup engine:above0.6V
2)
soR,sENsoR With throttlequicklyclosed:below0.4V
PTANK{FUELTANK PRES. Detectsfueltank prgssuresensor' With fuelfill caDopened:about2.5V
15|3.*15 LT GRN
SURESENSOR)
EL(ELD) DetectsELDsignal. With parkinglightsturnedon at idle:about
2.5- 3.5V
16*1 GRN/RED With low beamheadlights turnedon at
idle:about1.5- 2.5V
*1: USA model *9: D16Y5engine

*2r A/T (D16Y7,D16Y8engine) *10:M/T (D16Y5engine)
*3: CVT(D16Y5engane) *11:ExceptM/T (Dl6Y5engine)
*4: A,/Tand Dl6Y7engine * 12rD16Y5.D16YBengine
*5: ExceptA/T and D16Y7engine *13:D16Y8engine
*6: A"/T(D16Y8engine) *14: Dl6W engine
i7: CVT(Dl6Y5engine)and Dl6Y8engine *15:'97 D16Y7engine(coupe:KL model,sedan:KL lLX) model),
'98D16Y7
* 8 : . 9 6 D 1 6 Y 8e n g i n e( c o u p e i , ' 9 7D 1 6 Y 8e n g i n e(coupe:all engine:
'98 D16Y8
m o d e l s ,s e d a n rK L m o d e l ) , ' 9 80 1 6 Y 5e n g i n e ,
'99 - 00 D16Y5 (M/T) engine
engine, (cont'd)
11 - 9 1
Troubleshooting
Engine/P_o,wertrain
ControlModuleTerminalArrangement
('99- 00 ModelsexceptDl6Y5 enginewith M/Tl
ECM/PCMCONNECTOR
A I32PI
ECM/PCMCONNECTOR
A (32P) Wire sideot temaleterminals
NOTE:Standardbatteryvoltageis l2 V
Sign!l
3 BLU 2WSS(EVAP8YPAsSSOLENOID Drives EVAPbypass solenoid vatve, With gn'tion swnch ON (lll banery votlage
VSV {EVAPCONTNOLCANISTER Drives EVAPcontrot can isrer v€nt shut Wilh ignilion switch ON {tl): b€ttery vottage
LT GRN/I/VIIT
VENTSHUTVALVE]
C8S (CRUISECONTSOLSIG Oown shift signal inpot lrom c.uise conrrol When crurss control is used:purses
8LU/GNN
PCS{EVAPPURGECONTROL Drives EVAP purge conrrol sotenoid vatve. With engine running, enginecootant,betow r54.F (6a,C):
6 8ED/YEL SOTENOIOVALVE)
With engine.unning, €ngine coolant, abov€ 154.F
(68'C): duty conlrolled
ATPD {AT GEAR POSITION ootects A/T gear posnion swilch s,gnar.
YEL
SWITCH) In otherthan @ posilion:Apprcx. 5 V
(SECONDARY
SO2SHTC HEAT Drives sscondary h€ared oxygen senso. Wilh isn,rion swirch ON (ll):banery votrase
8 BLK,IflHT EDOXYGENSENSOS
HEATEF W i t h l u l l y w a r m 6 dd p € n g i r e r u n n ' n g : d u r yc o n t r o l e d
CONTFOL)
ATPNP (AT GEAF POSITION oereds A/T 9€ar position switch signat. I n P a r r o r n e u l r s l : 0V
LT GRN
SWITCH) I n a n y o t h e r p o s i t i o na p p r o x . 5 v
S C S( S E R V I CC
EH E C KS I G N A L ) Oetectsssruice check connecror signal with rh€ t6rminal connected:0 v
t0 88N (the signalcausing a OTC indication) With the rerm inaI disconneded: abour 5 V of ban€ry
D 4 I N D( D 4 I N D I C A T O N ] Drives Oa indicaio. lighr. W i t h D 4 i n d i c a t o rl i g h t t u r n e dO N : O V

GNN/BIK
With D4 indicator lightturned OFF:battery vo ttage
FTF (FUELPUI\,4P
SELAY) Orivos tuel pump relay,
G8N/YET 0V for two s€conds lfrer turnrng rgnilior swtcn ON
(ll), then batt€ry voltage
ACC (Al/CCTUTCHSELAY) Drives A./Cclutch reray.
11 BTI(RED With compressor ON:O V
Wilh comp.ssor OFF;battery vottage
18 MI! (A,IAIFUNCTIONINDICA. W i t h M l L t u r n e dO N : 0 V
GFN/OFN
TOF LIGHT) With l\,llLtornod OFF|batreryvotrsge
19 8tu N E P( E N G I N ES P E E DP U T S E I Oulputs6ngine speed pulse, W i l h e n g i n 6 . u n n i n gp
: utses
20 FANC {SADIATORFAN CON Orives radiarortan relay. W i r h r . d i s t o rt 6 n r u n n i n g : O V
GFN
TnoL) With radiatortan stopped: banery vottage
21 ELUA/EL K LINE Sends and r€ceivess.an lool signal. With ignition switch ON (ll):p!ts€s
ATP L {AT GEAS POSITION OelocisA"/Tgear posirion switch siSnat.
22'l BLU
swtTcH) In othfflhan E position:Apprcx. 5 V
SHO25 (SECONOARYHEATED Detectssecondsry hoar€doxygen sensor With lhronle f! lly or'6ned from idte with fu y
23 OXYCEN SENSOR,SENSOF2) warmod up engine: above 0.6 v
Wiih th.onl6 quickb, closd:below 0,4 V
24 STS ISTAFTENSWITCHSIG Debcrs staner switch signat. Wirh srarterswitch ON (tttJ:batteryvottoge
With sraftsr cwirch OFF:0 V
26 PSPSWiPlS PNESSURE DerecrsPSPswitch signat. Atidle with steoringwheolin srraightaheadposition:O V
GFN
SWITCII SIGNAL) At idl6with steering wheetal fult lock: barery vo ttags
27 ACS (AJCSWITCHSIGNALJ Oer*ts ,ay'C
swirch signat. Wiih ty'C switch ON;0V
BLU/REO
Wilh Ay'Cswitch OFF|aboor 5V
WHT/RED S L U i I N T E R L O CC
KO N T R O I Drivos interloct control unit. With ignltion switch ON (ll)and brake pedal
UNIT) depresed: batlory volrage
29 PTANK (FUELTANK PFESSUEE Oer6ds lu€l tank pr€ssura sonsor signat. W i l h i g . r r r d s w i r c hO N r t t ra n d f u e t t i c a p o o e n 6 d .
LT GRN
SENSOR)
Er(ELOI W i t h p a r k i n gl i g h l s r u r n e do n a r i d t e i a b o u i2 . 5 - 3 . SV
30 GRN/FEO
Wirh low beam he€dlights turnqd on ai idts: aboul 1.5
2 . 5V
32 AKSW (BFAKESWITCH) Detets brak€ swrtch signEt, With brake pedal r6l€ased:0 V
GRN/'WHT
Whh brake pedaldepres*d: battery voltEse
' 1 : A . / T( D 1 6 Y 7
D,1 6 Ye8n g i n e )
*2: rvt/T
13:CVT(D16Y5 engine)
11- 9 2
B (25PI
ECM/PCMCONNECTOR
FCM CONNECTORB {25P) NOTE: Standardbattery voltage is 12 V
Sign.l
Powor sou rca for the ECM/PCMconlrolcir whh ignilion swilch ON (ll)ibatteryvoltage
IGP1IPOWERSOUflCE)
YELtsLK With ignition switch OFF:0 V
contrclcncuit'
Ground fo. the ECM,/PCM Lessthan 1.0 V at slltimes
BLK P G l{ P O W EG
BN O U N D )
Drives No. 2 fu€l inieclor' Wirh enqine runnin9: dulv conlroll6d
FED l N J 2 ( N o 2 F U E LI N J E C I O R )
BLU l N J 3 ( N o . 3 F U E LI N J E C T O B ) Orives No.3 fuel inieclor'
YEL l N J , rl N o . 4 F U E LI N J E C T O F ) Drives No. 4 luel injector'
O.iv€s IAC valve {Posirivoside) Wilh engine running: duty conrrollod
IACV P (IDLEAIR CONTROL
6 BLI(BIU VAIVE POSITIVESIDE)
Drives EGF controlsolonoid valve With EGRoperaiing during driving wirh follv warmed
ESOL {EG8 CONTROL
up onginsl dutY controlled
BED SOLENOIDVALVE)
W i l h E G Rn o l o p € r . r i n g : 0V
HlC tstvr(PH-PL
CONTnOL G rcund for PH-PLcontrol linsar solsnoid
PNKSLK LINEAflSOLENOIDNEGATIVE
st0E)
A/Tclutch prsssure conrrol sol€nod valv€ With ignilion swirch ON (ll):dutv controll€d
LS- (A/TCLUTCH PFESSURE
CONTROL SOTENOIDVALVE' pow6r slpply negative elecrode
8.,
sroE)
Powor $urce for lhe ECI{,'PCMcontrolc'rcuit wnh ignirion swirch ON (ll): ban€ry voltag€
rGP2{POWE8 SOUFCE)
9 YEUBLK with ignirion swnch oFF:0 v
10 BLK GSOUNDI
PG2IPOWER Ground lor ths ECM/PCMcontrolctrcuil
11 8RN I N J l { N o , 1 F U E LI N J E q I O R ) orives No. r ru6l Iniocror.

Orivos WEC solanoid v.lvs. With onsino at low lpm:0V
WS (WECSOLENOID
VALVE)
with ens,n. ar hish tpm:bsneryl9!9gl-
12" GRN,.YEL
With ignition switch ON (ll)r b5n6ry volt€gs
ICM {I6NITION CONTROLMOD
13 YEUGRN Wilh engino running: Puls6
ULE}
Drivos the IAC valve lnogativ€ 3idel With €ngin€ ru nningi dr]tv controlled
IACV N (IDLEAIN CONTSOI
15 ORN VALVE NEGATIVESIOE)
A/T clutch pr€so.6 controlsolenoid valve Wirh ignition swatchON (lll: dutYcontrorled
LS + (A,/TCIUICH PRESSURE
RED CONTFOTSOIENOIOVALVE + pow6r slpply posiliv€ oroclrode
SIDE}
Orives PH-PLcontrol line€r solenoid With qnition switch ON (lll: Pulsing srgnal
HLC LSP (PH-PI CONTROI LIN.
EA8 SOLENOIDPOSITIVESIDE)
line6r
SCLSM(STAfiTCLUTCH Groundforstartclutchcontrol
PNK/BTU LINEARSOLENOION€GATIVE
SIDE)
Ground for lh€ EcM/PcM controlcircuit' L 6 s er h a n 1 . 0v . i a l l t i m e s
20 BnN/AtK LGI (LOGICGEOUNO)
Powet sourcetorlhe ECM/PCMcontrol circuit Battaryvoltage aitnEtrmes
VBU IVOLTAGE8AC( UP)
21 Power sourco tor th6 DTC m€mory'
Ground iorths ECMnCM conrrol circuir' tsss thah 1.0 v al all times
22 BFN/8IK LG2 (LOGICGSOUND)
Witn ongine funning: dutv conrol!6d
IACV (IOTEAIR CONTROL
23 8LI(BLU
Orives sran clutch control linesr solonoid. With ignilion swilch ON (ll): Pulsing sign3r
SC LSP {STANTCLUTCHLINEAR
25'3 YEL slDE)
PoSlrlvE
sotENorD
r1: A/r (D16\t, D16Y8ensins) '4: Ol6Y5, Dl6Y8, B164? onsina
' 3 : C V T{ O 1 6 Y 5 e n s i n o )
(cont'd)
11 - 9 3
Troubleshooting
Engine/P_owertrain
ControlModuleTerminal Arrangement
('99- 00 ModelsexceptDl6Y5 enginewith M/Tl (cont,d)
ECM/FCMCONNECTOR
C 13lPI
ECM/PCMCONNECTOR
C {31P) Wire sideof femaleterminals
NOTE;Standard i s 1 2V .
Sig.al
(PNIMARY
PO2SHTC HEATEO Drivss primary hoated orygen sensof With ignition switch ON (lr)rbanery volage
l BLK4/VHT OXYGENSENSOBHEATES
CON Wrh fJly warned up €ngir. ru..i19: duty.oaro ed
TROL)
ALTC (ALTESNATOBCONTSOL) Sends aliernalo. control sig nal, With fullywa.med upengine ronning; banery vohase
2 WHT/GFN
D u r i n gd . i v i n gw i t h s m a l l e l e c t . i c a t i o a dO;V
3 8ED/BLU K5 (KNOCKSENSOR) with sngine knocking: pulses
ATTF {AITEFNATOR FR SIGNAL' Detects slternaror FR si9n.l. W i t h t u l l y w a r m e du p e n g i n er u n n i n g : OV - b a t t e r y
5 WHT/RED
v o r t a g e ( d e p e n d i n g oenr e c t f i c at to a d )
E G R L( E G NV A I V E L I F T S E N Dete.ts EGRvalve lrft sensorsignat.
WHT/8LK
SOR)
GRN,4r'l/flT S G l I S E N S OGEB O U N D ) Groond fo. MAP s€nsor. L € s sr h a n 1 . 0v a t a l l t i m e s
8 8lu CKPP(CKPSENSORP SIOE' With engine running: pulses
9 CKPM {CKPSENSORM SIDEI Ground for CKP sensor.
BLU/BLK
wlvl (wEcPREssuSE
swtTcll D€toctsVTEC pfessure switch signat, W i t h € n g i n ea t l o w e n g i n o s p e e d : 0 V
SIGNAI) With engin€ at high engino speed : banery vo ttaae
PHO25 (PRII\,1AFY HEATED Oetectsprimary heated oxygen s6nsor lsen- With lhrottle f!l1y open€d from idtewith tuly,
16 O X Y G E NS E N S O RS, E N S O R1 ) wa.med !p engin€: Ebove 0.6 V
Wilh thronl€ quickly closed: b€tow 0.4 V
MAP (I\,4ANIFOLD
ASSOLUIE Dotocrsi,4APsensor signsl. With ignitioh switch ON (ll):about 3 V
FED/GRN
PFESSUSE SENSOB} A t i d l e i 6 b o u l1 . 0V ( d e p e n d i n go n e n g i n es p e e d )
18 GBN/8LK S G 2( S E N S O R
GSOUND) L e s st h a n 1 . 0V a r a l t t i m e s
'19 VCCl (SENSORVOLTAGEI Powersourcero
MAPsenso.. W i t h i g n i t i o ns w i l c h O N { l l ) : a b o u t5 V
YEUNED
W i r h i q n i t i o ns w i t c hO F F ] 0V
20 GNN IDCP (TDCSENSOBP SIDEI With ongine running: pulses
21 8ED TDCI\,I(TDCSENSORM SIOE) Ground lor TOC aensor.
22 BTU/NED C K F P( C K FS E N S O RP S I D E ) With engine running: p!lses
23 VSS {VEHIClESPEEDSENSOR) W i l h i g n r t | o ns w i c h O N r l l rs n d l r o n t w l - e e 'r o t a t i n g .
cycles 0 V about 5V or baneryvottage
25 BED/YEL IAT ONTAKE
AIFTEi,4PEBA. Detects IAT senso. signat. With ignition switch ON (ll): about 0.1 4.8 V
TUEESENSOR) ldepending on i.take air ternpe.ature)
26 ECT (ENGINECOOLANTTEI\,I. Oelects ECT sensor signal. W i t h i g n i r i o ns w i r c hO N { l l ) : a b o u t 0 . 1- 4 . 8 V
8ED,ryVHT
PESATUBESENSOR) (depending on engine coolant temperature)
TPS (THROTTLEPOSITIONSEN, DetectsTP sensor signal. Wilh th.onle fully op€n: about 4.a V
21 NED/BLK
SOF) With rhronle f!lly closed: about 0.5 V
VCC2(SENSORVOLTAGE) Provides s6nsor voltag€.
2a YEVBLU W i t h i g n i r i o ns w i r c hO N ( t t ) : a b o u 5t V
With ignilion swiich OFF:0 V
29 YEL CYPP(CYPSENSORP SIDE) W i l h € n g r n er u n n i n g :p r u s e s
3o BLK CYPM (CYPSENSORM SIDE] G,ound for CYP sonsor.
J1 WHT/FED CKFM (CKFSENSOBM SIDE) Ground fo. CKF sonsorsign6i.
* 1 ; 4 " / Tl D 1 6 Y 7D
, 1 6 Y 8e n s i n e l
4 3 :C V I ( 0 1 6 Y 5e n g i n e )
'4: D16Y5,D16Y8,81642 engin€
1 1- 9 4
O {16P)
ECM/PCMCONNECTOR
Wire sideol temaleterminals

ECM/PCMCONNECTOR D {16P)
(D16Y7,D16Y8enginel
NOTE: Standard battery voltage is 12 V.
5i!ml
Orivos look-up controlsol€noid wlv€ a. With lock-up ON: httery vollage

LCA (LOCK.UPCON]ROL
YEL
SOLENOIDVALVEA) With lock-up OFFi 0 V
SHB {SHIFTCONTFOL Drivos sh ift cont.ol solanoid valv6 B ln E posnion,in 1stlnd 2ndeoat,n E E pos'
SOLENOIOVALVE B) tion:Battsryvoltago
GRN,M/HT I n E l p o s i r i o ni n. 3 r ds e a ti n p d , E l i n . t h s e a ri n
l_d polition: o v
Drivs locl up conttol sol€noid v6lv€ B when fulllock-up: Banory vollaga
LC8 (IOCK UP CONTBOL
3'' GRN/BLK Wnh naf locl-uP: Pulsing si9n6l
SOLENOIDVALVE B)
Powe. sourc€ ol solGnoidvalve wirh ignirion sitch ON (ll): battory voltaoe
VSSOI (BATTEsYVOLTAGE
5', BLK/YEL Wirh ignnion switch OFF:0 v
FOB SOLENOIDVALVE)
ATPR(AT GEARPOSITION DetecrsAy'Tg6a. position switch signal.
In any olh€r position: APProx. 10 V
swrTcH)
SHA iSHIFI CONTROL Oriv€6sh ift conirol sol€noid valve A. in 2nd€nd3rdsearin lpd, &l
lntr,tr position,
SOLENOIDVALVEA)
posirion:Batt€ryvollsgo
8LU/YEL ;n 1d soarin E, E position,in.ih se6rin E
ATPO3(AT GEAR POSITION Oot6ctsAy'TS6.r poeirioo switch siSnal

PNK In Enyoth.r position: APPror, t0 v
SWITCH)
L ATPD4 {AT GEAE POSITION Oorocts A/I gs8r position switch signal.
9'' YEL In any oth6t position:APProx 5 V
swrTcH)
NC (COUNTERSHAFTSPEED DetocB counr€.shaftsp66d $osr sig.als D€p€nding on v6hicls 8pe€d;Pul.ins signal
BIU SENSOB) Wh6n v€hicls i5 ltoPPsd:0 v
O€l€cts mainshalt sp€€d 3.nsor 3ign.ls Wi$ engino rLrnninglPUls6s
NM (MAINSHAFTSPEEDSEN.
REO soR)
NMSG {MAINSHAFTSPEEO Groundfo, mainshaft sp@d sensor.
SENSORGFOUNO)
oetscts A/T 96ar pGitaon swhch signal In par* or n6ulral:0 V
ATPNP {AT GEAF POSITION
13'' !T GFN In sny olhd po3ition: APProx l0V
swrrcH)
ATPz{ATGEAEPOSITION Dor€cis!y'T gos. posilion swilch signal.
BLU In any oth6r Position:APProx, 10 V
swrTcHl
NCSG{COUNTEBSHAFT SPEED Ground lor countershaii sp€3d s6nsor.
16'' GAN S E N S OG
ER O U N D )
.1 A/J (Dl6Y7, Dr6Y8 engine)
rlo (cont'd)
11 - 9 5
Troubleshooting
Engine/P_oweft
rain ControlModuleTerminaI Arrangement
('99- 00 ModelsexceptDl6YSenginewith M/Tl (cont,dl
ECM/PCMConnectol D (16P1
ECM/PCMCONNECTON
D (r6P)
Wire side of female terminats

ECM/PCMCONNECTORD {16P)(Dl6YS engine: CVTI
NOTE:Standardbatteryvoltageis 12 V
f€rminal
Wire color Terminalname Description Signal
numDea
VEL(SECONDARY
GEAR Secondarygearshaftspeed Dependingon vehiclespeed:pulses
1+3 WHT/RED
SHAFTSPEED
SENSOR) sensor, When vehicle is stopped:0 V
INHSOL{INHIBITOR Inhibitorsolenoidcontrol. With inhibitor solenoidON: baftery
2*3 GRN/BLK SOLENOIDCONTROL) voltage
With inhibitorsolenoidOFF:0 V
SHLSM(SHIFT
CONTROLGroundfor shiftcontrollinear
3+3 GRN/YEL LINEAR
SOLENOID solenoid.
NEGATIVE
SIDE)
SHLSP (SHIFTCONTROL Drivesshift control linear With ignition switch ON (tl):pulses
BLU^/vHT LINEAR SOLENOID solenoidpower.
POSITIVESIDE}
VBSOLlBATTERY Power sourceof solenoidvalve. With ignition switch ON (ll):banery
5*3 BLK,/YE
L VOLTAGE FOR voltage
SOLENOID VALVE) With ignition switch OFF:0 V
ATPR (AT GEAR DetectsA,/Tgearpositionswitch
6*3 WHT InRposition:0V
POSITION SWITCH) srgnal. In anyotherposition:
Approx.10V
VELSG(SECONDARY Groundfor secondary gearshaft
BLKA/VHI GEARSHAFTSPEED speedsensor.
SENSOR GROUND)
NDN (DRIVEN PULLEY Detects drivenpulleyspeed In otherthanParkor neutral:pulses
10*. WHT
SPEED SENSOR) sensorsrgnal.
(DRIVEPULLEY
11*3 RED/BLU NDR Detects drivepulleyspeed In otherthanParkor neutraltpulses
SPEED SENSOR) sensorsrgnal.
NDRSG(DRIVE PULLEY Ground for drive pulley speed
12*3 GRN SPEED SENSOR sensor.
GROUND)
ATPS(ATGEAR DetectsAy'Tgear positionswitch I n S p o s i t i o n :V0
13*3 LT GRN/RED
POSITION SWITCH) srgnal. In anyotherpositioniApprox,10V
DIND1DINDICATOR DrivesD indicator. With D indicator
turnedON:5 V
14*3 GRN/BLK
LIGHT) WithD indicatorturnedOFF:OV
NDNSG(DRIVEN Ground for driven pulley speed
16*r RED^/VHT PULLEY SPEED sensor.
S E N S OGRR O U N D )
*3: CVT (Dl6Y5 engine)
11 - 9 6
DiagnosticTroubleCode(DTCIChart
DTC Delection liem ProbableCause Page
{MlL indication*l
ManifoldAbsolute . Vacuum connection
PressureCircuit . MAP sensor 11 1 1 5
Range/PerformanceProblem
ManifoldAbsolute Openor short in MAP sensorcircuit
PressureCircuit MAP sensor 't1'l
P0107 (3) 11
Low Input ECMiPCM
TCM*1
ManifoldAbsolute Openin MAP sensorcircuit
't 1 121
P0108 (3) PressureCircuit MAP sensor
H i g hI n p u t ECtvt/PCM
lntakeAir Temperature . IATsensor
P 0 . 1 1 1 * 1* 4
1 .5( 1 0 ) Circuit 11-124
Range/PerformanceProblem
IntakeAir Short in IATsensorcircuit
PO112 {10} TemperatureCircuit IAT sensor 11-125
Low Input ECMiPCM
lntakeAir Open in IATsensorcircuit 't1-126
P0113 (10) TemperatureCircuit IAT sensor
H i g hI n p u t ECM/PCM
E n g i n eC o o l a n t . ECTsensor
P0116 (86) TemperatureCircuit . Coolingsystem 11-124
Range/Performance Problem
EngineCoolant Short in ECTsensorcircuit
PO't't7 {6) TemperatureCircuit ECTsensor 11-129
Low Input ECM/PCM
E n g i n eC o o l a n t Openin ECTsensorcircuit
P0118 (6) TemperatureCircuit ECTsensor 11-130
H i g hl n p u t ECM/PCM
ThrottlePosition Openor short in TP sensorcircuit
Circuit TP sensor 11-132
?0122 t1l Low Input ECM/PCM
TCM*1
ThrottlePosition Openin TP sensorcircuit
P0123 (7) Circuit TP sensor 11-136
H i g hI n p u t ECM/PClvl
PrimaryHeatedOxygenSensor Short in PrimaryHO2S(Sensorl) circuit
CircuitLow Voltage PrimaryHO2S{Sensor1) 11 - 1 3 9
P0131*' (1) ( S e n s o1r ) Fuelsupplysystem
ECM/PCM
PrimaryHeatedOxygenSensor Open in PrimaryHO2S{Sensor1} circuit
P0132*' ('r) CircuitHighVoltage PrimaryHO2S(Sensor1) 11-143
( S e n s o1r ) ECM/PCM
PrimaryHeatedOxygenSensor . PrimaryHO2S(Sensorl)
(61) Slow Response . Exhaustsystem 11-145
P0133*'
( S e n s o1r )
PrimaryHeatedOxygen . Openor short in PrimaryHO2S
SensorHeater (Sensor1) heatercircuit
P0135*? (41) . ECM 11-151
CircuitMalfunction
(Sensor1)
will be indicatedby the blinkingof the MalfunctionIndicatorLamp(MlL)when the SCSservice
*: The DTCSin parenthesis
! ta connectoris connected
a1: Dl6Y5 engine(CVT)
*2: ExceptD16Y5engine(M/T)
(cont'd)
* 1 4 : ' 9 7m o d e l
* 1 5 : ' 9 6m o d e l
* 1 6 :' 9 8m o d e l
11-97
Troubleshooting
DiagnosticTroubleCode(DTCIChat (cont'dl ,Jla
DTC
lMlL indicationl Datectionhsm Probablo Cause Page
Secondary HeatedOxygenSensor Shortin Secondary
HO2SlSensor2) circuit
P0137 (63) CircuitLowVoltage Secondary H02S{Sensor2) 11 - 1 5 3
(Sensor 2) ECM/PCI\4
Secondary HeatedOxygenSensor Openin SecondaryHO2S(Sensor
2) circuit
P0r38 {63) CircuitHighVoltage SecondaryHO2S(Sensor
2) 11-154
(Sensor 2) EC[I/PCM
Secondary HeatedOrygenSensor Secondary H02SlSensor2)
P0'139 (63) SlowResponse 1l-156
(Sensor 2)
Secondary HeatedOxygenSensor . Openor shortin Secondary
HO2S(Sensor
P0141 (65) Heater 2) heatercircuit
CircuitMalfunction . ECM/PCM 11-157
(Sensor 2)
SystemToo Lean Fuel supply system
PrimaryHO2S(Sensor1)
P0171 (45) MAP sensor
Contaminatedfuel 11,164
Valve clearance
Exhaustleakage
SystemToo Rich Fuelsupplysystem
PrimaryHO2S(sensorl)
P0172 (45) MAPsensor 11-164
Contaminated fuel
Valveclearance
}l?
P0300*16' Random Misfire lgnitionsystem
and Fuelsupplysystem
some of MAPsensor
Po3o1 /r'' \ EGRsystem r1-r66
P0302 l72l IACvalve
P0303 l73l Contaminated fuel
P0304 \74l Lackof fuel
- Cylinder1 FuelInjector
P0301 /rt\ - Cylinder2
P0302 FuelInjectorcircuit
172l - Cylinder3 lgnitionsystem 11 167
P0303 l73l - Cylinder4
P0304 \74l Lowcompression
Misfire Detected Valveclearance
KnockSensor(KS)Circuit Openor shortin KnockSensor(KS)circuit
P0325*3 (23) Malfunction KnockSensor{KS) 11-170
ECM/FCtvl
CrankshaftPosition CrankshaftPositionSensor
P0335 (4) SensorCircuit CrankshaftPositionSensorcircuit 11-172
Malfunction ECM/PCM
Crankshaft Position . CrankshaftPositionSensor
P0336 (4) Sensor . Timing belt skippedteeth 11-172
Range/Performance
ExhaustGas ' EGRvalve
P040' r*r (80) Recirculation . E G Rl i n e
InsufficientFlow Detected
CatalystSystem . Th.eeWay Catalyticconverter
P0420 (67) EfficiencyBelow . SecondaryHO2S 11 253
Threshold
*3: D16Y5engine (CVT),D16Y8engine and B1642 engine
*4: D'16Y5engine
*16: '98 model
+17:'99 - 00 models
11 - 9 8
,'o DTC Detoction lt€m ProbableC.use Page
{MlL indication}
Evaporative
Emission Control EVAPPurgeControlSolenoidVaive
SystemInsufficient Openor shortin EVAPPurgeControl
PurgeFlow SolenoidValvecircuit 11-271
P0441*5 (92)
EVAPControlCanister
Vacuumlines
ECM/PCM
FuelTankPressure
SonsorCircuit . FuelTankPressure Sensor
P0451'11 (91) ' ECM/PCM 1 12 7 4
Range/Parformance
SensorCircuit
FuelTankPressure Shortin FuelTankPressureSensorcircuat
P0452{6 (9r) LowInput FuelTankPres$ure Sensor 11-275
ECM/PCM
SensorCircuit
FuelTankPressure ODenin FuelTankPressureSensorcircuit
P0453*6 {91) HighInput FuelTankPressureSensor 11-219
ECM/PCM
VehicleSpeed V€hicleSpeedSensor
P0500*1, (17) SensorCircuit VehicleSpeedSensorcircuit 11-176
Malfunction ECM
VehicleSpeed V€hicleSp€edSensor
P0501*'3 l17l SensorCircuit VehicleSpeedSensorcircuit r 1-176
Range/Performance PCM
ldle ControlSystem . IAC valve
P0505 (14) 11-192
lvlalfunction . Throttle Body
P0700*r3 Automatic
andsomeof Transaxle
P0715
P0720 Section 14
P0730 (70)*
L P0740
P0753
P0758
P0700*1 Transaxle
Automatic
and (70)* Section14
P0725
Barometric Pressure . ECM/PCM
(Barosensor)
( 1 3 ) Circuit 11 - 1 7 8
Range/Performance Problem
Barometric . ECM/?CM(Baros€nsor)
P1107 ( 1 3 ) Pressure Circuit 11-178
Low Input
Barometric . ECM/PCM
lBarosensor)
P1108 ( 1 3 ) Pressure Circuit 11 - 1 7 8
H i g hI n p u t
ThrottlePositionLower Than . I r sensor
P 1 1 2 1 * ' . * 1 6*. ' ? \71 Expected
11-138
ThrottlePositionHigherThan . TP sensor
P1122'14.*16.*n 17l 11-'138
Expected
ManifoldAbsolutePressure . MAPsensor
15) 11 ' 1 2 3
LowerThanExpected
ManifoldAbsolutePressure . MAPsensor 't1-123
P1129*1r.*16.*"(5) HigherThanExpected
*:The E indicatorlight and the MaltunctionIndicatorLamp (MlL) may come on simultaneously.

*1: D16Y5engine (CVT)
"5: '96 D16Y5engine,D16Y7engine,D16Y8engine (sedan).'97D16Y5engine,Dl6Y7 engine (coupe:KA, KC models,sedan:KA.
KC, KL (DX) models,hatchback:all models),D16Ygengjne (sedan:KA, KC models)
*6: '96 D16Y8engine (coupe),'97Dl6Y7 engine (coupe:KL model, sedan:KL (LX) model),'97 D'16Y8engine (coupe:all models,
sedan:KL model),'98-allmodels,'99-allmodels,'00-allmodels
! l
*12: ExceptA,,/T(D16Y7,D16Y8enginei
*13: A"/T(D16Y7,D16Y8engine)
* 1 4 : ' 9 7m o d e l (cont'd)
* 1 6 : ' 9 8m o d e l
" 17: '99 - 00 models
11 - 9 9
Troubleshooting
DiagnosticTroubleCode(DTGIChart(cont'dl
DTC
(MlL indicationl Detection lt6m Probablc Cause Page
PrimaryHeatedOxygenSensor Openor shortin PrimarvHO2S(Sensor1
P1162+1 (48) (Sensor1) Circuit PrimaryH02S(Sensor1) 11-146
Malfunction
PrimaryHeatedOxygenSensor . PrimaryHO2S(Sensor1)
P]163' (61) (Sensor'1)Circuit 11-145
SlowResponse
Pl164*r (61) (Sensorl) CjrcuitRange/ 11-150
Performance Problem
P1165*? (61) (Sensor1) CircuitRange/ 11-150
Performance Problem
PrimaryHeatedOxygenSensor Openor shortin PrimaryHO2S(Sensor1)
(Sensor'1)HeaterSystemElectrical heatercircuit
P1166' (41i Problem 11 - ' 1 6 1
PrimaryHO2S(Sensor1)
ECM/PCM
PrimaryHeatedOxygenSensor Openin PrimaryHO2S(Sensor1)VS+circuit
P1167*' (41) lSensor1) HeaterSystem PrimaryHO2S(Sensor1) Heater 11-163
Malfunction PrimarvHO2S{Sensor1)
PrimaryHeatedOxygenSensor . Shortin PrimaryHO2S(Sensor1) LABEL
P1168*' (48) (Sensor1) LABELLowInput circuit 11-151
PrimaryHeatedOxygenSensor . Openin PrimaryHO2S(Sensor1)IABEL

Pl169*? (48) (Sensor1)IABELHighInput circuit 11.152
. Shortin groundcircuit
WEC System Malfunction WEC SolenoidValve
Openor shortin WECSolenoid
Valvecircuit
P1259*3 (221 VTECPressureSwitch Section6
Openor short in VTECPressureSwitch
circuit
ECM,FCM
ElectricalLoad ElectricalLoadDetector
P1297*s (20) DetectorCircuit ElectricalLoadDetectorcircuit 11-179
Low Input ECM/PCM
Electrical Load ElectricalLoadDetector
Pr298+' l20l Detector Circuit ElectricalLoadDetectorcircuit 11 - 1 8 1
H i g hI n p u t ECM/PCM
BandomMisfire lgnitionsystem
ano Fuelsupplysystem
someof MAPsensor
P0301 l71l EGRsystem 11-166
P0302 l72l IACvalve
P0303 l73l Contaminated fuel
P0304 l74l Lackol fuel
*7: D16YS engine(M/T)
*8: D16Y5, D'16Y8 engine
*9: USAmodel
* 1 4 r ' 9 7m o d e l
*15r'96 model
11 - 1 0 0
DTC Detection ltem Probable Cause Page
(MlLindicationl
CrankshaftSpeed . CKFsensor
P1336 (54i FluctuationSensor 11183
IntermittentInterruption
CrankshaftSpeed CKFsensor
P1337 (54) Fluctuation Sensor CKFsensorcircuit 11-'183
N oS i g n a l ECM,PCM
CrankshaftPosition/Top ' CKP/TDC
sensorcircuit
P13s9 (8) DeadCenterSensor 11-187
Disconnected
Top DeadCenter . tuL sensor
P1361 (8) SensorIntermittent 11-172
Interruptron
Top DeadCenter TDCsensor
P1362 (8) SensorNo Signal TDCsensorcircuit 11-172
ECIV/PCM
CylinderPositionSensor . CYPsensor
P1381 {9) 11-172
IntermittentInterruption
CylinderPositionSensor CYPsensor
P1382 (9) No Signal CYPsensorcircuit 11-112
ECM/PCM
Evaporative Control
Emission Fuelfillcap
SystemLeakDetected
{FuelTank Vacuum connection
Area) Fu€ltank
Fueltank pressuresensor
P1456*5 (90) EVAPbypasssolenoidvalve 11-283
EVAPtwo way valve
EVAPcontrol canistervent shut valve
EVAPcontrol canister
L EVAPpurge control solenoidvalve
Evaporative
EmissionControl Vacuum connection
SystemLeakDetected(EVAP EVAPcontrol canister
Area)
ControlCanister Fueltank pressuresensor
EVAPbypasssolenoidvalve 11-283
P1457*6 (90) EVAP two way valve
EVAPcontrol canistervent shut valve
Fuel Tank
EVAPpurge control solenoidvalve
*6: '96 D16Y8engine(coupe),'97
Dl6Y7engine(coupe:KL model,sedan:KL (LXlmodel),'97D16Y8engine(coupe:all models,
models,'99-all
sedan:KL model),'98-all models.
models,'00-all
I ta (cont'd)
1 1 - 10 1
Troubleshooting
DiagnosticTroubleCode(DTCIGhart(cont'd)
DTC Detegtion hom Page
Probablo Csuss
lMlL indicationl
EGRValve EGRvalve(withlift sensor)
Lift Insufficient EGRvalvelift sensorcircuit
Detected EGRcontrolsolenoidvalve(A,/I)
EGRcontrolsolenoidvalvecircuit 't1-256
P1491*! \12J
E G Rl i n e
EGRvalvecircuit(M/T)
ECM
EGRValve EGRvalve (with lift sensor)
P1498*. 112) Lift Sensor EGRvalve lift sensorcircuit 11-265
High Voltage ECM
ldleAir ControlValve IACvalve
CircuitFailure '11-194
Pl508*10 (14) IACvalvecircuit
ECM
ldleAir ControlValve Openor shortin IACvalvecircuit
{14) CircuitFailure IACvalve 1l-198
ECM/PCM
EngineControl . ECM/PCM
Module/Powertrain
Control lvlodule
P1607 1-) 11-188
lnternal
CircuitFailureA
P1655*1 (30) TMA,/TMB SignalLineFailure ODenor sho.t in TMA,/TMB
circuit 11-189
P1705 AutomaticTransaxle
P1706
P1753
P1758
P1768
P1785
P1790
P1791
P1793 (70)* Section14
P1870
P1873
P1879
P1885
P1886
P1888
P1890
P1891
*: The E indicatorlightandthe Malfunction
Indicator
Lamp{MlL)maycomeon simultaneously.
*4: D16Y5engine(M/T)
+10:ExceptA/TandDl6Y7engine
*11:A,/TandD16Y7engine
*18:D16Y5engine(CW)(except'99- 00 models)
11-102
How to ReadFlowcharts
A flowchartis designedto be usedfrom startto final repair.lt's likea map showingyou the shortestdistance.But beware:
"map" anywherebut a "stop" symbol,you can easilyget lost.
lf you go off the
tSrARTl flowchart.
the conditionsor situationto starta troubleshooting
Describes
(boldtype)
FanoNl Asksyou to do something;performa test,set up a conditionetc.
@ Asksyou aboutthe resultof an action,then sendsyou in the appropriatetroubleshooting

direction.
tsroPI The end of a seriesof actionsand decisions.describesa final repairactionand sometimesdirectsyou to

{boldtype) 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 aretroubleshooting(seeillustrationbelow)'
. Most of the troubleshootingflowchartshave you resetthe EngineControlModuls (ECM)/Powertrain ControlModule
(pCM)and try to duplicatethe DiagnosticTroubleCode (DTC). lf the problem is intermittent
and you can't duplicatethe
code,do not continuethoughthe flowchart.To do so will only result in confusion and, possibly,
a needlesslyreplaced
ECM/PCM.
. ,,Open"and "Short" are common electricalterms.An open is a breakin a wire or at a connection.A short is an acci-
dentalconnectionof a wire to ground or to anotherwire. In simple electronics,this usuallymeanssomethingwon't
work at all. In complexelectronics(likeECM's/PCM'sl. this can sometim€smean somethingworks,but not the way it's
suDDosed to.
toosE
11 - 1 0 3
PGM-FISystem
SystemDescription
ENGINE L O D U L E( E C M Y
C O N T R OM
INPUTS POWERTRAIN CONTROL MODULE(PCM) OUTPUTS
CKP/TDC/CYP
Sensor
FuelIniectors
MAPSensor PGM-FlMain Belay{FuelPump)
MIL
IATSensor IACValve
TP Sensor !y'CCompressorClutchRelay
EGRValveLiftSensor*' RadiatorFanRelay*,
PrimaryH02S F ; i l r rj " - - - - - f i - t r i - ' r . ; l CondenserFanRelay
SecondaryHO2S ALT*'
VSS lcM
BAROSensor Fb"t."'i"d" c;;il EVAPPurgeControlSolenoid
ELD*' - \ r\
KS€ PrimaryHO2SHeater
StarterSignal ----t
/
F,h"'c;;tr*".io";-l -:/ SecondaryH02SHeater
ALT FRSignal EGRControlSolenoidValve*r
Air Conditioning
Signal @."r.l"sc;;ll EGRvalve*6
A/T GearPositionSignal EVAPBypassSolenoidValve*'
BatteryVoltage{lGN.1} B""k-pF"""till EVAPControlCanisterVentShut
ErakeSwitchSignal EaM/PcM
PSPSwitchSignal VTECSolenoidValve*5
FuelTankPressure Sensor*i DLC
VTECPressure Switch*5 Lock-upControlSolenoidValve*a
ClutchSwitchSignal*6 ShiftControlSolenoidValve*3
CountershaftSpeedSensornB LinearSolenoidValve*3
MainshaftSpeedSensorrs
*1: Dl6Y5engine
*2: USAmodel
*3: CW (D16Y5 ensine),D16Y8engineand 81642ensine
*4: '96 D16Y8enginelcoupe),'97Dl6Y7engine(coupe:KL model,sedan:KL (LX)model),'97D16Y8engine{coupe:all models,sedan:KL
model),'98-all
models,'99'allmodels,'00-all
models
+5:D16Y5,D16Y8,816A2 engine
*6: M/T (D16Y5enginei
*7: CVT1D'l6Y5 engine)
+8:A/T (D16Y7, D16Y8engine)
*9: '96 D16Y5engine,'96D16Y7engine,'96Dl6Y8 engine(sedan),'97D16Y5engine,'97Dl6Y7 engine(coupe:KA, KC models,sedan:
KA, KC,KL (LX)models,hatchback:all models),'97D16Y8engine(sedan:KA,KC modelsi
PGM-FI Sy3lem
The PGM-Fl system on this model is a sequential multipon fuel injection system.
Fuel iniector Timing and Duration
The ECM/PCM contains memories for the basic discharge durations at various engine speeds and manifold air flow rates.
The basic discharge duration, after being read out from the memory. is further modified by signals sent from various sen-
sors to obtain the final discharge duration.
ldle Air Control
ldle Air Control Valve llAC Valve)
When the engine is cold. the A,/Ccompressor is on, the transmission is in gear, the brake pedal is depressed,the P/S load
is high, or the alternator is charging, the ECM/PCMcontrols current to the IAC Valve to maintain the correct idle speed.
lgnition Timing Control
. The ECM/PCM contains memories for basic ignition timing at various engine speeds and manifold air flow rates.
lgnition timing is also adjusted for engine coolant temperature.
. Aknockcontrol system was adopted which sets the ideal ignition timing for the octane rating ofthegasoline used.*3
Othgr Control Funqtions
1. Starting Control
When the engine is started, the ECM/PCM provides a rich mixture by increasing fuel injector duration.
2. Fuel Pump Control
. When the ignition switch is initially turned on, the ECM/PCM supplies ground to the PGM-Fl main relay that sup-
plies current to the fuel pump for two seconds to pressurizethe fuel system.
. When the engine is running, the ECI\4PCM supplies ground to the PGM-FI majn relay that supplies current to the fuel
oumo.
. When the engine is not running and the ignition is on, the ECM/PCM cuts ground to the PGM-FI main relay which
cuts current to the fuel pump.
11-104
3. FuelCut-offControl
. Duringdeceleration with the throttlevalveclosed,currentto the fuel injectorsis cut off to improvefuel economyat
speedsover the followingrpm:
. D 1 6 Y 5e n g i n e( M / T ) : 8 5 r0p m
. D]6Y5engine(CVT),D'16Y8 engine(USAM/T):920 rpm
. Dl6Y8 engine(USAA,/I),D16Y7engine(USAA,/T);910rpm
. D16Y8engine(CanadaM/T),D16Y7engine(canada):990 rpm
' D16Y8engine(CanadaM/T):1,000rpm
. 8 1 6 A 2e n g i n e9: 7 0r p m
. Fuelcut-offactionalso takesplacewhen enginespeedexceeds6,900rpm (D16Y5,D16Y7engine;D'16Y8engine:
7,000rpm. 816A2engine:8.100rpm), regardlessof the positionof the throttlevalve,to protectthe enginefrom
'99 Dl6Y7 engine(A,/T)and '99 D16Y8engine(A./T), the PCMcutsthe fuel at enginespeedsover
over-rewing.With
5,000rpm when the vehicleis not moving.
IVC CompressorClutchRelay
When the ECM/PCMreceivesa demandfor coolingfrom the air conditioningsystem,it delaysthe compressorfrom
beingenergized, and enrichesthe mixtureto assuresmoothtransitionto the A,/Cmode
5 . Evaporative Emission(EVAP)PurgeControlSolenoidValve*'
When the enginecoolanttemperatureis above 154'F(68'C).the ECM/PCMcontrolsthe EVAPpurgecontrolsolenoid
valvewhich controlsvacuumto the EVAPpurgecontrolcanister.
Evaporative Emission(EVAP)PurgeControlSolenoidValve*a
When the enginecoolanttemperatureabove 154"F(68"C),intakeair temperatureabove32"F(0'C)and vehiclespeed
above 0 mile (0 km/h)or [Ay'Ccompressorclutch on and intakeair temperatureabove 160"F(41'C)],the ECM/PCM
controlsthe EVAPpurgecontrolsolenoidvalvewhich controlsvacuumto the EVAPpurgecontrolcanister.
6. ExhaustGasRecirculation (EGR)ControlSolenoidValve*?
When EGRis requiredfor controlof oxidesof nitrogen(NOx)emissions.the ECMcontrolsthe EGRcontrolsolenoid
valvewhich suppliesregulatedvacuumto the EGRvalve
1 . AlternatorControl
The systemcontrolsthe voltagegeneratedat the alternatorin accordance with the electricalload and driving mode,
which reducesthe engine load to improvethe fuel economy.
ECM/PCMFail-safe/Back-upFunctions
1. FailsafeFunction
When an abnormalityoccursin a signalfrom a sensor,the ECM/PCMignoresthat signal and assumesa pre-pro-
grammedvaluefor that sensorthat allowsthe engineto continueto run.
2. Back-uD Function
When an abnormalityoccursin the ECM/PCMitself,the fuel injectorsare controlledby a back-upcircuitindependent
of the systemin orderto permitminimaldriving.
3. Self diagnosisFunctionlMalfunctionIndicatorLamp(MlL)l
When an abnormalityoccursin a signalfrom a sensor,the ECM/PCMsuppliesgroundfor the lvllLand storesthe DTC
in erasablememory.When the ignition is initiallyturned on, the ECM/PCMsuppliesground for the MIL for two sec-
ondsto checkthe MIL bulb condition.
4. Two Trip DetectionMethod
To preventfalse indications,the Two Trip DetectionMethodis usedfor the HO2S,fuel metering-related. idle control
system,ECTsensor,EGRsystemand EVAPcontrol systemself-diagnostic functions.When an abnormalityoccurs,
the ECM/PCMstoresit in its memory.When the same abnormalityrecursafterthe ignitionswitch is turned OFFand
ON 0l) again,the ECM/PCMinformsthe driver by lightingthe MlL. However,to easetroubleshooting, this functionis
cancelledwhen you jump the servicecheck connector. The MIL will then blink immediatelywhen an abnormality
occurs,
5. Two (or Three)DrivingCycleDetectionMethod
A "DrivingCycle"consistsot startingthe engine.beginningclosedloop operation,and stoppingthe engine.lf misfir-
ing that increasesemissionsis detectedduringtwo consecutivedrivingcycles,or TWCdeteriorationis detecteddur-
ing three consecutivedrivingcycles,the ECM/PCMturns the MIL on. However,to easetroubleshooting, this function
.1.
is cancelledwhen you jump the servicecheckconnector.The MIL will then blink immediatelywhen an abnormality
occurs.
(cont'd)
1 1 - 10 5
PGM-FISystem
SystemDescription(cont'dl
Lean Burn Control {D16Y5engine: CvT)
TOC/CKP/CYP
SENSOR
MAP SENSOR
CKF SENSOR
Comparison oI currentair
fuel ratio to target ratio
ECM
The lean burn control system is basedon the characteristic increasein crankshaftangularacceleration
which occursin
when the air-fuelratiogetsleaner.
The CKFsensor,which is mountedon the crankshaft,monitorssnginespeed,lf crankshaftangularacceleration falls below
a certainlevel(targetair-fuelratiolevel),the amountof injectedfuel is reouceo.
lf crankshaftangularacceleration exceedsthis level.the amountof fuel is increased.
This system improvesfuel economyand driveabilityby controllingthe amount of injectedfuel in the lean burn range
immediatelvbeforecombustionstartsto deteriorate.
1 1 - 10 6
EngineControlModule/PowertrainControlModule(ECM/PCM)
I t'96- 98 Models,'99- 00 Dl6Y5enginewith M/Tl
checkfor a loosefuse No. 25 {METER
NOTE:lf this svmptomis intermittent, 7.5A) in the
The Malfunc{ion Indicator Lamp underdash{use/relaybox, a poor connectionat ECM/PCM terminalA18,or an intermit
{MlLl never comes on (evenlor tent ooenin the GRN/ORN wire betweenthe ECM/PCM (A18)and the gaugeassemblv.
two secondsl atter ignition is
turned on.
Turnthe ignitionswitchON (ll).

- Repair short or open in the
wile botwoen No. 25 {M€TERI
17,5Altus€ and gau99 assem'
ls the low oil pressurelighton? bty.
- ReplacoNo.25 IMETERI(7,5
A)tuse.
Try to start the engine.

A I32PI
ECM/PCMCONNECTOR
PGl {BLKI
Doesthe enginestan?
Checklor an open in the wiles

{PGlinosl:
2 . l d e a s u r ev o l t a g e b e t w e e n
b o d y g r o u n da n d E C M / P C M
connectorterminalsA10 and
A23 individually. Wire sideot femaleterminals
L Check tor an open in the wire ot

bulb (MlL line): Repair open in the wire(s)
1. Turnthe ignitionswitchOFF. b e t w e e n E C M / P C Ma n d G 1 0 1
2 . C o n n e c t h e E C M / P C Mc o n - ls thorelessthan 1.0V? (localod at the thetmostat hous_
nector terminal A'18to body ingl that had morethan 1.0V.
groundwith a jumperwire.
Substituto . known-good ECM/

PCM and recheck.It symptom/
indication go6s away, roPlace A (32P}
ECM/PCMCONNECTOR
the origin.l ECM/PCM.
2 6 8 l0 11
12 l 3 t 5 t 6 1 t I t 19 20 22 23 2a
- Repair open in th€ wires
25 27 xt 30
ls the MIL on? betwoen ECM/PCMlAl8l and
gaug6 a$embly.
- Replacethe MIL bulb, MrL I luanpenwrnr
IGRN/ORN) I

PCM and .echeck.lf symptom/ Wire sideof femaleterminals
indication goes away, replaco
! 1 , (cont'd)
11-107
PGM-FISystem
EngineControlModule/PowertrainControlModule(ECM/PCMI
('96- 98 Models,'99- 00 Dl6Y5enginewith M/Tl (cont'd)
NOTE:
The Maltunction Indicator Lamp . Whenthereis oo Diagnostic TroubleCode(DTC)stored,the MtL wi stay on if the SCS
(MlLl stays on o. comes on eftar servace connectoris connected andthe ignitionswitchis on,
two s€conds, . lf this symptomis intermittent, checklor:
- A looseFl E/M115A) fuse in the underhoodluse/relaybox
- A looseNo. 13 FUELPUMPfuse(15A) in the underdashfuse/relay box
- An intermittentshon in the wire betweenthe ECM/PCM(C7)and the servicecnecK
connector
- A n i n t e r m i t t e nst h o r t i n t h e w i r e b e t w e e nt h e E C M / P C M( A 1 8 )a n d t h e g a u g e
Check the Oiagnoslic Trouble assembly
Code{DTC}I - An intermittentshon in the wire betweenthe ECM/PCM{D4)and the MAp sensor
1. Connecta scantool or Honda An intermittentshort in the wire betweenthe ECM/PCM(D10),the Tp sensor,the
PGMTester. EGRvalve l:ft sensor (D16Y5engine)and/or the Fuel tank pressuresensor (,96
2. Turnthe ignitionswitchON (ll). Dl6Y8 engine(coupe),'97 016Y7engine(coupe:KL model,sedan:KL (LX)modeli,
3. Read the DTC with the scan '97 016Y8
engine{coupe:all models,sedan:KL modeti,'98,allmodels}
tool or HondaPGMTester. - PGM-FImain relay
. Seethe OBD ll scantool or HondaPGMTesteruser'smanualslor speciticoperating
instructions.
Are any DTC{s)indicated? Go to troubleshooting p.oc€dur€s

(se€pago 11{11.
Checkthe DTCby MIL indication:

2. Connectthe SCSservicecon,
n e c t o rt o t h e s e r v i c ec h e c k
connector.
3. Turnthe ignitionswitchON (lli.
Repair opon ol short in wire

botwoen the ECM/PCM (C8)
Doesthe MIL indicateany DTC? and Data Link Connector.
Go to troublelhooting proce-
dure ls6epage11-811. ECM/PCMCONNECTOR
C 13lPI
scs tBRNI
Try to startthe engine.
Doesthe engine start?
Wire side of female terminals
Check for a short in the wire (To page11 109)

(SCSlin€l:
1 . D i s c o n n e ctth e S C S s e r v i c e
connector.
2. Stop the engineand turn the
ignitionswitchON {lli.
3. Measurevoltagebetweenthe
ECM/PCMconnectorterminal
C7 and body ground.
Ropair short to body Iround in

ls thereapprox.5 V? the wire betweon ECM/PCMlCTl
and sorvicecheckconnector.
(Topage11,109)
11-108
l F r o mp a g e1 1 1 0 8 )
Checkfor a short in the wire {MlL

linell
2. Disconnectthe Eclvl/PCMcon-
nectorA (32P).
3. Turnthe ignitionswitchON {ll).
Ropair short to body gtound in

ls the MIL ON? the wir. between the ECM/PCM
lA18)and MlL.

PCM and recheck.lt 3ymptom/
indicaiion goes away, rePlace
ihe original ECM/PCM.
( F r o mp a g e1 1 1 0 8 )
InspectFl E/M (10 A) fuse in the

undeFhoodIuse/relaybox.
- Repair short in the wirg

b€tweon Fl E/M (15 A) luse
and PGM-FImain rolay.
- ReplaceFl E/M (15 Alfuse.
InspectNo. 13 FUELPUMP(15A)
fuse/relaY
fuse in the under-dash
- Repait lhort in the wire

botween No. 13 FUEL PUMP
115Al fuse and PGM-FImain
reray.
- RoplaceNo. 13 FUELPUMP
115Al tu3o.
Checkfor a short in a 3€nsor:
2. Disconneclthe 3P connector
from eachsensorone at time:
. TP sensor
. EGRvalvelift sensor(D16Y5
engrne)
. F u e l t a n k p r e s s u r es e n s o r
( ' 9 6 D 1 6 Y 8e n g i n e( c o u p e ) ,
' 9 7 D 1 6 Y 7e n g i n e ( c o u P e :
K L m o d e l , s e d a n :K L ( L X )
m o d e l ) , ' 9 7D 1 6 Y 8e n g i n e
l c o u p e :a l l m o d e l s ,s e d a n :
KL model,'98-allmodels)
! {To page11 110)

(cont'd)
11 - 1 0 9
PGM-FISystem
EngineControlModule/Powertrain ControlModule(ECM/pCMl
('96- 98 Models,'99 - 00 D16Y5enginewith M/Tl (cont,dl
( F r o mp a g e 1 1 - 1 0 9 )
ECM/PCMCONNECTOR
D {16P}
Doesthe N4lLgo OFF? Replacethe sensor that caused
the light to go out. VCCl {YEL/RED}
Check fo. a short in the wi.os

(VCClines):
':. Turnthe ignition
switchOFF.
2 . D i s c on n e c t t h e E C M / P C M
connectorD (16P).
3. Checkfor continuitybetween Ropair short to body ground
b o d y g r o u n da n d E C M / P C M in the wire betweon ECM/
c o n n e c t o tre r m i n a l sD 4 a n d PCM{O4)and MAP s6n3or. Wire sideof femaleterminals
D10individually. Repair short to body ground
in the wire between ECM/
PCMlD10l,the TP sensor,the
EGRvalve lift sensor{D16Y5
ls therecontinuity? engine) and/or the Fuel tank A (32P}
ECM/PCMCONNECTOR
pressuresensor {'96 Dl6Yg
enginelcoupe),'97 D16Y7
e n g i n e ( c o u p e :K L m o d e l ,
IGP 1
Checktor rn open in the wires s e d a n : K L ( L X l m o d e l ) ,' 9 7
(lGPlines): D16Y8 engine (coupe:all {YEL/BLKI
1. Disconnectthe fuel injectors models,sedan:KL model. €8- 2 I 11
and IACvalveconnectors, allmodelsl. 12 1 3 l 5 t 6 I t t 8 t 9 20 23 21
25 27 2a 29 3 0
3 . M e a su r e v o l t a g e b e t w e e n
c o n n e c t otre r m i n a l sA 1 1 a n d IGP2
(YEL/BLKI
v) (l
424 indivjdually.
- Repair open in the wirels)
between ECM/PCM (A11,
A24land PGM-Flmain relay. Wire sideof femaleterminals
- Check for poor connections
ls therebatteryvohage?
or loose wiras at the PGM-FI
main relay,
- Test the PGM-FImdin relav LG1
Checkfor an open in the wires lseepag611-237). {8RN/
(LGline3): BLK)
1. Reconnectall sensorconnec
tors. I 2 5 8 to l1
2. Reconnect the ECM/PCM con- '12 t t 1 1 t 5 l 6 1 7 t 8 t 9 20
23 2a
nectorD (16P).
2A 23 30
4. Measurevoltage between
b o d y g r o u n da n d E C M / P C M LG2
c o n n e c t o tr e r m i n a l sA g a n d {8RN/
A22individually. 8LK}
Repair open in the wirolgl

ls therelessthan 1.0V? b€twe€n ECM/PCM {A9, A22} and
G101that had more than 1.0V.
Substitute 6 known-good ECM/

PCM and r€check.lf symptom/
indication 9o€s away, replace
11-110
EngineControlModule/Powertrain ControlModule(ECM/PCM)
('95- 00 ModelsexceptDl6Y5 enginewith M/T)
NOTE:
The Mrlfunction Indicator LamP . Whenthere is no Diagnostic TroubleCodelDTC)stored,the MIL will staYon if the SCS
{MlL) never comes on {even tor seruiceconnectoris connectedandthe ignitionswitchis on.
two seconds) after ignition is . lf this symptomis intermittent,
checkfor:
turnedON lll). - A looseNo. 25 (METER) {7.5A) fusein the underdashfuse/relaybox
- A looseFl E/M(15Alluse in the undeFhoodfuse/relay box
- A looseNo. 13 FUELPUMPfuse(15A) in the under-dash box
fuse/relay
- An intermittentshon in the wire betweenthe ECM/PCM (A18)and the gaugeassem'
Turnthe ignitionswitchON lll). - an intermittentshort in the wire betweenthe ECM/PCM(C19)and the MAP sensor
- An intermittentshort in the wire betweenthe ECM/PCM{C28),the TP sensor,the
EGRvalvelift sensor(D16Y5engine)and/orthe Fueltank pressuresensor('96D16Y8
engine (coupe),'97D16Y7engine lcoupe: KL model, sodan:KL (LX) model)"g7
Dt6Y8 engine(coupe:all mod;ls, sedanlKL model),'98-allmodels,'99-al'models'
'00-allmodels.
- PGM'FImain relay
. See the oBD ll scantool or HondaPGM Testeruser'smanualsfor specificoperating
instructrons,
- Repair shott or open in tho

wire bstwoon No. 25 IMETER)
l?.5A)tuse and gaugatsom_
ls the low oil pressurelighton? blv.
- ReolaceNo. 25 (METERI(7.5
Alluse.
A I32PI
CONNECTOR
ECM,/PCM
Try to start the engine.
Checkfor an opon in the wire or

bulb (MlL line):
1. Turn the ignitionswitchOFF.
Doesthe enginestart? 2 . C o n n e c t h e E C M / P C Mc o n '
nectorterminal A18 to body
groundwith a iumperwire.
3. Turnthe ignitionswitchON (ll)
Wiresideof {emaleterminals
- Repair open in tho wire3

betwoon ECM/PCM (A18) and
gaugo .*tembly.
- Rool.ce the MIL bulb.

PCM and rochoc&. lf sYmptom/
Turn the ignitionswitchOFF. indication goes sw6y, repl.ce
InspectFl E/M(15A)fuse in the tho original ECM/PCM.
underhood Iuse/relaybox.
Rop.ir short in the wirc

betwo€n Fl E/M (15 A) luso
and PGM-Flmrin rGl.y.
Reol.ce Fl E/M (15 A)tusa.
lnspectNo. 13 FUELPUMP{15A}
luse in the under-dashfuse/relay
- Reoair short in the wiro

between No. 13 FUEL PUMP
115Al luse sod PGM-FImain
.f, -
relay.
ReolaceNo. 13 FUEL PUMP
115A) tuse. (cont'd)
(Topage11 112)
11-111
PGM-FISystem
EngineControlModule/Powertrain ControlModule(ECM/PCM)
('99- 00 ModelexceptDl6Y5 (M/Tl engine)(cont'd)
( F r o mp a g e ' 1 1 - 1 1 1 )
Checkloi an open in the wires

(lGPlinesl:
1. Disconnect thelueliniectorand
IACvalveconnectors.
3 , M e a s ur e v o l t a g e b e t w e e n
c o n n e c t o tr e r m i n a l s8 1 a n d
Bg individually.
- R e p a i ro p e n i n t h e w i r o ( 3 )
between ECM/PCMlBl, B9l
and PGM-Flmain relay.
- Check tor poor connections
ls there batteryvoltage?
or loose wires al the PGM-FI
main relav.
- Test tho PGM-FImain rehy
(3.e page 11-237).
ECM/PCMCONNECTOR
B {25P)
Checktor an open in the wires
(PG,LG lines):
1 . R e c o n n e ctth e f u e l i n i e c t o r
and IACvalveconnectors.
body ground and ECM/PCM
connectorterminals82, 810,
820 and 822 individually.
Repair open in the wirels)

b e t w e e n E C M / P C Ma n d G 1 0 1
ls therelessthan1.0V? LG1(BRN/BLKI
llocated ai the l6ft side of tho
intaks m.nifoldl thrt h.d more Wiresideof femaleterminals
than 1.0V.
C (31P)
ECM/PCMCONNECTOR
Check for a short in the wires

{VCCI,VCC2lin6s}:
Measurevoltage between body
ground and ECM/PCMconnector
terminals
C19andC28individually. Checktoa a 3hort in s 3ensor:
While measuring voltage vcc2 vccl
betweenbody ground and ECM/ f e m a l e t e r m i n a l s IYEL/BLUI {YEL/RED)
P C [ / tc o n n e c t o rt e r m i n a l sC 1 9
and C28 individually,disconnect
ls thereapprox.5V? the 3P connectorof each sensor
one at time:
. MAPsensor
. TP sensor
. EGRvalve
. Fueltankpressuresensor
Reoairshort in lhe wire betwe.en

ls thereapprox.5 V? M A P 3 a n s o r ,T P s e n s o r , E G R
valve, Fuel tank pres3ure3ensor
Substiiute a known-good ECM/ and ECM/PCM{Cl9, C28).
PCM and racheck. ll symptom/
indicetion goes eway, replace
th6 original ECM/PCM. Replace tho sansor that had
.pprox. 5 V.
11-112
NOTE:
The Malfunction Indicator LamP "in-"n tf'"r" is no DiagnosticTrouble Code (DTCistored,the MIL will stav on ;{ the scs
lMlL) staYson or comes on after serviceconnector andthe ignitionswitchis ON (ll)
is connected
checkfor:
. lf this symptomis intermittent,
- An intermittentshortin the wire betweenthe ECM/PCM (A10)and the servicecheck
connector
( A 1 8 1a n d t h e g a u g e
- A n i n t e r m i t t e nst h o r t i n t h e w i r e b e t w e e nt h e E C M / P C M
. s"" it'" Oab ll scantool or HondaPGMTesteruser'smanualsfor specificoperating

C h e c kt h e D i a g n o s t i cT r o u b l e instructions.
Code(DTC):
1. Connecta scantool or Honcla
PGMTester.
3. Read the DTC with the scan
tool or HondaPGMTester.
Go to troubloshooting Proc€dures
indicated?
Are any DTC(S) (seepage 1141).
check the DTCby MIL indic.tion:

2. Connectthe SCSservicecon_
n e c t o rt o t h e s e r v i c ec h e c k
'l 3. Turnthe ignitionswitchON (ll)

Repair open or 3hort in wiro
between ihe ECM/PCM(A21)
and Data Link Connector.
Doesthe MIL indicateanYDTC?
Go to troubleshooting Ploce_
du.es (seepage 11-811.
Try to start the engine
Substitute . known-good ECM/

PCM and recheck lt sYmptom/
indication goes awaY, rePlaca
th. original ECM,/PCM.
A I32P)
ECM/PCMCONNECTOR
C h e c kf o r a s h o r t i n t h e w i . e
(Scs line):
1. Turn the ignitionswitch OFF
and turn the ignition switch
o N1 ) .
2 - M e a su r e v o l t a g e b e t w e e n
body groundand the ECM/
PCMconnectorterminalA10 Wire side of female terminals
Reoair short to body ground in

ls there batteryvoltage? the wiro bstwaen ECM/PCM (A101
and service ch€ck connoctot.
(cont'd)
(Topage11-'114)
1 1 - 11 3
PGM-FISystem
EngineGontrolModule/PowertrainControlModule(ECM/PCMI
('99- 00 ModelsexceptDl6Y5 enginewith M/T) (cont'dl
{ F r o mp a g e 1 1 1l 3 )
Checkfor a short in the wi.e lMlL

linelr
2. Disconnectthe ECM/PCMcon
nectorA (32P).
Repairshorl to body ground in

l s t h e M I LO N ? the wire between the ECM/PCM
{A18}andMlL.
Substituto a known-good ECM/

PCM and r€check.lf symptom/
indication goes away, roplace
the o.iginal ECM/PCM.
11-114
ManifoldAbsolutePressure(MAP)Sensor('96Models)
problem (vacuumleak) in the
The scan tool indicatesDiagnosticTrouble Code (DTC)P0106:A mechanical
ManifoldAbsolutePressure(MAP)Sensorsystem'
TheMAPsensorconvertsmanifoIdabsoIutepressureintoeiectricaIsigna|sandinpUtstheEcM/PcM'
OUTPUT
VOLTAGE
(v13.5
3.0
2.5
2.0
1.5
1.0
0.5
0 lin. Hgl GAUGE

READING
300 (mm Hgl
- The MIL has been reported on
- OTCP0106is storod.
- Or from PtobableCauseLisl.
Problomverificetion:
1. Do the ECM/PCMResetPro-
cedure.
2. Start the engineand keep
enginespeedat 1,000rpm for
one minutewith the transmis'
sion in @ or I Position{Mff
in neutral).
ls DTCP0106indicated?
C h e c kt o r v a c u u m l e a k a g eo r
blockagebetweenthe MAP sen'
Checkthe MAP sensoroutPut: sor and throftlebody
3. Checkthe MAP with the scan
tool. ls thereleakageor blockage?
Chockthe MAP s€nsol output:

1. Stopthe engane.
tool.
(Topage11 116)
( T op a g e1 1 - 1 1 6 )
l l , {cont'd)
1 1 - 11 5
PGM-FISystem
ManifoldAbsolutePressure(MAP)Sensor('96Modelsl(cont'dl
( F r o mp a g e1 1 - 1 1 5 i
{ F r o mp a g e1 1 - 1 1 5 )
Chockto. poor response: Checklor poor response:

1 . S t a r t t h e e n g i n e .H o l d t h e 1 . S t a r t t h e e n g i n e .H o l d t h e
engineat 3,000rpm with M in engineat 3,000rpm with M in
E or E position, M/T in neu E or E position,M/T in neu-
tral untiltheradiator tan comes tral until the radiatorfan comes
on, then turn the ignition on, then turn the ignition
switchOFF. switchOFF.
2. Startthe engine. 2. Startthe engine.
3. Checkthe MAP with the scan 3. Checkthe MAP with the scan
tool. tool.
ls a N4APot 40.0kPa {300mmHg,

12.0in.Hg)or lessindicatedwithin
one secondafter staning the
engine?
ls a MAP of 40.0kPa(300mmHg,
12.0in.Hg)or lessindicatedwithin
The MAP sensor is OK st this time. one secondafterstartingthe
engine?

PCM and rechock. lt symptom/
indication go6s .way. .6plrce
th€ original ECM/PCM.
11-116
ManifoldAbsolutePressure{MAP}Sensor
('96- 98 Models,'99- 00 D16Y5enginewith M/T)
(high vacuum) problem in the
The scan tool indicatesDiagnosticTrouble Code (DTC)PO107:A low voltage
ManifoldAbsolutePressure(MAP)sensor.
Tho MIL has been roport€d on.

DTCP0107is storod.
Problamverification:
lool.
lntormittont failuro, sYatgmia OK

ls approx.101kPa(760mmHg, al thb timo. Chocklor Pool con_
30 in.Hg)indicated? noqtiona or looso wirca at C111
{MAP !6nsor) ond ECM/PCM.
(C111)
MAP SENSOR3P CONNECTOR
Chockfor an opon in wiJe (VCCI vccr

lino): (YEL/BEDI
2. Disconnectthe MAP sensor
3. Turn the ignitionswitchON (ll).

I MAP sensorconnectorNo l
terminaland No 2 terminal
Ropair open in tho wit b€twocn

ls thereapprox.5 V? ECM/PCM(Dill tnd MAP !enso].
Checkfor .n open or ahort in the

MAP 3€naor:
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,
0.6in.Hg)or lessindicated?
(D16Y5engine (with
YES
cw))
T
Chsckto. a short in the TCM:
2. Disconnect the 22Pconnector
from the TCM.
3 . T u r n t h e i g n i t i o ns w i t c hO N
0r).
4. checkthe MAP with the scan
tool.
( T op a g e1 1 - 1 1 8 )
(cont'd)
11-117
PGM-FISystem
ManifoldAbsolutePressure(MAp)Sensor
('96- 98 Models,'99- 00 D16Y5enginewith M/Tl (cont,d)
( F r o mp a g e1 1 - 1 1 7 )
ls approx.2 kPa('15mmHg,0.6
in.Hg)or lessindicated?

IC1l1I
Check for a short in ihe wire
{MAPline)l
1. Turnthe ignitionswitchOFF. MAP
2 . D i s c on n e c t t h e E C M / p C M (RED/GRNI
connectorD (16P).
the MAPsensorconnectorNo.3
terminalandbodyground.
Wiresideof femate;rminats
R6pairlhort in tha wire b€twaen

ECM/PCM {D3l .nd MAP !6ru0r.

PCM..nd recheck. normal MAP
is indiceted, .eplsce lhe original
ECM/PCM,
11-118
|'
ManifoldAbsolutePressure(MAP)Sensor
(;gg- OOModelsexceptDl6Y5 enginewith M/T)
A low input (high vacuuml problem in the
The scan tool indicatesDiagnostrcTrouble Code (DTC)PO1O7:
ManifoldAbsolutePressure(MAP)sensor'
signalsand inputsthe ECM/PCM'

The MAp sensorconvertsmanifoldabsolutepressureinto electrical
OUTPUT
VOLTAGE
lvl3.5
3.0
2.5
2.0
1.5
1.0
0.5
(in.Hgl GAUGE
0 REAOING
lq, 2oo 3q, (x, 5q) 6q) 700 (mmHgl
- The MIL h'3 been reported on

- OTCP0107b stor€d.
.-l Problemverilication:
1. Turnthe ignitionswitchON {ll)
2. check the N4APwith the scan
tool.
lntermittent failuro,3Ystomis OK
ls approx. 101kPa(760mmHg, at this time. Ch€ckfor Poor con'
30 in.Hg)indicated? nection3 or loose wiros at C111
IMAP sonsorl and ECM/PCM.
IC114)
Ch.ck for an opcn in wit. {vCC1

linel: vccl
1. Turnthe ignitionswitchOFF tYEL/RED)
2 . D i s c o n n e ctth e M A P s e n s o r
connector.
MAP sensorconnectorNo. 1
terminaland No 2 terminal
Wire sido of fomalg tormin6ls
Repairopsn in the wirg botween

ls thereapprox.5 V? ECM/PCM(C19)rnd MAP seGor.
(To page 11-120)
{cont'd)
1 1 - 11 9
PGM-FISystem
ManifoldAbsolutePressure(MApl Sensor
('99- 00 ModelsexceptDl6yS enginewith M/T) (cont,dl
( F r o mp a g e1 1 1 1 9 )
Checkfor an open or shon in the

MAP s€nsor:
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,
0.6in.Hg)or lessindicated?
MAPSENSOn
3PCONNECTOB
tcllilt
Check tor a sho.t in lhe wire
{MAPline):
2 . D i s c o nn e c t t h e E C N 4 / p C N 4 MAP
connectorC (31P). (RED/GRNI
the MAPsensorconnectorNo.3
terminalandbodyground.
Repairshort in the wire between

ECM/PCM{Cl7} and MAp s€n-
sor.

PCM and rech6ck.lf no.mal MAp
is indicated, replace the o.iginal
ECM/rcM.
1 1-120
! ManifoldAbsolutePressure(MAPISensor-
i;idlga lil;dels,'99- 00 Dl6Y5ensinewith M/T)
voltage (low vacuum) problem in the
The scan tool indicatesDiagnostrcTrouble code (DTC)Po108:A high
ManifoldAbsolutePressure(MAP)sensor.
The MIL has beenreportedon

OTCm108 is stolod.
Problemvetitication:
1 . S t a r t t h e e n g i n e .H o l d t h e
engine at 3,000rPm with no
load (in Parkor neutral)until
the radiatorfan comeson, then
let it idle.
tool.
lntormittent lailure, sFtom k OK
ls 101kPa(760mmHg,300 in.Hg) .t thb time. Chocklor Poor con'
or higherindicated? nections or loorg wires at Cll'l ICl11}
|MAP sensorl snd ECM/PCM.
Check tor an open in the MAP

36nSOt:
3P connector. MAP
3. Installa jumperwire betlveen IRED/GRNI
the MAP sensor3P connector JUMPERWIRE
terminals No 3and No 2.
4. Turnthe ignitionswitchON (ll). Wire sideol femaleterminals
l l 5. Checkthe MAP with the scan
tool.
ls 101kPa(760mmHg,30 0 in.Hg)
or higherindicated? vccl
IYEL/RED)
Checkfor an open in wire (SG1

line):
1. Removethe iumperwire.
MAP sensor3P connectorte.
minalsNo. 1 and No 2
Rapai. open in the wito batwoen
ls thereapprox.5 V? ECM/PCM(D12).nd MAP !en.or. D (16PI
ECM/PCMCONNECTOR
JUMPERWIRE
Check for an oPon in the wiie MAP
(MAPlinel: (RED/GRN)
con-
2 . C o n n e c tt h e E C M / P C M
nectorterminalsD3 and D12
with a iumPerwire.
3. Turnthe ignitionswitchON (ll). sG1
4. Checkthe MAP with the scan (GRN/WHT)
tool.
Wire sideof femaleterminals
ls 101kPa(760mmHg,30 0 in.Hg) Repairopon in the wiles bstlt oon
or higherindicated? ECM/PCM(D3l and MAP 3oGor.
lr, (cont'd)
Substituto a known'good ECM/
PCM and rochock.ll normal MAP
is indicated, replace tho original
ECM/PCM.
11-121
PGM-FISystem
ManifoldAbsolutePressure(MAPISensor
('99- 00 ModelsexceptD16YSenginewith M/T) (contd)
The scan tool indicatesDiagnosticTrouble Code (DTC)P0108:A high voltage flow vacuum)problem
in the
ManifoldAbsolutePfessure(MAp)sensor,
Tho MIL has boon rcDortodon.

DTC ml 08 b stolod.
Problemverification:
'1.Start
the engine.Hold the
engine at 3,000rpm with no
let it idle.
toot,
Intormittent f.ilu.e, rystom is OX
ls 101kPa(760mmHg.30 at thi! time. Chocktor poor con-
in.Hg)or higherindicated? n6ction3 or looso wirea at C111
(MAP 3en.or) and tho ECM/
PC-M.
(C111I
Check for an open in the MAP
aon5('r:
1. Turnthe ignalionswitchOFF.
3P connector.
3. Install a jumper wire betwesn
the MAP sensor3P conn6ctor
terminals No.3 and No.2. MAP
4. Turnthe ignitionswitchON {ll). IRED/GRNI
tool. JUMPERWIRE
ls 101kPa(760mmHg,30
in.Hg)or higherindicated?
Check fo. an opcn in wiro (SGl vccl

line): IYEL/RED)
1. Removothe jumperwire.
2. Measurevoltage between the
MAP sonsor3P connectorter
m i n a l sN o . 1 a n d N o . 2 .
Roprir opon in tha wiJo bctwoen
ls there approx. 5 V? thc ECM/FCM(C7l rnd the MAp
sonln t.
Chsck for an open in tho wi.e

ECM/PCMCONNECTOR
C (31PI
{MAPlino}:
2. Install a jumper wire on the
ECM/PCMconnectorsbetween
C7andC17.
tool,
Repairop€n in the wir6a bstwoon JUMPERWIRE

ls 101kPa(760mmHg,30
in.Hg)or higherindicated? tho ECM/FCM(C171and rh6 MAp Wiresideof femaleterminals
scnltoa.

PCM and rechcck,It normal MAP
is indiceted. r.place tho original
ECM/PCM.
11- 1 2 2
--Downloaded from www.Manualslib.com manuals search engine
ManifoldAbsolutePressure(MAP)Sensor(cont'dl
(MAP)lower than
The scan tool indicatesDiagnosticTroublecode (DTc) P1128:ManifoldAbsolutePressure
exoected.
- Tho MIL has been t€Portedon.

- DTCP1128is stored.
tool.
ls 54.1kPa(406mm Hg, 16.0 lntermitteni failu.e, sYstomi! OK

in. Hg)or higherindicated? at thb time.
higherthan
The scantool indicatesDiagnosticTroublecode (DTC)P1129:ManifoldAbsolutePressure{MAP)
L exoected,
- The MIL has beenroportedon.

- DTCP1129is slorod
Problemv6rilicaiion:
t h e r a d i a t o rf a n c o m e s o n ,
then let it idle.
tool.
ls 43.3kPa(325mm Hg, 128 Int6rmittent failuto, sy3tem i3 OK

in. Hg)or lessindicated? at thi3 time.
11-123
PGM-FISystem
IntakeAir Temperature(lAT)Sensor('96- 97 Models)
The scan tool indicatesDiagnosticTroublecode (DTC)P0111:A range/performance
problemin the lntakeAar
Temperature(lAT)Sensorcircuit.
The IAT sensor is a temperaturedependantresistor(thermistor).

The resistanceof the thermistordecreasesas the intake
air temperatureincreasesas shown below.
- The MIL hss beon reportedon.

- DTCP0111is stored. RES|STAI{CE
{tol
- Or from ProbableC.use List.
2. Disconnect the IAT sensor2P
connector,
3. Removethe IATsensor.
4. Reconnectthe IAT sensor2p . 32 .. ro. tr. 2r, zaa r..l
-20 o 20 /|o ao ao 100 rrotlcl
5. Leavethe IAT sensorexposed INTAIG AIR TEMPEMTURE

to ambaent temperature,
6. Turn the ignitionswitch oN fll).
7. Checkthe IAT with the scan
tool.
Rsplscgthe IAT sensor.
Checktho IAT sensoroutput:

1. Warm the IAT sensorwith a
hair dryer-
tool.
Didthe IATrise2"F(1.C)or more Int€rmittont failu.e, system is OK

from the ambienttemperature? at this time.
Replscethe IAT sensor.
1 1-124
I
IntakeAir Temperature(lATl Sensor
The scantool indicatesDiagnosticTroubleCode{DTC)P0112:A low voltage(hightemperature)problemin the
lntakeAir Temperature(lAT)sensorcircuit.
The MIL has beenTeportedon. RESISTANCE

IKOI
DTCP0112is stored.
1. TurntheignitionswitchON 1ll)
tool-
. a2 .. toa rra rrl l:rt t.al

20 0 20 ro ao ao too t2ot.cl
AIRTEMPEFATURE
INTAXIE
ls 302'F(150"C)or hagher(or
H Limit in Hondamode ot
PGMTester)or 0 V indicated?
ls the correctambrenttemper Roolac€tho IAT 3ensor.

atureindicatedi' ?
*2: lf the engineis warm, it will be
higherthan ambienttemPerature.
lntermittent failure, svstom is OK

6t this tim€. Checkfor Poor Gon-
.-l Checktor a shon in the IAT sen-

sor:
nections or loos€ wires st C112
{lAT.en3orl and ECM/PCM.
1. Disconnectthe IAT sensorcon

nector.
tool.
l s 3 0 2 " F( 1 5 0 ' C ) ohr i g h e (r o r

H'Limitin Hondamodeof
PGMTester)or 0 V indicated?
IAT SENSOR2P CONNECTOR
{C112)
Ch6ckfor s short in the wira (lAT

lin€):
-+-r
1. Turn the ignitionswitchOFF I-_T-
' l ' l
2. Disconnectthe ECM/PCMcon-
I
IAT
nectorD (16P)(C(31P))*'.
3. Checkfor continuitybetween {RED/YEL)
the IATsensor2Pconnectorler- =
minalNo.2 andbodyground. Wire sideof femalet e r m r n a r s
Reoairshort in the wire bstween
ECM/PCMtD8 (c25)'1) and IAT

PCM and recheck. It normel IAT
is indicated, replace the original
rf,
ECM/PCM.
* l: '99 - 0Omodels except Dl6Y5 engine with M/T-
11-125
PGM-FISystem
IntakeAir Temperature(lAT)Sensor
('96- 98 Models,'99- 00 D16Y5enginewith M/Tl
The scantool indicatesDiagnosticTroubleCode(DTC)POl13:A high voltageflow temperature)problem
in the
IntakeAir Temperature(lAT)sensorcircuit,
The MIL has beenreportedon.

DTCP0113b sto.6d.
Problemveritication:
tool.
ls -4'F 1-20"C)or less(or L Limit Intermittent tailuJe,systom is OK

in Hondamodeof PGNITester)or at this time, Check to. poor con-
5 V indicated? nections or loose wir.s at C112
{lAT senso.l .nd ECM/PCM,
Checkfor an open in the IAT sen-

sol:
1. Disconnect the IAT sensor2p taT sENsoR2PCONNECTOn
(Cl12l
connector,
2. Connectthe IAT sensor2P con-
n e c t o rt e r m i n a l sN o , 1 a n d
No.2 with a jumperwjre.
3. Checkthe intakeair tempera,
SG2
I ' j r l
'---.]__+
ture with the scantool. tAT
(GRN/BLKII I IRED/YEL}
JUMPER
WIRE
ls -4"F ( 20'C)or less(or L-Limit
in Hondamodeof PGMTester)or Repbcethe IAT sensor. Wire sideof femaleterminals
5 V indicated?
Check tor an open in th6 wires D (16PI

ECM/PCMCONNECTOR
{lAT.SGzline!):
2. ConnectECM/PCMconnector
terminalsD8 and D11 with a

4. Checkthe IAT with the scan sG2
tool. IAT IRED/YEL) (GRN/BLK)
JUMPERWIRE
ls -4"F ( 20'C)or less(or L-Limit R€p6ir opan in the wiro! hween Wiresideof femaleterminals
io Hondamode ol PGMTester)or EC-M/PCMlD8. 011l and IAT sen-
5 V indicated?

PCM end recheck. lf normal IAT
is indic.ted, replace the original
ECM/PCM.
11- 1 2 6
L IntakeAir Temperature(lAT)Sensor
('99- 00 ModeisexceptD16Y5enginewith M/Tl
(low temperature)problemin the
The scantool indicatesDiagnosticTroublecode (DTC)P0113:A high voltage
IntakeAir Temperature(lAT)sensorcircuit.
The MIL has be€nrePortedon.

DTCP0113i3 stored.
Probl€mvetification:
tool.
Intormittont f.iluro, tyrtom i. OK

ls -4"F (-20"C)or less(or L-Limit .t thi! tim.. Chocl for Poor con'
in Hondamodeof PGMTester)or nactions or looso wit6 !t C112
5 V indicated? tlAT ..n!or) rnd ECM/PCftl,
IAT SENSOR2P CONNECTOBIC112'
Checktor an open in tho IAT son'

304:
r-+-r
1. Disconnect the IAT sensor2P I t l , llAr
L1__f
sG2
connector, (RED/YELI
IGRN/BLK} I I
2. Connectthe IATsensor2Pcon_
n e c t o rt e r m i n a l sN o . 1 a n d JUMPER
No.2 with a jumPerwire. WIRE
3. Checkthe intakeair tempera-
ture with the scantool. Wire sideof femaleterminals
I
ls -4"F {-20"C)or less(or L-Limit
in Hondamodeof PGMTester)or
5 V indicated?
C (31PI
ECM/PCMCONNECTOR
Check lor an open in iho wirg3

{lAT,SG2 linesl;
terminalsC18and C25with a
iumperwire. JUMPERWIRE
4. check the IAT with the scan Wiresideof lemaleterminals
tool.
ls -4"F (-20"C)or less(or L-Limit Roprir opan in tho wilaa brlwocn

in HondamodeoI PGMTesterlor ECM/PCM (C18, C25l .nd IAT
5V indicated? !on30r.
substituts a known'good ECM/

PCM and recheck. ll normal IAT
is indicated, replace the otiginal
ECM/PCM.
11-127
PGM-FISystem
EngineCoolantTemperature(ECTISensor
The scan tool indicatesDiagnosticTrouble code (DTC)P0116;A range/performance
problem in the Engrne
CoolantTemperature(ECT)Sensorcircuit.
The ECTSensoris a temperaturedependantresistor(thermistor).

The resistance
of the thermistordecreases
as the engine
coolanttemperatureincreases
as shown oetow.
RESISTANCE
(ko)
THERMISTOR
- a 3 2 6 8r 0 al a 0 l ? 62 t 22 4 8 1 ' r r
-20 o 20 ao o D r@ Il, r'c)
ENGINE COOLANT IEMPERATURE
NOTE:lf DTCP0117and/orP01'18
are storedat the sametime as DTCP0116,troubleshootthose DTCSfirst. then recheck
for DTCP0116.
PossibleCause
. ECTsensordeterioration
. Malfunctionin the thermostatand coolingsystem
- The MIL has bognreportedon.

1. Start the engine.Hotd the
then let it idle.
2. With the scantool, checkthe
is 176 200'F{80- 93'C)or Intermiftent lailure. system is OK

0.0-0.TVindicated? ai thi. time. Ch.ck the thc.mo-
stat 6nd thc cooling system.
Check the thermostat and the

cooling system. ll they als OK,
raplacethe ECTsensor.
11- 1 2 8
|.
fD;r.tt The scantool indicatesDiagnosticTroubleCode(DTC)P0117:A low voltage(hightemperature)problemin the
|jg EngineCoolantTemperature(ECTIsensorcircuit.
The MIL has been,eported on.

DTCml 17 is storod.
Problomvorification:
2. Checkthe ECTwith the scan
tool.
ls 302"F(150"C)
or higher{or Intermittont failulo, sy3tom it OK
H-Limitin Hondamodeof at thk tim., Chockfor Poor oon-
PGMTester)or 0 V indicated? n.ctions or loo!. wiraa at C122
IECT3en orl and ECM/FCM.
ChecktoJ a short in the ECTs.n-

5('t:
the ECTsensor2P
1. Disconnect
connector.
rool.
ls 302"F(150"C)
or higher{or
' f H-Limitin Hond6modeof
PGMTesterl or 0 V indicated? (C122I
ECTSENSOR2P CONNECTOR
Check for a 3hort in tho wiro

IECTlinel:
nectorD (16P)(C{31P))*.
the ECTsensor2Pconneclorter-
minalNo,1 andbodyground.
B.gair short in the wiro bltween
ECM/PCM(D2 (C261'l.nd ECT
Substitute . lnown-good ECM/

PCM .nd rocheck.It normrl ECT
is indic.ted, replaco the original
ECM/PCM,
*:'99 -Oo modelsexceptD16Y5enginewithM/T
.1, (cont'd)
11-129
PGM-FISystem
EngineCoolantTemperature(ECT)Sensor
('96- 98 Models,'99- 00 D16YSenganewith M/T) (cont'd)
The sc€ntool indicatesDiagnosticTroubleCode(DTC)P0118;A high voltage(low temperature)problemin the
EngineCoolantTemperature(ECT)sensorcircuit.
- Tho MIL ha3bcen r€oortedon.

- OTCm118 b stored.
Problomvorificttion:
tool.
ls -4"F (-20'C) or less(or L-Limit Intcrmitt.nt failui.. rydom is OK

in Hondamode ol PGMTester)or at thir timc. Chackfor Door con-
5 V indicated? naction! or loor! wiaar at C122
IECT..n.orl .nd ECM/rcM,
ECt SENSOR2P CONNECTOR
{C1221
Chscklor sn open in thc ECT3an-
soa: ECT
1 . D i s c o n n e ct h e E C Ts e n s o r IRED/WHTI
2P connector.
JUMPERWIRE
z . L o n n e c rr n e E L t s e n s o rz F
connectorterminalsNo. 1 and sG2
No.2 with a jumperwire. (GRN/BLK)
tool. Wire side of female terminals
ls -4'F (-20'C) or loss(or L-Limit

in Hondamode ol PGMTesterlor ECM/PCMCONNECTOR
D Il6PI
5 V indicated?
JUMPERWIRE
sG2tGRN/81r0
Chack for an opon in the wire.
{ECT,SG2lin..l:
2. Connect ECM/PCMconnector
terminals D2 and D11 with a
jump€rwire.
4. Checkthe ECTwith the scan Wire side of Iemale terminals
tool.
ls -4'F 1-20'Clorless(o. L-Limit Repriroprn in tha wirar bstwoon

in Hondamode ol PGMTester)or CCM/PCM IDZ Dl1) .nd EGTrcn-
5 V indicated? aor.
Sub3titut. s known-good ECM/

FCM and r.chcck, It normel ECT
i! indicatod, roplaco tho origin.l
ECM/PCM.
11 - 1 3 0
PGM-FISystem
EngineCoolantTemperature(ECT)Sensor
t ('99- 00 ModelsexceptDl6Y5 enginewith M/Tl
The scantool indicatesDiagnosticTroubleCode(DTC)P0118:A high voltage(low temperature)problemin the
EngineCoolantTemperature(ECT)sensorcircuit.
The MIL has been reportedon,

oTC P0118is stored.
Problemverilication:
tool.
lntormittent failuro, systom is OK

ls -4'F (-20"C)or lesslor L-Limit at thb timo. Checklor poor con'
in Hondamodeo{ PGMTester)or nections or 10036wiraa at C122
5 V indicated? {ECTssnsorl and ECM/rcM.
{C122)
ECTSENSOR2P CONNECTOR
Checkfor an open in the Efi sen' ECT

(RED/Wr{T)
sori
1. Disconnect the ECTsensor2P JUMPERIVIRE
connector,
2 . C o n n e c tt h e E C Ts e n s o r2 P sG2
connectorterminalsNo, 1 and {GRN/BLK)
No.2 with a jumperwire.
3. Checkthe ECTwith the scan wire side of female terminals
tool.
I
ls -4"F 1-20"C)or less(or L-Limit
in Honda mode of PGMTester)or
5 V indicated?
C 131PI
ECM/PCMCONNECTOB
Check for sn open in the wires

IECT.SG2 linesl:
jumperwire.
3. Turn the ignitionswitchON (ll). JUMPERWIRE
4. Checkthe ECTwith lhe scan
tooi. Wiresideof femaleterminals
ls -4'F {-20"C)or less(or L-Limit Rspair opon in th6 wiros bstwoon

in Hondamodeof PGN4 Tester)or ECM/PCM (Cl8, C26l and ECT
5 V indicated? 3ensot.
Substitute 6 known-good ECM/

PCM and recheck.l{ no.mal EcT
is indicatod, .eplace the original
ECM/PCM.
11-131
PGM-FISystem
ThrottlePositionITP)Sensor('96- 98 Models,'99- 00 D16Y5enginewith M/Tl
The scantool indicatesDiagnosticTroubleCode (DTC)P0122:A low voltageproblemin the ThrottlePosition
(TP)sensorcircuit.
The TP Sensor is a potentiometer. lt is connectedto the throttle valve shaft. As the throttle position changes,the throttle
positionsensorvariesthe voltagesignalto the ECM/PCM.
OUTPUTVOLTAGEIVI
- Tho MIL h63 boon roportod on.
- DTCm122 i. storcd.
2
Probl6mvoritic€tion: 1 THROTTLE
1. Turn the ignitionswitchON (ll). OPENING
0
2 . C h e c kt h e t h r o t t l e p o s i t i o n FULL
with the scantool. THROTTLE
TP SENSOR3P CONNECTOR
ICllOI
ls there approx..49V when Int..mittent tailura, rFiem ir OK
the throttle is fully closedand at thit tima. Chocktor Door con-
approx.4.5V when the throttle nections or loorc wires !t C110
is lully op6ned? ITPlonrorl .nd ECM/FCM. s{i2 vocz
(GRN/BLKI (YEL/BLUI
Ch6ck lor rn opon in the wire

(VCC2linel:
2. Disconnectths TP sensor3P
connector. Wire sideot femal6terminals
4, Measure voltage between
the TP sensor3P conn€ctorter-
minalsNo.l and No.3.
ECM/PCMCONNECTOR
D IT6PI
ls thereapprox.5 V?
Checkfor rn opcn in wire IVCC2

line):
Measurevoltage betweenECM/ SG2 IGRN/ALKI
PCMconneclorterminalsD10and
011. Wire sideof femaleterminals
Chockfor rn open or 3hort in TP
lon30t:
Roplir op€n in thg wiro batwcsn
2. At the s€nsor side, measure ls thereapprox.5V?
ECM/PCM{DlO) rnd TP ren3or.
resistancebetweenthe TP sen-
sor terminals No. 1 and No. 2
with the throttle fully closed.
Substitut6 r known-good ECM/
PCM and rach6ck. lf pro$ribod
vohrge i! now avrilablc, replac€
{ T op a g el 1 - 1 3 3 ) tho o.iginel €CM/FCM.
Terminalsideof maleterminals
11-1 3 2
t
{Frompagel1'132}
ls thereapprox.0.5- 0.9k0?
'P SENSOR3P CONNECTOR
Checkfor an opsn or 3hort in tho

TP sensor:
Measureresislancebetweenthe
T P s e n s o rt e r m i n a l N o . 2 a n d
No. 3 with the throttlefully closod.
ls thereapprox.3.6- 5.4k0?
Chock lor an open in the ECM/

PCMITPSlin6l:
D {16PI
ECi'/PCM CONNECTOR
1. Reconnectthe TP sensor 3P
connector.
2. Turn the ignitionswitchON {ll}.
ECM/PCMconnectorterminals
TPSIRED/
Btx) t- sG2IGRN/BLK)
D l a n dD 1 1 .
hm
6 I t to tl 12
tl t5 ta
ls there approx.0.5Vwhen the Substitut. r known-good ECM/

throttleis fully closedand PCM and r.ch.ck. lf pt6crib.d
vohrga i. now !Y!il.blo, lcpl.co Wire side ol lemale terminals
approx.4.5Vwhen the throttle
is fully opened? tho odginal ECM/PCM.
lDl6Y5 engine
f
Checktor . short in tha TCM:
2. Disconnectthe 22P connector
from the TCM.
TPSIR€O/ SG2IGRN/BLKI
/t. MeasurevoltagebetweenECM BLKI
c o n n e c t o rt e r m i n a l sD 1 a n d
D11.
ls thereapprox.0.5 V whenthe
throftleis tully closedand
approx.4.5V whon the throttle
is fully opened?
Ropairrhort in the wir€ bdtwcon

ECM/PCM(D11,TCM and TP i.n.
30r,
11 - 1 3 3
PGM-FISystem
Throttle Position(TPlSensor('99- 00 ModelsexceptD16Y5enginewith M/T)
scantool indicatesDiaqnosttcTroubleCode (DTC)P0122:A low voltageproblem in the Throttleposition
lTO12Z
- _TI
{ | r, sensoacrrcurl.
The TP Sensor is a potantiometer.lt is connectedto the throttle valve shaft. As the throttle position changes,the throttle
position sensor varies the voltage signal to the ECM/PCM.
ERUSH
HOI.DEN
- Th. MIL har boon.6portcd on. OUTPUTVOLTAGE(VI
- DTCP0122b siored. BRUSH
5
BESIS?OF 4
1. Start the engine,Hold the 3
load (in Parkor neutral)until TERi'I AL 2
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 1
OFF, INNER THROTTLE
2. Turnthe ignitionswitchON (ll). BUS}IING OPE II{G
3 . C h e c kt h e t h r o t t l e p o s i t i o n
o
FULL
with the scantool. THROTTLE
{Cl1OI
ls there approx..49V when l||t rmittont failura, lyrtom b OK
the throttle is fully clos€dand at thi! tima. Chocktor poor con-
approx,4.5 V when the throttle nactionr o. looao wires rt C110
is fullyopened? {TP3.n!or} rnd ECM/PCM. sG2 vcc2
IGRN/8LKI (YEUBLUI
Checkfor an opan or 3hort in tho

wi.c (VCC2linc):
2. Disconnectthe TP sensor3P
connector, Wiresideof temaleterminals
4. Measure voltago between
the TP sensor3P connectorter ECM/PCMOONNECTOR
C 131P)
minalsNo. 1 andNo.3.
ls theroapprox.5 V?
Chccl tor .n opln in wiro IVCC2

lin€l:
Mgasurevoltago betweenECM/ Wire sideol femaleterminrls
PCMconnectorterminalsC18and
Ch.Gkfor rn opan or 3hort in TP

36nlot:
2, At the sensor side, moasure ls thereapprox.5 V? R.prir opcn in the wiro bctw.en
r e s i s t a n c eb e t w e e n t h e T P ECM/PCM(C281and TP 3€nror.
sensor3P connectorterminals
No. 1 and No. 2 with th€ throt,
tle fullyclosed. Subrtituto r known-good ECM/
PCM .nd rochcck. lf pro.c.ibed
voltaga i! now available,roplaco
(To page11-135) tho origin.l ECM/PCM.
Terminal side of male terminals
11-134
L Downloaded from www.Manualslib.com manuals search engine
L
(Frompage11-134)
lsrhereapprox.0.5- 0.9ko?
Chockfor an open or 3hort in the

TP 3en30r:
Measure resistancebetween the
TP sensor3P connectorterminals
No. 2 and No. 3 with the throttle
tully closed.
Terminalsideol maleterminals
ls thereapprox.4.5k0?
Check for .n opon in th€ ECM/ C (31PI

ECM/PCMOONNCCTOR
PCM(TPSlino):
1. Reconnectthe TP sensor con-
nector.
2. Turn the ignitionswitch ON {ll).
3. Measurevoltago between Cl8
terminaland C27terminalon
the ECM/PCMconneclor.
I ls there approx.0.5V when the Sub.lltut. . known-good ECM/ Wire sideoI femaleterminals
throttleis fully closedand PcM lnd r.chock. ll pr6cribod
approx.4.5V when the throttle vohago b now lvallabla, aeplrca
is fully open€d? tho originrl ECM/PCM,
Ropairahort in th. wiro b€{ween

ECM/FCMlC18l .nd TP ..n.o].
.1,
11-135
PGM-FISystem
ThrottlePosition(TP)Sensor(€6 - 98 Models,39 - 00 D16Y5enginewith M/T)
The scantool indicatesDiagnosticTroubleCode (DTC)P0123:A high voltageproblemin the ThrottlePosition
(TP)sensorcircuit.
The MIL has been reportodon.

DTCP0123is sto.ed.
Problomveritication:
with the scantool.
IC1lOI
ls thereapprox.10%whenthe Intermittont tailuro, system is OK
throttleis fully closedand at thb timo, Checkfor ooor con-
approx.90o/o when the throttle nociion3 or loos6 wiros at C110
is lully opened? ffP s€nsor)and ECM/PCM.
sG2 vcc2
IGRN/BLKI {YEL/BLUI
Chgckto. an opan in the TP son-

sot:
connector. Wire sideof femaleterminals
3. Turn the ignitionswitch ON (ll).
4. At the harnessside,measure
voltagebetweentho TP sensor
3P connecterterminalsNo, 1
a n dN o . 3 .
ls thereapprox.5V?
D (16P)
ECM/PCMCONNECTOR
Ch.ck tor .n open in the wira

(SG2linel:
Measurevoltage betweenECM/
PCMconnector terminalsD10and
D11.
SG2 (GRN/BLKI
ls thereapprox.5 V? Repairop6n in the wire betwoen

ECM/PCM(D11)rnd TP s6nsor.

PCM snd rech.ck. lf pra3cribed
voltago is now available,replsce
tho original ECM/PCM,
11 - 1 3 6
ThrottlePosition(TP)Sensor('99- 00 ModelsexceptD16Y5enginewith M/Tl
I
The scantool indicatesDiagnosticTroubleCode{DTC)P0123:A high voltageproblemin the ThroftlePosition
{TP)sensorcircuit.
The MIL has been reportedon

DTCP0123is slored.
1 . S t a r tt h e e n g i n e .H o l d t h e
t h e r a d i a t o rf a n c o m e s o n
then turn the ignition swatch
OFF,
2. Turnthe;gnitionswitchON (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.
{C11OI
ls thereapprox.10%whenthe lntormittenl tailure, 3ystom is OK
throttleis fullyclosedand at this time. Check tor Poor con'
approx.90%when the throttle neqtions or loo3€ wires at C'110
is fullyopened? (TPsensorltnd ECM/PCM. sG2 voc2
{GRN/BLKI {YEUBLU}
'l' Ch€ckfor an open in the TP s6n-

soJ:

4. At the wire harnessside, mea-
sure voltagebetweenthe TP
sensor3P connectorterminals
Wiresideof femaleterm;nals
N o .1 a n dN o . 3 .
ls there approx. 5 V?
C (31PI
ECM/PCMCONNECTOR
Check tor an open in the wire

(SG2lino):
PCMconnectorC (31Piterminals
C18and C28.
Repairopen in the wite betwe€n

ls thereapprox.5 V?
ECM/PCM(Cl81and TP son.or.
Wiresideof femal€terminals

PCM and recheck. lf Pr$cribed
voltage is now aveilabl6. replace
(cont'd)
11-137
PGM-FISystem
ThrottlePosition(TP)Sensor(cont'd)
I Pl 121 | The scan tool indicatesDiagnosticTroubleCode(DTC)Pl 121:ThrottlePosition(TP)lowerthan expected.
- The MIL hss been.eportedon.

- DIC P1121i. stored.
Problemvedficatiod:
with the scantool.
ls TP *% or higherindicated
when the throftle is tully Intermittent tailure, ryttem i! OK
openod? rtthistimo.
* : 1 1 . 8{ D 1 6 Y e5 n g i n e i
12.9{016Y7engine)
12.2(D16Y8engine)
13.7(816A2engine)
TroubleCode(DTC)P1122:ThrottlePosition(TP)higherthanexpected.
I P1122 I The scantool indicatesDiagnostic
- The MIL ha3 be6n repoJted on.

- DTCPl122 i. llorod.
P.oblomv6dfication:
with the scantool.
ls TP'70 or l€ssindicatedwhen Intormitt6ot frilu.o, aFtom b OK

the throttleis fullyclosed? at thb timo.
*: 16.5{Dl6Y5,Dl6Y8engine}
16.9(D16Y7engine)
16.5(81642engine)
11 - 1 3 8
PrimaryHeatedOxygenSensor{PrimaryHO2SI(Sensor1)
t ('96- 98 ModelsexceptDl6Y5 enginewith M/Tl
The HeatedOxygenSensor(HO2S)detectsthe oxygencontentin the exhaustgas and signalsthe ECM/PCM. In operation,
the ECM/PCMreceivesthe sjgnalsfrom the sensorand variesthe durationduring which fuel is injected To stabilizethe
sensor,soutput,the sensorhasan internalheater.The PrimaryHO2S(Sensor1) is installedin the exhaustmanifold.
HO2S:
SENSOR VOLTAGE{VI
ztRcoNlA
R|cH-AIR- - LEAN
FUEL
RANO
The scan tool indicatesDiagnosticTrouble Code (DTC)P0131;A low voltage problem in the Primary Heated
OxygenSensor(H02S)(Sensor1) circuit.
The MIL has be€nteportedon.

DTCP0131is siorcd.
Problomverificalion:
1. Do the ECM/PCMResetPro'
cedure.
2. Start the engine.Hold the
the radiatorfan comeson,
3. Test-drivewith the A/T in E
position(M/Tin 4th gear)
4. Check the Primary HO2S
(Sensor1) output voltagewith
the scantool duringaccelera-
tion usingwide openthrottle.
lntcrmift€nt failura, 3Y3temis OK

at this tims. Checkfor Poor con-
nections or loo3e wi.o3 at C123
(Primlry HO2S, 3sn3or 1) and
ECM/PCM,
(To page1I-140)
{cont'd)
11 - 1 3 9
PGM-FISystem
PrimaryHeatedOxygenSensor(PrimaryHO2S)(sensor1l
('96- 98 ModelsexceptDl6Y5 enginewith M/T) (cont'dl
( F r o mp a g e1 1 - 1 3 9 )
Checkfor a shon in the HO2S:

2. Disconnect the PrimaryHO2S
(Sensor1) 4Pconnector.
3. Startthe engineand let it idle.
(Sensor1)outputvoltagewith
the scantool,
Doesit stayat 0.1V or less? PRIMARYHO2Slsonsor 1l ,tP CONNECTOR

lC123l
Check for a short in lhe wire

(PHO2Slinel:
nectorD ('l6P).
the PrimaryHO2Slsensor 1)
4 P c o n n e c t o tre r m i n a lN o . 1
and body ground.
Repairshort in lhe wire b6tw6en

ECM/rcM (D7)and PrimaryllO2S
{Sensor1}.

PCM and recheck.ll symptom/
indicationgoes awry, replacothe
original ECM/PCM.
1 1-1 4 0
PrimaryHeatedOxygenSensor(Primary- Fjq?S)(Sensor1l
('99- 0b Modelsexiept D16Y5enginewith M/T)
T h e H e a t e d o x y g e n s e n s o r s ( H o 2 S ) d e t e c t t h e o x y g e n c o n t e n t i n t h e e x h a u s t g a s a n d s i ginjected.
n a | s t h eTo
E cstabilize
M / P c Mthe
'|noperati
variesthe durationduring which fuel is
the EcM/pcM receivesthe signarsfrom the sensorand
sensor,soutput,thesensornasaninternaIheater.ThePrimaryHo2S(sensorl)isinsta|ledinexhaustmanifo
81642engine:exhaustPiPeA)
SENSOR VOLTAG€(VI
TERMINALS
HEATER RICH+ AIR- - LEAN

HEATER FUEL
TERMINALS RATIO
(DTC)P0131:A low voltage problem in the Primary Heated

The scan tool indicatesDiagnosticTrouble Code
OxygenSensor(HO2S)(Sensor1) circuit
- The MIL has been t€Ported on.

- DTC P013'l is stored.

engine at 3,000rpm wrth no
the radiatorfan comeson
3. Check the PrimarY HO2S
lSensor 1) output voltagewath
the scantool during accelera
tion usingwide openthrottle
lntermittont f.ilure, 3ystem i3 OK

at thi3 time. Check tor Poor con'
Doesthe voltage stay at 0 5 v nections or loose wires el C123
or less? {Primary HO2S, Sensor 1) and
ECM/PCM.
C h e c k t h e f u e l p r e s s L l r e( s e e P a g e
11,109).
(cont'd)
(To page 11 142)
11-141
PGM-FISystem
PrimaryHeatedOxygenSensor(PrimaryHO2SI(Sensor1)
('99- 00 ModelsexceptDl6Y5 enginewith M/T) (cont'd)
( F r o mp a g e 1 1 1 4 1 )
Chockfo. a shori in the HO2S:

(Sensor1i 4Pconnector.
3. Stanthe engineand let it idle.
(Sensor1) outputvoltagewith
the scantool.
Doesit stayat 0.5V or less? Roplacothe HO2S(Sensor1).
PRIMARYHO2S{S€oror 1} 4P CONNECTOR
lc123l
Check tor a short in the wire

PHO2S
f----l
{PHO2Slinel:
1. Turnthe ignitionswitchOFF. ,wHl_l:-f;-l
2. Disconnectthe EcltI/PcM con-
nectorC {31P).
the PrimaryHO2Slsensor 1)
0ffi
_L
4P connectorterminal No. 1
and body ground. Wire side of femaleterminals
ReDairshorl in the wi.e between

E C M / P C M( C l 6 1 a n d P r i m a r y
HO2S(Sercor 11.

indication goes away, replace the
original ECM/PCM.
1 1-1 4 2
('96- 9b ModelsexceptDl6Y5 enginewith M/Tl
The scantool indicatesDiagnosticTroubleCode (DTC)P0132:A high voltageproblemin the PrimaryHeated
OxygenSensor(PrimaryH02S)(Sensor'l)circuit.
Probl€mverification:
cedure.
3. Test-drivewith the A/T in E
position(M/Tin 4th gear)
4. Check the PrimarY HO2S
(Sensor1) oLltPut voltagewith
the scantool duringdecelera'
tion using completelyclosed
throttle.
Int.rmittont fiilur., system it OK

at thb timo. Chockfor Poot con-
Doesthe voltagestay at 1.0V nections or loo3a wir63 at Cl23 PRIMARYHO2S(Sonso.'ll 4PCONNECToR
or more? lPrimarY HO2S,SensoJ 1l .nd tc123t
ECM/PCM.
PHO29 sG2
Checkfor an open in the Primary IGRN/
IWHT}
HO2S: BLKI
(Sensor1) 4P connector'
3 . C o n n e c tt h e P r i m a r YH O 2 5
lSensor l) 4P connectortermi- Wire sideot femaleterminals
n a l sN o . 1 a n d N o . 2 w i t h a

5. Check the PrimarY H02S
(Sensor1i outPutvoltagewith
the scantool.
lsthere1.0V or more?
Check for an open in the wiro

{PHO2Sline):
2. ConnectEcM/PcMconnector
t e r m i n a l sD 7 a n d D 1 1w i t h a D I16PI
ECM/PCMCONNECTOR
jumperwrre,
3. Turn the ignitionswitchON lll) JUMPERWIRE
4. Check the PrimarY HO2S PHO2S(WHT} SG2 IGRN/BLKI
(Sensor1) output voltagewith
the scantool,
Replir open in tho wirc b€twccn

ls there1.0V or more? ECM/PCM lo?) and Prim!.Y
HO2Slsonsor 1).
Wiresideof tem6leterminals
PCM and recheck. lf 3ymptom/
indicetion goos awey, roplace
the oliginal ECM/PCM.
11-143
PGM-FISystem
('99- 00 ModelsexceptD16Y5enginewith M/T)
The scan tool indicatesDiagnosticTroubleCode (DTC)P0132:A high voltageproblemin the primary Heated
OxygenSensor(PrimaryHO2S){SensorI ) circuit.

OTCP0132 is stored.
Problemvorificalion:
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
enganeat 3,000rpm with no
the radiatorfan comeson.
C h e c kt h e P r i m a r y H O 2 5
{Sensorlioutput voltagewith
the scantool duringdecelera-
taonusing completelyclosed
throttle.
Intermittent tailure, systom k OK

at this time. Chocktor poor con-
nections or looso wir* at Cl23 PRIMARYHO2Sls€n3or 1' 4P
(Primaly HO2S,Sonsor 1) and CONNECTOR
ECM/PCM. (c123t
Checklor an open in the Primary

H02S:
1. Turnthe ignitionswitchOFF. PHO2S sG2
2. Disconnect the PrimaryHO2S IWHTI (GRN/
lSensor1)connector. BLK)
3 . C o n n e c tt h e P r i m a r yH 0 2 S
(Sensor1)4P connector termi
n a l sN o . 1 a n d N o . 2 w i t h a
4. Turnthe ignitionswitchON (ll). Wiresideof temaleterminals

5. Check the Primary H02S
{Sensorl) output voltagewith
the scantool.
ls there1.5V or more?
Check lor an open in th€ wire

(PHO25lin€l:
jumperwire.
3. Turnthe ignitionswitchON {lli. ECM/PCMCONNECTOR
C 131PI
(Sensor1i output voltagewith
the scantool,
Roptir op.n in tho wire betweon

ls there1.5V or more? E C M / P C Ml C l 6 l a n d P r i m . r y
HO2Slsensor 11.
SG2 IGRN/8LK}
Subsiitute a known-good ECM/
PCM and r.check. lf symptom/ Waresideof femaleterminals
indication goos away, replece
11- 1 4 4
PrimaryHeatedOxygenSensor(PrimaryHO2S)(Sensor1l
Heated
tool indicatesDiagnosticTroubleCode(DTC)P0133:A slow responseproblemin the Primary
tFol3alThe scan
OxygenSensor{PrimaryH02S)(Sensor1) circuit.
Heated
The scantool indicatesDiagnosticTroublecode (DTC)Pl163:A slow responseproblemin the Primary
I P 1 1 6 3 OxygenSensor(PrimaryHO2S)(Sensor1)circuit
Description
2), the deteriorationof the
By controllingthe airlfuelratiowith a PrimaryHo2S {Sensor1) and a secondaryHO2S{Sensor
primaryHO2S(Sensor1) can be evaluatedby its feedbackperiod.when the feedback periodof the Ho2s exceedsa cer-
judged as deteriorated
tain valueduringstabledrivingconditions,the sensorwill be
and DTCP0133or P1163*will be stored'
when deteriorationhasbeendetectedduringtwo consecutivetrips.the MIL comeson
P0133,troubleshootthose DTCSfirst' then

NOTE:tf DTCP0131,P0132and/orP0135are storedat the sametime as DTC
the sametime as DTCP1163,troubleshootthose
troubleshootDTCP0133.lf DTCPl 162,P1168and/orP1169are storedat
DTCSfirst,then recheckfor DTCPl163.
PossibleCause
'l)
o PrimaryHO2S(Sensor Deterioration
o PrimaryHO2SHeater (Sensor
1)Deterioration
. Exhaustsystemleakage
Troublsshooting Flowchart
- The MIL has been reportedon

- DTC P0133and/or Pl163* is
stored,
ProblemVerilication:
cedure-
2. Connectthe scantool
4. Connectthe SCSservicecon-
nector.
5 . T e s t - d r i v eu n d e r I o l l o w i n g
conditions.
- 55 mph (88 km/h) steady
speed
- A/f in D position {M/T in
5th gear)
Untilreadiness codecomes
lntermittent failure, 3Y3tem i3 OK

at thi3 time. Ch.ck lol Poor con-
ncctions or loosc wiros at C123
{C145)!lPrimaryHO2S,Sensor1l
and ECM/PCM.
Replaceth6 Prim.ry HO2S (Sen'

sor 11.
*: P'l163(D16Y5enginewith M/T)
11-145
PGM-FISystem
Itil-"w HeatedOxygenSensor(primaryHO2S)(sensor1l
(Dl6Y5enginewith M/Tl
The scan tool indicatesDiagnosticTrouble Code (DTC)p1162:A malfunctionin the primary
HeatedOxygen
Sensor(PrimaryHO2S)(Sensor1) circutt.
Doscription
ThePrimaryHeatedorygen sensor(Primary Ho2s){sensor1) operates
overa wideairlfuelrange.The primaryHo2S
(Sensor1)is installed
in theexhaust
manifold.
SEI{SOR
ELEMENT
SENSOR
TERMINALS
NOTE:lf DTCPl162 is storedat the sametime as DTCPl167,troubteshootDTCp1162first,then recheck

for DTCp1167.
- lh6 MIL hes b6on reDortedon.
- DTCPl162 ir 3tored.
Problomv6rificationi
1. Do the ECMResetProcedure.
2. Startthe engine.
3. Wait at leasttlvo minutes.
Test drive tor severalmiles with

ls DTCP1162indicatod? the transmission in 3rd gear.Hold
the enginespeedat 1,500rpm.
Intermittent tailuro,systom is OK
at this timo. Checktor poor con-
ls DTCP1162indicated? nections or loose wires at C145
(Plimr.y HO2S, Senso. t) and
ECM,
Chock for an open in the wire

(lP+lins): C (31PI
ECMCONNECTOR
1. Turnthe ignitionswitchOFF. PRIMARYHO2S
2. DisconnectECM connectorC (SENSOR1)8P
{31P)from the ECM. CONNECTOR {Clir5)
from the PrimaryHO2S{Sen-
s o r1 ) .
the PrimaryHO2S(Sensor1)
and ECM connectorterminal
c23.
femaleterminals of female
terminals
Repairopen in the wire betwaon

ECM (C231end Prim.ry HO2S
lsen3orl).
Inspectlor poor terminal to termi-

nal contact at the Primary HO2S
lsensor 'l I connoctorand ECM.
It terminal contect is OK, roplace
lh6 Primrry HO2S{Sensor1}.
(To page 11-147)
1 1-146
ECMCONNECTORS
l F r o mp a g e ' 1 1 - 1 4 6 ) D {15P)
c (31Pl
Checkthe ECMinput vottage{lP-/

VS- lino):
1. Turnthe ignitionswitchOFF. sG2
2 Turnthe ignitionswitchON (ll) (GRN/BLKI
ECMconnectorterminalsC24 tP-/vs-tREol femaletermrnals
I 2 3 a 6 8 9 10
'17 22
ls theremorethan 0.5V? Ch.ck the ECM: 1 1 12 1 3 l a 1 5 t 6 16
1. Turnthe ignitionswitchOFF 23 2a 25 27 2a 29 30
2. DisconndctECM connectorC
{31P){romthe ECM. O\ rP-/vs-
3. Checklor continuity between :Z taeot
b o d y g r o u n da n d E C M c o n
nectorterminalC24
- Repair open in the wire
betw€en ECM {C2{l and Pri-
ma.y HO2S{S€nsor1l.
- Substitute a known-good ECM
and recheck.It symptom/indi
cation goes away. replacethe
odginalECM.
,l 5 5 I 9 10
Checkto. r short in the wi.e {lP-/ 3 a
2
VS- lin6l: 1 1 1 2 13 1 a 1 5 1 6 1 7 t 8 22
from the PrimaryHO2Slsen- 23 21 25 21 2A E 30
s o r1 ) .
2. Checktor continuity between 0) {REDr
body ground and ECMconnec-
tor terminalC24
Ropairshort in the wire bstween

the Primary HO2Slsensor 1) and
ECM (C24).
Check the ECM output voltage

{VS+linel:
N4easure voltage between ECM
connectorterminalsC25and D11.
Checkfor a short in the wire (VS+

2 35 a 1 8 9 10
line):
1. Turnthe ignitionswitchOFF. l 1 12 13 ta
'15 't6 17 18 22
2. DisconnectECM connectorC
ls theremote than 0.5V? {31P)Irom the ECM. 23 21 E 27 2A 29 30
3. Check{or continuitybetween
b o d y g r o u n d a n d E C Mc o n []) vs*
nectorterminalC25. I rwsrt
(cont'd)
( T o p a g e 1 1 -1 4 8 ) (To page 11 148)
11-147
PGM-FISystem
PrimaryHeatedOxygenSensor(PrimaryHO2SI(sensorl)
(Dl6Y5enginewith M/T) (cont'd)
( F r o mp a g e 1 l - 1 4 7 ) ( F r o mp a g e1 1 1 4 7 )
Substitute a known-good ECM

and rechock. tf symptom/indicr-
tion goes away, replacethe origi-
nalECM.
Checkfor a short in the wire llP+ | 2 3 r a 1 a 9 to

lin6):
1. Disconnectthe 8P connector tl 12 t 5 16 1 1 1 a
Irom the PrimaryHO2S(Sen-
s o r1 ) .
2. Checktor continuitybetween
body ground and ECMconnec-
p ffi;r,w''.""i0"or.
I lemate lerml
tor terminalC25.
Repairshort in the wiro botween

the Primarv HO2S{Sensor1} and
ECM {C25}.
Replaceth€ Primary HOzS {Sen-

sor 11.
7 a 9 t0
It 1 2 t3 t 6 '11 ta
ls theremorethan 5.0V? check the EcM:
2. Disconnectthe 8P connector VS+
sG2
from the PrimaryHO2S(Sen- {WHT}
{GRN/BLK}
sor 1).
2 3 5
4. MeasurevoltagebetweenECN4 , 9 ,10 1l 12
connectorC25andD11. l 3 'ta t 5 15
ls theremorethan 5.0V?
Check the ECM input voltage llP-/ Subslitute a known-good ECM

vS-linel: and rgcheck. It symptom/indica-
1 . S t a r t t h e e n g i n e .H o l d t h e tion goes away, repl.ce the origi-
engine at 3,000rpm with no nal ECM.
load (transmission in neutral)
untiltheradiator fan comeson,
then letit idle.
2. MeasurevoltagebetweenECM
connectorterminalsC24 and
Dt1.
1 2 i 3 5 a 9 t0
ls there2.6 2.8V? Checkth6 ECM output voltage 't2 'tt
(VS+linel: t5 t t rl 22
Measurevoltage between ECM

connectorterminalsC25and D11. VS+
sG2
{WHT) (GRN/8I-K}
2 3
6 l t 9 ll
(Topage11-149) (Topage 11 149) 13 15
11- 1 4 8
( F r o mp a g e 1 1 1 4 8 ) ( F r o mp a g e1 1 ' 1 4 8 )
Roplac€th€ Primary HOzS (Sen'

ls therelessthan2.8V? sor 11.

and recheck. lf symptom/indica'
tion goes awav, replaceth€ odgi'
nalECM.
Check the ECM oulput voltage

(lP+linel:
connector terminalsC23and D11 sG2
(GRN/BLKI
Wire sideof
femaletermanals
and recheck f symptom/indica- 1 2 3 a 6 8 9 10
ls theremorethan 0.4V? tion goes awaY,replacethe origi_
nal ECM. 1 1 12 1 3 1 4 1 5 1 6 1 7 1 8 22
21 25 a 30
Checkthe ECM: I lP+
2. DisconnectECM connectorC Check fot an oPen in tha wire
6) tBrK)
(31Plfrom t h eE C M . llP+ linel: C {31P}
ECMCONNECTOR
3. Checkfor continuitybetween 1. Turnthe ignitionswitchOFF.
b o d y g r o u n d a n d E C Mc o n - PRIMARYHO2S
2. Disconnectthe 8P connoctor (SENSOR
nectorterminalC23 1l8P
from the PrimaryHO2S(Sen-
sor'l). coNNECTORlC1a5l
the PrimarYHO2S(Sensor1)
and ECM connectortermrnal lP+
(BLK)
c23.
Wire sideof of female
femaletermrnals terminals
NO Repairopen in the wire belween

E C M { C 2 3 1a n d P r i m a r y H O 2 S
{Sensor11.
Substitute a known_goodECM
Checkfor a short in the wire llP+ and r6check. lf symPlom/indica'
line): tion goos away, replacethe odgi-
1. Disconnectthe 8P connector nalECM.
from the PrimaryHO2S{Sen'
s o r1 ) , 2 3 a 6 7 I I 10
b o d y g r o u n da n d E C M c o n -
nectorterminalC23.
1 1 1 2 1 3 1 l 1 5 16 1 1 1 8 ,4 22
23 2a 25 A 30
Repairshort in lhe wire belween

'l) A\ lP+
the Primary HO2S(Sensor dnd Ij/ IBLK)
ECM{C23).
(cont'd)
Replacethe Primary HO2S (Sen'
s o r1 ) .
11-149
PGM-FISystem
HeatedOxygenSensor(primaryHO2SI(sensor1l
l:in1.".fy
(D16Y5 enginewith M/D (cont'd)
The scan toor indicatesDiagnosti" code (DTC)pl164: A range/performance
-Tl:y|* probremin the primary
HeatedOxygenSensor(primaryHO2S) (Sensor1)circuit.
The MIL has beonreponed on.

DTCP1164is stored.
ProblemVerilication:
1. Do the ECMBesetProcedure.
untiltheradiatorfan comeson.
nector.
4. Test-drivein 4th gear. Starting
at 1,600rpm, accelerate using
wide openthrottlefor at least5
seconds.Thendeceleratetor at
least 5 secondswith the throt
tle completelyclosed.
Intgrmittent failure, syrtem b OK

at this time. Checktor Door con-
ls DTCPl164indicatedT noctions or loose wires at C1a5
(Primary HO2S. Senso. and
ECM.
The scan tool indicatesDiagnosticTrouble Code (DTC)p1165:A range/performance

problem the pnmarv
HeatedOxygenSensor(primaryHO2S)(sensor1) circuit.
- The MIL has been reoortedon.

ProblemVo.ification:
1. Do the ECMResetProcedlre.
2 . S t a r t t h e e n g i n e .H o t d t h e
u n t i l t h e r a d i a t o rf a n c o m e s
3. Connectthe SCSservicecon,
nector.
4 . T e s t - d r i v eu n d e r f o l l o w i n g
conditions.
- 55 mph steadyspeed
Transmission in 5th gear
Until readinesscode comes
Intermittent l.iluro, system b OK

at lhis time. Ch€cktor poor con-
ls DTCP1165indicated? noctions or loose wir6 at Ci45
(Prioary HO2S, Sen3or 1l .nd
ECM.
Replace the P.imary HO2S (S6n-

sor 11.
11 - 1 5 0
t
(DTC)P1168;A low voltageproblem in the PrimaryHeated
The scan tool indicatesDiagnosticTroubleCode
OxygenSensor(PrimarvHo2S)(Sensor1) LABELcircuit'
- The MIL has b6€nreponed on'

- DTCP1168is storcd
Problemvedfication:
1. Do the ECMResetProcedure
2. Startthe engine.
3. Wait at leasttwo minutes
lntalmittent failure' aYstomb OK

at thi3 time. Chocklor Poor con-
ls DTCP1168indicated? nection3 or loo3o wiro3 at C145
(Primary HO2S,S.n.or 1l and
ECM.
D {16PI
ECMCONNECTOR
LABEL{WHTI
Chockth. ECM:
2. Disconnectthe ECM connec'
torD 116P).
3. Check for continuity between
ECM connectorterminal D7 wire side of female terminals
and body ground
Sub3titut. e known-good ECM

6nd r.chock. lf rymptom/indica-
tion gocr away, r.Placs the origi_
nal ECM.
LABEL(WHTI
Check for t shott in lhg wire3

ILABELline):
(Sensor1) 8P connector'
2. Check for continuitv between
ECM connectorterminal D7
and body ground
Reoair short in the wir63 botlvoon

lhe Primary HO2S{Sensor1} end
ECM(O71.
(cont'd)

PGM-FISystem
IiT-"-w Heated9{ygglSensor(primaryHO2SI(Sensor1)
(Dl6Y5enginewith M/Tl lconr'd)
scan tool indicatesDiagnosticTroublecode (DTc) P1169:A high volrageprobtemin
-1T1163 Ih" the pnmary Heated
UxygenSensor{primaryHO2S)(Sensor.l) LABELcircuit.
- The MIL hrs been reported on.

- DTCPl169 i3 stored.
L Do the ECMResetProcedure.
2. Startthe engine.
3. Wait at leasttwo minutes.
HO2S(SENSOR
PSTMARY (145)
1l8p CONNECTOR
Intormittent f.ilure, sv*em b OK LABELIWHTI
at this time. Checkfor poor con-
ls DTCP1169indicated? n.ctions or loose wires at C145
(Prim.ry HO2S, Sensor 1l and
ECM.
Ch€ck Ior an op6n in th€ wire

(LABELline):
(Sensor1) 8P connector.
3. Turn the ignitionswitchON (ll). ECMCONNECTOR
O {16P}
Primary HO2Slsensor 1) 8P
connectorNo, 4 terminaland 2
1 3 a 5
body ground.
6 8 9 10 1 t 12
t3 1 4 15 16 sG2
Check lor an open in the wire (GRN/BLK)
ls there approx. 5 V? sideof
{SG2linel: female
e terminals tll
1. Turnthe ignitionswilchOFF.
2. DisconnectECM connectorD I ;G2
(16P)tromthe ECM. -- rl I IGRN/BLKI
3. Check for continuity betlveen
ECM connectorterminal D1l I 2 3 4
Ropairopon in the wires betweon
lhe P.imary HO2S{Sensor't} and and PrimaryHO2S(Sensor1) 6 8
ECMtD7l. 8P connectorterminalNo.3.
R€pairopen in th6 wire between

ls therecontinuity? the Primary HO2Slsensor 1) and
ECM(011).
Roplacethe Primary HO2S (Sen-

sor 1).
11-152
(Sensor2l
SecondaryHeatedOxygenSensor{secondaryHO2S)
problemin the SecondaryHeated
The scantool indicatesDiagnosticTroubleCode(DTC)P0137:A low voltage
OxygenSensor(SecondaryHO2S)(Sensor2) circuit'
- Tho MIL has beenreportedon

cedure.
engine at 3,000rpm wlth no
S e c o n d a r yH O 2 S( S e n s o r2 )
outputvoltageat 3,000rPm
lntermittent frilure, sYdem is OK
at this tim6. Checkfor Poor con'
nections or loolo wir.3 at C131t
Doesthe voltage staYat 0.3 V (locatodundor right.ido of desh)'
or less? C432. {located under middle of
dashl, cl25 lc782lr {Secondary
HO2S)tsensor 2l .nd ECM/PCM.
Ch6cktot a sho.t in the S€condery

HO23:
'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 S
lsensor 2) outputwith the scan
tool,
SECONDARYHO2S ls.n.ot 2)
(C125,C782')
,rPCONNECTOR
C h e c kt o r a s h o r t i n t h e w i r e
{SHO2Slinel:
2 . D i s c o nn e c t t h o E c M / P C M
connectorD {16P){A (32P))*'
3. Checkfor continuitybetween Wire side oI temale terminals
the SecondarYH02S (Sensor
2) 4P connector terminalNo 1
and body ground.
R€pairshort in tho wire bstwoen

E C M / P C M l D 1 4 ( A 2 3 1 * ' |a n d
SecondarvHOzS(Sensor2).

PCM and recheck lf 3ymptom/
indicalion go€s awaY, tePltco
the oiigin.l ECM/PCM. (cont'd)
*'t: D16Y8engine
*2:'99 - O0m;dels except D16Y5enginewith M//T
11 - 1 5 3
PGM-FISystem
OxygenSensor(Secondary
9ggoqOfry
-
Heated
'99
('96 98 Models; - 00 D16YS
HO2S){sensor2l
enginewith M/Tl I
The scantool indicatesDiagnosticTroubleCode(DTC)PO'138:
A high voltag€problemin the SecondaryHeated
OxygenSensor(Secondary HO2SI(sensor2) circuit.
- Ths MIL ha3 bcen r6port.d on.

- DTCm138 i. 3tored.
Problemvorilication:
cedure.
engine at 3.000rpm with no
the radiatorfancomeson.
3. With the scan tool, ch€ckthe
S e c o n d a r yH O 2 S{ S e n s o r2 )
outputvoltageat3,000rpm.
Into.mittant failurc, sy3tem b OK

rt thi3 tims. Ch6cktor poor con- SECONDARYHO2Sls.nsor 2l
n6clionr or loo3€ wiroa at C13'l* 4P CONNECTOR
C125tc782t*
(locat d und6r right lido of dr'h),
C/€2r (loc.tod und€r middle ol JUMPERWIRE
d.rhl, C125 {C782lr (Socond.ry
HO2SS6n3or2) .nd ECM/PCM. sHo2s sHo2sG
Chcd( for rn open in the Socond!ry IWHT/RED} (RED/YEL)
(GRN/WHT)*
f|o2s:
a
(GRN/BLK)*'
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 SecondaryHO2S Wiresideof femaleterminals
(Sensor2) 4P connectorter-
minalsNo. 1 and No.2 with a
JUmperwire.
4. Tu.n the ignitionswitch ON (ll).
5 . C h o c kt h e S e c o n d a r yH O 2 S
(Sensor2) output vollage with ECM/FCMCONN€CTORD Il6PI
the scantool.
ls there0.6V or more?
sH()2sG
Check tor an open in the wiro {YEL/RED)
(SHO2Slin6l: {GRN/BLK}'
1. Turnth6 ignitionswitchOFF. JUMPERWINE
terminalsD14 and D13with a Wire sideof femaleterminals
jumperwire.
3. Turn the ignitionswitch ON {ll}.
4 . C h e c kt h e S e c o n d a r yH O 2 S
( S e n s o r2 ) o l t p u t v o l t a g e
with the scantool.
Rapairop.n in the wiio botw.on

ls thore0.6V or more? ECM/PCMlD13 and/or Dlal and
S.cond.ry HO2Sls€nsor 21.
Subslituto a known-good ECM/

PCM .nd rccheck. lt symptom/
indication goe! rway, replace
'i D16Ygengine
*1i Dl6Y5 engine
a
1 1- 1 5 4
SecondaryHeatedOxygenSensor(SecondarytlO2S) (Sensor2l
('99- 00 lilodelsexceptDtGYSenginewith M/T)
problemin the secondaryHeated
The scantool indicatesDiagnosticTroublecode (DTC)P0138:A high voltage
OxygenSensor (SecondaryH02S) (Sensor2) circuit.
- The MIL has beon reportod on.

- DTCm138 is.tored.
Ploblem vorification:
1. Do the ECM/PCN4 ResetPro-
cedure.
2. Start the engine Hold the
the radiator{ancomeson
3 . C h e c kt h e S e c o n d a r YH 0 2 S
(Sensor2) output voltage at
3,000rpm with the scantool
lntormittont failuio, sYstom b OK
st thir timo. Checkfor Poor con_
nections ot loo39 wiJo3 af Cl3lr
Does the voltage stay at 0 6 V (locatedunder right ride ot desh),
or more? C432' (locatod undot middle of
dashl, Cl25 {C782lr (Secondaiy
HO2SSon3or2l and ECM/PCM.
Ct€d( tor an opan in the Secondary
l|o2s: SECONDARYHO2S{S€nsot2}
1. Turn the ignitionswitchOFF Cl25 lc782l'
4P CONNECTOR
2 . D i s c o n n e c tt h e S e c o n d a r Y JUMPERWIRE
HO2S(Sensor2) 4Pconnector.
3. Connectthe SecondaryHO2S
(Sensor2) 4P conneclorter_ sH02s sG2
minalsNo. 1 and No.2 with a
(WHT/RED) {GRN/BLKI
iumperwire.
5. Check the SecondarYHO2S
lSensor2) outptltvoltagewith
Wire sideof femaletermanals
the scantool,
lsthere0.6V or more? ECM/PCMCONNECTORS

A (32P1
Check lor an open in the wiro

(SHO2Sline):
2. ConnectECM/PCMconnector | .lutuPeawtne
gs92g 111yp17p5py
terminalsA23 and C18with a
jumperwrre,
4 . C h e c kt h e S e c o n d a r YH O 2 S
{ S e n s o r2 ) o u t P u tv o l t a g e
with the scantool.
Repairopon in tho wire betwecn

ls there0.6V or more? ECM/PCM (A23) and SocondarY
HO2S{Sansor2).
Wire sideot femaletermlnals
I r Substitut€ a known'good ECM/

PCM and recheck. It symptom/
indication goes awey, JePlaco
the otiginel ECM/PCM
*i 016Y8 engine
11 - 1 5 5
PGM-FISystem
SecondaryHeatedOxygenSensor(SecondaryHO2S){sensor2l
The scantool indic€tesDiagnostic
TroubleCode{DTC)P0139:A slow responseprobtemin the SecondaryHeated
-[FO13a]l UxygenSensor(HOzS)(Sensor
2) circuit.
- The MIL has beenreportedon.


load {in Parkor neutral)until
S e c o n d a r yH O 2 S( S e n s o r2 )
outputat 3,000rpm.
Intermiftent failure, system i! OK

at this tims. Check for pool con-
Doesthe voltagestaywithin nections or loos6 wiles at C131.
0.3- 0.6V for two minutes? {locatedundor ght lide of dash),
C432' (locrted under middle ot
d.shl Cl25 (C782lr (Socondary
HO2S)(Sonsor2) and ECM/FCM.
*: D16Y8
engine
11 - 1 5 6
HeatedOxygenSensor(HO2SIHeater
('96- 98 Mbdels,'99- 00 Dl6Y5enginewith M/Tl
probl€m in the Primary Heated
The scan tool indicatesDiagnostrcTrouble code (DTC)P0135:An electrical
tFo135l
OxygenSensor(PrimaryHOiS) (Sensor1) Heatersystem(ExceptD16Y5enginewith M/T)'
Heatedoxygen sensor
The;can tool indicatesDiagnosticTrouble code (DTC)P0141:A problem in the secondary
iPol4tl(secondarvHO2S)(Sensor2) Heatercircuit.
- The MIL h.s boenJeponedon.

- DTC P0135,and/or Polal .re
stoled.
Problemverificationl
ceduae, lniermittent tailura, sYttam i! OK
2. Startthe engine at thi3 time, Chsck for Poor con' PRIMARYHO2S(Son.or 1l aP CONNECTOR
neciion3 or loose wilG3 at SECoNDARYHO2Stsensor 2l ilP CONNECTORT
C131** (locat.d undo. right sido
ot dashl, C{32** (loc.ted under
middle ol dashl, C123 (PrimarY
HO2S.Sansor 1) C125 lc782l*r
{Socondery H02S, Sonsor 2l'
and EcM/PcM.
Checkfor an open or 3hort in tho
HO25:
2. Disconnectthe HO2S(Primary Terminalsideof maleterminals
or Secondary*)(Sensor1 or
Sensor2) 4Pconnector'
3 . A t t h e H o 2 s s i d e ,m e a s u r e
resistancebetween the HO2S
4P connectorterminalsNo. 3
a n dN o . 4 .
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
b o d y g r o u n d a n d t h e H O 2 S4 P PRIMARYHOzS (SENSOR1) 4P CONNECTOR
ICl23I
c o n n e c t o rt e r m i n a l sN o . 3 a n d SECONDARYHO2SISENSOR2) 4P CONNECTOR {C125I*
N o . 4i n d i v i d u a l l y
PO2SHIC,SO2SHTC
IBLK/WHT)

Chockfor an oPen ot short in tho
wire |PO2SHTC,SO2SHTC*linol:
1. Turnthe ignitionswitchON (ll). SECONDARY HO2SISENSOR2)
2. Measurevoltage between the ,tP CONNECTOR
1C782)'*
HO2S4P connectorterminals
N o . 3a n dN o . 4 .
so2sHTC
{BLK/WHT)
Wire sideoI femaleterminals

I ( T op a g e1 1 ' 1 5 8 ) *: p0141
**: D'16Y8
(To page11-158) (cont'd)
engane
11-157
PGM-FISystem
HeatedOxygenSensor(HO2S)Heater
('96- 98 Models,'99- 00 D16Y5enginewith M/T) (cont'dl a
( F r o mp a g e1 1 - 1 5 7 )
PRIMARYHO2S{SENSOR
1I 4PCONNECTOR
{c1231
SECONDARYHO2S{SENSOR 2}4P
coNNECTOR1C125)r
Checktor an op6n or 3hoft in the r-l --'1
wire {lGl lin6): l l i 2 l
M e a s u r ev o l t a g e b e t w e e nt h e
HO2S4Pconnector terminals No.3 tcl
f;T;t
(D16Y8engine:No. 4) and body
ground. - Repair open or shon in the |BLK/ &)
wire between Primary HO2S YELI Y
lson.or 1), {No. 15 ALTERNA-
TOR SP SENSORI(7.5 Al fuse Wiresideof fomalelerminals
and SecondaryHO2S,Sonsol
2t,.
- Replacethe No. 15 ALTERNA-
Check for an open in the wire TOR SP SENSOR17.5A) tuse.
IPO2SHTC, SO2SHTC'linel:
1. Turnthe ignitionswitchOFF. SECONDARYHO2S
2. Reconnectthe HO2S4P con- ISENSOR2) 4P CONNECTOR
nector. {c78ilf
nectorA (32P).
5. Measurevoltage between the IBLK/WHT)
ECM,/PCM connectorterminals
46 and410 {A5andA10)*.
ls there0.1V or less?
Ropail opan in the wire b€twoen
ECM/PCMlA6, A5l* and HO2S
{Primary,Secondary+1.
Wire sideof lemaleterminals a
Substitute a known-good ECM/ ECM/PCMCONNECTOR
A I32P)
PCM and recheck. ll symptom/
indication goes awry, repbce pozsxtc E/
tho origin.l ECM/PCM.
so2sHrcI IBI-K/WHTI^
,-----{v}- PG1
tBLK/WH0.J | . = , |
I IBLK}
(Frompage11-157) 3 uI JsTgTro ll
12 r3 t 5 t 6 I t ta r9 20 z2l 23 21
25 27 2A 2i 3o
Check tor a short in the wire Wire sid€ ot temale terminals

{PO2SHTC. SO2SHTC*line):
'1. Turn
the ignitionswitchOFF.
nectorA (32P1.
the ECM/PCMconnectortermi-
nal46 (A5)*and bodyground.
SO2HTC(BLK/WHTI* PO2SHTC{BLK/WHTI
Repairshort in thg wire betwe€n

ECM/PCMlA6, A5*l .nd HO2S
(P.im.ry, Socondary*).

indicetion goes away, rophce
*: P0141
*+: Dl6Y8engine
11-158
I i'ss - oo Mb-delsexceptD16Y5enginewith M/Tl
problem in the Primary Heated
The scan toot indicatesDiagnosticTrouble Code (DTC)P0135:An electrical
Fo13slOxygenSensor(PrimaryttOiS) (Sensor1) Heatersystem{ExceptD15Y5enginewith M/T)'
-scan
The TroubleCode(DTC)P0141;A problemin the SecondaryHeatedOigen Sensor
tool indicatesDiagnostic
Fol11l(SecondarvHO2S){Sensor2) Heatercircuit
- The MIL has been reponed on.
- DTC P0135.and/or P0141are
storod.
Problemvorification:
cedute. lntermiftent failuro, sYstomb OK
2. Stanthe englne. at thit limo. Ch6ck lor Poor oon' PRIMAFYHO2Sls.n.or ll rrPCONNECTOR
nectiont or looso wita! at HO2S(Srn.ol214PCONNECTOR'
SECOITIDARY
C131'* {loc.tod und.t right ido
ol drshl, C432'* (located undel
middlo of dashl, C123 (PrimarY
HOzS,Sensor 1) C125 (Ct82lr'
(socondary HO2S, Sensor 2)t
.nd ECM/PCM.
Chockfoi an open or short in the
HO25:
2. Disconnectthe HO2S(Primary Terminalsideof maleterminals
or Secondary*)lSensor 1 or
Sensor2) 4Pconnector'
3 . A t t h e H 0 2 S s i d e ,m e a s u r e
resistancebetween the HO2S
4P connectorterminalsNo. 3
a n dN o . 4 .
ls there10- 40 n?
b o d y g r o u n d a n d t h e H O 2 S4 P PRIMARYHO2S{SENSOR1} ilP @NI{ECTOR lc123l
c o n n e c t o rt e r m i n a l sN o . 3 a n d sEcoNDARY HO2SISENSOR2) aP @NNECTOR(C125)'
No.4 individuallY.
3l-, l-tl-t so2sHrc

Fo2sHrc.
ver.t l ^-1 .'l {BLK/wHrl
11'!'l-l
--=-
|u----{v)'---..-'I
Wire side of {emaleterminals
Checkfor an opon or short in lho
wire (PO2SHTC, SO2SHTC+line):
'1. Turnthe ignitionswitchON (ll). Ho2S (SENSOR2,
SECO'TIDARY
2. Measurevoltage between the 4P CONNESTOR{C7&llt'
H02S 4P connectortermlnals
N o . 3a n dN o . 4 .
so2sHTc
(BLKnflHTl IBLK/WHT)
r: p0141 {To page 11-160} (cont'd)

{To page11-160} * * : D 1 6 Y ge n g i n e
11 - 1 5 9
PGM-FISystem
('99- 00 ModelsexceptD16Y5enginewith M/T) (cont'dl
( F r o mp a g e1 1 - 1 5 9 ) PRIMARYHO2SISENSOR1I 4P CONNECTOB
{c123)
SECONDANY
HO2SISENSOR
2} 4P
(C125)*
coNNECTOR
Checkfor an open in the wires -r--r ,
{lGl* line}i
Measurevoltagebetweenthe pri
lr zl
-f-
mary HO2S4P connectorterminal 1 3 4 l
lc'l L--r-J-r
No. 3 (D16Y8engine:No. 4) and
body ground.
- Repeir open or shon in the relxr p1
wire between Primary HO2S YELI Y
lsensor 1), {No. 15 ALTERNA-
ls there batteryvoltage? TOR SP SENSOR)(7.5 A) fus€
Wiresideof temaleterminals
and SecondaryHO2S,Sensor
2t,.
- ReDlacethe No. 15 ALTERNA-
Check,or an open in the wires TORSP SENSOR{7.5 A tuse. SECONDARY HO2S
(PO2SHTC, SO2SHTC'linel: (SENSOR214P CONNECTOR
1. Turnthe ignitionswitchOFF. {c782}rr
2. Reconnectthe HO2S4P con-
nector,
3. Disconnectthe ECN4/PCM con
nectorC (31Pi(ECM/PCM con- IG1 IBLK/WHT)
nectorA (32P))i.
ECM/PCM connectorterminals
82 andCl 182andAB)*.
Wiresideof femaletelminals
Reprir open in the wirc betwo€n
ls there0.1V or less? ECM/PCM(Cl, A8i) and HO2S ECM/PCMCONNECTORS
(Primary,Secondary+).
NO

PCM and recheck.lf symptom/
(Frompage11 l59i
Check tor a short in the wires

IPO2SHTC, SO2SHTC*linel:
2. Disconnectthe ECM/PCM con-
nectorC (31Pi(ECM/PCM con
nectorA (32P)i*.
the ECM/PCMconnectortermi
nalC1{A8)*and bodyground.
ECM/FCMCONNECTORS
Repai. short in the wire b€tween
ECM/PCMlcl, A8.l and HO2S
(Pdmery,Secondary*1.

PCM end recheck.lf symptom/
*: P0141
**: Dl6Y8engine
1 1 - 16 0 Wire side of female terminals

HeatedOxygenSensor(HO2SIHeater(Dl6Y5enginewith M/Tl
The scan tool indicatesDiagnosticTrouble Code (DTC)P1166:An electricalproblem in the Primary Heated
OxygenSensor(PrimaryH02S)Heatersystem.
- The MIL has been lePorted
- DTCPl166 b stored.
2. Startthe engine.
Intermitlent failura, sYstemb OK
at this time (te3t drive maY be
ngcessary).Check for poor con-
ls DTCP'l166indicated? nections or loose wires between PRIMABYHO2SISENSOR1I 8P CONNECTOR
C145 (PrimaryHO2S,Sen3or1l
end ECM.
Checkthe Primary HO2S(Sensot
1l resistence:
(Sensor1) 8P connector.
3 . A t t h e P r i m a r yH O 2 S( S e n
s o r 1 ) , m e a s u r er e s i s t a n c e Terminalsideof
betweenNo. 1 and No. 2 ter_ maleterminals
Replacelhe Primery HO2S (Sen-

ls there2 13 O? sor 11.
Checkfor a shorted PrimarY

HO2Slsensor 1):
bodygroundand eachterminal.
ls there conlrnuily?
Checkfor a shorted PrimarY

HO2S{S€nsor1l:
Checkfor continuity betweenter'
m i n a lN o . 1 a n d t e r m i n a l N
s o.3,
4, 6, 7 and 8 individually.
I (Topage11'162)
(cont'd)
11-161
PGM-FISystem
HeatedOxygenSensor(HO2S)Heater(Dl6Y5enginewith M/Tl (cont'd)
( F r o mp a g e1 1 - 1 6 1 ) PRIMARYHO2S(SENSOR1} 8P CONNECTOR
{Cl45I
\. I
PO2SHTC
{BtK/WHT)
Ch6ckthe PO2SHTCcircuit:
1. Start engineand keepengine
rpm at idle.
2. At the engine wire harness,
m e a s u r ev o l t a g e b e t w e e n
PrimaryHO2S(Sensor1) 8P
connectorterminalNo. 1 ter
minaland bodyground.
Check for an open in the wire

(PGlinell
ls theremorethan5 V? MeasurcvoltagebetweenPrimary
HO2S(Sensor1) 8P connectorter-
minalsNo. l and No.2.
Repairopon in the wi.o bEtwoon

ls theremorethan 5 V? the HO2S.nd G101 (locatedat
th.rmonat housingl.
C h e c kl o r a s h o r t i n t h e w i r e
{PO2SHTC line):
Substitule a known-good ECM
.nd .echeck. lt 3ymptom/indica-
tion 906! rwry, roplacethe origi-
nal ECM,
ECMCONNECTOR
A {32P}
PO2SHTC
IALK/WHTI
o
! a
2. DisconnectECMconnectorA
(32P)tromthe ECM. 6 I 9l ro It
1 2 t3 l 5 t6 1 ' t 8 t 9 a 221 23 2a
E C Mc o n n e c t o rt e r m i n a l4 6 25 2' 2a E ito ,1 | ---
and body ground.
femaleterminals
Ropair3hort in tho wire betwoen
the ECM {46} and the Prim.ry
HO2Slson3or 11.

(PO2SHTC linel:
ECM connectorterminal46 and
the PrimaryHO2S(Sensor1)8P
connectorterminalNo. 1.
Repairopsn in the wir6 botween

ECM {A6} .nd the Primary HO2S
lsonror 1).
Substituto a known-9ood ECM

and rech6ck. lf symptom/indica-
tion goes away, replace the origi-
nal ECM.
\ a
1 1- 1 6 2
The scan tool indicatesDiagnosticTrouble Code (DTC)Pl167: A system malfunctionin the Primary Heated
Orygen Sensor{PrimaryHO2S)(Sensor1) Heatercircuit
- The MIL has be€nreportedon.

- DTCPl167 i3 3tored.
ProblemVeritication:
engine at 3,000mm with no
until the radiatorfan comes
on.
Intormittont failure, system i3 OK
at thia time. Chock for Poor con_ PRIMABYHO2SISENSOR1} 8P CONNECTOR
noction3 or looso wilgt ai Cl45 tc145l
indicated?
ls DTC1167
(Primary HO2S, Son3or 1l and
ECM.
Check lor sn open in the wire

(VS+linel:
{Sensor1)8P connector.
4. Measurevoltage betwe€n the
'1) C (31P)
ECMCONNECTOR
Primary HO2S(Sensor 8P
connectorterminalNo 6 and
body ground. ,l
2 3 4 5 8 9 10
Ch.ck the ECM:
M e a s u r ev o l t a g e b e t w e e nt h e 1 1 12 1 3 t 4 1 5 1 6 1 7 1 8
ls theremorethan 5 V? ECM connectorterminsl C25 and a 21 25 a 30
body ground.
VS+
{WHTI Wire sideof female
terminals
Repairopon in the wite ECM(C25)

ls theremorethan 5 V? and P m.ry HO2S(S€n3or11.
Replacothe Primary HO2S (Son-

sor 11. Substitute ! known-good ECM
and r6check.lf symptom/indica-
tion gos6 away, r.place tho origi'
nd ECM,
11 - 1 6 3
PGM-FISystem
FuelSupplySystem
D017-il Th""""ntool indicatesDiagnosticTroubteCode{DTC)p0171;Thefuetsystemistoo lean.
1P0172 | fne scantool indicatesDlagnosticTroubleCode(DTC)P0172:Thefuelsystemistoo rich.
Description
By monitoringthe LongTerm FuelTrim, long term malfunctionsin the fuel systemwill be detected.
lf a malfunctionhas beendetectedduringtwo consecutive
trips,the MIL will come on and DTCP0171and/orP0172will be
stored.
NOTE:lf some of the DTCSlistedbeloware storedat the sametime as DTCP0171andlot P0172,ltouhleshootthose DTCS
first.then recheckfor DTCP0l7l andlotP0172.
P 0 1 0 6 - 8P,1 1 2 8 **35. ,P 1 1 2 9 **35 M A PS e n s o r

P0135;PrimaryHO2SHeater
P0137.P0138:SecondaryHO2S
P0'141: SecondaryHO2SHeater
P0401:EGRFlow Insufficient*1
P0441:EVAPSystemInsufficientPurgeFlow*6
P1259:VTECSystem*,
P1491:EGR ValveLift Insufficient*r
P1498:EGRValveLift SensorHjghVoltage*r
*r: D16Y5engines
*' : Dl6Y5, D16Y8,81642engine
*3:'97 models
* a : ' 9 6m o d e l s
f 5:'98 - 00 models
*6:'96 D16Y5engine,'96D16Y7engine,'96D16Y8engine(sedan),'97D16y5engine,,97D16y7
engine(coupe:KA,KC mo+
els,sedanKA.KC,KL (DX)models.hatchback;
all models),'97D16Y8engine(sedan:KA,KCmodels)
PossibleCause
DTCP0'171 FuelPumpinsufficientf lovpressure

loo lean FuelFeedLineclogged,leaking
FuelPressureRegulatorstuckopen
FuelFilterclogged
FuelInjectorclogged,air inclusion
Gasolinedoesn'tmeet Owner'sManualspec.
PrimaryHO2S(Sensor1) deteriorated
MAP Sensorrange/performance*.
EGRSystemmalfunction(too much flow)*1
ValveClearance
Exhaustleak
DTCP0172 FuelPressureRegulatorclogged,stuckclosed
too rach FuelReturnPipeclogged
FuelInjectorleaking
Gasolinedoesn'tmeet Owner'sManualspec.
PrimaryHO2S(Sensor1) deteriorated
MAP Sensorrange/performance*a
EGRSysteminsufficientflow*1
EVAPPurgeControlSolenoidValveleaking,stuckopened
ValveClearance
11-164
t
Troubleshooting Flowchart
- The MIL ha3 b€onrePorledon.

- DTC P0171a^dlot P0172arc
stored,
is the fuel pressureOK?
ls the fuel pressuretoo high Checkthe fuel pt€ssureregulator

ortoo low? and fusl re{urn pipe.
Checkthe Primary HO2S:

1 . S t a r tt h e e n g i n e .H o l d t h e Check the tu6l pump. fuel leed
engine at 3,000rpm with no pipe, fu€l fiher, and Iuel Pressure
Ioad (in Parkor neutral)until regulator.
the radiatorIan comeson
2 . C h e c kt h e P r i m a r y H O 2 S
( S e n s o r1 ) o u t p u t w i t h t h e
scantool,
Doesit stayat lessthan 0.3V

or morethan 0.6V?
NO
'l Check lor a sticking or leaking

EVAPpurge control solenoid
Witha vacuumPumP,aPPIY vacu-

u m t o t h e E V A Pp u r g e c o n t r o l
s o l e n o i dv a l v e f r o m t h e i n t a k e
manifoldside.
Does it hold vacuum?
a-,-:- -
Checkthe MAP sensoroutputr
2. Checkthe MAPwith the scan
tool.
YES
Check th6 response of the MAP

sensoa:
1. Startthe engine.
tool.
l s a M A P o f 4 0 . 0 k P a 1 3 0 0m m H g ,
1 2 . 0i n H g ) o r l e s s i n d i c a t e dw i t h i n
one second after starting the
engine?
- Checkth€ valve cloarance.

- Checkthe EGRrystem lD16Y5
enginel.
- lf they are OK, r€placethe tuel
iniocto]3.
11 - 1 6 5
PGM-FISystem
RandomMisfire
The scan tool indicatesDiagnosticTrouble Code (DTC)
lFoiool*uo,[FTiool*' *' and P0304 P 0 3 0 0 * 5o r P 1 3 0 0 * 3* 1 a n d s o m e o f P 0 3 0 1- P 0 3 0 4 :
Randommisfire.
Description
Misfiredetectionis accomplishedby monitoringthe crankshaftspeedwith the crankshaftspeedfluctuation(CKF)sensor
which is attachedto the crankshaft.
lf misfiringstrongenoughto damagethe catalystis detected.the MIL will blinkduringthe time of its occurrence,
and DTC
P0300*5 or P1300*3'*'and some of DTCsP0301through P0304will be stored.Then,after misfirehas ceased,the MIL will
come on.
lf misfiringthat increasesemissionsis detectedduring two consecutivedriving cycles,the MIL will come on, and DTC
P0300*5 or P1300*3 *a and some of DTCSP0301through P0304will be stored.
NOTE:lf some of the DTCSlistedbeloware storedat the sametime as a misfireDTC.troubleshootthose DTCSfirst,then
recheckfor the misfireDTC.
P0106*4. P0107.P0108,P1128*3 *5,Pl129*3*5;MAP sensor
P 0 1 3 1P. 0 1 3 2H: O 2 S
P0171,P0112iFuelmetering
P0401,P 1491,P1498:EGRsvstem*1
P0505:ldle ControlSystem
P1253:VTECSystem*,
P 1 3 6 1P, 1 3 6 2T: D Cs e n s o r
P1381,Pl382:CYPsensor
P1508:IACvalve
PossibleCause
. Fuelpump insufficientfuel pressure,amountof flow
. Fuelline clogging,blockage,leakage
. Fuelfilter clogging
. Fuelpressureregulatorstuckopen
. EGRsystemmalfunction*1
. Distributormalfunction
. lgnitioncoil wire open.leakage *l: D16Y5engine
. lgnitioncontrolmodulemalfunction *2: D16Y5,D16Y8,Bt6A2 engine
. MAP sensorrange/performance, poor response*r *3: '97 models
. Valvescarbondeposit *4;'96 models
. Compressionlow *5: '98 - 00 models
. IACvalvemalfunctionr.
. VTECsystemmalfunction*,
. Fueldoes not meetOwner'sManualspec.,lackoffuel
. HO2S
. HO2Scircuit
Troubleshooting
By test-driving,determinethe conditionsduring which misfireoccurs,Dependingon these conditions,test in the order
describedin the table below.
Possible cause Crankshaft

EGR*1 Fuel Distributorand tAc
\ - --^ --- position(CKP) tcM MAP
\ system pressure lgnitionwires Clearance Valve sensor
\ rage sensor
11-230,
section6 section 23 section 23 section 6 1 1 - 1 9 4 11
231
Only low rpm and
load o @ @ o o
Only accelerating @ o @ @
Only high rpm and
toao o o @
Not specific o o @
I
NOTE:lf misfiredoesn'trecur,some possiblecausesare fuel that doesn'tmeet owne/s manual
spec,lackof fuel, carbondepositson sparkplug,etc.
1 1 - 16 6
MisfireDetectedin OneCylinder
P0301 | The scantool indicatesDiagnosticTroubleCode(DTC)P0301:Cylinder1 misfiredetected.
[F03O2l 16"""untool indicatesDiagnosticTroublecode (DTc)P0302:Cylinder2misfiredetected.
[FO3Ofl 16" ".un toot indicatesDiagnosticTroubte Code (DTC)P0303;Cylinder3 misfire detected.
I P0304I ths..rr toolindicates TroubleCode(DTC)PO3O4:

Diagnostic 4 misfiredetected.
Cylinder
D€scription
lMisfiredetectionis accomplishedby monitoringthe crankshaftspeedwith the crankshaftspeedfluctuation(CKF)sensor
which is attachedto the crankshaft,
and DTC
lf misfiringstrongenoughto damagethe catalystis detected,the MIL will blinkduringthe time of its occurrence,
PO3O1, P0302,PO3O3 or P0304will be stored.Then,afterthe misfirehasceased,the MIL will come on.
lf misfiringthat increasesemissionsis detectedduring two consecutivedriving cyclss,the MIL will come on, and DTC
P0301,P0302,P0303or P0304will be stored.
NOTE:lf some of the DTCSlistedbelow are storedat the sametime as a misfireDTC,troubleshootthose DTCSfirst,then
recheckfor the misfireDTC.
PO106*1, P0107,P0108.P1128*3'*5, MAP sensor

P1129*3'*5:
P 0 1 3 1P, 0 1 3 2H: O 2 S
P0171,P0172iFuelsuppiy system
P0335,P0336:CKFsensor
P0401.P1491,P1498:EGRsystem
P0441:EVAPsystemInsufficientpurgeflow*6
Pl359.P1361.Pl362:TDCsensor
P1381.Pl382:CYPsensor
I *o:'96 models
*6:'96 D16Y5engine,'96D16Y/engine,'96D16Y8engine{sedan),'97D16Y5engine,'97D16\4,engine(coupe:KA,
KCmodels,sedanKA.KC,KL (DX)models,hatchback:all models),'97D16Y8engine(sedan:KA,KCmodels)
PossibleCause
. Fuelinjectorclogging,fuel leakage,air leakage
. Fuelinjectorcircuitopen or shorted
. Sparkplug carbondeposits,fouling,malfunction
. lgnitionwires open.leaking
. Distributormalfunction
. ComDression low
. Valveclearanceout of spec
. VTECsystemmalfunction(D16Y5,D16Y8.81642engine)
. HO2S
. HO2Scircuit
r'a (cont'd)
11-167
PGM-FISystem
Misfirein DetectedOneGylinder(cont'dl
Troubleshooting Flowchart
- The MIL has beenreoortedon.

- DTC P0301.P0302.P0303,or
P030ilis indicated.
Checkthe fuel iniecto. lunction:

Stan the engine,and listenfor a
clickingsoundat the fuel injector
in the problemcylinder.
Checkfor an openor short in the

harnessbetweenECM/PCMand
the fuel iniector.
Repairopen or short in the wir€.
Replacethe fuel iniector.

Sub3titute a known-good
E C M / P C Ma n d r e c h e c k .I t
symptom/indication goes
away, replacethe original ECM/
PCM.
Problemverification: NOTE:
1. After checkingand recording . lf there is no treezedata of misfiring,
the freezedata,do the ECM/ just clearthe DTC.
PCMResetProcedure. . It there is no freezedata of misfiring,
2. Exchange the sparkplug from t e s t d r i v e su n d e rv a r i o u sc o n d i t i o n s
the problemcylinderwith one
from anothercylinder,
3. Connectthe SCSservicecon'
nector,
4. Test-drivethe vehicleseveral
timesin the rangeofthe free2e
data.
( T op a g e1 1 - 1 6 9 )
1 1 - 16 8
I
( F r o mp a g e 1 1 ' 1 6 8 )
Intermittent misfire due to spark

ls DTCP0301,P0302,P0303, plug fouling, etc. (firing is OK ar
or P0304indicated?
this time).
Doesthe misfireoccurin the Replacethe faulty spark plug.

othercylinder?
Check for fuel iniector mallunc-

l|on:
1. Exchange the fLrelinjector
from the problem cylinder
with one from another cylin
der.
2 . L e t t h e e n g i n e i d l e f o r t r r v om i n - NOTE:lf there is no freezedata of mis_
utes. firing, test drives under variouscondi
3. Test-drive the vehicle several tions are necessary.
times in the range ot the freeze
data.
lntermitt€nt mistire due to bad

ls DTCP0301,P0302,P0303,
l l or P0304indicated?
contact in the fuel iniector con-
nector (firing is OK at this time).
Doesthe mistireoccurin the Replacethe taulty fuel injector.

othercylinder?
Checklhe following items:

. Cylinderleak-down
. Compression
. Crankshattspeod tluctuation
{CKF)sensoi
1 1 - 16 9
PGM-FISystem
KnockSensor(KSl('96- 98 D16Y5enginewith CW and'96- 98 D16Y8
engine)
tool indicates TroubleCode(DTC)P0325:
Diagnostic A malfunction
in the circuitof the Knocksensor
Forr-l I,3,.""""
The MIL has bgenroportsdon.

DTCPO:t25is stored.
Problomveiilication:
1. Do the ECM/PCM ResetProce- DIAPHRAGM
oure,
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 0-
4,000 rpm tor at least 60 sec-
onds.
Intermittenl fsilu16,3y3l6m b OK
at thi3 timg lteat drivo mav ba
ls DTCP0325indicated? noc63saryl.
Chock tor poor conneclioni or
loose wire3 b€twccn C137{knock
len3or (KS)land ECM/PCM.
Checkfor a short in tho wire {KS
linel:
2. Disconnectthe knock sensor ECM/PCMCONNECTOR
D {16PI
2Pconnector,
3 . D i s c o nn e c t t h e E C M / P C M
connectorO (16P).
E C M / P C Mc o n n e c t o rt e r m i -
nalsD6 and body ground.
Reo.ir 3hort in the wire between Wire sideof femaleterminals

ECM/PCM{DG).nd knock 3.n-
(Cl371
KS 2P CONNECTOR
Chock for an open in the wire KS
(KSlinel: (RED/BLUI
ECM/PCM connectortorminalD6 1 \
and knock sensor 2P connector
terminalNo. l.
,_- ,--tl
I
Ropairopen in the wire bgtweon
ls therecontinuity? ECM/PCMlD6l and knock sen-
3('t. e s l le oI temal€
tertn i n irls
Substitutea known-goodknock
sensorand recheck.
1 2 1
KS
Rsplaceth. o.igin.l knock s€nsor. IRED/ 1 8 9 't0 1 t 12
BLU)
13 l4 t5 t6

PCM end recheck. lf 3ymptom/
indication goes rway, replace
rhe original ECM/PCM.
11-170
'99- 00D16Y8
Knocksensor(Ks)r99- 00D16Y5
enginewith cw, engineand
816A2engine
The scantool indicatesDiagnosticTroubleCode(DTC)P0325:A malfunctionin the circuitof the KnockSensor
{KS}.

DTCm325 is stored
OIAPHRAGM
cedure,
2 . S t a r tt h e e n g i n e H o l d t h e
then let it idle.
3 . H o l d t h e e n g i n e a t 3 . 0 0 0-
4,000 rpm for at least 60 sec'
onds.
lntermittent failure, system is OK
at thi3 time lt€3t drive maY b€
nocessaryl.
ls DTCP0325indicated? Chsck tor poor connectionsor
loose wiros at C137 {knock sen'
sor {KSll and ECM/PCM. C (31P)
ECM/PCMCONNECTOR
Ch€ckfor a short in tho wire (KS
linel:
2, Disconnectthe knock sensor
1Pconnector.
E C M / P C Mc o n n e c t o rt e r m i _
nalsC3 and body ground.
Repri. short in the wiro bqtwecn

ls therecontinuity? ECM/PCMlc3l and knock 3ensor.
(C1371
KS 2P CONNECTOR
KS
Check for an open in lhe wire
{KS linc):
ECM/PCMconnectorterminalC3
and knock sensorconnectorter-
minalNo. 1.
Replir open in the wire bdtweon ECM/PCMCONNECTOR

ECM/PCM{Ctl and knock sensor'
S u b s t i t L r t ea k n o w n ' g o o d k n o c k
sensor and recheck,

Replacetho otiginal knock sensor.
t substitute a known-good ECM/

PCM and recheck. ll symptom/
indication goes awaY, rePl6co
tha o.iginal ECM/PCM.
11-171
PGM-FISystem
CrankshaftPosition/TopDeadGenter/Gylinder Position(CKP/TDC/CYP)
Sensor
('96- 98 Models,'!n - 00 D16Y5enginewith M/Tl
scantool indicatesDiagnosticTroubleCode(DTC)P0335:A malfunctionin the Crankshaftposition(CKp)
tFos3slThe
sensorcircuit.
The scantool indicatesDiagnosticTroubleCode(DTC)P0336:A range/performance

problemin the Crankshaft
tFffi6l Position(CKP)sensorcircuit.
The scantool indicatesDiagnosticTroubleCode (DTC)P1361:Intermittentinterruotionin the Too DeadCenter

tPr361I (TDC)sensorcircuit.
The scan tool indicatesDiagnosticTroubleCode {DTC)P1362:No signalin the Top DeadCenter(TDC}sensor

fPfi62l circuit.
The scantool indicatesDiagnosticTroubleCode (DTC)P1381:Intermittentinterruptionin the CvlinderPosition

fFr38il{CYP)sensorcircuit.
The scantool indicatesDiagnosticTroubleCode {DTC)Pl382: No signal in the CylinderPosition(CYP}sensor

tF13s2-l
circuit.
Description
The CKPSensordeterminestiming for fuel injectionand ignitionof eachcylinderand also detectsenginespeed.The TDC
Sensordeterminesignitiontiming at start-up(cranking)and when crankangle is abnormal.The Cyp Sensordetectsthe
positionof No. 1 cylinderfor sequentialfuel injectionto eachcylinder.The CKP/TDC/CYP
Sensoris built into the distribu-
ror.
NOTE:lf DTCP1359is storedatthesametime as DTCP0335.P0336,P1361,Pl362,P1381and/orP1382,troubteshoorDTC

P1359first,then recheckfor those DTCS. Ot6y56ngine: Dt6y7,ot6y8enqin6s:
- The MIL hrs beenreportedon.

- D T C P 0 3 3 5 ,P 0 3 3 6 ,P 1 3 6 1 ,
P1362,P1381and/or Pl382 6re
stored,
Problemverification: TDC CKP

1. Do the ECM/PCM ResetProce- SENSORSENSOR SENSOR SENSOR SENSOR
dure. SENSOR ROTOR ROTOR ROTOR ROTOR ROTOR
2. Stanthe engine. BOTOR
DISTRIBUTOR1OP
Intermittent hilu.e, system b OK coNNECTORtC120t TDC P
ls DTCP0335,P0336,P1361,P1362, at this time. Checktor poor con-
P1381and/orP'l382indicated? n€ctions or 10036wiros at C120
{distributor}and ECM/PCM.
Check for an open in the CKP/

TDC/CYPsensor:
2. Disconnectthe distributor10P CYPM {BLK}
3. Measureresistancebetween
the terminalsof the indicated
sensor(*seetable).
SENSOR DTC SENSOR ECMfCM
IERMINATTERMINAT COLOR
ls there350- 700 0? Replacethe distributor ignition
housing (soesection23). CKP P033s 2 c2 BLU
m336 6 c12
TDC P1361 3 GRN
P1362 7 cl3 RED
CYP P!381 c4 YEL
P't382 c14
11-172 8 8LK

(Frompage | 1-172)
DISTRIBUTOR
Check fo. a sho.t in the CKP/ 10PCoNNECTOR{C1201
TDC/CYPsensor:
C h e c kf o r c o n t i n u i t yt o b o d Y TDCP (GRNI
ground on both terminalsof the
i n d i c a t e ds e n s or i n d i v i d u a l l y
1*seetable).
Replacothe di3tributorignition
ls therecontinuity? hoGing lsee section23).
Checkfor an open in the wires

ICKP/TOC/CYP line3):
1. Reconnect the distributor10P
connecaor.
2. Disconnectthe EcM/PCMcon-
nectorC {31P}. Terminalsideof
3. N4easure resistancebetween maleterminals
the terminalsof the indicated
sensoron the ECIM/PCM con-
nector{*seetabie}.
Repairopen in the indicated sen- C 131P)

ECM/PCMCONNECTORS
ls there 350 - 700 o? sor wires lrsee tablel.
CI(P P TDC P CYP P
(YEL)
Chock lor. short in the wires

ICKP/TDC/CYP lines):
body ground and ECM/PCM con-
nectorterminalsC2, C3 and/or C4
individually.
M
CKPM M IBLKI
Repai.short in the indic.ted sen_ (WHT) (REDI Wiresideof
ls therecontinuity? sor wire3 ('soe tablol, femaleterminals
TDC P CYPP
Substitute e known-good ECM/ (GRN) IYELI
PCM, and iecheck. ll sYmptom/ CKP P
indication goes awev, r€Place the
(BLU}
original ECM/PCM.
11-173
PGM-FISystem
CrankshaftPosition/TopDeadCenter/CylinderPosition(CKP/TDC/CYPI
Sensor
-
f99 00 ModelsexceptD16Y5enginewith M/T)
The scantool indicatesDiagnosticTroubleCode (DTC)P0335:A malfunctionin the CrankshaftPosition(CKP)
l-Fos3sl
sensorcircuit.
The scantool indicatesDiagnosticTroubleCode (DTC)P0336:A range/performance

problemin the Crankshaft
tFos36l
Position(CKP)sensorcircuit.
The scantool indicatesDiagnosticTroubleCode (DTC)P1361:Intermittentinterruptionin the Top DeadCenter

l {TDC)
tF1361 sensorcircuit.
The scantool indicatesDiagnosticTroubleCode {DTC)P1362:No signalin the Top DeadCenter (TDC)sensor

Fr362-1
circuit.
The
scantool indicatesDiagnosticTroubleCode(DTC)P1381:Intermittentinterruptionin the CylinderPosition
tF13sil(CYP)
sensorcircuit.
The scantool indicatesDiagnosticTroubleCode (DTC)P1382;No signal in the CylinderPosition(CYP)sensor

lTiaSt
: circuil.
DoscriDtion
The CKPSensordeterminestiming for fuel injectionand ignitionof eachcylinderand also detectsenginespeed.The TDC
Sensordeterminesignitiontiming at start-up(cranking)and when crankangle is abnormal.The CYPSensordetectsthe
positionof No. 1 cylinderfor sequentialfuel injectionto eachcylinder.The CKP/TDC/CYP
Sensoris built into the distribu-
tor.
NOTE;lf DTCP1359is storedat the sametime as DTCP0335,P0336,P1361.P1362,P1381and/orP1382,troubleshootDTC

P1359first,then recheckfor thoseDTCS. D16Y5 engino:
- The MIL has beenreportodon.

- DTC P0335, P0336. P1361,
P1362,P1381rnd/or P1382.re
stored.
Problemverific{tion: TDG CKP TDC CKP CYP

1. Do the ECM/PCMResetProce- SENSORSENSOB SENSOB SENSOB s€Nson
dure. SENSORROTOR BOTON ROTOR ROTOR BOTOR
2. Startthe engine. ROTOR D16Y7,
D16Y8ongine:
Intormittcnt failure, systom b OK
ls DTCP0335,P0336,P1361,P1362, at thb time. Check to. poor con-
P1381and/orPl382 indicated? nections or loose wires at C120
(dktributorl and ECM/PCM.
Check tor an open in the CKP/

TDC/CYP3enior:
2. Disconnect the distributor10P S E N S O R ECM/PCM
S E N S O R DTC
T E B M I N A I TERI\,4INAI C O L O R
connector,
3. Measureresistancebetween CKP P0335 2 c8 8LU
the terminalsof the indicated P0336 6 c9
sensor(*seetable).
TDC P1361 3 c20 GRN
Replrce the distributor ignition P1362 7 c21 BED
ls there 350 700 0?
hou3ing (!ee section 231. CYP P1381 c29 YEL
P1342 I c30 BLK
(Topage11-175)
1-1 7 4
Dl6Y5.816A2engine:
DISTRIEUTOR
l0PcoNNECTOR
{C120)
(Frompage11-174)
C h o c kf o r . 3 h o r t i n l h o C K P /
Tlrc s6n3o.:
C h e c k{ o r c o n t i n u i t y t o b o d y
ground on both tsrminalsof the
indicatedsensorindividuallY.
Terminalsideol
maleterminals
016Y7,Dt6Y8 engine:
DISTRIBUTOR
Chsck for an open in the wile3 (Cl201
8P CONNECTOR
ICKP/TIrcline6l:
1. R€connectthe CKP/TDCson-
sor 4P connector.
nectorC 131P).
the terminalsol the indicated
sensoron the ECM/PCMcon-
nector1*seetablel. Terminalsideol
maleterminals
Ropsiropon in tho indiclted son- C (31P)

ECM/PCMCONNECTOR
ls there 350- 700 o?
ior wiro3 l*!sa tabla). CKPM
IWHT}
Chack for a .ho in th6 wiros lDC M

{CKP/TDClino3l: (REDI
body ground and ECM/PCMcon-
nectorterminalsC8, C20 and/or
C29individually.
Rcpairrhort in th. indicat.d 36n_

lor wirar {'3ac trblol. Wiresideof femsleterminals
ECM/PCMCONNECTOR
Substituto . known-good ECM/ c l31P)
PCM lnd rechock. lf 3ymptom/ CKPP
indicatlon go6s aw.y, ropllc.
tho origin.l ECM/PCM.
wire sideof femaleterminals
t
11-175
PGM-FISystem
VehicleSpeedSensor(VSSI('96- 98 Models,'99- 00 D16Y5enginewith M/Tl
The scan tool indicatesDiagnosticTrouble Code (DTC)P0500:A malfunctionproblem in the VehicleSpeed
@ Sensor(VSS)circuitIexceptA!/T(D16Y7,D16Y8engine)1.
The scan tool indicatesDiagnosticTrouble Code (DTC)P0501:A range/performance

problem in the Vehicle
SpeedSensor (VSS)circuit [A,rT{D16Y7,D16Y8engine)].
The MIL has been reDortedon. ECM/PCMCONNECTORS

DTCP0500or P0501is stored.
A {32P} LG.t
{BRN/BLK}
1- Testdrivethe vehicle.
2. Checkthe vehiclespeedwith 2 3 9 l0 lt
the scantool. 12 1 6 1 1 t 8 t 9 20 23 21
Intermittent tailure, system is OK 2A 29 30

at this time. Checktor Door con-
ls the correctspeedindicated?
nectionsor loose wires at C117
{VSSlandECM/PCM.
Checkfor an open in the ECM/ c {31P}

PCM:
2. Elockthe rearwheelsand set I 3 8 1 9 1o
the parkingbrake. tl 12 ialr5 i6l 1 0 ./
3. Jackup the frontof the vehicle
and supportit with safety
stands.
4. Turnthe ignitionswitchON (ll). VSS IBLU/WHT}
5. Blockthe righttrontwheeland
s l o w l y r o t a t et h e l e f t f r o n t Wiresideot temaleterminals
6, Measurevoltagebetweenthe
nalsC18and A9.
Subslitute a known-good ECM/

Doesthe voltagepulse0 V PCM and recheck.lf symptom/
a n d5 V ? indic.tion goes away, replacethe
orisinal ECM/PCM.
LGI
Check tor a short in ihe ECM/ (BRN/8LK}
PCM:
2 . D i s c on n e c t t h e E C M / P C M I 2 3 5 6 a 9 l0 11
connectorC (31P). 12 l 3 l 5 t 6 1 t l 8 t 9 20 22 2a
3. Turnthe ignitionswitchON {ll). 27 20 29 30
4 . B l o c kt h e r i g h t f r o n t w h e e l
and slowlyrotatethe leftfront
ECM/PCM connectorterminals
C18andA9.

Does the voltage pulse 0 V PCM and recheck. lI symptom/
and s V? indication goes away. replace
1 2 9 10
t 2 l 13l . l 7 I l ,/ 1,/
- Repair short in the wire 2 3 1r . l s l t. , ) ,rl L
betwGenECM/PCM{C18}end
vss, TcM. VSS {BLU/WHT}
between ECM/PCM {Cl8} and
vss.
- lf wire is OK, test the VSS
lsee section 23).
11-176
VehicleSpeedSensor(VSS)('99- 00 ModelsexceptDl6Y5 enginewith M/T)
Thescantoo|indicatesDiagnosticTroub|ecode(DTc)Po5o0:Ama|functionproblemintheVehic|es
fFosoo-l
Sensor(VSS)circuitlexceptA//T(D16Y/,D16Y8engine)l'
Thescantoo|indicatesDiagnost|cTroub|eCode(DTC)Po5o1:Arange/performanceprob|eminthe
lFosoilSDeedSensor{VSS)circuittA,/T(D16Y7,D16Y8engine)1.
The MIL has beenreportedon
OTCP0500or P0501is stored.
1. Test-drivethe vehicle. ECM/PCMCONNECTORS
2. Checkthe vehiclespeedwith
the scantool B {25P)
lntermitt6nt failure, sYstemis OK
at thb time. Checktor Poor con-
ls the correctsPeedindicated? nections or loose wir6 at C117
{vss} .nd ECM/PCM
Check for an open in the ECM/

PCM:
2. Blockthe rearwheelsand set
the parkingbrake
3. Jack uP the front ofthe vehicle
and supportit with safety
stands.
5. Blockthe right front wheel and
s l o w l y r o t a t et h e l e f t f r o n t
I
6, Measurevoltagebetweenthe
E C M / P C Mc o n n e c t o rt e r m i _
nalsC23and 820. Wire sideol lemaleterminals
Substituto a known'good ECM/

D o e s t h e v o l t a g e P u l s e0 V PcM and rech€ck. ll sYmptom/
and 5 V or batteryvoltage? indic€tiongoes awaY,lsplace the
originalECM/PCM.
ECM/PCMCONNECTORS
Check for a short in the ECM/ B E5PI

PCM:
2 . D i s c on n e c t t h e E c M / P c M
connectorC (31P).
4 . B l o c kt h e r i g h t f r o n t w h e e l
and slowlyrotatethe leftfront
ECM/PCM terminals
connector
C23and 820.
Substiiute . known-good ECM/
D o e s t h e v o l t a g e P u l s e0 V PCM and r6check. lf symptom/
and 5 V or battery voltage? indication goes awaY, rePlace
- Reoair short in the wire

between ECM/PCM{C23}and
vss. TcM. Wire sideoI femaleterminals
t - Repai. open in the wire

between ECM/PCM{C231and
vss.
- lf wire is OK, tesr the VSS
{seesestion23).
11-177
PGM-FISystem
BarometricPressure(BAROISensor
The scantool indicatesDiagnosticTroublecode (DTC)Pi106:A range/performance
problemin the Baromerrrc
Pressure(BARO)Sensorcircuit.
The MIL ha3 beenr€Dortsdon.

DTCPl106 is stored.
1 . D o t h e E C M / P C Mr e s e tp r o -
cedure,
let it idle.
3. Connectthe SCS servicecon
nector.
4. Test drive with the A/T in E
position,M/T in 4th gear.
5 . A c c e l e r a t ef o r f i v e s e c o n d s
usingwide openthrottle.
ls DTCP1106indicated? Intormittont tailure, system is OK

at this time.
Substitut€ e known-good ECM/

indicationgoes .way, .oplscethe
o.iginal ECM/PCM.
fF1lot The scantool indicatesDiagnosticTroublecode (DTc)P1107:A low voltageprobtemin

the Barosensorcircurr.
tPlloal The scan tool indicatesDiagnosticTroubrecode {DTC)p1108:A

circuit.
high vortageprobrem in the Baro sensor
The MIL has been.oported on.

DTCP'l107o. Pl108 is stored.
P.oblemveritication:
1. Do the ECM/PClvl Resetpro
cedure,
ls DTCP1107or Pl108indicated? Intormittent frilure, syitem i3 OK

at this time.

PCM and rechock. It symptom/
indication goes away, .6place
11-178
- with M/T}
ElectricalLoadDetector(ELDI{'96- 98 Models,'tn 00 D16Y5engine
(DTC)P1297:A low voltage problem in the ElectricalLoad
The scan tool indicatesDiagnosticTrouble code
Detector(ELD)circuit.
'!. Do the ECM/PCMResetPro-
cedure.
2. Start the engine
3. Turn on headlights
lntermittent tailure,sYstemis OK
at this time. Checkfor Poor con-
ls DTCP1297indicated? nection3 or loose wires at C131 (c35'rl
ELD3PCONNECTOR
tlocatedunder righl side of da3h).
C354(ELDIandECM/PCM.
Ch.ck lor short in the ELD:

l-- ,
Measurevoltage betweenbody --f
l l l 2 l 3 l
..
groundand the ELD3Pconnector
t e r m i n aNl o . 3 . ao (GRN/REDI
Y
ls thereapprox.45 V?
O I16PI
ECM/PCMCONNECTOR
Checkfor a short in tho wile (EL
linel:
1. Turnthe ignitionswitchOFF'
2. Disconnect the ECM/PCM con
nectorD (16P)
connectorterminalD16
R6pairshort in the wire between

ECM/PCM(D161and ELD.

PCM and recheck lf symplom/
indication goes awaY, rePlace
the original ECM/PCM
r a
11-179
PGM-FlSystem
ElestricalLoadDetector|ELD)t'glf- 00 ModelsexceptD16y5enginewith M/Tl
The scan tool indicatesDiagnosticTrouble Code (DTC)P'1297;
A low voltage probtem in the ElectricalLoad
cedure.
2. Start the engine.
3. Turn on headlights.
Inlermittont failur6. systom i3 OK
at this time, Chocktor ooor con-
nestions or loose wires at C131
(locrted undor ight side ot d.shl, ELD3PCONNECTOR
tC354)
C354(ELDIand ECM/PCM.
Checkfor short in th6 ELD:
groundand the ELD3P connector
EL
t e r m i n aNl o . 3 . {GRN/REOI
ls thereapprox.4.5V?
ECM/PCMCONNECTOB
A I32PI
Check to. a short in the wne (EL
linel:
'L Turn
2. Disconnect the ECM/PCM con-
nectorA (32P).
3. Checktor continuity betlveen
connectorterminalA30.
ls therecontinuity? Repairshort in the wile between

ECM/PCMlA30) and ELD. Wire side of lemale terminals
Sub3titute a known-good ECM/

PCM and rech€ck. It symptom/
indication goes away. replace
11 - 1 8 0
- - 00 D16Y5enginewith M/T)
ElestricalLoadDetector(ELD)f96 98 Models''99
ThescantoolindicatesDiagnosticTroubleCode(DTC)P1298:AhighvoltageproblemintheElectrical
Detector(ELD)circuit
Problomvcrificttion:
1. Do the EcM/PClVl ResetPro-
cedure,
2. Startthe engine.
3. Turnon headlights. lntarmitt..rt l.ilur., ryttcm b OK
.t thia tim. Ch.ck lor Poo' con-
ls DTCP1298indicated) nections or looaa wir.3 at C131
lbcd.d und.r right ide ol dalhl'
Gl5a {EU)} .nd ECM/PCIYI {G's'I
ELD3PCONNECTOR
Ch.ck lor tn oPan in tho wir'
(lGl linol:
1 . T u r n t h e i g n i t i o na n d h e a d '
liohtsOFF
2. D]""onn""t the ELD 3P con_
nector-
3. Turnthe ignitionswitchON {ll)'
4. Measurevoltagebetweenbody
groundandthe ELD3Pconnec Wire side ol femaleterminals
'1.
tor terminalNo.
R.oair ogan in tha wira Mw"n
ru".rs ltTEnrlton SPSelSOn
t?.5 A, fu!. in th. undcr-dr3h
tu3e/r.l!Y box .nd ELD.
Chcck lor tn oP.h in thc wire

{GND lincl:
1. Turn the ignition switch and
h e a d l i g h t sO F F .
2. Disconnect the ELD 3P con_
nector'
body ground and the ELD 3P
c o n n e c t o .t e r m i n a l N o 2
Raprir opcn in the wira bstwt€n EL IGFN/REDI
ELD conncctor lnd G/O2.
Ch.ck lor !n oplo in tha wirc IEL

lin.l:
ELD 3P connectorterminal No 3
and ECM/PCM connector termi
nal D'16.
Rapaii opcn in the wira b€tw"n
wire side of lemale termrnals
ECM/FCM (I)161.nd th. ELD'
Ch.d( fo. r m.llunction in thc ELD:

1 . R e c o n n e c tt h e E L D 3 P c o n '
2. Start th€ engine and allow it

to idle.
3. Wh ile measuring voltage
beNveen ECM/PCM connector
terminals D16 and A9, turn
t h e h e a d l i g h t so n { l o w ) . Wire side of Iemale terminals
t'a Doesthe voltage droP?
Sub3titut. . known_good ECM/

PCM .nd rcch.ct. lt sYmptom/
indication goas away/ iapllc'
thc origin.l ECM/PCM 11 - 1 8 1
)
PGM-FISystem
ElestricalLoadDetector(ELDI('99- 00 ModelsexceptD16y5enginewith
M/Tl
The scan tool indicatesDiagnosticTroublecode (DTCIPl298: A high
vottageproblem in the EtectricalLoad
Problemve.itication:
1. Do the ECN4/PCM Resetpro
cedure.
2. Startthe engine.
3- Turn on headiights.
Inte.mittent teilu.e, svstem is OK
at this lime. Chockfor Door con- ELD3P CONNECTOR
(65/0
ls DTCP1298indicated? nections or loose wires at Ci31
{located under Jight side ot
daihl, C354(ELD)and ECM/PCM.
{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 . D i s c o n n e ctth e E L D 3 P c o n
Wiresideof fernaleterminals
4. Measurevoltagebetweenbody
groundand the ELD3P connec-
torterminalNo. 1.
ELD3P CONNECTOR
(CA54I
Repairopon in tho wiro batwe€n
No. 15 ALTERNATOR
ls there battery voltage? Sp SENSOR
{7.5 A} fuse in th6 undor-dash
TI
r l 2 l 3 l
Iuse/releybox and ELD.
I crvo
Check for an open in the wiro (o) (BrKr
{GNDlinel:
1. Turn the ignition switch and Y
headlights OFF. Wire sideof lemaleterminals
2 . D i s c o n n e ctth e E L D 3 P c o n
nector.
body ground and the ELD3P
connectorterminalNo.2,
EL {GRN/REOI
Repairopen in the wire bstwoen
ELDconnsctorand Gia02.
Check ,or an open in the wire IEL ECM/PCMCONNECTORS

linel:
A (32P1
nectorA (32P).
the ELD3P connectorterminal Chockfo. a malfunctionin the ELD:
No. 3 and ECM/PCMconnec- '1. Reconnect
the ELD connector
tor terminalA30. and ECM/PCMconnector Wiresideof lemale EI-IGRN/RED)
A (32P). terminals
ls therecontinuity? 2. Stan the engineand allow it
to idle. ECM/PCMCONNECTORS
3 . W h i l e m e a s u r i n gv o l t a g e A {32P)
between ECM/PCMconnector
Repsir op€n in the wire between terminals A30 and B2O,turn
ELD connector and ECM/PCM. the headlighrs on ow).

indication goes away. replace Doesthe vokagedrop?
lh6 original ECM/PCM.
Wire side of f€male terminals
11-182
CrankshaftSpeed Fluctuation(GKFISensor
\ '99 - 00 D16Y5enginewith .M/Tl
firC- 48 Models,
Speed
(DTC)P1336;Intermiftentinterruptionin the Crankshaft
The scantool indicatesDiagnosticTroubleCode
fPrk6l Fluctuation(CKF)sensorcircuit.
ThescantooIindicatesDiagnosticTroub|ecode{DTC)P1337:NosignaIinthecrankshaftspeedF|uctuatio
lFr3g7-lsensorcircuit.
D6scription
T h e d i a g n o s t i c s y s t e m h a s a p u | s e r r o t o r o n t h e c r a n k s h a f t a n d a p u | s e p i judges
c k - u p s e n s8n
o r oengine
n t h e emisfire
n g i n e boccurred
l o c k . T hife E c M / P
sensorsignal,and that
monitorsthe crankshaftspeedftuctuationbasedon the cKF
the fluctuationgoes beyonda predetermined limit'
- The MtL hds been reported on.

- DTC P1336and/or P1337a.e
stored.
P.oblem v€rific.tion:
1. Do the ECM/PCMResetProce-
dure.
2. Stanthe engine
I lntormittont lailur6, tY3tom b OK
at thit tima. Chock tor Poor con'
nactions or loota wito! at C102
IC-KFson$rl .nd ECt /PCM, and
mrka suro CKFtonaor mounting
boh ittigM.
Chockfor .n open in tho CKFaen-

30t:
1. Turnthe ignitionswitchOFF CKF SENSOR 3P CONNECTOR
2. Disconnectthe CKFsensor 3P
connector, L:l
.)l l.' -
3 . M e a s u r e t h e r e s i s t an c e Ir-T--T---.]
between the CKF sensor 3P l- 1 l 2 l 3 l l
connectorterminalsNo. 1 and ''---r
L
No.3. C K F MI I CKFP
twrfit 1,.^\ | lsLul
\.7
ls there1.6- 3.2kO? Terminalsideof maleterminals
Ch€cktor a short in the CKFson'

30ti
C h e c k{ o r c o n t i n u i t Yb e t w e e n
body groundand the CKFsensor
3P connectortermin6lsNo. 1 and
N o . 3i n d i v i d u a l l Y . CKF M CKF P
IWHT} IBLUI
I (cont'd)
(To page 11 184)
11 - 1 8 3
PGM-FISystem
CrankshaftSpeedFluctuation(GKFISensor
('96- 98 Models,'99- 00 D16V5enginewith M/Tl (cont,d) \ a
(Frompage11 183)
Checklor an open in the wires

ICKFlines):
1. Reconnectthe CKFsensor3p
2. Dlsconnect the ECM/PCM con-

nectorC (31P). ECM/PCMCONN€CTOR
C (31P}
3, Measureresistancebetween CKFP
E C M / P C Mc o n n e c t o rt e r m i (8LU/REO)
n a l sC l a n dC l 1 .
6rl-i a 6 7 8 9 10
Repairopen in the wire between rF 1 2 13 1 1 1 5 t 6 1 7 1 8
ls there1.6 3.2kO?
C h e c kf o r a s h o r t i n t h e w i r e
ECM/PCM{C1,C11}and the CKF
tl 21
CKFM
(WHT/REO)
27 2A 29 30
Wire side of female

{CKFline}: termtnats
body ground and ECM/PCMcon,
nectorterminalC1.
Repairshort in the wiro bstwoen

ECM/PCM{Cl) and the CKFson- CKFP
(BLU/RED)

PCM,and recheck.lf symptom/
indicationgoes awry, replacethe
original ECM/PCM.
11-184
CrankshaftSpeedFluctuation(CKF)Sensor -
t ('99- 00 MocielsexceptD16Y5enginewith M/T)
scantool indicates DiagnosticTroublecode (DTC)P1336:Intermittentinterruptionin the crankshaftspeed
Ftu6l The
Fluctuation(CKF)sensorcircuit
Fluctuation(CKF)
The scantool indicatesDiagnosticTrouble Code (DTC)P1337:No signal in the CrankshaftSpeed
tF13g7lsensorcircuat,
Description
T h e d i a g n o s t i c s y s t e m h a s a p u l s e r r o t o r o n t h e c r a n k s h a f t a n d a p u | s e p i c k - u p s e n s o r o n t h e e n g i n e b | o c k . T hife E c M / P
judgesthat an enginemisfireoccurred
monitorsthe crankshaftspeedfluctuationbasedon the cKF sensorsignal.and
the fluctuationgoesbeyonda predetermined limit'
- The MIL has b€onreportadon.

- DTC P1336and/or P1337are
stored.
1. Do the ECM/PCMResetProce'
dure.
2. Startthe engine
I lntermittcnt failuro, sydcm is OK
ai this time. Checklot Poor con_
noctions or loo3e wiros at C102
ICKFs€nsor) and ECM/FCM,and
make suro CKF sansor mounting
bolt b tight.
Checktor an open in the CKFsen_
1. Turnthe ignitionswitchOFF CKFSENSOR3P CONNECTOR

2. Disconnectthe CKFsensor3P
3. Measure the resistance r--r t

b e t w e e nt h e C K Fs e n s o r3 P |-.r-r'--]l
connectorterminalsNo. 1 and l l ll 2 l 3 l l
.l---'.-T_
No.3.
C K F MI I CKFP
t w H T l --\9-
|/Ai i lBlul
ls there1.6 3.2kO? Terminal side oI male terminals
Check for a short in ihe CKF sen_

sot:
Check for continuity between
body ground and the CKF sensor
3P connector terminals No 1 and
No.3 individuallY. CKFP
CKF M
(WHT) (BLU)
t (cont'd)
(To page 11-186)
11 - 1 8 5
PGM-FISystem
CrankshaftSpeedFluctuation(GKFISensor
('99- 00 ModelsexceptD16YSenginewith M/Tl (cont,d) \ I
(Frornpagel1-185)
Check Ior an opsn in the wires

(CKFlines):
1. Reconnect the CKFsensor3p
connector.
nectorC {31P}.
ECM/PCMCONNECTOR
C 13lPI
3. Measureresistancebetw€en
nalsC22and C31.
Repair opqn in th. wire bo{ween

l s t h e r e1 . 6 - 3 . 2k 0 ? ECM/PCM(CZ, Ctll and th. CKF
lon30r.
Check tor a short in the wire Wire sideof female

ICKFline): terminals
C h e c kf o r c o n t i n ! i t y b e t w e e n
body groundand ECM/PCMcon-
nectorterminalC22.
Roplir thort in tho wirg b.iwoon
a
ECM/FC'ftllc22l and tho CKF3€n-
I
PCM, and r.ch.ck. It symptom/
indication90o. aw!y, 6pbco the
originalECM/PCM.
11 - 1 8 6
Position(CKP/TDC/CYPI
DeadCenter/Cylinder
Position/Top
Crankshaft Sensor
Thescantoo|indicatesDiagnosticTroub|ecode(DTc)P1359:Aprob|eminthecrankshaftPosjtion/TopDe
sensorcircuit'
Position(CKP/TDC/CYP)
Center/Cvlinder
- The MIL has been reportedon

- DTCP1359is stored
1. Do the ECMResetProcedure
2 . S t a nt h e e n g i n el f t h e e n g i n e
won't start,crankit for at least
10seconds-
lntermittent failure, sYstem is OK

Check for poor connecllon3or
ls DTCP1359indicated? loose wires at C120 {distributor}
and ECM,/PCM.
C h e c kf o r p o o r c o n n e c t i o n so r
loose wires betweenthe distribu
tor and the ECM/PCM
l , a Substitute a known'good ECM/

PCM, and rccheck. lt 3ymPtom/
indication goes awtY, rePlace
rta
11-1A 7
PGM-FISystem
ECM/PCMlnternalCircuit
[Fi6oil th" """n tool indicates
Diagnostic
Troublecode(DTc)p1607:
An EcM/pcMlnternal
circuitprobtem.
- The MIL has beenreportedon.
Problernverification:
1. Do the ECN4/PCM Resetpro-
cedure.
2. Turnthe ignitionswitchON t).
3. Wait 10 seconds.
Substitule a known-good ECM/

indicationgoes away, .epl.ce the
origin.l ECM/PCM.
11-188
J A/T Signal(TMA/TMBI('96- 98 Dl6Y5enginewith GW)
I
signallinefailure
Code(DTC)P1681:TIVA,/TMB
[F16551lTh" ""un toot indicatesDiagnosticTrouble
C 131P}
ECMCONNECTOR
TMA IGRYI
1. Dothe ECMResetProcedure.
2. Drive the vehicleIor several
milesat varyingspeeds
lnt.rmittent failure, system is OK

at ihis time. Checktor Poor con-
ls DTCP1655indicated? nections or loos€ wires at C131
llocated under right side of dash),
C438ITCM)and ECM. fcu22P
CONNECTOR
Check lor an oPen in the wire
(TMAline):
2. DisconnectECM connectorC
(31P)from t h eE C M
4 - M e a s u r e v o l t a ge b e t w e e n
E C M c o n n e c t o rt e r m i n a lC g
and bodyground. ITMA line,:
Measurevoltage between TCM
22PconnectorterminalNo 7 and
body ground.
l l ls therebatteryvohage?
Ropairshod in the wire bstwe€n
ls there batteryvoltage? the EcM (C!l)and the TcM.
{TMBline}:
1. Turnthe ignitionswitchOFF Repairopen in the wire between
2. ReconnectECM connectorc th€ EcM {Ca)and the TcM.
(31P).
from TCM.
TCM 22P connectortermlnal
No.6 and body ground.
Check for a 3ho.t in the wire
{TMB lin6,:
ls there batteryvoltage? Measurevoltage between ECM
connectorterminalC30and body
ground, 2 3 1 6 7 8 9 10
1t '12 13 1 4 1 5 1 6 1 7 18
23 2a 25 29 30
Substitute a known'good ECM TMB*
and recheck. It symPtom/indica'
Wire side oI temale {PNK}
tion goes away, teplace the origi-
terminals
nal ECM.
Reoairshort in the wile b6tween

ls there bafteryvoltage? the ECM{C30}and the TCM.
t l , f,epair open in the wire between

the EcM (C30) and the TcM.
11 - 1 8 9
ldle Control System
SystemDescription
The idle speedot the engineis controlledby the ldle Air Control(lAC)Valve.
The valve changesthe amount of air bypassinginto the intakemanifoldin responseto electriccurrentcontrolledbv the
ECM/PCM. Whenthe IACValveis activated,the valveopenslo maintainthe properidle speed.
D16Y5,D16Y8,Br6A2engine(M/T):
VARIOUS
sEI{SORS
(ROTARYI
tac vat-vE EI{GINE
cooLAI{T
INTAKEMANIFOTD
Dl6Ys {CVTl,D16Y8enginelA/T):
;iy--, - ---<fltitf.trj
VARIOUS
D16Y7engine:
SENSORS
{ROTABY)
INTAKE
MANIFOLD
1 1 - 190
of air is increasedto raisethe idle speed
1 . After the enginestarts,the lAc valve opensfor a certaintime. The amount
-
about 150 300rpm.
properfast idle speed.The amount of
When the coolanttemperatureis tow, the IAC valve is openedto obtain the
bypassedair is thus controlledin relationto the enginecoolanttemperature'
IOLESPEED
lrpml
ENGI E
COOLANI TEMPERATURE
176
t" Fl
80 toc)
l l
't. W h e n t h e i d | e s p e e d i s o u t o f s p e c i i i c a t i o n a n d t h e s c a n t o o | d o e s n o t i n d i c a t e D i a g n o s t i c T r o u b | e c o d e ( D T c ) P 0 5
or P1508.checkthe followingitems:
. Adiustthe idle speed{seepage11-220}
. Starterswitchsignal(seepage11-202)
. Air conditioningsignal(seepage l1-204)
. ALT FRsignal(seePage11-2081
' Brakeswitchsignal(seepage 11-210)
. PSPswitchsignal(excaptCanadamodel)(seepage11-212)
. A,/Tgear position signal {seesection 14, Dl6Y5 engine (CVT):
p a g e1 1 - 2 1 6 )
. Clutchswitchsignal(D16Y5enginewith M/T)(seepage11-218)
. Hosesand connections
' IACvalveand its mountingO-rings
the idle speed(seepage11-220)

lf the aboveitemsare normal,substitutea known-goodIACvalveand readjust
| f t h e i d | e s p e e d s t i | | c a n n o t b e a d j u s t e d t o s p e c i f i c a t i o n ( a n d t h e s c a n t o o | d o e s n o t i n d i c a t e D T cthe
P0505or
lf symptom goes away, replace
after IAC valve replacement.substitutea known-goodECM/PCMand recheck.
originalECM/PCM.

ldle Control System
ldleControlSystem
lF0505 l Th" """n tool indicatesDiagnosticTroubleCode(DTC)PO5O5:
tdtecontrotsystemmalfunction.
NOTE: lf DTC P1508or P1509is stored at the same time as DTC P0505,troubleshootDTC p1508or p1bogfirst. then
recheckfor DTCP0505.
PossibleCause
. IACvalvemechanicalmalfunction
. Throttlebody cloggedpon, improperadjustment
. Intakemanifoldgasketleakage
. Intakeair hoselooseleakage
. Vacuum leak
. ECTsensorincorrectoutput
. ThrottlePositionsensorincorrectoutput*r
The MIL has beenreoortedon.

DTCP0505is stored.
Problem verification:
1. Start the engine. Hold the
eng;ne at 3,000 rpm with no
load (jn Park or neutral) until
t h e r a d i a t o rf a n c o m e s o n , t h e n
*r let it idle.
t2. with rhe scantoot, ct'eit Ge l
Throttle position should be

approx. 10%with the throt
tle fully closed.
En g i n e c o o l a n t t e m p e r a -
ture should be 194 205'F
(90 96.Ci.
lf they are not within the
s p e c . ,r e p a i rt h e f a u l t y s e n
L._ _9oI9[cr]41 l
3. Chec&the engine speed at
i d l e w i t h n o - l o a dc o n d ; t i o n s i
h e a d l i g h t s ,b l o w e r f a n , r e a r
defogger, radiator fan, and air
conditioner are not operating
\see page l1-22O - 223).
ls the idlespeedOK? Intermittent tailure, system is OK

at this time.
ls it 550 rpm or less?
(Topage 11,193) (Topage ll-193)
* 1 r ' 9 6 m o d e l so n l y
11-192
I { F r o mp a g e1 1 - 1 9 2 )
Checkthe IAC valve:

Disconnectthe 3P connectorfrom
the IACvalve.
D16Y8enginewith M/T 81642engine)

1D16Y5,
I
Checkthe IACvalve:
D i s c o n n e c tt h e 2 P c o n n e c t o r
from the IACvalve.
Doesthe enginespeeddrop or
the enginestall?
L Adiust the {base}idle speod (see

page 11-220- 2231.It it's impos-
aible,clean the ports in lhe throt'
tle bodv,
( F r o mp a g e 1 1 - 1 9 2 i
CheckIor vacuum leaks:

2 . R e m o v et h e i n t a k ea i r d u c t D16Y7engine:
from the throttle body.
4. Put your finger on the lower
pon in the th.ottlebody.
Ch€ck tor vecuum loaks, m.ke

sure the throttle valve is com_
Does the engine speed droP? pletaly closed,end repair as nec-
Adiust the idle speed (see page

11-220- 2231.lf it's impossible,
reolacethe IAC velve.
UPPER
PORT
1 1 - 19 3
ldle Control System
ldle Air Control(lAClVatve('96- 98 Dl6ys, Dl6yB enginewith M/Tl
The scan tool indicatesDiagnosticTrouble Code (DTC)P1508:A problem in the ldle Air ControtflAC)varve
circuit.
The IAC Valve changesthe amount of air bypassingthe throttle body in responseto a currentsignalfrom the ECM in
orderto maintainthe properidle speed.
The MIL hss b€on repo.ted on.

DTCP'l508i. itorod.
Problemvorification:
cedure,
Startthe engine,and warm it
uP to normal operatingtem-
perature.
Intormittont t!llur., sy.tcm b OK VALVE

ls DTCP1508indicated? at thb tim6. Chsck fol poor con-
ncctionr or loo3e wirot at C138
(lACvalv.l.nd ECM.
Check for an opcn in the wiro

(lGPlline): IAC VALVE2P CONNECTOR
ICl3A)
2. Disconnectthe IAC valve 2P
connector. ,flrcer
3. Turnthe ignitionswitchON (ll). h-:J iYEL/BLKI
4. Measurevohagebetweenbody !.__-,/ -lt
ground and the IAC valve 2P (v)
connectorterminalNo. 2. -T
-=
R.prir opan in the wiro botwa.n
IAC valv..nd PGM-FImain r.l.y.
Chockfor an opon or sho in the

wire (IACVlinal: ECMCONNECTOR
A I32PI
1. Turn the ignition switch OFF
and reconnectthe IAC valve
connector. 6 a 10 ll
2. Disconnectthe ECMconnector 12 t 3 r5 t 6 l 7 t 8 t 9 20 23 2a
A (32P). tAcv
3. Turnthe ignit;onswitchON (ll). (BLK/ t* 25
& a 2A 3o
4. Measurevoltage between ELUI
b o d y g r o u n da n d E C M c o n -
nectorterminalA12.
Wire sideoI lemal€terminals
(To page1l-195)
11-194
I
( F r o mp a g e1 1 - 1 9 4 )
Repair open or short in the wire

between ECM lAl2l and IAC
Checkthe IAC valve Iunction:

MomentarilyconnectECM con-
n e c t o rt e r m i n a l sA 1 2 a n d A 1 0
with a jumPerwire severaltimes.
Doesthe IACvalveclick?

and recheck. It symPtom/indica-
tion goes away, replacethe origi-
nal ECM.

ldle Gontrol System
ldle Air Control(lAG)Valve('99- 00 Dl6Y8 enginewith M/T, Bt6A2 enginel
scan tool indicatesDiagnosticTrouble Code (DTC)P1508:A problem in the ldle Air Controt AC) vatve
-[Fl50g l ]h"
CtrCUtt.
The IAC Valve changesthe amount of air bypassingthe throttle body in responseto a currentsignalfrom the ECM in
orderto maintainthe properidle speed.
The MIL has boon r€oorted on.

DTCP1508is srored.
Probl6mverification:
cedure.
2. Startthe engine,and warm it
up to normal operatinglem-
perature.
VALVE
Intermittent tailure, system is OK
ls DTCP1508indicated? at this timg. Check to. poor con-
noctions or loose wires at C138
{lAC valvel and ECM.
Ch6ck for an open in the wir€

{lGPllino}: IAC VALVE2P CONNECTOR
IC138'
connector. la rcpr
I - {YEL/8LKI
4. Measurevoltagebetweenbody - d2 t,-
\
ground and the IAC valve 2P

conneclortermina I No.2, Y-=
Wire side ot female terminals
Repairopon in the wire bgtwoen
IAC valve and PGM-Flmain relay.
Checktof an open or short in the

wire {IACVline}l
and reconnectthe IAC valve
2. Disconnectthe ECMconnector
B {25P).
b o d y g r o u n da n d E C M c o n
n€ctorterminal823.
Wire side of lemale terminals
(Topage11-197)
1 1 - 19 6
t
{ F r o mp a g e1 1 - 1 9 6 )
Repair opon or short in lhe wire

ls therebatteryvoltage? between EcM lBzl) and lAc valve.
Checkthe IAC valve fundion:

MomentarilyconnectECM con-
nectorterminals823 and 82 with
a iumpe.wire severaltames.

Doesthe IACvalveclick?

and rocheck. ll symptom/indicd-
tion go€s away, rePlacetho origi_
nal ECM.
11-197
ldle Control System
ldle Air Control(lAC)Valve('96- 98 A/T and Dl6Y7 enginel
TroubleCode(DTC)P1509:A problemin the idleAir Control(tAC)valvecircuit.
1P1509 ThescantoolindicatesDiagnostic
The (Rotary)IAC Valvechangesthe amount of air bypassingthe throttle body in responseto a currentsignalfrom the
ECM/PCMin orderto maintainthe properidle speed,
BIMETAL
The MIL has b€€nroportedon.

DTCP1509is stored.
oure.
2. Turnthe ignitionswitchON (ll). SHAFT VALVE STOPPER
Intermittent failura, systom ia OK
ls DTCP1509indicated? at this time. Checktor poo. con-
noctions or loose wires at C109
llAC valve) and ECM/PCM.
ECM/PCMCONNECTOR
A I32PI
Checkfor an opon in the wirer PGl IBLKI
{PGlines):
Measurevoltage between bodv
ground and ECM/PCIIconnector
terminalsA10 and A23 individu
Repairop€n in the wires betwoen

ls theremorethan 1.0V? ECM/PCMand G101llocatedat
tho thermostat housing).
Wire sideof lemaleterminals
Chock th€ ECM/PCM inpui volt-
agel
2. DisconnectECM/PCMconnec-
tor A (32P)fromthe ECM/PCM. 1 2 3 a 5 6 E l0 11
4 . M e a s ur e v o l t a g e b e t w e e n
12 1 3 1 4 r 5 1 6 1 7 1 8 t9 20 2:2 23 21
b o d y g r o u n da n d E C M / P C M 27 2A A 30
connectorterminalsA14 and rAcvN loRNl*
A13* individually. IACVP {BLK/BLUI
(To page 11-199)
Ch6ckth6 IAC valve:

2. Disconnectthe IAC valve 3P IAC VALVE3P CONNECIOR
connector,
3, Measureresistancebetween
IACvalve3P connectortermi-
IACV N IACV P
n a l N o . 2 a n dt e r m i n a l N
s o.1
a n d3 i n d i v i d u a l l y .
ls there 16- 28 g? IGP

Terminalsideof male
terminals
indication goos away, replace
th€ origin.l ECM/PCM.
*: IACV N line
11 - 1 9 8
t lFrompage11-198)
IAC VALVE3P CONNECTOR

IClG'}
Chock for an opon in tho wilo

(lGPlins):
IGPIYEL/BIX)
connector,
3. Turn the ignitionswitchON (ll),
4. At the wire hamess, measure
voltage between IAC valve 3P
body ground.
Raprir op€n in th€ wirc botw.€n

ls there bafteryvoltage? th. IAC vrlv6 and PGM.FI mtin
rehy.
Check for rn open in tho wil.s

(IACVP,IACV Nr linesl:
2. Disconnectthe ECM/rcM con-
necrorA (32P).
IAC valve 3P connecto.terma_
nal No. 3 and ECM/PCMcon-
n e c t o r t e r m i n a l A 1 4 ( an d
betweenIAC valve 3P connec- IACV N
tor terminal No. 1 and ECM/ toRNt* t I IACV P
l l rcM connectorterminalA13l*. (BLK/8LU}
ECM/PCM
Ropairopan in tha wito bgtwoon CONNECIOR A (32P)
ths IAC vrlv! rnd ECM or PCM
{A14,413.1. IACV P
(BLK/BLU}
't1
I o , t l0
Check for e lhort in tho wiros m x2 21
(IACVe nCV Nr linc): 1Z 13 ta 1 5 l 6 1 7 ta l 9 23
C h e c kf o r c o n t i n u i t y b e t w e e n 25 21 i6 a 3o
body ground and ECM/PCMcon-
n e c t o rt e r m i n a l sA 1 4 a n d A 1 3 * Wirc sideof lemaleteaminals
individually.
Rapair rhort in thr wi]. batwaon

ls therecontinuity? th. IACv.lvc .nd ECM/PCfvl{A14, ,| 31. 5 7 a I l0 tl
Ar3.t. 12 t3 r .l r st5 1 1 r8 t 9 20 22 23 2a
27 2a A 30
tAcv N (oRNt*
Checkthe IACV.lvo:
IACVP (BLK/SLU}
1. Disconnectthe IAC Valve 3P
IAC Valve 3P connectortermi-
nai No. 2 and terminalsNo. 1
and No.3 individuallY.
IACVP
ls there16- 28 O?
rla Subrtituto a known-good ECM/

PCMand r€ch€d( lt .vmptom/indi
calioo gp€. .way, ruplacetho odgi
ml Eqvt/FCM.
Terminalsideof mal6
tetmtnats
-: IACVN line
11 - 1 9 9
ldle Gontrol System
ldle Air Control{lAClValve('99- 00 A/T and Dl6Y7 enginel
TroubleCode(DTC)P1509:Aprobleminthe idleAirControl(lAC)valvecircuit.
1P1509 lThescantool indicatesDiagnostic
The (Rotary)IAC Valvechangesthe amount of air bypassingthe throttle body in responseto a currentsignalfrom the
ECM/PCMin orderto maintainthe properidle speed.
BIMETAL
HOLDER
BIMETAL
Tho MIL has b€enreportedon.

OTCP1509is sto.ed.
Problemverilicationr
dure.
2. Turnthe ignitionswitchON (ll). SHAFT VALVE STOPPER
Intermittont tailure, sy3tem i3 OK
ls DTCP1509indicated? at thb time. Checkfor poor con'
noctions or loose wiros at C109
(lAC velvel and ECM/PCM. ECM/PCMCONNECTOR
B {25P}
Checkfor an oDen in the wilos

IPG linesl:
ground and ECM/PCMconnector
terminals82 and 810 individually.
Ropail open in the wires be'tw€en

ls theremorethan 1.0V? ECM/PCM .nd G101 llocated .t
the the.mostat housingl.

Check tho ECM/PCM input volt-
age:
2. DisconnectECM/PCMconnec-
tor A (32P)tromthe ECM/PCM.
4, Measurevoltage between
c o n n e c t o tr e r m i n a l s8 6 a n d
815* individually.
(To page11-201)
Chockthe IACv.lve: IAC VALVE3P CONNECTOR

1. Turnthe ignitionsw;tchOFF.
connoctor.
3. Measureresistancebetween IACV N IACVP
IACvalve3P connectortermi'
nal No. 2 and terminalsNo. 1
and 3 individually.
IGP
ls there16- 28 O? Terminal side of male
terminals
YES
Sub3titute e known-good ECM/
PCM .nd recheck. lf 3vmptom/
indicalion goos away, replac6
thc original ECM/PCM.
*: IACV N line
11-200
I
(Frompage11 200)

{C1O9I
Check toi an open in thg wire

{lGPline):
1. Turnthe ignitionswitchOFF. IGP(YEL/BLK)
connector.
4, At the wire harness,measure
voltage between IAC valve 3P Wire sideof femaleterminals
body gro!nd.

the IAC valve and PGM-FI main
reraY.

IIACVP. IACVN' lines):
nectorA (32P).
3. Checklor continuitybetween
IAC valve 3P connectortermi'
nal No. 3 and ECM/PCMcon-
n e c t or t e r m i n a l B 6 ( a n d IACV N IACVP
beNveenIAC valve 3P connec (oRN)* {BLK/BLU'
t o r t e r m i n a lN o . 1 a n d E C M /
I PCMconnector terminal815)*. ECM/PCM
B (25PI
CONNECTON
Repairopen in the wiro ltstwcen
the IAC valvo and €CM/PCM (86, IACV N IACV P
815'1. (oRNt. IBLK/BLUI
Check for a shon in the wires

(IACVP, lACv N* linesl:
body ground and ECM/PCM con-
n e c t o r t e r m i n a l s8 6 a n d 8 1 5 *
individually.
Reoairshort in the wiro Mweon

ls therecontinuity? the lac valve end ECM/FCM(86,
815*).
Checkthe IAC valv€:

l. Disconnectthe IAC Valve 3P N
connector,
2. Measureresislancebetween
IAC Valve 3P connectortermi
nal No. 2 and terminalsNo 1
and No.3 individually
IACVALVE3P CONNECTOR
ls there16- 28 O?
IACV N IACV P
Substituta . known-good ECM/
L PCM and rochcdc f 3ymptom/indi

cation go€a away, r€dace the origi
nal ECM/Pqvl.
IGP
Terminal side of male
"r IACVN line
11-201
ldle Control System
StarterSwitch Signal('96- 98 Models,'99- 00 D16Y5enginewith M/Tl
Thjs signalsthe ECM/PCM
when the engineis cranking.
NOTE:
in E or E position
. A/T:Transmission
. M/T:in neutral
ECM/PCMCONNECTORS
Checktor an open or short in the a l32Pl LGl
wire ISTSlinel: {BRN/BLKI STS IBLU/ORNI
PCMconnectorterminalsA9 and 2 1 6 9 10 It 3 5 6 7 a 9 l0
C6 with the ignitionswitchin the l 2 l 3 l a 1 5 ! 6 1 7 1a 1 9 20 22 2a t t 12 t3 l 4 t 5 t 6 1 7 1E
startlllli position. 25 2l 2A 7t 30 23 2a 29 30
Wire sideot femalelerminals
Inspectthe No. 31 STARTERSIG-

NAL (7.5A) fuse in the underdash
fuse/relaybox.
- Repair .hort in the wire

botwoen tha ECM {C6l and
Staner 3witch signal is OK. tho No, 31 STARTERSIGNAL
{ 7 . 5A l t u s s o r t h e P G M - F I
main relay,
- Roolac. the No. 3'l STARTER
SIGNALl?.5 Al tu3€.
Repair opon in th6 wiro botwean

ih. ECII4/PCM (C6)and the No.31
STARTERSIGNAL{7.5Al tulo.
11-202
StarterSwitch Signal('99- 00 ModelsexceptDl6Y5 enginewith M/T)
\
when the engineis cranking
This signalsthe ECM/PCM
NOTE:
. M/f: Clutchpedalmust be depressed.
. A,/T:Transmissionin E or E position
ECM,/PCM
CONNECTORS
Ch€ckfor an open or short in the

wire {STSlinel:
P C [ / |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).
Inspectthe No.31 STARTER SIG-

NAL(7.5Alluse in the under-dash
W;resideof femaleterminals
- Repair3hort in tho wire be'

tween tho ECM/PCM lA24)
Staner 3witch signal is OK. and tho No. 31 STARTERSIG-
NAL 17.5Al fuse or the PGM-FI
mein relay.
- ReDlacothe No. 31 STARTER
SIGNAL17.5Al fuse.
I
Repairopen in the wirc betwean
the ECM/PCMlA24) and the No.
31 STARTERSIGNAL{7.5Alfuse.

ldle Gontrol System
Air GonditioningSignal('96- 98 Models,'99 - 00 Dl6Y5 enginewith M/Tl
This sjgnalsthe ECM/PCM
when there is a demandfor coolingfrom the air conditioningsystem.
ECM/PCMCONNECTORS
a {32P1 c l3lPl
LGl IBRN/8LKI ACS {BLU/RED)
2 3 6 1 I 9 't0 It t 3 a 8 9 t0
C h e c kf o r a s h o r t i n t h e w i r e 12 't3 1 a l 5 l 6 1 7 t 8 t 9 20 23 2a ll 12 l 3 l!a i 5 !6 17
'tE
{ACSline): 25 2l 2A 29 30 23 2a 25 29 30
2. Disconnectthe A/C pressure
switch 2P connector {see sec Wire sideof femaleterminals
tion 22).
4 . M e a s u r e v o l t ag e b e t w e e n
nalsC5 and A9.
Checkfor a .hort in the wi.e {ACS ACS(BLU/BEDI

line):
ls thereapprox.5 V? 2. Disconnect the ECM/PCM con-
nectorC (3lPi.
connectorterminalC5,
Reotir short in the wi.e between

ls there continuity? the ECM/PCMlc5l and rhe A/C
pressureswitch.
- Substitute a known-good
Check tor an op€n in the wire
ECM/rcM .nd re.fieck. f Dre-
IACClin6l:
1. Turnthe ignitionswitchOFF. scribed voltage is now avail
2. Reconnectthe A/C pressure tble, replace the original ECft4/
PCM,
switch 2P connector. -
3. Turnthe ignitionswitchON (ll). See the air conditioner inspe-
tion ls€e s€ction 221. LGl IBRN/BLKI
4 . M o m e n t a r i l yc o n n e c tE C M /
PCM connectorterminalsA9
a n d A 1 7 w i t h a j u m p e rw i r e 1 2 3 a s l s l r l l o l g lr o l r r I
1 2 1 3 1 4 l5 16 y ) n l t s l n l / @ ) z r I z r I
(To page11-205)
25 27
1!M1 1-/r
ACC
IBLK/RED) JUMPERWIRE
11-204
(Frompage11-204)
UNDER.HOODFUSE/BELAY
BOX 9P CONNECTOR
1C352)
Check for an open in the wir€
(ACClinel: 1 2 I a
ls therea clickingnoisefrom Momentarilyconnectunderhood
5 8 9
the IVCcompressor clutch? fuse/relaybox 9P connectorteF
minal No. 5 to body groundwith JUMPER
a iumperwire severaltimes. ACC(BLK/REDI
(BLK/RI
WIRE
Wiresideof female
terminals
ls therea clickingnoisefrom See air conditionor inspection

the Py'Ccompressorclutch? (see3oction221.

r h e E C M / P C Ml A l 7 l a n d t h 6
under-hood fu3e/rolaY box 9P
connectorlC352l.
r f A t32P)
ECM/PCMCONNECTORS
Check for the oPeration of the LGl c {31Pl

Alcl (BRN/BLK) ACSIBLU/RED)
1. Startthe engine.
2. Turnthe blowerswitchON I 2 3 a 9 10 1t 3 I 8 9 t0
3. Turnthe AJCswitchON. 12 1 3 1 5 l 6 1 1 l a 1 9 20 23 2a t t 12 't3 l a 't5 t 6 1 7 t a
25 27 2A 29 30 23 2a 29 30
Chock tor an open in the wire

IACSlinel:
Doesthe Ay'Coperate? Measurevoltage betweenECM/
PCMconnectorterminalsA9 and
c5.
Air conditioning signal is OK. Repair open in the wire b€tween

l s t h e r e l e s st h a n 1 . 0 V ? the EcM/PcM lC5) and the A/c
3witch.
- Substiiute a known-good
ECM/PCM and recheck ll
symptom/indication 9oes
t -
a w a y , . o p l a c et h e o r i g i n a l
ECM/PCM.
Seethe air condhionerinsP€c_
tion {sees€c{ion22).

ldle Control System
Air ConditioningSignal('99- 00 ModelsexceptDl6Y5 enginewith M/Tl
when there is a demandfor coolingfrom the air conditioningsystem.
ECM/PCMCONNECTORS
a l32P)
C h o c kt o r a s h o r t i n i h e w i . e
(ACSlin6):
switch2Pconnector.
E C M / P C Mc o n n e c t o rt e r m i
nalsA27 and 820.
ECM/PCMCONNECTOR
A {32P)
Checkfor a short in the wire (ACS

linel:
nectorA (32P).
Reoairshort in lhe wi.e botweon

the ECM/PCM(A271and rhe A/C
pressureswilch.
Srr66titutoa known{ood ECM/

Check to. an opon in tho wi.e
(ACClinel: PCt4tnd rechock. It prascrib€d ECM/PCMCONNECTORS
voltage is now available, re-
1. Turnthe ignitionswitchOFF. plac€the originalECM/rcM.
2. Reconnectthe A/C pressure A (32P1
Soothe air conditionerinsoec-
switch 2P conneclor.
tion {see s€ction 22}.
4 . M o m e n t a r i l yc o n n e c tE C N 4 /
PCMconnectorterminalsA17
a n d 8 2 0 w i t h a j u m p e rw i r e
(To page '!1-207)
LGl {BRN/BLK)
11-206
I
(Frompage11-206)
FUSE/RELAY
UNDER-HOOO
sox 9PcoNNEcroR
lca52l
Check for an open in the wite
IACClino): 1 2 3 a
ls therea clickingnoisefrom Momentarilyconnectunder_hood 5 6 8 9
the Iy'Ccompressorclutch? luse/relaybox 9P connectorteF
minal No. 5 to body groundwith JUMP€R ACC(8LK/REDI
a jumperwire severaltimes. WIRE
Wire sideof f e m a l e
terminals
ls therea clickingnoiselrom S6e air conditioner insPoction

the ly'C compressorclutch? l3oasection221
Ropairopen in tho wilo betwg€n

the ECM/PCMlA17) and the A/C
clutch rolay.
ECM/PCMCONNECTORS
A (32P1
Chock for the oporation of lho

AIC:
1, Startthe engine.
2. Turnthe blowerswitchON
switch ON.
3. Turn the ray'C
Check lor an open in the wiro

(ACSlino):
Doesthe Iy'Coperate? Measurevoltage betweenECM/
P C M c o n n e c t o rt e r m i n a l sA 2 7
and 820. Wiresideof {emaleterminals
Air conditioningsignal is OK.

Repair op6n in the wiro bctwoon
ls voltagelessthan1.0V? lhe ECM/PCMlA27l and tho A/C
3witch.
- Sub6iitut€ r known€ood ECtt /

PCM and rccheck. ll sYmP-
t o m / i n d i c a t i o n9 o e 3 . w a Y ,
replacathe originalECM/PCM
- Seethe ai. condhionGrin3p€c-
tion lseesoc{ion221.
11-207
ldle Control System
Alternator(ALTIFRSignal{'96- 98 Models,'99- 00 Dl6y5 enginewith M/Tl
when the Alternator(ALT)is charging.
Inspoctionof ALT FRSignal. ECM/PCMCONNECTORS

a {32P) c {31P)
LGl
(BRN/BLK)
Check tor a short in tfte wire (ALT
F linel:
1. oisconnectthe 4P (3P)*con-
nectorfrom the ALT.
2. Turnthe ignitionswitchON (ll). ALT F
3 . M e a s ur e v o l t a g e b e t w e e n {WHT/REO)
E C M / P C Mc o n n e c t o rt e r m i
nalsC17and A9.
Checklor a sho.t in the wire {ALT
F line): 1 1 7 8 I 10
r. I urn rne tgn|ltonswtlchul-f,
2. Disconnectthe negativebat- 11 12 1 3 14 15 16 17 18
ls thereapprox.5 V? tery cablefrom the baftery. 23 21 25 a 30

nectorC {31P). ALTF IWHT/REDI
4. Checkfor continuitybetween o
Checkth€ operation of the ALT: connector terminalC17.
2. Reconnectthe ALT 4P (3P)*
connectorto the ALT. Repairshort in the wire betwe€n
3 . S t a r t t h e e n g i n e .H o l d t h e the ECM/PCM{Cl71andth€ ALT.
load (in Parkor neutral)untjl
the radiatorfancomeson,then
letit idle.
4. [,4easu re voltage between Substitute a known-good ECM/
ECM/PCMconnectorterminals PCM and recheck. It prescribed
voltage is now available,roplace
C17andA9.
the originrl ECM/PCM.
Does the voltage decrease when

h e a d l i g h t sa n d r e a r d e f o g g e r a r e ALT FRsignal is OK.
turned on?
ALT CONNECTORS
IC1O4I
4P 3P*
Checktor an open in the wire (AlT
F linel:
1. Turnthe ignitionswitchOFF. 1 2 l
2. Disconnectthe negativebat-
tery cablefrom the battery.
3 . D i s c on n e c t t h e E C M / P C M
Flr
rr-ri-f JUMPER
JUMPER
WIRE
connectorC (31P). rwHr/(V) WIRE
4. Disconnectthe 4P (3P)*con, neor Y
nectorfrom the ALT. Wire sideof femaleterminals
5. Connectthe ALT 4P 13P)lcon
nectorterminalNo. 4 (No. 1)'
to body groundwith a iumper
b o d y g r o u n da n d E C M / P C M 3 I 7 8 9 10
connectorterminalC17, 1 l 12 13 l4 15 16 17 18 /l
23 21 25 E 30
ls therecontinuity? Repair op6n wire botween th€
ECM/PCM(C171rndth€ ALT.
o ALTF IWHT/REDI
*: Canadamodel
11-208
M/T)
t Alternator(ALT)FRSignal('99- 00 ModelsexceptDl6Y5 enginewith
when the Alternator{ALT)is charging
This signalsthe ECM/PCM ECM/PCMCONNECTORS
lnsoeclionoI ALT FB Signal.
Check{or a short in the wire {ALT

F line):
1. Disconnectthe 4P (3P)+con
nectorfrom the ALT
3. MeasurcvoltagebetweenEcM/
PCM connectorterminalsC5
and820. Check tor a short in the wirc (ALt Wire sideof femaleterminals
F line): C (31P}
ECM/PCMCONNECTOR
2. Disconnectthe negativebat_ ALT F (WHT/RED)
tery cablefrom the baRery'
ls thereaPProx.5 V? 3. Disconnectthe ECM/PCMcon'
nectorC (31P).
connectorterminalC5
Checkthe operation otthe ALT: Wire sideof temaleterminals
2 - R e c o n n e ct th e A L T 4 P ( 3 P ) * Repairshort in the wire between
connectorto the ALT the EcM/PCM {C5land the ALT.
engine at 3,000rpm wrth no
load {in Parkor neutraliuntil
l t t h e r a d i a t o rf a n c o m e s o n ,
then let it idle.
PCM and rechock.lf P.esc.ibed
4- MeasurevoltagebetweenECM/ voltage is now availabl€,ieplace
PCM connectorterminalsC5 tho original ECM/PCM
and820.
D o e s t h e v o l t a g e d e c r e a s ew h e n
h e a d l i g h t sa n d r e a r d e l o g g e r a r e ALT FF signal is OK.
turned on? IClO4I
ALT CONNECTORS
lP 3P*
NO
Checklor an op€nin the wire (ALT --?--

1 l 2 l
F line,: |#
1. Turnthe agnition switchOFF
2. Disconnectthe negativebat-
i 3 l . l JUMPER
otriJ JUMpER WlnE
tery cable{rom the battery.
3. Disconnect the ECM/PCM con' rwxrr(V) WIRE
nectorC (31P). neor Y
4. Disconnectthe 4P (3P)*con' Wire sideof femaletermlnals
nectorfrom the ALT.
5. Connectthe ALT4P (3P)*con- C (31PI
ECM/PCMCONNECTOR
nectorterminalNo 4 (No. 1)*
to bodYgroundwith a iumper
connectorterminalC5
Repair oPen wire betwoen t|lo

ECM,/PCM{C5)and the ALT. Wire sideof femaletermrnals
*: Canadamodel

ldle Control System
BrakeSwitch Signal('96- 98 Models,'99 - 00 Dl6YSenginewith M/Tl
when the brakepedalis deoressed.
Inspectionof BrakeSwitch Signal.
Are the brakelightson without

depressing the brakepedal?
Depressthe brakepedal.
Inspectthe HORN(15 A) fuse in

Do the brakelightscomeon? the under-hoodfuse/relaybox.
- Repair short in the wire

betweenthe brake3whch and
rhe HORN115At lu3e.
- Replacethe I|oRN 17.5A) tus€.
Repair open in the wire

betweenthe brakeswitch and
the HORN115Al fuse.
Inspect th6 br.ke switch {s6€
section l9l.
IBKSWline): ECM/PCMCONNECTOFS
1. Oepressthe brakepedal. LGl
2. Measurevoltage between D {16P) BKSW
A (32Pt IBRI\v (GRN/
ECM/PCNI connectorterminals
WHTI
Ag and D5with the brakepedal ,l
oepresseo. a 6 7 8 10 11 1 2 I
12 1 3 1 1 1 5 1 6 1 7 t 8 1 9 20 22 23 2a I 9 10 1 1 12
25 21 2A a 30 13 14 1 5 16
Wire sideof femalet€rminals

Repairopen in the wire b€tween
ls there battery voltage? the ECM/PCM{Dsl and the brake
switch.
Brakc switch sign.l is OK.
11- 2 1 0
M/Tl
BrakeSwitch Signal('99- 00 ModelsexceptDl6Y5 enginewith
I J
when the brakepedalis depressed
lnsoectionot BrakeSwitch signal.
Are the brakelightson without

depressing the brakePedal?
Depressthe brakePedal
Inspectthe HoRN {15 A} fuse in

Do the brakelightscomeon? the underhood fuse/relaybox'
- R.pair short in the wiro be'

tween the brake switch and
the HORN(15Alfuse.
Replac€the HORN(15A) tuse.
I -
- Repair open in the wite be'

tween the brako switch and
the HORN(15Alfuse.
- lnsoect the brake switch (3ec
section tgl.
ECM/PCMCONNECTORS
Check fot an oPen in the wire
{BKsw linel:
1. Depressthe brakePedal.
2. Measurevohagebeween ECM/
and 820 with the brakePedal BKSW(GRN/WHTI
depressed.
Bepair open in the wire between LG1 {BRN/BLK)

t h e E C M / P C M( A 3 2 ) a n d t h e
brake switch.
Wire side o{ female terminals
Brakeswitch signal i5 OK

ldle Control System
lgy"t9!"_"ring Pressure (PSPISwitchSignal

('96- 98 Models,'99- 00 DlGy5enginewitn fU/f) (USAI
This signalsthe ECM/PCN4
when the power steeringload is high.
Inspectiono{ PSPswitch signal. ECM/PCMCONNECTORS
Checkfor an opon in the wire {PSP

SW linelr
E C M / P C Mc o n n e c r o rt e r m i - WiresideoI temaleterminals
n a l sA 9 a n dC 1 6 .
Checklor an open in the wire (PSP
SW line): PSPSWITCH2P CONNECTOR
2. Disconnecl the PSPswitch2p PSPSW IGRNI
3. Turnthe ignitionswitchON (ll). II
ls therelessthan1.0V? 4. At the harnessside, connect
JUMPER l--L
the PSPswitch 2P connector
w f R E- 2 /
terminalN s o.l andNo.2
with a jumperwire. GND(BLKI
ECM/PCMconnectorterminals Wiresideol femaleterminais
Ag andC16.
- Repair open in the wiro

between the ECM/PCMlc16l
ls therelessthan 1.0V? and the PSPswitch.
Check the operation of the PSP - Repair open in BLK wire
switch: betwoen the PSP switch and
'1. Start
the engine G101.
2 . T u r n s t e e r i n gw h e e l t o f u l l
3 - M e a s ur e v o l t a g e b e t w e e n
A9 andC16.
ls therebatteryvoltage?
PSP switch signel is OK. (To page 11'2'13)
11- 2 1 2
t ( F r o mp a g e1 1 2 1 2 )
C h e c kl o r a 3 h o r t i n t h e P S P ECM/PCMCONNECTORS
switch:
from the PSPswitch.
nalsAg and C16.
Wire sideof temaleterminals
Checktor a short in the wiro {PSP 1 2 a 6 1 8 9 t0

SW linel:
'l
'1. Turnthe ignitionswitchOFF. tl 12 1 3 1 4 1 5 16 17 18
2. Disconnectthe ECM/PCMcon 23 21 25 a 30
ls there batteryvohage? nectorC (31P).
3. Checklor continuity between
PSPSW (GRNI
connectorterminalC16.
o
Repairahort in the wire between

the ECM/PCM(C16)and th6 PsP
switch.
Substitute a known_good ECM/

PCM end rechock. lf Prescribed
voltage b now avsilable. rePlace
1 -213
ldle Control System
PowerSteeringPressure(PSP)Switch Signal
('99- 00 ModelsexceptDl6y5 enginewith M/T) (USAI
when the powersteeringload is high.
ECM/PCMCONNEgTORS
Inspoctionot PSPswitch signal.
Checkfor an op€n in the wire (PSP

SW linel:
2. MeasurevoltagebetweenECN4/
PCMconnectorterminals426
and 820.
Checkfor .n open in tho wire IPSP
SW line):
1. Turnthe ignitionswitchOFF. Wiresideof femaleterminals
2. Disconnoct the PSPswitch2P
connector. PSPSWTTCH (qts6)
2P CONNECTOR
ls therelessthan1.0V? 4. At the wire side,connectthe PSPSW (GRN)
PSP switch 2P connector ter-
m i n a l sN o . 1 a n d N o . 2 w i t h a 1
jumperwire. JUMPERT---7 \
5. MeasurevoltagebetweenECM/
wlRE LJ- 2-l
PCNIconnoctorterminals 426
and 820. GNDIBLK)
Wi16sid6 of temale terminals

- Ropai. opgn in ths wire be-
tw.€n the ECM/PCM {A261
ls therelessthan 1.0V? rnd th6 PSPswitch.
Check the operation ot the PSP - Ropsir opon in BLK wi.o bo-
sw;tch: twoen tho PSP switch and
'1. Start
the engine G101.
2. Turn steeringwheelslowly.
3. MeasurevoltagebetweenECM/
PCM connectorterminals 426
and 820.
PSP switch sign8l i3 OX. ( T op a g e1 1 - 2 1 5 )
1 1-2 1 4
\
(Frompage11'2141
ECM/PCMCONNECTORS
C h e c kl o r a s h o r t i n t h o P S P
swhch:
from the PSPswitch
3. Turn the ignitionswitchON {ll)
4. MeasurevohagebetweenECW
and 820.
A I32P)
ECM/PCMCONNECTOR
Ch6ckfor a short in tho wiro IPSP
'l'
SW lino,:
nectorA (32P).
3. Check for continuity betweon
connectorterminalA26
Wiresideof lemaleterminals
Rogair short in the wiro b€{woon

the ECM/PCM(A26)and the PSP
switch.
Substitute a known_good ECM/

PCM rnd r.check. lf Prdcribod
vohago is now avaihblo' rcPl.co
the original ECM/PCM
-215
ldle Control System
AutomaticTransaxle(CVTIGearPositionSignal
('96-98 D16Y5enginewith CW)
This signalsthe ECMwhen the transmissionis in @ or @ position.
Checkthe operationoI the A/T

gear position switch:
1. Turnthe ignitionswitchON flt).
2. Observethe A/T shift position
indicatorand selecteachposi
tion separately.
See lhe A/T gear position indica-

tor insp€ction{seesec{ion l/tl.
Check tor a short in the wir6 (ATp

NPline):
Irom the gaugeassembly.
from the TCM.
4. Turnthe ignitionswitchON fll).
5. MeasurevoltagebetweenECM Wire side ot female terminals ATP NP
c o n n e c t o tr e r m i n a l sA 9 a n d
c29. {LT GRNI
Checkfor a short in the wire lATp

NPlinell 2 4 5 7 I 9 10
1. Turnthe ignitionswitchOFF. t 1 12 1 3 1 a 1 5 1 5 1 7 1 8
ls thereapprox.5 V? 2. Disconnectthe ECM connec
tor C (31P). 23 21 25 29 30
b o d y g r o u n da n d E C M c o n ATPI N P
nectorterminalC29. o (LT G
i BN)
Check for an open in the wire lATp
NP lina):
1. Turn the ignition switch OFF_
2. Beconnect the 14P connector
to the gauge assembly. Repairshort in the wire between
3. Reconnectthe 26P connector t h e E C M { C 2 9 1a n d t h e g a u g e
to the TCM. assemblv,
4 . S t ar t t h e e n g i n e .
5. Measure voltage between
ECM connector terminals A9
and C29 with the transmis
sion in E and E posationt Substitute a known-good ECM
and recheck. lf prescribed volt-
age is now avrilable, replace the
o.iginalECM.
( T op a g e1 1 ' 2 1 7 )
11-216
t ( F r o mp a g e1 1 - 2 1 6 )
between the ECM {C291and
lhe Ituge assomblv.
ls therelessthan 1.0V? - Repair open in the wire
betwoen the gauge assembly
and the A/T gea. Position
switch.
ECMCONNECTORS
LG1 IEBN/BLK)
Chockfor a short in the wite (ATP

NP line):
connectorterminalsAg and C29
with the transmission in gear.
ATP NP
Wire sideof femaleterminals (LTGRN)
ReDairshort in the wire be'tween
ls there batteryvoltage? ECM(C291and gauge a3somblY.
A/T g€ar position signal is OK

ldle Control System
ClutchSwitch Signal(Dl6YSenginewith M/Tl
{
This signalsthe ECMwhen the clutchis engaged.
Inrpactionot dutch rwitch signal.

ECMCONNECTORS
A {32P} LGl (BRN/BLK)
Check for on opon in the wiro

(CLSWlinel:
'!. Turnthe ignition
switchON (ll).
2. MeasurevoltagebetweonECt!4
A9.
Ch.ck tho clutch switch:

ls thare approx. 5 V? from the clutch switch.
4. Measurevoltageb€tweenECM
(
\-
ls thereapprox.5 V?
Check for a short in th6 wire

(CLSWline)l 2 6 1 8 9 10
1. Turnthe ignitionswirchOFF. 1 l 12 t 3 'ta t 5 l6 1 7 l8 22
2. Disconnectthe ECM connec
Chcck for an open in thg wire tor C (31P)tromthe ECM.
{CLSWlinel: 3. Checklor continuitybetween
ECM connectorterminal C29
cLsw
1. Depressthe clutchpedal.
2. MoasurevoltagebetweenECM and body ground. o (RED}
connectortorminalsC29 and
A9.
Repairshort in the wirc between

t h o E C M { C 2 9 1a n d t h o c l u r c h
switch.
(Topage11-219) Sub3titutg a known-good ECM

and rechock, It p.e3cribed vohago
i! now available,roplacethe orig-
inal ECM.
! a
11- 2 1 8
{ F r o mp a g e1 1 - 2 1 8 )
CLUTCHSWITCH2P CONNECTOR
j-t -
Checklho clutch switch:
from the clutch switch.
ls voltagelessthan 1.0V? 3. Checklor continuitybetween
the clutch switch connector
terminalsNo. 1 and No.2 with
the clutchpedaldepressed
Terminalsideof male
termrnals
- Adiu3t the clutch swiich.

- Reolacelhe clutch switch.
CLUTCHSWITCH2P CONNECTOR
{C41',
-f--r
Checkfor an open in tha wiie: I-l_-
' l ' l
1. Turnthe ignitionswitchON lll)
2. Measurevoltage between the clsw 1;1
clutch switch connectorterml' tREDr
nal No. 1 and body groundwith Y
the clutchpedaldepressed.
Wire 6ide of lemale
terminals
I Repairop€n in the wire betwoen

ls thereapprox.5 V? the EcM (C291and thc clutch
swilch.
Repairopen in BLKwire between

the clutch switch and Gircl.
Clutch switch signal is OK.
l r ,
11-219
ldle Control System
ldle SpeedSetting
Inspection/Adiustmenl Adjustthe idle speed,if necessary,by removingthe
cap and turningthe idle adjustingscrew.
'96, '97 Dl6Y5. '96 - 00 Dl5Y8
sngine with M/T
NOTE; After adjustingthe idle speed in this step,
NOTE: recheckthe ignitiontiming (seesection23).
. B e f o r es e t t i n gt h e i d l e s p e e d ,c h e c kt h e f o l l o w i n g lf it is out of spec,go backto step4.
items: IDLE
- The MIL has not beenreportedon.
- l g n i t i o nt i m i n g
- Sparkplugs
- Aircleaner
- PCVsystem
o ( C a n a d aP ) u l l t h e p a r k i n gb r a k el e v e r u p . S t a r tt h e
engine,then checkthat the headlightsare off.
1. Startthe engine.Hold the engineat 3.000rpm with

no load (taansmission in neutral)until the radiator
fan comeson, then let it idle.
2. Connecta tachometer.
3. Disconnect
the IACvalveconnector.
7. Reconnectthe 2P connectoron the IAC valve,then

do the ECMresetprocedure.
8. Restartand idle the enginewith no-loadconditions

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

670 i 50 rpm IUSA)
750 t 50 rpm {Canada}
9. ldle the enginetor one minutewith headlights{Low)

ON.and checkthe idlespeed.
ldle speed should be:

4. lf the enginestalls,restartthe enginewith the accel- 750 :r 50 rpm
eratorpedalslightlydepressed.Stabilizethe rpm at
1,000,then slowly releasethe pedaluntil the engine 1 0 . T u r n t h e h e a d l i g h t so f f . l d l e t h e e n g i n ef o r o n e
idles. minutewith heaterfan switchat Hl and air conditioner
on,thencheckthe idlespeed.
Checkidlingin no-loadconditionsr headlights.
blower
fan. rear defogger,radiatorfan, and air conditioner ldle speed should be:
are not operating. 8 1 0 1 5 0r p m
ldle spsedshouldbe: NOTE:lf the idle speed is not within specification,

450 1 50 rpm seeSymptomChan on page 11-84.
11-220
t '96.'97 D16Y5enginewith CVT,'96 - 00 D16Y8ongins D16Y5,D16Y8engine:
with A/T and'96 - 00 Dl6Y7 €ngine IDLE
ADJUSTING
Adiustthe idle speedusing a HondaPGM Testerif pos-

sible.lf not, usethe followingprocedure:
NOTEI
. Leavethe IAC valve connected
. Betore setting the idle speed. check the following
items:
- The MIL has not beenreportedon'
- lgnitiontiming
- SparkPlugs
- Air cleaner
- PCVsystem
2. Startthe engine.Hold the engineat 3,000rpm wirh

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
Dl6f, ongine:
comeson, then let it idle.
NOTE:When you removethe ACL housing,do not
disconnectthe IAT sensorconnector
3. Checkthe idle speedwith no-loadconditions:head-
iights, blower fan, rear defogger,radiatorfan, and
air conditionerare not operatlng
I ldl€ spoed should be:
USA:
D16Y5engine with CVT, D16Y7engine with A/T'

Dl6YB engine with A/T:
700 :r 50 rpm (in E or El Positionl
D16Y7engine with M/T:
670 i 50 rpm
Canada:
A f t e r t u r n i n g t h e i d l e a d j u s t i n gs c r o w 1 / 2 - t u r n '
checkthe idle speedagain.lf it is out of spec,turn
Dl6Y8 sngin€, Dl6Y7 engins:
the idle adjustingscrew1/2-turnagaan'
M/T 750t 50 rpm NOTE: Do not turn the idle adjustingscrew more
NT 7501 50 rpm (in E or El Position) than 1/2-turnwithout checkingthe idle speed'
l d l e t h e e n g i n e f o r o n e m i n u t e w i t h h e a t e rf a n
by removingthe switch at Hl and air conditioneron, then checkthe
Adjustthe idle speed,if necessary, idle speed.
cap and turning the idle adiusting screw 1/2-turn
clockwiseor counterclockwise ldle speed should be:
M/T 8 1 0 1 5 0r p m
A/T. CvT 810t 50 rpm (in El or E Position)
NOTE:
. Do not turn the idle adjustingscrewwhen the air
conditioneris on.
see
. lf the idle speed is not within specification.
t SymptomCharton page 11-84 (cont'd)
11-221
ldle Control System
ldle SpeedSetting (cont'dl
Inspeqtion/Adiustment lf necessary,adjustthe idle speed,by removrnglne
cap and turningthe idle adjustingscrew.
38 D16Y5engine whh M/T,'99 - 00 81642 engine After adjustingthe idle speed recheckthe ignitlon
timing (seesection23). lf it is out of spec,go back
NOTE:Beforesettingthe idle speed,checkthe follow- to step 4. |DLE
ing items;
- lgnitiontiming
- Sparkplugs
- Air cleaner
- PCVsystem
'1.
Startthe engine.Hold the engineat 3,000rpm with
no load (transmissionin neutral)until the radiator
fan comeson, then let it idle.
Connecta tachometer.
Disconnect
the IACvalve2Pconnectorand the EVAP
purgecontrolsolenoidvalve2P connector.
7. Reconnectthe 2P connectorsto the IAC valve and

the EVAPpurge controlsolenoidvalve,then do the
ECM reset procedure.
8. Restartand idle the enginewith no-loadconditions

for one minute,then checkthe idle sDeed.
ldle speed should bo:
USA:
D16Y5engine: 670 i 50 rpm
EVAPPURGE
CONTROL 81642 engine: 700 i 50 rpm
SOLENOIDVALVE Canada:
81642 engine: 750 t 50 rpm
lf the enginestalls,restartthe enginewith the accel-
eratorpedalslightlydepressed.Stabilizethe rpm at NOTE:lf the idle speedincreasesto 8lO t 50 rpm,
1.000,then slowly releasethe pedaluntil the engine this meansthe EVAPsystemis purgingthe canister.
idles. To stop the purging temporarily,raise the engine
speedabove 1,000rpm with the acceleratorpedal,
Checkidlingin no-loadconditions:headlights,blower then slowly releasethe pedal.
fan, rear defogger,radiatorfan, and air conditioner
are not operating. 9 . l d l e t h e e n g i n ef o r o n e m i n u t e w i t h h e a d l i g h t s
(Low)ON. and checkthe idle speed.
ldl€ speed should be: ldle speed should be:
450 i 50 rpm 750 i 50 rpm
1 0 . T u r n t h e h e a d l i g h t so f f . l d l e t h e e n g i n e f o r o n e
minute with heaterfan switch at Hl and air condi-
tioneron, then checkthe idle soeed.
ldls speed should be:
810t 50 rpm
l f t h e i d l e s p e e d i s n o t w i t h i n s p e c i f i c a t i o ns, e e
SymptomCharton page 11-84.
11-222
\
'98 - 0OD16Y5ongine with CvT 6. Removethe cap and turn the idle adiustingscrew
1/2-turnclockwiseor counterclockwlse
Adjustthe idle speedusing a HondaPGM Testerif pos- IDLE
sible.lf not, usethe followingprocedure:
NOTE:
. Leavethe IACvalveconnected.
. Before s€tting the idle speed, check the following
rtems:
- lgnitiontiming
- SparkPlugs
- Air clean€r
- PCVsvstem
'1. Connecta tachometer.
2. Stan the engine.Holdthe engineat 3,000rpm w'th

in E or E] position)until the
no load (transmission
radiatorJancomeson, then let it idle.
3. C h e c kt h e i d l e s p e e d u n d e r n o - l o a dc o n d i t i o n s :
head lights, blower fan, rear defogger, radiator fan, 7. After turning the idle adjusting screw 1/2-turn,check
and air conditionerare not operatlng. the idl€ speedagain.lf it is out of spec,turn the idle
adjustingscrew 1/2-turnagain.
ldlo spaod ehould bo: 700 t 50 rpm
NOTE: Do not turn the idle adjustingscrew more
I . lf the idle speed is within the specification, the than 1/2-turnwithout checkingthe idle speed.
procedureis comPlete.
. lf the idle sDeedis out of specitication,9o to step 4' Turn the ignition switch OFF.Reconnectthe EVAP
purge control solenoidvalve 2P connector'then do
4. tf the idle speed is 810 1 50 rpm, this means the the ECM reset Procedure.
EVAPsystem is purging the canister.To stop the
purgingtemporarily,raisethe enginespeed above 9. Startthe engine.ldlethe enginefor one minutewith
l,OO0rgm with the accelsratorpedal. Slowly release heaterfan switch at Hl and air conditioneron, then
the pedal.and rscheckthe idl€ speed. checkthe idle speed.
. tf the idle speed is within the specificstion,the
Drocedure is comPlete. ldle spaed should be:
. lf the idle sp€edis out of spocification,go to step 5. 810 t 50 rpm (in El or E Posiiion)
5. Disconnectth€ EVAPpurgs control solenoidvalve lf the idle speed is not within specification,see
2P connector. SvmptomCharton Page11-84.
EVAPPURGE
CONTROL
SOLENOIDVALVE
11-223
Fuel Supply System
FuelLines
NoTE: Checkfuel systemlines,hoses,fuel filter,and other componentslor damage,leaksand deterioration,
and replace
if necessary.
t/
,ee.- ;
4/
/.,/
Tl
...,.' ..4,/
i,/
I
22 N.m
(2.2kgt.m,16lbf.ft)
(D16Y5engine:28 N.m
2.8 kgtm, 21 lbf ft)
The illustration
shows'99 00 models.
11-224
I '96 - 98 models:
NOTE:Checkall hoseclampsand retightenif necessarY.
M
FUEL
/v
FILTER
PRESSURE
REGULATOR
I FUEL
TANK
FUEL
GAUGE
SENDING
UNIT BASEGASKET
Replace.
C l a m pI n r h e m i d d l e
@
C l a m pi n t h e m i d d l e
10-14mm
(0.39- 0.55inl
(cont'd)
11-225
Fuel Supply System
FuelLines(cont'dl
.99 - 00 models:
NOTE:Checkall hoseclampsand retightenif necessary.
: Do not disconnectthe hosefrom the pipe.
ONBOARDREFUELING
VAPOR
BECOVERYIORVRI
VENT SHUTVALVE
FUEL
GAUGE lt N.rn l1.a kgt.m,
r0 lbt ftl
ftr, n'fo'
PRESSURE
REGULATOR
Clampin the middle
Clampin the middle
11-226
Fittings
FuelTube/Ouick-Gonnect
I Disconnestion
Precautions
Do not smoke while working on the fuel !@ Do not smoke while working on the luel
!@
system, Keepopen flames away from your work a.ea' system. Keep open llames away lrom youl work area.
The fuel tube/quick-connect fittings assemblyconnects 1. Relievefuel pressure(seepages11'230,2311.

the in tank fuel pump with the fuel feed pipe.For remov-
i n g o r i n s t a l l i ntgh e f u e l p u m p a n df u e lt a n k ,i t i s n e c e s - 2. C h e c kt h e t u e l q u i c k - c o n n e ct itt t i n g sf o r d i r t , a n d
sary to disconnector connectthe quick-connect fittings. cleanif necessary.
Payattentionto lollowing:
3. Hold the connectorwith one hand and pressdown
. The fuel tube/quick-connect fittings assemblyis not the retainertabs with the other hand,then pull the
h e a t - r e s i s t a nbt ;e c a r e f u ln o t t o d a m a g ei t d u r i n g connectoroff.
weldingor other heat-generating procedures
NOTE:
. The fuel tube/quick-connect fittings assemblyis not o Be carelulnot to damagethe pipe or other pans
acid-proof;do not touch it with a shop towel which Do not usetools.
was used for wiping batteryelectrolyte.Replacethe . lf the connectordoes not move,keepthe retainer
fuel tube/quick-connect fitlings assemblyif it came tabs presseddown, and alternatelypull and push
into contactwith electrolyteor somethingsimilar. the connectoruntil it comesoff easily.
. Do not removethe retainerfrom the pape;once
. W h e n c o n n e c t i n go r d i s c o n n e c t i n gt h e f u e l t u b e / removed,the retainermust be replacedwith a
q u i c kc o n n e c tl i l t i n g s a s s e m b l y ,b e c a r e f u ln o t t o new one.
bendor twist it excessively. Replaceit if damaged
LOCKINGPAWL
A disconnected quick-connect fittingcan be reconnecled,
TAB
BETAINER
b u t t h e r e t a i n e ro n t h e m a t i n g p i p e c a n n o tb e r e u s e d
I once it has been removed from the pipe. Replacethe
retatnerwnen
. R e p l a c i ntgh e f u e lp u m p .
. Replacingthe fuel leed pipe.
. lt has beenremovedlrom the PiPe. CONNECTOR
. lt is damaged.
ACCESS PANEL
4. Checkthe contactareao{ the pipefor dirt and dam-

age.
. lf the surfacels dirty,cleanit.
. lf the surface is rusty or damaged,replacethe
fuel pump or fuel feed piPe.
PIPE
(cont'd)
11-227
Fuel Supply System
Fittings(cont'd)
FuelTube/Ouick-Connect
5. To prevent damage and keep out toreign matter, Connection
c o v e r t h e d i s c o n n e c t e dc o n n e c t o ra n d o i o e e n d
with plasticbags. !s@ Do not smokewhile workingon the fuel
system. Keep open llames away from your work area.
1. Checkthe pipe contact area for djrt and damage,

and cleanif necessary,
CONTACTAREA
PI.ASIICBAGS
Insert a new retainer into the connector if the retainer

is damaged, or after
. replacing the fuel pump.
. replacing the fuelfeed pipe.
. removing the retainer from the pipe.
N.w RETAINER
(lnsertinto
the connector.)
11-228
t Beloreconnectinga new fuel tube/quick-connectfining 4. Make sure the connectionis secureand the pawls
assembly,removethe old retainerfrom the matingpipe are firmly lockedinto place;checkvisuallyand by
pullingthe connector.
with the
tabs pulled
apan,remove
and discardthe
retarner
RCTAINER
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
New FUELTUBE/
a b o u t t w o s e c o n d s ,a n d f u e l p r e s s u r ew i l l r i s e .
OUICK.CONNECT
FITTINGASSEMELY Repeattwo or three times, and checkthat there is
no leakagein the fuel supplvsystem
3. Align the quick-connectfiftings with the pipe, and
align the retainerlockingpawls with the connector
grooves.Then pressthe quick-connect fittings onto
the pipe until both retainerpawls lock with a click-
I i n gs o u n d .
NOTE:lf it is hard to connect,put a small amount

of new engineoil on the pipe end.
Connectionwith new retainer:
11-229
Fuel Supply System
SystemDescription
The fuel supply system consistsof a fuel tank, in-tank Inspoction
high pressurefuel pump,PGM-FImain relay,fuelfilter,
fuel pressureregulator,fuel injectors.and fuel delivery 1. Relievefuel pressure.
and return lines. This system delivers pressure-regu-
latedfuel to the fuel injectorsand cuts the fuel delivery 2. Removethe service bolt on the fuel filter while hold-
when the engineis not running. ing the banjo bolt with anotherwrench.Attachthe
specialtool.
FuelPressurel'96 Modelsl
Relieving FUEL
PRESSURE
Beforedisconnectingfuel pipes or hoses,releasepres-
GAUGE
sure from the system by looseningthe 6 mm service 07406 - 00ir0(x)1
bolt on top of the fuel filter.
. Do not smoke whil6 working on the fuel system.

Kgsp opon flames or sparks away from youl work
area.
. Be sure to relieve fuel pressurewhile the ignition
switch is off.
1. Write down the frequenciesfor the radio's preset
buttons.
2. Disconnectthe batterynegativecablefrom the bat- REGULATOB
tery negativeterminal.
3. Removethe fuelfill cap,
4. Use a box end wrench on the 6 mm servicebolt at Startthe engine.Measurethe fuel pressurewith the
the fuel filter while holding the specialbanjo bolt engineidling and the vacuumhoseof the fuel pres-
with anotherwrench, sure regulatordisconnectedfrom the fuel pressure
5. Placea rag or shop towel over the 6 mm servicebolt. regulatorand pinched.lf the engine will not start,
6, Slowly loosenthe 6 mm servicebolt one complete turn the ignition switch ON (ll), wait for two sec-
rurn. onds, turn it off, then back on again and read the
fuel pressure.
Pr€3sureshould bo:
260 - 310 kPa (2.7- 3.2 kgt/cmr, 38 - 46 psi)
Reconnectvacuumhoseto the fuel pressureregulator,
Pressureshould bo:
200 - 25OkPa l2.O- 2.5 kgf/cm', 28 - 36 psil
lf the fuel pressureis not as specified,first checkthe

fuel pump {seepage 11-2361. 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 ,
. A fuel pressuregaugecanbe attachedat the 6 mm inspectfor;
servicebolt hole. - Pinchedor cloggedfuel returnhoseor line.
. Always reDlacethe washer betweenthe service - Faultyfuel pressureregulator(seepage 11-234).
bolt and the specialbanjo bolt wheneverthe ser- . lf the fuel pressureis lower than specified,inspect
vice bolt is loosened. for:
. R e p l a c ea l l w a s h e r s w h e n e v e r t h e b o l t s a r e - Cloggedfuelfilter.
removeo. - Faultyfuel pressureregulator{seepage 11-234).
- Fuelline leakage.
11-230
FuelPressure{'97and later Models)
t J
Inspaqtion
ReliGving
Beforedisconnectingtuel pipes or hoses,releasepres-
sure from the system by looseningthe 12 mm banjo 1. Relievefuel pressure.
bolt on top of the fuel filter.
2. Removethe 12 mm banjo bolt from the fuel filter
while holding the fuel Jilter with another wrench
@
o Do not smoke whilo working on the fuel sy3lom. Attachthe specialtools.
CLAMP
Ksgp op€n flames or sparks away tlom Your work
arga.
. Be sure to relievefuel pressule while the ignition
swhch is off.
1. Write down the frequenciesfor the radio's preset FUELPRESSURE

ADAPTER BOLT,12mm
buttons, tguxt8-PD6-0101
2. Disconnectthe batterynegativecablefrom the bat-

tery negativeterminal.
3. Removethe fuel fill cap.
4. Use a box end wrench on the 12 mm banjo bolt at

the fuel filter while holdingthe fuel filterwith anoth-
REGULATOR
er wrench.
Placea rag or shoptowel overthe 12 mm banio bolt. 3. Start the engine the fuel Pressurewith the
engine idling and the vacuum hose of the fuel pres-
Slowly loosenthe 12 mm banjo bolt one complete sure regulator disconnectedfrom the fuel pressure
I turn. regulatorand pinched lfthe enginewill not start,turn
the ignition switch ON {ll), wait for two seconds,turn
12 mm BAtt O
BOLT it off, then backon againand readthe fuel pressure'
33 N.m (3.i1kgf m, Pr$3uro ehould be:
25 tbf.f0 excepi 816A2 sngine:
260 - 310 kPa {2'7 - 3.2 kgf/cm" 38 - {6 Fi}
B16A2engine:
27O-32O kPa P.8 - 3'3 kgf/cm', '10- 47 psi)
4. Reconnectvacuumhosoto the fuel pressureregulator'

Pre33ure3hould be:
except B16A2engin€:
2OO- 250 kPa {2.0- 2'5 kgf/cm', 28 - 36 psi)
B16A2engino:
210- 260 kPa 121- 2.6 ksf/cm', 30 - 37 psi)
N O T E :R e p l a c ea l l t h e w a s h e r sw h e n e v e rt h e 1 2 lf the fuel pressureis not as specified,first checkthe
mm banio bolt is loosenedor removed. f u e lp u m p( s e ep a g e1 1 - 2 3 6 l)f t h e t u e l p u m p i s o K ,
checktho 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 11-
2341.
. lf the fuel pressureis lower than specified,inspect
for:
- Cloggedfuel filter.
- Faulty fuel pressureregulator(see page l1-
2341.
- Fuelline leakage.
11-231
Fuel Supply System
FuelInjectors
Replacement
@ Do not smoke when working on the tuel systgm, Keepgp6n flames away from your work area
'f.
Relievethe fuel pressure(seepages11-230,231J.
2. Disconnect the connectorsfrom thefuel injectors(D16Y7engine:Removethe air cleaner).
3. Disconnect the vacuumhosesfrom thefuel pressureregulator.Placeashoptoweloverthefuel returnhose,then dis-
connectit from the fuel pressureregulator.Disconnectthe vacuum hosesand 2P connectorfrom the EVAp purge
controlsolenoidvalve.
4. Removethe retainernuts on the fuel rail.
5. Disconnect the fuel rail.
6. Removethefuelinjectorsfrom the intakemanifold.
D16Y5,D16Y8engine:
NOTE:lllustrationshows D16Y8engine.
D 1 6 Y 5e n g i n ei s s i m i l a r .
12 N.m
11.2kgl.m,
8.7 rbt.ft)
12 N.m
11.2lgl.m,
8.7 rbt.ftl
FUEL
.q
w
Y
E4 ffi
}Y
O.RING
Replace. ffi
E wR
O.RING
Replace.
e V
g
E
CUSHION
RING
Replace.
V
E t cusl{toN
RING
Replace.
EVAP
PURGECONTNOL
Y
SOLENOIDVALVE SEAL
RING
Replace.
11-232
\ J
81642engine:
12 N.m
{1.2kgl m;
8.? lbt.ft)
FUEL
PRESSURE
REGULATOR
O.RING
Replace.
cusHloN
RING
Replace.
EVAP
PURGECONTROL
SOLENOIDVALVE SEAL
RING
\ Replace.
7. Slidenew cushionringsonto the fuel injectors.

8. CoatnewO-ringswithcleanengineoil,and putthem onthefuel injectors.
9. Insertthe fuel injectorsinto the fuel railfirst.
10. Coatnewsealringswith cleanengineoil,and pressthem intothe intakemanifold.
11. To preventdamageto the O-rings,installthefuel injectorsinthefuel railfirst,then installthem inthe intakemanifold.
'12. Installand tightenthe retainernuts.

13. Connectthe vacuum hosesand fuel return hose to the fuel pressureregulator,Connectthe vacuum hosesand 2P
connectorto the EVAPpurgecontrolsolenoidvalve.
(D16YIengine;Installthe air cleaner).
14. Installthe connectorson the fuel inl'ectors
15. Turnthe ignitionswitchON (ll),butdo not operatethe starter.Afterthe tuel pump runsfor approximately two seconds,
the fuel pressurein the fuel linerises.Repeatthis two or threetimes,thencheckwhetherthereis anyfuel leakage.
11-233
Fuel Supply System
FuelPressureRegulator
Te3ting Reolacement
@ Do not smoke during the tast. Keep open @@ Do not smoke while working on luel sys-
flamcs away from your work arsa. tem. Keepopen flame away from your work area,
1. Attachthe specialtool(s)to the serviceport on the 1. Placea shop towel underthe fuel pressureregulator,
fuel filter (seepages11-230,231). then relievefuel pressure(seepages 11-230,231l..
Pressureshould bo: 2. Disconnect

the vacuumhoseand fuel returnhose.
except 81642 engine
260 - 310 kPa |'2.7- 3.2 kgllcrn2,38 - /t6 psil 3. Removethe two 6 mm retainerbolts and the fuel
816A2engine: pressureregurator.
27O- 320 kPa 12.8- 3.3 kgf/cm,, 40 - 47 psi)
{with the tuel pressureregulator vacuum hose
disconnestedand pinched)
CLAMP
REGULATOR
Reconnectthe vacuum hose to the fuel pressure

regulator.
Checkthat the fuel pressureriseswhen the vacuum

hosefrom the fuel pressureregulatoris disconnected
again.
Applycleanengineoil to a new O-ring.and carefully
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 installit into its properposition.
pressureregutalor.
I n s t a l lt h e f u e l p r e s s u r er e g u l a t o ri n t h e r e v e r s e
orderof removal.
11-234
I FuelFilter
,96MODELS:
Replacement
r@
. Do not smoke whilc working on fuel system. Keep
12 mm
BANJO
BOLT
open flame away from your work arsa. 33 N.m
. While replacing the tuel filter, be catelul to koep a (3.4 kgl.m,
sale distance betwoen battery torminals and any 25 rbf.ftl
tools.
T h e f u e l f i l t e r s h o u l d b e r e p l a c e dw h e n e v e rt h e f u e l
pressuredrops belowthe specifiedvalue [260- 310 kPa
12.7- 3.2 ksl/cm',38 - 46 psi), |270 - 320 kPa (2.8 - 3 3
kgf/cm,,40 - 47 psi))* with the fuel pressureregulator
vacuum hose disconnectedand pinchedl after making
sure that the fuel pump and the fuel pressureregulator
are OK. *: 81642engine
1. Placea shop towel underand aroundthe fuelfilter.
2. Relievefuel pressure(see pages 11-230,231]-
R e m o v et h e 1 2 m m b a n j o b o l t a n d t h e f u e l f e e d
pipefrom the fuel filter,while supportingit with the
anotherwrench,as shown.
Removethe fuel filter ciamp and fuel filter'

,97 AND LATERMODELS:
I l n s t a l l t h e n e w f u e l f i l t e r i n t h e r e v e r s eo r d e r
removal,and notetheseitems:
a When assembling,use new washersas shown 1 2m m
. 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 eh o s e s BANJO
thoroughlybeforereconnecting them. BOLT
33 N.m
t3.4 kgf m,
25 lbf.fr)
\\i(o-r
\)
11-235
Fuel Supply System
FuelPump
Testing Replacement
!@ Do not smoke during the test, Keep open Do not smoke while working on tuel svs-
@E
flame away from your work atea, tem. Keepopen llames away from your work area.
lf you suspecta problemwith the fuelpump,checkthatthe 1. Removethe seatcushion(seesection20).

fuel pump actuallyruns;when it is ON (ll),you will hear
somenoiseif you holdyour earto the fuelfill portwith the 2. Removethe accesspaneltrom the floor.
fuel fill cap removed.The fuel pump should run for two
secondswhen ignitionswitchis firstturnedON (ll).lf the ACCESSPANEL
fuel pumpdoesnot makenoise,checkit asfollows:
L Removethe seatcushion{seesection20).
2. Removethe accesspanelfrom the floor.
3. Make sure the ignition switch is OFF,then discon-

nectthe Iueltank 2P connector. i
4. Connectthe PGM-FImain relay7P connectortermi-

n a lN o .4 a n d N o . 5 w i t h a j u m p e rw i r e .
PGM-R MAIN RELAY7P CONNECTOR

lC4,(|l
FUELPUMP IGN 1
IYEL/ (YEL/GRNI
GRN}
JUMPERWIRE
Checkthat batteryvoltageis availablebetweenthe

fuel pump connectorterminalNo. 1 and bodyground
whenthe ignitionswitchis turnedON (ll).
tcs6s)
CONNECTOR
= FUELPUMP
(YEL/GRNI
[t
L3l .i) 3. Disconnect
the 2P connectorfrom the fuel pump.
T Wire side of
temaletorminals 4. Removethe fuel pump mountingnuts.
5. Removethe fuel pump from the fuel tank.
lf batteryvoltage is available,checkthe fuel pump 6. Installpans in the reverseorderof removal.

ground.lf the groundis OK,replacethe fuel pump.
lf there is no voltage,checkthe wire harness(see
p a g e1 1 - 2 3 8 ) .
11-236
I J
Relay
PGM-FlMain
Description RelayTesting
T h e P G M - Fm l a i n r e l a va c t u a l l vc o n t a i n st w o i n d i v i d u a l
relays.This relay is locatedat the right side of the cowl. NOTE:
One relayis energizedwheneverthe ignitionis on which . It the enginestartsand continueslo run. the PGM Fl
suppliesthe batteryvoltageto the ECM/PCM,power to m a i nr e l a yi s O K .
the luel iniectors,and power for the secondrelay.The . U s et h e t e r m i n anl u m b e r sb e l o w ;
secondrelayis energizedlor two secondswhen the igni- ignorethe terminalnumbersmoldedinto the relay,
t i o n i s s w i t c h e dO N ( l l l ,a n d w h e nt h e e n g i n ei s r u n n i n g ,
to supplypowerto the luel pump. 1 . R e m o v et h e P G MF l m a i nr e l a y .
2. Attachthe batterypositiveterminalto the No. 2 ter-
minal and the batterynegativeterminalto the No 1
terminal of the PGM-Flmain relay.Then checkfor
PGM-FI
MAIN RELAY continuitb y e t w e e nt h e N o . 5 t e r m i n aal n d N o 4 t e r -
m i n a lo f e P G MF l m a i nr e l a y .
t h
. lf there is continuity,go on to step3.
P G M - Fm
. 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 l ain
relay and retest.
No.3
No. 1
FUEL PUMP
I To lGN.1 To 8AT O
To GROUND
To ECM/PCM
{(a11,A241,(81.B9l*l
To ST. SWITCH
To FUELPUMP
To ECM/PCM{A161 .r '99 model
3. Altachthe battervpositiveterminalto the No.5 ter-
minal and the batterynegativeterminalto the No. 3
terminalof the PGM-Flmain relay.Then checkthat
there is continuitybetweenthe No. 7 terminaland
No. 6 terminalof the PGM-Flmain relay.
. lf thereis continuity,go on to step4
. 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 P G M -m
F la i n
relayand retest.
4. Attachthe batterypositiveterminalto the No. 6 ter-
minal and the batterynegativeterminalto the No. 1
terminalof the PGM Fl main relay.Then checkthat
there is continuitybetweenthe No. 5 terminal and
No. 4 terminalof the PGM-Fimain relay.
. lf thereis continuity,the PGM-Flmain relayis OK.
lf the fuel pump still does not work,go to Harness
Testingon the nextpage.
t . lf there is no continuity,replacethe PGM Fl main
relay and retest. (cont'd)
11-237
Fuel Supply System
PGM-FIMainRelay(cont'dl
Circuit Troubleshooting
- Enginewill not start.

- lnsoection of PGM-FI main
relay and relay harne$.
PGM.FIMAIN RELAY7P CONNECTOR

{C443)
{GNOline}: GND
l. Turnthe ignitionswitchOFF. {8LK)
1 2
2. Disconnectthe PGM-Flmain
relay7P connector. a 5 6 7
3. Checkfor continuitybetween [,
the PGMFl main relay7P con-
nectorterminalNo.3 and body
ground.
Ropai. open in the wir€ between
the PGM-FImain .elavand G101.
Checkfor an open or short in the

wire {BATlin€}:
N 4 e a s u rveo l t a g e b e t w e e nt h e 1 2 3 BAT
{WHT/BLK}
PGM-FImain relay 7P connector a 5 6 ,
terminalNo. 7 and body ground.
- Repair open or sho.t in the
wire betweenthe PGM-FImain
r e l a ya n d t h e F l E / M { 1 5 A }
ls lhere battery voltage? fus€.
- Replace the Fl E/M (15Allu3e
in the under-hoodfuse/relay
oox.
Checktor an open or short in the
wire {lGl line):
2. Measurethe voltage between
the PGM-Flmain relay7P con'
nectorterminalNo.5 and body
ground.
- Repair open or short in the
wire betwoenthe PGM-FImain
relavand the No. 13 FUEL
ls there batteryvoltage? PUMP(15A)tuse.
- R € p l a c et h e N o . 1 3 F U E L
PUMP{15A} tus€ in the under-
d.sh fus€/relaybox.
Ch.ck for an open or short in the
wire {STSlino}r
1. Turnthe ignitionswitchto the
START(lll)position.
NOTE:
. M/T: Clutch pedal must be
oepresseo.
. A/T: Transmissionin E or
E position.
2, Measurethe voltagebetween
t h e P G M - F lm a i n r e l a y 7 P
connectorterminalNo, 2 and
body ground.
'96 98 models:(To page1l 239)

'99 - 00 models:(To page I l-240)
11-238,
I J ('96- 98 models)
- Repair open or 3hort in the

wire bstw€er the lGM-Fl main
rolsy .nd the No. 31 STARTER
{GRN/YELI
ls there bafteryvoltage? SGNAL 17.5A) tuse.
- Reolacethe No. 31 STARTER
SIGNAL (7.5 Al fu3o in the 2 3
unde.-dashtusg/rolavbox.
() a 6 t
Chock lor !n open in the wit.

lFLn line)l FLR
1. Turnthe ignitionswitchOFF (GRN/YELI A t32Pt
ECM/PCMCONNECTOR
nectorA (32P).
3. Check for continuity between 2 1 I l0 t1
the PGM-FImain relay 7P con-
12 r3 1'a l 5 't6 1 ' t t i 9 ml,/ x2 23 2a
nectorterminalNo. 1 and ECM/
PCMconnectorterminalA16. 25 21 2e 29 3ol./
Ropair op6n in th. walo betwoan
t h e E C M / P C Ml A 1 6 ) a n d t h c
PGM-FImain rolaY.
Ch6ckfor an opon in th. wi.e3

llcPl,lGP2linesl: PGl (BLK)
1. Reconnectthe ECM/PCN4 con-
nectorA (32P).
I 2. Reconnoctthe PGM-Flmain
relay connector, 12
1
't/t 1 5 t 6 1 7 t 8 t 9 zi
I
3. Turn the ignitionswitchON (ll)

ECM/PCMconnectortermanals
25 27 2A 4t 30
4l
A 1 1 a n d A 1 0 ,a n d b e t w e e n IGP2
A246nd A10. {YEL/BLKI
Repeir opon in th6 wire bet-

ween ttre ECiA/PCM (A11,A24)
and tho PGM-FImsin r.lty.
R€plac. tho FGM-FImain rc|.Y.
Checktor an open in the ECM/

PCM:
1. Turn the ignitionswitchOFF. FLR
2, Measurevoltage between IGRN/YELI PGl IBLK)
ECM/PCMconnectorterminals 3 l5 6 7l lslel tl 1l
A16and A10whenthe ignition 12 1 3 'ta l 5 t 6 't7 t 8 t 9 20 221 23 2a
switch is lirst turned ON (ll) for
25 27 28 4t
two seconds.
Substituta a known-good ECM/

PCM and rechcck. lf proacribod
ls thero1.0V or less? voltege is now availablc,r.Place
the originll ECM/PCM.
C h 6 c kt h . P G M - F Im . i n l o l a y
(.ee pagc 11-2371.
(cont'd)
11 - 2 3 9
Fuel Supply System
PGM-FIMain Relay(cont'd)
I J
_._(9x.qq-gqerll _
- Repair op€n or short in the PGM.FIMAIN FELAY7P CONNECTOR
{C4€}
wir€ betlveen the PGM-FImain FLR
relay and the No. 31 STARTER IGRN/YEL}
ls there batteryvoltage? SIGNAL17.5A) fuse.
- RoDlacethe No. 31 STARTER
S I G N A L{ 7 , 5 A l t u s e i n t h e
under-dashluse/rolay box.

(FLRlinel:
2. Disconnectthe ECM/PCM con-
nectorA (32P).
the PGM-FImain relay 7P con-
nectorterminalNo. 1 and ECM/
PCMconnectorterminalA16.

Repairopen in the wir6 botween
t h e E C M / P C M ( A 1 6 1a n d r h e
PGM-FImain relay.
ECM/PCMCONNECTOR
B {25PI
IGP2{YEL/BLKI
{lGPl, lGP2line3):
1. Reconnect
nectorA {32P).
the ECM/PCM
2 . R e c o n n e ct th e P G M - F m
relay connector.
con-
l ain
IGP2
(YEL/BLKI
'l'
ECN4/PCM connectorterminals
81 and 820, and between
Bg and 820.
- Repair open in the wire bet-
ween th. ECM/PCM(81, Bg)
snd the PGM-Fmain rolay.
- Roplaceth€ PGM-FImain relav. ECM/PCMCONNECTORS
A (32P1
Chocktor an open in th6 ECM/

PCM:
A16 and 82 when the ignition
switch is first turned ON lll) for
Sub3titute . known-good ECM/

PCM and rochock. lf prescribed
ls there1.0V or less?
vohege is now available,replace Wire side of fem6le terminals
Chock the PGM-Fl m.in r6lay

{see p.ge 11-2371.
11-240
I FuelTank
'96 - 98 models:
Replacement
from your work ar'a'
!@@ Do not smokewhile working on fuel system'Keepopen flame away
1. Relievethe fuel pressure(seepages\1-230'23'll'

2. Removethe seatcushion(seesection20).
3. Removethe accesspanelfrom the floor' '97 D16Y/ engine(coupe:
KL model'
('96 D]6Y8 engine (coupe)
4. Disconnectthe 2P (C565)and 3P (C564)connectors
sedanKL(LX)model).'97D'l6YSengine(coupe:allmodels'sedan:KLmodel'98-allmodels):and6P(C568)con
tor),
(see pages'l'l-225' 2271
5. Disconnectthe hose and quick-connectfittings
6. Jackup the and
vehicle, supportit with jackstands'
joint protector'
7. Removethefueltank cover('96,'97model)orthefuel hose
container'
8. Bemovethedrainbolt,and drainthefuel into an approved
as you pull,to avoiddamagingthem'
9. Disconnect the hoses{seepager i-izst. Sria" nu"i ihe clamps,then twist hoses
10. Placea jack.or othersupport,underthe tank'
11. Removethe strapnuts,and let the strapsfall free'
mount' carefully pry it off the mount'
12. Removethefueltank lf it stickson the undercoatappliedto its
13.|nsta||thedrainbo|twithanewwasher.thencoatthedrainbo|twithNoxrustl24B,A||owtheNoxrustdryfor20min
ules.
14. Installtheremainingpans in the reverseorderof removal'
SASEGASKET
Replace.
BASEGASKET
Replace.
TANK
STRAPS
DRAINBOLT
,19N.m {5.0 kgt m, 36 lbf.ftl
(cont'd)
11-241
FuelSupplySystem
FuelTank {cont'dl
39 - (xt models:
Replac6ment
@ Do not smokewhire working on fuer system.Ke€popenframaaway trom your work area.
1. Relievethefuelpressure(seepages11-230,23'll.
2. Removethe seatcushionlseesection2O).
3, Removethe accesspanelfromthefloor.
4. Disconnectthe2P(C565)and3P(CS64)connectorsand 6p (C569)connecror.
5. Disconnect the hoseand quick-connect fiftings(seepages1l-226,22j),
6. Jackup the vehicle,and supportit with jackstands.
7. Removethefuelhosejoint protectorand heatshield.
8. Removethedrainbolt.and drainthefuel intoan aporovedcontainer.
9 Disconnect the hoses(seepage11-226). Slidebackthe clamps.then twist hosesas you pull,to avoiddamagtngrnem.
10. Placea jack,or other support,underthe tank,
11. Removethe strapnuts,and let the strapsfallfree,
'12. Removethefuel
tank.lf itsticksonthe undercoatappliedto its mount,carefullypry itoffthe mount.
13. Installthedfain boltwith a new washer.then coat the d rain bolt with Noxrust124B,AllowtheNox.ustdrv for 20 min-
utes.
14. Installtheremainingpartsin the reverseorderof removal,
Replace.
DRAINBOLT
,19N.m (5.0 kgf.m,36lbf.ft)
11-242
Intake Air System
\ J SystemDescriPtion
pipe' Air C|eaner(ACL},intakeair duct, Thrott|e
The systemsupp|iesair for a|| engineneeds'|t consistsof the intakeair
intakeair pipe providesadditionalsilencing
Body (TB),ldle Air control (lAc) valve and intakemanifold.A resonatorin the
as air is drawn into the system.
D16Y5,D16Y8,816A2 engine {M/Tl

YEL/ - FromPGM-FI
aLK - MA|NRELAY
IAC VALVE
BLK/
BLU
-- ORN
INTAKE BLK/
AIR
DUCT Iaru
IROTARYI ENGINE
IAC VALVE COOLANT
INTAKE
D16Y5engine (CVT),D16Y8engine (A/T)' f'ttlxr ,tla"tpoto AIRDUCT
VARIOUS
D16Y7engine: SENSORS
BLK
INTAKE
AIR
tr
PIPE
{ROTARY) RESONATOR
IACVALVE
! r ,
11-243
lntake Air System
Air Cleaner(ACLI ThrottleCable
NOTE: Do not cleanthe ACL elementit with com- Inspection/Adiustment
pressedair {exceptdry type). 1. Startthe engine.Hold the engineat 3,000rpm with
D16Y5,D16Y8,816A2engine: comeson, then let it idle.
ACL ELEMENT 2. Checkthat the throftlecableoperatessmoothlywith

Normal conditions:
Replaceair cleanerelementevery no bindingor sticking.Repairas necessary.
30,000miles(48,000 km) or 24
monthswhichevercomesfirst. 3. Checkcable free play at the throttle linkage.Cable
S€voaeconditions: deflectionshoutdbe 10- l2 mm (3/B- 112in.l.
(Usenormalschedule
exceptin dusty conditions)
Replaceevery 15,OOO D16Y5,D16Y8engine:
miles(24,000km)or 12 months
whichevercomesfirst. CABLE
BRACKET LOCKNUT
DEFLECTION
10-12mm
BIA- 112inl
D16Y7engine:
D16Y7engine: LOCKNUT
DEFLECTION
1 0 - 1 2m m
ACL ELEMENT l3lA - lninl
Normal conditions:
Replaceair cleanerelementevery
30,000miles(48,000km) or 24
monthswhichevercomesfirst,
Seve.s conditions:
(Usenormalscheduleexcept
in dustyconditions)
Replaceevery l5,000
whichever comes first.
11-244
\ J
816A2 engine: lnstallation
Dl6Y5,Dr6Y8,D16Y,€ngine:
1. Openthe throttlevalvefully, then installthe throttle

LOCKNUT cable in the throttle linkage,and install the cable
housingin the cablebracket.
D16Y5,D16Y8engins:
LOCKNUT
DEFLECTION CABLE ADJUSTING

10-12mm BRACKET NUT
Bla- 112inl
t
lf deflectionis not within specs'loosenthe locknut'
turn the adjustingnut untilthe deflectionis as speci-
fied,then retightenthe locknut.
With the cable properlyadiusted,checkthe thronle

valve to be sure it opens fully when you push the
acceleratorpedalto the floor. Also checkthe throt-
tle valve to be sure it returns to the idle position
wheneveryou releasethe accelerator pedal'
Startthe engine.Hold the engineat 3,000rpm with

Hold the cable sheath.removingall slackfrom the

caDle
(cont'dl
11-245
IntakeAir System
ThrottleCable(cont'dl
4. S e t t h e l o c k n u to n t h e c a b l e b r a c k e t .A d j u s t t h e 816A2 engine:
adjustingnut so that its free play is Omm.
1. Openthe throttlevalvefully, then installthe throttle
5. Bemovethe cable sheathfrom the throttle bracket, c a b l ei n t h e t h r o t t l el i n k a g e a
. n d i n s t a l lt h e c a b l e
resetthe adjustingnut and tightenthe locknut. housingin the cablebracket,
O16Y5,D16Y8engino:
THROTTLELINK
ADJUSTINGNUT
9.8N.m LOCKNUT ADJUSTING

{1.0 kgl.m,
1.2 tbt.ttl NUT
DtGYT6ngine: Startthe engine.Hold the engineat 3.000rpm with

H o l d t h e t h r o t t l e l i n k t o t h e t h r o t t l e l e v e r ;t h e r e
should be no clearance.
Hold the cable sheath,removingall slackfrom the

cable.
Turn the adjustingnut untit it is 3 mm {1/8in.)away

from the cable bracket,
3 mm 11/8in.)
LOCKNUT ADJUSTINGNUT
9.8 N.m
(1.0kgt m,
7.2 tM.ttl
T i g h t e nt h e l o c k n u t .T h e c a b l e d e f l e c t i o ns h o u l d
n o w b e 1 0 - 1 2 m m l 3 / B- 1 / 2 i n . ) . l f n o r . s e e
Inspection/Adjustment.
11-246
Throttle BodY
I Dl6Y7 ongine:
Description
The throttlebodYis eithera single-barrel side-drafttype
(D16Y5,D16Y8,816A2 engine) or a down-draft type
(D16Y/engine).The lower portionot the throttlevalveis
heatedby engine coolantfrom the cylinder head' The
idle adjustingscrew which regulatesthe bypassair is
locatedon the top of the throttlebody
IDLEAD.'USTING
THROTTLE SCREW
POS|T|ONlTPl
SENSOR
STOPSCREW
{Do not adjust.)
816A2 engins:
LINK
THROTTLE
t
In3pection
1 . C h e c kt h a t t h e t h r o t t l e c a b l e o p e r a t e ss m o o t h l y
without bindingor sticking.
lf there are any abnormalities, checkfor:
. Excessivewear or play in the throttle valve shaft'
. StickYor binding throttle lever at the fully closed STOPSCREW
THROTTTE
(Do not adjust.)
Position.
. Clearancebetweenthrottle stop screw and throt-
tle leverat the fully closedposition' Replacethe throftle body if thsre is excessiveplay in the
throttlevalveshaftor iJthe shaftis bindingor sticking'
D16Y5,Dl6Y8 engine:
THROTTLESTOP SCREW (cont'd)

{Do not adjust.)
11-247
Intake Air System
ThrottleBody (cont'dl
\rJ
Removal
D16Y5,Dl6Y8,81642engine:
D15Y7engine:
IAT SENSOR
AIR CLEANER
{ACLI
MAP SENSOR
22 N.m
12.2kgl.m,
16 rbf.ftl
GASKET
Replace.
THROTTLECABLE
NOTE:
. Do not adjustthe throttlestop screw.
. After reassembly, adjustthe throttlecable{seepage l l-244).
. The TP sensoris not removable.
11-248
\
Disasssmbly
Dl6Y5,Dl6Y8 engine:
2.1N.m
(0.21ksf.m,1.5lblftl\
MAP SENSOR
page11'115
Troubleshooting,
b Y
TPSENSOR
IDLEAOJUSTING
3.5N.m t0.35kgl m,2.5 lblftl
B16A2sngine:
MAP
SENSOR
Page11-119
Troubleshooting,
z.'t N.m MAP

10.21 kgf'm, SENSOR TP SENSOR
1.5tbf.frl Page11 115
Troubleshooting,
11-249
IntakeAir System
FuelInjectionAir (FlA)ControtSystemI'99- 00 Dl6yg enginel
Dsscription
Whenthe enginerunninglenginecoolantbelow 149oF(6S"C)],
the fuel InjectionAir (FtA)ControlValvesendsintakeair to
the fuel iniectors.
FUEL
INJECTOB
E> : INTAKE
AIR
11-250
\ J
Fuol Iniection Air {FlA)Contlol Valve T$ting
1. Startthe engine.
2. Removethe vacuum hose from the fitting on the

intakeair duct, and connecta vacuumgaugeto the
nose.
NOTE:Enginecoolanttemperaturemust be below
149"F(65"C).
VACUUMPUMP/GAUGE,
0-30 in.Hg.
A973X- 041-XXXXX
Raiseand lower the engine speed,and make sure

the vacuum gauge readingchangesas the engine
speed changes.
lf vacuum reading does not change check these

rtems:
. The vacuum lines of FIA systemfor misrouting,
leakage,breakageand clogging.
. The FIA controt valve for cracksor damage
. The cooling system (seesection 10).
Hold the engineat 3,OOO rpm with no load (in Park

or neutral)until the radiatorfan comes on, th€n let
it idle and recheck.
lf vacuumreadingchangeschecktheseitems:
a The FIAcontrolvalvefor cracksor damage.
. The coolingsystem(seesection10).
11-251
EmissionGontrolSystem
SystemDescription ThreeWay CatalyticConverter
(TWCI
The emissioncontrol system includesa Three Way Cata-
lytic Convener(TWC),ExhaustGas Recirculation (EGR) Doscription
system,. PositiveCrankcaseVentilation(pCV)system and The Three Way CatalyticConverter (TWC) is used to
EvaporativeEmission(EVAP)Controlsystem.The emis- conven hydrocarbons(HC),carbonmonoxide(CO),and
sion control system is designedto meet federaland state oxides of nitrogen(NOx) in the exhaustgas to carbon
emissionstandards. dioxide(COr),dinitrogen(N,)and watervapor.
*: D16Y5engine
D15Y5,D16\r, engine:
ENGINESIDE
TailpipeEmission
Inspestion
@@ Do not smoke during ihis procedure.Keep

any open flame away from your work area.
1. Startthe engine.Hold the engineat 3,000rpm with

comeson. then let it idle.
Checkand, if necessary,adjustthe idle speed (see

page 11-220- 223).
Warm up and calibratethe COmeteraccordingto the

metermanufacturer's instructions.
Checkidle CO with the headlights,heater blower,

rearwindow defogger,coolingfan,and air condition-
er off.
N O T E : ( C a n a d aP
) u l l t h e p a r k i n gb r a k el e v e r u p . '99 -
00 D16Y8,81642 engine:
Startthe engine,then checkthat the headlightsare
off.
CO mete.shouldindicate0.1%maximum.
NOTE:'98 Dl6Y5 engine- lf the idle speedincress-

es to 8101 50 rpm, this meansthe EVApsystemis
purgingthe canister.To stop the purgingtemporari-
ly. raisethe enginespeedabove 1,000rpm with the
accelerator pedal,then slowly releasethe pedal.
FORWARD
e
-
11-252
\
(DTc)p0420:catatystsysremefficiencybelowthreshold.
lTo420l Th" """n toot indicatesDiagnosticTroubtecode
Description
outputduringstabledriving
This systemevaluatesthe catalyst'scapacityby meansof the Ho2s {Primaryand secondary)
has beendetectedduringtwo consecutivedriving the
cycles. MIL comeson and DTCP0420will
conditions.ll deterioration
be stored.
those DTCSfirst. then
NOTE:lf some of the DTCStistedbelow are storedat the same time as DTCP0420,troubleshoot
recheckfor DTCP0420
P0137,P0138:SecondaryHO2S(Sensor2)
H02S {Sensor2) Heater
Po14'1:Secondary
Possibl€Cause
. TWCDeterioration
. Exhaustsystemleakage

DTC P0420 is stored
1. Do the ECM/PCM ResetProce
dure.
I 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 wath no
3. Connectthe SCSservicecon
4. Testdrive 40 - 55 mph for

a p p r o x ,t w o m i n u t e s T h e n
deceleratefor at least 3 sec_
o n d s w i t h t h e t h r o t t l ec o m '
pletely closed-Then reduce
the vehiclespeedto 35 mph,
a n d t r y t o h o l d i t u n t i lt h e
readiness codecomeson
Intermittent Iailure, system is OK

l s D T C P 0 4 2 0i n d i c a t e d ? at this time.
Checkthe TWC {seesection 9l

lf necessary,replacethe TwC

EmissionControl System
(EGR)System(D16ySengine)
ExhaustGasRecirculation
Doscription
The EGRsystemis designedto reduceoxidesof nitrogenemissions(NOx)by recirculating exhaustgas throughthe EGR

valveand the intakemanifoldinto the combustionchambers.lt is composedof the EGRvalve.EGRvacuumconrrotvatve.
EGRcontrolsolenoidvalve.ECMand varioussensors.
The EcM containsmemoriesfor ideal EGRvalve lifts for varyingoperatingconditions,The EGRvalve lift sensordetects
the amountof EGRvalvelift and sendsthe informationto the ECM.The ECMthen comparesit with the ideatEGRvalvelift
which is determinedby signalssent from the other sensors.lf there is any differencebetweenthe two. the EcM cuts cur-
rentto the EGRcontrolsolenoidvalveto reducevacuumappliedto the EGRvalve.
EGRCONTROL
CVT: SOLENoID vALvE
EGNVALVELIFTSENSOR
BLK
I
11-254
4
The scantool indicatesDlagnosticTroublecod€ {DTc}Po4ol:lnsufficientflow in the ExhaustGas Recirculation
(EGR)svstem.
Doscription
the changesin MAP before
Deterioration(clogging,leakage,etc.)in the EGRline or EGRvalve is detectedby meansof
and afterthe operationof the EGRvalve.
DTC P0401will be
lf deteriorationhas been detectedduring two cons€cutivedriving cycles,the MIL will come on and
stored.
Po$ible Causeg
. Clogging.leakagein the EGRline
. FaultyEGRvalve
- Tho MIL ht! bacn rgportodon.

- DTCm40l is 3torod.
Problomvorification:
dure.
2. Connectthe SCS servicecon-
nector,
3. Tost-driveunderthe following
conditions.
- Without any electricalload
- Deceleratelrom 55 mPh
\ (88km/h)lor at least5 sec-
onos
lntormiftam f!ilu.a, ayltam ia OK

.t thb time,
- Clo.n tho inttkc mlnifold EGR

port wittr carbursto. clotner.
- Cl.an the pa$lgo insido tho
EGR valvo with crrburator
cloanol or aoglacatha vllvo.

ExhaustGasRecirculation(EGR)System(D16Y5enginewith GWI (cont'dl
J
T_hescantool indicatesDiagnosticTroubleCode(OTC)P1491:A malfunctionin the ExhaustGas Recirculation
lTl49il
- l E g h )s v s t e m .
CvT lM/T seepage 1l-2611:
The MIL has been reoortedon.

DTCP1491is stoled.
1. Do the ECM/PCM ResetProce-
dure.
2. Connectthe SCSservicecon'
the radiatorfan comeson,
4. Drivethe vehicleon the road
for approx.10 minutes.Try to
keepthe enginespeedin the
1,700- 2,500rpm range.
Intermittonl failure, system is OK

l s D T CPl 4 9 l i n d i c a t e d ? at this time. Checkfor Door con-
nections or loose wires at, C144
{EGRvelve}and ECM/PCM.
Check fo. vacuum to ihe EGR
1. Disconnectthe No. 16 hose from

t h e E G Rv a l v e .
2. Connect a vacuum pump/
gauge to the hose.
3. Start the engine and let it idle.
EGRVALVE
LIFTSENSOR #16 HOSE
ls thereany vacuum?
Check tor a malfunction in the

EGR control solenoid valve: (To page11 257)
'1.
D i s c o n n e c tt h e E G R c o n t r o l
solenoid valve 2P connector,
2 . B e c h e c kt h e N o . 1 6 h o s e f o r
PUMP/GAUGE,0-30 in.Hs
A973X-041-XXXXX
Check vacuum hose routing o,

ls there any vacuum? the entire EGR svstem. lf hose
routing is OK, replac€the EGR
control solenoidvalv6. EGR
VALVE
indicalion goes away, replace
11-256
\ EGRVALVE
(Frompage11-256) LIFTSENSOR #16HOSE
Check fo. a mallunction in the

EGFvalv€:
1. ldove the vacuumpump/gauge - 30 in.Hs
PUMP/GAUGE,0
to the EGRvalve.
4973X-041-XXXXX
2. With the engineat idle,apply
26.7kPa(200mmHg,8.0in.Hg)
ofvacuumto the EGRvalve.
Doesthe enginestallor run

roughand doesthe EGRvalve
holdvacuum?
EGRVALVELIFTSENSOR
3P CONNECTORlC14.l)
Check for an open in the wire zF\ vccz

I- . ] IYEL/BLU)
IVCC2linel: ll 2l3l---l
1. Turnthe ignitionswitchOFF. -r_ 7 |
2. Disconnect the EGRvalve lift
sensor3Pconnector.
v-,, I
SG2IGRN/BLK)
I ^ I
I{Vts
I 3. Turnthe ignitionswitchON (ll).
EGRvalve lift sensor3P con' D {16P)
ECMCONNECTOR
n e c t o rt e r m i n a l sN o . 3 a n d
No.2.
ls lhere approx.5 V?
vcc2 sG2
IYEL/BLU} (GRN/BLKI
C (31P}'
PCMCONNECTORS
Check for an oDen in the wire

{VCC2line}:
E C M / P C Mc o n n e c t o rt e r m i n a l s
D10and Dl1 (C18and C28)*. Wire side of female terminals
YES Rep.ir open in the wire between

l s t h e r ea p p r o x . 5V ? r h e E G Rv a l v e s n d E C M / P C M
{Dl0 {C28)*).
Sub3titute t known-good ECM/ (cont'd)

PCM end recheck. lt 3ymptom/
indication goos eway, replace
*: '99 - 00 models
(To page 1l-258) th6 original ECM/PCM.
1 1-257
(EGRISystem(Dl6Y5enginewith CW) (cont'dl
ExhaustGasRecirculation ./
{Frompage11-257}
Chocklor an opcn or short in th.

EGRv.lve lift .€nsor EGRVALVELIFTSENSOR
3P CONNECTOR{Cl251
2. At the sensorsid€, measur€
resistancebetween the EGR
EGRL
valve lift sensor 3P connector (WHT/BLKI
terminalsNo. 1 and No.2.
ls there continuity or resis' sG2

tanceot 100k0 or higher?
{GRN/BLK}
Terminalsideol maleterminal
Chocktor sn op€n or lhort in the

EGRvalve lift lonror:
Measureresistancgbetweenthe EGRL
EGRvalve lift s€nsor3P connec- IWHT/BLKI
tor terminalsNo. 1 and No.3.
ls there100k0 or higher?
ECIT'I
CONNECTOR
D II6PI
Ch.ck tor an ooon or rhon in thc

wiro IEGRLlinc):
1. Beconnecttho EGRv6lve lift EGRL sG2
sensor3P connector. {WHT/BLKI {GRN/BLK}
2. Turn tho ignitionswitchON (ll).
3. Measurevoltage between the Wir€ side of f€maleterminals
D9and Dl1 (C6and C18l*.
ls thereapprox.1.2V? C (31PI*
PCMCONNECTORS
{Topage11-259) (To page11-259)
11-258
I (Frompage11-258)
ECMCONNECTOR
O {I5PI
Check for a 3hort in the wire

{EGRLlinel:
ECM/PCMconnectorterminalDg
Repairop€n in the wire between Wire sideof lemaleterminals

th6 EGRvalve and the ECM/PCM
(D9 tc6trt.
C (31P)*
PCMCONNECTORS
ReDairshort in the wirc batweon

the EGRvalve and ECM/PCM{Og
(c5t*).
(From page 11-258)
I
EGRCONTROLSOLENOIDVALVE
Checkths vacuum routing: 2P CONNECTOR
' 1 . R e c o nn e c t t h e v a c u u m
p u m p / g a u g et o t h e N o . 1 6
hose.
3. At the EGR control solenoid
valve side, connect the bat-
tery positiveterminal to the
E G Rc o n t r o l s o l e n o i dv a l v e
connectotterminalNo. 1.
4 . W h i l e w a t c h i n gt h e v a c u u m
g a u g e ,c o n n e c tt h e b a t t e r y
negativeterminalto the EGR
controlsolenoidvalve2P con- Terminal side oI
nectorterminalNo.2, malelerminals
ls thereapprox.26.7kPa
1200mmHg,8.0in.Hg)of
vacuumwithin 'l second?
Chockthe vlcuum hos6s:
2. Inspectthe No. 16 and No. 10
hosesfor leaks,restrictionsor
mtsrouUng.
t (cont'd)
11,260)
11-259
EmissionControlSystem
ExhaustGasRecirculation(EGR)System(Dl6Y5enginewith CW) (cont'dl
t J
(Frompage11-259)
EGRCONTROLSOLENOID
VALVE2P CONNECTOR
{C142}
Wire side
of lemale ESOL
Chocklor an open in the wire (E IRED)
SOL linsl: terminals
Irom the EGRcontrolsolenoid ECM
CONNECTOR ESOL
3. Disconnectthe ECN4/PCM con- a t32Pl IRED)
nectorA (32P)(B (25P))*from
the EcM/PCM.
ECM/PCl,connectorterminal
47 (86)* and the EGRcontrol
solenoid valve 2P connector Wireside
t e r m i n aNl o . 2 . of female
-_-] terminals
- EGRCONTROLSOLENOID
VALVE2P CONNECTOR
ICl'2}
Wireside
of female
terminals
i l
I
ECM
CONNECTOR ESOL
B l25P) (REDI
Wireside
of female
rermtnats
Repair opon in th. wir. bstwocn

ls therecontinuity? tha EGR control 3ol€noid valvo
and tho ECM/PCM(A7 186l'1.
Check for . rhort in the wire

(ESOLlinel:
Checkfor continuity between the
EGRcontrolsolenoidvalve2P con-
nectorterminal No. 2 and body
ground,
R.p.ir ahort in tha wi.c b.twecn

the EGR control iolonoid vllye
and th. ECM/FCM{A7 (46}rl.
Check for an opon in the wiro

IGNDlinel:
EGRcontrolsolenoid vaive2Pcon-
nectorterminal No. I and body
ground,
Rcpai. op€n in the wir6 b6'twoen

the EGR control rol.noid valve
and G101.
Sub3titule a known-good ECM/

PCM and rechock. lf symptom/
indication goes away, replac€
*: '99- 00 models
11-260
System(D16Y5enginewith M/T)
\ J
M/T:
- Th6 MIL ha3b€onreponed on.

- DTCPl,{tl is 3tored.
Prcblem verification:
2. Connectthe SCSservicecon_
nector.
untiltheradiator fan comeson.
4. Drivethe vehicleon the road
for approx. 10 minutes.Try to
keep the enginespeedin the
1,700- 2,500rpm range. (C14'rl
EGRVALVE6PCONNECTOB
lnlermittont tailure, svalem is OK

1
at thi3 tim6. Checkfoi Poor con'
ls DTCP1491indicated? nections or looso wiro3 at Cl/K a
IEGRvalvsl and ECM.
G10l PNK
IBLK} IE.EGRI
Check tor a malfunction in the
EGRvalv6:
1. Turnthe ignitionswitchOFF. Wi16sideof maleterminals
2. Disconnectthe EGRvalve 6P
I connector.
3. Stantheengineandletit idle
EGRvalve6P connector termi'
n a l sN o . 4 a n dN o . 6 .
sG2 vcc2
{GRN/ {YEL/
Checkthe EGRvalve: BLK} BLU)
ls there batteryvoltage? 1. Turnthe ignitionswitchOFF
EGRvalve 6P connectortermi
n a l sN o . 2a n dN o . 3 .
and recheck. It symptom/indica_
tion goes away, replaceth€ origi-
nal ECM.
ls thereapprox.5V?
(To page11-262)

System(D16Y5enginewith M/T) (cont'dl
\ v
( F r o mp a g e1 1 - 2 6 1 )
ECMCONNECTOR
D {16P)
Check tor open in the wire (SG2

linel:
E C Mc o n n e c t otre r m i n a l sD 1 0
a n dD 1 1 .
vcc2 sG2
(YEL/BLU) IGRN/BLK)
Wire sideof femaleterm;nals

Repsir open in lhe wire beiween
ls thereapprox.5 V?
E C Ml O l l l a n d E G Rv a l v e .
EGRVALVE6P CONNECTOR
EGRL SG2 (GRN/BLK)

(WHT/
Checkthe EGRvalve: BLK}
'l'
2 , A t t h e s e n s o rs i d e ,m e a s u r e
resistancebetweenthe EGR
valve 6P connectorterminals
No. 1 andNo.2.
Termanal
sideof maleterminals
l s t h e r e c o n t i n u i t yo r r e s i s -
tanceof 100k0 or higher?
EGRL vcc2
{WHT/ {YEL/BLU}
Checkthe EGRvalve: BLK}
Measureresistancebetweenthe
E G Rv a l v e 6 P c o n n e c t o tr e r m i
n a l sN o . 1 a n d N o . 3 .
ls there100k0 or higher?
(To pase 11 263)
1 -262
T lFrompage11-262)
ECMCONNECTOR
D I16P'
Chock for rn opon in the wire

{EGRL linel:
1. Reconnect the EGRvalvecon
nector.
2. Tu.nthe ignitionswitchON (ll).
3. Measurevoltage betweon the
PCM connectorterminalsDg
a n dD l 1 .
WiresideoI femaleterminals
Checktor th€ wirc (EGRL line):

ls thereapprox.1.2V? ECM connectorterminal Dg and
body ground.
Roprir op6n in the wirs botwean

the EGRvalvo.nd th. ECMlD9).
t
Rooair ahort in tho wiro baftr,otn
tho EGRv.lv..nd the ECM lDgl.
EGRVALVE6P CONNECTOR
Ch€ckthe EGRvalve:
2. Disconnectthe EGRvalve 6P
connector.
3. Connectthe battery positive
terminal to EGRvalve 6P con-
nectorterminalNo. 6.
4. Stan the engineand let it id'e,
then connectthe batterynega_
tive terminalto EGRvalve 6P
connectorterminal No, 4,
wire sid6 of lemale te.minals
(cont'd)

System(Dl6Y5enginewith M/Tl (cont'dl
J
lFrompage11 263) EGRVALVE
6P CONNECTOR
{C144}
Checklor an op€n in the wire (E-

EGRline):
2. Disconnectthe ECMconnector,
A (32P)trom the ECM. CONNECTOR
3. Checklor continuitybetween A l32P)
E C Mc o n n e c t o rt e r m i n a lA 7
and the EGRvalve6P connec-
torterminalNo.6.
Wire side
of female
Repairopen in the wiro botween termtnals
the EGRvalv6.nd th€ ECM{A71.
Check tor a short in the wire {E-

EGRlin6l:
ECM connectorterminalA7 and
body ground.
J
ls therecontinuity? Reoairshorl in tho wiro belwe€n
the EGn vake rnd the ECMlA7l.
Check fo. an open in tho wiro

IGNDline):
EGRvalve6P connectorterminal
N o . 4 a n db o d yg r o u n d . 2
R6pai. open in th€ wir. between a
th6 EGF control solenoid v6lve
and G101. I G101
Q) raur
Substitute 8 known-good ECM
and recheck. It symptom/indica-
tion goes away, roplacethe origi-
nalECM.
-264
System(D16Y5enginel
\ J
The scan tool indicatesDiagnosticTrouble Code {DTC)P1498:A high voltage problem in the ExhaustGas
(EGRlvalvelift sensorcircuit.
Recirculation
- The MIL has beenreportodon.

- DTCP1498is storod.
Probl€mverification:
dure.
2. Stanthe engine.
Intermittent tailure,sy3lem is OK
at lhis time. Check tor poor con'
nections or loose wire3 at C144
|EGRvalveland ECM/PCM.
(C1441
EGRVALVELlFf SENSOR3P {M/T: 6Pl CONNECTOR
C h e c kf o r a n o p e n i n t h o E G R
valv6 lift sen3or: cvT:
2. Disconnectthe EGRvalve lift vcc2
sensor3P (M/T:6Plconnector. {YEL/BLUI
EGRvalve litt sensor 3P lM/T: SG2 IGRN/BLK)
6P)connectorterminalsNo. 3
a n dN o . 2 .
I ls thereapprox.5V?
M/T: sG2
{GRN/
BLKI
Check lor op€n in th€ wire (SG2

line):
PCMconnector terminals010 and
D1l (C18and C28)*. Wir€ side ol lemale terminals
Repairopen in tho wiro betwoen D (16P)

ECMCONNECTOR
ls thereapprox.5 V? ECM/PCMlDl1 (Cl8)r) and EGR
valvo lift sensor.
Substitute . known-good ECM/

indicrtion goes away, replaco
the original ECM/rcM. vcc2 sG2
(YEL/BLUI (GRN/BLK)
*:'99 - 00 D16Y5enginewith CVT
Wir€ sideof femaleterminals
C 131P)'
PCMCONNECTORS
11-265
VentilationIPCVISystem
PositiveCrankcase
tJ
Descripiion lrcpection
T h e P o s i t i v eC r a n k c a s eV e n t i l a t i o n( P C V )s y s t e m i s 1. Checkthe PCVhosesand connectionsfor leaksand

designedto preventblow-by gas from escapingto the clogging.
atmosphere.The PCVvalve contains a spring-loaded 2. At idle,makesurethere is a clickingsoundfrom the
plunger.When the enginestarts,the plungerin the PCV PCVvalve when the hose betweenthe PCVvalve
valve is lifted in proportionto intakemanifoldvacuum and the intakemanifoldis lightly pinchedwith your
and the blow-by gas is drawn directly into the intake fingersor pliers,
manifold.
D16Y5,D16Y8ongins:
D15Y5,D16Y8,816A2 ongins: BREATHER
HOSE
BREATHER
HOSE
PCVVALVE
Gentlypinchhere.
Dl6'|116ngin6:
Bl6A2 engins: VALVE
-: aLOW-BYVAPOR
PCV
-: FnESHAIF
lf there is no clickingsound, checkthe PCVvalve

grommetfor cracksand damage.If the grommet is
OK, replacethe PCVvalveand recheck.
11-266
EvaporativeEmission(EVAPIControls
\ 1
Description
The evaporativeemissioncontrolsare designedto minimizethe amount of fuel vapor escapingto the atmosphere.The
systemconsistsof the foliowingcomponents:
A. EvaporativeEmission (EVAP)Control Canisto]

An EVAPcontrolcanisteris usedfor the temporarystorageof fuel vapor until the fuel vapor can be purgedfrom the
EVAPcontrolcanisterinto the engineand burned.
B. Vapor PurgeControl System

EVAPcontrolcanisterpurgingis accomplishedby drawingfreshair throughthe EVAPcontrolcanisterand into a port
on the intakemanifold.The purgingvacuumis controlledby the EVAPpurgecontrolsolenoidvalve.
VALVEDUTYCON-
SOLENOID
EVAPPURGECONTROL
AFTER
TROLLED ENGINE
STARTING
I ' 9 6D 1 6 Y 5e n g i n e , ' 9 6D l 6 Y 7e n g i n e , ' 9 6D 1 6 Y 8 I ' 9 6 D 1 6 Y 8e n g i n e ( c o u p e ) , ' 9 7D 1 6 Y 7e n g i n e

e n g i n e( s e d a n ) , ' 9 D7 1 6 Y 5e n g i n e , ' 9 7D 1 6 Y 7 ( c o u p e :K L m o d e l ,s e d a n :K L ( L X ) m o d e l ) " 9 7
r A , K C m o d e l s ,s e d a n :K A , K c '
e n g i n e( c o u p e K D16Y8engine(coupe:all models,sedan:KL model)
'97 '98-allmodels,'99-allmodels,'00-allmodelsl
K L i D X ) m o d e l s ,h a t c h b a c ka: l l m o d e l s ) ,
D 16Y8engine(sedan:KA, KC models)l
ABOVE154'F(68'C)
ENGINECOOLANTTEMPERATURE ENGINECOOLANTTEMPERATURE ABOVE154'F{68"C)
INTAKEAIRTEMPERATUREABOVE32'F (O'C)
and
I VEHICLESPEEDABOVEO MILE(OKM/h}
or
CLUTCHON
l'lc COMPRESSOR
and
INTAKEAIRTEMPERATUREABOVE160"F(41'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 of fuel vaporto the EVAPcontrolcanister.
D. Onboard RefuelingVapor Recovery(ORVRISystem {'99 - 00 models}

Duringrefueling.the oRVR {onboard RefuelingVapor Recovery)vent shut valve openswith the pressurein the fuel
tank.and feedsthe fuel vaporto the EVAPcontrolcanister.
t (cont'd)
11-267
EvaporativeEmissionIEVAPIControls(cont'd)
'96 D16Y8ongins (coupol.'97 D16Y8€ngino (coups:all mod€ls,sedan:KL model),'98 D16Y5engine (all mod6lsl,'98
Dl5YB engine {all modols):
BLK/ From
{ YEL < No. 15
ALTERNATOR
EVAPPURG€ SP SENSOR
CONTROL (7.5A)
FUEL SOLENOIDVALVE
TANK
PRESSURE YEL/
SENSOR BLU
. LT GRN
V€NT SHUT GRN/
BLK
EVAP
BYPASS
SOLENOID L BLU
VALVE VARIOUS
L __ L TG R N /
SENSORS
WHT
EVAP RED/
TWO WAY YEL
VALVE
INTAKE
MANIFOI.I'
'97 D16Y7engin. (coupa:KL model, sedan: KL {LX) model},38 Dl6\r/ engine:
From
?:y- -<
No. 15
ALTERNATOR
YEL/ SP SENSOR
BLU 17.5A)
LT G]
FUEL GRN/
TANK BLK
PRESSURE
SENSOR
BLU
LT GRN/
WHT
EVAP RED/
BYPASS YEL
VALVE BLK
EVAPCONTROL
EVAP CANISTER
TWO WA
FUEL FILL
VALVE
CAP
FUELTANK
11-268
J
'96 Dl6Y5 engine,'96 D16Y8engine (sodanl,'97 Dl6Y5 sngino,'97 Dl6Y8 sngine (sedan:KA, KC modols):
EVAP
PURGE
EVAP CONYROL
TWOWAY SOLENOID
VAL VALVE From
No.15
BLK/YEL__ _ < - ALTERNATOR
SPSENSOR
VARIOUS
SENSORS
FUEL
FILL
CAP
I
'96 D16Y' engin.,.9? D16Y7 engine {coupe: KA, KC models, sedan: KA. KC, Kl- IDX) modols, hatchback: all models}:
From
No. 15
3lI/- - - -{ ALTERNAT'R
EVAP SP SENSOR
PUBGE RED/
CONTROL YEL
SOLENOID
VALVE
FUEL 8LK
FILL
CAP +
t \,"ro*,
MANIFOLD
(cont'd)
11-269
EvaporativeEmission(EVAPIControls(cont'd)
'99 - 00 Dl6Yg engine,'99- 00 Dl6Y5
€ngine,'99- 00 81642engine:
From
BLK/ - No. 15
FUEL YEL _ ALTERNATOR
TANK SP SENSOR
PRESSURE {7.5A)
SENSOR
YELI
EVAP
- GRN/
BYPASS
BLK
SOLENOID
VALVE
BLU
LT GRN/
*=ol WHT
YEL
EVAPPURGE
8LK
CONTROL
SOLENOIDVALVE
ONBOARDREFUELING
VAPORRECOVERY
IONVR)VENT
SHUTVALVE
FUELTANK
ONBOARDREFUELING
VAPORRECOVERY IORVN}VAPOR EVAPORATIVE
RECIRCULATION
VALVE EMISSION{EVAP)
EVAPCONTROL CONTROL
CANISTER CANISTER
FILTER
'99 -
00 D16Y7 engine:
From
BLK/ No. 15
YEL < ALTERNATOR
SP SENSOR
FUEL {7.5A}
LT GRN
TANK
PRESSURE
SENSOR
- BLU
LT GNN/
EVAP WHT
EYPASS
SOLENOID
VALVE
EVAP
TWOWAY EVAPPURGE
VALVE CONTROL
SOLENOIOVALVE
INTAKE
MANIFOLD
FUELTANK
ONBOARDREFUELING EVAPORATIVE
VAPORRECOVERY
{ORVRIVENT EVAPCONTROL EMISSION{EVAPI
SHUTVALVE CANISTER CONTROL
ONBOARDREFUELING CANISTER
VAPORRECOVERY IORVRIVAPOR FILTER
RECIRCULATION
VALVE
1 1-2 7 0
\ J
,96 D16Y5engine,,96 D16r,gngino,,96 Dt6Y8 engine {3edan)'37 D16Y5engino..97 D16r, engine {coupe:KA, Kc mod-
(s€dan:KA' KC mod€lsl:
els. sedan:KA, KC, KL {DX} models. hatchback:all modols}''97 Dl6Y8 ongine
(EVAP)control system
The scan tool indicatesDiagnosticTrouble code (DTC)P0441:EvaporativeEmission
insufficientpurgeflow.
Description
insufficientEVAPcontrol system
By monitoringthe purge line vacuumwith the MAP sensor,the ECM/PCMcan detect
purgeflow.
PossibleCau3e
. EVAPPurgeControlSolenoidValve
. EVAPPurgeControlSolenoidValveCircuit
. EVAPControl Canister
. VacuumLines
. ECM/PCM
Troubl93hootingFlowchart
- The MIL has bsGn.eportadon.

- DTC milal k rtored.
Pioblem vsrificJtion:
engine at 3,000rPm with no
load {in Parkor noutral)until
2. Do the ECM/PCMResetProce'
\ dure,
3. Connectthe SCS servicecon-
nector.
4. Test-driveunderfollowingcon-
ditionson the road
- Withoutany electricalload
- A/T in E or E Position
(M/Tin 3rd-sthgear)
- Engine sPeed betweon
1,200- 2.400rpm.
- Decelerate {rom 50 mph (80
knl/h)to 15mph (24km/h)
lntormittont lailuro, sFtorn b OK EVAPPURGECONTROI-
at thi. timo. Ch€cktor Poor con' sottNotD vALvE2P
ls DTCP0441indicatod? ncction3 or looac wir.3 at C144 CoNNECTOR (Cl1al
{EVAP purgo control tolonoid
vrtv.l .nd ECir/FCttl. r-+-r
Ch.ck fo. !n op€n in the wiro l|(il I ' l ' l
linel: lG-ro.*l'rr"r
2. Disconnectthe EVAP Purge O)
controlsolenoidvalve2P con_ Y
neclor,
3. Turn the ignitionswitchON (ll)
4. Measur€voltagebetweenbody Wire side of female
ground and the EVAPPurge terminals
control solenoidvalve 2P con-
nectorterminal No 1.
Rop.ir opor in tho wir6 b€two€n
the EVAP purgo codtiol tolonoid
v.lvo rnd tho No 15 ALIERNA'
TORSP SENSOR17.5A)lu.o.
(cont'd)
{To page11-272)
11-271
EvaporativeEmission(EVAPIControls(cont'dl
I
(Frompage11-271) ECM/PCMCONNECTOR
D I32P}
PGl IBLKI
Check the EVAP purge control

solenoidvalvei
1 . R e c o n n e c t h e E V A Pp u r g e
controlsolenoidvalve2P con-
nector. PCS{REO/YEL)
terminalsA15 and 410 with a
t 3 8 9 t0 'tt
Doesthe solenoidvalveclick Checkfor an open or short in the 12 l 3 'I't t 5 t 5 '11 I E 1 9 20 23 2a

when the jumperis connected? wire (PCSline):
?5 21 2A 29 30
PCMconnectorterminalA15 and PCS{RED/YEL)
body gro!nd.
Che'ckfor a short in the wir6 {PCS

line):
nectorA (32P).
3. Disconnectthe EVAP purge
controlsolenoidvalve2P con
nector.
Repai. short in the wir6s betwoon

the EVAP purge control solanoid
valveand ECM/rcM lA15l.
Checkthe vacuum lin€3: R€pair op€n in the wir$ betwo€n

Checkthe vacuumlinesol EVAP tho EVAP purge control solenoid
systemfor misrouting,leakage, valve and ECM/rcM lA15l.
breakageand clogging.
Are the vacuumlinesOK?
2 3 a 6 7 E 9 t0 It
12 t 3 'ta 't5 l 6 1 7 ta 1 9 20 22 23 21
2a 27 28 A 30
0) Pcs{REo/YELI
-272
\ J
(Frompage11-272) D16Y5engine: D16Y7,D16Y8engine
Check lhe EVAP Purge control

solsnoid valve: VACUUM VACUUM
1. Disconnectthe vacuum hose PUMP/ PUMP/
from the EVAPcontrolcanister' GAUGE, GAUGE,
2. Connectthe vacuumPumPto 0 - 30 in.Hg 0 - 30 in.Hg
the hoseandaPPIYvacuum A973X- As73x - 0il1 -
otl - xxxxx
xxxxx
Doesit hold vacuum?

EVAPCONTROL
CANISTER
D I32PI
ECM/PCMCONNECTOH
Checkthe EVAPcontrol canister:
PGl IBLKI
1. Reconnectthe vacuum hoseto
the EVAPcontrolcanlster.
2. Connectthe vacuum/Pressure
gaugetothe Purgeaarhose
terminalsA15 and A10 with a
iumperwire.
I 4. Startthe engine
5. Checkthe vacuum JUMPERWIRE
Wire sideotfemaleterminals
D16Y7, Dl6Y8 engine:
Checkthe EVAPtwo way valve

(seepage11-193)
Doesthe EVAPtwo waY valve Replacethe EVAPtwo wsY valve.
D16Y5sngin€:
VACUUM/
PBESSURE
GAUGE0-4in.Hg
07JAZ- 0010008
PCM .nd recheck.lt symPtom/
indicrtion go6s away, rePlacethe
original ECM/PCM.
VACUUM/PRESSURE
GAUGE
0-4 in.Hg
t o?JAZ- 001fl)OB
(cont'd)
11-273
EvaporativeEmission(EVAP)Gontrols(cont'd)
'99 - 0O
I J
models only:
The scantool indicatesDiagnosticTroubleCode(DTC)P0451:The FuelTankPressuresensorcircuitrange/

oerformanceDroblem.
Ths MIL has been reDortgd on. ECM/PCMCONNECTORS

DTCm/$1 i3 stored.
A (32P)
Checkthe tuel tank pros3ureser|-
sor:
dure.
2. Removethetuellillcap.
4. N4onitor 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
b e t w e e nb o d y g r o u n d a n d
ECN4/PCM connectorterminals
A29and C18.
wire sideot femareterminars sG2 IGRN/BLK)
ls thereapprox.2.5V7
Checktho tuel tank pressure!on-

soa:
1 . R e m o v et h e f u e l t a n k ( s e e
tl'
page 11 2421.
2 . R e m o v et h e f u e l t a n k p r e s -
s u r e s e n s o ra s s e m b l yf r o m
the fueltank.
3. Connectthe fueltank Pressure
S e n s o rs u b - h a r n e s6sP c o n -
n e c t o r t o t h e a c c e s sp a n e l
sideconnector,
4. Disconnectthe hose between
the EVAPtwo way valvg and VACUUM
the fuel tank pressuresensorat FUELTANK PUMP/GAUGE,0 - 30 in.Hg
the EVAPtwo way valveend. PRESSURE A973X- 041 -
5 . C o n n e c ta v a c u u mp u m p t o SENSOR xxxxx
the openend ofthat hose.
7. Monitor the FTPSensorvolt,
age with the Honda PGM
between ECM/PCMconnector
t e r m i n a l sA 2 9 a n d C 1 8 ,a n d
carefullypump vacuum on the
hoseone strokeat a time.
8. The voltagesho!ld smoothly
drop from the stading approx.
2.5 V down to approx. '1.5V.
STOPapplyingvacuumwhen
the voltagedropsto approx.1.5
V or damageto the fuel tank
pressuresensormay occur. EVAP TWO
FUELTANK WAY VALVE
PRESSURESENSOR
Doesthe voltagedrop to ASSEMBLY
approx.1.5V and hold?

PCM and r6check.It symptom/
indicltion 90e3aw.y, replac\.th€
original ECM/PCM.
11- 2 7 4
\ J
FuelTank Pro3suresensor 196 D16Y8engine (coupe).'97D15Y7'99 engine {coupe:KL model, sedan:KL (LX) modeu,'97
'98-all models) - 00 D16Y5engine with M/Tl:
D16Y8engine (coupe:all models, sedan: KL model,
Foc2l::il":"toolindicatesDiagnosticTroublecode(DTc)P0452:A|owvo|tageprob|emintheFue|TankPre
EcM/PCM.
The fuel tank pressuresensorconvertsfuel tank absolutepressureinto electricalsignalsand inputsthe
OUTPUT
VOLTAGE
tvt
4.5
- The MIL has beenreportedon

-? kPa +7 kPs
Checkthe vacuum lines: (-50 mmHg, 150mmHg,
C h e c kt h e v a c u u m l i n e s o f t h e -2 in.Hg) 2 in.Hg)
fuel tank pressuresensorfor mis-
r o u t i n g ,l e a k a g eb, r e a k a g ea n d PRESSURE
cloggrng.
\
O I16P)
ECM/PCMCONNECTOR
Problemv€ritication:
dure.
2. Removethe luel fill caP.
3. Turnthe ignitionswitchON lll)
4. Monitor the FTPSensorvolt_
PTANK
T e s t e r ,o r m e a s u r ev o l t a g e {LTGRNI
b e t w e e nb o d Yg r o u n d a n d lntermittent tailuro, sYstemi5 OK
ECM/PCM terminalDl5. dt this timo. Chockfor Poot con- Wire sideoI femaleterminals
neciion3 or loose wir* at C131
llocatod under right side ot dashl,
ls thereapprox.2.5V? C4O1(located .bove under'da3h FUELTANK
tuso/ielay box), C574 1C568)* PRESSURESENSOR
{located under acc€ss Panell. (C7921
3P CONNECTOR
C792 lfuel tank pressule sen3or)
Checktol an op€n in wite (VCC2 and EcM/PCM.
line):
1. Turn the ignitionswitchOFF vcc2
(YEL/BLU}
2. Reinstallthefuel fill caP.
3. Disconnect the fuel tank Pres'
suresensor3P connector-
5, Measurevoltage between the sG2
fuel tank pressuresensor3P
IGRN/8LK)
connectorNo. l terminaland
No.2 terminal. Wiresideof femaleterminals
Repairopen in the wite between
the fuel tank Pr€s3urea€n3orand (cont'd)
ls thereapprox.5 V?
th6 EcM/PcM (D1ol.
(Topage11'276)
11-275
EvaporativeEmission(EVAP)Controls(cont'dl
!
{Frompage11-275)
FUELTANK
PRESSURESENSOR
3P CONNECTOR{C7921
Check to. ! short in the wiro PTANK
IPTANKlinol: {LT GRN)
firel tank pressuresensor 3P con-
nector No. 3 terminal and No. 2
terminal,
sG2
{GRN/BLK)
Wire side of f€mal€ terminals
ls thereapprox.5V?
Check fo. a Short in the wire

IPTANKIinoI:
1. Turnthe ignitionswitchOFF. PTANK
2. Disconnectthe ECM/PCMcon, {LT GRNI
nectorD 116P).
the fuel tank pressuresensor
3P connectorNo.3 terminals
and body ground.
Repairthort in thc wire betwean

ls there continuity? tho fuel iank pre$uro 3€naorand
ECM/FCMtDl5t.
Substitute ! known-good ECM/

PCM and recheck. lf .ymptom/
indication go6s awry, replecoth6
origin.l ECM/PCM.
-276
\
'99 - 00 models excepi Dl6Y5 engine with M/T:
problemin the FuelTank Pressure

The scantool indicatesDiagnosticTroubleCode(DTC)P0452:A low voltage
sensor.
signalsand inputsthe ECM/PCM

The fuel tank pressuresensorconvertsfuel tank absolutepressureinto electrical
OUTPUT
VOLTAGE
(vl
t.5
The MIL has been.eported on.

DTCP0452is stored
0.5
Checkthe vacuum lines: -7 kP. +7 kP.
C h e c kt h e v a c u u m l i n e s o f t h e (-g) mmHg, 150mmHg,
fuel tank pressuresensorlor mis- -2 in.Hgl 2 in.Hgl
r o u t i n g ,l e a k a g eb, r e a k a g ea n d PRESSURE
cloggrng.
I Are the vacuumhnesOK?

A (32P)
ECM/PCMCONNECTOR
dure,
2. Bemovethe fuel fill caP. PTANK{LT BLUI
3. Turnthe ignitionswitchON {ll)
4. Monitorthe FTPSensorvoltage
with the HondaPGMTester'or
measurevoltagebetweenbody lntermitlent tailure,3Ystemb OK
groLrndand ECM/PCMconnec_ at this time. Checkfor Poor con' Wire sideof lemaleterminals
tor terminalA29. nections or loose wire3 at C131
{locatedunder right side of dash},
ls thereapprox.25 V? C401 {located above under'dash
tuse/relay box), C574 (C568)*
l l o c d t e d u n d e r a c c e s sP a n e l ) ,
C792 (tuel rank Prcssuresensorl FUELTANK
Checkfor an open in wire {VCC2 and ECM/PCM. PRESSURESENSOR
line): SUB.HARNESS
1. Turnthe ignitionswitchOFF. (C574(C568)rl
6P CONNECTOR
2. Reinstall theltrelfill caP
3, Removethe accessPanelfrom
the floor.
4. Disconnect the fuel tank Pres'
s u r e s e n s o rs u b - h a r n e s6s P
5. Turnthe ignitionswitchON (ll). vcc2 sG2

6. At the accessPanelside, mea_ (YEL/BLUI {GRN/BLK}
sure voltage betweenthe fuel
I tank Pressuresensorsub-nar-
ness6P connector No 5termi
Wire sideo{ temaleterminals
nalandNo.6 termlnal.
l l ls there approx 5 V?
Repair open in tho wire between
th6 fu€l tank Prossuro sen3oa and
(cont'd)
the ECM/PCM lc28).
(Topage'11-278)

EvaporativeEmission(EVAPIControls{cont,dl
J
(From page 11-277) FUELTANK
PRESSURE SENSOR
SU8-HABNESS
6P CONNECTOR1C574tC568)rt
PTANK
C h e c kf o r a s h o r t i n t h e w i r e {LTGRN}
{PTANKline):
A t t h e a c c e s sp a n e ls i d e , m e a
s u r e v o l t a g eb e t w e e nt h e f u e l
tankpressuresensorsub-harness
6P connectorNo. 2 terminaland
N o .6 t e r m i n a l .

ls thereapprox.5 V?
C h o c kl o r a S h o r t i n t h e w i . e
(PTANKline):
1. Turn the ignitionswitchOFF. PTANK
2. Disconnect the ECM/PCM con- ILT GRN}
nectorA (32P).
sub-harness 6P connectorNo.
2 terminalsand body ground.
Repairshort in the wi.e betwsen

the luel tank pressuresensorand
ECM/PCM{A291.
Subsiitute a known-good ECM/

PCM and rechock.lf symptom/
indicationgoes away, replac€the
original ECM/PCM.
1 1- 278
\
(coupo: KL mode|' 3edan: KL (Lxl modg||',97
Fue| Tank Pr€ssuresensor 196 Dr6Y8 engine (coupe},,97 D16Y7angino
39 - 0ODl6Y5 ongins with M/Tl:
Dl6Y8 engine (coupe:all modeb, sedan: Ki model.'98'all modols)
rFoG'l::;Jl"too|indicatesDiagnosticTroub|ecode(oTc)P0453;Ahighvo|tageprob|emintheFue|TankPr
The MIL has beon reponed on

DTCP0453b stored.
Checkthe vacuum lines:

C h e c kt h e v a c u u ml i n e s o I t h e
fueltankpressuresensorfor mis-
r o u t i n g ,l e a k a g eb, r e a k a g ea n d
clogging.

D Il6PI
ECM/PCMCONNECTOR
dure.
2. Femovethe fuel fill cap
3. Turnthe ignitionswitchoN (ll).
4. Monitor the FTPSensorvolt- PTANK
a g e w i t h t h e H o n d aP G M ILT GRNI
b e t w e e nb o d Y g r o u n d a n d Wiresideof tgmaletorminals
ECM/PCMconnectortermrnal lntormittont t iluro, 3Ystem is OK
\ D15. at this time. Checklot Poor con_
noctiona or loo3e wirat at C131
{loc.ted undor right 3id6 of d8hl, FUELTANK
ls thereapprox.2 5 V? CaOl llocatod rbov. under-dalh PRESSURE
SENSOR
fus6/relay boxl, C574 (C568lr (C792)
3PCONNECTOR
llocatod und6l accoss Pan6ll,
C792 lfuel tank Preasuloaonlorl
Check for an oPen in the wire end ECM/PCM. vcc2
(SG2line): *: coupe (YEL/BLU}
2. Reinstall the fuellill cap
3. Disconnect the fuel tank Pres-
suresensor3P connector. sG2
4. Turn the ignitionswitchON (ll) (GRN/BLKI
fuel tank Pressuresensor3P Wire sid€ of female terminals
connectorterminalsNo. 1 and
No.2.
Ropairopon in the wira b€tw€sn
ls thereaPProx.5 V? the fuel tank prasure sonlor and
ECM/PCM(Dl1).

(PTANKline):
fueltank Pressuresensor3P con-
nectorNo. 3 terminaland No. 2 sG2 PTANK
termrnal, IGRN/BLKI IGBN/RED}
ls thereapprox.5 V?
I (cont'd)
{To page 11-280)
11-279
\ v
l F r o mp a g e1 1 - 2 7 9 1
Check for an open in the wire ECM/PCMCONNECTOR

D {16PI
{PTANKline):
P C Mc o n n e c t otre r m i n a l sD 1 5
a n dD ] 1 .
PTANK SG2 (GRN/BLK}

Repairopen in the wire between {LTGRN)
ls thereapprox.5 V? E C M / P C Ml D 1 5 ) a n d l u e l t a n k
pressuaesensor. Wire sideof femaleterminals
Substitute a known'good ECM/

PCM end recheck.lt symptom/
indication goes awav, replacethe
original ECM/PCM.
-2AO
\
'99 - 0Omodols except Dl5Y5 engine with M/T:
rFo45'::n":"tooIindicatesDiagnosticTroub|ecode(DTc)P0453:Ahighvo|tageprob|emintheFUelTankP

DTCP0453is stored.
Checkthe vacuum lines:

C h e c kt h e v a c u u ml i n e s o t t h e
fueltank pressuresensorfor mis-
r o u t i n g ,l e a k a g eb, r e a k a g ea n d
clogging.

A {32P)
ECM/PCMCONNECTOR
dure,
2. Removethe fuel fill caP PTANK{LTGRN)
4. Monitor the FTPSensorvolt'
b e t w e e nb o d y g r o u n d a n d Wiresideof temaleterminals
ECM/PCMconnectorterminal lntermittent failuro. svstem b OK
A.29. at this time. Checkfor Poor con_
noctionsor loo3€wire3 at C131
FUELTANK
{locatedunder tight side of dash), PRESSUNESENSOR
ls thereapprox.2.5V? C4Ol {located above underdash
SUB.HARNESS
fuse/relay boxl, C57{ (C5681'
{C574(C568)}}
6P CONNECTOR
l l o c a l e d u n d e . a c c e s sP a n e l l ,
C792 {fuel tank Pressuresensorl
Ch€ck for an open in the wira aod ECM/PCM.
{SG2line):
1. Turn the ignition switch OFF.
2 . R e i n s t a l lt h e f u e l f i l l c a P vcc2 sG2
3. Remove the access Panel {YEL/BLUI IGRN/BLK)
lrom the floor.
4 . D i s c o n n e c tt h e f u e l t a n k P r e s -
s u r e s e n s o r s u b - h a r n e s s6 P Wiresideof femaleterminals
5. Turn the ignition switch ON (ll)

6 , A t t h e a c c e s sP a n e l s i d e , m e a -
sure voltage between the fuel
tank pressuresensor sub_har-
ness 6P connector termlnals
N o . 5 a n dN o . 6 .

ls thereapprox.5V? the fueliank Pres3ure3ensorand
ECM/PCM{Cl8).
PTANK
{LTGRNI
Check lor an oPen in the wire
{PTANKlinel:
At the accessPanel side, mea
s u r e v o l t a g eb e t w e e nt h e f u e l
tank pressuresensorsuo_harness
6P connectorNo. 2 terminaland
No. 6 terminal.
(cont'd)
ls there approx. 5 V?
(Topage11.282) 11-281
EmissionGontrol System
EvaporativeEmission(EVAP)Controls(cont'd)
I J
(Frompage11-281)
ECM/PCMCONNEfiORS
a {32P)
Check tor an open in th€ wire

(PTANKline):
Measurevoltage betweenECM/ PTANK ILT GRNI
P C i / lc o n n e c t o rt e r m i n a l sA 2 9
a n dC 1 8 .
Repsir open in tho wire between

ls thereapprox.5 V? ECM/PCM {A29} .nd fuol tank
oao!3urotensor.
SG2 IGRN/BLK)
Substitute a known-good ECM/ Wiresadeof femaleterminals

PCM and rscheck. It symptom/
indicationgoes aw.y, ..plsc. the
original ECM/FCM.
t I
\" a
11-282
\
(LX) model)"g7 Dl6Y8 ongine (coupe:all mod-
t,96 D16Y8engine (coup6l,'9? Dl6Y7 engine (coupe:KL model, sedan: KL
els, sedan:KL model,'98-8ll modelsl 39 - 00 Dl5Y5 engine with M/Tl:
(EVAP)controlsystemleak
The scantool indicatesDiagnosticTroublecode (DTc)P1456:EvaporativeEmission
Fr4t6l detected(fuel tank sYsteml
(EVAP)controlsystemleak
The scantool indicatesDiagnosticTroubleCode(DTC)P1457:EvaporativeEmission
fF14s7detected(EVAPcontrol canistersystem).
PossibleCauss
. Fuelfill cap
. VacuumConnections
. FuelTank
. EVAPControlCanisterVent ShutValve
. EVAPControlCanisterVentShutValveCircuit
. EVAPPurgeControlSolenoidValve
. EVAPPurgeControlSolenoidValveCircuit
. EVAPBypassSolenoidValve
. EVAPBypassSolenoidValveCircuit
. FuelTankPressureSensor
. FuelTankPressureSensorCircuit
VACUUM
. EVAPControl Canister - 30 in.Hg
PUMP/GAUGE,0
. Throttle Body A973X- 041 -
xxxxx
Troublsshooting Flowchart EVAP
CONTROL
I - The MIL ha3 been rePofted

on.
.4, cANrsrER
- DTCP1456or P1457is stored.
re ./ VALVE
Check the EVAP control canbtol

vent shut valve:
1. Disconnectthe vacuum hose
{S----r*::n
I r o m t h e E V A Pt h r e e w a Y
valve and connecta vacuurn
pump to the hose.
2 . R e m o v e t h e E V A Pc o n t r o l
canistervent shut valveIrofi
the canrster.
3. Turnthe ignitionswitchON (lli Chock for . shon in the wire
4. Applyvacuumto the hose. (VSv linel:
Disconnectthe 2P connector{rom
the EVAP control canister vent
Does the valve hold vacuum?
Repairshort in the wir€ betwcen
Doesthe valvehold vacuum? shut v.lve and tho ECM/PCM
Check the EVAP control canister tA29|.
vent shui valve:
1. Turnthe ignitionswitchOFF. A {32P)
ECM/PCMCONNECTOR
2. ConnectECM/PCMconnector Reohce the EVAP control canis-
terminalA29 to body ground ter vent shttt valve. 3 7 I 9 t0 1t
with a iumPerwire. 't2 t 3 t5 t 6 I t It t 9 20 2a 2a

3. Turn the ignitionswitchON (ll). 25 a A
4. Applyvacuumto the hose
ILT GRN/W{T) I JUMPERWIRE
Doesthe valveholdvacuum?
Wiresideof femll terminals
\ (cont'd)
(To page11-284i (To page 11 284)
11-283
1
(Frompage1l-283) (Frompagel1-283)
EVAPCONTROL
CANISTERVENT SHUT
VALVE2P CONNECTOR IC141}
Check for an open in tho wire l l t r t

(lGl line): + rcl
1. Turnthe ignitionswitchOFF. o) (8LK/YErl
2. Disconnectthe 2P connector I
lrom the EVAPcontrolcanis-
ter vent shutvalve. Wire sideot temaleterminals
EVAPcontrolcanistervent shut
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.
Repairopen in the wire betwe€n
the EVAP control c.ni3tei vent
shut valve and th6 No. 15 ALTER-
NATORSP SENSOR17.5Al fuse.
Cfisck tor an opon in the wire (VSV A (32PI

ECM/PCMCONNECTOR
line):
1. Turnthe ignitionswitchOFF. PGT(BLKI
'l'
2. Beconnectthe 2P connector
to the EVAPcontrol canister : l
vent shut valve. I 2 3 l ' l t l ' l l e l s lr oI r I
3. Turnthe ignitionswitchON (ll). 12 13 t6 €lnltlr@/lzzl zs f il
4. Measurevoltage between 25
nalsA29 and Al0.
VSV ILTGRN/WHT}
Wiro side of lemale
tgrminals
Rep.ir open in the wire betwoon

ls there battery voltage? the EVAP control canister vent
shut valve and th€ ECM/PCM
tA29t.
Replaceth6 EVAP control canis-

ter vent 3hut valve.
Checkthe vacuumwhon cold:

shown from the EVAPcontrol
canrsterand connecta vacuum
gaugeto the hose,
2. Start the engineand allow it VACUUM
to idle. PUMP/
N O T E :E n g i n ec o o l a n tt e m - GAUGE,0- 30 in.Hg
peraturemust be below 154oF 4973X -
(68'C)or lVC switch OFF. 041- XXXXX
3. Ouicklyraisethe enginespeed
to 3,000rpm.
{Topage1l-285}
11-284
\
(Frompage11-284)
Check the EVAP pirrge control
solenoidvalvei
ls therevacuum? lrom the EVAPpurge control
solenoidvalve.
to 3,000rpm.
InsDectvacuum ho56routing.
ll OK, replacethe EVAP Purge
control solenoidvalve.
EVAPPURGECONTROLSOI.INOID
Chock for a short in the wire VALVE2P CONNECTOR
IC114I
(PCSlinel:
Checkthe vacuum when hot: 2. Disconnect ECM/PCM connec'
1. Turn the ignitionswitchOFF tor A (32Pi.
2. Blockthe rearwheelsand set 3. Checkfor continuitybetween Wiresideot
the parkingbrake. the EVAPPUrgecontrol sole female
3. Jack up the front o{ the vehi- noid valve 2P connectortermi terminals
cle and supportit with safety nalNo.2 andbodyground.
stands,
4 . S t a r t t h e e n g i n e .H o l d t h e Reoairshort in the wire botween
engine al 3,000rpm wlth no ls therecontinuity? the EVAP purg€ cor|t]ol solenoid
load (in Parkor neutral)until valve and the ECM/pcM lA15l.
letit idle.
5, Checkfor vacuumat the vac- Substitute a known-good ECM/
uum hose with transmissaon PCM and recheck. lf sYmPtom/
i n g e a r ( A / Ti n B P o s i t i o n , indication goes eway. repl.c€ the
M/T in lst gear) after starting original ECM/PCM.
\ the engrne.
6. Ouicklyraisethe engine speed
to 3,000rpm. Check the EVAP Purg€ control ? ,
solenoidvalve:
I,l,lil?"",,,
from the EVAP Purge control
s o l e n o i dv a l v e a n d w a r m l t
EL,TW
YEL)
up to normal operatingtem_
peratureagain if necessary
3. Stanthe engine.
4. At the harnessside, measure
v o l t a g e b e t w e e nt h e E V A P
Purge control solenoidvalve
and No. 2 with the transmis
sion in gear (A,/Tin E Posi-
tion, M/T in 1stgear).
In3pectvacuum ho3€touting.
ll OK, replace EVAP Purge con-
lrol aolenoidvtlv€.
Check lo. an open in the wire

llGl linel:
At the harnessside, measurevolt
age betweenthe EVAPPurgecon- IBLK/YELI
trol solenoidvalve 2P connector
terminalNo. 1 and bodyground
Repeiropen in tho wire between
EVAP purge conttol solenoid valv€
and the No. 15 ALTERNATORSP
SENSOR(7.5A fu3e
\ (cont'd)
(To page11-286)
lTo page 11 286i
11-285
\ .
(Frompage11'285) (Frompage11 285)
ECM/PCMCONNECTOR
A {32P}
PGl
{BLK)
Check lor an op€n in the wire
{PCSline}:
2, Reconnectthe 2P connectorlo
the EVAPpurge controlsole-
noidvalve.
3. Turnthe ignitionswitchON (lll.
PCS
{RED/YEL) Wire side of
ECM/PCM connectorterminals temale
4 1 5 a n dA ] 0 .
terminals
Repai. op€n in the wire bGtween

the EVAP purge control solenoid
valveand the ECM/PCM{A151.
EVAPIWO WAY
PCMand retest. tf sympiom/indi-
cation goes away, replac6 the
original ECM/PCM.
Checkthe EVAPtwo way valvo:

See EVAPtwo way valve test (see
p a g e1 1 ' 2 9 4 ) . PUMP/
GAUGE,0- 30 in.Hg
A973X- EVAPBYPASS
Replace tho EVAP two way valve. 041 - SOLENOIDVALVE
xxxxx
Check the EVAP bypr$ 3olenoid
1. Disconnect the vacuum hose

from the EVAP two way valve
and connect a vacuum pump
to the hose.
2 . T u r n t h e i g n i t i o ns w i t c h O N l l l ) .
3. Apply vacuum to the hose. C h e c kt o r a s h o r t i n t h e w i r e
O.RING
{2WBSlinel:
Disconnect Beplace.
the 2P connectorfrom
Doesthe valvehold vacuum? the EVAPbypasssolenoidvalve. EVAP TWO WAY VALVE
Repairshort in the wire betwe€n

Does the valve hold vacuum? EVAP bypass sol€noid valve and
rhe ECM/PCMlA28).
(To page'l1 287)
11-286
I (Frompage11-286)
A (32P)
ECM/PCMCONNECTOR
Checkthe EVAP bypa3s3olenoid
I 2 5 7 8 t0 11
2. ConnectECM/PCMconnector '12 t t
terminalA28and bodyground 1 5 t6 t 8 t 9 20 23 21
with a jumperwire. 27 26 29 3o
ChGcktor an opon in lho wite
3. Turn the ignitionswitchON (ll). (lGl lin6l:
1. Turnthe ignitionswitchOFF 2WBS Wiro sideol
2. Disconnectthe 2P connector (BLUI Iemale
trom the EVAPbypass sole- _ terminals
JUMPER
noid valve. WIRE
EVAPbypasssolenoidvalve SOLENOID
EVAPBYPASS
2P connectorterminal No- 1 VALVE2PCONNECTOR
{C793I
and body ground.
Wire side of
femal€
terminals
R.pair open in tha wil€ botwoon

EVAPpurg. cor|trol 3olenoid valve
.nd tho No. 15 ALTERNATORSP
\ SENSOR17.5Al tu3e.
a l32Pl
CONNECTOR
ECM/P,CM
Check lor an open in the wire PGl (BLKI
{2WBSline): I
l. Turnthe ignitionswitchOFF.
2. Reconnsctthe 2P connector I I 7 l l s l e lr o l r ' I
to the EVAPbypasssolenoid 't2 r3 ,"l!j'"EBUP)._3)_!J
E nt ll 4al*l 4 l,-'l
4. Measure voltage between 2WaS{BLUI
ECM/rcM connectorterminals
A28andAl0.
Wir€ side of female
terminals
Ch6ck the following P..ts for
l 6 a k a g e t o a t m o s P h e r e ,a n d
roplir or rephco if neca3aary: Roprir opon in tho wiro betwoen
' fuel fill c.D ls there batteryvoltage? th. EVAP byp.$ 3ol6noid valve
. tu6l t.nk rnd tho EcM/PcM lA28l.
. tuel vapor pipe
. EVAPtwo way v3lvo
. EVAPbypa3! solanoidvtlY.
, fuel tlnk pra63uro3on3or
. EVAPcontrol canBte.
. EVAP control crnistor vent
shut vtlvo
. EVAP purgo control lolonoid
. vscuum hoseSand connoction3
\ (cont'dl
11-2A7
EvaporativeEmission{EVAP)Controls(cont'dl
\ J
'99 - 00 modols except Dl6Y5 engine with M/T:
The scantool indicatesDiagnosticTroubleCode(DTC)P1456:EvaporativeEmission(EVAP)controlsystemleak

tF1456-ldetected(fueltanksvstem).
The scantool indicatesDiagnosticTroubleCode(DTC)P1457:Evaporative
Emission(EVAP)controlsystemleak
tP14sz-ldetected(EVAPcontrolcanistersystem).
PossibleCause
. Fuelfill cap
. VacuumConnections
. FuelTank
. EVAPControlCanisterVent ShutValve
. EVAPControlCanisterVent ShutValveCircuit VACUUM
. EVAPPurgeControlSolenoidValve PUMP/GAUGE, 0 -30 in,Hg
o EVAPPurgeControlSolenoidValveCircuit A973X- oal -
. EVAPBypassSolenoidValve xxxxx
. EVAPBypassSolenoidValveCircuit EVAP
. FuelTankPressureSensor T-t CONTROL
. FuelTankPressureSensorCircuir CANISTER
. EVAPControlCanister t \ VENT
SHUT
. ORVRvent shut valve
VALVE
. ORVRvapor recirculation
valve
. ThrottleBody

DTCP1456o. P1457is stored. O.RING
Replace.
Check the EVAP cont.ol canister

vent shul valve:
1. Disconnectthe vacuum hose EVAP
f r o m t h e E V A Pt h r e e w a y CONTROL
valve and connecta vacuum CANISTER
pumpto the hose.
2 . R e m o v et h e E V A Pc o n t r o l
canistervent shut valve from
tne canrster.
3. Turnthe ignitionswitchON (ll). Check for a short in the wiro
4. Applyvacuumto the hose. (VSV linel:
Disconnectthe 2P connectorfrom
t h e E V A Pc o n t r o lc a n i s t e rv e n t
Does the vaive hold vacuum?
RoDair3hort in the wire botwe€n
Doesthe valvehold vacuum? the EVAP control canilter vent
shut valve and the ECM/PCM
Check the EVAP cont.ol canister
v€nl shut valve: {A4t.
2. ConnectECM/PCMconnector Reolacethe EVAP control canis- ECM/PCMCONNECTOR
A I32PI
t e r m i n a lA 4 t o b o d y g r o u n d ter veni shut valve.
with a jumperwire.
4. Applyvacuumto the hose.
Doesthe valvehold vacuum?
(To page 11'289) lTo page11-289)
11-288
\
{Frompagel1 288} (Frompage11-288)
EVAPCONTROL
CANISTERVENT SHUT
VALVE2P CONNECTOR IC141I
Check for an open in tha wire
(lGt linol:
from the EVAPcontrolcanis- tG1
ter vent shutvalve. IBLK/WHT}
EVAPcontrolcanistervent shut
valve 2P connectorterminal Wiresideof temaleterminals
No.2 andbodyground.
ls there batteryvoltage? shut valve .nd the No. 15 ALTER-
NATORSP SENSOR{7.5A)fu3e.
CONNECTORS
ECM,/PCM
a t32P)
Ch€d( for an op€n in the wiie IVSV
linel:
2. R€connectthe 2P connector
to the EVAPcontrol canister
vent shutvalve,
\ nalsA4 and 82.
Wire sideof female

termrnats
Repairopen in the wire bctween

the EVAP control canistorvent
ls there batteryvoltage? shut valve and lhe ECM/PCM
{44t.
Rcolacotho EVAP control canis.

t6r vent shut valvo.
Ch€ckthe vac[um when cold:

1, Disconnectthe vacuum hose
shown from the EVAPcontrol ?,
T-t
canisterand connecta vacuum
gaugeto the hose.
2. Start the engineand allow it
fl
to idle. VACUUM
N O T E i E n g i n ec o o l a n tt e m PUMP/
peraturemust be below 154"F GAUGE,0 -30 in.Hg
(68'C)or Ay'Cswitch OFF. A973X-
3. Ouicklyraisethe enginespeed 0/r1- XXXXX
to 3,000rpm.
{Topage11-290)
\ (cont'd)
11-289
-Downloaded from www.Manualslib.com manuals search engine
EvaporativeEmission(EVAPIControls(cont'dl I J
(Frompage11-289)
Ch€ck the EVAP purge control
solenoidvalv6:
from the EVAPpurge control
solenoidvalve.
to 3,000rpm.
Insped vacuum hose routing.
lf OK. roplace the EVAP purge
control solonoidvalve.
EVAPPURGECONTROLSOLENOID
Chock tor r short in the wir€ VALVE2P CONNECTOR
IC114I
{PCSline): PCS
Checkthe vacuum when hot: 1. Turnthe ignitionswitchOFF. IRED/YEL)
1. Turnthe ignitionswitchOFF. 2. Disconnect ECM/PCM connec-
2. Blockthe rearwheelsand set tor A (32P).
the parkingbrake. 3- Checktor continuitybetween of
3. Jack up the lront of the vehi- the EVAPpurge controlsole- temale
cle and supportit with safety noid valve 2P connectortermi- termrnars
stands. nalNo.2 andbodyground.
4 . S t a r t t h e e n g i n e .H o l d t h e Rooairshoft in the wire belwegn
engine at 3,000rpm with no ls therecontinuity? the EVAP pulg6 control solenoid
load (in Parkor neutraliuntil valvs and tho ECM/PCM{A61.
let it idle.
5. Checkfor vacuumat the vac- Substitute a known-good ECM/
uum hose with transmission PCM and rech6ck. lt 3ymptom/
in gear (A/Tin E position, indicrtion 90e3 rway, r6plac6 th€
lvl/T in 1st gear) after starting o.iginalECM/FCM.
the engine.
to 3,000rpm. Check th€ EVAP purge control
solenoidvalve: PCS
(RED/YEL)
1. Turnthe;gnitionswitchOFF.
2. Disconnectthe 2P connector tGl
from the EVAPpurgecontrol
IBLK/
solenoid valve and warm it YEL)
up to normal operatingtem-
peratureagain if necessary.
3. Startthe engine.
4- At the harnessside, measure
v o l t a g e b e t w e e nt h e E V A P
purge control solenoidvalve
2 P c o n n e c t o tre r m i n a lN o . 1
and No.2 withthetransmis-
sion in gear {A/T in E posi-
tion, M/T in lst geari.
In3pectvacuum hoaerouting.
ls therebatteryvoltage? lf OK, repl.ce EVAP purge con-
trol solonoidvalve.
Chock for an open in the wire

(lG1lina):
At the harnossside, measurevolt-
age beNveenthe EVAPpurge con-
trol solenoidvalve 2P connector
terminalNo. 1 and bodyground.
Repairopen in the wire b€lwe€n
EVAP purge contrl 3olenoid valv6
and lhe No. 15 ALTERNATORSP
SENSOR17.5A, fu3e.
( T op a g e1 1 - 2 9 1 ) { T op a g e1 12 9 1 )
11-290
I (Frompagel1 290) (Frompage11-290)
ECM/PCMCONNECTOR

{PCSlin6):
1. Turn the ignitionswitchOFF
2. Reconnect the 2P connectorto
the EVAPpurge controlsole-

4 . M e a s ur e v o l t a g e b e t w e e n
EClr/PCMconnectorterminals
A6 and 82. Wire sideof
temale
terminals
Ropairopen in the wire between

ls there batteryvoltage? the EVAP purge Gontrolsolenoid
vrlve and th6 ECM/PCMlA6l

PCMrnd re{61. lf symptom/indi'
cation goes away, rePlacethe
oiiginal ECM/PCM.
I
Checkthe EVAPtwo way valve:
See EVAPtwo way valve test (see
p a g e1 1 - 2 9 5 ) .
Roplace the EVAP two way valve
FUEL
TANK
Checkthe EVAP bypa$ solenoid
1 . R e m o v et h e f u e l t a n k ( s e e
page11-242J.
2. LiIt up the fuel tank with a
transmissioniack,and connect
sub harness6P connectorto
the accesspanelside connec_
tor,
from the EVAPtwo way valve
and connecta vacuumPumP
to the hose,
5. Applyvacuumto the hose.
VACUUM
tn
PUMP/GAUGE,0 - 30 in Hs
A973X- 041 -
xxxxx
EVAP TWO WAY (cont'd)
(To page 11 292) VALVE
11-291
EvaporativeEmission(EVAPIGontrols(cont'd) EVAPBYPASS
SOLENOIDVALVE Y
( F r o mp a g el 1 ' 2 9 1 )
Doesthe valvehold vacuum? {2WBSlinel:
Disconnectthe 2P connector{rom
the EVAPbypasssolenoidvalve.
Repairshort in the wire between

O o e st h e v a l v e h o l d v a c u u m ? EVAP bypass solenoid velve and
rhe ECM/PCM{A3).
Checkthe EVAP bvpr$ 3olenoid
terminalA3 and body ground
with a jumper wire. Ch€ck lor an op.n in the wire
3. Turnthe ignitionswitchON (ll). llcl linol:
from the EVAP bypasssole-
Doesthe valvehold vacuum? Wire sideol femaleterminals
noid valve.
3. Turnthe ignitionswitchON (lll.
4, Measurevoltage between the
EVAP bypasssolenoidvalve EVAPSYPASSSOLENOIO
2P connectorterminal No. 1 VALVE2P CONNECTOR
IC793}
and body ground.
Wire sideof
tG1
female
{BLK/WHT) terminals
Repair open in the wir6 b€tw€€n

EVAPpurg6 control 3olanoid valve
and the No. 15 ALTERNATORSP
SENSOR{7.5A) Iuse.
{To page 11 293) (To page11 293i
11-292
I (Frompage11-292i (Frompage11 292)
Check toi an opon in the wiro

(2wBS linol:
2. Reconnectthe 2P connector
to the EVAPbypasssolenoid

43 and 82.
Chock the tollowing parts tol

leakageto aimosphero,and
ropaii or replacoif necess6.y: Reprir opan in tho wire be(wean
. fuel fill cap ls there bafteryvoltage? th. EVAP byp.is solonoid valve
. fuel tank rnd rhe EcM/PcM (A31.
. fuel v.por pipe
. EVAPtwo way valve
. EVAPbypas solonoidvalve
. tuel tank pre3suaesen3or
. EVAPcontrol cankter
. EVAPcontrol canisier veni
\ 3hut valve
. EVAP purge conttol solenoid
. ORVRvent 3hut valve

. ORVBvaoor recirculationvalve
. vacuum hoses tnd connactions
\l (cont'd)
11-293
I J
EvaporativeEmission(EVAPITwo Way Valve Testing f96 D16Y5engine,'96D16Y7engine,'96D16Y8ongine
l'96 DIGYSenginelcoupel,'97Dl6Y7 engine(coupe:KL (sedanl,'97D16Y5engine,'97Dl6Y7 engine{coupe:KA,
model,sedan:KL (LX)modoll,'97 Dl6Y8 engine{coup€: KC models, sedan: KA, KC, KL {DX} models, hatchback:
'98-all modelsll: all modsls),'97D16Y8engine{sedan:KA, KC models}l:
alt models, sedan:KL model,
1. Removethe fuel fill cap.
1. Removethe fuel fill cap,
2. R e m o v et h e v a p o r l i n e f r o m t h e E V A Pt w o w a y
valve. and connectit to a T-fittingfrom a vacuum 2. R e m o v et h e v a p o r l i n e f r o m t h e E V A Pt w o w a y
gaugeand a vacuumpump as shown. 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 e a n d a v a c u u m p u m p a s
VACUUM/PRESSURE snown.
GAUGE VACUUM/
0- 4 in.Hg PRESSURE GAUGE,
0 - 4 in.Hg
07JAZ- 0010008
VACUUM
PUMP/GAUGE.
0 -30 in.Hg
A 9 7 3 X - 0 4 1- X X X X X
T-FITTING
T-FITTING
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
'l'
Apply vacuumslowly and continuously while watch-
ing the gauge.The vacuumshouldstabilizemomen- watching the gauge.The vacuum should stabilize
tarilyat 0.8- 2.1kPa(6 - 16 mmHg,0.2- 0.6in.Hg). momentarilyat 0.7- 2.0 kPa(5 - 15 mmHg,0.2- 0.6
l f t h e v a c u u m s t a b i l i z e s( v a l v e o p e n s ) b e l o w i n . H g) .
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 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
(16 mmHg,0.6 in.Hg),installa new valveand retest. 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. Move the vacuum pump hose from the vacuumfit-
ting to the pressurefitting, and move the vacuum Move the vacuum pump hose from the vacuumfit-
gauge hose from the vacuum side to the pressure ting to the pressurefitting, and move the vacuum
sideas shown. gauge hose from the vacuum side to the pressure
sideas shown.
PRESSURE
SIDE
Slowly pressurize the vapor line while watchingthe

5. Slowlv pressurize the vapor line while watchingthe gauge.The pressureshouldstabilizeat 1.3- 4.7 kPa
gauge.The pressureshouldbe stabilizemomentari ( 0 - 3 5 m m H g ,0 . 4- 1 . 4i n . H g ) .
l y a b o v e 1 . 0k P a( 8 m m H g .0 . 3i n . H g ) . . I t t h e p r e s s u r em o m e n t a r i l ys t a b i l i z e s( v a l v e
. l f t h e p r e s s u r em o m e n t a r i l ys t a b i l i z e s( v a l v e o p e n s )a t 1 . 3- 4 . 7 k P a( 1 0- 3 5 m m H g ,0 . 4- 1 . 4
' 1 . 0k P a ( 8 m m H g ,0 . 3 i n . H g ) t, h e in. Hg),the valveis OK.
o p e n s )a b o v e
valveis OK. . lf the pressurestabilizes below1.3kPa(10 mmHg,
. lf the pressurestabilizesbelow 1.0kPa(8 mmHg, 0.4 in.Hg)or above4.7 kPa(35 mmHg. 1.4 in.Hg),
\,
0.3 in.Hg),installa new valveand retest. installa new valve and retest.
11-294
\
EvaporativeEmission(EvAPl Two Way Valve T6ting 5. Slowly pressurize the vapor lin€ while watchingthe
gauge.
'99 - 00 modols: T h e p r e s s u r es h o u l d b e s t a b i l i z em o m e n t a r i l y
above1.0kPa(8 mmHg,0.3 in.Hg).
'L Removethe fuel tank (seepage 11-242). . 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)above 1.0 kPa (8 mmHg, 0.3 in.Hg),the
2. Remove the vapor line {rom the EVAP two way valveis OK.
valve(locatedabovethe EVAPcontrolcanister),and . ll the pressurestabilizesbelow 1.0kPa(8 mmH9,
connect it to a T-fitting from vacuum gauge and 0,3 in,Hg),installa new valveand retsst.
vacuumpumo as snown,
VACUUM/PRESSURE
GAUGE
0 - il in.Hg
07JAZ- 001(x)08
r y ( L
T.FITTING
"*'"""_,";f1
GAUGE,0- 30 in.Hg
4973X - (Xl -
xxxxx
J. Apply vacuumslowlyand continuouslywhile watch-
ing the gauge.
The vacuum should stabilizemomentarilyat 0.8 -
2.1kPa{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
(16mmHg,0.6 in.Hg),installa nsw valveand retest.
Move the vacuum pump hosefrom the vacuumfit-

ting to the pressurefitting, and move the vacuum
gauge hose from the vacuum side to the pressure
sideas shown.
(cont'd)
11-295
EvaporativeEmission(EVAP)Controls(cont'dl
ORVRVent Shut Valve Test Vatve Tcst
Float Test 1. Makesurethe fueltankis lessthanhalffull.
1. Makesurethe fuel tank is lessthan halffull. 2. Removethe fuelfill cap.
2. Removethe fuel fill cap to relievethe fuel tank pres- 3. Removethe fuel hose joint protector.Disconnectthe
sure,then reinstallthe cap. ORVRsignalhose.
3. Removethe fuel hose joint protector.Disconnect

ORVR
the ORVRvapor recirculationhose, and connecta SIGNAL
vacuumpump to the vaporrecirculationhose. HOSE
ORVRVAPOE
RECIRCULATION
VACUUM PUMP/
GAUGE,0- 30 in.H9
A973X- 041 -
xxxxx
Disconnectthe vacuum hose from the EVAPcontrol

andthen plugthe portwith a plug.
canister.
VACUUM
PUMP/GAUGE,
0 - 30 in,Hg
A973X-041-XXXXX
4. Plugthe hoseport.
A p p l y v a c u u m t o t h e O R V Rv a p o r r e c i r c u l a t i o n
nose.
. lf the vacuumholds,replacethe ORVRvent shut
valve{seepage 11-297).
. lf the vacuumdoesnot hold,the float is OK. CONTROL
CANISTER
VENT SHUT
VALVE
Disconnectthe vacuum hose from the EVAPcontrol

canistervent shut valve,and connecta vacuum pump
to the vacuumhose,
Pumpthe vacuumpump 80 times.

. lf the vacuumholds,go to step7,
. lf thevacuumdoesnot hold,goto step9.
11-296
\
7. Connecta secondvacuumpump to the OBVRsignal ORVRVent Shut Valve Replacement
nose.
1. Removethe fueltank(seepage11-242).
2. Removethe ORVRventshutvalvefrom the fueltank.

VACUUM PUMP/
GAUGE.0- 30 in.Hg 3. lnstalloarts in the reverseorder of removal.
A973X- 041 -
xxxxx
Apply vacuum (1 pump) to the ORVRsignal hose,

then checkthe vacuumon the pump in step6.
. lf the vacuumholds,replacethe ORVRvent shut
valve.
. lf the vacuum is released,the ORVRvent shut
valve is OK.
Disconnectthe ORVRquickdisconnectfrom the EVAP

canister,then plug the port on the canister.
Reapplyvacuum(80pumps).
. lf the vacuumholds,reDlacethe ORVRvent shut
valve,
. lf the vacuum does not hold, inspectthe EVAPcan-
ister vent shut valve O-ring.lf the O-ring is OK,
replacethe EVAPcanisterand repeatstep 4.
11-297
I
J
Transaxle
cf utch .""""" 12'1
13-1
............"'.'..".'...'.
ManualTransmission
........
AutomaticTransmission " ". 14-1
"........
Differential ...15-1
Driveshafts ." 16-1

J
Clutch
Speciaf Tools.......... ...........12-2
flfustratedIndex.......... ......12-3
clutch Pedal
Adjustment 12'4
....................
ClutchMasterCylinder
Removal/lnstallation .....12-5
SlaveCylinder
Removal/lnstallation .....12'6
PressurePlate
t Removal/lnspection ......12-7
ClutchDisc
Removal/lnspection ......12-8
Flywheel
Inspection 12-9
.......................
Replacement 12-9
.......................................
ClutchDisc,PressurePlate
lnstallation 12-10
.....................
ReleaseBearing
Removal/lnspection ......12-11
fnstalfation 12-12
.................,...

SpecialTools
I t J
Ref. No. Tool Number Description Oty PageReterence
o O T J A_FP M 7 O 1 1 A
_ PM70124
ClutchAlignmentDisc 12-7
\31 OTJAF ClutchAlignmentShaft 12-7, 8 , 1 0 ,1 1
( 't2-7,9,10,11
07LAB- PV00100 or RingGearHolder
07924,PD20003
@ 07746 - 0010100 Attachment,32 x 35 mm 1 21 0
07749- 00' ]0000 Driver 12-'tO
!o/ 0 7 9 3-6 3 7 1 0 1 0 0 H a n dl e 1 2 - ,18 , 1 0 ,1 1
(r\ U a
2-2
lllustrated Index
\
NOTE:
. Wheneverthe transmissionis removed,cleanand greasethe releasebearingslidingsurface
. lf the partsmarkedwith an asterisk(*) are removed,the clutchhydraulicsystemmustbe bled (seepage12-6)
. Inspectthe hosesfor damage,leaks,interference, and twisting
'RESERVOIFTANK
ASSISTSPRING
LOCKPIN
5x1,0mm
9.8 N.m (1.0kgf.m,
*CLUTCHLINE 7.2 tbtftl
15 N.m {1.5kgJm,
11 tbt.ft)
*CLUTCHMASTERCYLINDER
page12 5
Removal/lnstallation,
RELEASEBEARING
page12-11
Removal/lnspection,
page12-'12
Installation,
FLYWHEEL
I n s p e c t a opna,g e1 2 I
Replacement, Page12-9
CLUTCHDISC
page12-8
Removal/lnspection,
page12-'10
lnstallation,
'12x 1.0mm
118N.m {12.0kgt'm,86.8lbfft)
PBESSURE PLATE
page12 7
Bemoval/lnspection,
page12''10
Installation,
6x1.0mm
9.8 N.m (1.0kgf.m,
7.2 tbf.ft)
8 x 1.25mm
22 N m (2.2kgf.m, 16lbf ft)
ISLAVE CYLINDER
page12_6
12-3
Glutch Pedal
Adjustment
J
NOTE: 5 . T u r nt h e c l u t c hs w i t c h( o r a d j u s t i n gb o l t )i n a n a d d i -
. T o c h e c kt 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 tional3/4to 1 full turn.
switch,seesection23.
. The clutchis self-adjusting to compensatefor wear. TightenlocknutA.
CAUTION:lf there is no clearancebetween the mas- 7 . LoosenlocknutB on the clutchinterlockswitch.

ter cylinder pislon and push rod, the releasebearing
is held against the diaphragm spring, which can 8 . Measurethe clearancebetweenthe floor boardand
result in clutch slippage01other clutch problems. clutchpedalwith the clutchpedalfully depressed.
1. LoosenlocknutA, and backoff the clutchswitch(or 9 . Releasethe clutchpedal 15 - 20 mm {0.59- 0.79in)

adjustingbolt) until it no longertouchesthe clutch from the fully depressedpositionand hold it there.
peoar. Adjustthe positionof the clutchinterlockswitchso
t h a t t h e e n g i n ew i l l s t a r tw i t h t h e c l u t c hp e d a li n
2. LoosenlocknutC, and turn the push rod in or out to t h i sp o s i t i o n .
get the specifiedstroke {@} and height (@) at tne
c l u t c hp e d a l . 1 0 . Threadthe clutch interlockswitch an additionalin
3/4to 1 full turn.
3. TightenlocknutC.
'lL
TightenlocknutB.
4. Threadin the clutchswitch {or adiustingbolt) until
it contactsthe clutchpedal.
ASSIST SPRING
-Atl
9002) LOCKNUTB
9 . 8 N . m ( 1 . 0 k 9 1 . m , 7 . 2l b t . t t )
INTERLOCKSWITCI{
CLUTCH SWITCH
lo. ADJUSTING BOLTI
LOCKNUTA
9.8 N'm (1.0 kgI.m, 7.2 lbf,ft)
LOCKNUTC
18 N.m {1.8kql.m,13lbf.ft}
@ ( S T R O KaEt P E D A L )1:3 0- 1 4 0m m ( 5 . 1 2- 5 . 5 1i n )
@ (TOTALCLUTCHPEDALFREEPTAYI:12- 21 mm (0.47- 0.83in) includethepedalplay 1 10 mm (0.04- 0.39in)
(CLUTCH PEDALHEIGHT): ' ]65mm
@ {6.50in) to the floor
@ (CLUTCP H E D A LD I S E N G A G E M EH NE T I G H T8) :3 m m ( 3 . 2 7i n ) m i n i m u mt o t h e f l o o r
12-4
Glutch Master Gylinder
I RemovaUlnstallation
4. Removethe clutchmastercylinder.
CAU'NON:
. Do not sDillbrakelluid onthevehicle;it may damage
the paint; if brake fluid does contact the paint, wash
it off immediatelYwith water.
. Plug the end ofthe clutch line and reservoirhos€ with
a shop towelto preventbraketluid from coming out
1 . T h e b r a k et l u i d c a n b e r e m o v e df r o m t h e c l u t c h
mastercylinderreservoirwith a syringe
2. Disconnectthe clutch line and reservoirhose from

the clutchmastercylinder.
CLUTCHLINE
1 9 N . m1 1 . 9k g f . m ,
14 tbf.ttl
CYLINDER
MASTER
CLUTCH
l 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,
[.
3. Pry out the lock pin, and pull the pedal pin out of
the yoke.Removethe nuts
NUTS
8 x 1.25 mm
13 N.m {'1.3kgt.m,9.4lbfft)
iffi,
12-5
Slave Gylinder
Removal/lnstallation
CAUTION: 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 f
. Do not spill brake tluid on the vehicle;it may damage removal.
the paint; if brake fluid does contact th€ paint, wash
it off immodiatoly with water, NOTE:Makesure the boot is installedon the slave
. Plug the end ot the clutch line with a shop towel to cvlinder.
.
prevsnt brakefluid from coming oul. CLUTCH LINE
15 N.m (1.5 kgf.m,11 lbf.It)
-61'srp", High Temp Urea crease(p/N
08798- 90021.
: BrakeAssembly Lube or equivalentrubber SLAVECYLINDER
grease.
1. Disconnect
the clutchlinefrom the slavecvlinder.
-G4
(P/N08798- 90021
8 x 1.25mm
22 N.m 12.2 kgl.n,
16 lbl.lt)
:^. :l
.:i!!!!!
(Brak€Assembly
Lubol
Bleedthe clutchhydraulicsystem.
a 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
done.
. Always use GenuineHonda DOT 3 BrakeFluid.
2. Removethe slavecylinderfrom the clutchhousing. Using a non-Hondabrakefluid can causecorro-
sion and decreasethe life of the system.
. Confirmclutch operation,and checkfor leaking
fluid.
12-6
PressurePlate
Removal/lnsPection
\
1 . Inspectthe fingersof the diaphragmspringfor wear lnspectthe pressureplate surfacefor wear' cracks,
at the releasebearingcontactarea. a n db u r n i n g .
Checkthe diaphragmspringfingersfor heightusing Inspectfor warpageusinga straightedgeand leeler

the specialtools and a feelergauge. g au g e .
Standard{New}:0.6 mm (0.02inl max. NOTErMeasureacrossthe pressureplate at three

SeruiceLimit: 1.0 mm {0.04in} pornrs.
FEELER
GAUGE
Standard (Newl: 0.03 mm (0.001inl max.
STBAIGHTEDGE
CLUTCH ALIGNMENT DISC

OTJAF_PM7O11A
CLUTCH ALIGNMENT SHAFT
OTJAF-PM7012A
HANDLE
07936-37tOtOO
lf the height exceedsthe servicelimit, replacethe
pressurePlate.
3. Installthespecialtools
PLATE
PRESSURE
MOUNTING
BOLT
lf the warpageexceedsthe servicelimit, replacethe

pressureplate.
ALIGNMENTSHAFT
OTJAF-PM7012A
07LA8-PVOOIOO HANDLE
ot 07936-371010O
o7924-PD20003
GEARHOLDER
ENGINE
BLOCK
BOLT
ADJUSTER
BOLT
4. To prevent warping, unscrew the pressure plate

\rf m o u n t i n gb o l t s i n a c r i s s c r o s sp a t t e r ni n s e v e r a l
steps,then removethe pressureplate.
12-7
Clutch Disc
RemovaUlnspection
U
'1.
Removethe clutchdiscand specialtools. 4. M e a s u r et h e d e p t hf r o m t h e l i n i n gs u r f a c et o t h e
rivets,on both sides.
Rivet Depth:
CLUTCH
StandardlNewl: 1.3- 1.9mm {0.05- 0.07in} min.
CLUTCH DISC
CLUTCH ALIGNMENTSHAFT
oTJAF-pM7012A
xltori
07936-3710100
2. Inspectlining of the clutchdiscfor signsof slipping

or oil. lf it is burnedblackor oil soaked,replaceit.
Measurethe clutchdiscthickness.
Clulch DiscThickness:
Standard(Now):8.5- 9.1 mm (0.33- 0.36in)
Servic€Limit: 5.5 mm (0.22inl
CLUTCH
lf the depth is lessthan the servicelimit, replacethe

clutchdisc.
lf the thickness is less than the service limit. .eolace

the clutch disc.
12-8
Flywheel
\
1 . Inspectthe ring gearteethfor wear and damage 1. Installthespecialtool.
2. I n s p e c t h e c l u t c h d i s c m a t i n g s u r f a c eo n t h e
FLYWHEEL
flywheelfor wear,cracks,and burning.
3. Measurethe flywheelrunout using a dial indicator

t h r o u g h a t l e a s tt w o f u l l t u r n s P u s h a g a i n s tt h e
f l y w h e e le a c ht i m e y o u t u r n i t t o t a k e u p t h e
crankshaftthrustwasherclearance.
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
t\
installed.
Standard (New): 0.05 mm (0.002inl max.

ServiceLimit: 0.15mm {0.006in)
m\J
FLYWHEEL
MOUNTING
BOLTS
RITIGGEAR HOLDER
oTLAB-PV00100
ot
o7924-PD20003
I J 2. Removethe flywheelmountingbolts in a crisscross

patternin severalstepsas shown, and removethe
OIAL INOICATOR
flywheel,
lf the runout exceedsthe servicelimit. replacethe
flywheel. Removethe ball bearingfrom the flywheel
4. Turn the inner raceo{ the ball bearingwith your tin-

ger. The ball bearingshouldturn smoothlyand qui
etly. lf the inner race does not turn smoothly and
q u i e t l y ,r e p l a c et h e b e a r i n g .C h e c kt h a t t h e b a l l
bearingouter racefits tightly in the flywheel.lf it is
loose.replacethe ball bearing
FLYWHEEL
\ tO BALL BEARING (cont'dl
12-9
Flywheel Clutch Disc,PressurePlate
(cont'dl
Replacement Installation
Y
4. Drivethe new ball bearinginto the flywheel using 1. I n s t a ltlh e s p e c i atlo o l .
the specialtools as shown.
DRIVER
07749-0010000
CLUTCH DISC
07936-3710r00
ATTACHMENT,
32x35mm
07746-OOIOTOO
FLYWHEEL
{P/N08798-90021
RINGGEARHOLDER
07LAB-PVOO100
ot CLUTCHALIGNMENTSHAFT
07924-PD20003 OTJAF_PM7012A
BEARING
5. Align the hole in the flywheel with the crankshaft 2. Installtheclutchdisc usingthe specialtools.
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-ti9ht. 3. Installthe pressureplate.
6. Installspecialtool, then torquethe flywheelmount-

ing bolts in a crisscrosspatternin severalstepsas
snown.
MOUNTING BOLTS
1 1 8N . m ( 1 2 . 0k g l . m ,
87 tbf.ft)
WV
a// ,
RING GEAR HOLDER OTJAF_PM70124

oTLAB PV00'l OO HANOLE
07936-3710100
07924 PD20003
RINGGEARHOLDER
07LAB-PV00100
ol
07924 -PO20003
12-10
ReleaseBearing
Removal/lnspection
)
1. Removethe releasefork boot from the clutchhous-
4. Torquethe mountingbolts in a crisscrosspatternas
Ing.
s h o w n .T i g h t e nt h e m i n s e v e r a sl t e p st o p r e v e n t
warpingthe diaPhragmsPring.
2. Removethe releasefork from the clutchhousingby
squeezingthe releasefork set spring with pliers
Removethe releasebearing.
MOUNTING BOLTS
8 x 1.25mm
25 N.m (2.6 kgl'm. 19 rbf.ft)
RELEASEFORK
\ Checkthe releasebearingfor play by spinningit by

hand.
CAUTION: The releass bearing is packed with

grease.Do not wash it in solvent.
RINGGEARHOLDER CLUTCH ALIGNMENTSHAFT

oTLAB-PV00100 OTJAF_PM7O12A
ot HANOLE
07924-PD20003 07936-3710100
lf there is excessiveplay, replacethe releasebear-

ing with a new one.
12-11
ReleaseBearing
Installation
I J
NOTE:Use only Super High Temp Urea Grease 3. Move the releasefork right and left to make sure
(P/N08798- 9002). that it fits properlyagainstthe releasebearing,and
that the releasebearingslidessmoothly.
1. With the releasefork slid betweenthe releasebear-
ing pawls, installthe releasebearingon the main-
s 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 ef o r k t h r o u g ht h e
h o l ei n t h e c l u t c hh o u s i n g .
RELEASEFORKBOLT
1 2 x ' l. 2 5 m m
-Gr
08798-9002)
4. Install the releasefork boot; make sure the boot

sealsaroundthe releasefork and clutchhousino.
tP/N0a79a-90021
O . 3 - 0 . 9s 1 0 . 0 -1O . 0 3 o z l
2. 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 sequarely.
12-12
J
ManualTransmission
S40 Model
(All except'99- 00 2-doorSi' SiR)
. . . . . " . . . . . . ' . ' . . " . . .1. .3"-. 1
M a n u a lT r a n s m i s s i o n
S4C Model ('99 - 00 2-door Si, SiRl
. . . . . . . . . . . . . . . . . . . . .1. .3. -. 4
M a n u a lT r a n s m i s s i o n . .5'
\ ta

S40Model (All except'99- 00 2-doorSi' SiR)
ManualTransmission
SpecialTools 13-2
..'.......... Shift Fork AssemblY
Maintenance lndex ............... ."'...13-25
13-3
Oil .............................. Clearance 13'26
lnspection."......."........'..
Transmission
MBS Shift PieceInspection....-.....'.. 13'27
Back-upLight Switch
Replacement .........13-3 Synchro Sleeve,Synchro Hub
Troubleshooting '.......13-4 ".... 13'27
fnspection/lnstallation.......'......
TransmissionAssemblY SynchroRing,Gear
13-5
................. Inspection 13'28
'....'.."....
Removal
lnstallation 13-8
............. Shift Rod
13-10
lllustratedIndex ...............'........."........ Removal .'......"."""13'29
TransmissionHousing Differential
Removaf .."""""""' 13-12 lndex ......."'...... .'."' 13-30
I
\ J R"rr"r"" Shift Holder 13-30
BacklashInspection..........."......."...
13-13
lnspection....................... 13'31
BearingBeplacement'.............'."....
Clearance
Reverseldler Gear FinalDrivenGear Replacement'.....13-31
13-14
....'.........." 13-32
Thrust Shim Adiustment ..."...........
Removal
Mainshaft, Countershaft, Shift Fork Clutch HousingBearing
Disassembly 13-14
......'... Replacement .......'.13-34
MainshaftAcsemblY MainshaftThrust Shim
Index ............... .......13-15 Adiustment '....'.."..13-36
Clearance 13-16
Inspection..'.................... Transmission
Disassembly 13-17
.......... Reassembly 13-39
...........
Inspection 13-18
....'......... Oil Seals
Reassembly 13-19
........... Replacement .........13-43
Countershaft AssemblY GearshiftMechanism
......13-20 Overhaul 13-44
................
lndex ................
Clearance 13-21
lnspection."..........'......."
Disassembly ..."""' 13-22
Inspection 13-23
..............
Reassembly ..'.""...13-23

SpecialTools
ly tr
Ref. No. I Tool Numbet Description (Xy PageReference
I
o OTGAJ PG2O11O MainshaftHolder 1 13-38
@ OTGAJ PG2012O C ol l ar 1 13-37
o
.@
07GAJ- PG20130 MainshaftBase 1
I 13-37
07736- A010004 AdjustableBearingPuller,25 - 40 mm 1 13-34,35
!'5, 07746- 0010300 Attachment.42 x 47 mm 1 13-34.35
@ 07746- 0010400 Attachment,52x 55 mm 1 13-34,35
o 07746- 0030100 Driver,40 mm LD. 1
|
13-19,24
31,32
@ 07746- 0030300 Attachment,30 mm I.D. 1 13-19,24
6 07746- 0030400 Attachment,3Smm LD. 1 13-19,24
@ 07749- 0010000 Driver r t3-34,35,
43
@ 0 7 J A D- P H 8 0 1 0 1 DriverAttachment
I
1 13-43
@ 07JAD- PH80200 Pilot.26 x 30 mm 1 13,43
(3 0 7 9 4 7- 6 1 1 0 5 0o1r SealDriverAttachment 1 I 13-43
07947- 6110500
* Must be usedwith commercially-available
3/8"-j6 SlideHammer.
I o aa al v I
\91 o
ai
f!

Maintenance Back-upLight Switch
Oil
Transmission Replacement
NOTE:Checkthe transmissionoil with the engine OFF NOTE:To testthe back-uplight switch,seesection23
a n dt h e v e h i c l eo n l e v e lg r o u n d .
1. Disconnect the connector,then removethe back-up
1. Removethe oil filler plug, then checkthe level and light swirchconnectorfrom the connectorclamp.
conditionof the oil.
2. Removethe back-uplight switch.
OILFILLER PLUG
/14N.m (4.5 kgl.m,33 lbl.ft)
ProperLevel
WASHER
Replace.
T h e o i l l e v e lm u s t b e u p t o t h e f i l l e r h o l e .l f i t i s
below the hole, add oil until it runs out. then rein-
stallthe oil filler plug with a new washer.
lf the transmissionoil is dirty, removethe drain plug

a n dd r a i nt h e o i l .
4. the drainplug with a new washer,and refill

Reinstall ASHER
the transmissionwith the recommendedoil to the 25 N.m (2.5 kgf'm, 18lbf'ltl
properlever.
NOTE:The drain plug washershouldbe replacedat Installthe new washerand back-uplight switch
\ everyoil change.
Connectthe back-uplight switchconnector.
the oil filler plug with a new washer.
Reinstall
OilCapacity
1.8f (1.9US qt. 1.6lmp qtl at oil change
1.9{ (2.0US $, 1.7lmp qt) at overhaul
A l w a y su s e G e n u i n eH o n d aM a n u a lT r a n s m i s s i o n
Fluid {MTF).Using motor oil can causestiffershift-
i n g b e c a u s ei t d o e s n o t c o n t a i nt h e p r o p e ra d d i -
t|ves.
13-3
Troubleshooting
ReverseGearNoiseReductionSystem
-
Wheneverthe clutchpedalis depressedto shift into reverse,the mainshaftcontinuesto rotatebecauseof its inertia.
The resultingspeeddifferencebetweenmainshaftand reverseidlergear producesgear noise.
The reversegear noisereductionsystememploysa cam platewhich was addedto the reverseshift holder.When shifting
shjft piece,connectedto the shift lever,rotatesthe cam plate.This causesthe sth synchroset
into reverse,the sth/reverse
to stop the rotatingmainshaft.As there is no speeddifferencebetweenmainshaftand reverseidler gear,therewill be less
gear norse.
NOTE:This systemis not a fully-synchronized gear noisereductionsystem.

Therefore,you may heargear noisewhen
O you shift into reversewith the vehiclenot yet completelystopped.
@ you shift quicklyinto reverseduringfast idling.
Gear noise is oresent when shift-

ing into reverce after the engine
is started.
T e s t - d r i v et h e v e h i c l e .
ls the gearnoisepresentwhen Beplacethe 5th synchro hub and

shiftinginto 5th gear? 3leevee3 a set,
Measurethe clearancebetween
5th shift fork and 5th synchro
sleeve{seepage13'26).
1.0mm (0.04
ls the clearance
in) or less?
Measurethe MBS shift piecepin

(seepage13-27).
ls ( 6.8mm (0.27in) or more? Replacethe MBS shift piece.
ReDlace the reve6e ahift hold.r.
13-4
TransmissionAssembly
Removal
I 6. Disconnectthe vehiclespeedsensor(VSS)connec-
@
. Make sure iacks and safety stands are placed prop€dy, ror.
and hoist brackets are atlach€d to correct position on
the enginc. vss
. Apply parking brake and block rear whosls so car will CONNECTOR
nol roll olf stands and lall on you while working under
it.
CAUTION:Use fender coversto svoid damaging painted

surfaces.
1. Disconnect the negative{-) cablefirst,then the pos-

itive (+) cable from the battery'
Draintransmissionoil {seepage 13-3).
Removethe intakeair tube. intakeair duct and air

cleanerhousingassembly(seesection5).
Disconnectthe starter motor cables,transmission

groundwire and back-uplight switchconnector.
7. Removethe clutch line bracket,clutch line clamp,

6x1.0mm BACK-UPLIGHT and slavecvlinder.
9.8 N.m (1.0 ksf.m,7.2 lbI.ft) swlTcH CoNNECTOR
CAUTION:
. Do not opsr.te tho clutdh pedal once the 3lavc
\ cylindor has b6on romoved.
. Tske care not to bend tha clutch lin6.
ARTER
8 x 1. 2 5 m m
8.8 N.m {0.9kgt.m,6.5 lbf.ftl
5. Removethe wire harnessclamps.
(cont'd)
13-5
Removal(cont'dl
v
8. Removethe driveshafts(seesection161. '10. Remove
the shift rod and extensionrod.
NOTE:Coat all the precisionfinishedsurfaceswith

cleanengineoil or grease.Tie plasticbags over the
SI'IIFT
BOD
driveshaftends,
SET RING
10 x 1.25mrn
43 N.m 14.4 kgt.m,
DRIVESHAFT 32 rbf.frl
8x22mm
SPRINGPIN
Replace.
f-
EXTENSIONROD
PIN PUNCH,8.O mm
(Commercially
available)
'1'1.
Removethe enginestiffenersand clutchcover.
D16Y5,D16Y8engines:
COTTERPIN
10 x 1.25mm I x 1.25mm
Replace. SELF 24 N.m (2.4 kgf.m
1 2 x 1 . 2 5m m 44 N.m (4.5 kgt.m,
Replace. 33 tbf.tr) 17 lbt.frl
4 9 - 5 9 N . m ( 5 . 0- 6 . 0 k g t . m , 1 2 x 1 . 2 5 m m
36-43 lbf.ft) 64 N.m {6.5 kgt.m,47 lbf.tr)
9. Remove exhaust pipe A.

GASKETS
Replace.
COVER
IF\
sELF-LocKtNGNUT.''1/ EXHAUST
Replace. PIPEA
8 x 1.25mm SELF-LOCKING NUT
16 N.m {1.6kgf'm, Replace.
12 tbf.ft) D16Y5, D16Y7 engines:
SELF-LOCKING NUT
Replace. 8 x 1.25mm
33 N.m {3.4 kgf.m,25 lbt.ft) 24 N.m 12.4 kgf'tn,
I x 1.25mm D16YB engine:
22 N.m (2.2 kgf.m, 1 0 x 1 . 2 5m m 17 tbt.tr)
16 tbt'fr) 54 N.m 15.5 kgl'm,40 lbf.ttl
13-6
D16Y7engine: 14. Removethe rightfront mounvbracket.
'lOx 'l.25mm
44 N'm (4.5 kgl.m,
33 rbf.frl
8 x 1.25mm
24 N.m {2.4 kgl.m,
ENGINE
STIFFENER
1 0 X 1 . 2 5m m
It4 N'm (4.5 kqf'm,33 lbf'ltl
12. Installthe bolts in the cylinder head and attach a Replace.

chain hoist to the bolts,then lift the engineslightly 1 2 x 1 . 2 5m m
to unloadthe engineand transmissionmounts. 64 N.m t6.5 kgf.m,47 lbf'ft)
CHAINHOIST
Placea jack underthe transmission.
\ 1 6 . Removethe transmissionmount bracketand mount.
TRANSMISSION TRANSMISSION
MOUNT BRACKET
13. Removethe sDlashshield,
SPLASH SHIELD
(cont'd)
13-7
Removal(cont'd) Installation J
1 7 . R e m o v et h e t h r e e u p p e r t r a n s m i s s i o nm o u n t i n g Installthe transmissionassemblyin the reverseorderof
boltsand the lowerstartermountingbolt, removal.
Beforeinstalling,checkthat the two dowel pins are

installedin the clutchhousing.
When installingthe startercable,make sure that the
crimped side of the ring terminal is facing out (see
section23).
Apply greaseto the parts as shown, then installthe
releasefork and releasebearing,
NOTE: Use only Super High Temp Urea Grease

(P/N 08798- 9002).
STARTER RELEASEFORK BOLT

MOUNTING TRANSMISSION 1 2 x 1 . 2 5m m (P/N08798-90021
BOLT MOUI{TING EOLTS 29 N'm 13.0 kgt,m,
1 0 x 1 . 2 5m m 22 tbl.ttl R€LEASE
1 2 x 1 . 2 5m m BEARING
44 N.m (4.5 kgf.m, & N.m (6.5 kgt'm,47 lbl.ftl
33 rbnftl
RELEASE
18. Removethe rear mount bracketbolts and transmis- FORK
sion mountingbolts. 8()07
r a
SPECIALBOLT
Replace.
'll x 1.5mm
1 2 x 1 . 2 5m m 84 N.m (8.5 kgf.m,61 lbf.ftl
64 N.ft 16.5 kgl.m,47 lbl.ftl
{PiN 08798-9002)
tP/N08798-90021
0.3-0.9 g
1 0 . 0 1 - 0 . 0 3o z l
REAR
WASI{ER MOUNT
SPECIALBOLT BRACKET
Replace.
14 x 1,5 mln
84 N.m (8.5 kgl.m, 61 rbl.ftt
1(| Pull the transmissionaway from the engineuntil it

clearsthe mainshaft.then lower it on the transmis-
sion jack.
CAUTION: Take caro not to b6nd tho clutch lin€.

. Torque the mounting bolt and nuts in the sequence . Apply greaseto the slavecylinderpush rod.
shown.
'l.25 mm NOTE: Use only Super High Temp Urea Grease
O 12 x 1.25mm O) 12 x
64 N.m {6.5 kgt.m, {P/N08798- 9002}.
64 N.m 16.5kgl.m,
47 lbf.fr) 47 tbt.ft) 6 x 1.0mm
9.8 N.m (1.0kgl.m.
7.2 tbf.tr)
CLUTCH 8 x 1.25mm
@ 1 2 x 1 . 2 5m m UNE -6tl 22 N.m 12.2 kgl.n.
(P/N08798-9002) 16 tbf.frl
74 N.m (7.5 kgl'm,
54 tbt.fr) "F" mark points at
. Turn the breathercap so that the
a Check that the bushings are not twisted or offset. the front of the car as shown.
I a Install the clip as shown.
8 x 1.25mm FRONT
SHIFTROD
N.m t2.2 kgt.m, l6 lbl'tt)
Refill the transmissionwith the recommendedoil

(seepage 13-3).
Connectthe positive (+) cable first, then the negative
(-) cable to the battery.
a Checkthe clutchoDeration,
a Shift the transmissionand checkfor smooth opera-
tion.
a Turn the boot so the hole is facingdown. Checkthe front wheelalignment(seesection18).
a Makesurethe boot is installedon the shift rod.
13-9
lllustrated lndex
!
Referto the drawingbelowfor transmissiondisassembly/reassembly,
Cleanall the partsthoroughlyin solventand dry with compressedair.
luuricateattthepartswithoil beforereassembty.
I
NOTE:
. Thistransmissionusesno gasketsbetvveen the majorhousings;useliquidgasket(PiN08718-0001or08718-0003)
(seepage 13-41).
. Alwayscleanthe magnet@ wheneverthe transmissionhousingis disassembled.
. Inspectall the bearingsfor wear and operation.
a6_
'%/t'*.
k+-o
-{-g}.-_a
13-10
TorqueValue
A - 15 N.m (1.5kgf.m,1'1lbf.ft)
B - 27 N.m (2.8kgf.m.20 lbift)
C - 31 N.m {3.2kgnm,23 lbift)
O BALLBEARING(*T) @ 3RD//|THSHIFTFORK @ 72 mm THRUSTSHIMl*11

ANGULAR @ 5TH/REVERSE SHIFTFORK 80 mm THRUSTSHIM(*21
'13-33
BALL BEARING{*2I @ 52 mm SNAPRING Selection,page
O 5THSYNCHRO HUB @ 65 mm THRUSTSHIM(*11 @ DIFFERENTIAL ASSEMBLY
O 5TH SYNCHROSLEEVE 70 mm THRUSTSHIM(*21 Seepage 13-30
€) SYNCHROSPRING Selection,page 13-36 @ 14 x 25 x 17.5mm OILSEAL
o SYNCHRO B|NG @ OIL GUIDEPLATE Replace.
@ 5TH GEAR @ wASHERReplace. @ 35 x 56 x 8 mm OILSEAL
@ gz xgt x 23.5mm @ BACK.UPLIGHTSWITCH Replace.
NEEDLEBEARING 25 N.m (2.5 kgf'm, 18 lbf'ft) @ SHIFTROD
@ SPACERCOLLAR @ sET SCREW @ BOOr
@34x39x23mm 22 N.m {2.2 kgf.m, 16 lbl.ft} @ OILGUIDEPLATE
NEEDLEBEARING @ WASHERReplace. @ 3 0 x 4 7 x 2 1m m
(D 4TH GEAR 1 . 3 1 . 6m m ( 1 . 2 , 1 i n l
@ DS P R I N G NEEDLEBEARING(* 1}
O SYNCHRORING @ STEELBALL15/16in) 3 0 x 5 5 x 2 1m m
C) SYNCHROSPRING @ BACK-UPLIGHT NEEDLEBEARING {'2)
CO3RD/4THSYNCHROSLEEVE SWITCHHARNESSBRACKET @ COUNTERSHAFT
@ 3RD/4THSYNCHRO HUB @ TRANSMISSION HANGER @ 3 6 x 4 1 x 2 5 . 5m m
(} 3RD GEAR @ 32 MM SEALINGBOLT NEEDLEBEARING
@34x39x27.5mm 25 N.m (2.5 kgf.m, 18 lbt'ft) Checkfor wear and
NEEDLEBEARING @ OIL SEAL operatron.
\ G) MAINSHAFT Replace. @ lsT GEAR
G) WASHER @ OILDRAINPLUG @ FRICTIONDAMPER
@ SPRINGWASHER 39 N.m (4.0 kgf.m, 29 lbf.ft) @ SYNCHRORING
@ BALL BEARING @ WASHERReplace. @ SYNCHROSPRTNG
Checkfor wear and @}OILFILLERPLUG @ lST/2ND SYNCHRO HUB
operation. 44 N.m (4.5 kgf.m, 33 lbf'ftl @ REVERSEGEAR
(E 26x42x7 mm OILSEAL @ WASHERReplace. @ SYNCHRO SPRING
Replace. @)TRANSMISSIONHOUSING @ SYNCHRORING
@ 28 mm PLUGBOLT €) CLUTCHLINEBRACKET @ FRICTIONDAMPER
5,1N.m {5.5 kgf'm, /t0 lbt'ft) @ OIL GUTTERPLATE @ SPACER
@ lsT/zND SELECT SPRING @ REVERSELOCKCAM @39x4lx27mm
L. 36.26mm (1./P8in) @ REVEBSESELECTSPRING NEEDLEBEARING
@ SHIFTARM SHAFT L. 63.4 mm {2.,196in) @ 2ND GEAR
@ CLUTCHHOUSING @ REVERSESELECTRETAINER @ 3RDGEAR
@ INTEELOCKGUIDEBOLT @ SHIFTARM C @ 4TH GEAR
39 N.m (4.0 kgf.m, 29 lbf.ftl @ SHIFTARM B @ sTH GEAR
@ REVERSESHIFTHOLDER @ INTERLoCK @)BALLBEARING{* 1}
@ REVERSEIDLERGEAR @ COLLAR NEEDLEBEARING(*2}
@ REVERSEIDLERGEARSHAFT @ SHIFTARM A @ BALL BEARING
@ 5 x 22 mm SPRINGPIN @ SPRINGWASHER @)SPRINGWASHER
Replace. @ MAGNET @ LoCKNUTReplace.
@ 3RD/4THSHIFTPIECE @ sET BALL SPRINGBOLT 1 0 8- 0 - 1 0 8N . m
@ 5TH/REVERSE SHIFTPIECE 22 N.m (2.2 kgf.m, 16 lbf.ftl ftt.o* o- 1r.okst.m,l
@ MBS SHIFT PIECE @ 14 x 20 mm DOWELPIN 179.6- 0- 79.6rbtft I
@ 1ST/2NDSHIFI FORK
* 1 : D 1 6 Y 7e n g i n e
\ t *2: D16Y5,D16Y8engines
1 3 - 11
TransmissionHousing
Removal
NOTE:Placethe clutch housingon two piecesof wood 4. Loosenthe transmissionhousingattachingbolts in
t h i c k e n o u g ht o k e e p t h e m a i n s h a f tf r o m h i t t i n g t h e a crisscrosspattern in severalsteps,then remove
workbench. them.
1. Removethe back-uplight switch. Removethe 32 mm sealingbolt.
2. Removetransmissionhanger. 6. Expandthe snap ring on the countershaftball bear-

ing, and remove it from the groove using a pair of
TRANSMISSION snap ring pliers.
HANGER
32 mm SEALINGEOLT
BACK-UPLIGHTSWITCH SNAP RING
Removethe settingscrews.washers.springs,and 7. Separatethe transmissionhousingfrom the clutch

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

ter platefrom the transmissionhousing.
otL GUTTER
TE
STEELBALLS
O. 5/16 in
SETTINGSCREW
SPRING
L . 3 1 . 6 m m I 1 . 2 4i n l
(o
TRANSMISSIONHOUSING
1 3-1 2
ReverseShift Holder
Inspection
Glearance
)
1. Measurethe clearancebetween the reverseshift 3. Measurethe clearancebetween the reverseidler
shift piecepin.
fork and sth/reverse gearand the reverseshiftfork.
Standard: 0.05- 0.35 mm 10.002- 0.01,1inl Standard: 0.5- 1.1mm {0.02- 0.0,1in)
ServiceLimit 0.5 mm (0.02in) ServiceLimii: 1.8 mm 10.07inl
IDLERGEAR
REVERSE
REVERSE
REV€RSESHIFTFORK
lf the clearancesare more than the service limit. lf the clgarancesis morethan thg servicelimit, mea-
measurethe widths of the groove in the reverse sure the width of the reverseshift fork.
\ shifi fork.
- 0.512in}
Standlrd: 12.7- 13.0mm {0.5110
Standard:7.05- 7.25 mm (0.278- 0.285inl
SHIFTFORK
REVERSE
REVERSESHIFT HOLDER
REVERSESHIFT HOLOER
lf the widths of the grooves are not within the

standard,replacethe reverseshift holderwith a lf the width is not within the standard,replace
new one. the reverseshift holderwith a new one.
lf the width of the groovesare within the stan- lf the width is within the standard,replacethe
dard, replacethe sth/reverseshift piece with a revsrseidlergearwith a new one.
new one,
t
13-13
Mainshaft,Countershaft,
Reverseldler Gear Shift Fork
Removal Disassembly
1. Removethe reverseshift holder. 1. R e m o v et h e i n t e r l o c kg u i d e b o l t f r o m u n d e r t h e
clutchhousing.
SHIFT
REVERSE SHIFTARM8
HOLOER ATTACHING BOLT
CLUTCH
HOUSING
Remove the reverse id ler gear shaft and reverse

idlergear.
GUIDEBOLT
INTERLOCK
Removethe shift arm B attachingbolt.
REVERSE
IDLER Removethe mainshaftand countershaftassemblies
GEARSHAFT with the shiftfork from the clutchhousinq.
NOTE:Beforeremovingthe mainshaftand counter-

tape the mainshaftsplinesto pro-
shaft assemblies,
tectthe seal.
Tape the mainshaft

splines.
WASHER
SPRING
WASHER
1 3- 1 4
Mainshaft Assembly
lndex
I Notethe followingduring reassembly:
. The 3rd/4thand sth svnchrohubs are installedwith a press
. Installthe angularball bearingwith the thin-edgeouter racefacingthe sth synchrohub
. Installthe ball bearingwith the ball cagefacingup
cleanall the partsin solvent,dry them and apply lubricantto all contactsurfacesthe 3rd/4th
prior to reassembling,
and sth svnchrohubs.
BallcagefacesuP.
Thin edgeof outer

racelaces down.
BALLBEARING{*1)
3RD/4TH SYNCHROSLEEVE ANGULARBALLBEARING('2)
page 13'27 Checkfor wear and operataon.
Note the directionot installation
SYNCHROHUB
5TH SYNCHRO
SLEEVE
lnspection,page 13-27
SYNCHROSPRING
SYNCHRORING
Inspection, SYNCHRORING
p a g e1 3 - 2 8 Inspection,pase 13 28
sTHGEAR
I n s p e c t i opna, g e1 3 - 1 7
32 x 37 x 23.5 mm
NEEDLEBEARING
3RD GEAR Checkfor wear and
lnspection,page 13-16 CHAMFEB operation.
SPACERCOLLAB
34 x 39 x 27.5 mm I n s p e c t i o np,a g e 1 3 1 6
NEEDLEBEARING 34x39x23mm
Checkfor wear NEEDLEEEARING
ano opetaflon, Checkfor wear
and operation,
4TH GEAR
MAINSHAFT
rnspeclron,p a g e1 3 ' 1 6
I n s p e c t i o np,a g e 1 3 - 1 8 RING
page 13 28
Inspectaon,
SPRING
*1: D16Y7engine
*2: D16Y5,D16Y8engines
13-15
MainshaftAssembly
ClearanceInspection
NOTE: lf replacementis required,always replacethe 3. Measurethe clearancebetween 4th gear and the
synchrosleeveand hub as a set. spacercollar.
1. Measurethe clearancebetween2nd and 3rd gears, Standard: 0.06- 0.19 mm 10.002- 0.007in)
Standard: 0.06- 0.21 mm 10.002- 0.008in)
ServiceLimit: 0.33mm (0.013inl +
4TH GEAR
/ INDICATOR
di
-J-
i l
f r l "
- )
- f
I
2ND GEAR
TI -r ''==f{'
Hl I 3RO GEAR 5TH GEAR
lf the clearanceis more than the servicelimit, mea-

suredistance@ on the spacercollar.
Standard: ?2.V. - 22.86mm

10.8!t8- 0.900in)
SorvicaLimii: 22.81mm {0.8t8 inl
lf the clearanceis more than the servicelimit. mea-
surethe thicknessof 3rd gear, 4TH GEAR
SIDE
Standard: 3O.22- 3O.27mm
{1.190- 1.192in}
ServicaLimit: 30.15mm (1.187inl SPACER
COLLAR
3RD GEAR lf distanc€@ is lessthan the servicelimit, replace

the spacercollarwith a new one,
lf distance@ is within the servicelimit, measure
the thicknessof 4th gear.
Standard: 30.12- 30.17mm

(1.186- 1.188inl
Servic6Limh: 30.05mm (1.1&linl
4TH GEAR
lf the thicknessof 3rd gear is lessthan the ser-

vice limit,replace3rd gearwith a new one.
lf the thicknessof 3rd gear is within the service
limit, replacethe 3rdl4thsynchrohub with a new lf the thicknessof 4th gear is lessthan the ser-
one. vice limit, replace4th gearwith a new one.
lf the thicknessof 4th gear is within the service
limit, replacethe 3rdl4thsvnchrohub with a new
one,
13-16
Disassembly
T 6. Measurethe clearancebetweenthe spacer collar 1. Removethe ball bearingusing a bearingpuller as
and sth gear. shown.
BEARINGPULLER
Standard: 0.06- 0.19 mm 10.002- 0.007inl (Commercially
ServiceLimit: 0.31mm (0.012inl availablel
4TH GEAR
DIAL
INDICATOR
I
-<=q,
5TH GEAR
7. lf the clearanceis more than the servicelimit, mea-

suredistance@ on the spacercoilar

10.926- 0.928in)
Sowice Limit 23.51mm {0.926in}
SPACER
COLLAR
CAUTION: Remov€ths synchro hubs using a press

sTH GEAR and steel blocks as shown. Us€ of a iaw-type pullel
SIDE
can caus€damagelo the gear teeih.
lf distance@ is lessthan the servicelimit, replace S u p p o r t 4 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

the spacercollarwith a new one, mainshaftout of the sth svnchrohub as shown.
lf distance@ is within the service limit, measure
thicknessof 5th gear.
Siandatd: 28.1:2- 28.17 mm

1 1 . 1 1-91 . 1 2 1i n )
ServicaLimit: 28.35mm (1.116inl
sTH GEAR
lf the thicknessof 5th gear is lessthan the ser-

vice limit, replacesth Oearwith a new one.
lf the thicknessof sth gear is within the service
l i m i t , r e p l a c et h e 5 t h s y n c h r oh u b w i t h a n e w
one. {cont'd)
13-17
MainshaftAssembly
Disassembly(cont'd) Inspection
Y
3. Supportthe 3rd gear on steelblocks,and pressthe '1. Inspect
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
mainshaftout of the 3rd/4thsynchrohub as shown. wear and damage.then measurethe mainshaftat
pointsA, B, C, and D.
Siandard: A: 21.987- 22.000mm

10.8656 - 0.8661inl
B: 26.980- 26.993mm
11.0622- 1.0627inl
C: 33.98,1-34.000mm
(1.3380- 1.3385in)
D: 25.977- 25.990mm
|.1.0227- 1.0232inl
ServiceLimit: A: 21.930mm 10.8634inl
B: 26.930mm {1.0602in}
C: 33.930mm (1.3358in)
D: 25.920mm (1.0205in)
Checkfor wearanddamage
lf any part of the mainshaftis lessthan the service

limit,replaceit with a new one.
2. Inspectfor runout.
Standardi 0.02 mm (o.(Xtlin) max.

S€rviceLimii: 0.05 mm (0.002in)
N O T E : S u p p o r t t h e m a i n s h a f ta t b o t h e n d s a s
snown.
lf the runout is more than the servicelirnit,reolace

the mainshaftwith a new one.
13-18
)r'
I Reassembly
CAUTION: When installing the 3rd/4th and 5th synchro 3. Installthe sth synchrohub using the specialtools
hubs, support th€ shaft on steel blocks, and insiall the ano a press.
synchro hubs using a press.
NOTE:Referto page13-15for reassemblysequence.

DRIV€R,40 mm I O.
07746 -0030' 100
1. Support 2nd gear on steel blocks'then install the
3rd/4thsynchro hub using the specialtools and a
oress. ATTACHMENT,
30 mm l.D.
07746-O030300
sTH SYNCHROHU8
ATTACHMENT,
35 mm LO.
07746-OO3O/+OO
Installthe ball bearingin the directionshown using

\r' , 2I{D GEAR
the specialtools and a Press.
DRIVER,iO mm l.D.
07746 - lxxlollx'
Install the 3rd/4th synchro sleeve by aligning the BAI-LBEARING

stops of the 3rdl4th synchro sleeveand hub.
BallcagefacesuP
NOTE; After installing,checkthe operationof the 30 mm l.D.
ATTAGHMENT,
3rd/4thsvnchrohub set 077i16- 00303qt
SYf{CHRO SLEEVE
*1: D16Ytengane
*2: Dl6Y5,D16Y86ngines
13-19
CountershaftAssembly
Index
NOTE:The 3rd, 4th,and sth gearsare installedwith a press.
I.r
-re Prior_toreassembling,cleanall the partsin solvent,dry them and apply lubricantto all contactsurfacesexceptthe
3rd, 4th,and 5th gears.
Snapring groovefacesup.
LOCKNUTReplace.
108-O- 108 N.m
I 11.0-O-11.0kst.ml
I 79.6-0- 79.6 lbt.ft I
WASHER
BEARING
Check for wear and
Thin edgeol outer operatron,
racefacesdown.
/ BALL EEAR|NGt*1)
t NEEDLEBEARTNG (.2)
SYNCHROSPRING
Check for wear
and operatron,
SYNCHRORING
I n s p e c t a opna, g e1 3 - 2 8 GEAR
4TH GEAR
FRICTIONDAMPER
3RD GEAR
1ST GEAR 2ND GEAR
l n s p e c t i o np,a g e 1 3 2 1 , 2 8 lnspection,page 13-21, 28
39x44x27m m
NEEDLEBEARIfI'G
Check for wear and
operation.
SPACERCOLLAR
Inspection,page 13-21
FRICTIONDAMPER
SYNCHRORING
36 x 41 x 25.5 mm
NEEDLEBEARING
Check for wear and operataon. SYNCHROSPRING
Inspection,page 13-23 REVERSE GEAR

lnspection,page 13 27
1ST/2NDSYNCHROHUB
*1: D'16Y7
engine
13-20
ClearanceInspection
NOTE: lf replacementis required,always replacethe 3. Measurethe clearancebetween2nd and 3rd gears.
synchro sleeveand hub as a set.
Standard: 0.04- 0.12 mm (0.002- 0.005in)
1. Measurethe clearancebetween the countershaft ServicoLimit: 0.2,1mm 10.009in)
and lst gear.
Standard: 0.03- 0.10 mm (0'(X)l- 0'qt4 in)

Sorvic. Limit: 0.22 mm (0.009inl

sureth€ thicknessof the spacercollar'
GAUGE stlndard: 32.G1- 32'06 mm

{1.261- 1.262in}
S6rvicaLimh: 32'01 mm (1'260in)
I)t 2. lf the clearanceis more than the servicelimit, mea-

surethe thicknessof 1stgear.
SPACER
COLLAR
Standard: 30./tl - 30.'l'l mm
11.197 - 1.198in)
Servics Limit 30.36mm (1.195in)
lf the thicknessis lessthan lhe servicelimit, replace

1ST GEAB
the sDacercollarwith a new one.
lf ths thicknessis within the servicelimit, measure
the thicknessof 2nd gear.

11.256- 1.258inl
SoryiceLimit 31.85mm (1.25,1inl
2I{D GEAF
z4:_-
/ l- \ \ \ /
j'T "b/
P-
1^'.-1r.--l
--f
lf the thicknessof 1stgear is lessthan the service lf the thicknessof 2nd gear is lessthan the ser-
limit, replacelst gearwith a new one. vice limit, replace2nd gearwith a new one.
lf the thicknessof 1st gear is within the service lf the thicknessof 2nd gear is within the servace
limit, replacethe lsv2nd synchrohub with a new limit, replacethe lsv2nd synchrohub with a new
one. one,
13-21
Disassembly
\
CAUTION:Removethe gears using a press and steel 4. Support4th gearon steelblocks,and pressthe coun-
blocks as shown. Use of a iaw-type puller can damage tershaftout of 5th and 4th gearsas shown.
the gear teeth.
1 . S e c u r e l yc l a m pt h e c o u n t e r s h a fats s e m b l yi n a
benchvisewith wood blocks.
2. Raisethe locknuttab from the groove of the coun-

t e r s h a f t t, h e n r e m o v et h e l o c k n u ta n d t h e s p r i n g
washer.
5. Support1stgearon steelblocks,and pressthe coun-

tershaftout of 3rd gearas shown.
I./
3. R e m o v et h e b e a r i n g su s i n ga b e a r i n gp u l l e ra s
shown.
3RD GEAR
EEARINGPULLER 1ST GEAR

Inspection Reassembly
1 . Inspectthe gear surfacesand bearangsurfaceslor CAUTION:
w e a r a n d d a m a g e t, h e n m e a s u r et n e countershaft . Pressthe 3rd,4th, and sth gears on the countershaft
at pointsA, B, and C. without lubrication.
. When installing the 3rd. 4th, and 5th geals, support
Standard: A: 30.000- 30.015mm the shaft on steelblocksand installthe gearsusinga
( 1 . 1 8 1 11- . 1 8 1i7n l pless.
B: 35.984- 36.000mm
( 1 . i 1 1 6- 71 . 4 1 7 i3n l NOTE:Relerto page 13-20for reassemblysequence'
C: 24.980- 2i1.993mm
{0.9835- 0.9840in) 1. lnstallthe needlebearingon the countershaft'
SeryiceLimit:A: 29.950mm (1.1791inl
B: 35.930mm (1 '1146in) , 36x41 x 25.5mm
C: 24.930mm 10.9815 in) NEEDLEBEARING
COUNTERSHAFT
Check oil passages

for cloggrng-
I Check for wear

2. Assemblethe pans belowas shown.
ano oamage. NOTE:Checkthat the fingersof the frictiondamper

are securelyset in the groovesof the 1sv2ndsyn-
chro hub.
. lf any part of the countershaftis less than t h e
servicelimit, replaceit with a new one. 2ND GEAR
2. Inspectfor runout. 39x/+4x27mm

NEEDLEBEARING
Standard: 0.02mm (0.001inl max. SPACERCOLLAR
SeryiceLimit: 0.05 mm {0'002in)
FRICTIONDAMPER
SYNCHRORING
SYNCHROSPRING
REVERSEGEAR
lST/2NO
SYNCHROHUB
SYNCHROSPRING
SYNCHRORING
FRICTIONDAMPER
1ST GEAR
t , . lf the runoutis morethanthe servicelimit.replace

the countershaft with a new one.
3. Installthe partson the countershait
(cont'd)
13-23
(cont'd)
Reassembly .g
4. Suppon the countershafton a steel blockas shown 7. Installthe bearingsin the directionshown usingthe
and install 3rd gear using the specialtools and a sDecialtoolsand a oress.
press.
CAUTION: Install ths bearings with a maximum
PRESS pressureot 7.8 kN {800 kgt, 5,786lbfl.
sry
DRIVER,40 mm LO.
07746 -0030100
/rt-\
ATTACHMENT,
35 mml.o.
07746-0030400 Snapring
\ lacss up.
ATTACHMENT,
30 mm l.D.
5. Install4th gear usingthe specialtools and a press. 07745 - q'303tl)
DRlvER.40 mm
07746- 0030100
*1: 016Y7engine
ATTACHMENT,
35 mm LO.
Thin edgeof outer \ J
07746-0030400 racefaces down,
8. 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 a
t s s e m b l vi n
bench vise with wood blocks.
LOCKNUT
108+0r108N.m
(11.0* 0 - 11.0kgt m. 79.6 - 0 * 79.6 tbf.ft)
6. Install5th gear usingthe specialtools and a Dress.
DRIVER,40 mm l.D.
07746-0030100
ATTACHMENT,
30 mm l.D.
07746-0030300 5TI{ GEAR
Installthe spring washer,tighten the locknut,then

stakethe locknuttab into groove.

Shift Fork AssemblY
lndex
parts'
cleanall the partsin solvent,dry them, and applylubricantto any contact
erio, ,o reassembling,
I
3RD/4THSHIFTFORK
5THiREVERSE
SHIFTFORK
1ST/2NDSHIFTFORK
I
M8S SHIFT
PIECE
5TH/REVERSE
SHIFTPIECE
3RD/4TH
SHIFTPIECE
\a
13-25
Shift ForkAssembly
ClearanceInspection
J
NOTE:The synchrosleeveand the synchrohub should 3. Measurethe clearancebetweenthe shift piece or
be replacedas a set. shiftfork and the shift arm B.
l. Measurethe clearancebetweeneach shift fork and Standard: 0.2 - 0.5 mm {0.008- 0.02 in}
its matchingsynchrosleeve. SarviceLimit: 0.62 mm 10.0244inl
Standard: 0.35- 0.65 mm {0.014- 0.026int

ServiceLimit 1.0 mm (0.04in)

surethe grooveof the shift pieceor shiftfork,
\ J
surethe thicknessof the shiftfork fingers. Standard: 13.2- 13.4mm (0.520- 0.b28inl
Standard:
3rd/ilth: 7.il - 7.6 mm {0.291- 0.299in}
lst/2nd, 5th: 6.2 - 6.il mm (O.2,tt- 0.252in)
SHIFTFORK
lf the grooveof the shift pieceor shift fork is not

within the standard, replacethe shift piece or
lf the thicknessof the shift fork finge.s is not shiftfork with a new one.
within the standard,replacethe shift fork with a lf the groove of the shift piece or shift fork is
new one. within the standard,replacethe shift arm B with
lf the thicknessof the shift fork fingers is within a new one.
the standard.replacethe synchrosleevewith a
13-26
Synchro Sleeve,
SynchroHub
MBSShift PieceInsPection Inspection/lnstallation

' 1 . lnspectgear teeth on all synchrohubs and synchro
1. Measurethe width of the MBS shift piece.
s l e e v e st o r r o u n d e do f f c o r n e r s ,w h i c h i n d i c a t e
Standard; 6.9 - 7.1 mm 10272 - 0.280inl
ServiceLimit: 6.8 mm {0.268inl
I n s t a l le a c h s y n c h r o h u b i n i t s m a t i n g s y n c h r o
sleeve,and checkfor freedomof movement.
NOTE: lf replacementis required,always replace

the synchrosleeveand synchrohub as a set.
SYNCHRO
SLEEVE
lf the width of the MBS shift pieceis lessthan

servicelimit, replacethe MBS shift piece' When assemblingthe synchrosleeveand synchro
hub, be sureto matchthe three setsof longerteeth
(120degreesapart)on the synchrosleevewith the
three setsof deepergroovesin the synchroHub
CAUTION: Do not install th€ sYnchro sleeve with

its longsr t€sth in the synchro hub slots bocauseii
will damageths spring ring.
LONGERTEETH
t
13-27
SynchroRing,Gear
Inspection
\a
1. Inspectthe synchroring and gear. SYNCHRO
A: Inspectthe insideof the synchroring for wear.
B: Inspectthe synchro sleeveteeth and matching

teethon the synchroring for wear (roundedoff). SYNCHRO
r-\ /-\
oioi *-o*
C: Inspectthe synchro sleeveteeth and matching
teethon the gearfor wear (roundedoff).
, \ n
UtJ
GOOOWORN
D: Inspectthe gear hub thrustsurfacefor wear.
E: Inspectthe cone surfacefor wear and roughness.
Fr Inspectthe teeth on all gears for unevenwear,

scoring,galling,and cracks.
2. Coatthe cone surfaceof the gearwith oil. and place

the synchroring on the matchinggear. Rotatethe
synchroring.makingsurethat it does not slip.
Measurethe clearancebetweenthe synchro ring

a n dg e a ra l l t h e w a y a r o u n d . r /
NOTE:Holdthe synchroring againstthe gearevenly
while measuringthe clearance.
Synchro Ring-to-GearClearance
Standard: 0.73- 1.18mm {0.029- 0.046in}
ServiceLimit 0.4 mm {0.02in)
lf the clearanceis lessthan the servicelimit, replace

the synchroring and synchrocone.
13-28
Shift Rod
Removal
(5/16in)' 6. Removeshift arms C and B, and the interlock,then
NOTE:The steelbatlsareallof the samesize
removethe reverseselectspringand retainer'
1. Removethe differentialassembly'
7. Removethe shift arm A attachingbolt, the set ball
springbolt, set spring,and steelball'
2. R e m o v et h e 2 8 m m p l u g b o l t a n d l s t / 2 n d s e l e c t
spring.
8. Removethe shift rod' then removethe shift arm A'
3. Removethe shift arm C attachingbolt'
9. Removethe reverselockcam'
4. Removethe shift arm shaft'
10. Removethe magnet.
NOTE:Be carefulnotto losethe steelball'
5. Removethe steelball,spring,and collar'
LOCKCAM
REVERSE
SHIFTARM C l
I REVERSESELECTRETAINER
V /
' l J
SHIFTARM B
INTERLOCK
\s REVERSESELECTSPRING
L. 63.4 mm {2.50 inl
SPRINGL. 21.4 mm &-"onn"

(0.843 in)
BALL
SPRINGEOLT
SI{IFT ARM A
COLLAR SPRING
L . 2 5 . 6 m m 1 1 . 0 1i n l
14x20
OOWELPIN
ASSEMBLY
DIFFERENTIAL
,*(S* \ OIL SEAL

6S* \ srtrr ran,tsrarr Replace.
\ \
',)r,r"o
\ r..."r "rr,*n SHIFTROD
t. 36.26 mm {1.428 in,
\
28 mm PI-UGBOLT

Differential
BacklashInspection
'1.
Placedifferentialassemblyon V-blocks,and install
both driveshafts.
OIAL
THRUSTSHIM
Selectivepart
BALL BEARING
Check for wear and damage.
DIFFERENTIAL
C h e c kl o r c r a c k s .
SPEEDOMETER
DRIVEGEAR
ffi
cFrNAL
' eDRTvEN
c ' oo*^r'@
wea' -Zl
Measurebacklashof both piniongears.
BALL BEARING
Checkfor wear and damage. Standard {New); 0.05- 0.15 mm {0.002- 0.006in)
S I
10 x 1.0mm
101 N.m (10.3 ksf.m. 74.5 lbt.ftl lf the backlashis not within the standard,reDlace
Left-handthreads the differentialcarrier.
13-30
BearingRePlacement FinalDrivenGearRePlacement
1, Removethe bolts in a crisscrosspatternin several
NOTE: Checkbearingsfor wear and rough rotation lf
steps,then remove the final driven gear from the
the bearingsare OK,removalis not necessary'
ditferentialcarrier'
'1. Removethe ball bearingsusing a bearingpuller as
NOTE: The final driven gear bolts have left-hand
shown.
threads.
EALL B€ARING
I
lnstall new ball bearingsusing the specialtool as 1 0 x 1 . 0m m B O L T
shown. 1 o 1 N . ml l O . 3k g f ' m , 7 45 l b f ' f t )
Lelt'handthreads
NOTE: Drive the bearingssquarelyuntil they bot-
tom againstthe carrler.
DRIVER,40 mm LD.
?746-0030100
lnstallthe final driven gear by tighteningthe bolts

in a crisscrosspattern in severalsteps'
\1,

Differential
ThrustShim Adjustment
Y
1. Installthe differentialassembly,makingsure it bot- Installthe transmissionhousing(seepage l3-41).
toms in the clutchhousing,usingthe specialtool as
shown. NOTE:Do not apply liquidgasketto the matingsur-
faceof the clutchhousing.
T i g h t e nt h e t r a n s m i s s i o nh o u s i n ga t t a c h i n gb o l t s
DRIVER,
40 mm LD. (seepage13-42).
07746 0030100
I x 1,25mm
27 N.m (2.8 kgt'm, 20 lbf'ft}
Usethe specialtool to bottom the differentialassem-

bly in the clutchhousing.
Installthe thrustshim.
NOTE: Installthe same size thrust shim that was

t J
removed.
6. Measureclearancebetweenthrust shim and bear-

ing outer racein transmissionhousing.
13-32
7. lf the clearanceis more than the standard,selecta 80 mm THBUSTSHIM:D16Y5.D16Y8engines
new thrustshim from the followingtable
Part Numbel Thickness
NOTE:It the clearancemeasuredin step 6 is within 41441- PL3- B00 1 . 0m m ( 0 . 0 3 9 i4n )
the standard.go to step 10.
41442-PL3-800 1 . 1m m ( 0 . 0 4 3i3n )
Standard:0 - 0.10 mm l0 - 0.00/tinl 41443-PL3-800 1 . 2m m ( 0 . 0 4 7 i2n )
41444-PL3-800 1 . 3m m ( 0 . 0 5 1i2n l
72 mm THRUSTSHIM:D16Y7engin€
41445-PL3-800 1 . 4m m ( 0 . 0 5 5 i1n )
Part Number Thickness 41446-PL3-800 1 . 5m m ( 0 . 0 5 9I1n )
41441- PL3- A00 1.0mm (0.0394in) 41447-PL3-800 1.6mm (0.0630in)

'1.1 mm {0.0433
in) 4r 448- PL3- 800 1.7mm (0.0669in)
41442-PL3-A00
41443-PL3-A00 1.2mm {0.0472in) 4 t449- PL3- 800 1.8mm (0.0709in)
'1.0m
5 m ( 0 . 0 4 1 i3n )
41444-PL3-A00 1 . 3m m ( 0 . 0 5 1i2n ) 41450-PL3-800
'1.15mm (0.0453in)
41445-PL3-A00 1 . 4m m ( 0 . 0 5 5i1n ) 41451- PL3- 800
41446-PL3-A00 1 . 5m m ( 0 . 0 5 9 i1n ) 41452-PL3-800 1.25mm (0.0492in)
41447-PL3-A00 1 . 6m m ( 0 . 0 6 3i0n ) 41453-PL3-B00 1 . 3 5m m ( 0 . 0 5 3 i2n )
41448-PL3-A00 1.7mm (0.0669in) 41454-PL3-B00 1 . 4 5m m ( 0 . 0 5 7 i1n )
4r449-PL3-A00 1.8mm (0.0709in) 41455-PL3-B00 1 . 5 5m m ( 0 . 0 6 1i0n )
41450-PL3-A00 1 . 0 5m m { 0 . 0 4 1 i3n ) 41456-PL3-800 1.65mm (0.0650in)
41451-PL3-A00 1 . 1 5m m ( 0 . 0 4 5i3n ) 41457-PL3-800 1.75mm {0.0689in)

\ 41452-PL3-A00 1.25mm (0.0492in)
41453-PL3-A00 1.35mm (0.0532
in) 8 . Removethe boltsand transmissionhousing.
'1.45mm (0.057'lin)
41454-PL3-A00 9 . R e p l a c et h e t h r u s t s h i m s e l e c t e di n s t e p 7 , t h e n
41455-PL3-A00 1 . 5 5m m ( 0 . 0 6 1i0n ) recheckthe clearance.
41456-PL3-A00 1.65mm (0.0650in)
1 0 . Removethe bolts and transmissionhousing.Apply
41457-PL3-A00 1 . 7 5m m ( 0 . 0 6 8i9n ) l i q u i d g a s k e tt o t h e s u r f a c eo f t h e t r a n s m i s s i o n
housingand reassemble

Clutch HousingBearing
Replacement
l.
Mainshaft 3, Drivethe new oil seal into the clutchhousingusing

the specialtoolsas shown.
1. Removethe ball bearing using the special tool as
shown.
3i8 " -16 SLIDEHAMMER

(Commercially available)
ATTACI{MENT, 42 x 47 mm
07746 -0010300
07749-0010000
CLUTCH
HOUSING
ADJUSTAELEBEARING
t./
PULLER,25-40 mm Drivethe ball bearinginto the clutchhousingusing
07736-AO10004 the specialtools as shown.
2, Remove the oil seal from the clutch housing,
CLUTCH
ATTACHMENT,52 x 55 mm DRIVER
07746 0010400 07749-0010000
Replace.
13-34
Countershaft 2. I n s t a l lt h e o i l g u i d e P l a t e ,t h e n d r i v e t h e n e e d l e
b e a r i n gi n t o t h e c l u t c hh o u s i n gu s i n gt h e s p e c i a l
1. Removethe needlebearingusingthe specialtool as tools as shown.
shown.then removethe oil guide plate
3/g " -16 SLIDEHAMMER

{Commercially available)
NEEOLEBEAFING
GUIDEPLATE
'1: ATTACHMENT,42 x 47 mm
PULLER,25-40 mm
07736-AO1000A 07746-0010300
*2: ATTACHMENT,52 x 55 mm
07746 -0010400
ORIVER
07749 -0010000
CLUTCH
HOUSING
NEEOLEBEARING
OIL GUIDEPTATE
* 1 : D 1 6 Y 7e n q i n e
*2: D16Y5, D16Y8 engines
13-35
MainshaftThrust Shim
Adjustment
\
1 . R e m o v et h e t h r u s ts h i m a n d o i l g ui d e p l a t ef r o m 5. Selectthe propershim on the basisof the following
the transmissionhousing. calculations:
THRUSTSHIM NOTE:Useonly one thrustshim.
(BasicFormula)
( B )+ { C ) . 0 . 9 5= s h i mt h i c k n e s s
OIL GUIDE
PLATE
Exampleof calculation:
D i s t a n c e@ ( 2 . 0 0m m ) + D i s t a n c e@ ( 0 . 0 9m m )
TBANSMISSION = 2.09mm
HOUSING subtractthe spring washer height (0.95m m ) = tne
required t h r u s ts h i m( 1 . 1 4m m )
Installthe 3rd/4th synchro hub, spacer collar, 5th
synchrohub, ball bearing,and thrust washeron the 65 mm THRUSTSHIM:D16Y7engine:
mainshaft.Installthe assemblyin the transmission
Part Numbor Thickness
ho u s i n g .
23931- PL3 A10 0.60mm (0.0236in)
23932- PL3 A10 0.63mm 10.0284in)
@ gnol+lx syNcHRoHUB c 23933- PL3 A10 0.66mm {0.0260ini
D 23934 PL3- A10 0.69mm (0.0272
in)
E 23935-PL3-410 0.72mm 10.0283
in)
THRUSTWASHER
F 23936-PL3-410 0.75mm 10.0295 in)
G 23937-PL3-A10 0.78mm {0.0307in}
SPACERCOLLAR
23938 PL3- A10 0.81mm (0.0319 in)
I 23939- PL3 At0 0.84mm (0.0331 in)
sTH SYNCHROIIUB J
L
23940-PL3-Ar0
23941- PL3- A10
23942- PL3 A10
0.87mm (0.0343in)
0.90mm (0.0354in)
0.93mm (0.0366 in)
r 1
BALL EEARING 23943-PL3-A10 0.96mm (0.0378 in)
N 23944 PL3- A10 0.99mm 10.0390 in)
M e a s u r et h e d i s t a n c e@ b e t w e e nt h e e n d o f t h e o 23945-PL3-A10 1.02mm {0.0402 in}
transmissionhousingand thrustwasher. 23946- PL3 A10 1 . 0 5m m ( 0 . 0 4 1i3n )
o 23947 PL3- 410 1.08mm (0.0425 in)
NOTE: R 23948-PL3-A10 1 . 1 1 m m( 0 . 0 4 3i7n )
. Usea straightedgeand verniercaliper. s 23949 PL3- A10 1 . 1 4m m { 0 . 0 4 4i9n }
. Measureat three locationsand averagethe read- T 23950-PL3-A10 1 . 1 7m m ( 0 . 0 4 6i1n )
Ings. U 23951 PL3- A10 1.20mm (0.0472 in)
23952-PL3-Ar0 1.23mm {0.0484in)
4. Measurethe distance@ betweenthe surfacesof 23953-PL3-A10 1.26mm {0.0496in}
the clutchhousingand bearinginnerrace. X 2 3 9 5 4- P 1 3 , A 1 0 1.29mm (0.0508 in)
23955- PL3 A10 1.32mm (0.0520 in)
NOTE: z 23956-PL3-Ar0 1.35mm {0.0531in)
. Usea straightedgeand depthgauge. 23957-PL3-A10 1.38mm (0.0543 in)
. Measureat three locationsand averagethe read- AB 239s8- PL3 A10 1.41mm (0.0555 in)
Ings. AC 23959 PL3- A10 1.44mm (0.0567 in)
ENOOF CLUTCHHOUSING AD 23960- PL3 A10 1.47mm (0.0579in)
23961- PL3 410
L AG
23962 PL3- A10
23963-PL3-410
1.50mm (0.0591in)
1.53mm (0.0602
1.56mm (0.0614
in)
in)
AH 23964- PL3 A10 1.59mm (0.0626in)
AI 23965-PL3-A10 1.62mm {0.0638in)
23966 PL3- A10 1.65mm (0.0650 in)
AK 23967-PL3-A10 1.68mm {0.0661in)
23968 PL3- A10 1.71mm {0.0673in)
INNERRACEOF BALL AEARING 23969-PL3-A10 1.74mm (0.06a5 ini
AN 2 3 9 7 0 -P L 3- A 1 0 1 . 7 7 m m ( 0 . 0 6 9 7i n )
AO 2 3 9 7 1- P L 3 - A 1 0 1.80mm 10.0709
in)
13-36
70 mm THRUSTSHIM:Dl6Y5, Dl6Y8 engin€s 7, Installthe thrust washer and spring washer in the
mainshaft.
Part Number Thickness
23931- PL3- 800 0.60mm 10.0236 in)
23932-PL3-800 0.63 mm (0.0284in)
c 23933-PL3-800 0.66mm (0.0260 in)
D 23334-PL3-800 0.69 mm 10.0272in)
E 23935-PL3-800 0.72mm (0.0283 in) THRUSTWASHER
F 23936- PL3 800 0.75mm (0.0295 in) WASI{ER
SPRING
23937-PL3-B00 0.78mm (0.0307in)
23938-PL3-800 0.81mm (0.0319inl
23939-PL3-800 0.84mm (0.0331 in)
23940-PL3-800 0.87 mm {0.0343in)
23941- PL3- 800 0.90mm (0.0354 in)
L 23942-PL3-800 0.93mm (0.0366
in)
8 . lnstallthe mainshaftin the clutchhousing
23943-PL3-800 0.96mm (0.0378in)
N 23944-PL3-800 0.99mm i0.0390in) o Placethe transmissionhousingover the mainshaft
o 2394s-PL3-800 1.02mm (0.0102in)
and onto the clutchhousing.
P 23946-PL3-800 1.05mm {0.0413in}
o 23947-PL3-800 1.08mm (0.0{25in) 1 0 . Tightenthe clutch and transmissionhousingswith
'1.1'1
mm (0.0437
23948- PL3 800 4n)
several8 mm bolts.
23949-PL3-800 1.14mm (0.0449inl
T 23950-PL3-800 1.17mm (0.0461in)
N O T E : l t i s n o t n e c e s s a r yt o u s e s e a l i n ga g e n t
23951- PL3- 800 1.20mm (0.0472in)
betweenthe housings'
23952-PL3-800 1.23mm (0.0444in)
239s3-PL3-800 1.26mm {0.0496in)
8 x 1.25mm
X 23954-PL3-800 1.29mm (0.0508in) 27 N'm t2.8 kgf.m. 20 lbf'ft)
2395s-PL3-800 1.32mm (0.0520 in)
z 23956-PL3-800 1.35mm (0.0531 in)
1 1 . Tap the mainshaftwith a plastichammer.
23957-PL3-800 1.38mm (0.0543in)
A8 23958-PL3-800 1.41mm (0.0555 in) lz. Checkthe thrust clearancein the manner doscribsd
AC 23959-PL3-800 1.44mm {0.0567in) below.
AD 23960-PL3-800 1.47mm (0.0579in)
2396' t-PL3-800 1.50mm (0.0591in) CAUnON: Mc.suromont 3hould bo mlde !t room
23962-PL3-800 1.53mm (0.0602in) tomp9laturs.
AG 23963-PL3-800 1.56mm (0.0614in)
AH 23964-PL3-800 1.59mm (0.0626in) a. Slidethe mainshaftbase and the collarover the
23965-PL3-800 1,62mm (0.0638in) mainshaft.
23966-PL3-800 1.65mm (0.0650in)
AK 23967-PL3-800 1.68mm (0.0661in)
23968-PL3-800 1.71mm (0.0673in) CLUTCH
23969-PL3-800 1.74mm (0.0685in) HOUSING
AN 23970-PL3-800 1.77mm (0.0697in)
AO 2 3 9 7 1 -P L 3 8 0 0 1.80mm (0.0709 inl
6. Installtheoil guide plateand selectedthrustshim in

ths transmissionhousing
NOTE:
. C l e a nt h e t h r u s t w a s h e r , s p r i n g w a s h e l a n d MAITISHAFTBASE
07GAJ-PG20130
thrustshim thoroughlybeloreinstallation. COLLAF
. l n s t a l l t h e t h r u s t w a s h e r ,s p r i n g w a s h e r a n d 07GAJ-PG20120
thrustshim proPerlY.
THRUSTSHIM
I OIL GUIDE
PLATE
{cont'd}
TRANSMISSION
HOUSING
13-37
MainshaftThrust Shim I
I
Adjustment(cont'dl
u
b. A t t a c ht h e m a i n s h a f th o l d e rt o t h e m a i n s h a f ta s e. Zero a dial gaugeon the end ofthe mainshaft.
follows:
NOTEI
. B a c k - o utth e m a i n s h a f h t o l d e rb o l t a n d l o o s e n
the two hex bolts.
. F i t t h e h o l d e r o v e r t h e m a i n s h a f ts o i t s l i p i s
towardthe transmission.
. A l i g n t h e m a i n s h a f th o l d e r ' sl i p a r o u n dt h e
g r o o v ea t t h e i n s i d eo f t h e m a i n s h a f st p l i n e s ,
then tightenthe hex bolts.
MAINSHAFTHOLOER
BOLT
MAINSHAFT
HOLDER
07cAJ_PG20110
t. Turn the mainshaftholderbolt clockwise:stop turn,

MAINSIIAFT ing when the dial gange has reachedits maximum
HOLDER m o v e m e n t .T h e r e a d i n go n t h e d i a l g a u g e i s t h e
07GAJ-PG20110
amountof mainshaftend olav.
CAUTION: Turning the mainshaft holder bolt more

than 60 degre€s after the needle ot the dial gauge
stops moving may damagethe iransmission.
\,J
lf the readingis within the standard.the clearanceis
Seatthe mainshaftfully by tappingon the end with correcl.
a plastichammer. lf the readingis not within the standard,recheckthe
shim thickness.
d. T h r e a dt h e m a i n s h a f th o l d e r b o l t i n u n t i l i t j u s t
contactsthe wide surfaceof the mainshaftbase. Standard:0.11- 0.18mm {0.00it- 0.007in}

Transmission
Reassembly
NOTE:The steelballsare all ofthe samesize(5/16in). Insertshift arm shaft in the clutchhousing.
1. Installthe magnetand reverselockcam. 1 . Installthe collar,spring.and steelball into the case.

Compressthe ball and insertthe shift arm shaft,
2. Set shift arm A on the clutch housing,then install
the shift rod. 8 . Installshift arm C in shift arm A, then insertthe shift
arm shaft.
3. Installthe spring washerand shift arm A attaching
bolt. 9. Install the reverseselect retainer and reverse select
springonto shift arm shaft.
Installthesteelball,spring,and set ball springbolt.
1 0 . Installthe differentialassembly.
5. Installshift arm B in the interlock,then set it on the
clutchhousing.
6 x 1.0 mm
SI{IFT ARM C 15 N.m 11.5 kgt.m, 11 lbt'ftl
A:8x1.0mm
3'l N,m (3.2 kgt.m,23 lbf.ft)
REVERSELOCK CAM
REVERSESELECTRETAINER
sHtFTARM ' ___\.*^ REVERSESELECTSPRING

L. 63.4 mm 12.50in)
rNrERLocK p MAGNET
|Jiiill---=l@ SET BALL SPRINGBOLT

SHIFTAFM A 22 N.m 12.2 kgl.m, 16 lbf'ftl
COLLAR SPRING
L . 2 5 . 6 m m ( 1 . O 1i n )
CLUTCH
HOUSING
OIL SEAL
Replace.
SHIFTARM SHAFT
SHIFTROD
BOOT
\rl (cont'd)
13-39
Transmission
Reassembly
lcont'dl
11. Positionthe 36 mm springwasherand washeronto 15. Installthe reverseidler gear and reverseidler gear
the mainshaftbearing. shaft.
MAINSHAFT/COUNTERSHAFT
SHIFTFORKASSEMELIES
REVERSE
IDLER
GEARSHAFT
Tape the mainshaft
splines.
12. Installthe mainshaft,countershaft,and shift fork

GEAR
assemblies.
N O T E ;A l i g n t h e f i n g e r o f t h e i n t e r l o c kw i t h t h e
groove in the shift fork shaft,
16. Installthe reverseshift holder.
L J
1 3 . lnstallthe spring washerand shift arm B attaching
bolt.
I x 1 . 0m m REVERSE
SHIFT
31 N.m (3.2 kgl.m,23 lbt.ft)
IST/2ND SELECTSPRING SPf,ING
L. 36.26 mm 11.428in) WASHER
54 N.m 15.5 kgf.m,

40 tbt.ftl GUIDE BOLT
39 N.m 14.0 kgf.m, 29 lbf.frl
6 x 1.0mm
1 4 . Installthe 1sv2ndselect spring, 28 mm plug bolt. l5 N.m (1.5kgf.m,
and interlockguidebolt, 11 lbt.trl
NOTE: Apply Iiquid gasket (P/N 08718- 0001 or

08718- 0003)to the threadsof the 28 mm plug bolt
and interlockguide bolt.
13-40
17. Instalithe oil gutterPlate. 20. lnstallthe dowel pins and the transmissionhousing.
Lowerthe transmissionhousingwith the snap ring

pliers,and set the snap ring into the groove of the
OIL GUTTERPTATE countershaftbearing.
NOTE:Checkthat the snap ring is securelyseated

in the grooveof the countershaftbearing
32 mm SEALINGEOLT
25 N.m (2.5 kgf.m, 18lbf.ftl
TRANSMISSION
HOUSING
1 8 . I n s t a l lt h e o i l g u i d e p l a t ea n d t h r u s t s h i m o n t h e
transmissionhousing.
1 9 . Apply Iiquid gasketto the surfaceof the transmis-

s i o n h o u s i n gm a t i n g w i t h t h e c l u t c h h o u s i n ga s
shown.
NOTE:
. Use liquid gasket {P/N 08718- 0001 or 4 . 6- 8 . 3 m m
08718- 0003). 1 0 . 1 4 - 0 . 3 3i n l
. Removethe dirty oil fromthesealingsurface.
. lf 5 minutes have passedafter applying liquid
gasket,reapplyit and assemblethe housings.
. Allow it to cure at least20 minutesafter assem-
bly beforefillingthe transmissionwith oil.
Liquid gasket
22. Installthe 32 mm sealingbolt.
N O T E :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 1
08718- 0003)to the threads.
\ (cont'd)
13-41
Transmission
(cont'd)
Reassembly
23, Tightenthe transmissionhousingaftachingbolts in 2 5 . I n s t a l lt h e b a c k - u pl i g h t s w i t c ha n d t r a n s m i s s i o n
t h e n u m b e r e ds e q u e n c ei n s e v e r a ls t e p s s h o w n hanger.
Delow.
8 x 1.25mm 8 x 1.25mm
Tolque: 27 N.m 12.8kgf.m. 20 lbf.ft) 27 N.m 12.8 kgl.m, 20 lbt.lrl
TRANSMISSION
HANGER
EACK.UPLIGHTSWITCH
HARNESSBRACKET
//-',, \
/I .--"-4
o
;'c'-9,/t-)
25 N.m (2.5 kgt.m, 18 lbf.ft)

I./
24. Installthe steelballs,springs,and set screws.
K)w
s WASHER
STEELEALLS
D. 5i16 in
Replace.
L . 3 1 . 6 m m 1 1 . 2 4i n )
SETTINGSCREW
13-42
Oil Seals
Replacement
TransmissionHousing: ClutchHousing:
1. Removethe oil sealfrom the transmissionhousing. 1. Removethe oil sealfrom the clutchhousing.
l n s t a l lt h e o i l s e a l i n t o t h e t r a n s m i s s i o nh o u s i n g lnstallthe oil seal into the ciutchhousingusingthe

usingthe specialtools as shown. specialtoolsas shown.
ORIVERATTACHMENT
SEAL ORIVER oTJAO-PXaO101
ATTACHMENT
07947-6110501 or
07947-6110500 OIL SEAL
Replace.
OIL SEAL
Replace.
,26x30mm
\t, OTJAD PHAO2OO
13-43
GearshiftMechanism
Overhaul
NOTE:
.Inspectrubberpartsforwearanddamagewhendisassembling;replaceanywornordamagedparts.
. Installthe clip as shown.
. Turn the boot so the hole is facingdown as shown.
. Makesurethe boot is installedon the shift rod.
16 tbf.trl
EXTENSION
BOLT
SHIFTLEVERKNOE
7.8 N.m {0.8kgf.m,5.8 lbt.tt) )
EXTENSION
/,1:\ MOUNT
l': I cusHroN ,€
SHIFT
\l / / \ \ / -/ - s
LEVER \, et- ffi
Dusr\ .-\ \5
searr'p))
PY:,'\1^l lW "ot'o'
-"or.o*
".o.o)@1
sHlFr
\:/
p f***
-o-E
Q,gD
\\-ii,,l?'"
22 N.m SPRINGPIN
CLIP
t J
Replace.
ii,".i'----....-.9
sEAr
/ g-ia',rf,',,"' \\ sELF-LocKrNG
Nur
'6
.rrr*(,o"" o-","o,\ \ ;":'i:;u -- d
ul/
-Vvvvvvvvvvvvvvvvl tlourur Replace. | 1 22 N'm 12.2ksf'm, 16 lbt.ftl
SHIFT
IiUei__-.....p anecxer
?!il,
"r^r" ""'%ilfI I JI ,-/n
e*t @
^.-.-n{wl\^fr
7****r
t 1 REAR
JorN*lr,""17E@
t
sHrFTLEVER
BALLHOLDER
\
I _6, L\
\ -6r
SELF-LOCKING NUT
Replace.
6 x ' 1 . 0mm
9 . 8 N . m { 1 . 0 k g f . m ,7 . 2 l b f . l r }
13-44
S4CModel ('99- 00 2-doorSi, SiR)
ManualTransmission
SpecialTools 13-46 Countershaft Assembly
............'
Maintenance fndex ................ "....13-71
Transmission 13-47
Oi1...................'.......... Glearance 13'75
Inspection'......'...........'...
Back-up Light Switch Disassembly ..........13-76
Repfacement ...""" 13'47 fnspection .'............13'77
TransmissionAssembly Reassembly ".........13'78
Removal 13-/tB SynchroSleeve,SynchroHub
......'..........
lnstallation 13-52
............. Inspection 13'8C
..............
13-54
lllustratedlndex ................................... Installation 13-80
.............
TransmissionHousing SynchroRing,Gear
Removal 13-55
................. Inspection 13-81
.'............
BeverseShift Holder, Reverseldler Gear Differential
Clearancelnspection ..................."..13-57 lndex ................ ......13-82
Removal 13-58
................. BacklashInspection..."..........."'......13-82
ChangeHolderAssembly FinalDrivenGearReplacement ...... 13-83
Clearance 13-59
lnspection.................".... BearingReplacement....."'.......""'.. 13-83
Removal 13-61
....,,........... Thrust Shim Adiustment ......""'.....13-84
Disassembly/Reassembly 13-62
............... Clutch HousingBearing
Mainshaft, Countershaft, Shift Fork Replacement ..'......13-86
Removal 13-63 Mainshaft Thrust Glearance
.................
Shift Rod Adiustment '.........'.13-88
Removal 13-64 Transmission
.........."'....
Shift Fork Assembly Reassembly ."'.......13-91
lndex ................ ......13-65 Oil Seals
Clearance 13'66
lnspection.............'......... Replacement ..'......13-96
Mainshaft Assembly Gearshift Mechanism
lndex ............"" ......13-67 Overhaul 13-97
................
Clearance 13-68
lnspection.......................
Disassembly ..........13-71
fnspection '."'.......',13'72
Reassembly .......'...13-73

SpecialTools I
I
I
SpecialTools
Ref. No. Tool Number D€scription Oty Remark
I
o 0 7 G A J- P G 2 0 1 1 0 MainshaftHolder I 13-90
@ 07GAJ- PG20l30 MainshaftBase 1 13-90
o
-@
07JAD- PH80l0'1 DriverAttachment 1 13-96
07736- A010004 AdjustableBearingPuller,25- 40 mm 1 13-86,87
07746- 0010300 Attachment,42 x 47 mm I 13-86
@ 07746- 0010400 Attachment,52 x 55 mm 1 13-86,87
o 07746- 0030100 Driver,40 mm LD. 'l
13-73,79,83,84
@ 07746- 0030300 Attachment,30 mm LD. I 13-73,19
@ 07746- 0030400 Attachment,35 mm LD. 1 13-73,79
@ 0 7 7 4 6- 0 0 4 1 1 0 0 Pilot,28 mm 1 13-86
o 07749- 0010000 H a n dl e 1 13-86,87,96
@ 07947- SD90200 DriverAttachment 'I
13-96
* Must be usedwith commercially-available
3/8,,-16
SlideHammer.
./
aol
@ (t 4^

Maintenance Back-upLight Switch
Oil
Transmission Replacement
NOTE:Checkthe oil with the engineOFF.and the vehi- NOTE:To checkthe back-uplight switch,seesection23.
cle on levelground.
1. Disconnect the connector,then removethe back-up
1. Removethe oil filler plug, then checkthe level and light switchconnectorfrom the connectorclamp.
condition of the oil.
2. Removethe back-uplighr switch.
OILFILLER PLUG
ia4N.m {{.5 kgf'm, ProperLevel
33tbtfrl
Replace.
T h e o i l l e v e l m u s t b e u p t o t h e f i l l e r h o l e .l f i t i s
below the hole, add oil until it runs out, then rein-
stallthe oil filler plug.
lf the transmissionoil is dirty, removethe drain plug

and drainthe oil.
AACK.UP
Reinstallthe drainplug with a new washer.and refill 25 N.m 12.5kgf.m, 18 lbf'tt) Replace.
the transmissionoil to the properlevel.
\ NOTE:The drain plug washershouldbe replacedat lnstallthe new washerand the back-uplight switch.
everyoil change.
4. Checkthe transmissionoil level.
Reinstalltheoilfiller plug with a new washer.
Oil Capacity
2.2 f {2.3US. qt, 1.9 lmp. qtl at oil change.
2.3 f {2./fUS. qt. 2.0 lmp. qt} at overhaul.
A l w a y su s e G e n u i n eH o n d aM a n u a lT r a n s m i s s i o n
Fluid (MTF).Using motor oil can causestiffershift-
ing becauseit does not contain the proper addi-
tives.
OILFILLER PLUG
ila N.m{4.5kgf.m,33 lbt'ftl
\1,
l
,
TransmissionAssembly {
Removal
@Make sure Bemovethe wire harnessclamps.
iacks and safoty stands are placad plop-
erly (3eesection l). 7. the startermotor cablesand the vehicle
Disconnect
Apply parking braks and block rear wheels so car speedsensor(VSS)connector.
will not roll off stands and fall on you while working
under il.
CAUTION:Us6 fonder cove6 to avoid damaging painted

sudaces.
8 x 1.25mm
L Disconnectthe negative(-) cable from the battery, 8.8 N.m (0.9kgf.m,
then the positive(+l cable. 6.5 tbtftl
Drain the transmissionoil. then reinstallthe drain

plug with a new washer(seepage13-47).
Removethe intakeair duct and the air cleanerhous-

ing assembly(sees€ction5).
Disconnectthe back-uplight switch connectorand

the transmissiongroundwire.
Remove the lower radiator hose clamp from the

transmissionhangerB.
STARTER
MOTOR
\ J
LOWERRADIATOR CABLES
HOSECLAMP
8 x 1.25 mm
22Nm12.2kgl'm,
8. Removethe clutchline bracketand the slav6cylin-
16rbtft) oer.
NOTE: Do not operate the clutch pedal once the

slavecylinderhas beenremoved.
13-48
9 . R e m o v et h e t h r e e u p p e r t r a n s m i s s i o nm o u n t i n g 11. Disconnectthe heatedoxygen sensor(HO2S)con-
boltsand lowerstartermotor mountingbolt. nector,then removeexhaustpip€ A.
H02S
CONNECTOE
STARTER TRANSMISSION
MOTOR MOUNTING
MOUNTING BOLTS
BOLT 12 x 1.25mm Replace.
10x 1.25mm 6,1N.m (6.5kgdm, 47 lbf'ft| SELF.LOCKING NUT 10 x 1,25mm
a,tN.m14.5kgl.m. Replace. 54 N.m {5.5 kgf.m,
33 tbf.trl 'lll lbf.ft)
8 r 1.25mm
16 N.m (1.6 kgf.m, 12lbf'ft)
12. Removethe cotter pins and loosenthe castlenuts,

'10. Removethe enginesplashshieid. then separatethe ball joints from the lower arm
(seesection18).
13. Removethe right damPerfork.

10x 1.25mm
a3N.mlil.akgf.m,32lbf'ft| ,
!-
ria -11
: \/-/
't'' '-a
SELF.LOCKING NUT
R6place.
SPLASHSHIELD
12 x 1.25mm
6a N.m (6.5 kgl.m, RIGHT CASTI.TNUT
47 rbf ft) DAMPER 12x 1,25mm
FORK a9 - 59 N.m (5.0- 6.0 kgtm,
36 - i(t lbf.ftl
(cont'd)
13-49
Removal(cont'd)
14. Remove the driveshafts and the intermediate shaft 17. Removethe front and the rearenginestiffensrs.
(seesection16).
NOTE:Coat all precisionthe finishedsurfaceswith

cleanengineoil or grease.Tie plasticbags over the
driveshaftends,
t J
1 5 . Removethe bolt, then disconnectthe change elden- 18. Removethe clutchcover.
sion.
Removethe clip and the spring pin,then disconnect

the changerod.
8x22mm
SPRING PIN
CLIP Replace.
CLUTCHCOVER
6x1.0mm
12 N.m (1.2kg{.m,
9 tbf.ftl
x 'l .25 mm
24 N.m {2.4 kgt m,
17 rbt ftl
13-50
19. Removethe rightfront mounvbracket. 22. Removethe rear mount bracketbolts and the trans-
missionmountingbolts
10 x 1.25mm
,14N.m {4,5kgf.m,
SPECIALBOLT
Replace.
12 x 1.25mm 1 4x 1 . 5m m
5{ N.m 16.5kgf.m, 47 lbl.ft) 8il N.m (8.5kgtm,
61
WASHER
SPECIALBOLT
Replace. WASHERS
12 x 1.25mm
64 N.m 16.5kgl'm, 47 lbf ftl
) 23. Pull the transmissionaway from the engine until it
20. Placea transmissionjack under the transmission
and a jackstandunderthe engine. clearsthe mainshaft,then lower it on the transmis-
sionjack.
21. Removethe transmissionmount
TRANSMISSION
3-51
lnstallation
L f;
Installthe transmissionassemblyin the reverseorder of Torquethe mounting bolt and nuts in the sequence
removal. shown.
Checkthat the busingsare not twistedor offset.
. Beforeinstalling,checkthat the two dowel pins are
installedin the clutchhousing.
@ t2 x 1.25mm
. When installingthe startercable.make sure that the 6,tN.m16.5kgtm,
crimped side of the ring terminal is facing out (see 47 lbf.ft) O t2 x 1.25mm
section23). 6,rN.m(6.skg{.m,
. 17 tbf.ft)
Apply greaseto the parts as shown, then installthe
releasefork and releasebearing.
NOTE; Use only Super High Temp Urea Grease

(P/N08798-9002).
RELEASEFORKBOLT -R1
29 N.m 13.0kgf.m, tP/N 08798-
22 tbllrl
O 12 x 1.25mm
7ilNm17.5kgf.m,
5it lbt ft)
I
Installthe alip and the spring pin on the changejoint
as snown.
Turn the shift rod boot so the hole is facingdown as
snown.
Make sure the shift rod boot is installedon the change
(P/N 08798- 9rD2l rod.
CHANGEROO
SPRING
PIN
FL.-
ll heptace,
8 mm PIN
PUNCH
CHANGE ./
EXTENSfoN (/ "*,*
^ st
l?rffi
lo,iD(
l\K CLIP
13-52
. Apply greaseto the slavecylinderpush rod.
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 a G r e a s e
(P/N08798- 9002).
6x1.0mm
9.8N'm(1.0kglm,
7.2tbl.ft)
8 x 1.25 mm
-6,4 22N.n 12.2kgl'm,
(P/N 08798- 9m2) 16 tbf.ftl
with oil (seepage13-47).

a Refillthetransmission
a Connectthe positive(+) cablefirst, then the negative
( - ) cable to the battery.
a Checkthe clutchoPeration.
a Shift the transmission, and checkfor smooth opera-
tion.
Checkthe front wheelalignment(seesection181.

lllustrated Index
t
Referto the drawingbelowfor transmissiondisassembly/reassembly.
Cleanall the partsthoroughlyin solventand dry with compressedair.
attthe panswithoil beforereassembly.

Luoricate
I
NOTE:
. Thistransmission usesno gasketsbetweenthe majorhousings;useliquidgasket(P/N08718-0001or08718-0003)
(seepage '13-93).
. Alwayscleanthe magnet@ wheneverthe transmissionhousingis disassembled.
. Inspectall the bearingsfor wear and operation.
\ I
ir 6d
a h P
i a .l t f l t @
) K1T\A R I
l,l 1r
@ r t ? uh
"ii
L6q
i " \ ^ 'u
Br
?-c
t @ )
E,M A
# & f
o-*ffiX,
'F@
,
€D
13-54
Bolt Size TorqueValue
6x1.0mm 12 N.m (1.2kgnm,8 lbf'ft)

6x1.0mm 1 5 N . m( 1 . 5k g f ' m ,1 1 l b ff t )
c 8 x 1 . 0m m 1 5 N . m( l . 5 k g f . m 1
, 1l b i f t )
n '1.2m 5m 24 N'm (2.4kgim, 17lbift)
8x
E 8 x 1 . 2 5m m 27 N.m (2.8kgf.m,20lbf'ft)
F 8 x 1 , 0m m 30 N.m (3.1ksf m. 22 lbift)
:!, ANGULARBALLBEABING
5i WASHERReplace.
6 TRANSMrssioN HouslNG
:2, STOPRING 80 mm SHIM
:3] TAPERRING !9
..-I NEEOLEBEARING @ SHIFTPIECESHAFT
(6' INTERLOCK
l!-- SPACER
O SYNCHRORING @ sHrFrPECE
? SYNCHROSPRING 6} SHIFTARM HOLDER
E 5TH/REVERSE SYNCHROSLEEVE @ seucr nnrvt
...] sTH/REVERSE SYNCHROHUB I9 SELECTRETURNSPRING
O SYNCHBOEING @ 10 mm SHIM
.11-rsTH GEAR 6, 10 mm WASHER
1A 38 x 43 x 26 mm NEEDLEBEARING @ LOCKCOLLAR
I13)SPACERCOLLAR i6sl3 x l5 mm SPRINGPIN Replace.
t0 8 mm SPRINGWASHER
[!] /ITHGEAR
.T5)SYNCHRORING A) CHANGEPIECE
ll SPRING L.25.6mm (1.01in)
O SYNCHROSPRING '' MAGNET
17 3RD/4THSYNCHROHUB
?4)CLUTCHHOUSING
O 3RD/4THsYNcHRo SLEEVE ta. 14x 25 x 16 mm OILSEALReplace.
ii9 38D GEAR Boo
8I MAINSHAFT
A sHrFT
2i WASHER
ASSEMBLY
O D|FFERENT|aL
Seesection15
A SPRINGWASH€R iIO SHIFTRODBOOT
?I BALLBEARING 6 OIL GUIDEPLATE
.a4,28 x 41 x 7 mm OIL SEALReplace.
I .2i 35 x 56 x 8 mm OIL SEALReplace.
t-t 14 x 20 mm DowEL PIN
.'] OIL CHAMBERPLATE
@ 33 x 60 x 20 mm NEEDLEBEASING
O BEARINGRETAINER PLATE
lD LocK WASHERReplace.
.0 couNTERSHAFI
O REVERSE IDLERGEARSHAFT
.iI..,REVERSE IDLERGEAR A DISTANCECOLLAR
'd REVERSE SHIFI HOLDER 6 & x 4I x 22 mm NEEDLEBEARING
ait sHIFTPIECE 6. 1sr GEAR
'34 srH/REVERSE @ FRICTIONDAMPER
5 x 22 mm SPRINGPIN Replace.
3' 1ST/2NDSHIFTFORK O SYNCHRORING
,34' .d SYNCHROSPRING
3RD/4THSHIFTFORK
sstrr ronx
i9t)srH/nevense @ 1ST/2NDSYNCHROHUB
33 OIL GUTTERPLATE ..9i.REVERSEGEAR
!' SNAPRING C) DOUBLECONESYNCHRO
3d 72 mm THRUSTSHIM O FRICTIONDAMPER
S SPACER
@ OIL GUIDEPLATE
4t 10 mm WASHERReplace 6 T2 x TI x 24 mm NEEDLEBEARING
ti REVERSE TDLERGEARSHAFTBoLT (!' 2ND GEAR
54 N.m {5.5kgf m, 40lbIft) 61 3RDGEAR
4N TBANSMISSIONHANGERB iD 4TH GEAR
43]BREATHER CAP @ 5TH GEAR
(O NEEDLEBEARING
A,JTRANSMISSIONHANGERA (10BALLBEARING
IT' BACK-UPLIGHTSWITCH
25 N.m {2.5kgl.m,18lblftl @ SPRINGWASHER
aO14 mm WASHERRePlace
14 mm f,o LoCKNUTReplace.
mm SEALINGBOLT
16 mm 108- 0- 108N'm
tt 16 1 1 1 . 0 - 0 * 1 1 . 0k g fm ,
29 N.m (3.0kgf m,22 lbf ft)
:4s)32 mm SEALINGBoLT 80* 0- 80lbI.ft)
25 N m 12.5kgl m, 18 lbl'ft) IO CLUTCHLINEBRACKET
.!rl 40 x 62 x I mm OIL SEALReplace .d BACK.UPLTGHTSWITCHHARNESSBRACKET
00 STEELBALLD.5/15 iN
SPRINGL. 30 mm {1.2in)
12 mm WASHERReplace.
SETSCREW
22 N.m {2.2kg{ m, 16 lbl ftl
@l OILDRAINPLUG
39 N.m {4.0kgf m, 29lbtftl
WASHERReplace.
OILFILLER PLUG
4,t N.m {4.5kgl m, 33 lblftl
13-55
TransmissionHousing
Removal
NOTE:Placethe clutch housingon two piecesof wood 5. Loosenthe transmissionhousingattachingbolts in
t h i c k e n o u g ht o k e e p t h e m a i n s h a f tf r o m h i t t i n g t h e a crisscrosspattern in severalsteps,then remove
workbench. them.
'1. TRANSMISSION
Removethe back-uplight switch.
HANGERA
2. RemovetransmissionhangerB.
3. Removethe set screws,the springs,and the steel

balls.
BACK.UPUGHT
swrTcH
ATTACHINGBOLT
SETSCREW
o. R€movethe 32 mm sealingbolt.
1. Expandthe snap ring on the countershaftball bear-

ing, and removeit from the groove using a pair of
snap ring pliers,
I {
4. Removethe reverseidler gearshaftbolt.
32 mm SEALINGBOLT
WASHER
Replace.
REVEBSE
SNAPRING
13-56
ReverseShift Holder,
Reverseldler Gear
ClearanceInspection
Separatethe transmissionhousingfrom the clutch 1 . Measurethe clearancebetween the reverseshift
housing,and wipe it cleanof the sealant. shift piecepin
holderand the 5th/reverse
Removethe 72 mm thrust shim and the oil guide Standard:

platefrom the transmissionhousing Revsrs. Sids: 0.05- 0./t5mm {0'002- 0.018in}
5th Side: 0.4 - 0.9 mm (0.02- 0.0'l in)
72fifi
THRUSTSHIM SHIFTPIECE
sTH/REVERSE PIN
fi
lf the clearanceare not within the standard,mea-
sure the width of the grooves in the reverseshift
HOUSING
TRANSMISSION holder.
Removethe 16 mm sealingbolt and the oll gutter Standard:

plate. Rsvers€Side: 7.05- 7.25 mm (0'278- 0.285in)
5th Sid6: 7.,1- 7.7 mm (0.29- 0 30 inl
SIDE
REVERSE
OIL GUTTERPLATE
lf ths width of the grooves are not within the

standard, replacethe reverseshift holder with a
new one.
lf the width of the groovesare within the stan-
dard, replacethe sth/reverseshift piece with a
new one
{cont'd)
13-57
ReverseShift Holder,Reverseldler Gear
ClearanceInspection(cont'dl Removal
3. Measurethe clearancebetween the reversei d l e r 1. Removethe reverseshift holder.
gearand the reverseshift holder.
Standard: 0.5- 1.0mm 10.02 - 0.04inl

ServiceLimit: 1.8 mm (0.07inl REVERSE
SHIFTHOLDEB
REVERSE
SHIFTHOLDER
Removethe reverseidler gear and the reverseidler

gearshaft.
lf the clearanceis more than the servicelimit. mea,
surethe width of the reverseshift holder.
Standard:13.0- 13.3mm (0.512- 0.524in)
REVERSE
IDLER
lf the width is not within the standard,replace

the reverseshift holderwith a new one.
lf the width is within the standard,replacethe
reverseidlergearwith a new one.
13-58
ChangeHolderAssemblY
InsPection
Glearance
,
1 . Measurethe clearancebetweenthe shift pieceand 3. Measurethe clearancebetweenthe selectarm and
the shift arm holder. the interlock.
0.05- 0.20 10002 - 0.008inl

Standard: 0.1- 0.3 mm {0.004- 0.012in) Standard:
service Limit: 0.6 mm {0.02in) ServiceLimit:0.45mm (0.018inl
SHIFTPIECE
INTERLOCK
SHIFTARM HOLDER
lf the clearanceis more than the servicelimit, mea- 4. lf the clearanceis more than the servicelimit, mea-
surethe width of the groovein the shift piece' surethe width of the interlock.
Standard:8.1- 8 2 mm {0'319- 0.323in} Standatd: 9.9 - 10.0mm (0.390- 0.39'tin)
SHIFTPIECE
lf the width of the groove is not within the stan- lf the width is not within the standard,replace
dard,replacethe shift piecewith a new one' the interlockwith a new one.
lf the width of the grooveis within the standard, lf the width is within the standard,replacethe
replacethe shift arm holderwith a new one' selectarm with a new one.
(cont'd)
13-59
ChangeHolder Assembly
ClearanceInspection(cont'd)
7. Measurethe clearancebetweenthe selectarm and
I
9. Measurethe clearancebetweenthe shift arm holder
t h e 1 0m m s h i m . and the changepiece.
Standard:0.01- 0.2 mm (0.0004- 0.008in) Standard; 0.05- 0.35 (0.fi)2 - 0.014inl

SELECTARM
SHIFTARM HOLOER
l0 mm SHIM
vo
lf the clearanceis more than the servicelimit. mea_
8. lf the clearanceis not within the standard,select surethe grooveof the changepiece.
and installthe appropriatel0 mm shim for the cor-
rectclearancefrom the chartbelow. Standard: 12.05- 12.15mm {0.i[7it4- 0.47txtinl
mm Shim

24435-689-000 0.8 mm (0.031in)
B 24436-589-000 1.0mm (0.039in)
c 24437-689-000 1.2mm (0.047in)
D 24438-689-000 1 . 4m m ( 0 . 0 5 5i n )
E 24439-689-000 1 . 6m m { 0 . 0 6 3i n )
CHANGEPIECE
lf the groove is not within the standard,replace

the changepiecewith a new one.
lf the groove is within the standard,replacethe
shift arm holderwith a new one.
13-60
Removal
1. Bemovethe shift pieceshaft.then removethe shift
11. Measurethe clearancebetweenthe selectarm and
pieceand the interlock.
the changePiece.
SHAFT
SHIFTPIECE
Standard: 0.05- O'25mm 10'002- 0'010 in)
ServicaLimii: 0.5 mm {0.02in)
SELECTARM
INTERLOCK
2. Remove the change holder assembly'
U O
't2. lf the clearanceis more than the servicelimit, mea-
surethe width of the changePlece.
-
Standard: 12.05- 12.15mm {0.47'|{ 0 47tI| inl
PIECE
CHANGE
a lf the width is not within the standard,replace

the changePiecewith a new one'
a lf the width is within the standard,replacethe
selectarm with a new one.
13-61
ChangeHolder Assembly
P'io' to '"""sembring,creanaI the pans in sorvent,dry them and
I apprylubricantto any contactsurfaces.
l0 mm SH|M
R€TURNSPRING
,omm
wAsHEF
I
t /
@@d.
r]7
|
I
3 x 16 mm SpRtNG
Replace.
SELECTARM
13-62
Mainshaft,Countershaft,Shift Fork
Removal
1 . Removethe mainshaftand the countershaftassem- 4. Removethe chamberPlate.
blieswith the shiftforksfrom the clutchhousing.
CLUTCHHOUSING
NOTE:Tape the mainshaftspline beforeremoving
assemblies.
the mainshaftand the countershaft
Removethe springwasherand the washer'
MAINSHAFT
COUNTERSHAFT
Tapethe CHAMEEFPLATE
splrnes.
WASHER
v Removethe differentialassemblyfrom the clutch

housing.
DIFF€RENTIALASSEMBLY
CLUTCH HOUSING
13-63
Shift Rod
Removal
1.
l_
Removethe shift rod boots.
2. R e m o v et h e c h a n g ep i e c ea t t a c h i n gb o l t a n d t h e
springwasher.
3, Bemovethe set screw.then removethe spring and

the steelball.
4, R e m o v et h e s h i f t r o d , t h e n r e m o v e t h e c h a n g e
piece,
5. Removethe oil seal.
SETSCREW
OIL SEAL
CHANGEPIECE R€placs.
SPRING
L. 25.6
11.01inl
STEEL
(D.s/16
*ry SHIFT
noD
BOOTS
\,,rl
SPRINGWASHEN
ATTACHINGAOLI
13-64
Shift Fork AssemblY
lndex
-A
cleanall the partsin solvent,dry them and applylubricantto any contactpans
eriorro reassemblinq.
I
mm PINPUNCH
sTH/REVERSE
SI{IFTFORK
3RD/4THSHIFTFORK

Shift Fork Assembly
ClearanceInspection
NOTE:The synchrosleeveand the synchrohub should 3. Measurethe clearancebetweenthe shift pieceand
be replacedas a set. the shiftfork shafts.
1. Measurethe clearancebetweeneach shift fork and Standard: 0.2- 0.5 mm (0.008- 0.02inl
its matchingsynchrosleeve. ServiceLimit: 0.8 mm {0.03in)
Standard: 0.35- 0.65mm {O.Olit- 0.026inl

ServiceLimit: 1.0mm t0.04inl
SHIFTFOBK
lf the clearanceis more than the servicelimit. mea_ lf the clearanceis more than the servicelimit. mea-
surethe thicknessof the shittfork finoers.
Standard:7.4- 7.6 mm (0.291- 0.299in)

surethe width of the shift Diece.
t ,
Standard:11.9- 12.0mm (0.469- 0.it72in)
SHIFTPIECE
l f t h e t h i c k n e s so f t h e s h i f t f o r k f r n g e r sr s n o t lf the width of the shift piece is not within the

within the standard,replacethe shift fork with a standard,replacethe shift piecewith a new one.
new one. lf the width of the shift piece is within the stan_
lf the thicknessof the shift fork fingersis within dard,replacethe shift fork with a new one.
the standard,replacethe synchrosleevewith a
13-66
Mainshaft AssemblY
lndex
Notethe follow
. The 3rd/4thand the 5th synchrohubsare installedwith a press
. Installthe angularballbearingwith the thin-edgedcuterracefacingthe stop rrng'
Priorto reassembling.cleanall the partsin solvent,drythem,and apply lubricant to any contactsurfacesThe

them'
3rd/4thand the sth synchrohubs,however,shouldbe installedwith a pressbeforelubricating
ANGULARBALLBEARING
Inspectlor wear
and operation.
Notethe drrectlon
oI installatton.
STOPRING
TAPERRING
NEEOLEEEARING
SYNCHRO Inspectfor wear
SPRING and operation.
3RO/4THSYNCHROHUB SPACER
v 3RO/4THSYNCHROSLEEVE
SYNCHRORING
Inspection.
page13-81
SYNCHRO
SPRING
SYNCHRO SYNCHROHUB
SPRING
5TH/REVERSE
3RDGEAR SYNCHROSLE€VE
Inspection,
page13-81 Inspection, SYNCHEO
page13-68,81 SPRING
SYNCHRORING
NEEDLEBEARING Inspection,
page13 8'1
and operation.
GEAR
Inspeclron,
page13-70,81
NEEDLEBEARING
InspectIor wear
COLLAB
and operation.
4TH GEAR
Inspection,
p a g e1 3 ' 6 9 , 8 1
13-67
Mainshaft Assembly
ClearanceInspection
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 D l a c et h e 2. lf the clearanceis more than the servicelimit, mea-
synchrosleeveand the synchrohub as a set. surethe thicknessof 3rd gear.
1. Measurethe clearancebetween2nd and 3rd oears, Standard: 34.92- 3it.97mm t1.375- 1.377int
ServiceLimit: 3,1.3mm (1.350inl
Standard: 0.06- 0.21mm (0.002- 0.008inl
ServiceLimit:0.3 mm (0.01inl
I d
lf the thicknessof 3rd gear is lessthan the ser-
vice limit.replace3rd gearwith a new one.
lf the thicknessof 3rd gear is within the service
limit, replacethe 3rd/4thsynchrohub with a new
one.

3. Measurethe clearancebetween 4th gear and the 5. lf distance@ is not within the standard.replacethe
spacercollar. spacercollarwith a new one. lf distanceO is within
the standard.measurethe thicknessof 4th gear'
Standard: 0.06- 0.21 mm (0.002- 0.008inl
Servic€Limit: 0.3 mm (0.01inl Standard: 31.12-31'17mm {1.237- 1.239inl
ServiceLimh:31.3mm (1.232in)
It the clearanceis more than the servicelimit, mea-

suredistance@ on the spacercollar
Standard:26.03- 26.08mm {1.025- 1.027in}
lf the thicknessof 4th gear is less than the ser-

vice llmit, replace4th gearwith a new one.
lf the thicknessof 4th gear is within the service
limit, replacethe 3rd/4thsynchrohub with a new
one,
4TH GEAR
SIDE
SPACERCOLLAE
(cont'd)
13-69
Mainshaft Assembly
Inspection(cont'dl
Clearance \
6. Measurethe clearancebetween sth gear and t h e 8. lf distance(E is not within the standard,replacethe
spacercollar. spacercollarwith a new one.
lf distance@ is within the standard,measurethe
Standard: 0.05- 0.21mm (0.002- 0.008inl thicknessof 5th gear.
inl
Servicelimit: 0.3 mm 10.012
Standard: 31.12-31.47mm {1.237- 1.239in}
ServiceLimit:31.3mm {1.232in)
5TH GEAR
5TH GEAB
lf the thicknessof 5th gear is lessthan the ser-

u,a
suredistance€) on the spacercollar. vice limit, replacesth gearwith a new one.
lf the thicknessof 5th gear is within the servace
Standard:26.03- 26.08mm {1.025- 1.027inl l i m i t , r e p l a c et h e 5 t h s y n c h r oh u b w i t h a n e w
one.
SPACERCOLLAB
3-70
Disassembly
1. Removethe ball bearingusing a bearingpuller as 3. S u p p o r t3 r d 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
shown. mainshaftout of the 3rd/4thsvnchrohub, as shown.
BEABINGPULLER
BALLBEARING
CAUTION: Remove the synchro hubs using a ptess

and the sts€l blocks as shown. Use of a i8w'type
puller can causedamageto th€ gear teeth.
S u p p o r ts 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 sth synchrohub, as shown.
13-71
MainshaftAssembly
Inspection (
1. Inspectthe gear surfacesand the bearingsurfaces 2. Inspectfor runout. lf the runout is more than the
for wear and damage.then measurethe mainshaft servicelimit, replacethe mainshaftwith a new one,
at points A, B, and C. lf any partsof the mainshaft
are less than the service limit, reDlacemainshaft Standard: 0.02 mm 10.0008inl max.
with a new one. Ssrvice Limit: 0.05 mm 10.002inl
t
Standard: N O T E : S u o o o r t t h e m a i n s h a f ta t b o t h e n d s a s
A: 27.987- 28.000mm {1.1018- 1.1024in} shown.
B: 37.98i1- 38.fi)0 mm (1.,|!t5,0
- 1.4960inl
Ci27.977- 27.990mm 11.1015 - 1.1020inl
ServiceLimit:
A; 27.940mm {1.1000in}
B: 37.930mm (1./{133
in)
C:27.930mm (1.0996inl
Inspectfor wear
ano oamage.
Inspectoil passages
tor clogging.
1 3-7 2
Reassembly
CAUTION: 2. Installthe sth synchrohub using the specialtools
. Press the 3rd/4th and the 5th synchro hubs on the and a pressas snown.
mainshaft without lubrication.
o When installing the 3rd/,lth and the sth synchro PRESS
+
DRIVER, {0 mm l.O.
hubs, support the mainshaft on steel blocks, and 07746- 0030100
installthe synchro hubs using a prsss.
. Install the 3rd/4th and the sth synchro hubs with a
maximumplessur€of 19.6kN (2,000kg, 14,466lbl.
NOTE:Referto page13-67for reassemblysequence. ATTACHMENT, sTH SYNCHROHUB

35 mm LD.
1, Support 2nd gear on steel blocks,then install the 07716 - 0030,100
3rd/4thsynchro hub using the specialtools and a
press,as snown.
NOTE:
. A f t e r i n s t a l l i n g c. h e c kt h e o p e r a t i o no f t h e
3rd/4thsynchrosleeveand hub.
. Assemblethe 3rd/4th synchro hub and sleeve
togetherbetoreinstallingthem on the mainshaft.
3RD/4TH DBIVER,10 mm l.O.

SYNCHROHU3 07746- 00301U)
Closedend
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 pressas shown.
l.
/ lrrlcHlileNr. ss .- t.o.
07746- 0030,100
DRIVER,40 mm LD.
0?7a6- It030100
3RD/{TH
SYNCHRO
SLEEVE
2ND GEAR

GountershaftAssembly
Index
NOTE:The 4th and sth gearsare installedwith a press.
3 Priorto reassembling,
cleanall the partsin solvent,dry them and applylubricantto any contactsurfaces.The 4th
and 5th gears.however,shouldbe installedwith a pressbeforelubricatingthem.
SYNCHROSPRING
LOCKNUT Replace
REVERSE
GEAR 108"0-108N.m
-
i11.0 0- l1.0kgtm,
180-0-80lbttr
WASHER
EALLEEARING
and operation.
NEEDLE BEARING
lnspectfor wear
ano operaton.
5TH GEAR
DAMPER
4THGEAR
ST GEAR 3RDGEAR
Inspection,
page13-75
DISTANCE NEEDLEBEARING
NEEDLEBEARING
COLLAR
ano operatron,
and operatron,
COUNTERSHAFT
page13-77
Inspection, SPACER
FRICTIONDAMPER
DOUBLECONE
page13 81
Inspection,
13-74
I
Inspection
Clearance
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 1 s t g e a r a n d 3. M e a s u r et h e c l e a r a n c eb e t w e e nt h e 2 n d a n d 3 r d
distancecollar. gears.
Standard: 0,045- 0.205mm
10.002- 0.008in) Standard: 0.07- 0.14mm
ServiceLimit: 0.25 mm (0.01inl (0.003- 0.006inl
ServicoLimii: 0.24 mm (0.009in)
'-.
-=Jl
ll
71 il 3RD GEAR
2NDGEAR
, ' 2. lf the clearanceexceedsthe servicelimit. measure 4. lf the clearanceexceedsthe servicelimit, measure

the thicknessesof 1stgear. the thicknessesof znd gearand spacer.
I
lST GEAR
Standard:29.45- 29.50mm {1.159- 1.161in} 2ND GEAR
Standard:28.92- 28.97mm (1.139- 1.1't1inl
DISTANCECOLLAR
Standard:@36.5mm (1.4i1in)
@ ,12.0mm (1.65in) SPACERCOLLAR
@ 3 0 . 0m m ( 1 . 1 8i n ) Standard:29.07- 29.09mm {1.1it4- 1.1,15
inl
lf the thicknessesof 1st gear and distancecollar lf the thicknesses of 2nd gearand spacerare less
are less than the standard,replacewith a new than the standard,replacewith a new one.
one. s f 2 n d g e a r a n d s p a c e ra r e
l f t h e t h i c k n e s s eo
lf the thicknessesof 1st gear and distancecollar within the standard,replacethe lsv2nd synchro
are within the standard,replacethe lsv2nd syn- hub with a new one.
chro hub with a new one.
13-75
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 vi n a 4, Removethe bearing outer race,then remove the
benchvisewith wood blocks. needlebearingusinga bearingpulleras shown. a
It
2. Raisethe locknuttab from the groove in the coun- I
tershaft,then remove the locknut and the spring
washer.
BEARINGPULLEF
BEARING
CAUTION: Romovethe gears using a pr63 and the

stesl blocks as shown, Use of a ,aw-typo puller can
causedamagelo lhe gear tooth.
Removethe ball bearingusing a bearingpulle. as Support 4th gear on steel blocks, and press the
shown. countershaft
out of sth and 4th gears,as shown.
BEARINGPULLER
sTHGEAF
BALLBEARING
{TH GEAR
13-76
Inspection
1. Inspect the gear surfaces and the bearing surfaces 2. Insoectfor runout. lf the runout is more than the
for wear and damage,then measurethe counter- service limit, reolacethe countershaftwith a new
shaft at points A, B, and C. lf any parts of the coun- one.
tershaftare lessthan the servicelimit. reDlacecoun-
torshaft with a new one. Strndard: 0.02 mm {0.(x)08in) max.
Servic. Limit 0.05 mm (0.002in)
Standard:
A: 2/t.980- 2{.993 mm (0.9835- 0.9&O in} NOTE: SuoDortth€ countershaftat both ends as
B: 35.984- 37.000mm {1.4561- 1.4567in) shown.
G:33.fiD - 33.015mm {1.2992- 1.2998in)
Sorvicc Limit:
Ar 2/t.9't0mm 10.9819inl
B: 36.930mm {1.'l5qt in} Rotatelwo complele
C: 32.950mm {1.2972in} revotutons.
Insp€ctfor wear
t
Inspectoil passagefor clogging.
13-77
Reassembly
{
CAUTION: 4. lnstallthe reversegear.
. Pross4th and sth gears on the countershaft without
lubrication. I n s t a l lt h e s y n c h r os p r i n g . a n d t h e d o u b l e c o n e
. When installing ilth and sth geafs, support the shaft synchroas shown.
on steel blocks, and install the gears using a press.
. Install ilth and sth gear with a maximum pressureof
25.5 kN (2,600ksf, 18,806lbf).
NOTE;Referto page13-74for reassemblysequence.
'1. Installthe ;
distancecollar and the needle bearinos
on the countershaft.
Assemblethe friction damper,the needlebearing,

COUNTERSHAFT
and 2nd gear,then installthem by aligningthe fin-
gers on the frictiondamperand the groovesin the
1sv2ndsynchrohub with the fingersof the double
c o n e s y n c h r o a n d t h e g r o o v e so n 2 n d g e a r , a s
Installthe frictiondamper,the synchroring,and the snown.
synchrospringon 1stgear.
Installthespacer.
Installthe 1sv2ndsynchrohub by aligningthe fin- 2ND GEAR
gers on the frictiondamperand the groovesin the
1sv2ndsynchrohub,as shown.
lST/2NO
FRICTIONDAMPER
Install the parts assembledi n s t e p s 2 - 6 o n t h e

countershaft.
lSI GEAR
13-78
'1'1.
9 . S u p p o r t t h e c o u n t e r s h a f to n a s t e e l b l o c k , a n d Install the needle bearing, then install the ball bear-
install4th gear usingthe specialtools and a press. ing using the special tools and a press as shown.
as 5nown. PRESS
DRIVER,40 mm LD.
07746- 0030100
ATTACHMENT,30 mm LD.
07746- 0030300
ATTACHMENT,35 mm LD.
07746- 0030400
J.-
1 0 . S u p p o r t t h e c o u n t e r s h a f to n a s t e e l b l o c k , a n d 1 2 . 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
install5th gear using the specialtools and a press, benchvisewith wood blocks.
as shown.
lnstallthe spring washer,tighten the locknut,then
stakethe locknuttab into the groove.
LOCKNUT
1 0 8 - 0 - 1 0 8 N . m1 1 1 . 0 -0 - 1 1 . 0 k g t . m ,
80+ 0* 80 lbf'ftl
ATTACHMENT,30 mm I,D,
07746- 0030300
WOOD BLOCKS
13-79
Synchro Sleeve,Synchro Hub
Inspection Installation
1 , Inspectgear teeth on all synchrohubs and synchro When assemblingthe synchrosleeveand synchrohub,
sleevesfor rounded off corners. which indicates 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.
I n s t a l le a c h s y n c h r o h u b i n i t s m a t i n g s y n c h r o
sleeveand checkfor freedomof movement. CAUTION:Do noi install tho synchro sleevewith its
longer toeth in the synchro hub slots, because it will
NOTE: lf replacementis required,always replace damage the spring ring.
the synchrosleeveand synchrohub as a set.
SYNCItRO LONGER
TEETH
SLEEVC
13-80
SynchroRing,Gear
Inspection SYNCHROSPRING
'1. Inspectthe synchroring and gear.
A: Inspectthe insideof the synchroring for wear'

SYNCHRORING
B: Inspectthe synchro sleeveteeth and matching
teethon the synchroring for wear (roundedoff).
oo
GOODWORN
C: Inspectthe synchro sleeveteeth and matching
teethon the gearfor wear (roundedoff).
n n
U WORN
U
GOOO
D: Inspectthe gear hub thrustsurfacefor wear.
E: Inspectthe cone surfacefor wear and roughness.
F: Inspectthe teeth on all gears for unevenwear,

scoring,galling,and cracks'
2. Coatthe cone surfaceof the gearwith oil, and place

the synchroring on the matchinggear. Rotatethe
ring,makingsurethat it does not slip
Measurethe clearancebetweenthe synchro ring
t a n dg e a ra l l t h ew a y a r o u n d .
NOTE:Holdthe synchroring againstthe gear even-

ly while measuringthe clearance.
Synchro Ring-to-GearClearance
(0.029- 0.0'16in)
Ssrvice Limit:0.,0mm {0.02in}
Double Cone Synchro-to-GealClearanc€

Standald:
@: (Outer Synchro Ring to Synchro Con6l
0.5- 1.0mm 10.02 - 0.04in)
@: (Synchrocone to Gearl
0.5- 1.0mm (0.02- 0.04inl
O: {Outer Synchlo Ring to Gear)
0.95- 1.68mm (0.037- 0.066in) SYNCHROCONE
ServiceLimit:
@: 0.3 mm {0.01in}
@: 0.3 mm {0.01in)
O: 0.6 mm t0'02inl
lf the clearanceis lessthan the servicelimit, replace

the synchroring and sYnchrocone.
13-81
Differential
Index BacklashInspection
1. Placethe differential
assemblyon V-blocksand install
both axles.
M e a s u r et h e b a c k l a s ho f b o t h p i n i o ng e a r s .l f t h e
backlashis not within the standard,replacethe dif,
ferentialcarrier.
Standard(New):0.05- 0.15mm (0.002- 0.006inl
80 mm SHIM
page'13,84
Selection, DIAL INDICATOR
FINALDRIVENGEAR
Inspecttor wear and damage.
BALLBEAFING 101 N.m {10.3kgtm,74.5 lbf.ft)

Inspectfoawear and ooeration. Left-handthreads
13-82
FinalDrivenGearReplacement BearingReplacement
'1. Removethe bolts in a crisscrosspatternin several NOTE:Checkthe ball bearingsfor wear and rough rota-
steps,and removethe final drivengearfrom the dif- tion. lf bearingsare OK, removalis not necessary.
ferentialcarrier.
1. Removethe ball bearingsusing a standardbearing
N O T E :T h e f i n a l d r i v e ng e a r b o l t s h a v e l e f t - h a n d pullerand bearingseparatoras shown.
threads,
BEARINGPULLER
12x 1.0mm
101N.m {'10.3kgf.m,74.5lbf.ftl
Left hand
BEARINGSEPARATOR
lCommercially
availab16)
FINALDRIVENGEAR
Chamferon insidedaameterof
final drivengear faces carrier.
BALL BEARING
rla 2. I n s t a l ln e w b a l l b e a r i n g su s i n gt h e s p e c i a tl o o l a s
shown.
2. Installthe final driven gear by tighteningthe bolts
in a crisscrosspatternin severalsteps. NOTE: Drive the bearingssquarelyuntil they bot-
tom againstthe carrier.
BALL BEARING
13-83
Differential
ThrustShim Adjustment
(
1. Installthe differentialassembly,makingsure it bot Installthe transmissionhousing(seepage13-94).
toms in the clutchhousing,usingthe specialtool as
shown. NOTE:Do not apply liquidgasketto the matingsur-
faceof the clutchhousing.
4. T i g h t e nt h e t r a n s m i s s i o nh o u s i n ga t t a c h i n gb o l t s
ORIVER,40 mm LO. (seepage 13-94).
o7746-0030100
I x 1.25mm
27 N'm (2.8 kgf.m, 20 lbf.ftl
Usethe specialtool to bottomthe differentialassem.

bly in the clutchhousing.
Measureclearancebetweenthe 80 mm shim and

bearingouter racein the transmissionhousing.
l n s t a ltlh e 8 0 m m s h i m .
NOTE:lnstallthe 80 mm shim that was removed.
mm SHIM
13-84
7. lf the clearanceis not within the standard,selecta 8 . Removethe boltsand transmissionhousing.
new 80 mm shim from the followingtable.
Beplacethe 80 mm shim selectedin step 7, then
Standard:0 - 0.10mm (0 - 0.004inl recheckthe clearance.
80 mm Shim the transmissionand installthe trans-

1 0 . Reassemble
missionhousing.
Part Number Thickn6ss
'1.0mm (0.0394in)
41441- PL3- 800
B 41442-PL3-B00 1.1mm (0.0433in)
c 41443-PL3-800 1.2mm (0.0472in)
D 41444-PL3-800 1 . 3m m ( 0 . 0 5 1i2n )
41445-PL3-800 1 . 4m m ( 0 . 0 5 5 i1n )
41446-PL3-800 1 . 5m m ( 0 . 0 5 9 i1n )
41447-PL3-800 1.6mm (0.0630in)
H 41448-PL3-800 1.7mm (0.0669in)
41449-PL3-800 1.8mm (0.0709in)
K 4 1 4 5 0 - P L 3 - B 0 0 1 . 0 5m m ( 0 . 0 4 1 i3n )
41451- PL3- 800 1.'15mm (0.0453in)
IV 4 1 4 5 2 - P L 3 - 8 0 0 1.25mm (0.0492in)
N 4 1 4 5 3 - P L 3 - B 0 0 1.35mm (0.0532inl
t P 41454-PL3-800 1.45mm (0.0571in)
1 . 5 5m m ( 0 . 0 6 1i0n )
41455-PL3-800
R 4 1 4 5 6 - P L 3 - 8 0 0 1.65mm (0.0650inl
4 1 4 5 7 - P L 3 - 8 0 0 1.75mm (0.0689in)
NOTE;lf the clearancemeasuredin step 6 is within

the standard,it is not necessaryto 9o to step 9.
13-85
Clutch HousingBearing
Replacement
(
Mainshaft: 3. Drivethe new oil seal into the clutchhousingusing
L Removethe ball bearingusing the specialtools as
shown.
3/81_16SLIDE
HAMMER
{ c o m m e r c i a l l ya v a i l a b l e )
ATTACHMENT,42 x 47 mm
HANOLE
07746- 0010300
07749- 0010000
OIL S€AL
Replace.
ADJUSTAELEBEARING
PULLER,25 - 40 mm
07736- A01000A
4. Drivethe ball bearinginto the clutchhousingusing

2. Removethe oil sealfrom the clutchhousino. the specialtoolsas shown.
HANDLE
07749- 0010000 ATTACHMENT,52 x 55 mm
07746- 0010il{)0
CLUTCHHOUSING
BALLBEARING
PILOT,28 mm
07746- 0041100
13-86
3. Positionthe oil guide plateand new needlebearing
Countershaft:
in the bore of the ctutchhousing,then drive in the
1. Bendthe tab on the lockwasherdown,then remove needlebearingusingthe specialtools as shown
the bolt and bearingretainerplate.
NOTE:Positionthe needlebearingwith the oil hole
facingup.
NEEDLE
LOCKWASHER OIL HOLE
BEARINGRETAINERPLATE ^
g Reolace.
d---""-
cLutcHtlouslNG
t
Removethe needlebearingusing the specialtools
as shown,then removethe oil guide plate'
NEEDLE
BEARING
3/8' - 16SLIOEHAMMER
(CommerciallYavailable)
Installthe bearingretainerplateand new lockwash-
er, then bendthe tab againstthe bolt head'
8x10mm
15N'm (1.5kgt'm,rl |bt'ft)
LOCK
WASHER
Replace.
ADJUSTABLEBEARING
PULLER,25 - {o mm
07736- Aolmo A
13-47
Mainshaft Thrust Clearance
Adjustment
1. Removethe 72 mm thrust shim and oil guide plate
V .
5. Measuredistance@ betweenthe end of the clutch
from the transmissionhousing. housingand bearinginnerrace.
72 mm THRUSTSH|M NOTE;
. Usea straightedgeand depthgauge.
TRAt{SMtSStON . Measureat three locationsand averagethe read-
OIL GUIOEPLATE
HOUSING ings.
INNERRACEot EALLBEARING
lnstall the 3rd/4th synchro hub. spacer collar,5th

synchrohub. spacer,and ball bearingon the main_
shaft,then installthe above assemblyin the trans_ Selectthe prcpet72 mm thrust shim from the chart
missionhousing. by usingthe formulabelow.
lnstallthe washe[on the mainshaft, NOTE:Us€only one 72 mm thrustsntm.
4. Measuredistance@ betweenthe end of the trans- Shim Selection Formula:

missionhousingand washer.
Fromthe measurements you madein steps4 and 5:
NOTE; . Add distanceO lstep5) to distance@ (step4).
. Usea straightedgeand verniercaliper.
. Measureat three locationsand averagethe read_ . From this number, subtract 0.93 (which is the
ing. ENOot midpointof the flex rangeof the clutch housing
lnA sMtsstoN
HOUSING bearingspringwasher).
MAINSHAFT
. Takethis numberand compareit to the available
shim sizesin the chart.
{Forexample)
B;2.39
+ C:0.22 - 0.93
3RD/irTHSYNCHROHUB
2.61 = 1.68
SPACCRCOLLAR
Try the 1.68mm (0.0661in) shim.
5TH SYNCHROHUB
AALL BEARING
TFANSMISSION
HOUSING
13-88
72 mm Thrust Shim 7. lnstallthethrustshim selectedand oil guide platein
the transmissionhousing.
Part Number Thickness OIL GUIDEPLATE
72 mm THRUST
23931- P21 000 0.60mm {0.0236 in}
TRANSMISSION
2 3 9 3 2 - P 2 -10 0 0 0.63mm 10.0248 in)
HOUSING
c 23933 P21- 000 0.66mm (0.0260 in)
D 23934- P21 000 0.69mm (0.0272 in)
E 2393s-P21-000 0.72mm (0.0283 in)
F 23936-P21 -000 0.75mm (0.0295 in)
G 23937-P21-O00 0.78mm (0.0307in)
2 3 9 3 8 - P 2 -10 0 0 0 . 8 1m m ( 0 . 0 3 1i9n )
2 3 9 3 9 - P 2 -10 0 0 0.84mm (0.0331 in)
J 23940-P21 -000 0.87 mm (0.0343 in)
K 23941 P21- 000 0.90mm (0.0354 ini
L 23942- P21 000 0.93mm (0.0366 in)
2 3 9 4 3 - P 2 -10 0 0 0.96mm 10.0378 in) 8 . I n s t a l lt h e s p r i n gw a s h e ra n d w a s h e ro n t h e b a l l
N 23944- P21-000 0.99mm (0.0390 in) beaflng.
o 23945- P21 000 1.02mm (0.0402in)
P 23946- P21 000 1.05mm (0.0413 in) NOTE:
1.08mm (0.0425 . Cleanthe springwasher,washerand thrust shim
o 23947- P2l 000
'l
in)
R 2 3 9 4 8 - P 2 -10 0 0 1.'1 mm (0.0437in) throughlybeforeinstallation.
23949- P21 000 1.14mm (0.0449 in) . I n s t a l lt h e s p r i n g w a s h e r ,w a s h e r a n d t h r u s t
S
T 23950- P21 000 1 . 1 7m m ( 0 . 0 4 6i1n ) shim properlY.
23951- P21-000 1.20mm (0.0472in)
23952- P21-000 1.23mm (0.0484 in) -WASH€R
1.26mm (0.0496 -<]>-.-'
2 3 9 5 3 - P 2 -10 0 0 in)
t X 2 3 9 5 4 - P 2 -10 0 0
23955- P21-000
1.29mm (0.0508
1.32mm (0.0520
in)
in)
x
(-.-sK
(9r'
-sPRtNGWASHER
z 2 3 9 5 6 - P 2 -10 0 0 1.35mm (0.0531 in)

2 3 9 5 7 - P 2- 0
100 1.38mm 10.0543 in)
AB 23958- P21-000 1.41mm (0.0555 in) 9 . lnstallthemainshaftin the clutchhousing.
AC 23959 P21- 000 1.44mm {0.0567in)
23960- P21 000 1.47mm (0.0579 in) 1 0 . Placethe transmissionhousingover the mainshaft
AE 23961- P21-000 1.50mm {0.0591 in) and onto the clutchhousing.
23962 P21- 000 1.53mm {0.0602in)
' Il . Tightenthe clutch and transmissionhousingswith
AG 23963-P21 -000 1 . 5 6m m ( 0 . 0 6 1 1 i n )
AH 2 3 9 6 4 - P 2 -10 0 0 1.59mm {0.0626 in) several8 mm bolts.
'1.62mm {0.0638in)
2 3 9 6 5 - P 2 -10 0 0
23965-P21 - 000 1.65mm (0.0650 in) N O T E : l t i s n o t n e c e s s a r yt o u s e s e a l i n g a g e n t
AK 2 3 9 6 7 - P 2 -10 0 0 1.68mm {0.0661 in) betweenthe housings.
23968- P21-000 1.71mm 10.0673 in)
23969 P21- 000 1.74mm {0.0685 in) 8 x 1.25mm
2 3 9 7 0 - P 2 -10 0 0 1.77mm {0.0697in) 27 N.m (2.8 kgf.m. 20 lbf'ft)
AN
AO 23971- P21-000 1.80mm (0.0709 in)
12. Tap the mainshaftwith a plastichammer.
(cont'd)
13-89
MainshaftThrustClearance
Adjustment(cont'd)
13. Checkthe thrust clearancein the mannerdescribed
c. Seatthe mainshaftfully by tappingits end with a
oetow. plastichammer.
CAUTION: Measuremenl should be made at room

d. Threadthe mainshaftholder bolt in untjl it just
tempetature.
contactsthe wide surfaceof the mainshaftbase.
a. Slidethe mainshaftbaseover the mainshaft.
e. Zeroa dial gaugeon the end ofthe mainshaft.
MAINSHAFT f. Turn the mainshaftholder bolt clockwise;stoo

t u r n i n g w 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
m a x t m u mm o v e m e n t T . h e r e a d i n go n t h e d i a l
gaugersthe amountof mainshaftend
Dlav.
CAUTION: Turning tho mainshaft holder bolt

more than 60 degreesafter the needle of the dial
g€uge stops moving may damage the transmis_
ston.
DIALGAUGE
MAINSHAFTEASE
07GAJ- PG20.130
b. Attach the mainshaftholderto the mainshaftas

follows:
NOTE:
. Back-outthe mainshaftholderbolt and loosen
the two hex bolts.
. Fit the holder over the mainshaftso its lip is 07cAJ_ PG20110
towardsthe transmission.
. AIignthe mainshafh t o l d e r . sI i p a r o u n dt h e g. lf the reading is within the standard,the clear-
groove at the insideof the mainshaftsplines,
ance is correct.
then tightenthe hex bolts.
lf the readingis not within the standard.recheck
the shim thickness.
MAINSHAFT
HOLOER
BOLT Standard:0.11- O.18mm {0.004- 0.007in}
[--F-e
l6fffi
- l\nrx
| \-/ I/ Borrs
ff
MAINSHAFT
HOLDER
07GAJ- PG20110
MAINSHAFTBASE
07GAJ- PG20130
13-90
Transmission
ReassemblY
1. Installthe new oil seal
2. Setthe changePiece.
3. Installthe shift rod
4. Installthe steelball'the spring,and the set screw'
5. Installthe spring washer and changepiece attach-

ing bolt.
6. Installthe shift rod boots.
8x1.0mm SPRING
31 N.m 13.1kg-m, B()(
, /L.256fim
22lb-ltl
@ / t't o'ti"l I
CHANGE
PIECE
{zw"y-6@
@:4
SPRING
WASHER
OIL SEAL
Replace. q
Setthe springwasherand the washer'
and the shift

1 0 . lnstallthe mainshaft,the countershaft,
fork assemblies.
N O T E :A l i g n t h e f i n g e r o f t h e i n t e r l o c kw i t h t h e
groove in the shift fork shaft.
7. Installthe oil chamberPlate'
6 x '1.0mm
12 N.m (1.2kg-m,9lb-ft|
SHIFTFORKS
13-91
Transmission
(cont'd)
Reassembly
(
11. Installthe
c h a n g eh o l d e ra s s e m b l y . 13. Measurethe distance@ after mounting the shift
pieceshaft.lf it's incorrect.checkthe installation.
6x1.0mm
15 N.m {1.5kgf.m, Distance@: 11.9- 12.3mm {0./t7- 0.48inl
12 N.m {1.2kgf.m,9lbtftl
CHANGE
HOLDER
ASSEMBLY
1 2 . Installthe shift pieceand the interlock.then install

the shift pieceshaft.
14. Installthe .everseidler gear and the reverseidler
gearshaft.
REVERSE
IDLERGEAR
REVERSE
IDLE
13-92
15. Installthe reversechangeholder. 1 7 . Installthe oil gutterplate.
1 8 . Bendthe hook of the oil gutterplate,then installthe

16 mm sealingbolt.
-
6x1.0mm NOTE: Apply liquid gasket {P/N 08718 0001 or
'15N.m
11.5kgim, 11 lblftl 08718- 0003)to the threads.
16mm SEALING BOLT

29 N.mt3.0kgl'm,22 lbt'ft}
tl
Instsllthe oil guide plateand the 72 mm thrustshim
into the transmissionhousing.
1 9 . Apply liquid gasketto the surfaceof the transmis-
sion housingas shown'
NOTE:
. U s e l i q u i d g a s k e t ( P / N 0 8 7 ' 1 8- 0 0 0 1 o r
08718- 00031.
. Removethe dirty oilfrom the sealingsurface'
. lf 5 minut€s have passedafter applying liquid
gasket,reapplyit and assemblethe housings'
. Allow it to cure at least 20 minutes after assem-
blv bsforefitlingthe transmissionwith oil'
--- Liqui.lgask€t
(cont'd)
13-93
Transmission
(cont'dl
Reassembly
(
Installthe dowel pins. 23. Checkthat the snap ring is securelyseated in the
grooveof the countershaftbearing.
2 1 . I n s t a l lt h e t r a n s m i s s i o nh o u s i n gb y a l i g n i n gt h e
groove in the housingwith the finger on the stop
Dimension6) as instalt6d:4.6- 8.3 mm
fl ng.
(0.181- 0.327inl
GROOVE
24. Installthe clutch line bracket,transmissionhanger

A and back-uplight switch ctamp,then tighten the
Lowerthe transmissionhousingwith the snap ring transmissionh o u s i n ga t t a c h i n gb o l t s i n t h e n u m _
p l i e r s ,a n d s e t t h e s n a p r i n g i n t h e g r o o v eo f t h e beredsequenceshown below.
countershaftbearing.
ATTACHING BOLTS
TRANSMISSION 8 x 1.25mm
HOUSING 27 N m 12.8kgtm, 20tbt.trl TRANSMISSION
HANGERA
lar---'o o
"W
BACK.UPLIGHT
SWITCHCLAMP
13-94
l n s t a l l t h e s t e e l b a l l s ,t h e s p r i n g s ,a n d t h e s e t
25. Installthe 32 mm sealingbolt
screws.
N O T E :A p p l y l i q u i d g a s k e t( P / N 0 8 7 1 8- 0 0 0 1o r
08718- 0003)to the threads. Installthe back-uplight switchand the transmission
hangerB.
32 mm SEALINGBOLT
25 N.m {2.5 kgl'm,
8 x 1.25mm
BACK.UPLIGHTSWITCH 21 N.m (2.4 kgf m,
25 N.m 12.5kgt m, 18 lblttl 1 7lbf.ftt
EALL TRANSMISSION
I
I
HANGERB
I
\
\
\
I
\
SETSCREW
'12x 1.0mm
22 N.m (2.2kgf'm,
16 tbt.trl
26. Tightenthe reverseidler gearshaft bolt'
REVERSEIDLERG€AR
SHAFTBOLT
10 x 1.25mm
5a N.rn t5.5 kgl m, {0 lbtftl
13-95
Oil Seals
Replacement
{
Trrn3mirdon Housing: Clutch Housing:
1. Removethe oil sealfrom the transmissionhousing. 1. Removethe oil sealfrom the clutchhousing.
OIL SEAL
Replace.
Install the oil seal into the transmissionhousing Installthe oil seal into the clutchhousingusing the
usingthe sp€cialtools as shown, specialtoolsas shown.
HANDLE
07149 - d)l(xxto
HANDTI
0t?a9- 001o(xto
OILSEAL
Replace.
HOUSING OIL SEAL

Replace.
13-96
GearshiftMechanism
Overhaul
NOTE:
. Inspectrubberpartsfor wear and damagewhen disassembling; reDlaceany worn or damagedParts.
. Installthe springpin and the clip on the change joint as shown'
. Turn the shift rod boot so the hole is facingdown as shown'
. Makesurethe shift rod boot is installedon the shift rod'
I x 1.25mm
22 N.m 12.2kgf.m, 16 lbf.ft)
ffi-:t't:il1ii51i?"'*,
TU
/g3i'51!Exii h
V ExrENsroN V\
END
EXTENSION
EXTENSfON ilr'eol.T BUSHING
MOUNT -_.--_-_--- EXTENSIONEND
\ @2' WASI{ERB
\ --1'>=2v/,,/ -:liT.i'ff"
BALL SEAT EXTENSIONROD
.o,-.o*&--ffi{---*, g
N: LEvER
sHrFr
.*rr"r,o"-tf V-oiliiSi[a 8x22mm
MOUNTING I --::=t SHIFTI"EVER SPRINGPIN
BRAcxEr €9-l--enr xoloen Replace.
/
8 x 1.2smm I
ii-ri- ri.zrsr.-, u
:-,rro""a,
t
I
-.Q
16 tbf.ft) ,,,.
"u, /
,rar-aoa*,"o E ,",t.ruaa SHIFTROD 9.a-"t't
Replace.
6x1.0mm
9.8N.m ('1.0kgt'm, 8 x 1.25mm
7 tbr.ftt 22 N.m 12.2kgf'm, 16lblftl
, SPRINGPIN SHIFTRODBOOT
@ /
ZW
@ CLIP
€lt# -,\
HOLE
13-97
AutomaticTransmission
"'..'.."...'..'14-1
AutomaticTransmission'....
Continuously VariableTransmission
(Cy1l .......... 14-193
t ro

AutomaticTransmission
SpecialTools ......... .....'."".'-.-.' 14'2 Valve Body
Description .,....................-...... 14-3 Repair.................... ........'.... 14-139
power Flow ......,................. 14"6 Valve
ElestronicControlSystem ..... ................'..'.'.. 14-13 Assembly 1,1-1i10
HvdraulicControl .....'......" 1'l-19 ATF Pump
HydraulicF|ow...... .'.'.".'....11-21 Inspection . . . . . . . . . . . ' . . . . . . .1.4. .- 1 4 1
Lock-upSystem '............ ... t/t'33 Main Valvs Body
ElectricalSystem Disass€mbf y/lnspoction/R.sssembly .'.'.'.'..-.-. 11-112
Component Locations....,.............'......'.............'.,. 14'39 Secondsry Valve BodY
PCMCircuit Diagram Disa$embfy/lnspoction/Rsassembly......'.'.'.'.11-111
'96 - 98 Models) .........'..1/t-40
lA/T Control Syst€m: RegulatorValve Body
PCMTarminal Volt8ge/MeasuringCondhions Disa$embly/lnspoction/Rea3sembly..........'...14-1{5
{'96 - 98 Modebl Servo Body
A/T Control System ............ Disassombly/lnsp€ction/Reassembly .".'........ 14-146
PCMCircuit Disgram Lock-upValv6 Body
(A/T Conlrol System: '99 - 00 Modsls) '..........'14-44
Dis$s.mbf y/ln3poction/Rea$embly .'..-.-..'.'.' 11-117
PCMTerminal Voltage/MeasuringConditions
('99 - 00 Models) Mainsh!ft
A/T Control System ... til-46 Dkassembly/lnep€ctionReassembly..'...'........14'148
Troubleshooting Proceduros .... I rl-48 Inspoction .............'..........'. l it-149
Symptom-to-ComPonentChari Countsrshaft
'96 - 98 Models'..-.-..."'.'..11-52 Disa$embly/lnspeqtion/Rea3sembly.......'...'..1a-l51
Efectricaf SFiem -
EloqtricalSystem -'99 - 00 Modols ... .........". 1+54 Dba$ombly/Re$s.mblY 11-152
EleclricatTroubl$hooting ('96 - 98 Models) Inspestion ...................... 14-153
Troubleshooting Flowcharts 14-56 Ona-way Clutch
ElectricalTroubleshooting('9!t- 00 Models) Disassembh/lrupoction/Rca$embly .. "'........l4-155
Troublsshooting Flowchart3 1+81' Clutch
Lock-upControl Solenoid vslvo A/B AssemblY lllustlttcd Ind.x {A48A,B4RATransmlssion)..' 14-156
14-105 tustr.tod Index (MrnA Transmi$ionl ............til-158
L RePlacoment 1+105
Rea$emblY
14-160
11-162
Shift Cont.ol SolenoidValve A/B A3sembly
Test.....,...... 14-106 Difforrr ial
Replacement 14-106 llhdraied Index ........t4-156
LinearSolenoid AsssmblY B.ckhrh ln3poction . 14-167
Test.....,.,.......... 14-107 BoaringRoplacemont ..-..........11-167
Replacoment...... .....14-108 Diftrrsniial CarriorRepl8cemeni .'.-.............'...' lil-168
Mainshaft/CountorshaftSpo€dSonsors Oil Sall Romoval t4-t 59
Replacemsnt ......'."'........... lit'108 Oil Soal ln3tallstion/Sidc Clearance'......'.....'... 1'l'169
HydraulicSystem Torqua Convertcr Housing Boarings
Symptom-to-ComponeniChart Mlin3haft Besring/Oil Scal Roplac.ment ."..'.. lil-172
HydraulicSydem r+109 Counio6hatt Betring R.plscem.nt ..'.............14-173
RoadTe3t t 4 - 1 1 3 Tranlmission Housing Boarings
Stall Speed Msinsh.ft /CounteEhaft Bearings
1+116 B!pltcomgnt 11-171
Test
Fluid Level Rcvo.3s ldlor Gear
11-117 lnrtallation 11-175
Checkin9.........."..'.'.....
Changing 14-itB ParkStop
Pressure Testing 1+119 In3pection/Adiustmsnt...'......'.'............'...."""'14-175
Transmission Transmbgion
Reassombly lil-176
Transmission
11-122 Torquo Convertet/Drivr Plsie ............'.'............'.. . l4-182
Rgmoval ..
lllustrated Indax Transmission
11.726 Inrtallation .'..........'.'.'..... 1'l-183
Transmission/End Cover'. ....
11-128 Cooler Flushing .. .... lil-187
Transmission Hou3ing,.............'.'......'....""..-.-..
Torque Conve.ter Housing/ValvoBody ...........14-130 Shift Cabls
End Cover RemovaUlnttallation
11-132 Adiustmont 1,1-190
Shift Lever .,........ lit-191
TransmisgionHousing
R e m o v a .l . . ' . ' . . . . . . . . . . . . ' . . .1. 4
. - l 3 i l Shift lndicator Panel
Adiu3tmant . . ' . . . . . . . . . . . . . .1. .4. .- 1 9 2
Tolque Convgrter Housing/valvs Body
Rsmoval .........,...... ............. 14-136 ATF Coolor Hoses
Connection ..,............,.,....... l'l-192
Valve CaDs
Description .......'................. t 4'138
SpecialTools
l.- a
Ref. No. Tool Number
o
,6'\
07GAB- PF50101 MainshaftHolder 1 4 - 1 3 31, 8 0
07GAE- PG40200 or ClutchSpringCompressorBoltAssembly 14-160,163
OTGAE - PG4O2OA
€) 07HAC- PK4010A HousingPuller I 14-135
@) 0 7 J A D- P H 8 0 1 0 1 Driver Attachment 1 14-171
07JAD- PH80200 Pilot,26 x 30 mm 1 14-' t7'l
@- 07LAE- PX40100 ClutchSpringCompresso.Attachmenr 14-160,163
@ 07PM - 0010100 SCSServiceConnector 1 14-49
@ 07sM - 0010004 BackprobeSet 1 4 - 5 01, 1 3
o OTMAJ- PY4O1 1A IVT Oil PressureHose,2210mm r4-119
@ 07MAJ- PY40120 Ay'TOil PressureHose,Adapter 1 4 -11 9
@ 07406- 0020400 Ay'TOil PressureGauge Set dpanel I 14-119
@ 07406- 0070300 A,/TLow PressureGaugeWpanel 1 '14-1 19
@.. 07736- A010004 AdjustableBearingPulter,25 - 40 mm ,l
14-172,173
@ 07746- 0010500 Aftachment,62 x 68 mm 'l
14-172,'t73,114
@ 07746- 0010600 Aftachment,72 x 75 mm 1 14-172,174
@ 07746- 0030100 Driver40 mm l.D. I 14-153, 167.169,170
@ 07749- 0010000 Driver 1 1+171, 172, 173,17
@ 0 7 9 4 7- 6 1 1 5 0 1 Driver Attachment,68 mm 1 14-'t7'l
*07HAE- P150101 can be usedas a substitute.
**Must be usedwith commercially-available _
=k
3/8,, 16slidehammer.
ry o
E-E
@
lal
g
€)
@
o
L a
e
4 ----a\
o
w @ @
\<-t-'-
/
\26
@ @ @ @ @
14-2
Description
controlledunit which provides

The automatictransmissionis a 3-elementtorque converterand a dual-shaftelectronically
4 soeedsforward and 1 reverse.
Torque Convertel, Geats,and Clutches

The torqueconverterconsistsof a pump,turbineand stator,assembledin a singleunit.They are connectedto the engine
crankshaftso they turn togetheras a unit as the engineturns.Aroundthe outsideof the torque converteris a ring gear
which mesheswith the starterpinionwhen the engineis being started.The entiretorqueconverterassemblyseryesas a
flywheelwhile transmiuingpowerto the transmissionmainshaft.
The transmissionhas two parallelshafts:the mainshaftand the countershaft. The mainshaftis in Iine with the engine
crankshaft.The mainshaftincludesthe 1st,2nd and 4th clutches,gearstor 2nd, 4th, reverseand lst (3rd gear is integral
with the mainshaft,while the reversegear is integralwith the 4th gear).The countershaftincludesthe 3rd clutch,and
gearsfor 3rd,2nd,4th, reverse.1stand park.The gearson the mainshaftare in constantmeshwith those on the counter-
shaft.When certaincombinationsof gearsin transmissionare engagedby clutches.power is transmittedfrom the main-
to provideE, ld, E, and E positions.
shaftto the countershaft
ElectronicControl
The electroniccontrol svstem consistsof the PowertrainControl Module {PCM),sensors,a linear solenoid and four
controlledfor comtonabledrivingunderall conditions.The PCMis
solenojdvalves.Shiftingand lock-upare electronically
locatedbelowthe dashboard,under the front lower panelon the passenger's
side
HydraulicControl
The valvebodiesincludethe main vatvebody,the secondaryvalvebody,the regulatorvalvebody,the servobody and the
lock-upvalvebody throughthe respectiveseparatorplates,Theyare boltedon the torqueconverterhousang
The main valve body containsthe manualvalve,the 1-2shift valve.the 2nd orificecontrolvalve,the CPB{ClutchPressure
Back-up)valve,the modulatorvalve.the servo controlvalve,the reliefvalve,and ATF pump gears The secondaryvalve
(Clutch
body containsthe 2-3 shiftvalve.the 3-4shift valve,the 3-4 orificecontrolvalve,the 4th exhaustvalveand the CPC
pressureControl)valve.The regulatorvalve body containsthe pressureregulatorvalve,the torqueconvertercheckvalve,
the coolerreliefvalve,and the lock-upcontrolvalve.The servobody containsthe servovalvewhich is integratedwith the
reverseshift fork, and the accumulators.The lock-upvalve body containsthe lock-upshift valve and the lock-uptiming
valve.The linearsolenoidand the shift controlsolenoidvalveAy'Bare boltedon the outsideof the transmissionhousing,
and the lock-upcontrolsolenoidvalveAy'Bis boltedon the outsideof the torque converterhousing.Fluidfrom regulator
passesthroughthe manualvalveto the variouscontrolvalves.The clutchesreceivefluid from their respectiveteed pipes
or internalhydrauliccircuit.
Shift Control Mechanism

Inputfrom varioussensorslocatedthroughoutthe car determineswhich shiftcontrolsolenoidvalvethe PCMwill activate
Activatinga shift controlsolenoidvalvechangesmodulatorpressure,causinga shift valveto move.This pressurizes a line
to one of the clutches,engagingthat clutchand its gear,
corresponding The shift controlsolenoidvalvesA and B are con-
trolledby the PCM.
Lock-upMechanism
fluid is drainedfrom the backof the torqueconverter
position,in 3rd and 4th.and in E positionin 3rd, pressurized
In ,Dt1
through a fluid passage,causingthe lock-uppistonto be held againstthe torque convertercover.As this takesplace,the
mainshaftrotatesat the same as the enginecrankshaft. Togetherwith hydrauliccontrol,the PCMoptimizesthe timing of
the lock-upmechanism.The lock-upvalvescontrolthe rangeof lock-upaccordingto lock-upcontrolsolenoidvalvesA and
B, and linearsolenoid.When lock-upcontrolsolenoidvalvesA and B activate,the modulatorpressurechangesThe lock-
up controlsolenoidvalvesA and B and the linearsolenoidare controlledby the PCM.
(cont'd)
14-3
Description
(cont'dl
Gear Selection
The shift leverhassix positions:E PARK.E REVERSE,
\-a
N NEUTRAL,E 1stthrough 4th gear ranges,E 1stthrough3rd
gear ranges,@ 2nd gear.
Position De3cription
E PARK Frontwheelslocked;parkpawl engagedwith pa* on countershaft.

All clutchesreleased.
E REVERSE Reverse;reverseselectorengagedwith countershaftreversegear and 4th clutchlocked.
N NEUTRAL All clutchesreleased.
E DRIVE Generaldriving;startsoff in 1st,shiftsautomatically

to 2nd,3rd,then 4th,dependingon vehicle
{1stthrough4th) speedand throttleposition.Downshiftthrough3rd,2nd and 1ston deceleration to stop.The lock-up
mechanismcomesinto operationin @ positionin 3rd and 4th gear.
Ei DRtvE Usefor rapidacceleration at highwayspeedsand generaldriving;up-hilland down,hilldfiving;stans

('lstthrough3rd) otf in 1st,shiftsautomaticallyto 2nd, then 3rd, dependingon vehiclespeedand throttle position.
Downshiftsthrough 2nd to lst on decelerationto stop.The lock-upmechanismcomes into operation
in 3rd gear,
B SECOND Usefor enginebrakingor bettertractionstartingoff on looseor slipperysurfaces;staysin 2nd

gear,does not shift up and down.
Startingis possibleonly in E and E positionsthroughthe useof a slide-type,neutral-safety

switch.
Automatic Transaxle(A/f, Gear Position Indicator

The Ay'Tgear positionindicatorin the instrumentpanelshowswhich gear has beenselectedwithout havingto look down
at the console.
Clutch€s
The four-speedautomatictransmissionuseshydraulically-actuated clutchesto engageor disengagethe transmission gears.
When hydraulicpressureis introducedinto the clutchdrum, the clutchpiston moves.This pressesthe frictiondiscsand
steel platestogether,lockingthem so they don't slip. Poweris then transmittedthroughthe engagedclutch packto its
hub-mountedgear.Likewise, when the hydraulicpressureis bledfrom the clutchpack,the pistonreleases the frictiondiscs
and the steelplates,and they are free to slide past each other.This allowsthe gear to spin independentlyon its shaft,
transmittingno power.
lst Clutch
The 1stclutchengages/disengages 1stgear,and is locatedat the end of the mainshaft,just behindthe right sroecover.
The 1stclutchis suppliedhydraulicpressureby its ATFfeed pipewithin the mainshaft.
2nd Clulch
The 2nd clutchengagegdisengages 2nd gear,and is locatedat the middle of the mainshaft.The 2nd clutchis joined
back-to-back to the 4th clutch.The 2nd clutchis suppliedhydraulicpressurethroughthe mainshaftby a circutrconnect-
ed to the internalhvdrauliccircuit,
3rd Clutch
The 3rd clutchengages/disengages 3rd gear,and is locatedat the end of the countershaft.
The 3rd clutchis suoolied
hydraulicpressureby its ATFfeed pipewithin the countershaft.
ilth Clutch
The 4th clutchengages/disengages 4th gear,as well as reversegear,and is locatedat the middleof the mainshaft.The
4th clutchis joined back-to-back
to the 2nd clutch.The 4th clutch is suppliedhydraulicpressureby its ATF feed pipe
within the mainshaft.
14-4
One-way Clulch
The one-wayclutchis positionedbetweenthe countershaft1stgearand the parkgea.,with the parkgear splinedto the counter-
shatt,The 1st gear providesthe outer racesurface,and the parkgear providesthe inner racesurface.The one-wayclutch
locksup when power is transmittedfrom the mainshaft1st gear to thetountershaft 1st gear.The lst clutchand gears
remainengagedin the 1st,2nd.3rd,and 4th gear rangesin the p!1,p! or L?lposition.
However,the one-wayclutchdisengages are appliedin the E, E or @ position.

when the 2nd,3rd, or 4th clutches/gears
gears "speedrange"of the
This is becausethe increasedrotationalspeedof the on the countershaftoverrides the locking
one-wayclutch.Thereafter, the one-wayclutchfree-wheelswith the 1stclutchstill engaged.
zNO CLUTCH ,lTH CLUTCH
1STCLUTCH
MAINSHAFT
COUNTERSHAFT
ONE.WAYCLUTCH
PANKGEAR
3ROCLUTCH
OUTSIDEOF ONE.WAY
CLUTCH
The sprags engage/
INSIDEOF ONE.WAY disengage outside
CLUTCH and insideoI the
Splaned
with counter
shaft
LOCKINGCONDITION OVER-RIDING
LOCKINGSPEEDCONDITION
14-5
Description
PowerFlow
1STGEAR 2ND GEAR 3RDGEAR 4TH

TOROUE REVERSE PARK
\ART CONVERTER
2ND 3RD
POSMON\ CLUTCH GEAR GEAR
CLUTCH CLUTCH CLUTCH
E o o
E o o o
E o
1ST o o*,
2ND o o*, o
D] 3RD o o*1 o
4TH o o*1 o o
o O*r
tr 2ND o o+r o
3RD o o*1 o
E o o*1 o
O: Operates,x: Doesn'toperate.
*1: Althoughthe 1stclutchengages,drivingpower is not transmittedas the one-wayclutchslips.
*2: The one-wayclutchengageswhen accelerating, and slipswhen decelerating.
14-6
lXl Position
Hydraulicpressureis not appliedto the clutches.Poweris not transmiftedto the countershaft.
E Position
Hydraulicpressureis not appliedto the clutches.Poweris not transmittedto the countershaft.
The countershaftis lockedby the parkpawl interlockingthe parkgear.
TOROUECONVERTER
rST CLUTCH
COUNTERSHAFT
FINALDRIVE
3RD CLUTCH
14-7
Description
PowerFlow (cont'dl
lst Gesr(E or @ position)
L
In lE or E position,
theoptimumgearis automaticallyselected
from 1st,2nd,3rd
and4thgears,according
to conditions
suchasthe balance betweenthrottleopening(engineload)andvehiclespeed.
pressure
1. Hydraulic is appliedto the 1stclutch,whichrotatestogetherwiththe mainshaft,
causingthe mainshaft
1st
gear to rotate.
Poweris transmittedto the countershaft1stgear,which drivesthe countershaft

via the one-wayclutch.
Poweris transmittedto the final drive gear,which drivesthe final drivengear.
TOROUE
CONVERTER
MAINSHAFT1ST GEAR
lST CLUTCH
MAINSHAFT
AY CLUTCH
FINALDRIVEGEAR
PARKGEAR
COUNTERSHAFT
1ST GEAR
14-8
2nd Gear {8, E or E position)
E Positionis providedto drive only 2nd gear.
1. Hydraulicpressureis appliedto the 2nd clutchon the mainshaft,and power is transmiftedvia the 2nd clutchto the
mainshaft2nd gear.
2, Powet transmitted to the mainshaft 2nd gear is conveyed via tho countorshaft 2nd gear, which drivos the counter-
shaft.
3. Poweris transminedto the final drivBgear,which drivesthe final drivenge8r.
NOTE: Hydraulic pressureis also applied to the 1st clutch, but since the rotation speed of ths 2nd gear excaadsthat
'lst gear is cut off at the one-way clutch.
of lst gear, power from
TOROUECONVERTER
2ND CLUTCH
MAII'ISHAFT
2I{D GEAR
COUNTEBSHAFT
(cont'd)
14-9
Description
PowerFlow (cont'dl
3rd Gear (bl or bd positionl
1. Hydraulicpressureis appliedto the 3rd clutch.Powerfrom the mainshaft3rd gear is transmittedto the countershaft
3rd gear.
2. Poweris transmittedto the final drive gear,which drivesthe tinal drivengear.
NOTE:Hydraulicpressureis also appliedto the 1stclutch,but sincethe rotationspeedof 3rd gear exceedsthat of 1st
gear,powerfrom lst gear is cut off at the one-wayclutch.
TOROUECONVERTER
MAINSHAFT3RD GEAR
MAINSHAFT
COUNTERSHAFT
3RD GEAB
3RD CLUTCH
DRIVENGEAR
14-10
4th cear lE position)
mainshaft4th
1. Hydraulicpressureis appliedto the 4th clutch,which rotatestogetherwith the mainshaft,causingthe
gearto rotate.
2. Poweris transmittedto the countershaft4th gear'which drivesthe countershaft'
3. Poweris transmittedto the final drive gear,which drivesthe final drivengear'

gear exceedsthat of 1st
NOTE:Hvdraulicpressureis alsoappliedto the lst clutch,but sincethe rotationspeedof 4th
gear,powerfrom 1stgear is cut off at the one-wayclutch
TOROUE
MAINSHAFT4TH GEAR
COUNTERSHAFT
FINALORIVENGEAR
14-11
Description
PowerFlow (cont'd)
El Po3ition
1, Hydraulicpressureis switchedby the manualvalve to the servo valve,which moves the reverseshift fork to the
reverse position. The reverseshift fork engageswith the reverseselector,reverseselector hub, and the countershaft
reversegear.
Hydraulicpressureis also appliedto the 4th clutch.Power is transmitt€dfrom the mainshaftreversegear via the
reverseidler gear to the countershaftreversegear.
The rotation direction of the countershaftreversegear is changedvia the reverseidler gear,
Poweris transmittedto the final drive gear,which drivesthe final drivengear.
TOROUE
MAINSHAFT
COU TERSHAFT
REVERSE
IDLER
REVERSE
SELECTOR
HUB
REVERSE
SETICTOR
FINALON|VENGEAR REVERSE
SHIFT
FORK
14-12
ElectronicControlSYstem
four solenoid
The electronaccontrotsystemconsrstsof a Powertraincontrol Module(PcM),sensors,a Iinearsolenoidand
controlled
electronically for comfortabledriving under all conditions The PCM is located
valves,shifting and lock-upare
belowthe dashboard,underthe front lower panelon the passenger's side
PGM-FI
Control Sy3tem
A/T Control SYstom
Shift Control
Lock-uDControl
14-13
Description
ElectronicControlSystem(cont'd)
Shift Control
a
The PCM instantaneously determineswhich gear should be selectedby varioussignalssent from sensors,and actuates
the shift controlsolenoidvalvesA and B to controlshifting.Also.a GradeLogicControlSystemhas beenadoptedto con-
trol shiftingin E positionwhile the vehicleis ascendingor descendinga slope,or reducingspeed.
Shift Control Solenoid Shift Control Solenoid

Poshion Gear
Vslve A Valve B
1st OFF ON
8,tr 2nd ON ON
3rd ON OFF
E 4th OFF OFF
tr 2nd ON ON
E- Reverse ON OFF
*See page 14-31for reverseinhibitorcontroldescription.
Lock-upControl
From sensor input signals,the PCM determineswhether to turn the lock-upON or OFF,and activateslock-upcontrol
solenoidvalveA and/orB accordingly.The combinationof drivingsignalsto lock-upcontrolsolenoidvalvesA and B and
the linearsolenoidpressureis shown in the table below.
Lock-upControl Lock-upControl Linoar Solonoid

Lock-upConditions
Solenoid Valvo A SolenoidValve B Prggguro
Lock-upOFF OFF OFF High
Duty operation
Lock-up,Half ON Low
OFF* ON
Lock-up,Full ON ON High
LOCK-Up Duty operation
ON
duringdeceleration OFF- ON
14-14
GRADELOGICCONTROLSYSTEM
How it works:
The pCM comparesactualdrivingconditionswith drivingconditionsmemorizedin the PCM,basedon the input from the
vehiclespeedsensor,the throttlepositionsensor,the barometoricpressuresensor,the enginecoolanttemperaturesensor,
the brakeswitchsignal,and the shift leverpositionsignal,to controlshiftingwhile a vehicleis ascendingor descendinga
slope,or reducingspeed.
SIGNALSOETECTED
Judgemenl ot Conirolling Arca
O.iving Resi3lence
. Ascendingmod€
lFuzzyloqicl
. GradualAscendingmode
' Ste€p Ascendingmode
. Oescendingmode
. Gr.du.l Descendingmode
. Steep D6cending mode
14-15
Description
ElectronicControlSystem{cont'dl
L .
AscendingControl
When the PCMdeterminesthat the vehicleis climbinga hill in E position,the systemoxtendsthe sngagementareaof
2nd gear and 3rd gear to prevent ths transmissionfrom fr€quently shifting between 2nd and 3rd gears, and between 3rd
and 4th gears,so the vehiclecan run smooth and have more power when needed.Thereare two ascendingmodeswith
different3rd geardrivingareasaccordingto the magnitudeof a gradientstoredin the pCM.
NOTE:
. The PCMmemorycontainsshift schedulesbetween2nd and 3rd gears,and between3rd and 4th gearsthat enablethe
PCM'sfuzzylogicto automatically selectthe most suitablegearaccordingto the magnitudeof a gradient
. Fuzzylogic is a form of artificialintelligencethat lets computersrespondto changingconditionsmuch like a human
mind would,
DsscondingControl
When the PCM determinesthat the vehicleis going down a hilt in E position,the shift-upspeedfrom 3rd to 4th gear
when th€ throftle is closed becomesfaster than the set speed for flat road driving to widen the 3rd gear driving area.
This, in combinationwith engine brakingfrom the decelerationlock-up,achievessmooth driving when the vehicle is
descending. Thereare two descendingmodeswith differentdownshift(4 - 3) schedulesaccordingto the magnitudeof a
gradientstoredin the PCM.When the vehicleis in 4th gear,and you are deceleratingon a gradualhill, or when you are
applying the brakeson a steep hill, the transmissionwill downshift to 3rd gear. When you accel6rate,the transmissionwill
then return to 4th gear.
ASCENDINGMODE DESCENDING
MODE
4TH SHIFTING
CHARACTERISIICS
CONTROLAREA
ff.1"11", vehicr.
3pe€d
ff;Tlr., vohicre
speed
GRADUAL
ASCENOING
CONTROL
AREA
Docel6rationControl
Whenthe vehiclegoes arounda corner.and needsto first decelerateand then accelerate.the rcM setsthe datafor deceleration
control to reducethe number of times the transmissionshifts.When the vehicle is deceleratingfrom speedsabove 26 mph
(41km/h),the rcM shiftsthe transmissionfrom 4th to 2nd earlierthan normalto copewith upcomingacceleration.
14-16
Circuit Diagram and Terminal Locations-'96 - 98 Modols
IGNITIONSWiTCH
tc1
IOCI(- UPCONTBOL
SOTENOID VALVEA
IGPl
IGP2
vcc2 LOCK-UPCONTSOT
TPS soLtNoto valvE I
sG2
SIIIFTCONTFOL
sHrFrc0mioL
B
SOLENOIDVATVE
UI{EARSOLENOIO
14-17
Description
ElectronicControlSystem(cont'dl
L I
CircuitDiagramand TerminalLocations-'99 - O0Models
GNTONSWICH
,,--b. rcj
PG2
LOCK.UPCONIFOL
SOLEI\Q
D VALVEA
IGP2
v3u
vcc2 LOCKUPCON'IROL
SOLENODVALVEB
sc2
SHFI CONTROL
SHIFTCONTFOL
SOLENOIDVALVEE
L NEAFSOLEIOIO
6NII ONSWICH
14- 1 8
HydraulicControl
controlledsolenoids'
and electronically
The hydrauliccontrolsystemis controlledby the ATF pump,valves,accumulators,
TheATFpUmpisdrivenbysp||nesontheendofthetorqueconverterWhichisattachedtotheengine.F|uidfrom
pumpf|owsthroughtheregu|atorva|vetomajntainspecifiedpressurethroughthemainva|vebodytothemanuaIva|
directingpressuretoeachofthec|utches.Theva|vebodyinc|udesthemainvaivebody,theregu|atorvalveb
|ock-upva|vebody,thesecondaryVa|vebody,theservobody,theIinearso|enoid,theshiftcontro|so|enoid
valveAy'Bassemblyand the lin-
assembly,and the lock up controlsolenoidvalveA/B assembly.The shift controlsolenoid
housing.
transmission The lock-upcontrolsolenoidvalve A,/Bassemblyis
ear solenoidare boltedon the outsideof the
boltedon the outsideof the torqueconverterhousing
SHIFTCONTROL
SOLENOIOVALVEA/8
ASSEMBLY
LINEARSOLENOID
SERVOBOOY
VALVE
REGULATOR
VALVEBODY
VALVEBOOY
CONTROL
SOLENOIDVALVEA/B ATF PUMPGEARS
(cont'd)
ASSEMBLY
14-19
Description
HydraulicControl(cont'dl
Msin Valve Body
The main valvebody housesthe manualvalve,the 1-2shift valve,

the 2nd orificecontrolvalve,the cpB valve,the modu-
lator valve'the servocontrolvalve,and the reliefvalve.The primary
functionsof the main valve body are to swatchfluid
pressureon and off and to controlthe hydraulicpressuregoing
to the hydrauliccontrolsvstem.
2ND ORIFICECONTROT
VALVE
1-2 SHIFT VALVE
RELIEFVALVE VALVE
CONTROL
VALVE
SocondaryValve Body
The secondaryvalvebody is locatedon the main valvebody.The

secondaryvalvebody housesthe 2-3shift vatve,the 3-4
shift valve,the 3-4 orificecontrolvalve,the 4th exhaustvalve,and the
CpCvalve.
3-4 SHTFTV
2.3 SHIFTVALVE
4TH EXHAUSTVALV€
CPCVAL
VALVE
14-20
\
RegulatorValve BodY
valve body consistsof the regulatorvalve'the
The regulatorvalve body is locatedon the main valve body.The regulator
checkvalve,the coolerreliefvalve,and the lock-upcontrolvaive'
torque-converter
VALVE
REGULATOR
VALVE
REGULATOR
BODY
CONVERIER
COOLERRELIEFVALV€
CHECKVALVE
CONTROLVALVE
Lock-upValve BodY
valveis locatedon the regulatorvalvebodv
The lock-upvalvebody with the lock-upshift valveand the lock-uptiming
LOCK,UPSHIFTVALVE
LOCK-UPNMING VALVE
icont d
1+21
Description
HydraulicControl(cont'dl
RegulatorValve
The regulatorvalve maintainsa constanthydraulicpressurefrom the ATF pump to the hydrauliccontrol

system,white
alsofurnishingfluid to the lubricatingsystemand torqueconverter.The fluid from the ATF pump flows through
B and 8,.
The regulatorvalve hasa valveorifice.The fluid enteringfrom B flows throughthe orificeto the A cavity.This pressure
of
the A cavitypushesthe regulatorvalveto the right side,and this movementof the regulatorvalve uncovers
the fluid port
to the torqueconverterand the reliefvalve.The fluid flows out to the torqueconverter,and the relief
valveand regulator
valvemovesto the left side.Accordingto the levelof the hydraulicpressurethrough B, the positionof the regutator
vatve
changesand the amountof the fluid from B' through D and c also changes.This operationis continued.
maantaining the
line pressure,
NOTE:When used."|eft" or "right" indicatesdirectionon the illustrationbetow.
ENGINENOTRUNNING ENGINERUNNING
To TOROUECONVERTER Lubrication
STATORSHAFTARM
Stator RoactionHydraulicProssur6Control
Hydraulicpressureincreasesaccordingto torque,are performedby the regulatorvalve using the stator

torque reaction.
The stator shaft is splined with the stator in the torque converter,and its arm end contactsthe regulator
sprangcap. when
the vehicleis accelerating or climbing(TorqueConvert€rRange),the statortorque reactionacts on the statorshaft,and
the statorarm pushesthe regulatorspringcap in the directionof the arrow in proponionto the reaction.Jne stator
reac-
tion spring compresses, and th€ reoulatorvalve movesto increasethe line pressurewhich is regulatedby the regulator
valve. The line pressurereachesits maximum when the stator torque reaction reachesits maximum.
TOROUE
CONVERTER
REGULATOR
VALVE
SPRINGCAP
STATOR ATORSHAFTARM
14-22
\
Servo Body
valvewhich is integratedwith
The servo body is locatedon the secondaryvalve body.The servo body containsthe servo
the reverseshiftfork,and the accumulators
2NO ACCUMULA
SERVOBODY
1STACCUMULATOR
3RDACCUMULATOR
SERVOVALVE/SHIFT
FORKSHAFT
'98 models;the '99 - 00 modelsare similar'

NoTE: The illustrationshowsthe'96 -
14-23
Description
HydraulicFlow
GeneralChart ol Hydraulic Pressure
lra
ATFPump- peguratorvarve-_l- Linepressure-f- Moduratorpressure- Linearsorenoid
-Clutch pressure
|
pressure
-Torque Converter
t-Lubrication Pressure
Distribution of HydraulicPressur€
. RegulatorValve -]- TorqueConverterpressure
F_ Lubricationpressure
i- To regulateLinepressure
. Manualvalve _ To selectLine pressure_ clutch pressure

' ModulatorValve i/odulator pressure_ ___f_ Shift ControlSolenoidValves
F_ Lock_up ControlSolenoidValves
L_ LinearSolenoid
. 1-2Shift Valve-
. l
2-3 ShiftValve - Ctutchpressure
. 1-
3-4 ShiftValve
PORTNO. DESCRIPTION
OF PRESSURE
P ORTNO. DESCRIPTION
OF PRESSURE
P ORTNO. DESCRIPTION
OF PRESSURE
MODULATE
1 LINE 6B (SHIFTCONTROL 41 4THCLUTCH
SOLENOIDVALVEB)
MODULATE
LINE (LOCK-UP
CONTROL 56 LINEARSOLENOID
SOLENOIDVALVEA)
MODULATE
LINE 6D (LOCK-UP
CONTROL 90 TOROUECONVEBTER
SOLENOIDVALVEB)
MODULATE
2 LINE 6D' (LOCK-UP
CONTROL 91 TOROUECONVERTER
SOLENOIDVALVEB)
LINE 7 LINE 92 TOROUECONVERTER
LINE 8 LINE/CPC 93 ATF COOLER
3" LINE 9 LINE 94 TOROUECONVERTER
4 LINE '10
1STCLUTCH 95 LUBRICATION
LINE 20 2ND CLUTCH YO TOROUECONVERTER
LINE 20A 2NDACCUMULATOR 97 TOROUECONVERTER
5 LINE 99 SUCTION
MODULATE 30 3RDCLUTCH X DRAIN
MODULATE
6A (SHIFT
CONTROL 40 4THCLUTCH
SOLENOID
VALVEA)
14-24
\
@ Position
(ATF)is drawn from (99)and dis-
As the engineturns,the ATF pump also startsto operate,Automatictransmissionfluid
pump becomes the line pressure (1).The line pressure(1) is regulated
chargedinto (1).Then,ATF flowing from the ATF
inlet pressure (92) enters (94) of the torque converter through the lock-up
by the regulator valve. The torque conv€rter
(901. torque converter ch€ck valve prevents the torque converter pressurefrom rising'
shift valve and dischargesinto The
Underthis condition,the hydraulicpressureis not appliedto the clutches'
"1eft"or "right" indicatesdirectionon the hydrauliccircuit'
NOTE:When used,
14-25
Description
HydraulicFlow (cont'd)
L?jPosition
The line pressure(1) flows to the manualvalve and the modulatorvalve.The line pressure(1)
changesthe trnepressure
(4) and (25)at the manualvalve.and changesto the modulatorpressure
at the modulatorvalve.But the moouratorpres-
sure (6) does not flow to each shift valve becauseshift control solenoidvalvesA and B
are turned oN by the pcM. The
line pressure(4) passesthroughthe cPB valveand the cPc valve.and changesto the line pressure(s),
th;n flows to the
1-2shift valve.The line pressure{S)from the l-2 shift valvechangesto the 2nd clutchpressure(20)
at the 2-3 shift valve.
The 2nd clutch pressure(20) is appliedto the 2nd clutch.and the 2nd clutch is engaged.The
line pressure(4) passes
throughthe 1-2shift valve and the orifice,and changesthe lst clutchpressure,The 1stclutchpressure(10)
atsoflows to
the 1stclutch.However,no power is transmittedbecauseof the one_wayclutch.
NOTE:When used,"Ieft" or "right" indicatesdirectionon the hvdrauliccircuit.
14-26
E! or l8! Position
1. lst Gear
The flow of fluid throughthe torqueconvertercircuitis same as in E position,The line pressuretlows to the manual
valveand the modulatorvalve.The line pressurechangesto the modulatorpr€ssure(6)at the modulatorvalveand to
the line pressure(4)at the manualvalve.The modulatorpressure(61flows to the lsft end of the 1-2shift valveand the
3-4 shiftvalvebecauseshift controlsolenoidvalveA is turnedOFFand B is turnedON by the PCM.The 1-2shiftvalve
is moved to the right side.The line pressure(4) changesto the lst clutchpressure(10)at the 1-2shift valve and the
oritice.The lst clutchpressure(10)is appliedto the 1st clutchand tho 1st accumulator;consquently,the vehiclewill
move as the enginepower is transmitted.
"|eft" or "right" indicatesdirectionon the hydrauliccircuit'
NOTE:When used,
(cont'd)
14-27
Description
2nd G.!r
As tha speedof the vehiclereachesthe prescribedvalue,shift controlsolenoidvalve

A is turnedoN by meansof the
PCM The modulatorpressure{64} in the left end of the 1-2 shift valve is r€leased
by turning shift controtsotenoid
valve A oN The 1-2 shift valve is moved to the left side and uncoversthe port
to allow line pressure{5) to the z-3
shift valve. The line pressure(5) changesto the 2nd ctutch pfessure
l2O)at the 2-3 shift valve. The 2nd clutch pressure
(20)is appliedto the 2nd clutch,and the 2nd clutchis engaged.
Fluid flows by way of:

- Line Pressure(4) + cPB varve - Line pressure(s) * 'r-2
shift varve - Line pressure(5) * 2-3 shift varve
- 2nd ClutchPressure(20)+ 2nd Clutch
The hydraulic pressurealso flows to the 1st clutch. However,no power is transmittod
becauseof the one-way ctutch.
NOTE:When used,"|eft" or ,,right,,indicatesdirectionon the hydrauliccircuit.
14-28
I
3. 3rd Gear
As the soeedof the vehiclereachesthe prescribedvalue,shift controlsolenoidvalveB is turned OFFby meansol the
pCM. Shift controlsolenoidvalve A remainsON. The modulatorpressure(6) flows to the right end of the 1-2 shift
valve and the left end oJ the 2-3 shift valve. The 2-3 shift valve is moved to the right side by the modulator pressure
(68).The 2-3 shift valvecoversthe port to stop line pressure(5)to the 2nd clutchand uncoversto the 3-4 shift valve
(30)at the 3-4
as the 2-3 shift valve is movedto the right side.The line pressure(5) becomesthe 3rd clutchpressure
shiftvalve.The 3rd clutch pressure (30) is appliedto the 3rd clutch, and the 3rd clutchis engaged'
Fluid flows by way of:

- Line Dressure(4)* CPBValve- LinePressure(5)* 1-2ShiftValve- LinePressure(5)* 2-3ShiftValve
- Line Pressure(5)* 3-4 ShiftValve- 3rd ClutchPressure(30)- 3rd Clutch
The hvdraulicpressurealso flows to the 1st clutch.However,no power is transmittedbecauseof the one-wayclutch
as in 2nd gear.
"|eft" or "right" indicatesdirectionon the hydrauliccircuit.
NOTE:When used,
14-29
Description
HydraulicFlow lcont'dl
4th Goar {E Position}
As the speedof the vehiclereachesthe prescribedvalue,shift controlsolenoidvalveA is turned OFFbymeans

ofthe
PCM Shift control solenoidvalve B remainsoFF. The modulatorpressure(6) flows to the left
end of the t-2 shift
valve and the left end of the 3-4 shift valve.The modulatorpressure(64) in the left end of the 1-2shift
valve equals
the modulatorpressure{68) in the right end of the 1-2shift valve,the 1-2 shift valve remainsat left
side by the ten-
sion of the valvespring.
The 3-4 shift valveis movedto the right side by the modulatorpressure(64).The 3_4shift valve
coversthe port to the
3rd clutchand uncoversthe port to the 4th clutchas this valve is movedto the right side.The 4th clutchpressure(4.1)
from the 3-4 shift valve becomesthe 4th clutch pressure(40) at the manual valve.The 4th clutch pressure(401
is
appliedto the 4th clutch,and the 4th clutchis engaged.
Fluidflows by way of:

- Linepressure(4)* CPBValve- Line Pressure(5)+ 1-2Shift
Valve- Linepressure(5)* 2-3 ShiftValve
- LinePressure(5)- 3-4 ShiftValve- 4th Clutchpressure(41)+
ManualValve_ 4th Clutchpressure(40)
* 4th Clutch
The hydraulicpressurealso flows to the lst clutch.However,no power is transmittedbecauseof the

one-waycrutch
as in 2nd and 3rd gear.
NOTE:When used,"|eft" or "right,,indicatesdirectionon the hydrauliccircuit.
14-30
L
E Position
pressure(1) changesto the
The flow of fluid through the torque conveftercircuitis the same as in E position The line
(3) to the line (3')at the 'l-2shift valve
pressure
line pressure(3)and flows to the l-2 shift valve.The iine pressure changes
(Reverserangeposition)and uncoversthe port to
and flows to the servovalve.The servovalveis movedto the right side
allow line pressure{3") to the manualvalve, The line pressure{3')from the 1-2shiftvalveflows throughthe servovalveto
clutch pressure (40).The 4th clutch pressure(40)is appliedto the 4th clutch,and
the manualvalve and changesthe 4th
the 4th clutchis engaged,
ReverseInhibitor Control
(10 km/h)'the PCMoutputsthe
Whenthe E positionis selectedwhile the vehicleis movingforwardat spe€dsover 6 mph
oFF,shift controlsolenoid
1stspeedsignalto shift controlsolenoidvalvesA and B; shiftcontrolsolenoidvalveA is turned
port to stop line pressure(3') to the
valve B is turned ON. The 1-2 shift valve is moved to the right side and coversthe
pressure (40) is not appliedto the
servovalve.The line pressure(3' )is not appliedto the servovalve,and the 4th clutch
4th clutch, as a result, power is not transmitted to the reversedirection'
'left" or "right" indicatesdirectionon the hydrauliccircuit'
When used.
14-31
Description
lll Position
The flow of fluid through the torque convertercircuitis the same as in E position.The line pressure(1) changes
to the
line pressure(3)and flows to the l-2 shift valve.The line pressure(3)changesto the line pressure(3,)at
the 1-2shift valve
and flows to the servovalve.The servovalveis movedto the right side (Reverserangeposition)and uncovers port
the to
allow line pressure(3") to the manualvalveas in @ position.The line pressure(3") from the servovalveis Intercepted
by
the manualvalve.However,hydraulicpressureis not suppliedto the clutches,and the power is not transmitted.
NOTE:When used,"|eft" or "right" indicatesdirectionon the hydrauliccircuit.
14-32
Lock-upSystem
\
Lock-upClutch
1. Ooeration(clutchonl
with the lock-upclutch on, the fluid in the chamber betweenthe torque convertercover and the lock-uppiston is drained
off, and the converterfluid exertspressurethrough the pistonagainstthe torque convertercover,As a result,the conven-
er turbine is lockedto the conveftercover.The effect is to bypassthe converter,therebyplacingthe vehiclein direct drive
PISTON
LOCK.UP DAMPERSPRING
The power flows by way ot:
Engine
{
Driveplate
i
Torqueconvertercover
I
Lock-uppiston
Damperspring
I
Turbine
Mainshaft
ODeration{clutch off}
"clutch on." As a result,the lock-uppiston moves away from
With the lock-upclutch off, the fluid flows in the reverseof
the convertercover,and the torque converterlock-upis releassd.
TURBNE
TOROUECOI{VERTER
Engine COVER
t
Driveplate \
I
Torqueconvenercover
{
Pump
I
Turbine
Mainshaft
(cont'd)
MAINSHAFT
14-33
Description
Lock-upSystem(cont'd)
In B.rlposition,in 3rd and 4th, and lDl_- positionin 3rd.
pressurized fluid is drajnedfrom the back of the torque
converterthrough a fluid passage.causingthe lock-up
pistonto be held againstthe torque convenercover.As
this takesplace,the mainshaftrotatesat the samespeed
as the engine crankshaft,Togetherwith the hydraulic
c o n t r o l ,t h e P C M o p t i m i z e dt h e t i m i n g o f t h e l o c k _ u p
system.Under certainconditions,the lock_upclutch is
appliedduringdeceleration, in 3rd and 4th gear.
The lock-upsystemcontrolsthe rangeof lock_upaccord_

ing to lock-upcontrol solenoidvalvesA and B. and the
linearsolenoid.When lock-upcontrolsolenoidvalvesA
TOROUECONVERTER and B activate,modulator pressurechanges.Lock_up
controlsolenoidvalvesA and B and the linearsolenoid
a r e m o u n t e do n t h e o u t s i d eo f t h e t o r q u e c o n v e r t e r
housing.and are controlledby the pclvl.
LOCK.UPCONTROL
. VALVE Lock-upConditions/Lock-upControl SolenoidValves/
LinearSolenoid Pressure
Lock-upControl
LOCK.UPCONTROL Lock-up Lineal
SOLENOIDVALVE Solenoid Valve
Conditions Solenoid
A B Pressure
Lock-upOFF OFF OFF High
Lock-up.Half Dutyoperation
ON
OFF- ON
Lock-up.Full ON ON High
Lock-up
during Dutyoperation
TOROUECONVERTER ON Low
deceleration OFF* ON
CHECI(VALVE
MODULATORPRESSURE
RELIEFVAI-VE
LOCK.UPTIMING
VALVE
^ .-- LINEARSOLENOIDPRESSURE
r cooLER RELTEF
r______rr VALVE
ATFPUMP
14-34
I
No Lock-up
. Lock-upControlSolenoidValveA: OFF
. Lock-upControlSolenoidValveB: OFF
. High
LinearSolenoidPressure:
The pressurized fluid regulatedby the modulatorworks

on both endsof the lock-upshiftvalve.Underthis condi-
tion, the pressuresworking on both ends of the lock-up
shift valveare equal,the lock-upshift valve is movedto
the right side by the tensionof the valve spring alone.
The fluid from the ATF pump will flow through the left
side of the lock-upclutchto the torqueconvener;that is,
the lock-upclutchis in OFFcondition.
TOROUE
CONVERTER
"left" or "right" indicatesdirection
NOTE:When used,
circuit.
on the hydraulic
LOCK.UPCONTROL
SOLENOIDVALVE
MOOULATORPRESSURE
RELIEFVALVE
LOCK-UPTIMING
VALVE
LINEARSOLENOIOPRESSURE
9 L ] I COOLER RELIEF VALVE
ATFPUMP
(cont'd)
14-35
Description
Lock-upSystem(cont'dl
Half Lock-up
. Lock-upControlSolenoidValveA: ON
Lock-upControlSolenoidValve8: DutyOperation
OFF- ON
LinearSolenoidPressure:
Low
The PCMswitchesthe solenoidvalveA on to releasethe

modulatorpressurein the left cavityof the lock_upshift
valve.The modulatorpressurein the right cavityof the
lock-upshift valve overcomesthe springforce;thus the
lock-upshift valveis movedto the leftside.
The line pressureis then separatedinto the two pas-
TOROUECONVERTER
sagesto the torque converter:
Torque ConverterInner pressure:enters into right
sadeto engagelock-upclutch
TorqueConverterBackpressure:entersinto left side
LOCK.UPCONTROL to diseogagelock-upclutch
VALVE The back pressure(F2)is regulatedby the lock-upcon-
trol valve, whereasthe position of the lock-uptiming
valve is determinedby the linearsolenoidDressureand
LOCK.UPCONTROL tension of the valvespring.Also the positionof the lock_
SOI.TNOIDVALVE up control valve is determined by the back pressureof
A 8 the lock-upcontrol valve, torque converter pressurereg_
ulatedby the torqueconvertercheckvalve,and modula_
tor pressuredeterminedby the lock-upcontrolsolenoid
valve B. The PCMswitchesthe lock-upcontrolsolenoid
valve B on and off rapidly{duty operation}undercertain
conditions to regulate the back pressure(F2)to lock the
torque convener properly.
NOTE:When used, "left" or "right" indicatesdirection

TOROUECONVERTER on the hvdrauliccircuit.
CHECKVAI-VE
MODULATOR
PRESSURE
RELIEF VALVE
LOCK-UPTIMING
VALVE
^ LINEARSOLENOTD
PRESSURE
cooLERRELTEF
L____J'r valvE
ATF PUMP
14-36
Full Lock-up
. Lock-upControlSolenoidValveB: ON
o LinearSolenoidPressure:
High
W h e n t h e v e h i c l es p e e df u r t h e r i n c r e a s e st.h e l i n e a r
s o l e n o i dp r e s s u r ei s i n c r e a s e dt o h i g h i n a c c o r d a n c e
with the linearsolenoidcontrolledbv the PCM.
T h e l o c k - u pt 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 g f o r c e
and moves to the left side. Also, this valve closesthe
fluid port leadingto the left side of the lock-upcontrol
TOROUECONVERTER Under this condition.the modulatorpressurein the left

s i d e o f t h e l o c k - u pc o n t r o l v a l v e h a d a l r e a d y b e e n
releasedby the lock-upcontrol solenoid valve B; the
lock-upcontrol valve js moved to the left side. As this
t a k e s p l a c e ,t h e t o r q u e c o n v e r t e r b a c k p r e s s u r ei s
releasedfully. causingthe lock-upclutchto be engaged
fully.
"|eft" or "right" indicatesdirection

NOTE:When used,
LOCK.UPCONTROL
SOLENOIDVALVE on the hvdrauliccircuit.
MODULATORPRESSURE
RELIEFVALVE
LOCK.UPTIMING
VALVE
LINEARSOLENOIOPRESSURE
'r
,-.r' cooLERRELTEF
vALvE
ATFPUMP
{cont'd)
14-37
Description
Lock-upSystem(cont'dl
DecelerationLock-up
. Lock-upControlSolenoidValveB: DutyOperation
OFF- ON
a 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 maintainedso as to lock the torque
converterproperly.
TOROUECONVERTER NOTE:When used, "left" or "right" indicatesdirection

on the hydrauliccircuit,
LOCK-UPCONTROL
SOLENOIDVALVE
MOOULATORPRESSURE
RELIEFVALVE
LOCK.UP
TIMING
VALVE
LINEARSOLENOIDPRESSURE
COOLERRELIEFVALVE
ATF STRAINER
ATFPUMP
1434
ComponentLocations
CONTROL
POWERTRAIN
MODULE(PCM)
TRANSAXLE{A/TI
GEARPOSITIONSWITCH
COUNI€RSHAFT
SPEEDSENSOR
SOI,TNOIDVALVE
ASSEMBLY
SOLENOIDVALVE SPEEDSENSOR
ASSEMBLY
1+39
PGMGircuitDiagram(A/T ControlSystem:'96 - 98 Modelsl
-HOODFUSE/RELAY
UNDEfl BOX
(80A1N0.42
No.41 U N D E RD A S H
l40A) N o . l 3( 1 5 A ) FUSE/REIAY 8OX
No.47{7.5A)
/8LU YEUBLK BtK Btx

c10 424 At0 423
Arp
Np lon,ô l r,, lotrr l 6lt l 3]t lot*
824 t88 tB17
'96:BLU/BED '96:GRN 8LU
'97,'98rGFN/BLK
GAUGE
ASSEMBTY
A,TGEAR
POSITION
INDICATOR LTGRN
'96:BLU/RED
'97,'98: al
--
T T T
YEL GRN BLU
GRN/8LK
BLK/BTU F- BTK/BI.U
F_wHr
RED F- GRN
GRNiELK
GRN f- GRN
BLU F- Bru
NorE: :ro5v
t
: r o1 2 v
T

SERVICE CONNECTOR
CHECK
NCSG ILS- ILS+ ISHA ISHB ltc A ltc B
RED WHT
t
l l
l
'
It Tl
l l
Lo-l T
BRNiBLK
MAINSHAFT
SENSOR
SPEED
SHIF'CONTROL LOCK
VALVE SOLENOIO
SOTENOID
ASSEMEI-Y
VALVE
ASSEMELY
II
-UP CONTROL
I-
G1 0 1
PCMTerminelLocations
14-41
PCMTerminalVoltage/MeasuringGonditions('96 - 9g Models)
A/T ControlSystem
The PCMterminalvoltageand measuringconditionsare shown for the connectorterminalsthat relateto the A"/Tcontrol
system.The other PCMterminalvoltageand measuringconditionsare describedin sectionI l.
A l32P)Conn€ctot B I25P)Connector C (31P)Conngctor D (16P)Connector
PCMCONNECTOR
A I32P}
Terminal Numbor Signal Dcacription MoasuringConditions/Te.minalVoltage
A1 to A8 - see section 1I -
A9 LG1 Ground
A10 PG1 Ground
A11 IGPl Power supply system With ignitionswitchON (ll):8atteryvoltage
With ignition switch OFF:0 V
412 to A2l - see section I I -
Ground
423 PG2 Ground
A'24 IGP2 Power supply system With ignitionswitchON (ll):Batteryvoltage
A25 to A32 - seesectionl1 -
PCMCONNECTORB (25P}
Terminal Number Signal Description MeasuringConditions/T6rminalVoltage
B1 LS- Linearsolenoidpower supply lgnitionswitchON (ll):Pulsingsigna.
negativeelectrode
82 Linearsolenoidpowersupply lgnitionswitchON (ll):Pulsingsignal
positive electrode
SHA ShittcontrolsolenoidvalveA In 2nd gear and 3rd gear in E, E position,
control and in @, @ position:Batteryvoltage
In lst gearand 4th gear in E. E position:0 V
B4 LCB Lock-upcontrol solenoid valve B Whenfull lock-up:Batteryvoltage
control When half lock-up:Pulsingsignal
B5 LCA Lock-upcontrolsol€noidvalveA When lock-upis ON: Batteryvoltage
control With no lock-up:0 V
86 to 87 Not used
B8 ATP D3 IVT g6ar positionswitch@ posi- l n E p o s i t i o n ;O V
tion signalinput In otherthan E position:Batteryvoltage
B gt o 8 1 0 Not used
14-42
I
PCMCONNECTORB {25P1{cont'dl
TerminalNumber Signal Description Measuring Conditions/TerminalVohage
811 SHB Shift controlsolenoidvalveB In 1stgearand 2nd gear in -q1,q11 position,
control and in E] position:Batteryvoltage
In 3rd gearand 4th gear in lD.J,
[Dr-position:0 V
B't2 SLU Interlockcontrol When ignitionswitchis ON (ll),brakepedal
deoressedand accelerator Dedalreleased:0 V
813 D4 IND D4 Indicatorlight control When ignitionswitchis firstturnedON (ll):
Batteryvoltage for two seconds
In E position:Bafteryvoltage
B't4 NMSG Mainshaftspeedsensorground Always:0 V
E tc NM Mainshaftspeedsensorsignal Dependingon enginespeed:Pulsingsignal
input When engineis stopped:0 V
816 ATP R Ay'Tgear position switch E I n E p o s i t i o n0: V
positionsignalinput In otherthan E position:Batteryvoltage
817 ATP 2 A/T gear position switch E posi- I n E p o s i t i o n0 :V
tion signalinput In orherthanE position: Battery
voltage
8 1 8t o 8 2 1 Not used
s22 NCSG Countershattspeedsensorground Alwaysr0 V
B23 NC speedsensorsignal
Countershaft Dependingon vehiclespeed:Pulsingsignal
input Whenvehicleis stopped:0 V
B24 ATP D4 Ay'Tgear position switch lor posi- InEposition:0V
tion signalinput In otherthan 6 position:5 V
ATP NP A,/Tgear position switch E and I n E a n dE p o s i t i o n0sV
:
N positionsignalsinput In otherthanE andN] positions: Batteryvoltage
C {31P)
PCMCONNECTOR
TerminalNumber Signal Description Measuring Conditions/TerminalVoltage
Cl to C6 - seesection11 -
c1 Servicechecksignal With ignition switch ON (ll) and servicecheck

connectoroDen;5 V
With ignition switch ON (ll) and servicecheck
connectorconnectedwith sDecialtool: 0 V
C8 to Cg - seesection11-
c10 VBU Back-uppower system Always batteryvoltage
C 1 1t o C 3 1 - seesection'11-
D (16P}
PCM CONNECTOR
TerminalNumber Signal Description MeasuringConditions/TerminalVoltage
Dl to D4 - seesection11-
D5 STOPSW Brakeswitchsignalinput Brakepedaldepressed:Batteryvoltage
Brakepedalreleased:
0V
D 6t o D 1 6 - seesection1 l -
14-43
PCMGircuitDiagram(A/T GontrolSystem:'99- 00 Models)
UNOEF DASI
FL]SE/FELAY
BOX
ta T06 TDr.
UISEF,DASH
FISSIELYmX
r,Jo
25(75A) GAUGE
ISSEMBLY
Lr GRN -----l l"-- LTGRll

L eultru----iF erk€Lu INT€RLOCK
CCNTFOL
uN|l
ert*rll
I STARTEF
r-->l
I
l__ sL!
14-44
CONNECTOF SPEEO
1r6P) SENSOF
Y f7
II
II I
I I
ECI
"*ttot**" 1*u)
ttt*'" ,5-,
I
II
SHIFICONTFOL
solEt€to vALvE
ASSEMSLY
fl**',*"
I
BLK
I
G401

Conditions('99- 00 Models)
PCMTerminalVoltage/Measuring
A/T ControlSystem
The PCMterminalvoltageand measuringcondjtionsare shownfor the connectorterminalsthat are relatedto the A//Tcon-
trol system,The other PCMterminalvoltageand measuringconditionsare describedin section,11.
PCMConnoctorTgrminrl Locations
PCMCONNECTOR
A {32PI
Terminal Numbel Signal Description M€asuring Conditions/TerminalVoltage

A10 5L5 Servicechecksignal With ignitionswitchON (ll)and servicecheck
connectoropen:Approx, 5 V
With ignitionswitchON (ll)and servicecheck
connectorconnectedwith sDecialtool: 0 V
A14 D4 IND E indicatorlight control When ignitionswitchis first turnedON (ll):
ApDrox. 10 V for two seconds
In E position:Approx.1OV
428 ILU InterlockControl When ignitionswitchON (ll),brakepedal
depressed, pedalrereaseo:
and accelerator
Batteryvoltage
A.32 STOPSW Brakeswitchsignalinput Brakepedal depressed:battery voltage
Brakeoedalreleased:0V
8 (25P}
PCMCONNECTOR
Terminal Number Signal Descdption MeasuringCondhions/TorminalVoltag6

B1 !GP1 Power supply system With ignitionswitchON (ll):Batteryvoltage
PGl Ground
B8 LS AM Linearsolenoidpowersupply With ignitionswitchON (ll):Pulsingsignal
negativeelectrode
B9 IGP2 Power supply system With ignition switch ON (ll): Bafteryvoltage
810 PG2 Ground
917 LS AP Linearsolenoidpower supply With ignitionswitchON (ll):Pulsingsignal
positiveelectrode
B20 Ground
VBU Back-uppowersupply Always battery voltage
822 Ground
14-46
D {16P)
FCM CONNECTOR
Terminal Number Signal Do3cription Measuring Conditions/TorminalVohage
D1 LCA Lock-upcontrolsolenoidvalveA When lock-upis ON: Batteryvoltage

control With no lock-up:0 V
SHB ShiftcontrolsolenoidvalveB In E position,in 1stand 2nd gearin E, E
control position: Batteryvoltage
ln 3rd gear in E, E, in 4th gear in E posi-
t i o n ; 0V
D3 LCB Lock-upcontrolsolenoidvalveB Whenfull lock-up:Batteryvoltage
control With half lock-up:Pulsingsignal
D4 Not used
D5 VB SOL Lock-upcontrolsolenoids,shift with ignitionswitchoN (ll):Batteryvoltage
controlsolenoidsand linear With ignitionswitchOFF:0 V
solenoidpower supplyelectrode
D6 ATP R Ay'Tgear position switch tnEposition:0V
E positioninput In otherthanE position:
Approx.10V
SHA ShiftcontrolsolenoidvalveA In E] position,in 2nd and 3rd gearin p!, [Q]
control position: Batteryvoltage
In 1stgear in E, @ position,in 4th gear in El
Dosition:0 V
A/T gear position switch In E position:0V
o
D8 ATP D3
E positioninput In otherthan @ position:Approx.10 V
\ D9 ATP D4 Ay'Tgear position switch In El position:
0V
E position switch In otherthanE position:
Approx.5 V
D10 NC Countershaftspeedsensorsignal Dependingon vehiclespeed:Pulsingsignal
input Whenvehicleis stooped:0 V
D11 NM Mainshaftspeedsensorsignal Dependingon enginespeed:Pulsingsignal
Inpur When engineis stopped:0 V
D't2 NMSG Mainshaftspeedsensorground
D13 ATP NP Ay'Tgear position switch E and I n E a n dE p o s i t i o n0sV
:
E positioninput In otherthanE andE positions: Approx.10V
D14 AfP 2 Ay'Tgear position switch tnEposition;0V
E positioninput In otherthanE position:
Approx.10V
D16 NCSG Countershaftspeed sensor
ground
14-47
Troubleshooting Procedures
Chcckingthe DiagnosticTrouble Code IDTC)

with an OBD ll Scan tool or Honda PGM Tester
when the PCMsensesan abnormalityin the input or output systems,the pl indicatorlight in the gauge assemblywill
blink.When the 16PData Link Connector(DLC)(locatedunder the dash on the driver,sside) is connectedto the OBD ll
ScanTool or HondaPGM Testeras shown,the scantool or testerwill indicatethe DiagnosticTroubleCode (DTC)when
the ignitionswitchis turnedON{ll).
OBD ll SCANTOOLor
HONDAPGMTESTER
DAYALINKCONNECTOR
{16P}
lf the El indicatorlight or the MIL hasbeenreportedon, or lf a driveabilityproblemis suspected,

follow this procedure:
1. Connectthe OBD ll ScanTool (conformingto SAE J19781or HondaPGMTesterto rhe 16p DLC.(Seethe OBD ll Scan
Tool or HondaPGMTesteruser'smanualfor specificinstructions.lf you are usingthe HondaPGMTester,makesure it
is set to the SAE DTCtype.)
2. Turn the ignitionswitchON (lll, and observethe DTCon the screen,
3, Recordall fuel and emissionDTCS,A/T DTCS,and freezedata.
4 lf there is a fuel and emissionsDTC,first checkthefuel and emissionssystemas indicatedbythe DTC(exceptfor DTC
P0700).DTCP0700meansthere is one or more A,/TDTC,and no problemswere detectedin the fuel and emissionscir-
cuit of the PCM.
5. Write down the radiostationoresets.
6. Resetthe memorywith the PGMTesteror by removingthe BACKUP fuse in the passenger's under-dashfuse/relaybox
for more than 10 seconds.
7. Drivethe vehiclefor severalminutesat speedsover 30 mph (50 km/hr),and then recheckfor DTCS.lf the A"/TDTC
returns,go to the Symptom-toComponentCharton pages14-52and 14-53for'96 - 98 models,and pages14-54and
14-55for the'99 - 00 models,lf the DTCdoes not return,there was an intermittentproblemwithin the circuit.Make
sureall pins and terminalsin the circuitare tight, and then go to stepg.
8. Resetthe radiopresetstations,and setthe clock.
14-44
Chockingth€ DiagnosticTroubleCode (DTCI
with the ServicoCheckConneqtorand Sp€cialTool
Whenthe PCMsensesan abnormalityin the inputor outputsystems,the @ indicatorlight in the gaugeassemblywill blink
When the Service CheckConnector(locat€d under the dash on the passengsrside) is connectedwith the special tool as
TroubleCode(DTC)when the ignitionswitchis turnedON (ll).
shown,the E indicatorlightwill blinkthe Diagnostic
When the E indicator light has been reported on, connectthe ServiceCheckConnectorwith the specialtoo'.
Thenturn ON (ll)the ignitionswitchand obssrvethe E indicatortight.
GAUGEASSEMBLY
CONNECTOB
SERVICE
CHECK
CONNECTORI2PI 07PAZ-0010100
Codes 1 through 9 are indicated by individual short blinks, Codes 10 and above are indicat€d by a sories of long and short
blinks.One long blink equals1Oshort blinks.Add the long and short blinkstogetherto determineth€ code.After deter-
-
mining the code, refer to the electricalsystem Symptom-to Component Chart on pages 1+52 and 1+53 for'96 98 mod-
'99 -
els,and 14-54and 14-55for the 00 models.
Short blink loncel
S€r DTC1
s.. DTC2
Long blink Short blink lfiYa tim.!,
S€c DTC 15
(cont'd)
14-49
(cont'dl
1. Removethe kickpanelon the passenger's
side {seesection20}.
2. Removethe PCM.and turn the PCMover.
Inspectthe circuit on the PCMaccordingto the troubleshootingflowchart with the spocialtools and a digital multime-
ter as shown.
How lo Use tha BackprobeSet
Connectthe backprobeadaptersto the stackingpatchcords,and connectthe cords to a multimeter.Usingthe wire

insulationas a guide for the contouredtip of the backprobeadapter,gently slidethe tip into the connectorfrom the
wire side until it comesin contactwith the terminalend ofthe wire.
BACKPROSE
BACKPROBE
SET
07saz- (xtl(xtoA
{two required)
DIGITALMULNMEIER
(Comm€rcially6vailabl€l
-aHM-32-003
or equival€nt
14-5 0
PCMResetProcedure
1. Turn the ignitionswitchoff.

'10secondsto resetthe PCM'
2. Removethe BACKUPfuse (7.5A) from the under-hoodfuse/relaybox for
NOTE:
the radio
. Disconnectingthe BACKUP fuse also cancelsthe radio presetstationsand clock setting Make note of
presetsbeforeremovingthe luse so you can them
reset
. in" gCfUmemorycan also be clearedby usingthe OBD ll ScanTool or HondaPGMTester'
Final Procedure
NOTE:This proceduremust be done afterany troubleshooting.
2. Resetthe PcM.
tool from
3. Disconnect the oBD ll scan Tool or HondaPGMTesterfrom the DataLinkconnector,or removethe special
the ServiceCheckConnector.
4. Turn the ignitionswitchON (ll),and setthe radiopresetsand clocksetting'
5'ToVerifytheprob|emisrepaired,test.drivetheVehic|eforseveralminutesatspeedsover30mph(48km/h).
14-51
Symptom-to-Component
Ghart
ElectricalSystem-'gG - 98 Models
E Indicaior
DTCII MIL Dotection ltem Page
Light
P1753 Lock-upcontrolsolenoidvalveA
Blinks ON
fl) 14-56
P1758 Lock-upcontrolsolenoidvalveB
Blinks ON
\21 14-58
P1705 Ay'Tgear position switch (short to groundl
(51 Blinks ON 14-60
P1706 A,/Tgear position switch (open)
(6) OFF ON 14-62
P0753 ShiftcontrolsolenoidvalveA
Blinks ON
l7l 14-64
P0758 ShiftcontrolsolenoidvalveB
Elinks ON
{8) 14-66
POl20 Countershaftspeed sensor
(9) Blinks ON 14-68
'96 - 97
Mainshaftspeedsensor
models:
P0715
OFF ON
{15) '98 model: 14-70
Blinks
P1768 Linearsolenoid
Blinks ON 't4-72
{16)
P0740 Lock-upcontrol system
(40) OFF ON 14-74
P0730 Shift control system
(41) OFF ON 14-75
P0700*, Automatictransmissioncontrolsvstemin the pGM-Fl
(none) control svstem
*1: The DTCin the parentheses
is the code E indicatorlight indicateswhen the DataLinkconnectoris connectedto the
Honda PGM Tester.
*2: Wheneverthe HondaPGM
Testeror ScanTool detectsan automatictransmissioncontrolsystemDTC,p07OO will be
set in the PGM-FIcontrol svstem.
14-52
l-d indicatorlight does not blink,performan inspectionaccordingto the table below.
lf the self-diagnostic
SYmPtom Inspection Ref.Page
E indicatorlight does not come on tor two secondsafterignition 11-16

switchis first turnedON {ll}.
E indicatorlight is on constantly(not blinking)wheneverthe ignition 14-78
switchis ON (ll).
Shift levercannotbe movedfrom @ positionwith the brakepedal 't4-79
Inspection
depressed.
to recreatethe symptom by test-driv-

NOTE:lf a customerdescribesthe symptomfor code Pl706 {6),it will be necessary
ing, then recheck
the DTC.
14-53
Chart
ElectricalSystem-'99 - 00 Models
E Indicator
DTC*I MIL Dotostion ltem Page
Light
P1753 Lock-upcontrolsolenoidvalveA
Blinks ON '14-80
fi)
P1758 Lock-upcontrolsolenoidvalveB
Blinks ON
t2l 14-82
P1705 Ay'Tgear position switch {short to ground)
Blinks ON
{5} 14-84
P1706 y'VTgear position switch {open)
(6) OFF ON 14-81
P0753 ShiftcontrolsolenoidvalveA
Blinks ON
\71 14-89
P0758 Shift control solenoid valve B
(8) Blinks ON 14-9r
P0720 Countershaftspeed sensor
(9) Blinks ON r4-93
P0715 Mainshaftspeedsensor
(15) Bl i n k s ON 14-95
P1768 Linearsolenoid
(16) Blinks ON 't 4-97
PO740 Lock-upcontrol system

(40) OFF ON 14-99
P0730 Shift control svstem
(41) OFF ON 14-100
P0700*, Automatic transmissioncontrol system in the pGM_Fl
(none) OFF
controt svstem
*1: The DTc in the parentheses
is the code E indicator tight indicateswhen the Data Link connector is connected
to the
Honda PGM Tester.
*2: Whenever the Honda PGM Tester
or scan Tool detects an automatic transmission control system DTc, p07oowill be
set in the PGM-FIcontrol svstem
14-54
E indicatorlight does not blinkand followingsymptomsappear,performan inspectionaccordingto
the table below.
page
Reference
1."""". y{*fu
fiSh,
E i"dl.r." 14-101
oN (ll). 14-102
lE indicatorlight does not come on for two secondsafterignitionswitchis first turned
14-104
Shift levercannotbe movedfrom E positionwith the brakepedaldeprsssed'
14-55
ElectricalTroubleshooting(,96- gg Models)
Troubleshooting
Flowchart- Lock-upcontrorsorenoidVarveA
NOTE:Recordallfreezedata beforeyou troubleshoot.
. OBD ll Scrn Toot indicatesCode Po$ible Cau3e

P1753. . Disconnecledlock-up control
. S e l f - d i a g n o s i s@ i n d i c a t o r
solenoidvalvo A connector
light blinks once. . Short or open in lock-uDcontrol
solenoidvalv€ A wire
. Fauliy lock-up contlol solonoid
valve A
PCMCONNECTORS
Checkfor a Short to Powo.:

A l32P)
2. Disconnect the A (32p)and B
( 2 5 P )c o n n s g l 6 p s1 r q - t h a
PCM.
3. Turnthe ignitionswjtchON 0t).
the 85 and Ag or A22 termi
nals.
Repair shoit to power in the wire

betw€en the 85 terminal and thg
lock-up coDtrol tolenoid valve A.
Mea3ureLock-upControl Sole-
noid Valve A RGislance:
'1. Turn
2. Measure the resistance
betweenthe 85 and A9 or A22
terminals.
Checklor looso PCM conn€ctoB.

12- 25 O?
ls the resistance lf nece$.ry, substituto a known-
good aolonoid valve ass€.nblvol
PCMend rech6ck.
To page'14-57

Frompage14-56 PCMCONNECIOBS
Ch6ck Lock-up Control Solenoid

Valve A tor a Short Cilcuiti
lrom the lock-upcontrol sole-
noid valveassemblY.
the 85 and Ag or A22 termi-
nats.
Wire sideof lem6leterminals
Ropair 3hort to giound in iha wila

b.twoqn th6 85 terminrl rnd tho
locl-up control 3olanoid valvo A.
LOCK.UPCONTROL
SOrINOID CONNECTOR
lml
-,f
YEL
Mo..ura Lock-up Control Sole' (o)
noid Velve A Reri3tanc. at tho
SolenoidConn6cto.:
Measure the resistancebetween
I
the No. 2 terminalof the lock-up
control solenoidconnectorand Teaminalsideof maloterminals
body ground.
Chock for opan in tha wit.

ls the resistance12_ 25 O? ba(w.an tha 85 torminll lnd the
lock-uocontrol lolanoid vtlYa A.
Roplscetho lock"up cont.ol 3ol€_

noid vllvo arsembly.
14-57
ElectricalTroubleshooting('96 - 9g Modelsl
TroubleshootingFtowchart- Lock-upcontrol sorenoidVarveB
NOTE:Recordall freezedata beforeyou troubleshoot.
. OBD ll ScanTool indicrtes Code PossibleCause

P1758. . Disconnectedlock-up control
. Self-diagnosisE indicrtor light
solenoid valve B connector
blinkstwice. ' Short or open in lock-upcontrol
solonoid valve B whe
. Faulty lock-up control solenoid
valve B
PCMCONNECTORS
Checkfor a Shon to Power:

1. Turnthe ignitionswitchOFF. A {32P)
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 t).
the 84 and A9 or A22 termi-
nals.
Repeir short to power in the wire

between the 84 teiminal and the
lock-up control solenoid valve B.
MoasureLock-upControl Sole-
noid Valve B Resistance:
b e t w e e nt h e 8 4 a n d A g o r
A22terminals.
Check for loose FCM connectors,

12- 25 O?
ls the resistance lf necessary, substitute a known-
good solenoid valve assembly ol
P1CMand rech6ck.
To page 14-59

Frompage14 58 PCMCONNECTORS
Check Lock-up Control Solenoid

Valve B for a Short Circuh:
from the lock-uPcontrolsole'
noid valveassefibly.
the 84 and A9 or A22 terma-
nals,
WiresideoI lemaleterminals
Rgprir 3hort to ground in tho wite

ls therecontinuity? Hwoon the 84 torminal and the
lock-uocontlol solonoidvalvs B.
LOCK.UPCONTROL
SOLENOIDCONNECTOR
IFl;II
-r:-]
Measu.o Lock-uP Control Sole'
noid Valve I Resistance at tho 6nn/eLKfi
SolenoidConnector:
Measurethe resistancebetween
the No. 1 terminalo{ the lock-up
control solenoid connectorand
I
body ground.
Terminalsidoot maleterminals
Chcck tor opcn in the wirs

12- 25 O?
ls the resistance b€tlve.n the 84 ierminal and tho
lock-upconttol solonoidvllvc B.
Reolacethe lock'up control sole-

noid valve assemblY.
14-59
ElectricalTroubleshooting('96 - 9g Models)
TroubleshootingFlowchart- A/T GearpositionSwitch (Shortl
NOTE:Recordallfreezedatabeforeyou troubleshoot.
' OBD ll Scln Toot indic.tes Cod6 Poiriblo Caus6

P1705. . Short in A/T go.. position
. Sofidi.gno3b E indicato] tighr
awhch wira
blinksfivatim... . FauhyA/T goa. position swhch
NOTE:Code P1705(5) is causedwhen

the PCM receives two g e a r p o s i t i o n
Observo th. A/T Go.r po3ition inputsat the sametime.
Indicator:
1. Turnthe ignitionswitchON l).
2. Observethe A"/Tgear position
i n d i c a t o r ,a n d s h i t t t o e a c h
posttron,
Do any indicatoGstay on Tho sy3tem b OK.t this timo.

when the shift lever is not in Checkth6 wilc harnari for dam-
those positions? rga. PCMCONNECTORS
M.r.ur. ATP R Vohlge:

1. Shiftto all positionsotherthan
E.
2. Nileasurethe voltage between
the 816 and Ag or A22 tormi-
nats,
Check for short in tha wiro
bstwacn the 816 tcrminal and th6 Wiresideof femaleterminals
A/T go.r porition rwitch or A/T
ls there batteryvoltage? g..r position indicltor. It wira i3
OK, ch.ck for loo!€ FCfit connoc-
to13. lf nacetaary, subrtitute a
known€ood Pcllt and roa|rsck.
Meesur. ATP NP Vohage:
1. Shiftto allpositionsoth€rthan
EorE.
2. Moasurethe voltage between
the 825 and A9 or A22 termi
nats.
Check for short in the wire
b.tw..n th6 B:I5torminrt and th.
A/T gclr poahion indicator. o. .
short in tha wirrs between th.
A/T gclr position indicator rnd
the A/T gerr poiition switch. lf
wir.3 r.o OK, chack tor looso
PCM conn.ctorr. It n.cosarry.
sub.tituto a known-good pCM
M.Gur. ATP D4 Voltago: .nd r.chock.
1. Shiftto allpositionsotherthan
lD.l.
2. Measurethe voltage betw€en
rhe 824 and Ag or A22 termi-
nals.
Check tor 3hort in tho wiro

bc{wocn the 824 terminrl and tho
ls there approx. 5 V? A/T ge.r poiition switch. lI wile
ia OK, chock tor loo3o plCM con-
YES ncctoaa. It nacossarv,sublthute a
known-good PCMand rech€ck.
To page14-6':
1 4- 60
PCMCONNECTORS
From page 14-60 '96:GRN'97- 98:PNX
MeasuroATP D3 Voltage:
tr.
2. Measurethe voltage between B (25P1
nals.
Ch.ck tor short in the wire
botwoen tho 88 terminal and ihe
A/T goar position 3witch ol A/T
ls there batteryvoltage? gosr position indicator, ll wirc is
OK, chock for loo3€PCM connec-
tor3. lf nece3rary, substituta a
known-good PCMlnd roch€ck
Morsuro ATP2Voltage:
6t
2. Measurc the voltage between
the 817 and Ag or A22 terml-
n6ls.
Check for short in the wile

b€twesn the B'l 7 terminal and the
A/T ge.r pGition switch or A/T
ls there batteryvoltage? gear po3ition indicator. lf wire i3
OK, check for loo3o rcM connec'
to13. lf necossarY, substitute a
known-goodPICMand recheck.
check for loose PCMconnectors.

lf noc*sarY. sub3titute a known_
good PCMand r.chock.
14-61
ElectricalTroubleshooting('96- gg Modelsl
TroubleshootingFlowchart- A/T GearpositionSwitch (Open)
. OBD ll ScanTool indicatesCode PossibleCauso

P1706. . DisconnectedA/T gear position
. Self-di.gnosk E indicatortight
switch conn€ctor
blinks six timos. . Open in A/T gear position
switch wire
. FaultyA/T gear position switch
PCMCONNECTORS
MoasureATP I Voltage:
1. Turnthe ignitionswitchON 1 ).
2. Shiftto E position.
the B'f6 and Ag ot A22 tetmi-
nats.

Ropai. op€n in the wire betwe€n
the Bl6 terminal.nd the A/T gear
position swhch.
Measur€ATP NP Voltage:
1. Shiftto E or E position.
the 825 and A9 or A22 termi,
nals,
Repeir open in the wir€ between

tho B25terminal and th6 A/T geer
position indicator or tho A/T 96.r
position 3witch.
MeasureATP 04 Voltege:
the 824 and A9 or A22 termi
nals,
Rcpair open in the wire between

ls there voltage? tto 82{ to.minal and th6 A/T geat
lrosition 3witch.
NO
To page 14 63
1+62
Frompage14-62
PCMCONNECTORS
'95: GRN37 -'98: PNK
MeasureATP 03 Voltagei
1. Shiftto E Position.
2. lvteasurethe voltagebetween
nals.
Ropairopen in tho wils between

the 88 terminal .nd tho A/T goar
oosition switch
Mea3ur. ATP2Vohage:
1. Shiftto E Position.
the 817 and Ag or A22 termi'
nals,
Repairopen in the wirc botweon

the B17terminalrnd the A/T
geer poaition 3witch.
Chockfor loose PCM conn€ctoB.

lf nec*sary, sub3titute e known'
good PCMand rocheck.
14-63
ElectricalTroubleshooting('96 - 98 Modelsl
TroubleshootingFlowchart- Shift GontrolSolenoidValveA
' OBD ll ScanTool indicatesCode Po$ible Cau3e

P0753. . D i s c o n n e c t e ds h i f t c o n t r o l
. Sett{iagnosis E indicatorlight
solenoidvalve A connector
blinks seventim6. . Short oi open in shift control
solenoidvalve A wire
. Faulty shirt control solenoid
PCMCONNECTORS
Checktor a Short to Power:

1. Turnthe ignitionswitchOFF. A t32Pl
2. Disconnect the A (32P)and B
{ 2 5P i c o n n e c t o r st r o m t h e
PCM.
the 83 and A9 orA22 terminals.
Wire sideol femaleterminals
Repairshort to powe. in the wir6

between the 83 terminal .nd the
shift control solonoid valvo A.
Moa3ure Shift Control Solenoid

Valve A Resistanc€:
2, Measure the resistance
betweenthe 83 and A9 or A22
terminals.
Ch€ckfor loose PCMconnectors.

12- 25 0?
ls the resistance lf n€c6srry, subatitute a known-
good solenoid valve a3,semblyor
PCMend rocheck.
To page14-65

Frompage14-64
PCMCONNECTORS
Check Shift Control Sol.noid

v.lve A loi a Short Circuh:
'1. Disconnectthe 2P connector
from the shift control solenoid
valveassemblY.
the 83 and Ag or A22terminals.
Wiresideo{ femaleterminals
Roprir shon to ground in th. wil.

b.tw€on th. B:t t.rmin.l rnd tho
ihift conLol aolonoid valvc A
SHIFTCONTROLSOLENOID
CONNECTOR
----!=--
Mea3ur. Shift Control Solonoid

FI-I1
=r==--
v.lvo A Rgistance !t tho solendd
Connoc'tor: alurvEL5f
the No. l terminalofth€shiftcon_
trol solenoid connectorand body
II
ground.
Terminalsideol maleterminals
Chack to. open in th. rtir.

12- 25 O?
ls the resistance b.t^raan tha 8:l Lrtnlnll tnd tho
thift conlrol 3olanoid valva A.
14-65
ElectricalTroubleshooting('96 - g8 Modelsl
TroubleshootingFlowchart- Shift ControlSolenoidValveB
NOTE:Recordallfreezedatabeforeyou troubleshoot,
. OBD ll ScanTool indic.tes Code PossibleCause

P0758. ' Disconnected shift control
. Solt-diagnosisE indicatorlight
solenoidvalve I connectol
blinks eight times. . Short or open in shift control
solenoidvalve B wire
. Faulty shift control 30lenoid
valve B
PCMCONNECTORS
Chockfor a Short to Power:

1. Turnthe ignitionswatchOFF. A t32P)
(25P)connectors from the PCM.
3. Turnthe ignitionswitch ON (ll).
nals,
Repairshort to powar in the wire

botwcen the 811 torminal and
the shift control solenoidvalve 8.
Measure Shift Cont.ol Solenoid

Valve B Resktance:
2 , M e a su r e t h e r e s i s t a n c e
b e t w e e nt h e B l l a n d A 9 o r
A22terminals.
Checl for loose PiCM connector3.

lf nec€ssary, sub3titute a known-
12- 25 O?
ls the resistance
good solenoid v.lve assembly ol
PCM and recheck.
To page 14 67

Frompage14-66
PCMCONNECTORS
C h e c kS h i f t C o n l r o l S o l € n o i d
valve B tor a Short Circuit:
1. Disconnectthe 2P connector , 2 ll r . 5
trom the shift control solenoid
valveassembly.
nals,
Replir shon to ground in th€ wire

ls therecontinuity? betwe.n the 811 terminal and the
3hift control solenord valvo B.
SHIFTCONTROLSOLENOID
CONNECTOR
GRN/WHT
Measure Shift Control Solenoid
vrlve B Resistanceat the Sole-
noid Connector:
the No.2 terminaloftheshiftcon
trol solenoid connectorand body Terminalsideol maleterminals
ground.
Check tor ooen in the wire

12 25 O?
ls the resistance betw..n thc 81 1 t€tminal ard tha
shift control solonoidvrlv6 B.
14-67
ElectricalTroubleshooting('gO- 98 Modelsl
TroubleshootingFlowchart- CountershaftSpeedSensor
NOTE;Recordallfreezedata beforeyou troubleshoot.
. OBOll Scln Tool indicat6 Code Po$iblo Causa

m7z). ' Loosg or laulty conncction
. S6lt-dirgnosis E indic.tol
botwocn tho PCM and c.i hrr-
light blink! nin. tim6, n1't!
' Disconnoctad countorahott
lpo€{ san3or oonnoctot
. Short or opon in countorshaft
speed lonsor wire
. F ulty counte.lhalt spe6d s6n-
sol
ls the countershaftspoedsensor
installedproperly?
COUNTERSHAFT
SPEEDSENSOR
CONNECTOR
lFI,]1
-F=r
Moa3ureCountoEhaft Sp€ed S6n-
sor Reaktanc€ at tho Son3or Con- 9 l
noctor
trom the countershaftspged
L_l
sensorconnector, Terminalsideol maleterminals
2. Measurethe resistanceof the
countershaftsDeedsensor,
ls the resistance400 - 600 0?
PCMCONNECTOR
B I25P}
Chock Countersh.ft Spood Scr|3ol

for a Shoft Circuit:
1. Disconnectthe B {25P)con
nectorfrom the PCM.
the body groundand the 823
t e r m i n a la n d 8 2 2 t e r m i n a l
individually.
Repai. .hort in th. wiroa b.t$re€n

tho 823 lnd 822 torminals .nd
lho counteBhaft lpocd aenro..
To page 14-69
14-68
l'Downloaded from www.Manualslib.com manuals search engine
PCMCONNECTOR
8 I25PI
MeasureCounteFhaftSp€€dS6n-
sor Resistance:
1. Connect the countershaft
speedsensor2P connector,
between the B23 and 822 tel
mtnals.

Repair looso terminal ol opon in
the wiro3 between th6 823 and
ls the resistance400- 600 0? 822 terminal3 and the counter-
shaft soeedaen3or.
Checktor looscrcM connestors.

sub3titutea known-
ll nocessary,
goodPCMandrecheck.
14-69
TroubleshootingFlowchart- MainshaftSpeedSensor
. OBD ll ScanTool indicatesCode N O T E :C o d e P 0 7 1 5( 1 5 )o n t h e P C M

Po$ible Cause
doesn'talwaysmeanthere'san electrical
m715. . Disconnect€dmainshaft sD€ed problemin the mainshaftor countershaft
. S e l f - d i r g n o s i 3E i n d i c a t o r
Sensor@nnoctot s p e e ds e n s o rc i r c u i t ;c o d e P 0 7 1 5( 1 5 )
light indicstesCode 15. . Short or open in mainshatt may also indicatea mechanicalproblem
sJt€eds6nsoawire in the transmission.
. Faulty mainshaftlpeed s6nso.
Checkthe mainshaftand counter-

shaftspeedsensorinstallation.
Are the mainshaftand countershaft

speedsensorinstalledproperly?
MAINSHAFTSPEEO
SENSORCONNECTOR
MoasureMainshaftSpoedSgnsol
Rosistanceat the Sensor Con-
n€ctor:
from the mainshaftspeedsen-
sor connector.
2. Measurethe resistance ot the
mainshaftspeedsensor. Terminalsideof maleterminals
ls the resistance400 600 O?
PCMCONNECTOR
B I25PI
Check Mainshaft Sp6ed Sensor

for a Short Circuil:
1. Disconnect the B {25P)connec'
tor lrom the PCM.
bodygroundand 815terminal
and the 814terminalindividu,
Repai. shon in the wi.os bstwoen
ls therecontinuity? the 815 and 814 te.minals and
the mainshatt .Dood 3ensor.
To page 14-71
14-70
Frompage14-70
B I25PI
PCMCONNECTOR
Mea3uroMain3haftspeed sensor
Resistance:
1. Connectthe ma;nshaftsPeed
sensol2Pconnector,
2 . [ / l e a s ur e t h e r e s i s t a n c e
betweenthe 815 and 814 ter_
minals.
Run the Electical TrouH€.hooting Wire sideoI femaletermlnals

Flowcirrt for cod. P0720l9l.
ls the resistance400- 600 O? Check for loose P1CMconnoctors.
ll n€cesslrY,3ubstitute a known'
good PCMand racheck.
MAINSHAFTSPEEDSENSOR
CONNECTOR
CheckNM wire Continuityl

from the mainshaftspeedsen'
sor connector.
the 815terminaland the No. 1
terminal of the mainshaft
speedsensorconnector.
Rgpsi. opon in thc wira bctwg€n

the 815 torminrl and th6.tain_
shatt soeodlensoa,
CheckNMSGWire ContinuitYr
814 terminaland the No.2 termi
nal of the mainshaftsp€edsensor
connector,
Repairopen in the wira botwGon

the 814 terminal and lhe main'
shsft spo€d 3en3or.
Checkfor loo3o PCMconnoctoB.

ll neca$8ry, subditute a known-
good PCMand rgchock.
14-71
TroubleshootingFlowchart- LinearSolenoid
NOTE:Recordall freezedata beforevou troubleshoot,
OBOll ScanTool indicatesCode Po$ible Caus6

P176a. . DisconnoctodlineaJ solonoid
S e l f - d i a g n o s i 3E i n d i c a t o r connectot
light indicatesCode 16, . Short or open in linoar solenoid
' Faultylinoar solonoid LINEARSOLENOID

CONNECTOR
l;r]l
Measure Linear Solenoid Resist-
ance at the SolenoidConnecto.: TT
lrom the linearsolenoidcon
nector,
YL I I
3. Measurethe resistance ofthe
linearsolenoid. Terminalsideol maleterminals
ls the resistance
approx.5.0O?
PCMCONNECTOR
B I25PI
WHT RED
CheckLinearSolenoidfor a Shon
Circuit:
1. Disconnect the B 125P)
connec-
tor from the PCM.
the body ground and the B1
terminaland 82 terminalinda-
vidually.
Repair short in the wires bgtwoen

the Bl and 82 terminab and the
lineti solsnoid.
Meaaure Linoar Solenoid RGi3t-

anc€:
1 . C o n n e c t h e l i n e a rs o l e n o i d
connector.
betweenthe 81 and 82 termi-
nals,
Ropair looso terminal or open in

ls the resistance
approx.5.0O? the wires botwe€n the 81 and 82
telminals end the linear solenoid.
To page14-73
14-72
Ftom page 14-72
PCMCONNECTOR
A I32P}
Checkthe G.ound Circuit:

A9 and A10terminals.
. Rapair opan in the wiro

botweon th6 tormin.b Ag rnd
A10and G101. Wirosideof t6maleterminals
. Raprir looc€ iunction connrc{or.
. R.p.ir poor ground {G101}.
Chock tor 100!6 PCM connectors.

ll nocessary,substituto a known-
good PCMand r6ch6ck.
14-73
ElectricalTroubleshooting('96 - 98 Models)
TroubleshootingFlowchart- Lock-upControlSystem
NOTE:Recordall freezedata beforevou troubleshoot.
. OBD ll Sc6n Tool indicatG Code PossibleCause

m7{0. Faulty Lock-upcont.ol system
. Self-diagnosis
E indicatorlight
indicatesCode40.
Checktor Another Code:

Checkwhether the OBD ll scan
tool or the E indicato,light
indicatesanothercode.
Doesthe OBDll scantool or Perform lhe Troublo3hooiing

the E indicatorlight indicate Flowchart tor the indicated
anothercode? Code(s).Recheckfor cod. P07il0
lilol aftor iroubl€3hooting.
NOTE:Do not continuewith this troublesnoonno
until the causesof any
otherDTCShavebeencorrected.
Tast 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
page14-119and 14-120).
Repairtho hydreulicaystem a3
necessary{3eepage 14-119).
R e p l a c et h e L o c k - u p C o n t r o l
Solenoid Valve Assembly and
R6check;
1 . B e p l a c et h e l o c k u p c o n t r o l
solenoidvalve Ay'Bassembly
(seepage14-105).
2. Turn the ignitaonswitch OFF
and reset the PCM by remov
ing the BACKUP (7.5A) fuse
in the underhood fuse/relay
box for morethan 10seconds,
3. Usingthe scantool, checkto
be sure that the enginecool
a n t t e m p e r a t u r ei s i n 1 7 6 ' F
(80'C)and above.
4 . 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
than one minute.
5. Recheck for codeP0740(40).
Doesthe OBDll scantool

indicatecode P0740{40)? The systom k OK at this time.
14-74
TroubleshootingFlowchart- Shift ControlSystem
. OBD ll ScanTool indicatesCode PossibleCause

P0730. Faultyshift control system
. S e l l - d i a g n o s i sE i n d i c a t o r
light indicatesCodeill.
Checktor Another Coder

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
indicateanothercode.
Perlorm ths Troubleshooling

Doesthe oBD ll scantool or Flowch.rt for the indic.t.d
the E indicato'.tightindi Code(sl.Rechecktor code m730
cateanothercode? l4'lI atter troubleshooting.
until the causesot any
NOTE:Do not continuewith this troubleshooting
other DTCShave beencorrected.
Test lst, 2nd, 3rd and 4th Clutch

Pressure:
Measurethe 1st,2nd,3rd and 4th
clutchpressure(seepage 14119
t h r u1 4 - 1 2 1 ) .
Ropair the hydrlulic systom !s

ls eachclutchpressurewithin
necessary{see page 14-119 and
the servicelimit?
11-1211.
ReplaceShift Control Solenoid

valve Assembly,Linear Solenoid
Assamblyand Rechock:
1 . R e p l a c et h e s h i f t c o n t r o l
solenoidvalve A'/Bassembly
(seepage14-106).
2 . R e p l a c et h e l i n e a rs o l e n o i d
assemblylseepage14 108).
and resetthe PCMmemory by
removingthe EACKUP (7.5A)
tuse in the under hood fuse/
relaybox for more than l0
seconds,
4 . D r i v et h e v e h i c l ea t o v e r 1 2
mph (20 km/h)in 1st,2nd,3rd
and 4th gearfor morethan 30
secondsat P1 position.
5. Recheck tor codeP0730(41).
Doesthe OBDll scantool or

the Ed indicatortightindi The swt6m is OK et this time.
catecodeP0730{41)?

TroubleshootingFlowchart- E IndicatorLight DoesNot GomeOn
Tha E indicator light does nol

come on when the ignition swhch
is first turned ON (lll. {lt should
come on tol about two s€conds.l
Chockthe SeJvicoCheckConnec-
tor:
Make sure the specialtool (SCS
SeryiceConneclor)is not connect-
ed to the servicecheckconnector.
ls the specialtool (SCSService Disconnectthe special tool trom

Connector)connectedto the ser thc sarvice check connoctor and
vice checkconnector? rocheck.
Checkth6 E indicator Light:

Shift to lD.l oosition.
Checktor loose PCM connecto6.

ll nece3sary, sub.titute a known-
good FCM and r.chock.
PCMCONNECTOR
A I32PI
Checkthe Ground Circuit:
'1. Turnthe ignition
switchOFF.
2. Disconnecrthe A {32P}connec-
tor lrom the PCM.
the A9 terminal and body
ground and the A22 terminal
and body ground.
Repair op6n in tho wirgs

between tho A9 ot M2 tormi-
nalsand G101.
Rcpairpoor glound {G101).
To page14-77
14-76
Frompage14-76
A I32PI
PCMCONNECTOR
Measure Powor Supply Cilcuit

Voltage:
t e r m i n a l sA 9 a n d A 1 1 a n d
b e t w e e nt e r m i n a l sA 2 2 a n d
424.
RGpairopon or short in the wire
boiween the A11 andlot Ml lor'
minals,the PGM-Flm.in rel.Y,
end the tu36 box.
Mo.sure D4 IND Voltago: BRN/BLK

2. Connectthe A {32P}connector
to the PCM.
3. Connecla digital multitester
to the B13and Ag or A22 ter-
minals,
4. Turn the ignition switch ON (ll) BRN/BLK
'96:BLU/RED
and makesure that the voltage ,97,'98:GRN/BLK
is availablefor two seconds.
Chack tor opan in thc wita

bctwoon tha 813 larminal and
th. gauge ar!.mbly. lf wi.c i!
OK, chock for . frulty E indica-
tor light bulb or a l.uhy g.ug.
a.!.mbly printod circuit bolrd.
Chock for loose PCM connoctort.

Chocktho A/T gGatpolition
switch. lI n6ca$sry, substitute a
known-good PCMand rochock.
14-77
TroubleshootingFlowchart- E IndicatorLight On Constantly
Th6 E indicstor light is on con-

! a
st.ntly {not blinkingl whenevei
the ignition switch is ON lll).
B (25P)
PCMCONNECTOR
Measure04 IND Voltage:
2. Disconnect the B 125P) connec-
tor from the PCM.
t h e 8 1 3 t e r m i n a la n d b o d y
ground,
Repair3hort to pow€. in the wiro

between the 813 terminal end
thc gauge asiombly.
Meaiure ATP Dil Voltage:

2. Connectthe I (25P)connector
to the PCM.
4. Shifttoany positionotherthan
ground.
Checkfor a short to ground on tho

wir6. It wire i3 OK, .eplac6 the A/T
goar po3ition indbator,
14-7 A
l.Downloaded from www.Manualslib.com manuals search engine
TroubleshootingFlowchart- BrakeSwitch Signal
Symptom
Shift lever cannol b€ moved f.om
B pGition with the brako podrl
depr8sed.
CheckBrako Light Operation:

Deoressthe brakepedal.
Rop.ir faulty braks switch cilcuit

Are the brakelights ON?
lsos soction231.
PCM CONNECTORS
MeasureSToP SW Vohag€:
2. Disconnect the A l32P)and D
{ l 6 P ) c o n n e c t o r sf r o m t h o
PCM.
3. Measurethe voltage belween
the D5 and A9 or A22 termi-
nals with the brake Pedal
depressod.
Rap.i. opon in the wira bctn oen

ls there batteryvoltage? tha 05 terminal and tho btrkc
lwitdr.
. Brakeswitch 3ign.l is OK.

. Ch6cklor looao PCMoonnoctors.
It nocassary,aubctilute a known-
good PCM and r€check.
. Inspoctthe brake switch circuit
{s6esection 231.

TroubleshootingFlowchart- Lock-upControlSolenoidValveA
NOTE: Recordall freezedata before vou troubleshoot.
\ a
. OBD ll ScanTool indic.t6 Code PossibleCause
P1753. . Disconnoctedlock-uD control
. S e l f - d i a g n o s i s@ i n d i c a t o r
solenoid valve A/B alsembly
light blink3 once. connector
. Short or opon in lock-upconkol
solenoid valv6 A wire
valva A
' Open in VB SOLwire
Checklor a Short to Power: FCM CONNECTORS
L Turnthe ignitionswitchOFF.
2. Disconnect the B (25P)and D
( 1 6 P )c o n n e c t o r sl r o m t h e
PCt\4. B (25Pt ll D {16P1
the Dl and 820 or 822 termi-
nats.
LGl IBRN/BLXI LG2 (BRN/BLK)

Ropairshort to powcr in the wire
bstwoon tho Dl tolminal and the
lock-upcor|lrol lolonoid valvo A.
Measu.e Lock-up Cont.ol Sole-

B (2sPt ll D {16P1
noid V.lvo A R63btanc6:
between the Dl and 820 or
822terminals.
LGl (BRN/BLKI LG2 IBRN/8LK)
12- 25 O?
ls the resistance To page 1+81
I t25Pt D (16P1
MeasureVB SOLVohage:
the D5 and 820 or 822 termi-
nals.
Check for blown No. 15 17.5Al

fu3€ in the undordash fuse/raby
box. l{ th€ tusa ii OK, r.pair opon
in the wira b€twoen th€ 05 torfti-
nal and thc und€r{ash fuso/r€lay
box.
Checkto.loose tarminalfit in the

PCM connecloa3.ll necessary,
substilute a known-good PCM
and rocheck.
14-80
B {25P}
PCMCONNECTOR
Frompage14-80
Checklor continuity between the

8 2 0 t e r m i n a la n d b o d y g r o u n d ,
a n d b e t w e e nt h e B 2 2 t e r m i n a l I.G1(BRN/BLKI
and body ground.
Wiresideof l6maleterminals
Ropair opon in thc wircs betwe6n

the 820 lnd 822 tolminals .nd
ground {G10ll, and tepair Pool
ground (G10'l).
PCM OONI{ECTORS
Check Lock-up Cont.ol Solonoid

valve A for a Shon Cilcuit: B (25p) ll o l16P)
trom the lock-upcontrol sole-
noid valve ry'Bassembly.
2. Check for continuity betlv€en
th6 D1 and 820 or 822 termi-
nals.
IBRN/BLK} LG2IBRN/BLK}
Wire side ot femaleterminals

R6p.ir 3hort to glound in thc
wir. b.two.n the Dl torn|in.l
ard th. lock-up conttol iol.noid
valva A.
Maasuro Lock-up Control Sol.- LOCK.UPCO TROLSOTINOIDVALVE

noid Vllve A Ro.istance at tho A/B ASSEMBLYCON]TECTOR
I2P}
SolanoidConn6ctor:
Measure the resistancebetween
the No. 2 terminal of the lock-up
control solenoidvalve y'y'Bassem-
]F]AL
r-f-
bly connectorand body ground. LCA {YEu
I
(o)
Y
I
'12 R6placotho lock-up control solo_
ls the resistance - 25 O? noid valve A/B.$6mblY. Terminalsideof maleterminals
Chack for opon in tho wiro

botweon the Dl t..minal and tho
lock-upcontrol solenoidYalvaA.
14-A1
TroubleshootingFlowchart- Lock-upControlSolenoidValveB
NOTE|Recordallfreezedata beforeyou troubleshoot.
' OBD ll ScanTool indic.tes Code PossiblaCause

P1758. . Oisconnectedlock-uD control
. S e l f - d i a g n o s i sE i n d i c a t o r
solenoid velve A/B assembly
light blinks twice. connector
. Short or open in lock-upcontrol
solenoid valv€ B wire
valve B
' Open in VB SOLwire
Chackfor a Short to Power: rcM CONNECTORS
2. Disconnect the I (25P)and D
PCM. B t2sP) ll D t15P)
3. lurn the ignitionswitchON (ll).
the D3 and 820 ot 822 tetmi-
nals,
Repairshort to power in the wire Wiresideol femaleterminals

between the D3 terminal and the
lock-upcontlol solenoidvalve B.
MeasureLock-upControl Sole-
noid Vdlve I R8i3tance:
1. Turnthe ignitionswitchOFF. I {2sPt ll D (16Pt
between the D3 and 820 or
822terminals.
12- 25 O?
ls the resistance To page 14-83
B (25P1 D t16Pt
MeasureVB SOLVoltago:
nals.
Checkfor blown No. 15 {7.5 Al

fus€ in the under-dashluse/reley
ls there batteryvoltage? box. It the fuse is OK, repair open
in the wir6 between th6 DStermi
nal and the under-dashfuse/reby
oox,
Chockfor loose te.minal fit in the

PCM connectors. It necessary,
substitute a known-good PCM
end recheck.
14-82
Frompage14-82 B (25PI
PCMCONNECTOR
2 3 51 6 I
l0 1 1 / 15
Checkfor continuitYbetweenthe
a n d b e t w e e nt h e 8 2 2 t e r m i n a l LG1 (BRN/BLK) LG2 (BRN/BLKI
and body ground
o o
Repairopen in the wires between
the 820 and 822 terminals and
ground |G101),and repair Pool
ground(G1011.
Check Lock-up Control Solenoid -

Valve B lor a Short Cilcuit:
B (25P1 llo t16Pt
from the lock_uP controlsole-
noid vaiveA/B assemblY.
the D3 and 820 or 822 termi
nals.

Rep.ir short to ground in lho
wire between lhe D3 terminal
and the lock-up contlol solenoid
valve B.
LOCK.UPCONTROLSOLENOIDVALVE
MeasureLock-upControl Sol6' (2PI
A/B ASSEMBLYCONNECTOR
noid Valve B Resistanceat the
Sol6noidConn€ctor:
Measurethe resistancebetween t;T J
llt z
the No. 1 terminalof the lockuP ! ] 4
control solenoidvalve A'lBassem_ LC B (GRN/BLKII

bly connectorand body ground- t
(o)
YI
Repl.ce the lock-up control 3olc
12- 25 0?
ls the resistance noid valve A/B a$emblY. Terminalsideof maletermrnals
Ch6ck {or open in the wire

between the D3 terminal dnd ihe
lock-upcontrol sol€noid valve B.
14-83
ElectricalTroubleshooting('gg - 00 Models)
TroubleshootingFlowchart- A/T GearpositionSwitch (Short)
. OBD ll ScanTool indicrtB Code Po$ible Cause

P1?05. ' Short in A/T go.r position
. S o l t - d i a g n o 3 i 3E i n d i c a t o r
swhch wire
light blink. tive times. . FaultyA/T goar position switch
NOTE:Code P1705(5) is causedwhen

Observothe A/T Gear Position t h e P C M r e c e i v e dt w o g e a r p o s i t i o n
Indicetori inputsat the sametime.
1. Turnthe ignitionswitchON fit).
2. Observethe lVT gear position
indicator,and shift each posi,
!on separately.
Doesany indicatorstayon The sFtom is OK at thi3 time.

when the shiftleveris not in Check the wi.e harnessfor dam-
that position? aga.
Do all gearpositionindicators
go out?
PCM CONNECTORS
B {25P1 llD (16P1
MoasureATP R Voltage:
1. Shiftto all positionsotherthan LGl (BRN/BLK) LG2 (BRN/BLKI
E.
2. Measurethe voltagebetween Wiresideof femaleterminals
the DGand 82Oo( 822 terfii-
nats.
Check tor short in the wire

batwoen tha DB terminal and the
A/T go.r porhion switch or A/T
g6ar po3ition indicator, and
chock for opon in the wires
ls there batteryvoltage? between the B20 and B22 t€rmi-
n.ls and body ground (G10 . tf
wir€c rro OK, chsck fo. loo3e tel-
ftinal fit in the FCM connectors.ll
noceisary, substiiute e known-
good FCM and r€check.
To page14-85
14-84
Frompage14-84
PCMCONNECTORS
B {25P) o t16Pl
Measule ATP NP Voltage:
1. Shiftto all positionsotherthan 2 l6 8 1 1 2 tV-s-
31115
pl orE. 10n\/ t7 / \ 1 67 I 9 1 0 t 1 2
the D13and 820 or 822termi-
o zlzz /l/1,/ 113
TI
\a t9
nals. LGl (BRN/BLK)
I L---{O--l ATP NP (LT GRN)
\=/
LG2 {BRN/BLKI
,/t\_
Check for ahott in lhe wire
between ths D13 torminal and Wirc sideo{ femaletermlnals
tho A/T go.r PGition iwitci, and
in rho E .nd E polition signal
wires Mwgon tho A/T gsar Posi'
ls there bafteryvoltage? tion indicrtor and th. A/T gGar
po3ition 3witch. ll wiJ.! .ro OK,
check lor loose torminal fit in the
PCM connoctor3.lf nocet3.rY,
substitute . known-good PCM
and r6check.
g t25P) D t16P)
MeasureATPD4voh.g€:
1. Shifttoallpositions
otherthan 3 115 8l l2 5
E 9 10 111/ t6l/ 17 l sl t l a 1 12
2. Measurethe voltage between 20 ) W Wl/l '3111/ll
the Dg and 820 or 822 termi-
nals. LGl (BRN/8IJ()
+
LG2(BBN/BLKI
ATP D4 IYEL)
-<_
Ch.ck lor 3hort in ths wilo
betweon tho lxl termin.l and tho
A/T ge.r pGhion switch. It wites
ls there approx. 5 V? are OK. chock fo. looao t€rminal
fit in the PCM conn.ctoB. lf noc_
.*sary, sulFtitute a known-good
PCM.nd rechock.
Moa3ureATP D3 Vohsge:
tr.
the D8 and 820 or 822 termi- LGl IBRN/BLK)
nals.
LG2 (BRN/BLK}
Check tor 3hort in the wits

betweon the D8 torminal and the
A/T goer position switch or A/T
gcar position indicltor. It wires
ls there batteryvoltage? are OK, check for loo3€ torminal
fit in tho FCM conn€ctoG. lf nec_
a3$ry, 3ubatitute e known'good
PCM and r.check.
To page l4'86
14-85
TroubleshootingFlowchart- A/T GearpositionSwitch (Short)(cont,dl
FCM CONNECTORS
B {25P) D l16Pl
MeasuleATP 2 Vohage: 1 2 8
1. Shiftto all positionsotherthan [Ll 1 2 3 5
l 9 1 0 1 / 1 1 3/ 151/)11 7 8 9 t 0 1 12
2. Measurethe voltage between ,/ 20
the D14and 820 or 822termi- LGl (BRN/BLK}
nals, ATP 2 {BLUI
between the D14 terminal and
the A/T gear position switch or
ls there batteryvoltage? A/T ge.r position indicator. It
wires aaeOK, checkloa loose ter-
minal th in ths PCMconnectors.ll
necessary,substitute a known-
good FCM and recheck.
Ch6ckfor loose terminal fit in the

PCM connoctors. lf necessary,
and recheck.
14-86
TroubleshootingFlowchart- A/T GearPositionSwitch (Open)
. OBOll ScanTool indicatd Codc Po$ible Cause

P1706. . DisconnectodA/T goar position
' S s l f - d i a g n o s i sE i n d i c a t o r switch conngdor
light blink3 six tim6. . Open in A/T gear position
switch wire
. Fautty Aft gear poshion switch
Test the Ay'Tgear position switch
(seesection23).
PCMCONNECTORS
MoasureATP R Volt.ge: B(25Pt llDtl6Pl

'1. Turnthe ignitionswitchON ('l).
2. Shift to E position.
the D6 and 820 ot 822 termi'
nals.
IARN/BLK) LG2IBRN/BLKI
Repoiropon in the wire bitween

the D6 torminll and the A/T go.r
position switch.
D (16P1
MeasuroATP NP Volt ge: ,|
1. Shiftto E or E position. 2 { 6 2 3 5
2. Measlre the voltage between I
't0 1 1 / t5l/ 1 8 9 12
the D13and 820 or 822 termi-
nals,
LG1 {BBN/BLKI ATP NP (LTGRNI
Ropairop€n in thc wire betwoon

the D13terminrl and the A/T
ge.r position switch.
(cont'd)
Io page14-88

TroubleshootingFlowchart- A/T GearpositionSwitch Open{cont,d)
Frompage14-87
PCMCONNECTORS
B l2sPl D {16P)
Moalure ATP 04 Vohago:
1. Shiftto pll position. 1 2 415 6 I
9 10 11)./ t5l/ 11 1 8 9 1 12
the Dg and 820 or 822 termi
nals. zo ztzzll//l hsr),41
LGl {BRN/BI.KI
fj r-cz]_c;l
tgaNlelxr
-
ATP D4 (YEL}

Repair opon in the wire betweon
the lrg terminal and the A/T goat
poshion switch.
MeasureATP D3 Vohage:
1. Shiftto l& position.
the D8 and 820 or 822 termi- I.G1IERN/BLKI
nats.
LG2IBRN/BLKI
Reprir opcn in the wirc b?twoen

the D8 terminrl and tho A/T goar
Dositiontwitch.
B (25P1 D {16P}
Mersurc ATP 2 Voltage:
1. Shiftto E position. I 2 5l l6l/ 8
2. Measurethe voltage between 9 10 11)/
the Dl4 and 820 or 822 termi- Itsln 7 8 9 12
nals,
LGl IBRN/BLKI ATP 2 IBLUI
Reprir opon in the wire betweon

tho Dl4 te.minal rnd the A/T
go.r position switch.
Ch6cktor loose terminal tit in the

PCM connectors. ll necossery,
subslitute . known-good pCM
and recheck.
1 4- 88
TroubleshootingFlowchart- Shift ControlSolenoidValveA
NOTE:RecordallJreezedata beforeyou troubleshoot.
. OBD ll ScanTool indic.ts6 Code PossibleCru3.

Pot53. ' Disconnectod 3hift control
. Solt-diagno.isE indicrtot light solonoid valva A/B a33emblY
blinks seven time6. connactot
. Short or opon in shift cont.ol
solonoidvalvo A wits
. Faulty shift control .olenoid
Chock tor a Short to Power:
1. Turnthe ignitionswitchOFF. . op.n in vB SOLwi.e
2. Disconnect the g (25P)and D PCM CONNECTOBS
( 1 6 P )c o n n e c l o r sf r o m t h e
PCM,
3. Turn the ignirionswitchON (ll) I t25Pt ll D {16P)
,1. Measurethe voltage between
nals,
LG1{BRN/BLK} LG2IBRN/BLKI
Rcpairshort to powet in the wile
b€t^reen tho D7 termin.l .nd the
shift control aolonoid valve A.
Mee3ur. Shift Control Solonoid

Valve A Roaisttnce:
822 terminals.
LGl IBRN/BI-K) LG2IBBN/BLK)
ls the resistance12 - 25 O? To page 14-90
BrzsPt o trQil
Me.3uro vB SOLVoh.ge:
nals.
Check tor blown No. 15 17.5A)

fuse in tho underdaah fula/rol.Y
box. ll the tusr is OK, .epair oPen
ls there bafteryvoltage? in th. wiio betwe.n the D5 ter'
min.l and th. underdssh tuso/
relav box.
Checkfor loose t6tminalfit in th€

PCM connoctors. It necessary, (cont'd)
substitute e known-good PCM
and rechock.
14-89
TroubleshootingFlowchart- Shift ControlSolenoidValveA (cont,O)
Frompage14-89
PCMCONNECTOR
B {25P}
Checklor continuitybetweenthe
820 terminal and body ground,
a n d b e t w e e nt h e 8 2 2 t e r m i n a l
and body ground.
LGl (BRN/BLKI
Repair open in ihe wires
between th€ 820 and 822 termi-
n a l s e n d g r o u n d { G 1 0 l l .a n d
repa,rpoor ground{G101}.
Check Shitt Control Solenoid

Valve B for a Short Circuit:
1. Disconnectthe 2P connector rcM CONNECTORS
from the shiltcontrolsolenoid
valve A,/Bassembly.
Bt25Pt llD t16Pt
the D7 and 820 or 822 termi,
nals.
LGl {BBN/BLKI LG2 (BRN/BLKI
R€pairshort to ground in the wiie Wiresideof femaleterminals

ls therecontinuity? bartwe€nthe D7 te.minal and the
shift control solonoidvalveA.
Meesuro Shift Control Solenoid SHIFTCONTROLSO|'INOID VALVE

Valve A RGistance at the Solenoid A/B ASSEMBLYCONNECTOR I2PI
Connector:
t h e N o . 1 t e r m i n a lo f t h e s h i f t
c o n t r oI s o l e n o i d v a l v e A / B
a s s e m b t yc o n n e c t o ra n d b o d y SHA {BLU/YELI
grounct,
ls the resistance
12 25 O? Repl.cetho shift control solenoid
valve A/B rss€mblv.
Check for open in the wire

between the D7 termindl and the
shift control 3olonoidvalve A.
14-90
TroubleshootingFlowchart- Shift ControtSolenoidValveB
NOTE:Recordall freezedatabeforeyou troubleshoot.
. OBD ll ScanTool indic.l6 Code PossiblgCause

P0758. . Disconnectgd ihilt control
' Self-diagnosbEl indicatorlight solenoidvalve A/B conneciot
blinkseighl tim6. r Short or oDen in shift conlrol
3olgnoidvrlve B wito
. Faulty 3hift control solenoid
velve B rcM CONNECTORS
Checktor a Shortto Power: . Op€n in VB SOLwire
( 1 6 P )c o n n e c t o r fsr o m t h e -
B (25Pt I lD {16P)
PCM.
nals,
LGl IBRN/BLKI LG2IBRN/BLK)
Repaft3hon to Powor in the wir€

b€tirvoonthe D2 termin.l and the
3hift control solenoid valve B.
M€asure Shift Control Solenoid

Valve B R6isttnce:
822 terminals.
LGi (BRi|/BLKI LG2IBRN/8LK)
12- 25 O?
ls the resistance To page14-92
B {25P1 D (t6Pl
Me.sure VB SOLVohage:
the D5 and 820 or 822 termi'
nars.
Checklol blown No 15 {7.5 Al

fuse in the under-d.sh luae/rolav
box. ll the fuse is OK, repair open
ls there battery voltage? in ihe wire between tho D5 ter-
minal and the under'dashfus€/
relav box.
Checkfor loo3eterminal fit in the

PCM connectols. lf necossarY,
substitute a known_goodPCM (cont'd)
and rocheck,
14-91
ElectricalTroubleshoot:ng('gg - 00 Models)
TroubleshootingFlowchart- Shift ControlSolenoidValveB (cont,dl
Frompage'14-91
PCMCONNECTOR
A {25PI
a n d b e t w e e nt h e 8 2 2 t e r m i n a l
and body ground.
LGl (BRN/BLK)
Ropair opan in the wirgs
b.twocn the 820 rnd 822 te.mi,
n.ls and ground lG10t), and
..p.ir poor ground lG10t).
Wiresid€ot femaleterminals
Check Shift Control Sol.noid

Vrlve B tor a Short Ci.cuit:
1. Disconnectthe 2P connector FCM CONNECTORS
from the shift control solenoid SH B (GRN/WHTI
valve A/B assembly. -
2. Checkfor continuitybetween B(25P1 llDt
nals.
IBRN/BLKI LG2IBRN/BLK)

Repair3hort to ground in tho wire
botw.en tha 02 torminsl and the
shift com.ol rolonoid v.lv. B.
Meaiuro Shift Cont.ol Solonoid

Vrlve B Raailtrnca at the Solonoid SHIFT@NTROL SOENOID VALVE
Conn€c,toa: A/A ASSEMBLYCONNECTOR(2PI
Messure the r€sistancebelween . - _
t h e N o . 2 t e r m i n a lo f t h e 6 h i f t
control solenoid valve A/B 1 ) 2
-.T-
a s s e m b l yc o n n e c t o ra n d b o d y
ground. I sne tcanlwxrt
(o
YI
12- 25 O?
ls the resistance R.pl.co th. 3hift control lolenoid sideoI maleterminals
Terminal
v!lv. A/8.lsombly.
Chack for open in the wi.e

betwoon th€ D2 termin.l and the
3hift control lolanoid valv6 8.
14-92
TroubleshootingFlowchart- CountershaftSpeedSensor
NOTE: Recordall freezedata beforeyou troubleshoot
. OBD ll ScanTool indicat6 Code Po$iblo Cause

PO720. . Loos€ or fsulty conneclion
. Self-diagnosisE indicatorlight between the PCM and vehicle
blinks nin6times. hainoss
' Disconnectod countersh.ft
spoed senaof connoctor
. Short or opgn in counteBhaft
C h e c kt h e c o u n t e r s h a f st P e e d 3Deedaensorwire
sensorinstallation,and check it . Faulty counloEhaft 3p€ed sen'
lor damage. soa
ls the countershaftspeedsensor
installedproperly,and not dam- Reinstallor replaceand rechock.
aged?
COUNTERSHAFfSPEED
SENSORCONNESTOR
Measurg Counlershatt SPeed

Sgn3ol R6istance at tho Son3ol
Connector:
from the countershaftsPeed
sensor.
2, MeasurocountershaftsPeed
sensorresistancaat the sensor
connector. TerminalsideoI maleterminals
ls the resistance400- 600 O?
D I16PI
FCM CONNECTOR
Chcck CounteEh.tt SPeed Sen'
NCIBLUI
sor lor a Short Circuit:
1 . D i s c o n n e ct th e D { 1 6 P )c o n
nectortrom the PCM.
body groundand the D10ter_
minal and D16 terminal indi-
vid!ally.

R6oai. short in tl|€ wi.6a bstwa€n
the D10 and D16 t.rminali end
tho countdthatt rP€od senaor.
rconl c
To page 14 94
1+93
ElectricalTroubleshooting('gg - 00 Modelsl
TroubleshootingFlowchart- CountershaftSpeedSensor(cont,d)
Frompage14-93
Measure CounteJahaft Speed PCMCONNECTOR

D I16PI
SensorCircuittor an Open:
1. Connect the countershalt
speedsensorconnector,
betweenthe Dl0 and D16ter
mtnats.
Roptir loo.€ t6.minal or opan in
ls the resistance400 - 600 O? th6 wir€! betwo€n lho D10 lnd
D16 t.rmina13and the count.r-
shatt apaadaaNor.
Checkfor loose t.rminal frt in the

PCM connectors. It necalsary,
3ubstitute a known-good PCM
and recheck.
14-94
TroubleshootingFlowchart- MainshaftSpeedSensor
NOTE:Code P0715(15)on the PCMdoesn't
. OBD ll ScanTool indicatesCode PossibleCausg alwaysmean there'san electrrcal problemin
m715. . Diaconn€ctedmainshaft spoed the mainshaftor countershaftspeed sensor
. Sell-diagno3isE indicator indi- sen3orconnector circuit;code P0715{15) may also indicatea
catesCode 15. 'Short or open in mainshaft mechanical problemin the transmissjonAny
sDeed sen3or wile p r o b l e mc a u s i n gi r r e g u l a rc o u n t e r s h a ft to
. Faulty main3haltspeedsensor mainshalt speed differencecan cause thls
code.
Checkthe mainshaftand counter-
shatt speedsensorsinstallation,
and checkthem for damage.
Are the mainshaftand countershaft

speedsensorinstalledproperly, Rsinalallor replaceand rocheck.
and not damaged?
MAINSI{AFTSPEED
Mea3u.e Meinshalt SPeod SENSORCONNECTOR
Sensor Residance al the Sen3or
Connector:
ll ,.
f r o m t h e m a i n s h a f ts P e e d
sensor.
l.TT
2, Nreasuremainshaftspeedsen_
sor resistanceat the sensor
(- io- l l
connector.
t l
TerminalsideoI maleterminals
ls the resistance400- 600 O?
D (16P)
PCMCONNECTOR
Check Mainshaft Sp.ed Sen3o.
for a Short Circult:
1. Disconnectthe D (16P)con-
nectortrom the PCM. NMSG (WHT)
body groundand the D11ter'
m i n a la n d D 1 2t e r m i n a il n d i
vidually.
Bopair 3hort in the wiros b€twe€n

ls therecontinuity? the 011 and D12 termin.ls rnd
th€ main3hett sp€€d aensoa.
(cont'd)
To page 14 96
14-95
TroubleshootingFlowchart- MainshaftSpeedSensor(cont,dl
Frompagel4-95
PCMCONNECTOR
D {16PI
Measure Mainshatt Speed
SensorResistance:
1. Connectthe mainshaftspeed
sensorconnector.
2 3 /)
NMSG {WHTI
2. Measurethe resistancebet- 6 18
ween the Dl1 and D12termi- rghrll [e]
nats. (
NM IREDI I

Run the Electricel Troubl€shooting
Flowchart lor cod6 m?m l9).
ls the resistance400- 600 0? Ch€ck lor loo.o te.minol fit in th6
PCM connectors. lf necossary,
substitute r known-good PCM
end .echeck.
CheckNM Wire Continuity:

from the mainshaftspeedsen- 1 23 5
sor. 6 7 8
t1v
the D11terminaland the No.2 NM (REDI
terminal ot the mainshaft
speedsensorconnector, MAINSHAFTSPEED
o
SENSOROONNECTOR RED
Ropair opon in the wiro lratwoen Wire sideof femaleterminals

tho Dll tsrminal and tha main-
3hatt spe€d sensor.
CheckNMSG Wire Continuity:

Checkfor continuity betweenthe 6 1 78 9 ll 12
Dl2 terminaland the No. 1 termi-
nal of the mainshaftspoedsen-
t1v
Io NMSG IWHTI
WHT
1
Repai. open in the wire betwoen

the D12 terminal and the mein-
shaft 3peodsansor.
CheckIor loose terminal fit in the

PCM connectors. lf necesaary.
and recheck.
14-96
TroubleshootingFlowchart- LinearSolenoid
NOTE: Recordall freezedata before you troubleshoot.
. OBD ll Scln Tool indic.t.t Codo Poitibl. Cau3.

P1768. . DisconnactedlinoaJ tolanoid
. Self-diagnosisE indicltol indi- connaclol
cat6 Cods 16. . Shorl or opon in linolr solonoid
. Flulty linoar 3olenoid

. ODonin VB SOLwit. PCftI @NNECTORS
Moasur. VB SOLVoltago: . ODenin PG lino
2. Disconnect the B {25P)and D
PCM. B t25Pl D {16P1
3. Turn the ignitionswitchON (lll.
nals.
Wire side ol female terminals

Ropair opan or thort in dla wi.9
hrw..n th. D5 t.rminrl .nd th.
und.r-d.rh fu ta/r.l.y box.
PCM OONNECTORB I25PI

Ch.ck th. Ground Circuit:
2. Checklor continuity betwoen
the terminals82 and 822 and
b e t w e e nt e r m i n a l s8 1 0 a n d
820.
Rapair opal| in tfr wi|! batlwao

th. tcrrnln.l. 82, B10, B:20..nd LGT(BNN/BLKI LG2 {BBN/BLKI
BZI .id Gt01. R.p.ir poor ground
tG10rl. Wir6 side of Iemale terminals
M.!sure Linea. Solenoid

Rcai3tancc rt tha Solanoid LINEAFSOITNOIDOONNECTOR
Conn6ctor:
1. Disconnect the linearsolenoid
connectol,
2. Measurethe resistanceof the
Flr-11
=T=T
linearsolenoid.
o l
Y I
L_l
Terminalsideof mal€termanals
ls the resistanceapprox. 5 O?
To page 14-98
(cont'd)
1+97
TroubleshootingFlowchart- LinearSolenoid(cont'dl
Frompage14 97
Check Linea. Solenoid tor a

Short Ci.cuit:
Checkfor continuitybetweenthe PCMCONNECTOR
A {25PI
body groundand the 88 terminal
and B17terminalindividually.
Repairshon in the wir6 between

th€ 88 and 817 terminals and the
lin€arsolenoid,
Measure Linear Solenoid

Resistance: LSAM(WHTI
1 . C o n n e c t h e l i n e a rs o l e n o i d
connector,
2 . M e a su r e t h e r e s i s t a n c e
betweenthe Bg and 817 ter
mtnals,
Repair loose te.minal or open in

ls the resistance
approx.5.0O? the wire botwoenthe 88 .nd Bl7
t.rmin.b end the linoar3olenoid.
Checkfor loose terminal tit in the

PCM conn€ctors, lf necessary,
substitut6 a known-good PCM
and recheck.
14-9 8
TroubleshootingFlowchart- Lock-upControlSystem
OBD ll ScanTool indicatesCode Possibl€Cause

m14/J. Faulty Lock-upcontrol sy3tem
S€lf-diagnosis.D4lindicalorlight
indicatesCode40.
Checkfor Another Code:

t o o l o r t h e : E i n d i c a t o rl i g h t
indicatesanothercode,
P e r f o r mt h e T r o u b l e s h o o t i n g
ooesthe OBDll scantool or Flowchart tor the indicated
rhe E indicatorlight indicate
Codels|. Rocheckto. code P0740
anothercode? (40).fter troublBhooting.
until the causesof any

NOTE:Do not continuewith this troubleshooting
other DTCShave beencorrected.
Test 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 1 9a n d 1 4 - 1 2 0 ) .
ls the lanepressurewithinthe Repairthe hydrrulic sy3tem as

servicelimit? n6c6ssary(seepage 14-1191.
R e p l a c et h e L o c k - u p C o n t r o l
Solenoid Valve Assembly and
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
(seepage14-105).
and reset the PCM by remov
ing the EACKUP (7.5A) fuse
in the underhood {use/relay
box for morethan 10seconds.
3. Usingthe scantool, checkto
be sure that the enginecool-
a n t t e m p e r a t u r ei s i n 1 7 6 ' F
(80'C)and above.
4 . 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
than one minute,
5. Recheck for codeP0740{40).
Doesthe OBDll scantool

The svstem i3 OK .t this time.
indicatecodeP0740(40)?
14-99
. OBD ll ScanTool indicrtd Code Po33ibl.Crus6

m730. Frulty 3hift control ryrtom
. S e l f - d i r g n o s i sE i n d i c a t o r
light indicst€. Codo41.
Checkfor Anoth€. Code:

t o o l o r t h e E i n d i c a t o rl i g h t
indicateanothercode.
DoestheOBDllscantool or Prrf orm tho Troublc!hooting

the E indicatorlight indi- Flowch.rt for th. indicrt.d
cate anothercode? Cod.l3l. R.ch.ck tor cod. m730
141|.tt r troubldhootlng.
NOTE:Do not continuewith this lroubleshootinguntil the causesot any
other OTCShave beon corrected.
Test 13t, 2nd, 3rd .nd 4th Clutch

Prglture:
Measurethe 1st,2nd,3rdand 4th
clutchpressure(seepage 14-119
t h r u1 4 1 2 1 ) .
ls each clutch pressurewithin R.prir tho hydrlulic ayrtam aa

the servicelimit? n.c.3t..y lr.o p!9. lil-119 rnd
1+1211.
Roplace Shift Control Solenoid

Valve Asembly. Linoar Sol.noid
Assembly.nd Recheck:
1 . R e p l a c et h e s h i f t c o n t r o l
solenoidvalve A/B assembly
(seepage14-106).
2 . R e p l a c et h e l i n e a r s o l e n o i d
assembly{seepage14-108}.
3. Turn the ignitionswitch OFF
and resetthe PCMmemory by
removingthe BACKUP (7.5A)
fuse in the under-hoodfuse/
relaybox for more than 10
seconds,
4 . D r i v et h e v e h i c l ea t o v e r 1 2
mph (20 kn/h) in 1st,2nd, 3rd
and 4th gear lo. more than 30
secondsat lPll position.
5. Recheck for codeP0730(41).
DoestheOBDIlscantool or
the E ;ndicatorlight indi- Th. sFtcm b OK .t this time.
catecodeP0730(41)?
14-100
TroubleshootingFlowchart- El IndicatorLight On Constantly
The Dll indicator lighi is on con-

stantly {not blinking)whenever
the ignition switch is ON (lll.
A I32P)
PCMCONNECTOR
MoasureD4 IND Voltage:
2 . D i s c o n n e ct th e A { 3 2 P }c o n -
nectorfrom the PCM.
t h e A 1 4t e r m i n a a l ndbody
ground.
Repsirshort to power in the wire

between the A14 torminal and Wiresideof lemaleterrnanals
the gauge assembly.
MeasureATP D4 Voltagel
1. Turnthe ignitionswitchOFF. D {16P)
PCMCONNECTOR
2. Connectthe A (32P)connec
tor to the PCM.
3. Turnthe ignitionswitchON (ll). 2 5
4 . S h i t t t o a n y p o s i t i o no t h e r 6 1 e11( 12
than [ql.
5. Measurethe voltagebetween t{ Iro
t h e D 9 t e r m i n a la n d b o d y ATPD' (YELI
ground.
ls thereapprox.5 V? Wire sideof femaleterminals
Test the A/T gear position switch

( s e es e c t i o n 2 3 ) .
CheckIor a short to ground in

the wire betweon the D9 termi-
nal and A/T gear position switch.
It wire is OK, substitute a known-
good PCMand recheck.

TroubleshootingFlowchart- E IndicatorLight DoesNot ComeOn
The Pll indicator light does not

come on when the ignition
switch is fi.st turned ON (ll). llt
should come on for about two
seconda.l
Check the Service Check Con-

nector:
Makesure the specialtool (SCS
ServiceConnector)is not connect-
ed to the servicecheckconnector?
ls the specialtool{SCSService Disconnectthe special tool from

Connector) is not connected
to the service check connector and
the seNicecheckconnector. r6check.
Checkthe Dll lndicator Lighti

Shiftto d position.
Checkfor looseterminal fit in the

Doesthe @ indicatorlight PCM connecto13.It necessary.
comeon? sub3titute a known-good PCM
and recheck.
B (25P}
FCM CONNECTOR
2 . D i s c o n n e ct th e B ( 2 5 P )c o n -
i 2 t 5 6 q
nectorfrom the PCM. 9 10 t7
ground,and betweenthe 822 LGl {8RN/ALKI LG2 {BRN/8LK}
terminaland body ground. o) (o
Repair open in the wires Wire sideol temaleterminals

between the B20 rnd 822 termi-
n a l sa n d g r o u n d( G 1 0 1 ) a
, nd
rep.ir poor ground (G1011.
Measure Power Supply Circuit

Voltage:
1. Turnthe ignitionswitchON {ll}.
terminals B1 and 822 and
b e t w e e nt e r m i n a l s B g a n d
820.
LGl IBNN/BLK} LG2 {BRN/BLK)
Repair open or short in the wi.o

between th6 81 and/or 89 termi-
nals and the PGM-FImain relav,
and between th€ PGM-FImain
r€ley rnd the under-hoodtus€/
relay box.
To page14''103
14-102
Frompage14-102 PCMCONNECTORS
Measu.e D4 IND Voltago:

2. Connectthe B (2SPiconnector
to the PCM.
3. Connecta digital multimeter
to the A14 and 820 or 822 ter-
4. Turnthe ignitionswitchON (ll),

and makesurethat voltageis
availablefor two seconds. Wire sideol femaleterminals
Chock for ooon in tho wite

between the A't4 tsrminal .nd
the gauge.3s.mbly. ll wite i3
OK, chock to. a t.ulty indicator
light bulb or. feulty gaugc
e336mblyp.inted circuit board.
CheckD4 IND lor a Short Citcuit:

Checklor continuity betweenthe
A14terminaland bodyground.
Rop.ir short in thc wirg b€twoen

th. Al4 tormin.l .nd tho gaugo
ls therecontinuity?
a$ombly. ll wiro is OK. chock
tho gsugo a3rambly.
Checkfo. loose terminal tit in thc

PCM connectoB. Chock the A/T
gear position switch. It ncce3-
sary, substitute a known-good
PCMand rechock.
14-103
('99- 00 Modelsl
ElectricalTroubleshooting
TroubleshootingFlowchart- BrakeSwitch Signal
Shift lever cannot be moved trom

E position with tho b.ake pedal
depressod.
CheckBrake Light Operation:

Depressthe brakepedal.
Are the brakellghtsON? Repairt ulty brake switch circuit

{sees€ction23}.
PCMCONNECTORS
Mea3ureSTOPSW Vohage: B {25P)
{ 2 5 P }c o n n e c t o r sf r o m t h e
PCM,
the A32 and 820 or 822termi-
n a l s w i t h t h e b r a k ep e d a l
depressed.
Repairopen in the wire betwsen

ls therebatteryvoltage? the A32 terminal rnd tho brrk6
switch.
. Brak€switch sign.l is OK.

. Check for loose terminal fil in
lhe PCM conn€ctors. lf neces-
sary. substitute a known-good
PICMand recheck.
. InsDectthe breke 3witch circuit
lsee section231.
14-104
Lock-upGontrol SolenoidValve A/B Assembly
Test Replacement
'1, Disconnectthe 2P connectorfrom the tocK-upcon- NOTE:Lock-upcontrolsolenoidvalvesA and I must bs
trol solenoidvalve1y'8assembly. removed/replacedas an assembly.
1. R e m o v et h e m o u n t i n gb o l t s a n d l o c k - u pc o n t r o l
SIOEOF
TERMINAL
MALETERMINALS solenoidvalveAy'Bassemblv.
6 r 1 . 0m m
1 2 N . m( 1 . 2k g f . m , 8 . 7l b l . f t l
/:'-
Cleanthe mountingsurface
and fluid psssages.
LOCK.UP
CONTROL
VALVEA/B
SOLENOID
ASSEMBLY
Cleanthe mounting surfaceand fluid passagesof
Measurethe resistancebetween the No. 2 terminal th6 lock-upcontrol solenoid valve assembly,and
(solenoidvalve A) of the lock-upcontrol solenoid instsll a new lock-upcontrol sol€noid valve Ay'Bwith
valveconnectorand body ground,and betweenthe a new filtsr/gask€t.
No. 1 terminal(solenoidvalveBl and body ground.
Checkthe connector for rust, dirt or oil, and racon-
STANDARD:12 - 25 O nect it securely.
Replacethe lock-upcontrol solenoidvalve assem-

bly if the resistanceis out of specification.
lf the resistanceis within the standard,connectthe

No. 1 terminalof the lock-upcontrolsolenoidvalve
connectorto the battery positiveterminal. A clicking
soundshouldbe heard.Connsctthe No. 2 terminalto
the batterypositiveterminal.A clickingsound should
be heard. Replacethe lock-upcontrol solenoid valve
assemblyif no clickingsoundis heard.
1+105
Shift Control SolenoidValve A/B Assembly
Test Replacement
1. Disconnectthe 2P connectorfrom the shift control NOTE: Shift control solenoid valves A and B must be
solenoidvalveA,/Bassemblv. removed/replacedas an assembly.
1. Removethe mountingboltsand shiftcontrolsolenoid

valveA,/Bassembly.
5xL0mm
12 N.m CONNECTOR
BRACKET
(1.2kgf.m,8.7lbf.ft)
SHIFTCONTROL
VALVEA/B
SOLENOID
ASSEMBLY FILTER/GASKET
Beplace. Cleanthe mountingsurface
and fluid passages.
N4easurethe resistancebetweenthe No. 1 terminal
(solenoidvalveA) of the shift controlsolenoidvalve
connectorand body ground,and betweenthe No. 2
terminal(solenoidvalveB) and body ground. Cleanthe mounting surfaceand fluid passagesof
t h e s h i f t c o n t r o l s o l e n o i d v a l v e a s s e m b l y ,a n d
STANDARD:12 - 25 O installa new shift controlsolenoidvalveAy'Bwith a
new filter/gasket and the clamp bracket.
Replacethe shift controlsolenoidvalve assemblyif
is out of specification,
the resistance Checkthe connectorfor rust. dirt or oil. and recon-
nect it securelv,
lf the resistanceis within the standard,connectthe
No. 1 te.minal of the shift control solenoid valve
connectorto the batterypositiveterminal.A clicking
sound should be heard.Connectthe No. 2 terminal
to the battery positive terminal. A clicking sound
should be heard.Replacethe shift control solenoid
valveassemblyif no clickingsound is heard.
14-106
LinearSolenoid Assembly
Test
1. the linearsolenoidconnector.
Disconnect lf not, removethe linearsolenoidassembly.
Checkthat the linearsolenoidfluid passageIor dust

or dirt.
1. C o n n e c t h e N o . 2 t e r m i n a lo f t h e l i n e a rs o l e n o i d
LINEARSOLENOID
connectorto the batterypositiveterminaland con-
nectthe No, 1 terminalto the batterynegativeterma-
nal.Checkthat the valvemoves.
Disconnectone of the batteryterminalsand check

that the valvereleases.
NOTE:You can see the valve movementthrough

the fluid passagein the mountingsurfaceof the lin-
ear solenoidassembly.
LINEAR
SOLENOID
Measurethe resistancebetweenthe No. 1 and the

No. 2 terminalsof the linearsolenoidconnector.
STANDARD:applox. 5 O
replacethe
lf the resistanceis out of specification,
linearsolenoidassembly.
4. Connectthe No. 2 terminalof the linsarsolenoidcon- VALVE

nector to the batterv positive terminal and connect
the No. 1 terminalto the batterynegativeterminal A
clickingsoundshouldbe heard.
lf the valvebinds,or movessluggishly,or the linear

solenoiddoesnot operate,replacethe linearsolenoid
assembly.
14-107
Mainshaft/Countershaft
LinearSolenoidAssembly Speed Sensors
Replacement Replacement
1. Removethe mountingbolts and the linearsolenoid 't. Removethe mm
6 bolt and the countershaftspeed
assemory. sensorfrom the rightside cover.
Cleanthemountingsurface 6 x 1 . 0m m
andfluid passages. 1 2N.m (1.2kgf.m, COUNTERSI{AFT
8.7rbf ft) SPEEDSENSOR
6x1.0mm \
12 N.m 11.2kgl m, \ O.RING
8.7 tbf.ftl Replace.
\ / ,
%/E:) MAINSHAFT
SPEED
SENSOR
@
@
MAINSHAFTSPEED
GASKET LINEAR SENSOBWAS}IER 6x1.0mm
SOLENOID (D16Y7enginel 12 N.m (1.2kgf m,
ASSEMELY 8.7 tbf.ft)
Cleanthe mountingsurfaceand fluid passageof the Removethe 6 mm bolt and the mainshaftsDeed
linearsolenoidassemblyand transmissionhousing. sensorfrom the transmissionhousino.
Installa new linear solenoidassemblywith a new Replacethe O-ringwith a new one beforeinstalling
gasl(et. the countershaftspeedsensoror th€ mainshaftspeed
sensor.
NOTE;Do not pinch the gasketwhen installingthe
linearsolenoid;makesurethat the gasketis installed NOTE:Installthemainshaftspeedsensorwasheron
properlyin the mountinggrooveof the linearsole- the mainshaftspeed sensor.The mainshaftspeed
noid. sensorwasher is used on models with the D'|6Y7
engine.
Checkthe linearsolenoidconnectorfor rust,dirt or
oil, and connectit securely,
14-108
Symptom-to-ComponentChart
HydraulicSystem
C h e c kt h e s e i t e m s o n t h e C h e c kl h e s e l e m s o n
SYMPTOM P R O B A B L EC A U S E L i s t the NOTESLIst
Engineruns,but vehicledoesnot move in any gear. 1.2,3,5,6,7.36,38 K , L ,R ,S

Vehiclemovesin E, E, but not in lrl, pr-, position. 6, 8, 9, 10,30, 54 c,M,o
movesin Dl, E, El,lut notin E position.
Vehicle 6,11,12.24 C,L
Vehiclemovesin -o1],@, @, Uutnot in E position. 4 , 6 , 1 4 ,1 5 c,L,o
Vehiclemovesin E position. 10,12,13,14,16,29,33,34,35 C,D
idlevibration.
Excessive 4 ,5 ,4 1 4
1 . 2 ,1 9 , 3 2 , 3 6 ,a
flareson startingotf in E, [Dl]position
Pooracceleration;
Stallrpm hiqh in !!1, p!1,E position. 1 , 2 , 3 , 6 , 3 44,1 K,L,R
stall rom hioh in D.r, lD,loosition. 6. 8. 10 C,D
5t"[ rprnrsn ^ a"t"t-at 6,12 C,D
14 N
11, 32. 45,41, 48
No shift 19,20,40,48,49 G,L
Failsto shiftin 81, pll position;from lst to 3rd gear 22,49
F a i l st o s h i f t i n 0 3 , D . o o s i t i o n ; f r o m l s t t o 4 t h q e a r 22.23,48
Erraticupshifting.
1'2 upshift,2-3 upshift,3-4 upshift 58
1-2upshift 21,48
22,t9
3'4 upshift 23,la
Harshupshift{1 2). 12,19,20,29.50,51,57.54
Harshupshift(2'3). 13,19,20,24,27, 29,50.51, 51, 58 C,D,E,H,L
Harsh upshift (3'4). 14,19,20,25,28,29.50,51, 51, I C , D ,E ,I , L
Harshdownshift(2-1) 19, 20. 24, 43,54, 57, 58 o
Harshdownshift(3-2). 12,19,20,25,43,55,57,5A C,D,E,H
Harshdownshift(4-3). 13,19,20,26,43,56,57,58 C, D, E, I
1 3 ,1 9 , 2 0 , 2 4 . 2 1 , 5 1 F I
Flareson 2-3 upshift.
Flareson 3-4 upshift. 14,19. 20,25.24,51 E,L,N
Excessive shockon 2-3uPshift. 13.19,20,24,27. 43.50.51, 58 E,L,N

Excessive shockon 3-4 uPshift. 14,19,20,25.2A,8, 50,51, 58 E,L,N
Lateshiftfrom El positionto Lq! or &l position. 10,30
Lateshiftfrom E positionto E position. 4 , 1 4 ,2 1 , 5 3 o
in all shiftleverpositions
Noisefrom transmission 2,31 K,L,O
V e h i c l e d o e s n o t a c c e l e t a t em o r e t h a n 3 1 m p h { 5 0 k m / h ) 17
shift lever does not operate smoothly. 6, 39 P
F a i l st o s h i f t ; s t u c k i n 4 t h g e a r . 19,48,49
will not shiftintoparkin [a]position
Transmission 6, 18,39
S t a l l r p m h i g h ; a l l c l u t c h p r e s s u r e sa r e i n s p e c i f i c a t i o n . 41 D,K,O
Lockup clutchdoesnot disengage. 19,44,45,46.41,50,51.54
Lockup clutchdoesnot operatesmoothly. 19,41,44,45,46,47,50,51,58 L
19,41,4t, 15,46,41,50, 51,57,58 F I
Lock-upclutchdoesnot engage.
Vibrationin all positions
(cont'd)

Checktheseitems,onth€^ ltemson the
The followingsymptomscan be caused PROBABLE CAUSEDUETO
by improperrepairor assembly NOTESList
IMPROPER REPAIR List
Vehiclecreepsin N position. R 1 ,R 2
Vehicledoes not move in &l or Pll position. R4
Transmission locksup in E position. R 3 ,R 1 1

drag in transmission.
Excessive R6 K,R
vibration,rpm related.
Excessive R7
Noisewith wheelsmovingonlY. R5
Main sealpops out. R8
Variousshiftingproblems. R 9 ,R l O
REPAIR
CAUSEDUETO IMPROPER
PROBABLE
lmproperclutchclearance.
lmpropergearclearance.
Parkleverinstalledupsidedown.
one-way{sprag)clutchinstalledupsidedown.
Reverseselectorhub installedupsidedown.
ATF pump binding.
Torqueconverternot fully seatedin ATF pump.
Main sealimproperlyinstalled.
Springsimproperlyinstalled.
Valvesimproperlyinstalled.
Shiftfork bolt not installed.
14-11
Symptom-to-ComponentChart
HydraulicSystem(cont'dl
Seeflushingprocedure,page 14-187and 188.

set idle rpm in gearto specifiedidle speed.lf still no good,adjustmotor mountsas outlinedin engine
sectionof this manual.
lf the largeclutchpistonO-ringis broken,inspectthe pistongroovefor rough machining.
lf the clutchpackis seizedor is excessively
worn. inspectthe otherclutchesfor wear,and checkthe orifice
controlvalves,CPCvalveand linearsolenoidfor free movement.
lf the linearsolenoidis stuck,inspectthe clutchesfor wear.
G. lf the l-2 shift valveis stuckclosed,the transmissionwill not upshift.lf stuckopen,the transmissionhas
no 1stgear.
n, lf the znd orificecontrolvalveis stuck.inspectthe 2nd and 3rd clutchoacksfor wear.
lf the 3-4 orificecontrolvalveis stuck,inspectthe 3rd and 4th clutchoacksfor wear.
lf the clutchpressurecontrolvalveis stuckclosed,the transmissionwill not shift out of 1stgear.
lmproperalignmentor main valvebody and torqueconverterhousingmay causeATF pump seizure.The
symptomsare mostlyan rpm-relatedtickingnoiseor a high-pitchedsqueak.
lf the ATF straineris cloggedwith particlesof steelor aluminum,inspectthe ATF pump and differential
pinionshaft.lf both are OK and no causefor the contaminationis found,replacethe torqueconverter.
lf the l st clutchfeed pipe guide in the end cover is scoredby the mainshaft,inspectthe ball bearingfor
excessivemovementin the transmissionhousing.lf oK, replacethe end coveras it is dented.The o-rino
underthe guide is probablyworn.
Replace the mainshaftif the bushingfor the 4th feedpipeis looseor damaged.lf the 4th feedpipeis danF
aged or out of round, replacethe right side cover.
Replace the mainshaftif the bushingfor the 1stfeedpipeis looseor damaged.lf the 1stfeedpipe is darn-
agedor out of round,replaceit.
A worn or damagedspragclutchis mostlya resultof shiftingthe transmissionin or E positionwhile
the wheelsrotatein reverse,suchas rockingthe vehiclein snow.
Inspectthe framefor collisiondamage.
Inspectfor damageand wear:
1. Reverseselectorgearteethchamfers.
2. Engagement teethchamfersof countershaft4th and reversegear.
3. Shiftfork for scuffmarksin center.
4. Differentialpinionshaftfor wear u nder pinion gears.
5. Bottomof 3rd clutchfor swirl marks.
Replaceitems1,2,3 and 4 if worn or damaged.lf transmission makesa clicking,grindingorwhirringnoise,
alsoreplacemainshaft4th gear,reverseidlergear.and countershaft 4th gearin additionto 1, 2, 3 or 4.
lf differentialpinion shaft is worn, overhauldifferentialassembly,and replaceATF strainer,and thoroughly
cleantransmission, flushtorqueconverter, coolerand lines.
lf bottom of 3rd clutchis swirled and transmissionmakesgear noise,replacethe countershaftand final driven
gear.
Be very carefulnot to damagethe torqueconverterhousingwhen replacingthe main ball bearing,you
may also damagethe ATF pump when you torquedown the main valvebody.Thiswill resultin ATF pump
seizureif not detected.Usethe oroperroors.
Installthe main sealflush with the torqueconverterhousing.lf you push it into the torqueconverter
housinguntil it bottomsout, it will blockthe fluid returnpassageand resultin damage.
14-1 1 2
Road Test
NOTE:Warm up the engineto normaloperatingtemperature (the radiatorfan comeson)'

1. Apply parkingbrakeand blockthe wheels.Start the engine,then shift to E positionwhile depressingthe brake
Dedal,Depressthe accelerator pedaland releaseit suddenly.The engineshouldnot stall'
2. Repeatsametest in E Position.
3. Test-drivethe vehicleon a flat road in the E position.Checkthat the shift pointsoccurat approximatespeedsshown
in the table.Also checkfor abnormalnoiseand clutchslippage.
NOTE:Throttlepositionsensorvoltagerepresents the throttleopening
a. Unboltthe PCMfor roadtesting;referto page14-50.
b. Setthedigitalmultimeterto checkthe th rottlepositionsensorvoltagebetweenPCMterminals;
. '96 - 98 models:D1 {+)and A9 (-) or 422 (-}.
. ' 9 9- 0 0 m o d e l sC
: 2 7( + )a n d B 2 0 t - )o r B 2 2 { - } .
BACKPROBE
ADAPTER
BACKPROBE SET
07sAz- 001oq)A
{tworequiredl
DIGIIAL MULTIMETER
lCommerciallyavailable)
KS-AHM-32-003,
or equivalenl
'96 - 98 Modelsr
I (25P1 c (31P}
PCMCONNECTORS
'9!t - 00 Models: D (16P)
A t32Pt B t25Pl c (31P)
LG1IBRN/BLK)
1+113
Road Test
(cont'dl
.91Position:Dl6Y7 engine
. Upshift
Throttle Opening Unit of speed lst + znd 2nd * 3rd 3rd t 4th Lock-upON
Throttlepositionsensor mph 9-12 20-23 28-32 21-24
voltage:0.75V km/h 15-19 32-37 45-52 34-39
Throttlepositionsensor mph 40-45 62-67
v o l t a g e : 2 . 2V5 km/h 95 - 104 't08
34-40 99 -
Fully-opened throttle mph 33-38 1 0 1- ' t 1 2 99 - 109
Throttlepositionsensor
voltage:4.5V km/h 53-61 102-115 163- 180 '159- 176
Downshift
Throftle Opening Unit of speed Lock-upOFF 'lth + 3rd 3rd + 2nd 2nd t lst
Fullyclosedthrottle 't9 - 22
mph 1 7- 2 0 6-9(3rd+lst)
voltage:0.5V km/h 30-35 27-32 10- 15 (3rd+ 1st)
Fully-opened throttle mpn 95 - 105 85-95 54-61 25-30
voltage:4.5V km/h 153- 169 1 3 7- 1 5 3 87-98 40-48
-q1Position: DI6YBengine
. Upshift
Throttle Opening Unit of speed lst + 2nd 2nd - 3rd 3rd + 4th Lock-up ON
Throftlepositionsensor mph 9-12 20-23 2A-32 2 1- 2 4
voltage:0.75V km/h 15-19 32-37 45-52 34-39
Throttlepositionsensor mpn 2 1- 2 5 40-45 59-65
v o l t a g e : 2 . 2V5 9 5- 1 0 4
km/h 34-40 99 - 108
Fully-opened throttle mph 32-37 6 2- 7 0 96 - 107 9 5- 1 0 6
km/h 52-60 1 0 0- 1 1 3 't55- 't53- '170
voltage:4.5V 112
Downshift
Throttle Opening Unit ot speed Lock-upOFF 'lth + 3rd 3rd+2nd I 2nd+lst
Fully-closed
throttle mph 19-22 1 7- 2 0 6-9(3rd+ 1st)
voltage:0.5V km/h 30-35 27-32 l0 - 15 (3rd+ lst)
Fullyopenedthrottle mpn 9 1- 1 0 1 54-61 25-30
'147- 163
voltage:4.5V km/h 1 3 7- 1 5 3 87-98 I 40-48
NOTE:
. Lock-upON:The lock-upcontrolsolenoidvalveA turns ON.
. Lock-upOFF:The lock-upcontrolsolenoidvalveA turns OFF.
14-114
then shift from Dl positionto Z position The
Accelerateto about 35 mph (57 km/h)so the transmlssionis in 4th,
vehicleshouldimmediatelybeginslowingdown from engine braking'
-Ddposition to damage
CAUTION: Do not shift from -91or E position at speeds ov6r 63 mph {100 km/hl; You mav
the transmission.
positions'
Checkfor abnormalnoiseand clutchslippagein the following
E (2ndGear)Position clutchslippage.
from a stop at full throttle.checkthat there is no abnormalnoiseor
ll Accelerate
should not occurwith the selector in this posirion'
b. Upshiftsand downshifts
E (Reverse) Position
and clutchslippage'
i"cceleratefrom a stop at fullthrottle,and checkfor abnormalnoise
Test in B (Park)Position
into E position Beleasethe brake;the veh'
Parkthe vehicleon slope(approx.l6'), applythe parkingbrake'and shift
cle shou,dnol move
1+115
Stall Speed
Test
CAUTION:
. To prev€nt transmissiondamage,do not t6st stall speedfor more than
ro sgcondsat a time.
. Do not shift the levor while raising the engine speed.
. Bo sule lo remove the pressuregauge betoro testing stall speed.
'1.
Engagethe parkingbrake,and blockthe front wheels.
2. Connecta tachometerto the engine,and startthe engine.
3. Makesurethe Ay'Cswitchis OFF.
4. After the enginehaswarmed up to normaloperatingtemperature(the radiatorfan

comeson). shift into E position.
5. Fullydepressthe brakepedaland accelerator

for 6 to g seconds,and noteenginespeed.
6. Allow two minutesfor cooling,then repeatthe test in @ and @ positions.
NOTE:
. Stallspeedtestsshouldbe usedfor diagnosticpurposesonly,
. Stallspeedshouldbe the samein o., E and positions.
E
Stall Spsed RPM:

Specification:2.700rpm
ServiceLimit: 2,550- 2,850rDm
TROUBLE PROBABLECAUSE
Stallrpm high in D., E and E positions . Low fluid levelor ATF pump outDur
. CloggedATF strainer
. Pressureregulatorvalvesluckcloseo
. Slippingclutch
Stallrpm high in El position . Slippageof 4th ctutch
Stallrpm high in E posirion . Slippageof 2nd clutch
Stallrpm high in E position . Slippageof lst clut"tr or. t"t g""io*-*"y "lut"h
Stallrpm low in LDa
. El and E positrons . Engineoutput low
. Torqueconverterone-wayclutchslipping
1 4-1 1 6
Fluid Level
Ghecking
NOTE: Keep all foreign particlesout of the transmis- 7. Insertthe dipstickbackinto the transmissionin the
sron. directionshown.
1. Warm up the engineto normal operatingtempera-

ture (the radiatorfan comeson)
FRONT
Parkthe vehicleon the level ground, then turn off
the engrne.
Removethe dipstick(yellow loop) from the trans-

mission.and wipe it with a cleancloth.
Insertthe dipstickinto the transmrssron
Installthedipstickin the extent

of the directionshown.
DIPSTICKIYELLOWLOOPI
R e m o v et h e d i p s t i c ka n d c h e c kt h e f l u i d l e v e l l t
s h o u l d b e b e t w e e nt h e u p p e r m a r k a n d l o w e r
marks.
K
L UPPERMABK
LOWERMARK
lf the levelis belowthe lower mark,pour the recom-

m e n d e df l u i d i n t o t h e t i l l e r h o l e t o b r i n g i t t o t h e
upper mark. Always use GenuineHonda Premium
FormulaAutomaticTransmissionFluid (ATF).Using
a non-HondaATFcan affectshift quality
14-117
Fluid Level
Changing
NOT€: Keep all foreign particlesout of the transmis-
sion.
'1.
Bringthe transmissionup to operatingtemperature
(the radiatorfan comeson) by drivingthe vehicle.
Parkthe vehicleon the level ground, and turn the

engine off.
R e m o v et h e d r a i n p l u g . a n d d r a i n t h e a u t o m a t i c
transmissionfluid (ATF).
NOTE:lf a coolerflusheris to be used,seepage 14-

187and 14-188.
TRANSMISgION
ENDOOVER
DNAINPLUG
1 8x 1 . 5m m SEALINGWASHER
49 N.m (5.0kgtm, 36lbf.ftl Replace.
Reinstallthe drain plug with a new sealingwasher,

then refill the transmissionwith the recommended
fluid into the filler hole to the upper mark on the
d i p s t i c k .A l w a y s u s e G e n u i n e H o n d a p r e m i u m
FormulaAutomaticTransmissionFluid (ATF).Using
a non-HondaATFcan aftectshift quality.
Automatic TransmissionFluid Capacity:

2.7 | |'2.9US ql,2.a lmp qtl at Ghlnging
5.9 f 16.2US qt. 5.2 lmp qt) at overhaul
1 4- 1 1 A
PressureTesting
@
I While testing, be caroful of th€ rotating front wheels.
. Make sure lifts, iacks, and satoty stands are placod properly (seesection 1)'
CAUTION:
. Beforoiesting, be sure the transmissionfluid is tilled to tho proper level'
. Warm up tho engine before testing'
1. Raisethe vehicle(seesection1).
2. Warm up the engine,then stopthe engineand connecta tachometer'
3. Connectthe oil pressuregaugesto eachinspectionhole.
TOROUE:18 N.m (1.8 kgf'm, 13 lbnft)
to entel
cAUTloN: connact the oil pressurogauges securely;be suro not to allow dust and other foreign Parlicles
the inspestion holos'
A/T OILPRESSUREGAUGE HOSE

A/T OIL PRESSURE
SETw/PANEL ADAPTER
07t06- 0020400 07Mru - PY0120
(4 requiJedl
A/T LOWPRESSUREGAUGE A/T OIL PBESSUREHOSE

SETWPANEL 2210mm
07406- 0070300 OTMAJ- PY4{)llA
14roquircdl
Startthe engine,and measurethe respectiveptessureas follows'

a Line Pressure
. 1st Clutch Pressure
. 2nd,3rd and 4th ClutchPressure
Installa new washerand the sealingbolt in the inspectionhole.and tightento the specifiedtorque'
TOROUE:l8 N.m (1.8 kgf'm,13lbf'ft)
NOTE:Do not reuseold sealingwashers;alwaysreplacewashers'
(cont'd)
14-119
PressureTesting
(cont'd)
Line Pressure/1stClutch PressurcMeasurement
1. Setthe parkingbrake,and btockboth rearwheelssecurely.
2. Startthe engine,and run it at 2,OOO

rpm.
3. Shiftto N or E position,then measureline pressure.
NoTE: Higherpressuremay be indicatedif measurements

are made in shift leverpositionsotherthan @ or @ posi
tron.
4. Shiftto tq;lposition,hold the engineat 2,000rpm, and measure1stcrutchpressure.
1STCLUTCHPRESSURE
INSPECTION HOLE
(Markedwith "1")
LOCK.UPCONTROL
SOLENOIDVALVEA/8
ASSEMBLY
VALVEA/B ASSEMBLY
SHIFTLEVER FLUIDPRESSURE
PRESSURE SYMPTOM PROBABLE
CAUSE
POS|TtON
Standard ServiceLimit
Line N orE No (or low) Torqueconverter, 830 - 880 kPa 780 kPa
lrne pressure ATF pump,pres- {8.5- 9.0 kgf/cm?, (8.0kgf/cm' ,110psi)
sure regutator. 120- 130psi)
torqueconverter
checkvalve
1stClutch D;l Noor low 1st 1 s tC l u t c h
pressure
14-120
2nd, 3rd and 4th Clutch PressureMeasurement
1. Setthe parkingbrake,and blockboth rearwheelssecurely'
2. Startthe engine,and run it the engineat 2,000rpm'
pressure
3. Shiftto E position,then measure2nd clutch
pressure
4. Shiftto El position,then measure3rdclutch
pressure'
5. Shiftto E position,then measure4th clutch
pressure'
6. Shiftto E position,then measure4th clutch
2ND CLUTCHPR€SSURE
INSPECTIONHOLE
INSPECTION HOI'E
(Markedwith "3")
FLUIDPRESSURE
SHIFTLEVER SYMPTOM PROBABLECAUSE
PRESSURE POStT|()N standard I sorviqe Limit
800 - 850 kPa 760 kPa

2nd Clutch tr No or low 2nd 2nd Clutch
(8.2- 8.7 kgflcm', (7.7kgf/cm' ,110Psil
pressure
120- 120psi)
8'10- 860 kPa 760 kPa
3rd Clutch tr No or low 3rd
pressure
3rd Clutch
(8.3- 8.8 kgt/cm', (7.8kgt/cm',110Psi)
120- 130psi)
p.l No or low 4th 4th clurch
4th clutch
E presSure Servo Valve or 4th
Clutch
1+121
Transmission
Removal
@ 4. Removethe transmissiongroundcable,and discon_
Maks sure lifts, iacks and safety stands are placed nectthe lock-upcontrolsolenoidconnector.
properly, and hoist bracket ate aftached to the cor_
rec{ position on the engine lsee section 1).
Apply parking brake and block rear whoels so vehicle
will not roll off stands and fall on you while working
under it.
CAUTION: Use tender covers to avoid damaging paint-

ed surfaces.
1, Disconnectthe battery negative(_) terminal from

the battery,then removethe positive(+)terminal.
2. Removethe intakeair duct.
D16Y7engins:
Removethe intakeair duct and resonator.
LOCK.UPCONTROL
D16Y8engine: SOLENOIDCONNECTOR
Removethe intakeair duct and the air cleanerhous-
ing assembly,
3. Removethe starter cables and cable holder from

the starter motor.
5, Disconnectthe vehiclespeedsensor(VSS)connec_
tor and the countershaft
MOTORCABLE
VEHICLE
SPEED
MOTORCABLE
14-122
6. Removethe transmissionhousing mounting bolts 8. R e m o v et h e d r a i n p l u g , a n d d r a i n t h e a u t o m a t i c
and the rearenginemountingbolt. t r a n s m i s s i o nf l u i d ( A T F ) .R e i n s t a ltlh e d r a i n p l u g
with a new sealingwasher.
DRAINPLUG Replace.
18 x 1.5mm
MOUNTINGBOLTS '9 N m t5 o kgf'm' 36 lbf'ft|
7. Disconnect the shiftcontrolsolenoid,the linearsole-

noid,and the mainshaftspeedsensorconnectors'
9. Remove the splash shield.
SHIFTCONTROL LINEARSOLENOID
SOLENOIDCONNECTOR CONNECTOR
SPLASHSHIELD
BRACKET
{cont'd)
14-123
Transmission
Removal(cont'd)
'10. Remove
the cotter pins and castlenuts, th€n separate 16. Removethe shift cablecover.then removethe shift
the balljoints from the lower arms (seesection 1gl. cableby removingthe controllever,
DAMPERPINCHBOLT
CAUTION: Take car6 not to bond the shift cable.
NUT
FORI( COTTERPIN
FORK BOLT Replace.
11. Removethe right damper fork bolt. th€n separate WASHER
right damperfork and dampor.
1 2 . Prythe right and left driveshaftsout ofthe differential. 1 7 . Removethe right front mounvbracket.
1a Pullon the inboardjoint to removethe right and left 1 8 . Remove the ATF cooler hoses at the ATF cooler
drivsshafts(seesection 16). lines.Tufn the ends of the ATF cooler hosesuo to
preventATF from flowing out, then plug the ATF
1 4 . Tie plastic bags over the driveshaftonds. cooler hosgsand lines.
NOTE: Coat all precisionfinished surfaceswith clean NOTE: Checkfor any sign of leakageat the hose
engineoil. ioints.
t9. Removethe exhaustpipe A,
NOTE: Dl6YB engine is shown; D16y7 engine is

similar.
SELF-LOCKING
NUT EXHAUSTPIPEA
Replace. MOUNT/BRACKET
14-124
19. Removethe engine stiffener and the torque con- 23. Placea jack under the transmission.and ra6a :'.
verter cover. transmissioniust enoughto take weight otf ol tF.
mounts.then removethe transmissionmounl
TRANSMISSION
MOUNTBRACKET
COVER
20. Removethe eight drive plate bolts one at a tlme

while rotatingthe crankshaftpulley.
24. Removethe transmissionhousing mounting bolts
2 1 . Removethe distributor. and the rearenginemountingbolts.
Attacha hoistingbracketto the engine,then lift the 25. Pull the transmissionaway from the engineuntil it
engineslightly. clearsthe 14 mm dowel pins, then lower it on the
transmissionjack.
TRANSMISSIONHOUSING
HOIST
BRACKET
lf necessary,removethe torque converteranc:"

startermotor.
1+16
lllustrated Index
Transmission/End
Cover
a-'tEO
14-126
O ROLLER @)END COVER
O COLLAR @ lsT CLUTCHFEEDPIPE
O o-RINGReplace. @ O-RINGSReplace.
@ FEEDPIPEFLANGE @ FEEDPIPEFLANGE
@ O-RINGReplace. C) SNAP BING
@ SNAP RING @ MAINSHAFTLOCKNUT(FLANGENUTI 21 x 1 25 mm
€) 3RD CLUTCHFEEDPIPE Replace.
€) COUNTERSHAFT LOCKNUT(FLANGENUT) @ CONICALSPRINGWASHERRePlace
23 x 1.25mm Replace. @)lST CLUTCHASSEMBLY
o coNlcAL SPRINGWASHERReplace. @ o-RlNGs Replace.
@ PARKGEAR €) THRUSTWASHER
@ ONE.WAYCLUTCH @)THRUSTNEEDLEBEARING
@ COUNTERSHAFT lST GEAR @ NEEDLEBEARING
@ NEEDLEBEARING @ MAINSHAFTlST GEAR
@ COUNTERSHAFT lST GEARCOLLAR @ MAINSHAFTlST GEARCOLLAR
@ o-RlNGs Replace. @)ATF COOLERLINE
@ ENDcovER GASKETReplace. @ SEAUNGWASHERSReplace.
E) DOWELPINS @ LINEBOLT
@ PARKPAWLSTOP @ ATF DIFSTICK
@ LocK WASHERReplace. @ ATF COOLERLINE
@ PARKSTOPSelectivepart @ UNE BOLT
€D PARKLEVER @ SEALINGWASHERSReplace.
@ PARKLEVERSPRING @ VEHICTTSPEEDSENSOR
€D DRAINPLUG @ O-RINGReplace.
€) SEALINGWASHERReplace
@ o-RINGReplace.
@ COUNTERSHAFT SPEEDSENSOR
@) PARK PAWL
@ PARKPAWLSPRING
@ PARKPAWLSHAFT
@ LINEARSOLENOIDASSEMBLY
@ LINEARSOLENOIDGASKETREPIACE.
TOROUESPECIFICATIONS
Bolt/Nut No. Torque Value Size Remarks

'12N'm (1.2kgim,8.7 lbift) 6x1.0mm
6B 14 N.m (1.4kgf.m,10 lbf'ft) 6x1.0mm
8F 22 N.m (2.2 kgf.m, 16 lbf'ft) 8 x 1 , 2 5m m
12A. 28 N.m (2.9 kgf.m, 21 lbf'ft) 1 2x 1 . 2 5m m Linebolt
'l8D 49 N.m (5.0 kgf.m, 36 lbf'ft) 1 8x 1 . 5m m Drainplug
2'tM 78 N.m (8.0 kgf'm, 58 lbf'ft) 2 1 x 1 . 2 5m m Mainshattlocknut:Left-handthreads
23C 103N.m {10.5kgf'm,75.9lbift) 2 3 x 1 . 2 5m m Countershaftlocknut:
Left-handthreads
14-127
lllustrated Index
Transmission
Housing
6A
I
e
:!_..
14-128
O LocKWASHER Replace, @ THRUST NEEDLE BEARING
O REVERSESHIFTFORK @ MAINSHAFI
O COUNTERSHAFT REVERSE GEARCOLLAR @ S€ALINGRINGS,35 mm
G) COUNTERSHAFTREVERSE GEAR @ SEALINGRING,29mm
@ NEEDLEBEARING @}NEEDIEBEARING
@ REVERSESELECTOR @ SETRING
O SELECTOR
REVERSE HUB @ sHrFTCONTROL SOLENOID VALVEA/B ASSEMSLY
@ COUNTERSHAFT 4THGEAR @ HARNESS CLAMPBRACKET
O NEEDLEBEARING @ SHIFTCOI,ITROLSOI"ENOID FILTER/GASKETReplace.
@ DISTANCEGOLLAR, 28 mm Selectivepart @ CONNECTOR BFACKET
O COUNTERSHAFT GEAR
2ND @DTNANSMISSION HANGER
@ THRUSTNEEDIEBEARING @ BREATHER CAP
@ COUNTERSHAFT 3RDGEAR @ MAINSHAFT SPEED SENSOR
@ NEEDLEBEARING @ MATNSHAFT SPEEDSENSOR WASHER {Dl6Y' ongine}
@ COUNTEBSHAFT 3RDGEARCOLLAR @ O-RINGReplace.
@ THRUSTNEEDLE BEAFING @ SNAPRING
WASHER
O SPLINED @ MAINSHAFT TRANSMISSION HOUSING BEARING
@ 3RDCLUTCHASSEMBLY @ OOUNIERSHAFT TRANSMISSION HOUSINGBEARING
@ O-RtNGsReplace. @ REVERSE IDLERGEARSHAFTHOLDER ASSEMBLY
@ COUNTERSHAFT @ NEEDI.EBEARING
@ SNAPRING @ olL SEALReplace.
@ THRUSTWASHER @ SETRING,fll mm Selectivepart
NEEDTE
€) THRUST BEARING HouslNG
@rnANsMrssloN
@} 4TH
MATNSHAFT GEAR/REVERSE GEAR @ REVERSEIDI."ER
GEAR
@iNEEDLEBEARINGS @ DowELPINS
@ THRUSTNEEDLE EEARING @ TRANSMISSION HOUSING Replace.
GASKET
@)MAINSHAFT4THGEARCOLLAR @ DIFFERENfIALASSEMBLY
@ 2ND/4THCLUTCH ASSEMBLY @ OILSEALReplace.
@ o-RlNGsReplace. @ TOROUECONVERTER HOUSING
@ THRUSTWASHER,36.5 x 55 mm Sel€ctivepart
@ THRUSTNEEDLE BEARING
@ MAINSHAFTzNDGEAR
@ NEEDLEBEARING
TOROUESPECIFICANONS
Boh/Nut No. Torquovalue Size Romarks

12 N.m {1.2kgf.m,8.7lbf.ft) 6x1.0mm
6B 14 N.m (1.4kgf'm,10lbf'ft) 6x1.0mm
10A 44 N.m (4.5 kgf.m, 33 lbf'ft) 1 0x 1 . 2 5m m
14-129
lllustrated lndex
TorqueConverterHousing/ValveBody
to\
\*
14-130
O ATF FEEDPIPE @ MAIN SEPARATORPLATE
O ATF STRAINER @ SUCTIONPIPECOLLAR
O SERVOBODY @ ATF MAGNET
'99 - 00 modelsservobody has integrallymolded @ COUNTERSHAFT TOROUECONVERTER HOUSING
servodetent. BEARING
@ SERVOSEPARATORPLATE @ ATF GUIDEPLATE
(' SECONDARYVALVE BODY @ ToRoUE CONVERTER HOUSING
@ DOWELP|NS @ OILSEALReplace.
@ MAINSHAFTTOROUECONVERTER HOUSING
O SECONDARYSEPARATORPLATE
@ SERVODETENTBASE('96 -'98 models) BEARING
O ATF FEEDPIPES @)olL SEALReplace.
(D ATF FEEDPIPES @ LOCK-UPCONTROLSOLENOIDFILTER/GASKET
O SHAFTSTOP Reolace.
@ CONTROLSHAFT @ LOCK-UPCONIROL SOLENOIDVALVEA/B ASSEMELY
€D DETENTARM SPRING @ CONNECTORBRACKET
@ DETENTARM
(9 DETENTARM SHAFT
@ FILTERReplace.
(? CHECKBALLS
@ TOROUECONVERTER CHECKVALVE
@ TOROUE CONVERTER CHECKVALVE SPRING
@ DOWELPINS
@ LOCK.UPVALVE BODY
@ LOCK-UPSEPARATORPLATE
@ REGULATOR VALVE BODY
@} DOWEL PINS
@ COOLERRELIEFVALVE SPRING
@ COOLERRELIEFVALVE
@ O-RINGReplace.
@ STATORSHAFT
@ STOPSHAFT
@ ATF FEEDPIPE
@ MAIN VALVE BODY
@ ATF PUMP DRIVENGEARSHAFT
@ ATF PUMP DRIVENGEAR
@ DOWELPINS
65)ATF PUMP DRIVEGEAR
TOROUESPECIFICANONS
Bolt/Nut No. Torque Valug Siz€ Remarkg
12 N.m (1.2kgf.m,8.7lbnft) 6x1,0mm
14-131
End Cover
Removal
NOTE:
. Cleanallpartsthoroughlyin solventor carburetorcleaner,and drywith compressedair,
. Blow out all passages,
. When removingthe right sidecover,replacethe following:
- O-rings
- Mainshaftand countershaftlocknuts
- Conicalspringwashgrs
- End cover gasket
- Lockwasher
- Sealingwashers
ENDCOVER 6 x 1.0mm BOLT

13 Bolts
PARKITVER
LOCKWASHER
PARKPAWL
tST GEAFCOLLAR
LINEAOLT COUI{TERSI{AFT
SEALINGWASHERS
14-132
1. Removethe 13 bolts securingthe end cover,then 5 . Removethe specialtool from the mainshaftafter
removethe cover. removingthe locknuts.
Slipthe specialtool onto the mainshaftas shown. 6 . Removethe 1stclutchand mainshaft1stgearassem

bly and mainshaft1stgearcollarfrom the mainshaft.
HOLOER
MAINSHAFT 7. Removethe parkpawl.springand shaft.
- PFs0101
07GAB
8. Removethe parkleverfrom the controlshaft.
9. Using a universaltwo-jaw puller, removethe park

g e a r , o n e w a y c l u t c h a n d c o u n t e r s h a f t1 s t g e a r
assemory.
PULLER
(CommerciallYavailable)
PARKGEAR
Engagethe parkpawl with the parkgear.
4. Cut the locktabs of the mainshaftand countershaft

locknutsusing a chiselas shown. then removethe
locknutsand conicalspringwashers
CAUTION: Keep all of lhe chiseled particles out of

the transmission.
NOTE: 1 0 . Removethe needle bearing and the countershaft

. Mainshaftand countershaftlocknuts have left- 1stgearcollarfrom the countershaft
handthreads.
. Alwayswear safetyglasses. 1 1 . Removethe ATF coolerlinesand ATFdipstick.
cHrs€L
LOCKNUT
LOCKTA8
14-133
Transmission
Housing
Removal
TRANSMISSIONHOUSING
MOUNTINGBOLTS
1 8B o l t s
TRANSMISSION
HANGER
TRANSMISSION
HOUSING
MAINSHAFT
SUB.ASSEMBLY
MAINSHAFT
SENSORWASHER
lD16Y7engine)
SUB.ASSEMBLY
MAINSHAFT
SPEEDSENSOR
TRANSMISSION DIFFEBENTIAL
HOUSINGGASKET ASSEMBLY
TOROUECONVERTER
HOUSING
14-134
Torque ConverterHousing/ValveBody
Removal
ATF FEEOPIP€
PIN
LOCK-UPVALVE
BODY 6x1.0mm
LOCK-UPSEPARATOR SERVODETENT STRAINER

PLATE BASE
ATFFEED
REGULATOR
PIPES
VALVESODY
CONTROL
DOWELPIN SHAFT
COOLERRELIEFVAL DETENT
ARM SHAFT
DETENT
ARM
SERVOEODY
SEPARATON
ATF FEEDPIPE
6x1.0mm 6x1.0mm
5 Eolts 3 Eolts
MAIN VAL
BODY VALVEBODY
ATFPUMP
GEARSHAFT PIN
ATF PUMP
DRIVEN SECONDARY
MAIN SEPARA SEPARATOR
PLATE
PLATE
NOTE:The illustrationshowsthe '96 - 98 models,the '99 - 00 modelsdo not havethe servodetentbase;the servodetent
is integralwith the servobody.
14-136
NOTE; 1 3 . C I e a nt h e i n l e t o p e n i n go f t h e A T F s t r a i n e rt h o r -
. Clean all parts thoroughly in solvent or carburetor oughly with compressedair. then checkthat it is in
cleaner,and dry with compressedair. good condition,and the inletopeningis not clogged.
. Blow out all passages.
. When removingthe valvebody,replacethe O-ring.
l, Removethe ATF feed pipes from the servo body,

secondaryvalvebody and main valvebody.
For'96 - 98 models:Removethe ATF strainerand

servo detent base (two bolts).
For'99 - 00 models:Removethe ATF strainer(one
bolt).
Removethe servo body and servo separatorplate

{'96- 98 models:sevenbolts,'99- 00 models:eight
bolts). INLETOPENING
Removethe secondaryvalve body, shaft stop and

secondaryseparatorplate(threebolts).
Removethe lock-upvalve body and separatorplate

{sevenbolts). 1 4 . Test the filter by pouring clean ATF fluid through
the inlet opening. Beplacethe ATF strainerif it is
Removethe regulatorvalvebody (one boltl. cloggedor damaged.
7 . Removethe stator shaft and stop shaft. NOTE:The ATF str8inercan be reused if it is not
clogged.
Removethe detentspringfrom the detentarm. then
remove the control shaft from the to.que converter
housing.
Removethe detentarm and detent arm shaft from

the main valvebody.
1 0 . Removethe main valvebody (five bolts).
NOTE:Do not let the eight checkballsfall outofthe

m a i n v a l v e b o d y w h e n r e m o v i n gt h e m a i n v a l v e
body.
't'1. Removethe ATF pump drivengear shaft,then remove
the ATF pump gears.
12. Removethe main separatorplate and two dowel

pins.
14-137
Valve Caps
Description
C a p sw i t h o n e p r o j e c t e dt i p a n d o n e f l a t e n d a r e Capswith hollow ends are installedwith the hollow
installedwith the flat end toward the inside of the end awayfrom the insideofthe valvebody.
valve body. Capswith notchedends are installedwith the notch
Capswith a projectedtip on each end are installed towardthe insideof the valvebody.
w i t h t h e s m a l l e rt i p t o w a r d t h e i n s i d eo f t h e v a l v e Capswith flat ends and a hole throughthe centerare
body.The smalltip is a springguide. installedwith the smaller hole toward the inside of
the valvebodv.
Toward outside of valvo body. Toward outsido of valve bodv.
Efla
Toward insido ot valvo body. Toward inlido ot valve bodv,
C a p s w i t h o n e p r o j e c t e dt i p a n d h o l l o w e n d a r e Capswith flat ends and a groovearoundthe cap are

installedwith the tip toward the inside of the valve installedwith the groovedside toward the outsideof
body.The tip is a springguide. the valvebody.
Towa.d outside o, valv6 bodv. Toward oulsido of valv6 body.
"-\"h
,A
\za9 Sectional view.
Toward insid€ of valv6 bodv. Toward insido ol valvo body.
14-138
Valve Body
Repair
NOTE:This repair is only necessaryif one or more of 5. Removethe #600 paper and thoroughly wash the
the valvesin a valve body do not slidesmoothlyin their entirevalve body in solvent.then dry it with com-
bores.You may use this procedureto free the valvesin pressedair.
the valvebodies.
Coatthe valvewith ATF,then drop ir into its bore.
1 . S o a k a s h e e t o f # 6 0 0 a b r a s i v ep a p e r i n A T F f o r It should drop to the bonom of the bore under its
about30 minutes. own weight.lf not, repeatstep4, then retest.
2. Carefullytap the valve body so the stickingvalve

dropsout of its bore.
C A U T I O N :l t m a y b € n e c e s s a r yt o u s e a s m a l l
screwdriver to pry the valve free. Be careful not to
scratchthe bore whh the screwdriver.
3. Inspectthe valvefor any scuff marks.Use the ATF-

soaked#600 paper to polishoff any burrs that are
on the valve,then wash the valvein solventand dry
it with compressedair. VALVE BODY
-M
4. Roll up half a sheetof ATF-soaked paper,and insert
it in the valvebore of the stickingvalve.
Twistthe paperslightly,so that it unrollsand fits the
b o r e t i g h t l y ,t h e n p o l i s ht h e b o r e b y t w i s t i n gt h e
paperas you push it in and out.
CAUTION: The valve body is aluminum and doesn't
W
require much polishing to remove any burrs,
ATF-soaked
#600 abrasive Paper
7. Removethe valve.then thoroughlyclean it and the
valve body with solvent. Dry all parts with com-
pressedair. then reassembleusing ATF as a lubri
cant.
14-139
Valve
Assembly
NOTE: . Set the spring in the valve and installit in the valve
Coat all parts with ATF before assembly. body. Push the spring in with a screwdriver,then
installthe springseat.
. Installthe valve, valve spring and cap in the valve
body and securewith the roller.
-_^?=w_
5-'--------P/
=/ /-\ (-,.1\)
,. )
l_/1
SPRIITGSEAT
VALVE BODY
VALVE BODY
Installthe valve,springand cap in the valvebody.

Pushthe cap,then installtheclip.
VALVE AODY
VALVE
SPRING
14-140
ATFPump
Inspection
1. Installthe ATF pump gears and ATF pump driven 2. Measurethe side clearanceof the ATF pump drave
gearshaft in the main valve body and drivengears.
NOTE: ATF Pump GearsSide {Radial)Clearance:

. Lubricateall partswith ATF during inspection. Standard (New):
. Installthe ATF pump drivengearwith its grooved ATF Pump Drive Gear
and chamferedsidefacingup as shown. 0.105- 0.1325mm {0.004- 0.q)5 in}
ATF Pump Drivsn Gear
0.035- 0.0625mm (0.0014- 0.0025inl
ATFPUMPORIVEN GEAR MAIN VALVESOOY
Groovedand chamfe.edside
YZ]
o?
ATF PUMP
DRIVENGEAR
ATF PUMP Inspectteethfor wear and damage
DRIVEGEAR
lnspect
teethforwearanddamage.
3. Removethe ATF pump driven gear shaft. Measure

the thrust clearanceof the ATF pump driven gear-
to-valve bodY.
ATF Pump Drive/Drivon Gear Thrust {Axial} Cloarance:

Standard (Now): 0.03- 0.05 mm 10'001- 0.002inl
MAIN VALVE BODY SorviceLimit: 0.07 mm (0.003in)
1+141
Main Valve Body
Disassembly/lnspection/Reassembly
NOTE:
. Cleanallpartsthoroughlyin solventor carburetorcleaner,and drywith compressedair. Blowoutall passages.
. Replacethe valvebody as an assemblyif any pans are worn or damaged.
. Checkall valvesfor free movement.lf anyfail toslidefreely,seeValveBody Repaironpage,l4-139.
. Coatall partswith ATF duringassembly.
CAUTION: Do not use a magnet to removs tha check balls; it may magnetizothe balls.
I.2 SHIFTVALVE
CPBVALVE VALVECAPCLIP
ORIFICE
CONTROLVALVE
BALLS,8
lST ACCUMULATOR
CHOKE
MODULATOR
VALVE
RELIEFVALVE VALVE
MAIN VALVEEODY
Inspectfor wear,scratches
and scoring.
SEBVOCONTROLVAL
VALVECAP
14-142
CHECKBALL
CHECKBALLS
w
CHECKBALLS
MAIN VALVEBODY
(Sectionalviewl
SPRINGSPECIFICATIONS U n i t :m m ( i n )
Standard (New)
No. Springs
Wire Dia. o.D. Free Length No. ot Coils
o Reliefvalvespring 1 . 1( 0 . 0 4 3 )
'1.4(0.055)
8.6 (0.342) 3 7 . 1( 1 . 4 6 1 )
35.0(1.378)
13.4
@ Modulatorvalvespring 9.4 (0.374) 10.9
@ CPBvalvespring 0.9 (0.035) 8.1 t0.3221 47.2(1.8s8) 1C?
'15.3
@ 1-2shiftvalvespring 0.9 (0.035) 7.6 {0.302) 4 1 . 3( 1 . 6 2 6 1
@ 2nd orificecontrolvalvespring 0.7 (0.028) 6.6 (0.262) 34.8(1.370) 22.0
@ Servocontrolvalvespring 1.0(0.039) 8.'t to.322l 52.1t2.O51l 20.8
1+143
SecondaryValve Body
NOTE:
. Cleanallpartsthoroughlyin solventor carburetorcleaner.and drywith compressedair, Blowoutall passages.
. Replacethe secondaryvalvebody kit. P/N27700- P4R- 315 (Thesecondaryvalve body kit includesthe linearsolenoid
assembly)if any partsare worn or damaged.
. Checkallvalvesfor free movement.lf anyfailto slidefreely,seeValveBodyRepaironpage14-139,
. Coatall partswith ATF duringassembly.
. The CPCvalveis installedin the secondaryvalvebody, held in placeby the lockbolt.
2.3 SHIFTVALVE
3.4 SHIFTVAL
.TH EXHAUSTVALVE
LOCKBOLT
CAUTION:Do not move.
SECONDARY VALVEBODY
6nd
scoring.
3-'l ORIFICE
CONTROLVAL
VALVE
SPRINGSPECIFICATIONS
U n i t :m m ( i n )
Standard {New)
No. Springs
Wire Dia. o.D. FreeLongth No. of Coils
o
ra,
3-4shift valvespring 0.910.035) 7.6 (0.302) 57.O12.2441 26.8
2-3shift valvespring 0.9{0.035) 7.6 (0.302) 57.O12.2441 26.8
.n
4th exhaustvalvespring 0.9{0.035) 6.1 10.2421 36.4(1.433)
3-4orificecontrolvalvespring 0.7{0.028) 6.6 (0.262) 37.5(1.476) 24.6
14-144
RegulatorValveBody
NOTE:
. cleanall partsthoroughlyin solventor carburetorcleaner,and drywith compressedair. Blowoutall passages
. Replacethe valvebody as an assemblyif any partsare worn or damaged.
. checkallvalvesfor free movement.lf anyfail toslidetreely,seevalve Body Repaironpage1+139.
1. Holdthe regulatorspringcap in placewhile removingthe stop bolt. once the stop bolt is removed.releasethe spring
cap slowly.
CAUTION: The regulator 3pring cap can pop out when the stop boh is removod'
2. is the reverseorderofths disassemblyprocedure.

Reassembly
NOTE:
o Coatall partswith ATF duringassembly.
. Align the hole in the regulatorspringcap with the hole in the valve body,then pressthe springcap into the valve
body,and tightenthe stop bolt.
\ ^/^'ou*'oRsPRrNGcAP
STOPBOLT
6x1.0mm
12 N.m 11.2 8.7 tbf.lrl
*N@
REGULATOR VALVEBODY
Inspectlor wear, scratches
and scorlng.
REGULATOR
VALVE
\=f -.-*
/F *fi { a-tLocK.uPcoNrRoLvALVE
cooLERRELlEFvALVr"r?
ry
^LvE//
cHEcKv
roRouEcoNvERrER
v^r* "r**::f\
vi{LvEcAp
SPRINGSPECIFICANONS Unit:mm (in)
Standard (Now)
No, Springe
Wire Dia. o.D. Free Lengrth No. of Coils
'r4.7(0.584)
o RegulatorvalvesPringA 1.8{0.07' r) 87.8(3.457)
o RegulatorvalvespringB 1.8(0.071)
4.5(0.177)
9.6 (0.381)
35.4(1.407)
44.0(1.732)
30.3(1.193)
11.0
1.9
@ Statorreactionspring
@ Coolerreliefvalvespring 1.0(0.039) 8.4{0.334) 3 3 . 8( 1 . 3 3 1 ) 8.2
Torqueconvertercheckvalvespring 1.0(0.039) 8.4 {0.334} 33.811.3311 a.2
't4.1
@ Lock-upcontrolvalvesPring 0.7 (0.028) 6.6{0.262} 38.0{1.4961
14-145
Servo Body
NOTEI
. clean all partsthoroughlyin solventor carburetorcleaner,and dry with compressedair. Blow out all passages.
. Replacethe valvebody as an assemblyif any partsare worn or damaged.
. Coatall partswith ATFduringassembly.
. Replacethe O-rings.
. The servobody showsthe '96- 98 models:the '99 - 00 modelshavean integrallymoldedservodetent.
SERVO
BODY
I n s p e c tf o r w e a r , s c r a t c h e sa n d s c o r i n g .
,______.-
g
1l
"-------'g
v
I
ZruO
lCCUr,irUr-nrOn
---rrr___-p
O.RING
n\='l Replace.
3,ii11---------*5
1STACCUMULATOR
PISTON
^rrr4
3ROACCUMULATOR
PISTON
4TH ACCUMULATOR
PISTON
SNAPRINGS
SPRINGSPECIFICATIONS
U n i t :m m ( i n )
Standard {New)
No. Springs
Wire Dia. o.D. FreeLength No. of Coils
o 'Ist accumulatorspring
2.1(0.083) 16.0(0.636) 89.1(3.s08)
(a 4th accumulatorspringA 2 . 6( 0 . 1 0 2 ) 17.0(0.676) 87.0(3.425) 14.2
4th accumulatorspringB 2 . 3( 0 . 0 9 1 ) 10.2lo.402J 5 1 . 6( 2 . 0 3 1 ) 13.8
@) 3rd accumulatorspringA 2 . 8( 0 . 1 1 0 ) 1 7 . 5( 0 . 6 9 5 ) 89.3(3.516)
3rd accumulatorspringB 2.210.0871 31.0 11.220) 3 5 . 1( 1 . 3 8 2 )
2nd accumulatorspringC 2.2 t0.0a7l 14.5(0.576) 68.012.677) '13.9
o 2nd accumulatorspringA 2.4 (0.094)
'1.6(0.063)
2 9 . 0( 1 . 1 5 2 ) 39.0(1.535)
@ 2nd accumulatorspring B 9.0 (0.358) 20.7(0.815)
14-146
Lock-upValve BodY
NOTE:
with compressedair' Blow out all passages'
. Cleanall pans thoroughlyin solventor carburetorcleaner'and dry
a Replacethe valvebody as an assemblyif any partsare worn or d€maged'
ValveBody Repaironpage14-'139'
. Checkallvalvesfor free movement ttanytaitio stlaefreely'see
. Coatall partswith ATF duringassembly
LOCK.UPVALVEBODY VALVECAP
and sconng.
LOCK-UPTIMINGVAL
SPRINGSPECIFICATIONS U n i t :m m ( i n )
7.6 (0.302) 73.1 t2.902J

Lock-upshiftvalvesPrang
8 . 1( 0 . 3 1 9 ) ao.7 13.'1771
Lock-uptiming valvesPrlng
14-147
Mainshaft
Disassembly/lnspestion/Reassembly
NOTE:
. Lubricateall partswith ATF during reassembly.
.Inspectthethrustneedlebearingsandtheneedlebearingsforgallingandroughmovement,
. Beforeinstallingthe O-rings,wrap the shaftsplineswith tapeto preventdamagingthe O_rings.
. Locknuthasleft-handthreads.
LOCKNUT{FLANGENUTI
21 x 1.25mm
78 N.m (8.0 kgl.m,58 lbt.ftt
Replace.
Left-handthreads
SNAP RING CONICALSPRINGWASHER
Reolace.
lST CLUTCH
ASSEMBLY
THRUST WASHER
O-RINGS
Replace.
THRUST NEEOI.E
BEARING THRUSTWASHER
THRUST NEEDLE
4TH GEAN BEARING
MAINSHAFT BEARING
Checksplinesfor excessive BEARINGS
wear and oamage. 1ST GEAR
Check bearingsurtacefor scoring,
scratchesand excessivewear.
THRUST NEEDLE 1ST GEAR
BEABING COLLAR
4TH GEAR COLLAR TRANSMISSION

HOUSINGBEARING
2ND/4TH CLUTCH
ASSEMBLY
O-RINGS
Replace.
THRUSTWASHER,36.5 x 55 mm
Selectivepart.
THRUSTNEEDLE
EEARING
SEALINGRINGS,
35 mm 2NO GEAB
Install the sealing ring NEEDLEBEABING

mating faces as shown,
THRUSTNEEDLE
RING, BEARING
29 mm
NEEDLEBEARING
SETRING
14-148
Inspection
a ClearanceMeasurement 3. Torquethe mainshaftlocknutto 29 N'm (3.0kgf'm,
22 tbt,ftl.
NOTE: Lubricateall parts with ATF during assembly.
NOTE:Mainshaftlocknuthas left-handthreads.
1, Removethe mainshaftbearingfrom the transmis-
sion housing(seePage14-1741.
2. Assembleths parts below on the mainshaft.
NOTE:Do not assemblethe O-ringsduring inspec-

tlon.
29 N'm t3.0 kgl'm, 22 lbt'ft)

LOCKNUT CONICAL SPRIIIGWASHER
lST CLUTCHASSEMBLY Hold 2nd gear againstthe 2nd clutch'then measure

the clearancebetween 2nd gear and 3rd gear with a
feelergauge.
TXRUSTWASHER
NOTE: Take measurementsin at least three places,
1STGEARCOLLAR
and use the av€rageas the actual clearance'
TRA SMISSION
HOUSII{GBEARING STANDARD:0.05- 0.13 mm 10.002- 0.005in)
SNAP RING
THRUSTWASHER
4TI{ GEARCOLLAR
2ND/4THCLUTCH
ASSEMBLY
THRUSTWASHER
36.5 x 55 mm
Selectivepart.
THBUSTNEEDLE
BEARING
2ND GEAR
AEABII{G
IHRUST NEEDLE THRUST WASHER,

BEARING 36.5 x 55 mm
MAINSHAFT
(cont'd)
1+149
Mainshaft
Inspection(cont'd)
5. l f t h e c l e a r a n c ei s o u t o f t o l e r a n c e ,r e m o v e t h e
thrustwasherand measurethe thickness.
THRUST
WASHER
6. Selectand installa new washer,then recheck.
THRUSTWASHER36.5 x 55 mm
No. Part Number Thickness

1 90441- P4P- 010 4.00mm (0.157in)
90442-P4P-010 4 . 0 5m m ( 0 . 1 5 9
in)
90443-P4P-010 4 . 1 0m m ( 0 . ' 1 6i1n )
4 90444-P4P-010 4 . 1 5m m ( 0 . 1 6 3
in)
90445-P4P-010 4.20mm (0.165in)
90446-P4P-010 4.25mm (0.167in)
7 90447-P4P-010 4.30mm (0.169in)
8 90448-P4P-010 4 . 3 5m m ( 0 . 1 7 1i n )
90449-P4P-010 4 . 4 0m m ( 0 . 1 7 3
in)
10 90450-P4P-000 4 . 4 5m m ( 0 . 1 7 5
in)
7 . After replacingthe thrust washer, make sure the

clearanceis within tolerance.
14-150
Countershaft
NOTE:
. Lubricateall partswith ATF beforereassembly'
gallingand rough movement'
. tnrp"",,n",t -"t needlebearingsand the needlebearingsfor
wrap the shaftsplineswith tape to preventdamagingthe O-rings
. Beforeinstallingthe O-rings.
. Locknuthas left-handthreads
LOCKNUT(FLANGENUT}
23 x 1.25mm
103 N.m
{10.5 kgf'm, 75.9 lbf'tt)
Replace.
L e f t ' h a n d lhreads
GEAR
REVERSE
CONTCAL SPRING
WASHER
Replace.
GEAR
NEEDLEBEARING CLUTCH
SELECTOR
1ST GEAR
SELECTOR
BEARING
4TH GEAR
NEEDLEBEARING lST GEAR COLLAR
DISTANCECOLLAS,
28 mm TRANSMISSION
Selective pa . HOUSINGBEARING
2'{D GEAR
THRUST NEEDLE
COUNYERSHAFT BEARING
Check splineslor excesslve
wear and damage 3RD GEAB
Checkbearingsurfacefor scoring'
scratchesand excessivewear'
NEEDLEBEARING
3RD GEAR COLLAR
THRUST NEEDLEEEARING
SPLINEOWASHER
3RD CLUTCH ASSEMBLY
Replace.
1+151
Countershaft
1. Using a hydraulicpress,pressout the countershaft 2. Assemblethe parts on the countershaftas shown
while supporting4th gear. oetow.
NOTE:Placean attachmentbetweenthe pressand NOTE;

the countershaft
to preventdamageto the shaft. . Lubricateall partswith ATFduringassembly.
. Beforeinstallingthe O-rings,wrap the shaft splines
CAUTION: Do not allow the countershaftto fall and with tapeto preventdamagingthe O_rings.
hit the g.ound when pressedclear.
4TH GEAR
NEEDLEEEARING
DISTANCECOLLAR, 28 mm
Selective part.
2ND GEAR
THRUSTNEEOLEBEARING
3RD GEAR
NEEDI.EEEARING
3RO GEAR COLLAR
THRUST NE€OLEBEARING
SPLINEDWASHER
3RD CLUTCH ASSEMBLY
O.RINGS
Replace.
COUNTERSHAFT
14-152
Inspection
Measurement
r Clearance
3. Installthe reverseselectorhub on the countershaft
sub-assembly,and then pressthe reverseselector
hub usingthe specialtool and a pressas shown' NOTE;Lubricateall partswith ATFduringassembly
1. Removethe countershaftbearingfrom the trans-

missionhousing(seepage l4-174)
2. Installthepartsbelowon the countershaftusinglhe

specialtool and a pressas describedon this page
NOTE:Do not assemblethe O-ringsduring inspec-

tion.
REVERSESELECTOR
HUB
4TH GEAR
NEEDLEBEARING
DISTANCECOLLAR, 28 mm
SelectavePart.
2ND GEAR
THRUST NEEDLEBEARING
3RD GEAR
BEARING
3RD GEAR COLLAR
THBUST NEEDLEBEARING
SPLINEOWASHER
3RD CLUTCH ASSEMBLY
(conl'd)
14-153
Gountershaft
(cont'dl
Inspection
3. I n s t a l lt h e p a r t s b e l o w o n t h e c o u n t e r s h a fst u b - 4. Measurethe clearancebetweenthe 2nd gear and
a s s e m b t yt,h e n t o r q u et h e l o c k n u t o 2 9 N . m ( 3 . 0 the 28 mm distancecollarwith a feelergauge.
kql.m , 22 blf.ftt .
NOTE:Takemeasurements in at leastthree places.
NOTE:Countershaft
locknuthas left handthreads. and usethe averageas the actuarctearance.
0.10- 0.18mm {0.004- 0.002inl

STANDAFD:
LOCKNUT
Left hand threads
CONICALSPRING
WASHER
PARKGEAR/ONE.WAY
CLUTCH/1ST
GEAR
ASSEMBLY
NEEOLE
BEARING
OISTANCECOLLAR,28 mm
.IST GEAR COLLAR
TRANSMISSION
HOUSING
BEARING
REVERSEGEAR
(=)-----' COLLAR
v
lf the clearanceis out of tolerance.removethe 2g

mm distancecollarand measurethe width.
S e l e c ta n d i n s t a l la n e w d i s t a n c ec o l l a r ,t h e n
recheck.
DISTANCECOLLAR,28 mm
No. Part Numb€r widrh

1 90503-PCg-000 3 9 . 0 0m m ( 1 . 5 3 5i n )
2 90504-PCg-000 3 9 . 1 0m m { 1 . 5 3 9i n )
90505-PCg-000 3 9 . 2 0m m ( 1 . 5 4 3
in)
90507-PCg-000 3 9 . 3 0m m { 1 . 5 4 7i n )
90508-PC9-000 3 9 . 0 5m m ( 1 . 5 3 7
in)
90509-PCg-000 m m ( 1 . 5 4 i1n )
39.15
7 90510-PCg-000 3 9 . 2 5m m ( 1 . 5 4 5
in)
I 90511-PCg-000 3 8 . 9 0m m ( 1 . 5 3 1i n )
90512-PCg-000 3 8 . 9 5m m ( 1 . 5 3 3
in)
7. Afret selectinga new distancecollar, recheckthe

clearanceand makesure it is within tolerance.
14-154
One-way Clutch
1. Separatecountershaft1st gear from the park gear 3. Inspectthe partsas followsl
by turningthe parkgear in the directionshown
PARKGEAR
Inspeclthe parkgear
for wear and scorrng.
lST GEAR
COUNTERSHAFT
ONE-WAYCLUTCH
Inspectthe one-way
clutch for damageand
2. Removethe one-wayclutchby prying it up with the laulty movement.
end of a screwdriver.
ONE-WAY CLUTCH
1STGEAR
COUNTERSHAFT NOTE:lnstallin this direction.
lST GEAB
Inspectcountershaltlst gear
for wearanclscorlng.
After the partsare assembled,hold countershaft1st

gear and turn the park gear in the directionshown
to be sure it turns freely.Also make sure the park
gear does not turn in the oppositedirection.
ONE'WAY CLUTCH
COUNTERSHAFTlST GEAR
SCREWORIVER
14-155
Clutch
lllustratedIndex(A4RA,B4RATransmission)
3RDCLUTCH
CLUTCH O-RINGS
DRUM Beplace. CLUTCHptSTON
CLUTCHEND
PLATE
SNAPRING
lST CLUTCH
CLUTCHEND
SNAPRING
SPRINGRETAINER
RETUNNSPRING
CLUTCHDRUM
CLUTCHPLATES
Standardthickness:
1.6mm (0.063in)
CHECKVALV€
14-156
2NDi4TH CLUTCH
SNAPRING
CLUTCHPISTON
DISCSPRING
SNAP RING
SPRINGRETAINER
RETURNSPRING
CHECKVALVE
O.RINGS
Replace. 4TH CLUTCHDRUM
CLUTCHPLATES
Standardthickness:O-RINGS
2.0mm {0.079in) Replace.
SNAPRING
14-157
Clutch
lllustratedIndex(M4RATransmission)
3RD CLUTCH
CLUTCH
DRUM
CLUTCHPISTON
DISCSPRING
CLUTCIIEND
rST CLUTCH
CLUTCHE D
SI{AP RIiIG
CLUTCHPLATES
Standardthickness:
1.6mm (0.063in)
CHECKVALVE
14-158
SNAPRING
2ND/4THCLUTCH
CLUTCH
PISTON
VALVE 2.0mm (0.079in)
2ND CLUTCH
DRUM
CLUTCHPISTON
RETURNSPRING
RETURNSPRING
\l-.
SNAPRING
14-159
Clutch
Disassembly
1 . Removethe snap ring. then removethe clutchend 3. Installthespecialtools as shown.
plate,clutchdiscsand plates.
CLUTCHSPRING
COMPRESSOR
SCREWDRIVER ATTACHMENT
07LAE-PX40,t 00
SNAP RING
CLUTCHSPRING
COMPRESSOR
ATTACHMENT
2. Removethe discspring. 07LAE- PX()100
o1
NOTE:Except2nd clutch. CLUTCH 07HAE- P150100
COMPRESSOR
AOLTASSEMBLY
DISC SPRING 07GAE- PG4tt200
ol
O'GAE - FG4O2OA
CLUTCH SPRING
COMPRESSOR
ATTACIIMENT
oTLAE-PX40100
1
CLUTCI{ DRUM
CLUTCHSPRING
COMPRESSOR
ATTACHMENT
07LAE- Px/Ol00
CLUTCH ot
COMPRESSOR 07HAE- PLs0100
BOLTASSEMBLY
07GAE - PG/O200
OTGAE- PG4O2OA
14-160
CAUTION: lf eithd end of the 3pocialtool issotoveran 5. Removethe snap ring. Then removethe specialtools,
area ot the spring rstainer which is unsupport€d by tho spring retainerand returnspring.
return spring, tho r€tain€l may be damagod. Bo eure the
special tool is adiusted to have full contact with tha
spring retainor.
Do not sat horo. SPRINGRETAIItIER
Wrap a shop rag aroundthe clutchdrum, and apply

air pressureto the ATF passageto remove the pis-
ron.
Placea finger tip on the other end while applying
air pressure.
OSHA.APPROVED
SPRINGRETAINER
4. Compfessthe returnsprang.
PISTON
14-161
Clutch
Reassembly
NOTE: 3. Installthe pistonin the clutchdrum, Apply pressure
. C l e a na l l p a r t st h o r o u g h liyn s o l v e not r c a r b u r e t o r and rotateto ensureproperseating,
cleaner,and dry them with compressedair.
Blow out all passages. NOTE:Lubricatethe pistonO-ringwith ATF before
a Lubricateall partswith ATF beforereassembly. installing.
1 . Inspectthe checkvalve;if it's loose,replacethe pis- CAUTION: Do not pinch the O-ring by insta ing the
to n. piston with too much force.
CLUTCIIDRUM
CHECKVALVE
2. Installnew O-ringson the clutchpiston.

I n s t a l lt h e r e t u r ns p r i n g a n d s p r i n g r e t a i n e r a
, nd
O RINGS positionthe snap ring on the retainer.
CLUTCI{DRUM
PISTON
14-162
5. Installthe specialtools as shown. CAUTION:lf eithe. end of the sDecialtool is set
over an area of the spring retainer which is unsup-
CLUTCHSPRING ported by the rsturn spring, the ietainer may be
COMPRESSOR damaged. Bs sure the specialtool is adjusted to
ATTACHMENT have full contact with the spring retainer.
07LAE- PX40100
CLUTCHSPRING Sot hsro.

COMPRESSOR
ATTACHMENT
07LAE- PX40100 Do not sot hore.
SPRING or
07HAE- P150100
SPECIAL TOOL
CLUTCH SPRING
COMPRESSOR
ATTACHMENT
07LAE-PX40100 RETAINER
6. Compressthe returnspring.
CLUTCHSPRING
COMPRESSOR
ATTACHMENT
07LAE- PX4010o
CLUTCHSPRING 07HAE- PL50100
COMPRESSOR
BOLTASSEMBLY
07GAE- PG40200
O7GAE. PG4O2OA
(cont'd)
14-163
Glutch
(cont'd)
Reassembly
7. Installthe
s n a pr i n g . 1 0 . Soakthe clutchdiscsthoroughlyin ATF for a mini-
mum of 30 minutes.
l l . Startingwith a clutch plate, alternatelyinstall the

clutch platesand discs.Installthe clutch end plate
with flat side toward the disc.
NOTE:Beforeinstallingthe platesand discs,make

sure the insideof the clutchdrum is free of din or
other foreign mafter.
CLUTCHENDPLATE
Installin this direcrion.
SNAP RING
8. Removsthe specialtools.
o Installthe discspring.
NOTE: Installthe disc spring in the direction

shown, except 2nd clutch.
12. Installthesnap ring.
SCREWDRIVER
SNAP RING
14-164
13. Measurethe clearancebetweenthe clutchend plate CLUTCHEND PLATE
and top discwith a dial indicator'Zero the dial indi-
catorwith the clutchend plateloweredand lift it up A4RA, g4RA Transmission:
to the snap ring. The distancethat the clutch end
platemovesis the clearancebetweenthe clutchend Plate No. Part Number Thickness
plateand top disc. ,l 22551- P4R- 003 2 . 1m m ( 0 . 0 8 3in)
2 22552-P4R-003 2.2 mm (0.087in)
NOTE|Takemeasurements in at leastthree places, 2 . 3m m ( 0 . 0 9 1i n )
J 22553-P4R-003
and usethe averageas the actualclearance. 4 22554-P4R-003 2.4 mm (0.094in)
5 22555-P4R-003 2.5 mm (0.098in)
Clutch End Plste-to-TopDisc Clearance: 6 22556-P4R-003 2 . 6m m ( 0 . 1 0 2i n )
1 22557-P4B-OO3 2 . 7m m { 0 . 1 0 6i n )
Clutch SerYiceLimit 8 22558-P4R-003 2 . 8m m { 0 . 1 1 0i n )
'14
1st 0.65- 0.85mm (0.026- 0.033in)
q
22559-P4R-003 2 , 9m m ( 0 . 1 i n )
2nd 0.65- 0.85mm (0.026- 0.033in)
3rd 0.40- 0.60mm (0.016- 0.024in) M,IRATransmi$ion:
4th 0.40- 0.60mm (0.016- 0.024in)
Plate No. Part Number Thickness
OIAL INDICATOR
1 22551- PCg- 000 2.4 mm (0.094in)
22552-PCg-000 2.5 mm (0.098in)
3 22553-PCg-000 2 . 6m m { 0 . 1 0 2i n )
22554-PCg-000 2 . 7m m ( 0 . 1 0 6in)
22555-PCg-000 2 . 8m m ( 0 . 1 1 0i n )
22555-PCg-000 2 . 9m m ( 0 . 1 1 4i n )
'l 3 . 0m m { 0 . 1 1 8i n )
22557-PCg-000
.' 22558-PCg-000 3 . 1m m ( 0 . 1 2 2in)
q
22559-PCg-000 3 . 2m m ( 0 . 1 2 6in)
10 22560-PCg-000 3 . 3m m ( 0 . 1 3 0i n )
11 22561- PCg- 000 2 . 1m m ( 0 . 0 8 2i n )
't2 22562-PCg-000 2.2 mm {0.086in)
CLUTCHEND Clearance
PLATE 13 22563-PCg-000 2.3 mm (0.090in)
14 22574- P4V- 003 3 . 4m m ( 0 . 1 3 4in)
CLUTCHDISC 15 22561- P4V- 003 3 . 5m m ( 0 . 1 3 8i n )
'16 22562- P4V- 003 3 . 6m m ( 0 . 1 4 2i n )
17 22563-P4V-003 3 . 7m m ( 0 . 1 4 6 in)
18 22564-P4V-003 3 . 8m m ( 0 . 1 5 0 in)
15. After replacingthe clutchend plate.make sure that

1 4 . l f t h e c l e a r a n c ei s n o t w i t h i n t h e s e r v i c el i m i t s , the clearanceis within tolerance.
select a new clutch end plate from the following
table.
NOTE: lf the thickestclutch end plate is installed,

but the clearanceis still over the standard,replace
the clutchdiscsand clutchplates.
PLATENUMBER Thickn6ss
CLUTCHENO PLATE
14-165
Differential
lllustratedlndex
SET RING, 80 mrrt
BOLT
1 0 r 1 . 0m m
'10'l N'm (10.3 k91.m,74.5 lbf.ftl
efef Left-hand threads
FINALDRIVENGEAR
Inspecttor excessivewear.
Installin this direction.
BALL BEARING
Inspectfor faulty movement.
DIFFERENTIALCARRIER
Insoectfor cracks,
ROLLER,5x10mm
SPEEDOMETER ORIVE
GEAR
lnstallin this direction.
SNAP RING
Installin this direction.
EALL BEARING
Inspectfor faulty movement-
14-166
Backlashlnspection BearingReplacement
1. Placedifferentialassemblyon V-blocksand install NOTE: Checkbearingsfor wear and rough rotation.lf
both axles. bearingsare OK, removalis not necessary.
1, Removebearingsusinga bearingpuller.
BEARINGPULLER
(Commerci6lly
available)
Checkbacklashof both piniongears
Standard {Now): 0.05- 0.15 mm {0.002- 0.006in)
lf backlashis out of tolerance,replacethe differen-

tial carrier. 2. Installnew bearingsusingthe specialtoolas shown.
14-167
Differential
DifferentialCarrierReplacement
L Removethe final driven gear from the differential 5. Align the hookedend of the snap ring with the pin-
carrier. ion shaft as shown,then installthe snap ring in the
differentialcarrier groovs.
threads. SNAPRING
Hookedend Installin this
Install thisdireclon.
direction.
Pry the snap ring off differentialcarrier,then remove
the speedometer drivegearand 5 x 10 mm roller.
SNAP RING
SPNI G PIN
Installthe final drivengear,then tightenthe boltsto

the specifiedtorque.
TOROUE:101 N.m (10.3kgf'm, 74.5 lbf.ftl

threads.
3. Installthe 5 x l0 mm rollerin the differentialcarrier,

BOLTS
1 0 r 1 . Om m
1Ol t{.m 11O.3kgf.m,
74.5 lbl.frl
Left-hand rhreads
FINALDRIVEN
GEAR
lnstallin this
direction.
DIFFERENTIAL
CARRIER
Installthe speedometerdrive gear with its cham-
fered side facingthe carrier.Align the cutouton the
bore of the speedometerdrive gear with the 5 x 10 7. Install a new ball bearing (se€ page 14-157).
mm roller.
14-168,
OilSealRemoval Oil SealInstallation/Side
Glearance
1. Remov€the differentialassembly. 1. Installa 2.50mm (0.098in) set ring,80 mm in trans-
missionhousing.
2, Removethe oil sealfrom the transmissionhousing,
NOTE:Do not installthe oil sealvet.
RING,80 mm
TRAITISMISSlON
OIL SEAL HOUS|l{G
Roplace.
R e m o v et h e o i l s e a l f r o m t h s t o r q u e c o n v e r t e r
housing. Installthe differentialassemblyinto the torquecon-
verterhousingusingthe specialtoolas shown.
OIL SEAL
Replace. I n s t a l lt h e t r a n s m i s s i o nh o u s i n ga n d t i g h t e nt h e
bolts{seepage 14-178and 14-179).
TOROUECONVERTEF
HOUSING
{cont'd)
14-169
Differential
Oil SealInstallation/Side (cont'd)
Clearance
4. Tap on the transmissionhousingside of the differ- 5. N4easure the clearancebetweenthe 80 mm set ring
entialassemblywith the specialtool to seatthe dif- and outer race of the ball bearinoin the transmis-
ferentialassemblyin the torqueconverterhousing. s i o nh o u s i n g .
0 - 0.15mm (0 - 0.006inl
STANDARD:
DRIVER40 mm l.D.
SET RING,80 mm
BALL BEARING
lf the clearanceis more than the standard,selecta

new set ring from the table,and install:
SETRING,80 mm

90414-689-000 2.50mm (0.098in)
904r5-689-000 2 . 6 0m m { 0 . 1 0 2i n )
90416-689-000 2 . 7 0m m { 0 . 1 0 6i n )
90417-689-000 2 . 8 0m m ( 0 . 1 1 0i n )
90418-689-000 2 . 9 0m m ( 0 . 1 1 4i n )
904r9-PH8-000 3 . 0 0m m ( 0 . 1 1 8i n )
NOTE:lf the clearancemeasuredin step 5 is stan-

dard, it is not necessaryto perform steps 7 and 8.
7. Removethe transmissionhousing.
Replacethe 2.50mm (0.098in) 80 mm set ring with

the one of the correctthicknessselectedin step6.
14-170
9. lnstallthe new oil seal flush with the transmission
housjngusing the specialtools as shown
DRIVER
077i(} - 0010000
PILOT. DRIVERATTACHMENT,68 mm
26x30mm 079i17-6110501
07JAO- PH80200
10. lnstall the new oil seal flush with the torque con-
verterhousingusingthe specialtoolsas shown
DRIVER
07749- 0010000
14-171
TorqueConverterHousingBearings
MainshaftBearing/OilSealReplacement
1. Removethe mainshaftbearingand oil seal using 2. Drive in the new mainshaft bearing until it bottoms
the specialtools as shown. in the housingusingthe specialtools as shown.
DRIVER
3/8"16 SLIOE
HAMMER 077€ - 0010000
ADJUSTAELEBEARING
PULLER,25 - ilo mm
07736- A01000a
lnstallthe new oil sealflush with the housingusing
DBIVER
07749 - 0o l0(xt0
ATTACHMENT,
72x75 mfi
07746- 0010600
1 4-1 7 2
CountershaftBearingReplacement
'1. Removethe countershaftbearingusing the special
tools as snown.
3,/8'.16SLIDEHAMMER
{Commerciallvavailable)
AOJUSTABLE
BEARING
PULLER,
25-{Omm
07736- A0'1000A
2. Installthe ATF guide plate.
5. Drive the new bearing into the housing using the

specialtools as shown.
ATTACHMENT,
62x68mm
0 - 0.03 mm
(0 - 0.001inl
14-173
TransmissionHousingBearings
Mainshaft/Countershaft
BearingsReplacement
L To removethe mainshaftand countershaftbearings Expandeach snap ring with snap ring pliers,insert
from the transmissionhousing,expand each snap t h e n e w b e a r i n gp a r t - w a yi n t o t h e h o u s i n gu s i n g
ring with snap ring pliers,then pushthe bearingout the specialtools and a press as shown, Installthe
usingthe specialtools and a pressas shown. bearingwith the groovefacingoutsidethe housing.
N O T E : D o n o t r e m o v et h e s n a p r i n g s u n l e s si t ' s NOTE:Coatall partswith ATF.

necessary to cleanthe groovesin the housing.
Releasethe pliers,then push the bearingdown into
PRESS the housinguntil the ring snapsin placearoundit.
\ 07749- 0010000
DRIVER
07749- 0010000
ATTACHMENT,
62x68mm
07746-
IRN
{L{r.)n
\bZ ATTACHMENT
. Mainshaft Bearing Removaluse:
077/16- 0010600
. Counte6haft Bsaring Removaluse:
MAINSHAFTBEARING ATTACHMENT,62 x 68 mm
07746- 0010500
DFIVEB
07749- 0010000
After installingthe bearingverifythe following:
TTACHMENT . The snap ring is seatedin the bearingand hous-

ing grooves.
. The ring end gap is correct.
ENDGAP:0-7mm
(0- 0.28in)
ATTACHMENT
. Mainshaft BearingInstallation us€:
ATTACHMENT.72 x 75 mm
07746- 0010600 SNAP RING
. Countershaft Bearing Installation use:
077/16- 0010500
14-174
Reverseldler Gear Park Stop
lnstallation Inspection/Adiustment
'1.
1, lnstallthe reverseidler gear. Setthe parkleverin the E position.
Measure the distance between the park pawl shaft

and the parkleverrollerpin as ahown.
STANDARD:72.9- 73.9 mm 12.87- 2.91 inl
/A\
Measuring
\v
Installthe reverseidler gear shaftholderand needle PARKPAWL

bearinginto the transmissionhousing,then tighten SHAFT
the bolts.
6 x 1.0 mm lf the measurementis out of tolerance,selectand

12 N.m ll .2 kgf'm, i n s t a l lt h e a p p r o p r i a t ep a r k s t o p f r o m t h e t a b l e
8.7 tbf.ftl Delow.
PARKSTOP
PARKSTOP
Mark Part Numb€r Lr 12
I 2 4 5 3 7 - P A g - 0 0 3 1 1 . 0 0m m 11.0m
0 m
(0.433in) (0.433
in)
2 4 5 3 8 - P A g - 0 0 3 1 0 . 8 0m m 10.65mm
(0.425in) (0.419
in)
2 4 5 3 9 - P A g - 0 0 3 1 0 . 6 0m m 1 0 . 3 0m m
(0.417 in) (0.406in)
After replacingthe park stop, make sure the dis-

GEAR tanceis within tolerance.
14-175
Transmission
Reasembly
NOTE;
. Coat all parts with ATF.
. Beplacethe followingparts:
- O-rings
- Lockwashers
- Gaskets
- Mainshaftand countershaftlocknutsand conical
springwashers
- Sealingwashers
TOROUE:l2 N.m (1.2 ksf'm,8.7 lbf.ft)
6 x 'l.0 mm
7 Bolts
FEEDPIPE:A
LOCK.UPVALVE DOWELPINS.2
BODY
6xl.0mm ATF STRAINER
LOCK.UPSEPARATOR 1 Bolt ATFFEED
PLATE PIPES:
a
REGULATOR
VALVE
BODY
DOWELPINS.
6x1.0mm
COOIERRELIEFVALVE 7 Bolts
SERVOBODY
TOROUECONVENIER
CHECKVALVE
STATORSHAFT SERVOSEPARATOR
PLAYE
O.RING
STOPSHAFT
ATF FEEOPIPE:H
5x1.0mm
5 Bolts
MAIN VALVEBODY
ATF PUMP
SECONOARY
GEARSHAFT
SEPARATORPLATE
ATF PUMPDFIVEN
GEAR CONTROL
/ SHAFI
MAIN SEPARATOR - t'se- ooôd"t"t
PLATE '
7r(
DOWELPINS,
TOROUECONVERTER
HOUSING
lli
tri
NOTE:The illustrationshows the'96 - 98 modsls,the'99 - 00 modelsdo not havethe servo
detentbase;the servo
detentis integralwiththe servobodv.
1 4-1 7 6
1 . Installthe ATF magnetand suctionpipe collarin the Installthe servo body and separatorplate on the
torqueconverterhousing.if necessary. secondaryvalve body ('95 - 98 models: seven bolts.
'99 - 00 models:eight boltsl.
lnstallthe main seDaratorplate and the two dowel
pins on the torqueconverterhousang.
Installthe ATF pump drive gear,ATF pump driven a For '96 - 98 models: Installthe servo detent base
gear and ATF pump driven gear shafton the torque and the ATF strainer(two boltsl.
converter housing. For'99 - 00 models: Installthe ATF strainer (one
bolt).
NOTE; Install the ATF pump driven gear with its
groovedand chamferedsidetacingdown. 1 0 . Tightenthe five bolts on the main valve body to 12
ATFPUMP N.m ('1.2kgf.m,8.7lbf.ft).
Makesure the ATF pump drive gear and ATF pump
drivengearshaft move smoothlY'
1 1 . lf the ATF pump drive gsar and ATF pump driven

gear shaft do not move freely, loosen ths five bolts
ATF PUMPDRIVEN on the main valve body, and disassemble the valve
GEARSHAFT
bodies.
Realignthe ATF pump driven gear shaft and reassem-
ATF PUMP ble the valve bodies,then retighten the bolts to the
DRIVENGEAR specifiedtorque,
Groovedand chamfered CAUTION: Fsilule to align tho ATF pump driven

side taces separalor MAIN SEPARATOR
PLATE goar shaft corr.ctly will rscuh in a s€izedATF pump
plate.
drive goar or ATF pump d ven gear shaft.
4. Loosely install the main valve body with five bolts.
Make sure the ATF pump drive gear rotatessmoothly
in the normal operating direction and the ATF pump
driven gear shaft moves smoothly in the axial and
normaloperatingdirections.
Install the secondaryvalve body, separatorplate
and two dowel pinson the main valvebody.
NOTE:Do not installthebolts.
6. Installthe controlshaft in the housingwith the con-

trol shaftand manualvalvetogether.
7. lnstall the detent arm and arm shaft in the main PUMP
valve body, then hook the detentarm springto the
detent arm,
PLATE
SERVOSEPARATOR
1 2 . Installthe stator shaft and stop shaft.
't3. Installthe bolts and the shaftstop on the secondary
valve body, then tighten the bolts (three boltsl.
1 4 . Installthe torqueconvertercheckvalve,coolerrelief
valveand valvespringsin the regulatorvalve body.
then install the regulatorvalve body on the main
valve bodv (one bolt).
DETENTARM SPRING
DETENT
1 5 . Installthe lock-upvalve body on the regulatorvalve
bodv (sevenbolts).
MANUAL VALVE Installthe ATF feed pipes in the main valve bodY,
the threeATF feed pipesin the secondaryvalveand
the four ATFfeed pipesin the servobody. (cont'dl
14-177
Transmission
(cont'd)
Reassembly
TRANSMISSIONHOUSING
TRANSMISSION MOUNTINGBOLTS
HANGER 10 x 1.25mm
*'' 4{ N.m {4.5 kg{.m,33 lbI.ft)
Ufln TRANSMISSION
HOUSING
REVERSEGEAR
MAINSHAFT
SUB.ASSEMBLY
$*U./ COLLAR
REVERSE
GEAR
_\,]ffil LOCKWASHER
SHIFTFORK
MAINSHAFTSPEED COUNTERSHAFT
SENSOR WASHER SUB.ASSEMBLY
(D16Y7engine)
MAINSHAFT
SPEED
OIFFER€NTIAL
ASSEMBLY
TRANSMISSION
HOUSINGGASKET
TOROUECONVERTER
HOUSING
14-178
reversegear
2 1 . lnstallthe needlebearing,countershaft
1 7 . l n s t a l lt h e r e v e r s ei d l e r g e a r a n d t h e g e a r s h a f t
h o l d e r( s e ep a g e1 4 - 1 7 5 ) . and reversegearcollaron the countershaft.
1 8 . lnstallthe differentialassemblyin the torque con- 22. Align the spring pin on the control shaft with the
verterhousing. transmissionhousinggrooveby turningthe control
shaft.
1 9 . A s s e m b l et h e m a i n s h a f ts u b - a s s e m b l ya n d t h e SPRINGPIN
c o u n t e r s h a fst u b - a s s e m b l yt ,h e n i n s t a l lt h e m CONTROLSHAFT
togetherin the torqueconverterhouslng
MAINSHAFT
SUB-ASSEMBLY
COUNTERSHAFT
SUB.ASSEMBLY
Installthe two dowel pins and a new gasketon the

torqueconverterhousing.
24. Placethe transmissionhousingon the torque con-

verterhousing.
CAUTION: Make sure that lhe mainshaft speed

sensor is not installed on the transmission housing
before installing the transmission housing on the
20, Turn the shift fork so the large chamferedhole is torque conv€rter housing.
tacing the fork bolt hole, then install the shift fork
with the reverseselector,and tighten the lock bolt' l n s t a l lt h e t r a n s m i s s i o nh o u s i n gm o u n t i n g b o l t s
Bendthe locktab againstthe bolt head a l o n g w i t h t h e t r a n s m i s s i o nh a n g e r ,t h e n t i g h t e n
the bolts in two or more steps in the sequenceas
shown.
SHIFTFORK TOROUE:,l,t N'm l{.5 kgf'm, 33 lbf'ft}

TRANSMISSION
LOCKWASHER HANGER
Replace.
6 x 1.0mm
4 N.m
('l.4 kgl'm, 1O lbt'ft)
Large chamtered hole
(cont'di
14-179
Transmission
(cont'dl
Reassembly
26. Slipthe specialtool onto the mainshaftas shown, 3 1 . I n s t a l lt h e m a i n s h a f t1 s t g e a r c o l l a ro n t h e m a i n _
shaft.
MAINSHAFTHOLDER
07GAB- PF50101 32. Wrap the shaft splineswith tape to preventthe O-
rings,then installnew O-ringson the mainshaft,
33. Assemblethe thrust washer,thrust needlebearing,

needle bearing,and mainshaft?st gear in the lst
clutchassembly,then installthem on the mainshaft.
34. Installnew conicalspring washersand locknutson

eachshaft.
CAUTION: Install the conical spring washers in the

direction shown.
27. Installtheparkleveron the controlshaft.
MAINSHAFT
28. A s s e m b l et h e o n e - w a yc l u t c h a n d t h e p a r k g e a r LOCKNUT
with the countershaftlst gear(seepage l4-1S5). Left handthreads
29. Installthe countershaftlst gear collar.needlebear_

ing, and the countershaft1stgearlparkgear assembly
on the countershaft.
lSTCLUTCH PARK
ASSEMBLY GEAR
CONICAL SPRING WASHERS

installin thisdirection.
35. Tightenthe locknutsto the specifiedtorque.
NOTE:
. D o n o t u s e a n i m p a c t w r e n c h .A l w a v s u s e a
torque w.ench to tighten the locknut.
30. Installthe park pawl shaft, spring, pawl, and pawl . Mainshaftand countershaftlocknuts have left_
stop on the transmissionhousing,then engagethe handthreads.
parkpawlwith the parkgear.
TOROUE:
MAINSHAFT 78 N.m (8.0 kgf.m, 58 tbf.ft)
COUNTERSHAFTt03 N.m 1r0.5kgf.m, 75.9 tbt.ftl
14-180
40. Instslltheend coverwith two dowel pinsandanew
36. Removethe specialtool from mainshaft,then stake
gasket(thirteen bolts)'
eachlocknutusinga 3.5 mm punchas shown'
TOROUE:12 N'm (1.2tgf'm. 8.7 lbf'ft}
COUNTERSHAFT
LOCKNUT
0.7- 1.2mm
(0.03- 0.05 in)
ENDCOVER
a'f Set the park lever in the El position, then verify that
4 1 . lnstall the ATF cooler lines with new sealing wash-
the park Pawl engagesthe Parkgear
9rs.
38. lf the Dawl does not engagefully, checkthe park
pawl stop clearance(see page 14-175). TOROUE:28 N.m {2.9 kgf'm. 21 lbt'ft1
Installthe ATF diPstick.

ao Tighten the lock boll and bend the lock tab'
Erl.Omm
14 t{.m (1.4 kgf'm, 10 tbl.ftl
\.- (o)
LOCK
WASHEF
14-181
Torque Converter/Driveplate
6x1.0mm
12 N.m (1.2 kgt.m, 8.7 lbf.ft)
74 N.m 17.5 kgl.m, 54 lbf.ftl

Torque in a ctisscaossoattern.
E PLATE
14-182
Transmission
lnstallation
1. Flushthe ATF cooler as describedon page l4-187 6. Installthe transmissionmount bracket.
and 14-188.
12 x 1.25mm
Install the torque converter assembly securely with 6il N.m {6.5 kgf.m, a7 lbf'ft)
a new O-ringon the mainshaft
45 N.m {4.5 kgf.m,

MOTOR
STARTER
14 mm DOWELPIN
TOROUE O-RING PIN

lil mm DOWEL TRANSMISSIONMOUNT
12 x 1.25mm
CONVERTER Replace 74 N.m (7.5 kgf.m,
54 tbt.fr)
lnstall the starter motor on the torque converter
housing,then installthe two 14 mm dowsl pins in
the torqueconverterhousing. 7. Installthe remainingtransmissionhousing mount-
ing boltsand remainingrearenginemountingbolt.
Placethe transmissionon a jack,and raiseit to the
REARENGINE
engineassemblylevel. MOUNTINGBOLT
14 x 1.5mm
Attach the transmissionto the engine,then install el N.m (8.5 kgt'm,
two transmissionhousingmounting bolts and two 61 tbl.ft)
rearenginemountingbolts. Replace.
REARENGINE
MOUNNNG BOLTS
1,1r15mm
TRANSMISSIONHOUSING &| N.m 18.5kgf m, 61 lbf'ft]
MOUNTINGBOLTS Replace.
12x 1.25mm
64 N.m {6.5 47 tbf frl
WASHER
HOUSING
MOUNTINGBOLTS
12 x 1.25mm
ENGINE g N m (6.5kgf m, 'l? lblftl
MOUNTING
BRACKET
8. Remove the transmission jack.
(cont'd)
JACK
14-183
Transmission
Installation(cont'dl
9. Attach the torque converter to the drive plate with 14. Installthe control lever with a new lock washerto
eight drive plateboltsand torqueas follows: the controlshaft,then installthe shift cablecover.
Rotatethe crankshaftpulleyas necessaryto tighten
the bolts to 1/2 of the specified torque. then to the CAUION: Taks care not to bend the shift cable.
final torque, in a crisscrosspattern.
After tighteningthe last bolt, checkthat the crank- SHIFTCABLE
shaft rotatesfreely.
TOROUE:12 N.m {1.2 kgl.m, 8.7 tbt{r}
10x 1.25mm
4,r N.m 14.5kgf.m,33 lbtft)
L(rcK WASHER
Replace.
6x1.0mm
12 N.m (1.2kgt m, 8 x 1,25r'|m
8.7 rbt ft) 22N-m
12.2tgt m. 16lbnftl
SHIFT CAAE COVER x 1.0mm

tit N.m11.4kgtm,
I \ 1.25mm 10tbr,ft,
2/t N.m {2.4kg{.m,
17 tbt ftl CONVERTEB 15. lnstallthe exhaustpipeA.
COVER
NOTE: D16Y8engine is shown; D16y/ engine is sim_
10. Installthe torque convener cover and the €ngine ilar.
stiffener.
'11. Tighten
the crsnkshaft pull€y bolt, if necessary(see
section61.
12. Connectthe ATF cooler hosesto the ATF cooler lines
(seepage1,t192).
ATF COOIIR
UNE
Replace.
SELF.LOCKING NUT
Replace.
10 x 1.25mm GASKET 10 x 1.25mm
a,l N.m {4.5kgl.m, Replace. 54 N.m (5.5 lgf.m,
33 rbt.ftt 40 tbt ftl
RIGHTFRONT 12 x 1.25mm SELF.LOCKING NUT NUT
MOUNT/BRACKET6.t N.m (6.5kg{.m,
Replace. Replace.
47 tbt ftl 8 x 1.25mm 8 x 1.25mm
22 N.m {2.2 kgl.m, 16lbtfrl 16 N.m {1.6kgI.m,
12 tbf.ft)
13. Installthe rightfront mounvbracket.
14-1A4
16. Installa new set ring on the end of eachdriveshaft' 20. Connectthe mainshaftspeedsensor,the linearsole-
17. Installtheright and left driveshafts(seessction16) noid and the shift controlsolenoidconnectors.
CAUTION: Whil6 installing the driveshafE in the
diffarential, be surs not lo allow du3t and othor for-
SOLENOIO
SHIFTCONTROL LINEAR
SOITNO|o
eign particl€s to enler into the transmission. CONNECTOR
CONNECTOR
NOTE:
. Cleanthe areaswhere the driveshaftscontactthe 6 r 1.0mrn
transmission(differential)thoroughly with sol- 12 N.m (1.219f.m,
E.7lbf.frl
vent or carburetorcleaner,and dry with com-
pressedair.
. Turn the right and left steeringknucklefully out-
ward, and slide each driveshaft into the differen-
tial until you feel its set ring clip engagethe side
gear.
18. Installthe damperfork,then installthe rightand left
ball jointsto the eachlower arm with the castlenuts
and new cotter Plns.
DAMPERPINCHBOLT
10 x 1.25 mm
a3 N.m l4.iakgf.m,
32 tbl.ftl
CONNECTOR
21. Connectthe countershaftspeed sensor and the vehi-

cle speedsensor (VSS)connectors.
SPEED
VEHICI..E
SENSOR CONNECTOR
4l
COTTER
SELF.LOCKING NUT CASTLENUT Replace.
12 x 1.25mm 12 x 1,25mm
-
49 59 N.m
6il N.m t6.5 kgf'm, il7 lbf ftl
Replace. {5.0- 6.0 kgf m, 36 - iB lbf'ft|
19. Install the splash shield.
COUNTERSHAFT
SPEEDSENSOR
CONNECTOR
(cont'dl
14-185
Transmission
Installation{cont'd)
Connectthe lock-upcontrolsolenoidconnector.and 24. Installtheintakeair duct.
installthe transmissiongroundcable.
D16Y7engine:
Installthe intakeair duct and the resonaror.
6 x '1.0mm
12N.m{1.2kgf.m,8.7lbl.ft}
D16Y8engine:
lnstallthe intakeair duct and the air cleanerhous_
angassembly.
25. Refillthe transmissionwith ATF (seepage 14_1.18).
26. Connectthe positive(+) cable first. then the nega-

tive (-) cable to the battery.
27. Checkthe ignitiontiming (seesection23).
28. Startthe engine.Setthe parkingbrake,and shift the

transmissionthrough all gears.three times. Check
the shift cableadjustment(seepage14_190).
29, Checkthe front wheelalignment(seesection1g).

TRANSMISSION LOCK.UPCONTROL
GROUNDCABLE SOLENOIDCONNECTOR
3 0 . L e t t h e e n g i n e r e a c ho p e r a t i n gt e m p e r a t u r e( t h e
cooling fan comes on) with the transmissionin N
or @ position,then turn it off and checkthe fluid
Connectthe stanercableson the stanermotor.and level(seepage 14- 7).
installthe cableholder.
31. Roadtest as describedon pages14-113thru ,14_116.
NOTE; When installingthe starter cable terminal.
makesurethat the crimpedside of the ring terminal
is facingout (seesection23).
6x1.0mm
12 N.m 11.2kg{.m.8.7tbtftl
{0.9kg'f.m,7 lbf.ftl
STARTERCAELE
14-186
CoolerFlushing
To prevent iniury to.face and eyas, always 7. With the water and air valvesoff, attachthe water and
!!!@ to the flusher'lHotwaterif available.)
air suDolies
-ea. safetv glasses ot a face shield when using the
transmissionflusher.
NOTE:This procedureshouldbe performedbeforerein-

stallingthe transmission.
1. Checkthe tool and hosesfor wear and cracksbefore

using.lf wear or cracksare found,replacethe hoses
beforeusing.
Usingthe measuringcup,fill the tankwith 2'l ounces

(approximately2/3 full) of biodegradableflushing
fluid (J35944- 20).Do not substitutewith any other
f l u i d . F o l l o wt h e h a n d l i n gp r o c e d u r eo n t h e f l u i d
contarner.
Securethe flusherfiller cap, and pressurizethe tank

with compressedair to between 550 - 829 kpa (5 6 - 8, Turn on the flusherwater valve so water will flow
80
8.45kgflcm' . - 120Psi). throughthe coolerfor 10 seconds.
NOTE:The air line shouldbe equippedwith a water NOTE;lf water does not tlow throughthe cooler,it
trap to ensurea dry air system. is completelyplugged.cannotbe flushed,and must
be replaced.
Hangthe tool underthe vehicle.
9. Depressthe trigger to mix the flushing fluid into the
Attach the tank's dischargehose to the return line water flow. Usethe wire clip to hold the trigger down'
of the transmissioncoolerusinga clamp.
1 0 . While flushingwith the water and flushingfluid for
Connectthe drain hoseto the inlet line on the trans- two minutes,turn the air valve on for five seconds
missioncoolerusinga clamP everv 15- 20 secondsto createa surgingaction'
AIR PRESSURE: MAX 845 kpa{8.45kgf/cm' ,120psi)
IMPORTANT: ' 1 1 .Turn the water valve off. Releasethe trigger,then
Securelyclampthe oppositeend oJthe drain hoseto a
bucketor floor drain. reversethe hosesto the coolerso you can flush in
the oppositedirection.Repeatsteps8 through 10'
TRANSMtssroN
I
12, Releasethe trigger,and rinsethe coolerwith water
onlv for one minute
13. Turn the water valveoff, and turn off the water supply
14. Turn the air valve on to dry the systemout with air
for two full minutesor until no moistureis visible
leavingthe drain hose.
CAUTION: Residualmobturo in tho cooler or pipas

can damagethe transmksion'
{r Water
15. Removethe flusherfrom the coolerline.Attachthe
drain hoseto a contalner.
TRANSMISSIONCOOLER
FLUSHER 16. Installthe transmission,and leavethe drain hose
{Commcrci.llYavail.blel attachedto the coolerline
Kent-MooreJ384O5'A
or equivelent
{cont'd)
14-187
Transmission
CoolerFlushing(cont'dl
1 7 . Makesurethe transmissionis in the E position. TOOL MAINTENANCE
Fill the transmissionwith ATF, and run the engine
for 30 secondsor until approximately0.95f (1.0US 1. Empty and rinseafter each use.Fill the can with water
qt.,0.8lmp qt.) is discharged. and pressurizethe can. Flushthe dischargeline to
ensurethat the unit is clean.
1 8 . Removethe drain hose, and reconnectthe cooler
returnhoseto the transmission(seepage l4-192). 2. lf dischargeliquiddoes not foam,the orificemay be
blocked.
1 9 . Refillthe transmissionwith ATF to the oroDerlevel
(seepage 14-118). 3. To clean,disconnectthe plumbingfrom the tank at
the largecouplingnut.
FILLERCAP
ORIFICE
GRT{G
Removethe in-line filter from the dischargeside and

clean if necessary.
The fluid orifice is tocatedbehind the filter.

Clean it with the pick stored in the bottom of the
t a n k h a n d l e ,o r b l o w i t c l e a n w i t h a i r . S e c u r e l v
reassembleall Darts.
14-18A
Shift Cable
Make sure lifts are placed properly (see 4. Removethe shift cableholder.
!@@
seqtion1).
5. Bemovethe shift cablecover.
1. Removethe front console(seesection20).
6. Removethe control Iever from the control shaft,
2. Shift to E position,then removethe lock pin Jrom then remove the shift cable. Take care not to bend
the cablewhen removing/installing it
the adjuster.
I x '1.25mm SHIFTCABLEHOLDER
22 N.m
12.2kgl'm.
16 tbl.ftl SHIFTCABLE
6x1.0mm
12 N.m
LOCKWASHER ('1.2ksf.m,
Replace. 8.7 rbtftl
6 x 'l.0mm
CONTBOLLEVER 14 N.m
(!.il kgt.m. 10lbl.ftl
7. lnstall the shift cable in the reverseorder of removal'

SHIFTCABI.f
C h e c kt h e c a b l e a d j u s t m e n to n r e a s s e m b l y( s e e
7 N.m page 14-190).
(07kst'm,5lbl'ftl
3, Remove the shift cable bracket.
SHIFTCABLE 6x1.0mm
BRACKET 9.8 N.m
{1.0kgf m, 7.2
14-189
Shift Cable
Adjustment
@ Make sure lifts are ptaced properly (see 3 . C h e c kt h a t t h e h o l e i n t h e a d j u s t e r i s p e r f e c t l y
section1). alignedwith the hole in the shift cable.There are
two holes in the adjuster.They are positioned90.
1. Removethe front console(seesectionZ0l. apart to allow cable adjustmentin 1/4 turn incre-
ments.
2. Shift to @ position.then removethe lock pin from
the adiuster.
Cable Cable Exact

Too Short Too Long Alignment
4. lf the hole is not perfectly aligned, loosen the lock-

nut on the adjusterand adjustas required.
5. Tightenthe tocknutto 7 N.m (0.7kgf.m,5 tbf.ft).
6. Installthe lock pin on the adjuster.lf you feel the

lock pin binding as you reinstallit, the cableis still
out of adjustmentand must be readjusted.
7 . M a k e s u r e t h e l o c k p i n i s s e a t e di n t h e a d j u s t e r
securetv.
8. Move the shift lever to each gear, and verify that the
shift positionindicatorfollows the automatictrans-
7 N.m (0.7kgtm. axlegear positionswitch.
5 tbtftl
9 . S t a r t t h e e n g i n e ,a n d c h e c kt h e s h i f t l e v e r i n a l l
gears. lf any gear does not work properly, refer to
troubleshooting (seepage 14-109thru 1'4-'112).
10. Insertthe ignition key into the key cylinderon the

Ay'Tgear positionindicatorpanel,and verifythat the
shift lock leveris released.
14-190
Shift Lever
PUSHKNOBSPRING
SCBEW
N.m {0.3kgtm.2 lbf ft)
Apply non-hardeningthreadlocksealant
SCREW
SILICONEGREASE 3 N.m {0.3kgifm,2 lblft)
GEARPOSITIONINDICATORPANEL
COVER
BUSHING
SHIFTINDICATOR -61
LEVER SILICONEGREASE
SHIFTLOCK
SCREW SHIFTLEVERASSEMBLY
3 N.m {0.3
2/""*"
,.@
* _.\__r.\
6x1.0mm
9.8 N.m {1.0kgf.m,
-Rt \ooru.r.,
7.2 tbt.ft)
A/T GEARPOSITION
PLATE
A/T GEARPOSITIONSWITCH
SHIFTLEVERBRACKETBASE
SHIFTLEVER
BASECOLLAA
6x1.0mm
9.8 N.m 11.0kgf.m.7.2lbf.ft)
14-191
Shift Indicator Panel ATFCoolerHoses
Adiustment Connection
'1.
Checkthat the index mark on the indicatoralions 1. Connectthe ATFcoolerhosesto the ATFcoolerlines
with the N mark on the shift indicatorpanelwhen and ATF cooler,and securethem with the clips as
the transmissionis in NEUTRAL. shown.
INDEXMARK
TRANSMISSION CLIP
3 N.m {0.3 kgf.m, 2lbt.ftl
lf not aligned.removethe front console{seesection

20t.
Removethe shift indicatorpanel mounting screws

and adjustby movingthe panel,
NOTE:Wheneverthe shift indicatorpanelis removed,

reinstallthepanelas describedabove,
14-192
ContinuouslyVariableTransmission(CVTI
S p e c i aTlo o l s . . . . . . . . . . . . . .1. 4 . -194 lllustratedIndex
Description . . . . . . . . . . . . . . . . .1. 4 . .- 1 9 5 Transmission/Lower ValveBodY
Assembly . . . . . . . . . . . . .1. .4. -. 3 0 8
Clutches/Reverse Brake/Planetary
. . . . . . . . . .1 4 - 1 9 8 Transmission Housing/Flywheel Housing ... 14-310
Gear/Pulleys
p o w e rF l o w ..............1 , .4. .-.2. 0 0 EndCover/f ntermediateHousing ..........'.'.... 14-312
ElectronicControlSYstem TransmissionHousing/
(,96- 98 Modets) ......14-203 Lower Valve Body Assembly
R e m o v a l. . . . . . . . . . ' . . . . .. " 14-314
ElectronicControl System
('99- oo Models) " 14-205 TransmissionHousing/Flywhesl Housing
'....... 14-208 Removal................. ........1+316
HydraulicControl
'14-212 EndCover/lntermediate Housing
HydraulicFlow .'..-.....'...
.....-...'.' 14-222 Removal.........,............... 14-318
ParkMechanism
EleqtricalSystom Manual Valve Body
Disassembly/lnspection/Reassemblv .'.'.'.....14-320
ComponentLocations
'96 - 98 Models """"""' 14-224 Forward Clutch
,99- 00 Modets ............. 14-225 l l t u s t r a t eIdn d e x . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1. .4.-. 3 . .2. .1.
.................. 14-322
TCM CircuitDiagram('96- 98 Models)............. 14-226 Disassemblv
Reassemblv , ,, . ',','......14-324
TCM Terminal Voltage/
MeasuringCondiiions('96- 98 Models) '....14-228 SecondaryGear Shaft
PcM CircuitOiaqram '99 25 x 35 mm ThrustShim Selection..'.'....-...14-324
{A/TControlSystem: - 00 Models}...--.... 14-230 Differential
PCMTerminalVoltage/Measuring Conditions lllustratedlndex ...,.....................,.,...-.-.-...'... 14-329
('99- 00 Models) BacklashInspection .-....14-329
A/4 ControlSystem .'.'...14-232 ....'...14-330
'14-234 BearingReplacement......'........'....'...
Troubleshooting Procedures ... . .........',........."' 14-330
DifferentialCarrierReplacement........'........
Symptom-to-ComPonent Chart Oil SealRemoval ........... 14-331
'96 - 98 Models......'..... '14-234
ElectricalSystem- Oil SealInstallation/Side Clearance ....... . . 14-331
'11-210
ElectricalSystem-'99 - 00 Models..'....-..-. FlywheelHousingInputShaftOil Seal
Electrical Troubleshooting Replacement .....,.... ...'.'..14-333
Troubleshooting Flowcharts TransmissionHousingBearings
('96- 98 Models) """'11-242
Driven Pulley Shaft Bearing
Troubleshooting Flowchart Replacenient ...................'. . ...................'.. 14-334
('99- 0OModets) ......14-265 Shaft Bearing
SecondaryGear
LinearSolenoids/lnhibitor Solenoid Reolacbment ...................... . .......... . ........14-335
T e s t. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1. 4 - 2 9 f FlywheelHousing Beating
DrivePulley/Driven Pulley/Secondary Gear SecondaryGear Shaft Bearing
Shaft Speed Sensors R e o 1 a c e m e n t . . . . . . . . . . . . . . . . . . , . . . . . . . . .1. .4.-. 3 . .3. .5. . . . . . . . . .
Replacement .........'...... .14-292 RingGear Bearing
Start Clutch Control Replacement......... . . . . . . .1.4 - 3 3 6
StartClutchCalibrationProcedure...........,. 14-293 Control Shaft Assembly
HydraulicSYstem R e m o v a l / l n s t a l l a t.i .o. n .................'.....1 . .4. .-.3. 3 6
Symptom-to-ComPonent Chart Transmission
HydraulicSystem '.'.......14-294 Reassembly .................. 14-338
R o a dT e s t . . . . . . . . . . . . . . . . . . . .1. 4
. .-.2. .9. .6 Flywheel/Drive Plate .. . ....... ......... . ....-.....'.'...14-341
StallSpeed Transmission
Test......................... ......14-294 lnstalation ..................... 14-348
FluidLevel CoolerFlushing .'.........14-352
Checking/Changing .......14-299 shift cable
Pressure Testing ................. 14-300 Removal/lnstallation....'........." """ 14-354
LowerValveBodYAssemblY Adjustment . . . . . . . ' . . . . . . .1. 4 - 3 5 5
Replacement . . . . . . . . . . , . .1.4 - 3 0 2 S h i f tL e v e r . . . . . . . . . . . . . . . . . .1 . .4. .' .3.5, .6
ATF Filter Shift IndicatorPanel
Removal/lnstallation .....14-303 Adjustment ..............1 . .4 - 3 5 7
Transmission ATF Cooler/Hoses
Transmission l n s t al l a t i o n. . . . . . , , . . . . . . .... 14-357
R e m o v a.l . . . . . . . . . . . 14-304

SpecialTools
Ref. No. I Tool Number

o 07GAE- PG40200 ClutchSpringCompressorBoltAssembly I 't4-322,325
@ 07JAD- PH80200 Pilot.26 x 30 mm 1 14-333
alr * 07LAE- PX40100 ClutchSpringCompressorAttachment 2 14-322,325
@ 07PM- 0010100 SCSServiceConnector I 't4-235,293
07sM- 0010004 BackprobeSet a 14-236, 296
07TAE- P4V01l0 ReverseBrakeSpringCompressor ,l
r4-319,339
o 07TAE- P4V0120 Stan ClutchRemover 1 't 4-311
@ 07TAE- P4V0130 Stan ClutchInstaller 1 14-342,343
6l 07tvlAJ- PY4011A A/T Oil PressureHose,2210mm 't4-300
@ 07MAJ- PY40l20 Ay'TOil PressureHose,Adapter 14-300
o 07406- 0020400 Ay'TOil Pressurecauge Set Wpanel 1 14-300
@ 07406- 0070300 Ay'TLow PressureGaugew/panel ,1
14-300
@-" 07736- A0r 0004 AdjustableBearingPuller,25 - 40 mm 1 14-335
@ 07746- 0010100 Attachment,32 x 35 mm 1 14-333,
336
@ 07746- 0010500 Attachment,62 x 68 mm '1
14-335
@ 07746- 0010600 Attachment,72 x 75 mm I 14-334,
335
o 07746- 0030100 Driver40 mm l.D. 1 14-330,
331
@ 07749- 0010000 Driver 1 14-333,
334,335,
336
0 7 9 4 7- 6 1 1 0 5 0 1 Driver Aftachment,68 mm 14-333
01947 - 6340201 DriverAttachment,58 x 72 mm 14-333
*07HAE- PL5010lcan be usedas a substitute.
**Must be usedwith commercially-available
3/8.,- 16 slidehammer.
E*E
o
e @
1:,'Jt*
dAt:-
IR
>.'.--t-'- t'
\;4
aio o e' io(313
@ 18l
@ @
@
@
14-194
Description
The ContinuouslyVariableTransmission(CVT)is an electronically

controlledautomatictransmissionwith drive and driv
en Oullevs,and a steelbelt.The CVTprovidesnon stagespeedsforward and one reverse.The entireunit is positionedin
l i n ew i t ht h e e n g i n e .
Transmission
Aroundthe outsideof the flywheelis a ring gear which mesheswith the starterpinion when the engineis being staned.
The transmissionhasfour parallelshafts:the input shaft,the drive pulleyshaft.the drivenpulleyshaft,and the secondary
gearshaft.The input shaftis in linewith the enginecrankshaft. The drive pulleyshaftand the drivenpulleyshaftconsistof
movableand fixed face pulleys. Both pulleys are linkedby the steelbelt.
The input shaft includesthe sun gear.The drive pulleyshaft includesthe forwardclutchwhich mountsthe carrierassem-
bly on the forwardclutchdrum. The carrierassemblyincludesthe piniongearswhich meshwith the sun gearand the ring
gear.The ring gear hasa hub-mountedreversebrakedisc.
The drivenpulleyshaft includesthe startclutchand the secondarydrive gearwhich is integralwith the parkgear'The sec-
ondary gear shaft is positionedbetweenthe secondarydrive gear and the final driven gear.The secondarygear shaft
includesthe secondarydriven gear which servesto changethe rotationdirection.becausethe drive pulleyshaft and the
driven oullev shaft rotate the same direction.When certain combinationsof planetarygears in the transmissionare
engagedby the clutchesand the reversebrake,power is transmittedfrom the drive pulleyshaftto the driven pulleyshaft
to provideE, E, E, and El.
ElectronicControl
'96 - 98 Models:
The electroniccontrolsystemconsistsof the TransmissionControlModule (TCM),sensors,three linearsolenoids,and a
controlledunderall conditions'
inhibitorsolenoid.Shiftingis electronically
The TCM is locatedbelow the dashboard, behind the kickpanelon the driver'sside.
'99 - 00 Models:
The electroniccontrol svstem consistsof a PowertrainControl Module (PCM),sensors,three linear solenoidsand an
inhibitorsolenoid.Shiftingis electronicallycontrolledunderall conditions.A GradeLogicControlSystemto controlshift-
ing in E positionwhile the vehicleis ascendingor descendinga slope.
The PCMis locatedbelowthe dashboard,underthe kickpanelon the passenger's side.
HydraulicControl
The lower valve body assemblyincludesthe main valve body,the PressureLow (PL)reguiatorvalvebody,the shift valve
body, the start clutch control valve body, and the secondaryvalve body. They are positionedon the lower part of the
t r a n s m i s s i ohno u s i n g .
The main valvebody containsthe PressureHigh (PH)controlvalve,the lubricationvalve,and the pitot regulatorvalve.
The secondaryvalve body containsthe PH regulatorvalve,the clutchreducingvalve,the startclutchvalve accumulator,
and the shift inhibitorvalve.The PL regulatorvalve body containsthe PL regulatorvalve and the PH-PLcontrol valve
which is ioinedto the PH,PLcontrollinearsolenoid.The inhibitorsolenoidvalveis boltedon the PLregulatorvalvebody.
The shift valvebody containsthe shiftvalveand the shift controlvalve.which is joinedto the shift controllinearsolenoid.
The startclutchcontrolvalve body containsthe startclutchcontrolvalve,which is joinedto the startclutchcontrollinear
solenoid.The linearsolenoidsand the inhibitorsolenoidare controlledby the TCM or PCM.The manualvalvebody which
containsthe manualvalveand the reverseinhibitorvalve,is boltedon the intermediatehousing.
The ATF pump assemblyis locatedon the transmissionhousing,and is linkedwith the input shaft by the sprocketsand
feed pipes,and the reversebrakereceives
the sprocketchain.The pulleysand the clutchreceivefluid from their respective
fluid from internalhydrauliccircuit.
Shift Control Mechanism

Inputfrom varioussensorslocatedthroughoutthe vehicledetermineswhich linearsolenoidthe TCM or PCMwill activate.
Activatingthe shift controllinearsolenoidchangesthe shift controlvalve pressure,causingthe shift valveto move.This
pressurizes the drive pulley pressureto the drive pulleyand the driven pulley pressureto the driven pulleyand changes
their effectivepulleyratio.Activatingthe startclutchcontrollinearsolenoidmovesthe startclutchcontrolvalve.The start
clutch control valve uncovers the port, providing pressure to the start clutch to engage it (cont'd)
14-195
Downloaded
,! from www.Manualslib.com manuals search engine
Description
(cont'd)
Gear Sel€stion
The shift leverhassix positions:@ pARK,E REVERSE,

E NEUTRAL, g SECOND,
E DR|VE, and El LOW.
Poshion De3cription
E PARK Frontwheelslocked;parkpawl engagedwith the parkgearon the drivenpulleyshaft.The start
clutch and the forward clutch released.
E REVEBSE Reverse;reversebrake engaged.
E NEUTRAL Neutral;the start clutch and the forward clutch released.
D DRIVE Generaldriving;the transmissionautomatically

adjuststo keepthe engineat the bestspeedfor
drivingconditions.
E SECOND For rapid accelsrationat highway speeds;the transmissionshifts into a lower range of ratios for
better accelerationand increasedengine braking.
E LOW Forenginebrakingand powerfor climbinO;the transmissionshiftsinto the lowestrangeof the

ralros.
Staning is possibleonly in E and E positionsthrough the use of a slid6-type,neutrafsafety switch.
Automrtic Transaxle{A/T} Gear Position Indicltor

The A-lTgear position indicator in the instrument panel shows which gear has been selectedwithout having to look down
at the console.
14-196
STEELBELT
STARTCLUTCH
INPUTSHAFT
DRIVEPULLEY
ATF FILTER
14-197
Description
Clutches/Reverse
Brake/Planetary
Gear/Pulleys
Clulches/ReverseBrake
T h e C V T u s e st h e h y d r a u l i c a l l y - a c t u a tcel u
d t c h e sa n d b r a k et o e n g a g eo r d i s e n g a g et h e t r a n s m i s s i o n
g e a r s .W h e n
hydraulicpressureis introducedinto the clutchdrum and the reversebrakepistoncavity,the clutchpistonand the reverse
brakepiston move.This pressesthe frictiondjscsand the steelplatestogether,lockingthem so they don't slip. Poweris
then transmittedthrough the engagedclutch packto its hub-mountedgear. and through engagedring gear to pinion
gears.
Likewise,when the hydraulicpressureis bled from the clutchpackand the reversebrakepistoncavity,the pistonreleases
the frictiondiscsand the steelplates,and they are free to slidepasteach.This allowsthe gearto spin independently on its
shaft,transmittingno power.
Start Clutch
The startclutch,which is locatedat the end of the drivenpulleyshaft,engages/disengagesthe secondarydrive gear.
The startclutchis suppliedhydraulicpressureby its ATFfeed pipeswithin the driven pulleyshaft.
Forward Clutch
The forwardclutch,which is locatedat the end of the drive pulleyshaft,engages/disengages
the sun gear.
The forwardclutchis suppliedhydraulicpressureby its ATFfeed pipewithin the drive pulleyshaft.
ReverseBrake
The reversebrake,which is locatedinsidethe inte.mediatehousingaroundthe ring gear,locksthe ring gear in E posi-
tion. The reversebrakediscsare mountedto the ring gear and the reversebrakeplatesare mountedto the intermediate
housing.The reversebrakeis suppliedhydraulicpressureby a circuitconnectedto the internalhydrauliccircuit.
PlanetaryGear
The planetarygearconsistsof a sun gear,a carrierassembly,and a ring gear.The sun gear is connectedto the input shaft
with splines.The pinion gearsare mountedto the carrierwhich is mountedto the fo.ward clutchdrum. The sun gear
inputsthe enginepower via the input shaftto the planetarygear,and the carrieroutputsthe enginepower.The ring gear
is only usedfor switchingthe rotationdirectionof the pullevshafts,
In E. E, and E positions(forwardrange),the pinion gearsdon't rotateand revolvewith the sun gear, so the carrier
rotates.In E] positjon{reverserange),the reversebrakelocksthe ring gear and the sun gear drivesthe pinion gearsto
rotate.The pinion gearsrotateand revolvein the oppositedirectionfrom the rotationdirectionof the sun gear,and the
carrierrotateswith piniongear revolution.
Pulleys
Eachpulley consistsof a movableface and a fixed face, and the effectivepulley .atio changeswith engine speed.The
drive pulleyand the drivenpulleyare linkedby the steelbelt.
To achievea low pulley ratio, high hydraulicpressureworks on the movableface of the driven pulleyand reducesthe
effectivediameterof the drive pulley.and a lower hydraulicpressureworks on the movableface of the drive pulleyto
eliminatethe steelbelt slippage.To achievea high pulleyratio,high hydraulicpressureworks on the movablefaceof the
drive pulleyand reducesthe eifectivediameterof the driven pulley,and a lower hydraulicpressureworkson the movable
faceof the drivenpulleyto eliminatethe steelbelt slippage.
14-198
ATF PUMP ATF PUMP
DRIVENSPROCKET
DRIVEPULLEY FORWARDCLUTCH
REVERSEBRAKE
RING GEAR PISTON BEVERSEBRAKE
FLYWHEEL CARRIER
RINGGEAR
DRIVEPLATE
PLANETARY
PINIONGEARS
INPUTSHAFT
ATFPUMP
DRIVECHAIN
ATF PUMP
DRIVESPROCKET
DRIVENPULLEY
SHAFT
STARTCLUTCH
FINALDRIVEGEAR
DRIVENPULLEY
GEAR
SECONDARY STEELBELT
SHAFT
a-- il DRIVEGEAR
SECONDARY
i___ PARKGEAR
14-199
Description
PowerFlow
E Position
. StartClutch:released
. ForwardClutch:released
. ReverseBrake:released
Hydraulicpressureis not appliedto the startclutch.forwardclutch,and the reversebrake.Poweris not transmittedto the
secondarydrive gear.
E Position
. StartClutch:released
a ReverseBrake;released
Hydraulic pressureis not applied to the start clutch, forward clutch, and the reversebrake.Power is not transmitted to the
secondarydrive gear. The secondarydrive gear is locked by the park pawl interlockingthe park gea..
FI-YWHEEL FORWARD
INPUTSHAFT
SUN GEAR
STARTCLUTCH
ORIVENPULLEY
FINALORIVE
GEAR
PARKGEAR
FINALDRIVENGEAR
14-200
E, E, and E Positions{Forward Rangel
. Start Clutch:engaged
. ForwardClutch:engaged
o ReverseBrake:released
1, The hydraulicpressureis appliedto the forward clutch and the start clutch,and the sun gear drives the torward
clutch.
2. The torwardclutchdrivesthe drive pulleVshaft.which drivesthe drivenpulleyshaft linkedby the steelbelt.
3, The drivenpulleyshaftdrivesthe secondarydrive gear,via the startclutch.
4. Poweris transmittedto the secondarydrivengear,which drivesthe final drivengear.
NOTE:The working hydraulicpressureon the movablefaceof eachshaftdependson the throttleopeningposition.
DRIVEPULI.fY
FLYWHEEL STEELAELT
CLUTCH
INPUTSHAFT
STARTCLUTCH
DRIVEN
SECONDARY
GEAR
(cont'd)
FINAL DRIVENGEAR
14-201
Description
Power Flow (cont'd)
E Position
. Start Clutch:engaged
. ReverseBrake:engaged
1. The hydraulicpressureis appliedto the reversebrakeand the startclutch.The sun gear drivesthe piniongears,and
the piniongearsrevolvearoundthe sun gear.The carrierassemblyrotatesin the oppositedirectionfrom the rotation
directionof the sun gear.
2. The carrierassemblydrivesthe drive pulleyshaft via the forward clutchdrum, and the drive pulleyshaft drivesthe
drivenpulleyshaftlinkedby the steelbelt.
3. The drivenpulleyshaftdrivesthe secondarydrive gearvia the startclutch.
4. Poweris transmittedto the secondarydrivengear,which drivesthe final drivengear.
DRIVEPULLEY STEELEELT
DRIVE REVERSE
BRAKE
PULLEY
CARRIER
ASSEMBLY
INPUTSHAFT
SUN GEAR
PINIONGEAB
RINGGEAB
STABTCLUTCH
DRIVENPULLEY
SECONDARY
DRIVE
GEAR
FINAL
GEAB
SECONDARY
ORIVEN
GEAR
FINALORIVEN
GEAR
14-202
ElectronicControlSystem('96- 98 Modelsl
(TcM),sensors,three linearsolenoids,and an
The electroniccontrolsystemconsistsof the Transmissioncontrol Module
controlledunderall conditions
inhibitorsolenoid.Shiftingis electronically
The TCIMis locatedbelowthe dashboard,behindthe kickpanelon the driver'sside'
when the vehicleis
The TcN4controlsthe transmissionto reduceenginespeedand retainthe engine'scoolingefficiency
drivenwith Iull throttleacceleration
t h, e T C M r e g u l a t e st h e p u l l e yh y d r a u l i cp r e s s u r et o
y r i v e na t f u l l t h r o t t l ea c c e l e r a t i o n
l f t h e v e h i c l ei s c o n t i n u o u s l d
increasethe pulleyratio,which,as the result.reducesthe engine speed and retainsthe designedcoolingefficiencyAfter
the vehiclehas beendrivenat a lower enginespeed for a while, the TCM increases the pulleyratioto the originalratio.
For smooth startingin the E position, the TcM sends a signal to the EcM to cut off the rvc clutch{if the A!/cis on) and
increases the engine speed to 900 rpm when the transmission is shifted to the E position'
properly.the TCM regulates

The start clutchfunctionsto make smooth startingpossible.To let the start clutchfunction
entine's negativepressure memorized in the E position'
the startclutchhydraulicpressurebasedon the
z
z
S*ond.ry G..r Sh:ft
(cont'd)
14-203
Description
ElectronicControlSystem('gG- 98 Modelsl(cont'dl
Circuit Diagramand Terminal Locations
GNITIONSWITCN
Pri- PtcoNTnoL
LrN ns0LtN0t0
SIAiT CLUTCH
CONTSOL
LINEAFSOLENOID
: MAP(PBI
g s61
sHtFTCONmOI
LINIAftSOLENOID
E rtDiRxo
g TM8
scs
i\\c-...............-+B
BFAXELIGHT
PAS|(ING
8MI(E SWITCH
i\--------.--_ rcr
1 2 3 5 1 8 I 1 0 1 1 't2 2 5 7 8 9 10
14 17 20 23 26 12 1 3 t 4 t6 17 18 20
14-204
ElectronicGontrolSystem('99- 00 Modelsl
(PCM).sensors,three linearsolenoidsand an
The electroniccontrotsystemconststsof a Powertraincontrol Module
controlledunderall conditionsA GradeLogiccontrol systemto controlshift-
inhibitorsolenoid.shifting is electronically
ing in E positionwhile the vehicleis ascendingor descendinga slope'
fn"pCVirlocatedbelowthedashboard,underthekickpanelonthepassenger'sside'
is
The pCM controlsthe transmassion to reduceenginespeedand retainthe engine'scoolingefficiencywhen the vehicle
drivenwith full throftleacceleration
the pulley hydraulicpressureto
lf the vehicle is continuouslydriven at lull throttle acceleration,the PCM regulates
and retains the designedcoolingefficiencyAfter
increasethe pulleyratiowhich. as the result,reducesthe enginespeed
while, the PCM increases the pulley ratioto the originalratio'
the vehiclehas beendrivenat a lowerenginespeedfor a
position,the PcM cuts off the ,Vc clutch(if the A/c is on) and increases the enginespeedto
i"i ".nl",rr startingin the E
900 rpm when the transmissionis shiftedto the E position'
functionproperly,the PcM regulates
The start clutchfunctionsto make smooth startingpossible.To let the start clutch
pressure memorized in the E position'
the startclutchhydraulicpressurebasedon the engine'snegative
FCM
s*o.d.ry G..t Sh.h
(cont'd)
14-205
Description
ElectronicControlSystem('99- 00 Modelsl(cont'dl
Grade Logic Control System
How it works:
The PcM comparesactual driving conditionswith memorizeddriving conditions.basedon the input from the vehicle
speedsensor,the throttlepositionsensor,the manifoldabsolutepressuresensor,the enginecoolanttemperaturesensor,
the brakeswitchsignal,and the shift leverpositionsignal,to controlshiftingwhile the vehicleis ascendingor descending
a slope.
AscendingControl
When the PCM determinesthat the vehicleis climbing a hill in E position,the system selectsthe most suitableshift
schedule(pulleyratio)accordingto the magnitudeof a gradient.so the vehiclecan run smooth and have more power
when needed.Thereare threeascendingmodeswith differentshift schedulesaccordingto the magnitudeot a gradientin
the PCM.
DescendingControl
when the PCMdeterminesthat the vehicleis going down a hill in E position.the systemselectsthe most suitableshift
schedule(pulley ratio) accordingto the magnitudeof a gradient.This, in combinstionwith engine braking,achieves
smoothdrivingwhen the vehicleis descending,Thereare three descendingmodeswith differentshift schedulesaccord-
ing to the magnitudeof a gradientin the PCM.
14-206
-'99 - 00 Models
Circuit Diagram and Terminal Locations
IGN1TIONSWTCH
PH.PLCOiTSOL
SOLEI€ID
LINEAF
IGPl
SIAFTCLIJICHCOTITROL
LINEiFSOLET€IO
vcc2
TPS
SHIFICONTNOT
LINEARSOLEI{OIO
INNIBTOFSOLETIOIO
14-207
Description
HydraulicControl
The hydrauliccontrolsystemis controlledby the ATF pump.the valves,and the solenoids.The ATF pump
is drivenby the
input shaft.The ATF pump and the input shaft are linkedby the ATF pump drive chain and the
sprockets,The inhibitor
solenoidvalve and the linearsolenoids.which are locatedon their valve body, are controlledby the
TCM or pcM. Fluid
from the ATF pump flows throughthe PH regulatorvalveto maintainspecifiedpressureto the drive pulley,
the driven pul-
ley,and the manualvalve,
The lower valve body assemblyincludesthe main valve body,the PL regulatorvalve body,the shift
valvebody,the start
clutchcontrolvalvebody,and the secondaryvalvebodv.
Main Valve Eody

The main valvebody containsthe pH controlvalve,the rubricationvalve,and the pitot regulatorvalve.
PH Control Valve
The PHcontrolvalvesuppliesPHcontrolpressure(PHCIin accordance with the pH-pLcontrolpressure(HLc),and sup-
plies PH control pressureto the PH regulatorvalve,which also regulatssPH pressure.
At kick-down,it increasespH
controlpressurewhich increases the high (PH)pressure.This shortensthe shift speedby releasingthe reverseinhibitor
pressure(Rl)fromthe inhibitorsolenoidvalve.
LubricationValve
The lubricationvalvecontrolsthe lubricationpressureto eachshaftand maintainslubricationpressure.
Whenrne pres-
sure is too high,the spring is compressed.
This movesthe lubricationvalveand opensthe fluid leakpassage.
Pitot Regulalor Valv6

The pitot regulatorvalvecontrolsthe startclutchpressure(SC)in accordance
with the enginespeed,when the electron-
ic controlsystemis faulw.
MAIN VAIVE
BODY
14-208
SecondaryValve Body
valve accumulator'
The secondaryvalve body containsthe PH regulatorvalve.the clutchreducingvalve' the start clutch
and the shift inhibitorvalve
PH RegulatorValve
pump. and suppliesPH pressureto the
The pi regulatorvalve maintainshydraulicpressuresuppliedfrom the ATF
pressure
is at
regulated the PH regulatorvalveby the PH control
hvdrauliccontrolcircuitand the lubricationcircuit.PH
pressure(PHC)from the PH controlvalve.
Cluteh ReducingValvo
the clutch reducing pressure
The clutch reducing valve receivesPH pressurefrom the PH regulator valve and regulates
(cR).The clutchreducingvalvesuppliesclutch pressure (cR) to the manual valve and the start clutchcontrolvalve'and
pressurecontrolvalve.the shift controlvalve,and the inhibitor solenoidvalve'
suppliessignalpressureto the PH-PL
Start Clutch Valv€ Accumulator

the hydraulicpressurethat is suppliedto the startclutch'
The startclutchvatveaccumutatorstabilizes
Shift Inhibitor Valve

from electroniccontrol to hydraulic
The shift inhibitor valve switchesthe fluid passageto switch the start clutch control
control system is faulty. lt also suppliss clutch reducing pressure(cR) to the pitot regulator
control when the electronic
valveand the pitot lubricationpipe.
START CLUTCHVALVE
SECONDARYVALVE
BODY
SHIFTINHIBITOEVALVE
VALVE
REDUCING
VAL
PH REGULATOR
(cont'd)
14-209
Description
HydraulicControl{cont'dl
PL RegulatorValve Body
The PL regulatorvalve body containsthe PL regulatorvalve and the PH-PLcontrolvalve.which is joined wirh the pH-pL
controllinearsolenoid.The inhibitorsolenoidis boltedon the pL regulatorvalvebody.
. PL RegulatorValve
The PL regulatorvalvesupplieslow p.essure(pL)to the pulleyto eliminatesteelbelt slippage.
The PL pressureis controlledby the pH-pLcontrolpressure(HLC).
. PH-PLControl Valve
The PH-PLcontrolvalve controlsthe PL regulatorvalve accordingto enginetorque.The PH-PLcontrolvalvesuoolies
PH-PLcontrolpressure(HLC)to the PH controlvalveto regulatePH pressurehigherthan pL pressure.The pH-pLcon-
trol valveis controlledby the PH-PLcontrollinearsolenoid.which is controlledby the TcM or pcM,
. InhibitorSolenoid
The inhibitorsolenoidcontrolsthe reverseinhibitorvalveby turningon and off. Also,the inhibitorsolenoad
controlspH
controlpressure(PHC)by applyingreverseinhibitorpressure(Rl)to the PHcontrolvalve.The inhibitorsolenoidis con-
trolledby the TCM or Pclvl.
Start Clutch Control Valv€ Body

The startclutchcontrolvalve body containsthe startclutchcontrolvalve.Both are joinedto the stan clutchcontrollinear
solenoid.
. Start Clutch Control Valve

The startclutchcontrolvalvecontrolsstartclutchengagementaccordingto the throttleopening.The start clutchcon,
trol valveis controlledby the stan clutchcontrollinearsolenoid,which is controlledbv the TCM o. pCM.
STARTCLUTCHCONTROL
vAt-vE
LOWERVALVEBODY
ASSEMBI-Y
PH.PLCONTROL
LINEARSOLENOID
14-210
Shift Valve BodY linearsolenoro.
shift controlvalve.Bothare ioinedto the shiftcontrol
The shiftvalvebody containsthe shift valveand the
r tl'ft1il1rf"","" pH
Theshiftvarvedistributes
varve.
(sV)fromtheshiftcontror
by shiftvarvepressure
is controred
pulley'to shiftthe transmission'
pi""aur" "nO PL pressureto drive pulleyand the driven
t t*"rilf:::lr';ivarve opening and vehicle speed rhe shift

contrors the shift varve in accordancewith the throttre When the elec-
solenoid,which is controlledby the TcM or PcM
controlvalveis convorr"ouv ti" "iirt "ontrol linear valveto uncoverthe port leadingthe
"witchesthe shift inhibitor
tronic controlsystemis faulty,t;; snift controtuutue
pitot regulatorpressureto the startclutch
SHIFTCONTROL
CONTROLVALVE
VALVEBODY
inhibitorvarve.Themanuatvarvebodvis bortedto the

varveandthe reverse
the manuar
T;J:"i"""1ff"t""ilody contains
intermediatehouslng
. ManualValve position'
the fluid passageaccordingto the shift lever
uncovers/covers
The manualvalvemechanicallY
' (Rl). lt interceptsthe hvdraulic circuit to the

ff:e;;;.'::'?Xftl::T",* is contro ed by the reverse inhibitor pressure
at speedsover approximatelv6 mph (10 km/h)'
reversebrakewhile the vehicleis movingforward
REV€RSEINHIBITOR
VALVE
MANUAL VALVE
BODY
MANUALVALVE
14-211
Description
HydraulicFlow
GeneralChart of Hydraulic prossure
'Shift Valve
. ShiftinhibitorVatve
PH REGULATOR
VALVE
NO. DESCRIPTION
OF PRESSURE NO. DESCRIPTION
OF PRESSURE
cc CLUTCHCONTROL PP PITOTPIPE
coL ATF COOLER PR PITOTREGULATOR
CLUTCHREDUCING RCC RECIRCULATION
DN DRIVENPULLEY RI REVERSE
INHIBITOR
DR DRIVEPULLEY RVS REVERSE
BRAKE
FWD FORWARD
CLUTCH sc STARTCLUTCH
HLC PH-PLCONTROL sl SHIFTII"IHlBITOR
LUB LUBBICATION SUC SUCTII'N
PH PRESSURE
HIGH SHIFTVALVE
PHC PHCONTROL X LEAK
PL PRESSURE
LOW
14-212
E Position
Astheengineturns.theATFpumpa|sostartstooperate.F|uidfromtheATFpumpf|owstothePHregu|atorva|veandt
c|Utchreducingva|ve.ThePHregu|atorva|veregu|ateshighpressure(PH).andsendittotheshiftVa|veandthePLr
latorvalve.Thehighpressure(PH)flowstothemovablefaceofthedrivenpulleyviatheshiftvalve'andturnsintolow
pressure(PL)atthePLregu|atorva|ve.Thelowpressure(PL}f|owstothemovab|e'aceofthedrivepu||eYviatheshif
valve.At this time, the pulleyratio remarnslow'
T h e h i g h p r e s s u r e ( p x ) u e c o m e s t t r e c t u t c h r e d u c i n g p r e s s u r e ( C R ) a t t h e c | uvalve'
t c h r eand
d u cthe
i n gshift
va|V e . T h evalve'
control c | u t cand
hreducing
valve'the PH-PLcontrol
sure (CR)flows to the startclutchcont'oi uatt". tn"lt"n'al
is interceptedbYthose valves
Underthis condition,hydraulac pressureis not appliedto the clutchesand reversebrake'
(cont'd)
14-213
Description
HydraulicFlow(cont'dl
lll position, at low spo€d range
The flow of fluid up to the drive pulley,the driven pulley,and the

clutchreducingvalve is the same as in El position.The
pulleyratio is low becausethe drivenpulleyreceiveshigh pressure(PH),
and the drive pulleyreceiveslow pressure(pL),
The clutchreducingpressure{cR) flows throughthe manualvalve
to the forwaroclutch,ttrenforwardciulcn is engaged.
The forwardclutchthen drivesthe drive pulleyshaft,which drives
the d(ven pu ey shaft.
Also' clutch reducingpressure{cR) flows to the start clutch
control valve, and becomesclutch control pressure
clutch control pressure(cc) becomesstart clutch pressure(sc) at {cc).
the shift inhibitorvalve.stan clutchpressure{sc) is
appliedto the startclutchto engagethe startclutch.
14-214
E position, at middle sPeedrange
Asthespeedofthevehic|ereachestheprescribedVa|ue,theshiftcontro||inearsolenoidisactivatedbytheTcMorPc
T h e s h i f t c o n t r o | | i n e a r s o | e n o r o c o n t r o I s t t r e s n i f t c o n t r o I V a | v e(SV) t o a c t i v a t shift
e s h icontrol
ftVa|ve p r e sShift
valve s u r evalve
( S V ) 'pressure
c|utchreducing
shift valve pressure at the
sure (CR)trom the clutchreduclngvalve becomes
( S V ) f l o w s t o t h e | e f t " n o o t t r ' " s t ' i t t u " t u e . t h e s h i f t V a | V e t o t h e r i g h t s i d e a n d p oport
s i t i o n i n g i tlow
i n t hpressure
e m i d d |(PL)
e o f ito
t sthe
trave|.The
tiHl a ,tr" pulleys,and uncoversthe leading
shiftvalvecoversth" pon ao",oo nLior".irr" pulley ratio is in the middle'
pressure(PL).At this time, the
pu eys.The drive pu ey and tne oriJenpriLy |."""iu" to*
the start clutch'
Pressureremainsto applythe forwardclutchand
NOTE:When used,
(cont'd)
14-215
Description
@ position, at high spe6d range
As the speedof the vehiclereachesthe prescribedvalue,the

shift controllinearsol€noidmovesthe shift controrvatveto
increaseshift valve pressure(SV)at the left end of the shift valve.
ttre srrit vatvemovesto the right side comparedto its
positionat the middle pulley ratio.The shift valve uncovers
the port leadinghigh pressure(pxito ttre d.ve puley and
uncoversthe port leadinglow pressure(PL)to the drivenpulley.
The drive pu|ey receiveshigh pressure(pH)and the driv-
en pulleyreceiveslow pressure(pL).The pulleyratiois high.
Pressureremainsto applythe forwardclutchand the startclutch,
NOTE:When used,"left,,or,,right" indicatesdirectionon the hydraulic

circuit.
14-216
E position
pulley'and the clutchreducingvalve is the sameas in E position The
The flow of fluid up to the drive pulley,the driven
and the drive pulleyreceiveslow pressure{PL).
pulleyratio is low b"car"" tt " o riu",i'prti"vi"""v"" t'igtrpressure.(pH) (RVS)to the
the port that leadsreversebrakepressure
The manualvalve is shiftedinto the B position,and it uncovers reverseinhibitor (Rl)is
pressure
meansof the TcM or PcM, and
reverseinhibitorvalve.The inhibitoiJenoid turns off by
a p p l i e d t o t h e r i g h t e n d o f t h e , " u " , " " i n t , i u i . o , u , | v e . T h e r e v e r s e i n h i b i t o r v a |pressure
v e m o v e(cR)
s t o tbecomes
he|eftsid e , a n dbrake
reverse uncoversth
clutch reducing
port that leadsreversebrakepr"a"ur" tivst,o,he reversebrake. the ring
The reversebrakeis engaged,and it locks
pressure(RVS)at the manuat*r"-, "nJ tro*" to the reversebrake.
gear.
NOTE:When used,
(cont'd)
14-217
Description
HydraulicFlow(cont'dl
E position
ReverseInhibitor Conirol
lf the E positionis selectedwhile the veiicle is moving forward

at speedsover 6 mph (10 km/h),the inhibitorsolenoid
doesn'tturn off by meansof the TcM or PCM Reverseinhibitorpressure(Rl)
is not appliedto the reverseinhibitorvalve
as the reverseinhibitorsolenoidturns on. The reverseinhibitor
valve is kepton the right side,and coversthe pon ro srop
reversebrakepressure{RVS}to the reversebrakefrom the
manualvalve.Reversebrike pressure(RVs)i; not appried
the reversebrake,and power is not transmittedto the reverse to
direction.
NOTE:When used,"left,' or,,right,,indicatesdirectionon the hydraulic
circuit.
14-218
E position
position'
pulley' and the clutch reducingvalve is the same as in E
The flow of fluid up to the drive pulley,the driven valve' and is
controlvalve,the manualvalve,and the shift control
Clutchreducingpressure(CR)t'"*" i" ii" startclut;h
interceptedbYthosevalves.
to the clutchesand reversebraKe'
Underihis condition,hydraulicpressureis not applied
- --l
fr
4t1.1
'rltll , 1
(cont'd)
14-219
Description
lll position, when th€ electroniccontrol system is fauhy.
when the electroniccontrolsvstem(linearsolenoidsand sensors)is faulty,

the transmissionusesthe pitot pipe pressure
(PP)to 311o-rh" u"hicleto drive.
when all linearsolenoidsand sensorsare off becauseof a faulty electronrc

controlsystem,clutchreducingpressure(cR)
flows to the startclutchcontrolvalve,the manualvalve,the PH-PLcontrol
valve,and the shift controlvalve.clutch reduc-
ing pressure(cR) becomesshift varvepressure(sV) at the shift contror
varve,and shift varvepressure{sv) is appriedto
the left end of the shift valve and the right end of the shift inhibitorvalve.
The shift valve movesto the right side.and
uncoversthe pon that leadshigh pressure(PH)to the drive pulleyand
uncoversthe po.t tlr"t r""1" ro,,"-pressure(pL)to
the driven pulley At this time, the pulley ratio is high, The shift inhibitorvalve
movesto the left side,and uncoversthe
port that leadsshift inhibitorpressure(Sll to the pitot lubricationpipe
and the pitot regulatorvalve.tne prtot lubrication
pipe dischargesfluid insideof the pitot flange,and discharged
fluid entersinto the pitot pipe and it is appliedto the left
end of the pitot regulatorvalve.The pitot regulatorvalve moveslo the
right side,and uncoversthe port that leadspitot
regulatorpressure(PR)to the shift inhibitorvalve.Pitot regulatorpressure
{pR)becomesstartclutchpressure{sc1at the
shift inhibitorvalve,and is appliedto the stan clutch.The stan clutch
rs engaged.The forwardclutch pressure(FWD)is
appliedto the forwardcrutch,and the forwardcrutchis engaged.This alows
the vehicreto drive.
NOTE:When used."|eft" or ,,right',indicatesdirectionon the hydraulic
circuit.
14-220
system is faulty'
E] position, when the elestronicGontrol
pulley'and the startclutchis the sameas in El position
The flow of tluid up to the drive pulley,the driven pressure{RVS}to the
it uncoversthe port that leadsreversebrake
The manualvalve is shiftedinto the lE position'and reverse inhibitor valve becauseof
(Rl)is appliedto.the right end of the
reverseinhibitorvalve.Reverse,"nlu-i,"ip*r""i"
a f a u l t y i n h i b i t o r s o l e n o i d . T h e ' " t ' " , " " i n f t i U i t o ' v a l v e m o v e s t o t h(cR)
e l e fbecomes
t s i d e ' a nreverse
d u n c o vbrake e p o r t t h(RVS)
e r s t hpressure a t l e aat
d sthe
reverse
reducingpressure
brakepressure{RVS)to the ,"u"r." ir"t"- cru,ch gear'This allowsthe vehi-
reversebrakeis engagedand locksthe ring
manualvalve,and,lows to the ,e\r"rs" lr"re. ttre
cle to drive in reverse.
"left" or "right" indicatesdirectionon the hydrauliccircuit'
NOTE:When used,
14-221
Description
ParkMechanism
The park mechanismlocksthe transmissionby engagingthe park pawl with
the park gear which is integralwith the sec-
ondarydrive gear'The secondarydrive gear engageswith the secondarydrivengear
which engageswit-hthe final driven
gear.
shiftingto E positioncausesthe parkcone (installedat the end of the parkrod) press
to the park pawl onto the parkgear.
Evenif the end of the park pawl rideson the top of the parkgearteeth,slight
movementof the vehiclewill causethe park
pawl and the parkgearto mesh with eachother completely
becausethe parkcone receivesthe tensionfrom the parkrod
spring The park pawl receivesthe tension(whichactsto separatethe park pawl
from the park gear)from the park pawl
spring.
STARTCLUTCH
PARKPAWI-
PABKGEAR
PARKCONE
PARK ROD
PARKPAWL
PARKROO
SPRING
1 4-222
Component Locations
36 - 98 Models
BRAKESWITCH
ENGINECONTROL
MODULEIECMI
AUTOMATICTRANSAXLE(A/T}
GEARPOSITIONSWITCI{
SECONDARYGEARSHAFT MANIFOLDABSOLUTE
SPEEOSENSOR IMAPI SENSOR
THROTTI.IPOSITION{TPI
VEHICLESPEEOSENSOR
SENSOR
{vss}
/i/ i
DRIVENPULLEY ,' / ,','4
$r,
SPEEDSENSOR
,i/:1
t"--.---.- i,,
-_,-:-_a.--:
il
INHIBITOR SOLENOID
STARTCLUTCHCONTROL PH.PLCONTROL
LINEARSOLENOID LINEARSOLENOID
PULLEY
SPEEDSENSOR
SHIFTCONTROL
LINEARSOLENOTD
14-224
h
'99 - 00 Models
CONTROL
AUTOMATIC TRANSAXLE IA/TI

GEARPOS]TIONSW]TCH
SECONDANYGEAR SHAFT MANIFOLDABSOLUTE

SPEEDSENSOR IMAPI SENSOR
THROTTLEPOS]TIONITP)
VEHICLESPEEDSENSOR SENSOR
tvss)
DNVENPUL]-EY
SENSOR
SPEED
PH.PLCONTBOL
STARTCLUTCHCONTROL LINEABSOLENOIO
LINEARSOIENOID PULLEY
SPEEDSENSOR
SHIFTCONTROL
LINEARSOLENOIO
14-225
TCM CircuitDiagram('96- 98 Modelsl
U N D E NH
. O O DF U S E ] R E LBAO
YX
No.521l5A)
l
N o . 4 ll 8 0 A ) N o . 4 7 ( 7 . 5 A )
PARKING
BRAKE
I
swrTcH I G N I T I OCNO I L
V
I YI
I
I i
UNDER OASH
FUSE/RELAY
80X
I
I I
GnN,4,vHT
I
GRN/REO
I
BI-U
, t ,I -
rsl
lG1 sToP
swT
Tot 2v HBR(
sw- rur
A / TG E A R
POSITION
INDICATOR LTGRN
ELKiBI-U
RED
GRN/BLK
cRN---l F----- GnN

Bru-J F------ 61U
8LK NoTEiif :ro 5V

^ A ',o J'
I
I
I T
: T ot 2 v
Tl
G401
G404
14-226
WHT/REDELUMHT GRY PNK
B2O LB5 B7 B6
'i-
wHT I wHTqED I PNUSLK I PNK,BLU 1 G8N/YEL J GRN/BLK
Lli:"*l
|
T
I
nroieru
T
--
cnN
T
I
wirr
T
nro,wHr
T T
BLKMHTI
J wxitnro I eruxialrI
T T T
GRN{WHT-...1_...
T
PNKiBLU GBN,^vEt
I
T -.T-. T
BLUIEL^^.,1,.
YFt -_..1_.-.
GRNiBIK J +. L'
il
_ L , r-T' _ r -r_ r L
-T- -T-r l l
'r-- T-T T T t l
I I I I | | c*Hl**t I 'i' I sLU'i^'Hr
I -t P-
I I | | | | pr'rxisLr I I GBN/YEI
PNK7BLU GRN/BIK
I BRN/BLK BLK
l l l l l l t l l l l
d s t g @
3FIYE,',X!b'J
SFiYbtt"','J-
@ @ l e
8i0ft 3il[ip' T
SEigY#ISBniho,
] rNHrBlT0R
SOLENOID
I
I
n-:
I I
I
5PEE'sENsoR
!8[$fo,o !'$,'Afl]: !'8$nlo'ol -
G1 0 1 G1 0 1
TCMTeflnlnalLocations
>< X
'11 6 7 8 10
2 3 5 7 10 2 5
14 17 20 2 5 26 14 17 18 20 ,/1,/
TCM-A (26P)Connertor T C M- B l 2 2 P ) C o n n e d o r
14-227
TCMTerminalVoltage/Measuring
Gonditions
('96- 98 Modelsl
TCM Terminal Loc.tions
2 4 1 8 9 1 0 1 1 12 1 3
1 1 1 5 16 1 7 20 23 25 26
TCM-Al25P)Connecto. TCM-B(22P)Connectot
TCM CONNECTOR A (26P}
TerminalNumbet Signal Dsscription MoasuringConditions/Torminsl

Vohrgo
A1 SCLS_ Stanclutchcontrollinearsolenoid Engineidling,E position:
powersupplynegativeelectrode Approx. 0.4 V
HLC LS- PH-PLcontrol linearsolenoidDower Engineidling,E position:
supply negative electrode Approx.0.7V
Shiftcontrollinearsolenoidoower Engineidling,E position:
supplynegativeelectrode Approx.0.8V
A4 LG1 Ground
NE Enginespeedsignalinput Withenginerunning:Pulsingsignal
A6 Not used
A7 ATP L A/f gear positionswitchEl position InEposition:OV
signalinput In otherthanEl position:Approx.1OV
A8 ATPS ly'T gearpositionswitchE position In lg position:0 V
signalinput In otherthanE position:Approx.10V
A9 ATP D A{/Tgear positionswitchE position In lll position:0 V
signalinput In otherthanE position:Approx.10V
Ar0 ATP NP A,/TgearpositionswitchE or E InEorEposition:oV
positionsignalsinput In otherthanE orE position: Approx.1OV
A11 ATP R A,/Tgear positionswitchE position In lE position:0 V
signalinput In otherthanE position:Approx.1OV
A.12 tGl Powersupplysystem With ignitionswitchON (ll):Baneryvoltsge
With ignitionswitchOFF:0 V
A13 PG1 Ground
414 Startclutchcontrollinea.solenoid Engineidling,E position:
powersupplypositiveelectrode Approx.2.5V
A15 HLCLS+ PH-PLcontrolline8|.solenoidpower Engineidling,El position:
supplypositiveelectrode Approx.5.0V
A16 SH LS+ Shift control linear solonoid oower Engineidling,E position:
supply positive electrode Approx.6.0V
417 Ground
A18 Not used
A19 Not used
420 D IND E indicatorlight control When l9l indicator light comes on: Approx. jO V
When lll indicatorlighr OFF:0 V
A2'l Not used
422 Not used

VBU Back-uppower system Alwaysbatteryvoltage
424 Not used
A.25 tG1 Powersupplysystem With ignition switch ON (lt):Bafteryvoltage

With ignitionswitch OFF:0 V
PG1 Ground
14-228
TCM CONNECTORB (22P}
Terminal Numbel Signal Description Measuring Conditions/Terminal Voltage
B1 S O LI N H Inhibitorsolenoidcontrol With inhibitorsolenoidON: Bafteryvoltage

-M
82 MAP(PB) anifold Absolr-rte
Pressure
IMAP) With iqnition switch ON (ll):Approx.2.5 V
sensorsignalinPUt With e;gine adling:Approx. 1.0V (dependingon
enginespeed)
B3 Not used
-Throttle
B4 TPS Position(TP)sensorsignal With ignitionswitch ON (ll) and throftlefully open:
input 4 . 1 4- 4 . 4 2V
With ignition switch ON (ll) and throttle fully
closed:0.44- 0.56V
VSS VehicleSpeed Sensor(VSS)signal With ignition switch ON (ll) and rotatingfront
Inpur wheels0 r -5Vcycle
TMB Data communicationwith ECM: With ignilion swltch UN lll): rulslng slgnar
Transmissioncontrol data outpUt
TMA Data communicationwith EClvl: With ignition swltch uN {ll,: l-ulslng slgnal
81
PGM Fl control data inPut
B8 N D NS G Driven pulley speedsensorground
NDN Driven pulley speedsensorsignal ln other thTnE and E position:Pulsingsignal
B9 input -tn
810 NDR Drivepulleyspeedsensorsignal ottrerttranE anaE position:Pulsingsignal
Input
811 Not used
STOPSW BrakeswitchsignalinPut With brakepedaldepressed:Batteryvoltage
812 0V
With brakepedalreleased:
813 DIAG-H Datacommunication: Wittr ignitio.rs*itct' ON (ll):Approx 5.0 V
(TXD/RXD) Diagnostictrouble code outPut
814 Se-ice ctrectsignat With ignition switch ON (ll) and servicecheck
connectoroPen:APProx.5 V
With iqnition switch ON (ll) and servicecheck
"onn"itot. connect"dwith specialtool: 0 V
815 VEL Secondary gearshaftspeedsensor on vehiclespeed:Pulsingsignal
Depending
signalinput 0V
Whenvehicleis stoPped:
816 VEL SG Secondarygear shaft speedsensor
grouno
817 N D RS G Drive pulley speedsensorground
818 HBRKSW Parkingbrakeswitch signal inPut With parkingbrakelever pulledr0 V
With parking brakelever released:Batteryvoltage
819 Not used

B20 VREF +5 V relerence With ignitionswitchON (ll):Approx 5 V
821 Not used
Not used

PCMCircuitDiagram(A/T ControlSystem:'gg - 00 Models)
tGNtTtc{l UNDER.OASN
SWTCH FUSF]NEUY
8OI
UADEFD'SI
FUSSFEUY 8OX
r{o.2s(7 5A)
iPrE: T rosv
I N lD
,:--
^1 GETBPOSITIoi{
14-230
EI€INE
COOLTI'II
TEUPEFATUFE
SENSOF
SPEED
SEllsoF
Y
I
I
T I I
GFN8U
l l l l J-
EE H
.-l-
tI t
u00u
t I
t
I NHIEITOR
ilillfSIft,' *fl&'u''!l^"
soLEl€|0
iflfl.S$' I soLEr,roro
I
:
14-231
Conditions('99- 00 Modelsl
PGMTerminalVoltage/Measuring
A/T ControlSystem
The PCMterminalvoltageand measuringconditionsare shownfor the connectorterminalsthat are relatedto the A/T con-
trol system.The other PCMterminalvoltageand measuringconditionsare describedin section11.
PICMConnoctorTerminrl Location3
Terminal Number Signal Descriplion MeasuringCondhions/TorminalVoltage

A7 ATP D A,/Tgear position switch InEposition:OV
E positioninput In otherthan E] position:Approx.1OV
A9 ATP NP A/T gear position switch In E andEl positions:
0V
@ and S positionsinput In otherthanE] andE position:
Approx.1OV
A10 Timing and adjustmentservice With ignitionswitchON {ll} and servicecheck
checksignal connectoroDen:5 V
With ignitionswitchON (ll) and servicecheck
connectorconnectedwith soecialtool:0v
ATP L A,/Tgear position switch In E position;OV
I positioninput In otherthan E position:Approx.10 V
STOPSW Brakeswitchsignaloutput Brakepedal depressed:Batteryvoltage
Brakepedalreleased:0 V
PCMCONNECTORB I25P}
Terminal Number Signal Description MoasuringCondhions/TerminalVohage

B1 IGPl Powersupplycircuitfrom main With ignitionswitchON (lll: Batteryvoltage
relay With ignitionswitchOFF:0 V
82 PG1 Ground
B8 HLCLSM PH-PLcontrollinearsolenoid
power supply neqativeelectrode
B9 IGP2 Powersupplycircuitfrom main With ignitionswitchON (lll: Batteryvoltage
relay With ignitionswitchOFF:0V
810 PG2 Ground
817 HLCLSP PH-PLcontrollinearsolenoid With ignitionswitchON {ll):Pulsingsignal

power supplypositiveelectrode
818 SC LSM Startclutchcontrollinear
solenoidpower supplynegative
electrode
s20 LGI Ground
821 VBU Back-uppowersupply Always battery voltage
B22 Ground
825 SC LSP Stan clutchcontrollinear With ignition switch ON (ll): Pulsing signal
solenoidpowersupplypositive
electrode
14-232
\ a D {16P)
PCMCONNECTOR
TerminalNumbs] Signal Description Measuring Conditions/TerminalVoltage
D1 VEL Secondarygearshaftspeed Dependingon vehiclespeed:Pulsingsignal

sensorsignalinput APProx.0 V
Whenvehicleis stoPPed:
02 S O LI N H lnhibitorsolenoidcontrol With inhibitorsolenoidON: Batteryvoltage

D3 SH LSM Shift controllinearsolenoid

power supplynegativeelectrode
D4 SH LSP Shift controllinearsolenoid With ignitionswitchON (ll):Pulsingsignal
power supplypositiveelectrode
D5 VB SOL Powersupplyfor solenoidvalves With ignitionswitchON (ll):Bafteryvoltage
With ignitionswitchOFF:0V
D6 ATP R A,/Tgear position switch E InEposition:0V

positioninput In otherthan B position;Approx.10 V
D] V E LS G SecondarygearshaftsPeed
sensorground
D8 Not used
D9 Not used
D10 NDN Drivenpulleyspeedsensorsignal In otherthan E and E position:Pulsingsignal
anput
D11 NDR Drivenpulleyspeedsensorsignal ln otherthan E and E position:Pulsingsignal
input
D12 N D RS G Drivepulleyspeedsensorground
D13 ATPS A,/Tgear position switch E I n E p o s i t i o n0: V
positioninput In otherthan E position:Batteryvoltage
D14 D IND D indicatorlight control When ignitionswitchis firstturnedON (ll):

Batteryvoltage for two seconds
In E position:Batteryvoltage
D15 Not used

D16 NDN SG Drivenpulleyspeedsensor
ground
14-233
l. How To BeginTroubleshooting
When the E indicatorlight has been reportedon, use the appropriateprocedurebelow to diagnoseand repatrthe
proDlem.
A . W h e nt h e @ i n d i c a t olri g h th a sc o m eo n :
l connectthe HondaPGM Testeror an oBD ll ScanTool to the 16PData Link Connector(DLc) locatednearthe left
kickpanel.
2 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) .
3 . Checkthe DTC and note it. Also checkand note

the freezeframedata.
R e f e rt o t h e D i a g n o s t i Tc r o u b l eC o d eC h a r ta n d
b e g i nt r o u b l e s h o o t i n g . o0\e--loo
INOICATOR
LIGHT
NOTE:SeetheOBDll ScanTool or HondaPGMTesteruser'smanualsfor specificoperatinginstructions.
Some PGM-FIproblemswill also makethe E indicatorlight come on. After repairingthe pGM-Flsystem,disconnectthe
BACKUP fuse (7.5Al in the under-hoodfuse/relaybox for more than l0 secondsto resetthe TCM or PCMmemory,rnen
recheck.
NOTE:Disconnecting the BACKUP fuse also cancelsthe radio presetstationsand the clock setting.Make note of the
radiopresetsbeforeremovingthe fuse so you can resetthem,
OATALINKCONNECTOB
I16P}
14-234
connectedto the
B. DTCSwill be indicatedby the blinkingof the E indicatorlight with the SCSserviceconnector
(The ServiceCheck (2P)
Connector is locatedunder the dash on the passen
ServiceCheckConnectoras shown.
ger'ssideof the vehicle.)Turn the ignitionswitchON (ll).
i i i:j
,,,/
CONNECTOR
{2PI CONNECTOR
07PAZ- 00101(x)
aboveare indicatedby a seriesof long and short

codes 1 through9 are indicatedby individualshon btinks.codes 10 and
b|inks.one|ongblinkequa|sloshortb|inks.Addthe|ongandshortb|inkstogethertodeterminethecode.After
m i n i n g t h e c o d e , r e f e r t o t h e e | e c t r i c a | s y s t e'99
msymptom-to-componentchartonpagesl4-238and14.239forthe,96_9
- 00 models
models,and on pages14-240and 14'241for the
Shorl blink (oncc)
Soc DTCI
Sor DTC2
Long blink Short blinks |tive tim€sl
Scc DTCI5
the PGM-FIsystem,disconnectthe
some pGM-Ftproblemswi atso makethe E indicatorlight come on. After repairing
BACKUPfuse(7.5A)intheUnder.hoodfuse/re|ayboxformorethanl0secondstoresettheTcMorPcMmemory
recheck.
(cont'd)
14-235
(cont'd)
C. lf the inspectionfor a particularcode requiresvoltageor resistance
checksat the TCM or PCMconnectors,remove
the driver'sside kick panel,and unbolt the TCM, and at the PCMconnectors,removethe passenger'sside kick
panel,and unbolt the PCM.Turn the ignitionswitchOFF,and connectthe backprobesetsand a digitalmultimeter
as describedbelow.Checkthe systemaccordingto the proceduredescribedfor the appropriatecode(s)listedon
the followingpages.
6x1.0mm
9.9N.m{1.0kgt m,
6 x 'l,0 mm
9.EN.m (1.0 kgf.m,
7.2 rbtftt
How to use lhe Backprob€SE{
Connect the backprobeadaptersto the stacking patch cords, and connect the cords to a multimeter, Using the wire
insulationas a guide for the contouredtip of the backprobeadapter,gently slidethe tip into the connectorfrom the
wire side until comesin contactwith the terminalend of the wire.
BACI(PROBESET
07saz- 001txtoa
Itwo requirodl DIGITALMULTIMETER
(Commarciallyavsibblel
KS-AHM-32-(x)3,
or oquivalent
ADAPTER
coRo
14-236
ll. TCM ResetPlocedure
1. Turn the ignitionswitchoff.
2. Removethe BACKUp fuse (7.5A) from the under-hoodfuse/relaybox for 10 secondsto resetthe TCM or PCM.
NOTE:
. Disconnectingthe BACKUPfuse also cancelstheradio presetstationsand the clocksetting Makenole ofthe radio
presetsbeforeremovingthe fuse so you can resetthem
BACKUP
t7.sAl FusE
. The TCM or PCMcan also be clearedby usingthe OBD ll ScanTool or HondaPGMTester'

OBD ll SCANTOOLo.
PGMTESTER
DATALINKCONNECTOR
{16PI
lll. Final Procedut€
NOTE:This proceduremust be done afterany troubleshooting
'1.Turn the ignitionswitchoff.
2. Resetthe TcM or PCM.
3. Disconnect the OBD ll ScanTool or HondaPGMTesterfrom the DataLink Connector(16P),or removethe specialtool
from the ServiceCheckConnector.
4. Turn the ignitionswitchON (ll),and setthe radiopresetsand clocksetting.
14-237
Chart
DTC* O Indicator MIL

Light Detectionltem Page
P1790 Throttlepositionsensor
(3) Blinks ON 14-242
P179'l Vehiclespeedsensor
(4) Blinks ON 14-243
P1705 Ay'Tgear position switch (short to groundl
(5) Blinks ON 't
4-244
P1706 A/T gear position switch {open)
(6) OFF ON 14-246
P0725 lgnitioncoil
(11) Blinks ON 14-248
P1793 Manifoldabsolutepressuresensor
Blinks ON 14-249
112l
P1 8 7 0 Shiftcontrollinearsolenoid
(30) Blinks ON 14-250
P'1873 PH-PLcontrollinearsolenoid
(311 Blinks ON 14-25'l
P1879 Startclutchcontrollinearsotenoid
(32) Blinks ON 14-252
P1882 Inhibitorsolenoid
Blinks ON 14-253
P1885 Drivepulleyspeedsensor
Blinks ON
(34) 1l-Zb4
P1886 Driven pulley speed sensor
(35) Blinks ON 14-255
P1888 Secondarygear shaftspeedsensor
(36) Blinks ON 14-256
T to55 ECMor TCM
(37) Blinks ON 14-257
P1890 Shift controlsystem
Blinks ON 14-259
l42l
P1891 Start clutch control svstem
(43) Blinks ON 14-260
*: The DTCin parentheses
is the code @ indicatorlight indicateswhen the DataLinkConnectoris connectedto the Honda
PGMTester.
14-23a
E indicatorlight does not blink,performan inspectionaccordingto the table below.
Symptom Inspection Ref.page
E indicatorlight does not come on for two secondsafterignitionswitch 14-262

is firstturn on (ll).
E indicatorlight is on constantly(not blinking)wheneverthe ignition 14-264
switchis on (ll).
NOTE:
. lf a customerdescribedthe symptomfor code P1706(6),it will be necessaryto recreatethe symptom by test driving,
then recheckthe DTC.
. Sometimethe E indicatorlight and the MalfunctionIndicatorlamp (MlL)may come on simultaneously. lf so, repairthe
pGM-Flsystem accordingto the DTc, then reset the memory by removing the BACK uP fuse in the under-hood
(50 km/h)'then
fuse/relaybox for more than 10 seconds.Drivethe vehiclefor severalminutesat a speedover 30 mph
recheckthe DTC.
14-239
Symptom-to-Com
ponentChart
DTCT E Indicatot
MIL Detostion ltem Page
Lighr
P1705 A,/Tgear positionswitch(shortto grouno,
(5) Elinks ON 14-265
P1706 A"/Tgear position switch (open)
(6) OFF ON 14-26€
P1870 Shiftcontrollinearsolenoid
(30) Blinks ON 14-271
P1873 PH-PLcontrollinearsolenoid
(31) Blinks ON 14-213
P1879 Stan clutchcontrollinearsolenoid
Blinks ON
t32l 14-215
P1882 Inhibitorsolenoid
(33) Blinks ON 't4-277
P1885 Drivepulleyspeedsensol
(34) Blinks ON 't
4-279
P1886 Drivenpulleyspeedsensor
(35) Blinks ON 14-281
P1888 Secondarygear shaft speed sensor
(36) Blinks ON 14-283
P1890 Shift control system
Blinks ON
\421 14-245
P1891 Start clutch control system
(43) Blinks ON 14-286
r: The DTc in parentheses
is the codeE indicatorlight indicateswhen the DataLinkconnectoris connectedto the Honda
PGM Tester.
14-240
table below.
E indicatorlight does not blink.performan inspectionaccordingto the
SYmPtom Inspection Ref.page
IDIindicatorlight does not come on for two secondsafter ignitionswitch 14-284

is firstturnedON (ll).
lE1indicatorlight is on constantly(not blinking)wheneverthe ignition 14-290
switchis ON {ll).
NOTE:
by test driving,
. lf a customerdescribedthe symptomfor code Pl706 (6),it will be necessaryto recreatethe symptom
then recheckthe DTC.
lf so, repair
. iometimes, tfre E indicatorlight and the MalfunctionIndicatorlamp (MlL) may come on simultaneously
by removingthe BACK UP RADIO fuse in the under-
the PGM-Flsystemaccordrngto the DTC,then resetthe memory
Drivethe car for severalminutesat a speedover 30 mph {50 km/h)' then
hood fuse/relaybox for more than 10 seconds.
recheckthe DTC.
14-241
ElectricalTroubleshooting('96- 98 Modelsl
TroubleshootingFlowchart- Throttleposition(Tpl Sensor
. OBOll ScanTool indic.tes Code PossibleCause

P1790. . Disconnectedthroftle position
. Self-diagnosisE indicator light
(TPl3ensorconnoctol
blinks three times. . Short or open in TP sensorwire
. FauhyTP sensol
Checklor Anothar Code or MIL

Blinking:
1. Turnthe ignitionswitchON 1 ).
2. Checkwhetherthe OBD ll scan
tool indicatesanothercode or
the MalfunctionIndicatorLamp
(MlL)blinks(seesecrion11).
Doesthe OBDll scantool indicate

anothercode
oristhe MILblink- Repairthe PGM-FIsystom (3ee
ing? section 111.
MeasureVREFVoltage: TCM CONNECTORS

2. Disconnect the A (26P)and B BLK
{ 2 2 P }c o n n e c t o r sl r o m t h e
TCM.
3. Turn the ignition switch ON
{fl).
4. Measurethe voltage bet\iveen WHT/RED
the 820 and A13 or 426 termi-
nals, Wire s;deof femaleterminals
Repairopen or short in thc wire

ls lhereapprox.5 V? b,stween the Bao tcrminal rnd the
ECM.
MeasureTPS Voltago:
Measurethe voltagebetweenthe A {26P1
B4 and A13 or 426 terminals.
ls there0.4- 0.6V? Repail open in the wire tr€tweon

the Erl t6.minal ind the TP sen3o..
Checkfor loose TCM connectors.

lf necessary,substitute a known-
good TCM and r6check.

(VSS)
TroubleshootingFlowchart - Vehicle Speed Sensor
NOTE:Recordall freezedata beforeyou troubleshoot'
Po$ribleCtuse
. OBD ll ScanTool indicatesCode
P1791. . D i s c o n n e c t e dv e h i c l e s p e e d
. Setf-diagno3isE indicato. light sensor (VSS)connectol
blinks tour times. . Short or open in VSS wire
' Faulty VSS
Refer to seclion 23 for vehicle

soeedsensor IVSSItest
Check the VSS Voltage: @

1 . R a i s et h e v e h i c l e . Make sure lifts, iacks,and sal€tYstands are placedproperly lsoe section 1)'
2 . S h i f t t h e t r a n s m i s s i o nt o l E . Set the parking brake securelv,and block the rear wheels'
posrtlon. . iacr upile rront or the vehicle,and support it with safety st'nds'
3 . D i s c o n n e c tt h e A ( 2 6 P )a n d B
(22P) connectors from the
TCM CONNECTORS
TCM.
4 . T u r n t h e i g n i t i o ns w i t c h O N { l l ) .
5. Rotate the front wheel and
check for the voltage between
the 85 and 413 or A26 termi-
nals. Blockthe other wheel so
at does not turn
Check for oP€n in the wire

between the 85 terminal and the
D o e s 0 V a n d a p p r o x5 V o r m o r e vehicle speed sensor {VSS}. lf
appearalternatelY? wire is OK, check the vSS (see
soction23).
Checkfor loos€ TCM connedors

lI nec€ssary,substitute a known'
good TCM and recheck.
14-243
ElectricalTroubleshooting('96- 9g Models)
TroubleshootingFlowchart- A/T GearpositionSwitch (Short)
. OBD ll ScanTool indicatesCode PosribleCause

P1705. . Short in A/T go.r position
. Seif-diagnosis@ indicator light
switch wire
blinksfive times. . Faulty A/T g€ar polition switch
NOTE: Code P1705(5)is causedwhen

t h e T C M r e c e i v e st w o g e a r p o s i t i o n
Obsorvethe A/T gear position Inputsat the sametime.
indicetor:
1[).
2. Observetho Ay'Tgear position
i n d i c a t o r ,a n d s h i f t t o e a c h
positionseparately.
Do any jndicatorsstayon when the Th6 lyrtcm i3 OK at thi. tima. TCM CONNECTOR
A {26P}
sh;ft leveris not in that position? Check the wi.s hamels for drm.
ag9.
MeasureATP R Vohage:
E.
the 411 and A13 or A26termi-
nats.
Check for sho.t in tho wire
b€twoonthe Al1 t rminaland th6
A/l ge.r polhion switch or A/T
ls thereapprox.10V? gear position indicstor. lf wilo is
OK check for loos6 TCM conncc-
tora. It nocassery, subrtitute a
known-good TCM and r€chsck.
MeasureATP NP Volt.ge:
1 . S h i f t t o a l l p o s i t i o n so t h e r
than @ or @.
the A10 and 413 or 426 termi-
nals,
Ch.ck tor 3hort in th€ wirc
b€twe€n thc Al0 termin.l and
the A/T 96r. porition indicrtor,
or a short in the wilea b?twecn
ls thereapprox.10V? tho A/T gerr porition indic.to.
and the A/T geer position
switch. It wires ar6 OK, chsck for
loose TCM conn.clols. ll nccNe3-
sa.y, substituto a known-good
TCM rnd locheck.
Measure ATP O Vohage:
1 . S h i f t t o a l l p o s i t i o n so t h e r t h a n
E,
the Ag and A13 or 426 termi
nals.
Checl tor short in the wire

lr€tweon tho A9 terminal and the
l s t h e r e a p p r o x . ' 1 0V ? A/T g6a. position 3witch. lf wire
b OK. check tor loos€ TCM con-
nectors. lf nocelsary, substhute a
known-goodTCM and rechack.
To page14-245
14-244
A (26P)
TCM CONNECTOR
From page l4-244
Measure ATP S Vollage:

1 . S h i f t t o a l l P o s i t i o n so t h e r t h a n
2. Measure the voltage between

the A8 and A13 or A26 termi
nals.
Wire sideof femaletermanals

Check lor shott in the wire
between the A8 terminal and the
A/T gea. Position switch or the
ls thereapprox.10V? A/T gearpositionindicator.lf wire
is OK, check for loose TCM con_
nectors. lI necessary,substitute a
known-goodTCM and recheck.
MeasureATP L Voltage:
'1. Shiftto all positionsotherthan
E-
the A7 and A13 or A26 termi-
nals.
Check for short in the wi.e

between the A7 terminal and the
A/T gear position switch or the
ls thereapprox.10V? A/T gear position indicator. lf wire
b OK. check for loose TCM con-
nectors. ff necessary,substilute a
known-goodTCM and recheck.
Checklor loose TCM connectors.

lf necessary.substitute a known'
14-245
ElectricalTroubleshooting(,96- 9g Models)
TroubleshootingFlowchart- A/T GearpositionSwitch (Openf
. OBD ll ScanToot indicat* Code Pos.riblsCause

P1706, . DisconnoctedA/T gear position
. Solf-diagnosisE indicator tight
blinb six times. switch connector
. Open in A/T gear position switch
. Faulty A/T gear position switch
TCM CONNECTOR
A I26PI
Measule ATP R Volt.gei

1. Turn the ignitionswitch ON l).
2. Shifito E position.
the A11 and 413 or ,426termi-
nals.
Repairopen in tho wire betwoen
lhe A11 terminaland the A/T
goar po3ition switch.
MeasureATP NP Volt.gei
1. Shifrto E orE position.
2. Measurethe voltage betlveen
the A10 and A13 or 426 termi
nals.
Repairopen in the wiro between

the A10 terminal.nd tho A/T
gea. poshion swhch.
MeasureATP D Vohage:
the Ag and A'13or 426 termi-
Repairopen in the wire lretween

the A9 terminel and the A/T gear
position 3witch.
To page14-Z4j
14-246
From page 14 246 A l26p)
TCM CONNECTOR
MoasureATP S Voltage:
1. Shiftto E Position
the A8 and 413 or 426 termi
nals,
Bepair open in the wir€ between Wire sideof femaleterminals

the A8 t€rminal and the A/T gear
position switch.
MeasureATP L Vohage:
1. Shiftto E Position
the A7 and A13 or 426 termi-
nals.

the A7 terminal and the A/T geal
Dositionswitch
Chocktor loose TCM connectors.

lf necessary,substitute a l(nown-
good TCM and recheck,
14-247
ElectricalTroubleshooting('96- 9g Models)
TroubleshootingFlowchart- lgnitionCoil
NOTE:Recordall freezedata beforeyou troubleshoot,
. OBD ll ScanTool indicatesCode Po3ribleCause

POl25. . Dbconnected ignition coil con-
. Soll-diagnosisE indicarol light
indicatesCode 11. nectol
. Short o. op6n ignition coil wire
' F.ulty ignition coil
MeasureNE Voltrge:
1. Disconnectthe A {26p) con
nectorfrom the TCM.
2. Startthe engine.
the A5 and 413 or A26 termi-
nals,
R6p.i. open or short in the wire

b€lween the A5 te.minsl and tho
ls there battery voltage? ignhion coil. It wir€ b OK, check
the ignition coil test lsoc aoction
23t.
Check for loose TCM connector.

It nec$sery. substilute a known-
good TCM and .echeck.

Sensor
TroubleshootingFlowchart- ManifoldAbsolutePressure{MAPI
NOTE:Recordall freezedata beforeyou troubleshoot
PG.iblo Cau3€
. OBD ll ScanTool indicatesCode
P1793, . Dkconnoctodmanilold .bsoluto
. self-diagno3b E indicato. light ore33urcIMAP) sensor connoc'
indicat€sCode 12. lor
. Short or opcn in MAP s.nsor
MAP sen3or
Chock tor Another Cod€ or MIL

Blinking:
2. Checkwhetherthe OBD ll scan
tool indicatesanother code or
the Mal{unctionIndicatorLamP
(MlL)blinks(ssesection11).
Doesthe OBDllscan tool indicate

anothercodeor isthe lVlLblink-
in9?
TCM CONNECTORS
MeasureVREFvoltage:
2. Disconnectthe A (26P)and B
( 2 2 P )c o n n e c t o r st r o m t h e
TCM.
4, Measurethe voltage between
the B2Oand A13 or A26termr WHT/RED
nals.
R€pair opon or 3hort in the wire

lsthereaPprox.5V? botwoan the 820 t€.minal and
the EcM.
MsasureMAP IPB)volt.ge:
Measurethe voltage betlveenthe
82 and A13 or 426 terminals.
Repair opon ot shorl in the wiro

ls thereapprox.3 V? betwesn the 82 torminal end th€
MAP sensol.
Checkfor loo3eTCM conn€stors.

lf nec*sarY, sub3titute a known'
good TCM and rechock.
14-249
ElectricalTroubleshooting(,96- 9g Modelsl
TroubleshootingFlowchart- Shift ControlLinearSolenoid
. OBD ll ScanToot indicatesCode PossibleCause

P1870. ' Disconnected3olenoid h.rn€is
. Selt-dirgnosis[d indic.tor tight
indicatosCode30. connoctor
. Short or open in 3hift control
linear solenoidwire
. Faulty shift control linear sole-
SOLENOIDHARNESS
noid 8P CONNECTOR
MeasureShift ControlLinoarSole- BLU/WHT

noid Resistanceat the Solenoid
HarnessConnector:
1. Disconnectthe 8p connector
fromthe solenoidharnesscon
nector.
2 , M e a s ur e t h e r e s i s t a n c e
betlveenthe No. 3 and the No. GRN/YEL
7 terminalsofthe solenoidhaF
nessconnector. Terminal stde of male terminals
3.8- 6.8O?
ls the resistance
TCM CONNECTOR
A I26PI
Check Shift Controt Linear Sote-

noid for a Short Circuit:
1 . D i s c o n n e ct th e A ( 2 6 p )c o n ,
nectorfrom the TCM.
body ground and the A3 ter
minal and the A16 terminal
individually.
Repair shon in tho wire6 betweon

the A3 and A16 termin.ts lnd tho
body ground.
GRN/YEL
M e a s u r eS h i t t C o n t r o l L i n e . r l l 1 2 l :1 5 7 8 9 10 1 1 12 13
SolenoidResistance:
1. Connectthe 8P connectorto IriGlx 1 7 2t) 23 25 26
the solenoidharnessconnec,
8LU/YEL
tor.
betweenthe 43 and A16 ter-
Repairloose terminal oa open in

ls the resistance
3.8 6.8O? the wires between the 43 and
A16 terminal3and the solenoid
harnessconnector.
Chockfor loose TCM connectorc.

ll necessary,substitute a known-
14-250
Troub|eshootingF|owchart_PH-PLControJLinearSo|enoid
NOTE| Recordall treezedata beforeyou troubleshoot
. OBD ll ScanTool indicatesCodo Possiblecause

P1873. ' Disconnectedsolenoid harness
. sef-diagnosis E indicalor light connectof
indicat6 Code 31. . Short or oPen in PH_PLcontrol
linear solenoidwire
. FaultyPH-PLcontrol linear sole_
noid
SOLENOIOHARNESS
Measure PH-PLControl Linear 8P CONNECTOR
Solenoid Resistanceat the Sole_ GRN/WHT
noid HatnessConnectot:
from the solenoidharnesscon-
nector,
betweenthe No 2 and the No.
6 terminalsofthe solenoidhar
nessconnector' PNK/BLK
Terminalsideof maletermlnals
3.8- 6.80?
ls the resistance
A (26P)
TCM CONNECTOR
o PNK/BLK
Check PH-PLControl Lineer
Solenoidfor a Short Circuit: I 2 3 4 5 7 8 I 10 l 1 1 2 13
1 . D i s c o n n e ct th e A 1 2 6 P c) o n -
nectorlrom the TCM 1 1 't5 1 6 1 7 20 /,,/ 23 25 26
body ground and the A2 ter IGRN/wHr
minal and the A15terminal
individually.
o
Repair short in th€ wires
between the A2 and A15 lermi_
nals and the body glound.
Measute PH-PLControl Linear

*r}l PNK/8LK
SolenoidResi3tance:
1. Connectthe 8P connectorto t'T, 3 a 5 I 9 1 0 1 1 12 1 3
the solenoidharnessconnec-
tor,
E[ 16 20 23 25 26
2 , M e a su r e t h e r e s l s l a n c e GRN/WHT
betweenthe ,q2 and A15 ter_
Rep.il loose tetminal or oPen in

th6 wires betwccn the A2 and
3.8-6 8 O?
lsthe resistance A15 lerminals and the solenoid
harnessconn€ctol.
Checkfor loose TCM connactors

lf neceasery,Substitutea known-
good TCM and rechock.
14-251
ElectricalTroubleshooting('96- gg Modelsl
Troubleshooting
Flowchart- start clutchcontrolLinearsolenoid
NOTE: Recordall freezedata before you t.oubleshoot.
. OBOll ScanTool indicatG Code Po$iblo C.u.o

P1879. ' Di3aonnoctodsolanoid harncat
. Self-dilgno.is E indicator light
connactol
indiclt$ Code32. . Short or opon in start clutch
control linoar tolanoid wira
. Faulty ttart clutch control lino.r
solanoid
Me.suro Sta.t Clutch Control SOLENOIDHARNESS

LinearSolenoid Rosirtrnco st th. 8P CONNECTOR
SolenoidHrrn6rs Connecto.:
1. Disconnectthe 8P connector YEL
from the solenoidharnesscon-
nector.
betweenthe No. 4 and the No.
8 terminalsotthe solenoidhar-
nessconnectot.
PNK/BLU
3.8- 6.80?
ls the resistance Terminalsideof maleterminals
TCM CONNECTOR
A I26P}
Chock Start Clutch Control Lin-

oar Solenoidtor a Short Circuit:
1. Disconnectthe A (26p) con,
nectorfrom the TcM.
body ground and the A1 ter-
r n i n a la n d l h e A l i l t e r m i n a l
individually.
Raprir 3hort in tha wira3
b.ftvcen tho A1 .nd Atil t .mi.
n.l. .nd thr body ground.
Measure Stan Clutch Cont.ol

LineerSolenoidF6aist.ncei
-{r- PNK/BLU
1. Connectthe 8P connectorto
tor.
betweenthe 41 and Al4 ter-
minals,
E 2 3 a 5
a 15 t 6 1 '
YEL
1
20
I 9 1 0 l l 12 13
a 25 2G
Rcplir loose tcrminal or oDcn in

ls the resistance
3.8- 6.8O? thG wiras b.tween the Al rnd
Ala torminal3 rnd tha 3olanoid
hamaas connactor.
Checkfor loose TCM connecto.s.

lf necessary, substitute a known-
good TCM and iecheck.
14-252
TroubleshootingFlowchart- InhibitorSolenoid
NOTE:Recordall treezedata betoreyou troubleshoot
. OBD ll ScanTool indic.td Code Po$ibls Cause

P1882. . Dbconnected solenoid hatness
. Selt-di.gnGis E indicator lighl connedor
indic.tos Code 33. ' Short or opon in inhibitor sole'
noid wire
. Faultv inhibitor solenoid
Mea3ureInhibhorSolenoidResid- SOLENOIDHARNESS
ance at the sol€noid Harness 8P CONNECTOR
Connector:
f r o m t h e s o l e n o i dh a r n e s s
connector.
2. Measure the reslstance
betlveenthe No 5 terminal of
tor and body ground.
11.7- 21 0 0?
ls the resistance
Check Inhibitor Solenoid lor a

Short Circuii:
1 . D i s c o n n e ctth e B ( 2 2 P )c o n -
nectorfrom the TCM.
t h e B 1 t e r m i n a la n d b o d y
gro!no.
Repairrhort in the wire ltetwegn

the 81 dnd the bodY ground.
Mea$rr€ Inhibitor Solenoid ResBt'

anoe:
1. Connectthe 8P connectorto
the solenoidharnessconnec_
IOr.
betweenthe Bl and body
ground.
Reoair loose terminal or open in

11.7- 21.0O?
ls the resistance the wire betwean the 81 and the
solenoid hame3sconnector'
Ch6ckfor loose TCM connectors.

ll necessary, substhule a known_
good TCM and techeck.
14-253
ElectricalTroubleshooting{'96 - 9g Models)
TroubleshootingFlowchart- DrivepulleySpeedSensor
NOTE:Recordall freezedata beforeyou troubleshoot,
' OBD ll ScanTool indicatesCode Po$ible Cause

P1885. . Oisconn€cted drive pulley speed
. Self-diagnosisE indicator tight
sensorconnector
indicatesCode34. . Shon or op€n in drive pulley
spgedsonsorwire
. Faulty drive pulley spoed s.n-
sot
C h e c kt h e d r i v e p u l l e y s p e e d s e n ,
sor installation.
ls the drivepulleyspeedsen-
sor installedproperly? ORIVEPULLEYSPEED
SENSOR2P CONNECTOR
M6a3ureDrive PulleySp€ed S€n- lT_ T---_l

sor Resistanceai the Seosor Con-
nectot:
-rr1 | 2 tl
t| ]--+i
from the drive pulley speed
sensorconnector.
lt 9l
2. Measurethe resistance
drivepulleyspeedsensor.
of the
L_t
TerminalsideoI maleterminals
ls the resistance350 - 600 O?
TCM CONNECTOR
8 I22PI
Check Orive Pulley Speed Sen- REO/BLUJ ( l
sor tor a Short Circuit:
1. Disconnect the B (22P)connec-
tortromthe TCM.
2. Checkfor continuitybetveen
body groundand the 810 ter-
2 4 5 6
1 2 1 3 t 4 15 1 6 1 7 1 8
8 9 10
20
v
m i n a la n d 8 1 7 t e r m i n a il n d i GRN
vidually. o
Rspair shon in the wi.es botwoen

the Bl0 and 817 te.minals and Wiresideof femaleterminals
the driva pulloy 3peod 3eniol.
Measure Drive Pulley Sp€€d Sen-

sor Re3istance:
1. Connectthe drivepulleyspeed
sensor2P connector.
2 , M e a su r e t h e r e s i s t a n c e REO/8LU
betweenthe 810 and 817 ter-
mtnals.
1 2 1 5 iliI;W1M
Repair loos6 t.rmin.l or open in 12 1311 15 1 6 tdil)lil/l
350- 600O?
ls the resistance th. wiros botweon tho Bl0 and
817 torminals and thg driva pul- GRN
ley sp€gd sensor.
Check tor looso TCM connoctor.

ll necessary,substituto a known-
14-254
TroubleshootingFlowchart- DrivenPulleySpeedSensor
. OBD ll ScanTool indicatesCode Po3sibleCause

P1886. . D i s c o n n e c t e dd t i v e n P u l l e Y
. Sell-diagnosisE indicator light so6edsensorconnector
indicatesCode 35. . Short or open in driven PulleY
apeedsen3orwire
. Faulty driven PulloYsPeod 3en-
DRIVENPULLEYSPEEO
SENSOR2P CONNECTOR
ls the drivenPulleyspeedsen-
sor installedproPerlY?
l-_r-
| 1 2 l
:-
M€asure Driven Pulley SP€edSen_
sor Resbt nce at the SensorCon-
neclof:
tt 9t
from the driven PUlleyspeed L_.1
sensorconnectol.
ot the Terminalsideof maletermrnals
2. Measurethe resistance
drivenpulleyspeedsensor.
350 6000?
ls the resistance
TCM CONNECTORI l22p)
REO/BLU WHT
^\, o
Check Driven Pulley Speed Sen-
sor {or a Short Circuit:
1. Disconnectthe B (22P)connec_ 1 2 a 6 8 9 10
tor from the TCM. '16 '17 18 20
12 13 1 a 15
body ground and the BB ter
minaland 89 terminalindivid'
Repair sho.t in the wiles between Wire side oI female terminals

lhe 88 and Bg lerminals tnd the
driven pulleY3Peed3€nsor.
RED/BLU] WHT
Measure Driven Pulley SPeedS€n-
sor Reistance:
1 . C o n n e c t h e d r i v e nP u l l e Y
o
speedsensor2P connector' 1 2 1 6 8 10
2 . M e a s ur e t h e r e s i s t a n c e
betweenthe 88 and Bg terml_ 12 1 3 1 a 1 5 1 6 1 7 1 8 20
nals.
Repair loos€ terminal or oPen in

the wires between the Bg and Bg
350- 600O?
ls the resistance torminals and the dtiven Pulley
3D6eO S6n50a,
Check lor loose TCM connector.

lf necessary,substitute a known_
good TCM and rechack.
14-255
TroubleshootingFlowchart- SecondaryGearShaftSpeedSensor
. OBD ll ScanTool indicatesCode Po$ible Cause

P1888. . Disconnectedsecondarygeal
. Selt-diagnosisIq indicator light
shaft speodsen3orconnectol
indicatesCode 36. . Short ol open in s€condary gear
shaft spe€d sen3or wiro
. Faulty secondary gear shatt
speeds€nsor
Checkthe secondarygear shaft
speedsensorinstallation.
SECONDARY GEARSHAFTSPEED
ls the secondary
gearshaftspeed SENSOR2P CONNECIOR
sensorinstalledproperly?
MeasureSecondaryGear Sheft llll;ll

Speod Sensor R8istance at the T_T
SensorConnector:
l @
from the secondarygearshaft t l
2. Measurethe resistanceol the
LJ
secondarygear shalt speed Terminals i d e o f m a l e t e r m i n a l s
350- 6000?
ls the resistance
TCM CONNECTOR
B {22P}
Check Counterchaft Speed Son-
sor for a Short Circuit:
1. Disconnectthe B 122P)connec I 2 1 5 6 9 10
torfromtheTCM. 12 131 a 15 16 1 7 18 20
body groundand the 815 ter WHT/REDT - ORN/BLU
m i n a la n d 8 1 6 t e r m i n a il n d i
vidually. D (o.
Repair short in the wir€6 bctuveen
ls therecontinuity? th. 815 and 816 torminrls.nd Wire sideof femaletermanals
the s€condary ge.r shaft speod
Measu.e Secondary Gear Shatt

Speed Sensor Resistance:
1. Connectthe secondarygear 1 a 5 6 7 8 I 10
shaftspeedsensor2P connec- 1 2 13 1 4 1 5 1 5 1 7 1 8 20
betweenthe 815 and 816 te.
mrnals.
WHT/REI
A
I
ORN/BLU
Reprir loose terminal or opcn in

ls the resistance
350 600O? the wires between the 815 and
8'16terminals and the secondary
g€ar shaft sp€ed s€nsor,
Check lor loose TCM connector.

lf n€cessary, substitute a known-
14-256
TroubleshootingFlowchart- TMA and TMB Signals
NOTE:Recordall freezedatabeforeyou troubleshoot'
. OBD ll Scsn Tool indicate3Codo PossibleCause

P1655. . Shorl or op.n in TMA wi.o
. Self-diagnosbE indicator light botwo6n 87 terminal and ECM
indicalesCod6 37. . Short or open in TMB wiro B (22P)
TCM CONNECTOR
bdtwoon BGto.min.l .nd ECM
GRY
. F.ulty ECM
. FaultyTCM
o
CheckTMA Wire Continuity: I 2 a 5 8 9 10
1. Turnthe ignitionswitchOFF. 20
12 1311 1 5 16 17 18
2- Disconnectthe I (22P)con-
nectorlrom the TCM
3 . D i s c o n n e ct th e c ( 3 1 P )c o n ' C 13lPI
ECMCONNECTOR
nectorfrom the ECM
4. Checkfor continuitybetween GRY
t h e 8 7 t e r m i n a lo f t h e T C M
and the Cg terminaloI the 1 2 3 a 5 6 l8 9r0
ECM, 1 112 t 3 l a 16 18/ /
29130/
WiresideoI temaleterminals
Ropail open in the wire betwcen
the TCM and the ECM.
::)
Check TMA Wir€ for a Short Cir-
cuit: I 2 a 5 6 8 9 10
Checkfor continuitybetweenthe 20
12 t 3 1 4 1 5 1 6 1 7 1 8
87 terminalof the TCM or the Cg
t e r m i n a lo l t h e E C M a n d b o d y
ground.
check rhe EcM:

1 . R e c o n n e ctth e C ( 3 1 P )c o n '
nector to lhe ECM, and the B
(22P)connectorto the TCM
t h e C 9 t e r m i n a lo I t h e E C M
and body ground.
Chocktor loose ECMconnectors.

ls thereapprox.10V? lf nscossary,subdituta a known'
good ECM.nd lecheck.
(cont'd)
To page14 258
14-257
ElectricalTroubleshooting('96- 98 Models)
TroubleshootingFlowchart- TMA and TMB Sigrrals(cont,d)
from page14 257
CheckTMB Wire Continuity: TCM CONNECTOR

8 {22P}
1. Turnthe ignirionswitchOFF.
2. Disconnect the C (31P)connec, PNK
tor from the ECM,and the I o
(22P)connectorfrom the TCM.
3. Checkfor continuitybetween 2 I 6 7 t 8 I 10
t h e 8 6 t e r m i n a lo l t h e T C M
a n d t h e C 3 0 t e r m i n a lo f t h e 12 1314 16 17 18 20
ECM,
ECMCONNECTOR
C 131P}
2 a 5 6 7 8 I 10
ll 12 1 3 l a 17118
Repairopen in the wire betwe€n
rhe TcM and the EcM. /l/l )/)/l/l )aol'ol/
PNK
Check TMB Wire tor a Short Cir-

cuit:
Checkfor continuitybetweenthe PNK
8 6 t e r m i n a lo t t h e T C M o r t h e o
C 3 0 t e r m i n a lo t t h e E C M a n d
body ground. 2 4 5 6 , 8 9 10
12 1 3 1 1 1 5 1 6 1 1 1E 20
ls therecontinuity?
Checkthe TCM:
1 . R e c o n n e ctth e B ( 2 2 p )c o n -
nectorto the TCM, and the C PNK
(31P)connectorto the ECM.
3. Measurethe voltage between 2 1 5 7 8 10
t h e B 6 t e r m i n a to f t h e T C M
and body ground. 1 2 13 1 4 1 5 1 6 1 7 1 8 20
ls thereapprox.S V?
Checkfor loose TCM connoctors.

lf necessary,substitute e lnown-

Po$ible Cause
OgD ll ScanTool indicatesCode
P'1890. Faulty 3hift control system
Self-diagnosi3E indicator light
indicatesCode 42.
Checkfor Anolhet Code:

C h e c kw h e t h e rt h e E i n d i c a t o r
lightindicatesanothercode.
P e r t o r mt h e T r o u b l e s h o o l i n g
ls the E indicator light indi Flowchrrt to. th€ indicet.d
cate another code? Codelsl.
CheckStall SpeedRPM:
M e a s u r et h e s t a l l s p e e dR P M
(seepage14-298).
ls the stallspeedover 3,500rpm?
l s t h e s l a l l s p e e d b e l o w 2 . 0 o 0r p m )
T e s t - d r i v ea n d C h e c k En g i n e
Speed:
1 . D r i v et h e v e h i c l ea t 3 0 m P h
(50 km/h) constantlYfor sev_
eral manutes.
2. Checkthe enginespeed
ls the engine speed within the

s p e c i f i c a t i o n( s e e p a g e 1 4 2 9 6
and 14 297\?
14-259
TroubleshootingFlowchart- Start ClutchControlSystem
OBOll ScanTool indic.le3 Cod6 Po$ible Ceuaa

P1891. Frulty start clutch cont.ol 3ys-
Solt-diagnosisE indicator light tem
indicatesCode(1.
Checkfor Another Codo:

C h e c kw h e t h e rt h e @ i n d i c a t o r
light indicatesanothercode.
ls the E indicatorlightindi- Poiform tho Troublcahootlng

cateanothercode? Flowchrrt lor the indicat.d
Code(sl.
Test Strrt Clutch Oper.tion:

from the solenoidharnesscon,
nector.
3. Start the engine,and shift to
E position.
4 . C h e c kw h e t h e r t h e v e h i c l e
moves.
Rcplacath. strrt dudt r$amt ly.
CheckCreepingSpe€d:
2. Reconnectthe 8P connectorto
tor,
3. Start the engin6,and shift to
E position.
creeps,and chockthe creep-
Ing speed.
Does the vehicle move and is

the creepingspeed approx.3
mph (5 km/h)?
To page 14-261
14-260
From page 14 260
CheckStall Speed RPM:

Measurethe stallspeedRPM(see
page14'298).
ls the stallspeedover3,500rpm?
Warm Up Engine and Recheck

Failure:
1 . W a r m u P t h e e n g i n et o n o r '
m a l o p e r a t i n gt e m P e r a t u r e
(theradiatorfan comeson)
2. Checkwhetherthe startclutch
problemappearsagain.
Doesthe problemappear?
The svstem is OK at this time.
rl,
14-261
J
ElectricalTroubleshooting('96- 98 Modelsl
TroubleshootingFlowchart- Pl IndicatorLight DoesNot GomeOn
The E Indicator light does not

come on when the ignition switch
is tirst turned ON {ll). {lt should
come on for aboul two s€conds,)
Chockthe ServiceCheckConnec-
lot:
Make sure the specialtool (SCS
S e r v i c eC o n n e c t o ri)s n o t c o n
nectedto the seryicecheckcon
nector,
ls the specialtool (SCSService Disconn€ctthe sDecialtool from

Connector) connected to the ser- the seruicecheck connector and
vicecheckconnector? recheck.
Checkthe E IndicatorLight:
Shift to [5] oosition.
Doesthe E indicatorlight Checkfo. loose TCM connectors.

lf neceasary, substitute a known-
comeon?
good TCM .nd rochock.
A {26P)
TCM CONNECTOR
BLI
Ch€ckth6 Ground Circuit: l-
1. Turnthe ignitionswitchOFF. I
2 . D i s c o n n e ct th e A 1 2 6 P c) o n - 1 2 3 a 5 8 9 1 0 1 t 12 nl
nectorfrom the TCM.
t h e A 1 3 t e r m i n a la n d b o d y
1a 15 16 17 20 23 25 rt
ground and the 426 terminal 8LK
and body ground.
o
.Repair open in the wires

betwoon lhe A13 or A26 termi-
nel3and G101.
. Repai.poorground{G1011.
To page14-263
14-262
Ftom page14 262
A I26P)
TCM CONNECTOR
BLK/WHT I BLK
Measure Powet SUPPIYCi.cuit
Voltage:
1. TurntheignitionswitchON (ll)
2 a 7
r
1 0 1 1 12 13
s 1 2a n d A 1 3a n d
t e r m i n a lA
b e t w e e nt e r m i n a l sA 2 5 a n d 14 t5 16 17 20 23 25 26
426.
A
I BLK
BLK/WHT I
between the A'12andlor Ms ler-
ls there batteryvoltage? minrls and the under-dashfuse
DOX,
MeasureD IND Voltage:

2. connect the A (26P)connec
tor to the TcM.
3. Connecta digkal multitester
to the A20and A'13or A26ter
minals.
4. Turnthe ignitionswitchON (ll),
and makesure that the voltage GRN/BLK
is availablefor two seconds.
Check tor opon in the wire

between the A20 l6rminal and
the gaug€ assembly. It the wite
is OK, check tor a faultY ipl indi-
calor light bulb or a faulty gauge
assemblyprir ed circuit boatd. A (25P}
TCM CONNECTOR
CheckD INOfor an Shott Circuit:
2 . D i s c o n n e ct th e A ( 2 6 P )c o n - 1 2 a 5 8 9 1 0 1 1 12 1 3
nectorfrom the TCM. 1 l 15 16 1 7 20 23 25 26
the A20terminalandthe No.I GRN/BLK
terminalof the gaugeassem- GAUGEASSEMBLY
bly connector(seesection23). 14PCONNECTOR
o
Bepair open in the wire between a 5
the A20 terminal and the gauge 7 8 9 10 1 1 12 14
assembly.
GRN/BLK

Checktor looso TCM connecto.s.
C h e c kt h e A / T g e . r P o s i t i o n
switch. lf nec6ssary,substitute a
known-goodTCM and r€check

TroubleshootingFlowchart- lq IndicatorLight On Constantly
The E indic.tor light is on con-

stantly {not blinking}whonever
the ignilion switch is ON llll.
TCM CONNECTOR
A {26PI
MeasureD INOVoltage:
2 3 4 7 8 1 0 l l 12 13
2 . D i s c o n n e ct th e A ( 2 6 P )c o n ' 1a 15 16 1 7 20 23 25 26
nectorfrom the TCM.
GRN/BLK
t h e A 2 0 t e r m i n a la n d b o d y
ground,
Repeir3hort to power in thc wire

between tho A20 terminal and
ihe gauge ass€mbly.
MeasureATP DVohage:
1. Turnthe ignitionswitchOFF. YEL
2. Connectthe A (26P)connec-
tor to the TCM.
3. Turnthe ignitionswitchON (ll). 1 2 3 a 5 7 8 9 1 0 1 t 12 1 3
4. Shift to any positionotherthan
E, 1a t5 16 17 20 a 25 26
t h e A 9 t e r m i n a la n d b o d y
ground.
Check tor a short to ground on

the wire. ll wire is OK, .epl.ce
the A/T gear position indic.tor.
14-264
TroubleshootingFlowchart- A/T GearPositionSwitch (Short)
. oBD ll scln lool indicats code Po3sibleCause

P't705. . Short in A/T gear po3ition 3witch
. Self-diagnosbE indicator light
blinksfivetim€s. . F.ulty A/T ge6r Positionswitch
NOTE: Code P1705(5)is causedwhen

t h e P C M r e c e i v e dt w o g e a r P o s i t i o n
inputsat the sametime.
Obseive tho A/T Gear Polition
lndicetor:
2. Observethe A,/Tgear positaon
indicator,and shift oach Posi-
tion separately.
Doesany indicatorstay on Tho ry3t6m is OK at this tims.

when the shiftleveris not an Check th€ wiro hsrno!! tor
that position? damage.
PCMCONNECTORS
Bt25Pt llO(16P1
M.Furo ATP R Vohtge:

1. Shift to all positionsother than
E.
2. Measurethe voltage between LGl (BRN/8LKI LG2(BRN/8LKI
the D6 and 820 or 822 termi'
nals,
Chock for lhort in tho wit€

betwe€n the D6 telminal and thg
A/T ge.r position 3witch or A/T
gear po3ition indicttoi, !nd
chcck for open in the witgs
ls thereapprox.10V? botwo€n the 820 lnd 822 tetmi_
n.ls and body g.ound (G1011. F
wiro3 ere OK, checktor loo3oter'
minal fit in the PrCMconnoctors.
ll n6c€3sary, 3ubstitute a known-
good PCMand rochock.
(cont'd)
To page14 266
14-265
Troubfeshooting Flowcharl - AIT Gear Position Switch {Short) {cont,d}
Frompage14 265
MeasureATP NP Voltage:
'1. Shiftto all positions A t32Pl jl
otherthan B {25P)
EorI
the A9 and 820 or 922 te(mi-
nals.
LGl IBRN/BLK) LG2 {BRN/BLK}

betwoen ths Ag terminal and the
A/T gerr position switch, .nd in
the E .nd E position3ignal
wiros botween the A/T gear
ls thereapprox.10V? position indic.tor and the A/T
gear positaonswitch. lf wircs .re
OK, checktor looseterminal tit in
the PCM connectols. lf n€ces-
3ary, substitute a known-good
PCMand rocheck.
Me.sure ATP D Vohago: ATPD (YEL)

1 . S h i f t t o a l l p o s i t i o n so t h e r
t h a nE . a l32Pl ll B (25P1
the 47 and 820 ot 822 tet-r'i-
nals,
LG1 {BRN/ALKI LG2 IBRN/BLK)
Check tor 3hort in lhe wire

b€twaen thc A7 terminel and the
A/T g6ar position switch. lf wir.s
ls thereapprox.10V? are OK, ch.rckto. loose terminal
fit in th6 PCM connectoF. lf nsc-
ossary.substhute a known-good
PCM and ..check.
To page 14-267
14-266
Frompage14-266
PCMCONNECTORS
M6asureATP S Voliag€:
1 . S h i f t t o a l l p o s i t i o n so t h e r B t2sP) D (16P1
than E.
the D13and 820 or 822 termi
nals.
LG1{BRN/BLKI ATP S {LT GRN/RED)
LG2 (BRN/BLKI
Wire sideof Iemaleterminals

between the D13 terminal and
the A/T gear position lwitch or
'10 A/T goar position indicator. It
ls thereapprox. V? wir6s are OK, checklor loose l€r-
minal fit in the PCM connectors.
ll nec*3arv, substitute a known'
good PCMand r6check.
PCMCONNECTORS
t32Pl B t25Pl
MeasureATP L Voltage:
1 . S h i { t t o a l l p o s i t i o n so t h e r
than E.
nals.
Check lor sho.t in ihe wire

betwgon the A22 terminal and
th. A/T geat position switch or
A/T gear position indicator. It
ls thereapprox-10V? wires are OK, ch€ckfor 10036ter-
minal fit in the PCM connectors.
lf n6cessery,substitute a known_
Checktor loos€ terminalfit in the

PCM connectors, It nec6s3arY,
and rech6ck.

ElectricalTroubleshooting{'99- 00 Models)
Flowchaft- AIT GearPositionSwitch (Openl
Troubfeshooting
NOTE:Recordallfreezedata beforevou troubleshoot.
. OBD ll Scan Tool indicstE Code Po$ible Cau3e

P1706. . OilconnectedA/T goar position
. Selt-diagnGi! E indicato. light
switch
blinks six tim€a. . Op€n in A/T go.r po.ition switch
wi?o
. Faulty A/T gear polition switch
Test the IVT gear position switch

(seesection23).
PCM@NNECTORS
Measu.eATP R Voltage:
2. Shiftto E position. B {25P) I tO (16P1
nals,
(BRN/BI.XI LG2IBRN/BLKI
wire side of fomale terminals

Ropair opcn in the wi.. hr.raGn
th6 DOtorminrl lnd the A/t g..r
position awitch.
ATP NP ILT GRNI

MeasureATP NP Vohage:
'1. Shiftto
E or N position.
2. Measurethe voltage between A t:r2Pt Il s tzspt
the A9 and 820 ot 822 letmi-
nals,
I-G1(BRN/BLKI LG2 {BRN/BLK)
Ropair op6n in th€ wiro b€{woan

the Ag t.rminal and the A/T go..
position .witch.
To page14 269
14-264
Frompage14-268
Moasule ATP D voltago:

1. Shiftto El position. A {32P} ll B l25Pl
the A7 and 820 or 822 termi
nals.
LGl IBRN/BLK) LG2 (BRN/BLKI
Repairopen in the wira betwo6n

the A7 torminal and the A/T ge.r
po3ition switch.
MeasureATP S Vollag6:
'1. Shiftto position.
E
the D13and 820 or B22termi
nals.
LGl IBRN/BLK}
Repairop€n in tho wire between

ihe D13 terminal .nd the A/T
gear position switch,
To page14-270 (cont'd)
14-269
ElectricalTroubleshooting{'99- 00 Models}
TroubleshootingFlowchart- A/T GearPositionSwitch (Openl(cont'dl
Frompage14-8-269
PCMCONNECTORS
B (25P1
MsasuroATP L Voftage:
nals,
Bepair opon in the wiro bgtw€en

lho A22 torminal and the A/T
goar poihion lwitch.
PCMCONNECTOR
B I25PI
Check LG Wiro for .n Open Cir-
cuit:
'] Turnthe ignitionswitchOFF. 1 2 .15 / 7 I
2. Checklor continuitybetween 9 't0 l 1 Br1/l/41it8
the 820 t€rminaland body
ground,and betweenthe 822
LGT(BFN/ALK}
ll
terminaland body ground. l L G 2IBRN/BLKI
o) (o)
Ropai' op.n in the wir€a botw.€n

the 820 rnd 822 toJminals .nd
body ground, and .opsi. pool
ground(Gl01l.
Check tor loose te.minal frt in th6

PCMconn€ctors, lf n€cessary,sub-
stitut€ a knowo-good PCM and
a6check,
14-270
TroubleshootingFlowchart - Shift Control Linear Solenoid
J
.OBD ll Scan Tool indicatos PossiblcCause

Code P1870. . Disconn€ctedsolenoid harnos3
. Solf-diagnosisE indic.lor light connectol
indic.t€s Code 30. . Short or oDen in shilt control
linetr solonoidwiro
. Faulty shift control linear sole_
noid
. Op€n in VB SOLwite
. ODen in PG'l and PG2 wires or
poor ground {G10'l)
PCMCONNECTORS
M6a3ureVB SOLvoltage:
1. Turnthe ignitionswitchOFF. -
B(25P) Dll6P)
2. Disconnect the B 125P)and D
PCM,
nals.
LG1IBRN/BLKI
wire sideot femaleterminals
f, Repairopen or shod in the wire

between the D5 terminal and the
under-dashtuso/telay box.
B PsPI
PCMCONNECTOR
PG,IIBLK)
Checkthe Ground Circuitl
the terminafs 82 and 822 and
820.
LG1 IBRN/BLKI LG2IBRN/BLK)
Repairopen in the wi.e betwoen

the termin.ls 82, B10, B20,and
822 and G101. Repair Pool
ground(G101).
a {cont'd)
10 page14-272
14-271
('99- 00 Models)
TroubleshootingFlowchart- Shift GontrolLinearSolenoid(cont'dl
tuom page14 271
HARNESS8P CONNECTOR
SOI."ENOID
M e a s u r eS h i f t C o n t r o l L i n e a r SH LSP
Solenoid R6sistanceat the Sole-
noid Hrrness Connector:
1. Disconnectthe solenoidhar
ness8P connector.
betweenthe No. 3 and No- 7
terminalsoI the solenoidhar SH LSM
ness8P connector,
3.8- 6.8o?
ls the resistance
PCMCONNECTOR
D {16P}
SHLSMIGRN/YELISHLSP{BLU/WHTI
Check Shift Control Lin€ar Sole-
noid tor a Short Circuit:
body groundand the D3terminal
and D4terminalindividually.
Rep.ir short in th€ wir€ tr€twlren

ihe D3 and D4 torminab .nd the Wire side oI temale terminals
shift cont.ol line.. solenoid.
SH LSM {GRN/YELI SH LSP IALU/WHT}

Measure Shitt Conirol Lineer
SolenoidResbtance:
1. Connectthe solenoidharness
8P connector.
betweenthe D3 and D4termi-
nats.
Repeir loose ierminrl or open in

3.8- 6.8O?
ls the resistance the wire3 between tho D3 and D4
terminals end the shift control
linear solenoid.
Checktor loose terminal fit in the

PCM connector3,It necessary,
and recheck.
14-272
TroubleshootingFlowchart- PH-PLControlLinearSolenoid
NOTE: Recordall freezedata before you troubleshoot.
. OBD ll Scan Tool indicates Possiblsc.use

Codo P1873. . Oisconn6dod solenoid harness
. sslt-disgnosisE indicltor light conn6ctol
indicatesCode 31. . Short or ooen in PH-PLcontrol
linear solenoidwire
. F.ulty PH-PLcont.ol linear sole-
noid
. ODenin VB SOLwire
. Op€n in PGl and PG2 wires or
poor groundlG101l
PCM CONNECTORS
Mo.surevB SOLVohagg:
2. Disconnect the 8 (25P)and D
( 1 6 P )c o n n e c t o r sf r o m t h e B (25P1 D {16P}
PCM,
3. Turn tho ignitionswitchON (ll),
nals,
(BRN/BLX)
Ropairopen or shod in the wiJe

bstwaon tho D5 terminal and the
under-dalh tuso/relaybox.
B (25P|
PCMCONNECTOR
Checkthe Ground Circuh:
2. Checktor continuity between
820.
LGT IBRN/BLKI LG2IBRN/BLK)
Fepair open in tho wiro b€tw€en

tho torminds 82, 810, 820, and
822 and G101. Repair Poor
ground(G1011.
(cont'd)
Fo page 14-274
14-273
Electrical ('99- 00 Models)
Troubleshooting
TroubleshootingFlowchart - PH-PLGontrol Linear Solenoid (cont'd)
Frompagel4-273
SOLENOIDHARNESS8P CONNECTOR
Mea3ure PH-PLControl Linear HLCLSP

Solenoid Rosistanceat lhe Sole-
noid HarnessConnector:
1. Disconnectthe solenoidhar-
ness8P connector.
betweenthe No. 2 and No. 6
terminalsoI the solenoidhar
ness8P connector. HLCLSM
Terminal side of male terminals
3.8- 6.8O?
ls the resistance
B (25PI
PCMCONNECTOR
HLCI.SM (PNK/BLK)
CheckPH-PLControl LinearSole-
noid lor a Short Circuit:
body groundand the 88 terminal
and 817 terminalindividually.
Rep.i. 3hort in the wiro bsh^,een

lhc 88 and 817 terminals and the Wiresideof femaleterminals
PH-PLcont.ol linear solenoid.
HLCLSM {PNK/BLKI
Measure PH-PLControl Linear -j-

SolenoidResistance: 3 5 / 1 1i 8
1. Connectthe solenoidharness I l0 A/'.nlisl
8P connector, 20 i.((
betweenthe 88 and 817 termi-
nals.
HLCLSP IGRN/WHT}
Repair loose te.minal or open in

ls the resistance
3.8-6.8 O? the wires between the 88 rnd
817 te.minlb .nd the PH-PLcon-
trol linear solenoid.
Checklor loose ierminal fit in the

PCM connectoTa.lf necessary,
.nd recheck.
1 4- 2 7 4
TroubleshootingFlowchart- Start ClutchControlLinearSolenoid
Po$ible Cause
'OBD ll Scan Tool indicates
Code Pl879. . Disconnectedsolenoid harness
. self-diagnosisE indicstor light connedol
indicatesCode 32. . Short or open in sta.t clutch
control linear solenoidwiro
. Faulty3tart clutch conttol lin€ar
solenoid
' Ooen in VB SOLwire
. Open in PGI and PG2 wires or
poor ground{G101)
PCMCONNECTORS
MeasureVB SOLVoltag6:
2. Disconnect the B {25P)and D B l25P) -- o l16P)
( 1 6 P ) c o n n e c t o r s{ r o m t h e
PCM.
nals,
LGl IBRN/BLK)
Reprir opon or short in the wire

ls there batteryvoltage? between the D5 terminal and the
undei-d.sh luse/relaYbox.
B {25PI
PCMCONNECTOR
Checkthe Ground Ciicuit:
the terminafs 82 and 922 and
820.
LGl (BRN/BLKI
Rep.ir open in the wire betwesn

the terminab 82, 810, 820. tnd
ls therecontinuity? 822 and G101. RePair Poor
groundlG101l.
(cont'd)
To page14-276
14-215
Electrical ('gg- 00 Modelsl
Troubleshooting
TroubleshootingFlowchart- start clutch control Linearsolenoid(cont,d)
Frcmpage14.275
Measurs Start Clutch Control

Linear Solenoid R€aistanceat ths
Solenoid Harne€sConnector:
SC LSP
1. Disconnectthe solenoidhar-
ness8P connector.
2 , M e a s ur e t h e r e s i s t a n c e
betweenthe No. 4 and No. I
terminalsof the solenoidhar-
ness8P connector,
SC LSM
T6rminalsideof maleterminals
ls the resistance
3.8- 6.80?
Check Start Clutch Control Line.r

Solenoid tor a Short Circuit:
Checkfor continuity between tho
body ground and the 818 termi-
nal and B2Sterminal individually.
R€p.ir short in th. wire bctw.on

th6 818 and 825 termin.lr rnd Wire side of f6maleterminals
the 3hift cont ol linc.r solonoid.
Measure Start Clutch Control

LinearSolenoidR6ist.nco:
1. Connectthe solenoidharness
8P conn€clor.
2. Measure the resistance SC LSM
(PNK/BLU)
betlveenthe 818 and 825 ter,
mtnats,
Raprir looa. t€.minal or opan in

ls the resistance
3.8-6.8 O? tha wirars lratwe.n the B18 and
825 terminal3 and tha st!rt
clutch control linoar 3olanoid,
Checkto. loose tarminal fit in tho

PCM connactors. It necessary,
and recheck.
14-276
TroubleshootingFlowchart- lnhibitorSolenoid
.OBD ll Scan Tool indicaies Po3sibleCause

Codo P'l882. . Oi3connec'tedsolenoid harn6s
. Self-diagnosisE indicttor light connectoa
indic.tes Code 33. . Shorl or open in inhibitor 3ole-
noid wir€
. Faulty inhibitor solenoid
. ODenin vB SOLwire
. Open in PGl and PG2 wires or
poor ground{G101}
PCM CONNECTORS
Me'sure VB SOLvoltagel
PCM.
4. Measu.e the voltage between
the D5 and 820 or B22termi-
nals.
(BRN/BLKI

ls there bafteryvoltage? between the D5 tolminal and the
undor-dashlu36/relay box.
B {25P}
PCMCONNECTOR
Ch€ckthe Ground Circuit:

b e t w e e nt e r m i n a l sB ' 1 0a n d
820.
LGl IBRN/BLKI LG2(BRN/BLKI
R€pairopen in the wire between

the torminal3 82, 810, B20, and
B 2 2 . n d G 1 0 1 . R e P a i rP o o r
ground{G101).
(cont'd)
To page14-278
14-217
('99- 00 Models)
Troubleshooting
Electrical
TroubleshootingFlowchart - Inhibitor Solenoid (cont'dl
Ftom page 14-277
Mersure Inhibitor SolenoidR6b-
t.nce at the Solenoid Harne3s
Conn€ctor:
1. Disconnectthe solenoidhar,
ness8P connector,
2. Measure the resistance SOL INH
betweenthe No.5 terminalof
the solenoidharness8P con-
nectorand bodyground.
11.7- 21.0O?
ls the resistance
Check Inhibitor Solonoid fo. . B t25P) ll D t16P)

Short Ci.c!it:
D2 and 820 or 822terminals.
LGl IBRN/BLKI
Wire sideoI temaleterminals

R.p.ir 3hort in thc wire botwaan
th€ 02 t.rminal and the inhibhot
solenoid.
Measur6 Inhibitor Solenoid

Re3istance: B t25Pt otl6Pt
1, Connectthe solenoidharness
8P connector.
2, Measure the lesistance
822terminals.
LGl {BRN/ALKI
Rcpair loo3. tarminal or opan in

11.7- 21.0O?
ls the resistance tho wha brtw.€n tho D2 to.mi-
nal .nd tho inhibitor lolonoid.
Checkfol looso torminal fit in the

PCM connectors. lf n€cessaay,
and r€check.
14-274
Troubleshooting Flowchart - Drive Pulley Speed Sensor
NOTE:Recordallfreezedata beforeyou troubleshoot'
.OBD ll Scan Tool indicates PossibleCau3€

Code Pl885. . Disconnected diive PulleY
. Selt-diagnosbE indicator light soeeds6n3orconnectol
indicatosCode 34 . Short or open in drive Pull.Y
sooed sonsor wire
. FaultY drive PulleY spo€d sen'
301
checkthe drive pulleYsPeedsen-
sor installation,and check it for
damage.
ls the drive PulleYspeedsen-

sor installedproperly,and not Rein3tallor roplaceand techeck
damaged?
DRIVEPULEY SPEED
SENSOR@NNEfiOR
Measuro Drive PulleY Speed Sen_

sor Ro3istanco at the Sonsol
Connector:
1. Disconnectthe 2P conneclor
from the drive Pulley speed
sensor,
2. Measuredrive Pulley speed Terminalsideof maleterminals
sensor resislanceat the sen-
sor connecror.
ls the resistance350 - 600 O?
D (16PI
PCMCONNECTOR
CheckDrivo PulleYSP6€dSen3o.
lor . Short Circuit:
1. Disconnectthe D {16P)connec- NDR SG IGRNI
torlrom the PCM.
body groundand the D11ter
minal and D'l2 terminal indi
vidually.
Wire sideo{ Iemaleterminals
Repai. short in the wiles

between the Dll lnd D12 termi-
nals and iho drive Pull.Y speed
(cont'd)
To page14-280
14-279
Electrical ('gg- 00 Models)
Troubleshooting
TroubleshootingFlowchart- DrivepulleySpeedSensor(cont,d)
Frompage14-279
PCMCONNECTOR
D {16P}
MeasureDrivo PulleySpeed Sen-
sor Circuit tor an Open:
1 . C o n n e c tt h e d r i v e p u l l e y
2 . l v l e a s rue t h e r e s i s t a n c e
betweenthe Dl1 and Dl2 ter-
minals.
R6pair loose tgrminal or opan in

ls the resistance350 - 600 O? the wiros betwo€n tho D1,l .nd
Ol2 tarminrl! .nd th. drivs pul-
ley speed *n3or.
Ch6ckfor loose lerminal tit in the

PCM connectors, ll nece3saay,
substituto a known-good PCM
6nd r€check.
14-280
TroubleshootingFlowchart- DrivenPulleySpeedSensor
NOTE: Recordall freezedata betore you troubleshoot'
Po3sibleCaus€
'OBD lt Sc.n Tool indicates
Code Pl886. ' O i s c o n n e c t e dd r i v e n P u l l e Y
. Self-diagnosbE indicator light speeds6nlor connoctor
indicrt€. Codo35. . Short or opon in d.iven Pulley
soeedsonsol wirc
. Faulty driven Pulley speed sen_
sor
C h e c kt h e d r i v e n P u l l e ys p e e d
sensorinstallation,and check it
Ior damage.
lsthe drivenpulleYspeedsen'
and not
sor installedProPerly, Boin3tallor ropl.ca and recheck.
damaged?
DRIVENPULLEYSPEED
SENSORCONNECTOR
M..sure Drivon PulloY SPoed

Sonsor Rosblanco at the S6n3or
Conn6ctori
trom the driven PUlleysPeed
sensor,
2. lveasuredriven Pulleyspeed Terminalsideol maleterminals
sensorresistanceat the sen_
sor connector.
ls the resistance350 - 600 0?
D If6P)
FCM CONNECTOR
NDN IWHTI
Check Dtivon Pulloy SP€ed Sen'

sor for a Short Circuit:
1. Disconnectthe D (16P)connec-
torfrom the PCM.
2. Check tor continuity between
body groundand the D10ter'
minal and Dl6 terminal indi-
vidually.

Raoair shott in tho wi.6s
betwoon th. Dlo end D16 tormi'
nak .nd the ddven Pulley spo€d
(cont'd)
Fo page 14'282
14-2A1
ElectricalTroubleshooting['gg - 00 Models)
TroubleshootingFlowchart- DrivenpulleySpeedSensor(cont,dl
Frompagel4 281
M6asure Driven Pulley Speed

SensorCircuit Ior an Op€n:
1 . C o n n e c t h e d r i v e np u l l e y
betweenthe D10and Dl6 ter-
minals.
NON SG IRED/WHTI
Rgpair loose terminal or open in

ls the resistance350 - 600 O? the wires botwosn the Dlo and
016 torminab rnd the drivon Dul-
ley speed3ensoa,
Checktor loose terminal tit in the

PCM connectors, lf necessary,
sub3titute a lnown-good PCM
and rech6ck.
14-282
TroubleshootingFlowchart- SecondaryGearShaftSpeedSensor
Po$ible Causo
' OBD ll Scan Tool indicates
Code P1888. . OisconnectodsecondarYgear
. Self-diagnosisE indicalor light shaft speedsensorconn66or
indicats Code 35. ' short or open in secondarygear
shaft spe€dsensorwiro
. Faulty secondarY gear 3haft
sPeedsensor
Checkthe secondarYgear shaft
s p e e ds e n s o ri n s t a l l a t i o na, n d
checkit for damage.
gearshaft
ls the secondary
speedsensorinstalled Reinatallor replaceand rocheck.
properly,and not damaged?
SECONDARYGEARSHAFT
SPEEOSENSORCONNECTOR
Measure SocondarY Gear Sh.ft

Speed Sen3or Resistanceat the
SensorConnector:
trom the secondarygearshaft
speedsensor. Terminalsideof maleterminals
2. Measuresecondary gearshaft
speedsensor resistanceat the
sensorconnector.
350- 6000?
ls the resistance
D I15P)
PCMCONNECTOR
VEL (WHT/REO) VEL SG IALK/WHTI
Check SecondarY Gear Shaft

SpeedSensorlor a Short Circuit:
1. Disconnedthe D (16P)connec-
tor from the PCM.
body ground and the D1 ter-
m i n a l a n d D 7 t e r m i n a li n d i -
vidually.
Wire side oI female terminals
Repair short in the wiros

b.tween the Dl and D7 termi_
n e 1 3a n d t h € s e c o n d a r Yg e a l
3haft lpeed sonsor.
(cont'd)
To page14-284
14-243
ElectricalTroubleshooting('gg - 00 Modelsl
TroubleshootingFlowchart- SecondaryGearShaftSpeedSensor(cont'd)
Frompage14 283
Moasu.€ Secondary Gaar Shaft

Spo6d Sonsor Circuit tor an
Openi
1. Connectthe secondarygear
shaftsp6edsensorconnector,
betweenthe Dl and D7 termi
nals,
Wi16side of femalet6rminals
Repair looao terminal or opon in

ls the resistance350 - 600 O? the wiraa batuvacn the Dl and D7
t.rminrls snd the second!ry
geer rhatt 3peod 3.nior.
Checkfor loosoterminal lit in the

PCM connectors. lf necessary,
substilute a known-good PCM
.nd recheck.
14-284
NOTE:Recordallfreezedata beforeyou troubleshoot
' OBD ll ScanTool indicatesCodo Possiblecause

P1Ato. Faultvshift control svstem
. Self-diagnosisE indicator light
indicatosCode 42.
Checkfor Anoth€r Code:

Checkwhether the E indicator
P€rform the Tloubleshooting

ls the E indicatorlightindi Flowchart for the indicated
cateanothercode? Code(sl.
CheckStall SpeedRPM:
M e a s u r et h e s t a l l s P e e d R P M
(seepage14-298).
ls the stall speedover 3,500rpm?
ls the stallspeedbelow 2,000rpm?
T e s t - d r i v ea n d C h e c k E n g i n e
Speed:
L Drive the vehicle at 30 mph
150km/h) constantlyfor sev-
eral mlnutes.
2. Checkthe enginespeed
ls the enginespeedwithinthe
specification(seePage14'296
and 14'297)?
14-245
('gg- 00 Models)
ElectricalTroubleshootang
TroubleshootingFlowchart- Start ClutchControlSystem
. OBD ll ScanTool indicatesCode Possibl€Cause

P1891. Faultv start clutch control sys-
. Self-diagnosisE indicator tight
lem
indicatesCode 43.
Checkfor Another Codel

C h e c kw h e t h e rt h e E i n d i c a t o r
ls the E indicatorlight indi- Perform the Troubleshooting

cateanothercode? Flowchart tor the indic.ted
Codelsl.
Test Stsn Clutch Operation:

from the solenoidharnesscon
nector.
3. Start the engine,and shift to
E position.
moves.
Repl.c€ the stan clutdt rasemHy.
Check Croeping Sp€6d:

2 . R e c o n n e c tt h e 8 P c o n n e c t o r t o
the solenoid harness connec
3. St€rt the engine, and shift to

E posation.
4. Check whether the vehicle
creeps, and check the creep
ing speed.
Does the vehicle move and is

t h e c r e e p r n gs p e e d a p p r o x , 3
mph (5 km/h)?
fo page14 287
14-2A6
t a Frompage14'286
CheckSrall Speed RPM:

Measurethe stallspeedRPM(see
page14-298).
ls the stallspeedover 3,500rPm?
Warm Up Engine and Becheck

F ilure:
1 . W a r m u p t h e e n g i n et o n o r
m a l o p e r a t a n gt e m P e r a t u r e
(theradiatorfan comeson).
2. Checkwhetherthe stan clutch
problemappearsagain.
I a Doesthe problemappear?
The 3v3tem ia OK at thi! iime.
14-2a7
TroubleshootingFlowchart- El IndicatorLight DoesNot ComeOn
The D indicator light does not

come on whon ths ignhion switch
is tirst turned ON {lll. llt should
come on tor abouttwo s€conds.)
Checkthe ServiceCheckConnec-
tor:
Makesure the specialtool {SCS
S e r v i c eC o n n e c t o rils n o t c o n
nectedto the servicecheckcon-
nector,
l s t h e s p e c i a lt o o l ( S C S
Disconnectthe sp€cial tool f]om
Service Connectorl connected
the seruice chcck connoclor and
t o t h e s e r v i c ec h e c k c o n n e c -
aecheck.
tor?
Checkthe E Indicalor Light:

Shiftto E posjtion.
Checktor loose te.minal fit in the

Doesthe E indicatorlight PCM connectors, lf nocessary,
and aecheck.
PCMCONNECTOR
B I25PI

2 . D i s c o n n e ct th e B ( 2 5 P )c o n
nectorfrom the PCM.
t h e 8 2 0 t e r m i n a la n d b o d y LGl {BRN/BLK)
ground,and betweenthe 822
terminaland body ground.
Fepair open in th. wiros Wire sideot femaleterminals

ls therecontinuity? b€tw.en the 820 end 822 termi-
n a l s a n d g r o u n d { G 1 0 1 1 !, n d
repair poor ground {G1011.
Measure Power Supply Circuit

Voltage:
1. Turnthe ignitlonswitchON (ll).
terminals Bl and 822 and
b e t w e e nt e r m i n a l s B 9 a n d
820.
Ropairop€n or short in tho wire LGlIARN/BLK) LG2IBRN/BLKI

b€tween the Bl and/or B!| tarmi-
ls there batteryvoltage? nds and the PGM-FImain .ohy,
and between tho PGM-FImain
relay and the under-hood fuso/
r€lav box.
To page14-289
14-2AA
Frompage14-289 PCMCONNECTORS
D {16P1
MsaaureD IND Volt.ge: 1 2 3 r s 1 / 7I 2 1 5

1. Turnthe ignitionswitchOFF. 9 10 nn fT /fl 6 l 1 12
2. Connecttho B (25Plconnector
to the PCM. - -T---=4'+:l
1311
o lzlzz ,rl/zs
3. Connecta digital multimeter
to the D14and 820 or 822ter- LG2IBRN/BLKI\=/ |
mtnals.
il. Turn the ignition switch ON (BRN/BI.X) D4 IND (GRN/BLK}
(lll, and makesure that voltage
is availablefor two seconds
Check for open in the wire
between tha D14 terminal rnd
the gauge a33emblY.lf wiro ia
OK, chock for . frulty indicator
light bulb or a Iaulty gaug.
a3r6mblyprintod circuit board.
r l z3 5
CheckD IND for a Short Circuit: 6 i / l / t0 1112

Checklor continuitYbetweenthe l0
D14terminaland body ground.
D' INDIGRN/BLKI
o
Rgpair3hort in the wire b.tween

the D14 tcrminal and tho gauge
a*somblY.
Checkfor loose terminsl fh in the

PCM connectors Check tho A/T
goar posilion switch. It neces'
saiy, iubstitute a known_good
PCMrnd rochock.
4-289
('gg- 00 Models)
TroubleshootingFlowchart- E IndicatorLight On Constantly
The E indicator light is on con-

stantly {not blinkingl whenever
the ignition switch is ON lll|.
FCM CONNCCTOR
D tl6PI
Mersure D IND Voltage:
1. Turnthe ignitionswitchOFF. 2 3 I 5
2 . D i s c o n n e ct th e D ( 1 6 P )c o n - 6 1 t0 12
nectorfrom the PCM.
tsll / rc
the 014terminaa l ndbody
II D4rND(GRN/BLK)
ground,
o
Repairshort to power in tho wire
bstween the Dl4 termin.l snd
the gaug€ r3sembly. Wiresideof femaleterminals
MeasureATP DVoltage:
rcM CONNECTOR
A I32PI
2 . C o n n e ctth e D ( 1 6 P ic o n n e c - ATP Dil {YELI
tor to the PCM.
4. Shiftto any positionotherthan
E,
5. lMeasure the voltagebetween
t h e 4 7 t e r m i n a la n d b o d y
ground.
ls thereapprox.10V? Wire sideof lemaleterminals
Test the A/T gear position switch

{seesection23).
Checkfor a shorl lo ground in

the wire between tho A7 termi-
nal and A/T ge.r polition switch.
l, wire is OK, substitute a known-
14-290
Solenoid
LinearSolenoids/lnhibitor
Test
)
1. Disconnectthe 8P connectorfrom the solenoidhar- 7. lf all ot the resistancesare within the standard,a
nessconnector. c l i c k i n gs o u n d s h o u l db e h e a r dw h e n c o n n e c t r n g
the battervterminalsto the solenoidharnesscon-
nectorterminalsbelow:
Shift control linear solsnoid

No.3: BattervPositiveterminal
HARNESS
SOLENOID No. 7: Batterynegativeterminal
CONNECTOR PH-PLcontrol linear solenoid
No.2: Battervoositiveterminal
No. 6: Bafterynegativeterminal
Start clutch control linear solenoid
No. 4: BatteryPositiveterminal
No.8: Batterynegativeterminal
lnhibitor solsnoid
No,5: BattervPositiveterminal
Body ground:Batterynegativetermrnal
SOLENOIDHARNESSCONNECTOR
ATF OIPSTICK
l f n o c l i c k i n gs o u n d i s h e a r d , r e p l a c et h e l o w e r
Measurethe resistanceof the shift control linear valvebody assemblY,
solenoidbetweenthe No. 3 and No. 7 terminalsof
the solenoidharnessconnector. NOTE: lf the lower valve body assemblyreplace-
ment is required,see Lower Valve Body Assembly
Replacement (page14-302).
Measurethe resistanceof the PH-PLcontrol linear
solenoidbetweenthe No. 2 and No. 6 terminals
Measurethe resistanceof the start clutch control

linearsolenoidbetweenthe No 4 and No. 8 termi-
nats,
STANDARD:38-6.8O
M e a s u r et h e r e s i s t a n c eo f t h e i n h i b i t o rs o l e n o i d
betweenthe No. 5 terminaland body ground
S T A N D A R D : 1 1-. 7
2 1 . 0O
R e p l a c et h e l o w e r v a l v e b o d y a s s e m b l y i f a n y
solenoidresistance is not within its standard.
14-291
DrivePulley/DrivenPulley/Secondary
GearShaft Speed
Sensors
Replacement
CAUTION: While replacingthe speed sensor,be sure not to allow dust and other foreign parliclos to enter into the trans-
mission.
'1.
Disconnect
the connectorsfor the drive pulley,the drivenpulley,and the secondarygear shaftspeedsensor.
2. Removethe 6 mm bolt from the transmissionhousing,and removethe drive pulley.the driven pulley,and the sec-
ondarygearshaftspeedsensors.
3. Replacethe O-ringsbeforereinstallingthe drive pulley,the driven pulley,and the secondarygear shaft sp€edsen-
sors.
6x1.0mm
12 N.m (1.2kgf.m,8.7 lbf.ft)
DRIVENPULLEYSPEEDSENSOB
6x1.0mm
12 N.m (1.2kgt.m,
8.7 tbf.ft)
14-292
Start ClutchControl @
T Start ClutchCalibrationProcedure
NOTE:When the following parts are replaced,the TCM Shift into E o|. E position.To store the engine
must memorizethe feedbacksignalfor the start clutch negativepressurein memory.Iet the engine idle in
control. E or E positionfor one minute underthe follow-
ing conditions:
. TCM
. Transmissionassembly . With the brakepedaldepressed,
. Stan clutchassembly . with the y'\/cswitch oFF.
. Lowervalvebodv assembly . With the combinationlight switchOFF.
. Engineassemblyor overhaul . With the heaterfan switchOFF.
. Turn OFFall otherelectricalsystems
'96 Model Only
NOTE: Start step 5 within 60 secondsafter the radi-
CAUTION: Do not uso this procsdure on'97 - (X)mod- ator fan goes off.
'97 - 00
els or you will damage the transmission. On
models, the TCM or PCM memorizes ths loodback sig' Shift into E position,and let the engineidle for two
nals when you drive the vehicle. minutes to store the feedbacksignal in memory
underthe sameconditionsas in step5.
1. E n g a g et h e p a r k i n g b r a k e , a n d b l o c k t h e f r o n t
wheelssecurely. 7. Connectthe HondaPGMTester.Checkthat the TCM
hascompletedthe startclutchcalibration.
2. Connectthe SCS serviceconnectorto the Service
C h e c kC o n n e c t o ra s s h o w n . ( T h e S e r v i c eC h e c k NOTE:
connector (2P) is located under the dash on the . The TCM will not storethe feedbacksignalwhen
passenger's sideof the vehicle.) the CVT fluid temperatureis below 40"C(104'F)
rl ,
even if the engine coolanttemperaturereaches
the normaloperatingtemperature.
. Repeatthese proceduresuntil the start clutch
calibrationis completed-
D i s c o n n e c t h e S C S s e r v i c ec o n n e c t o rf r o m t h e
ServiceCheckConnector.
'97 - 00 Models
The TCM ('97- 98 models)and PCM('99- 00 models)

memorizethe feedbacksignal when you drive the
vehicleas follows:
. After warming up the engine (the radiator fan

CONNECTOR
I2PI CONNECTOR
07PAZ- lDl01(xt comesonl.
. Shift into E position.
. Turn OFFall electricalsystems,
. Drive the vehicle up to the speed 37 mph (60
Startthe engine,and warm it up to normal operat- km/h).
ing temperature(the radiatorfan comeson twice). . A f t e r t h e s p e e d r e a c h e s3 7 m p h ( 6 0 k m / h ) ,
releasethe acceleratorfor 5 seconds.
Fullydepressthe brakepedaland accelerator
for 20
secondsin the E] position.
14-293
Chart
HydraulicSystem
SYMPTOM Checktheseitemson the PBOBABLE CAUSEList
Engineruns,but vehicledoes not move in any position. 't,2,3,4,5,6,7,8,9,
1 0 ,2 0 ,3 4 ,3 5 ,3 6 ,3 8 ,4 1
Vehicledoes not move in @, [. p positions. 1 0 ,1 1 ,1 2 ,2 0 ,4 1
Vehicledoes not move in E position. 5, 'to,11, 12,17,1A,19,20,39,41
No shift to higherratio, 9 , 1 3 ,1 4 .1 5 ,1 6 , 3 5 , 3 7 , 4 0
Pooracceleration. 9, 13,' t4,'t5,16.20,35,37, 38, 40
Flareson moving. 9,'t0,20,2't,35,36,38,40,42
Excessive
shockwhen depressingand releasing
.^âlA/.r^r Â.1. I
9, 10, 20, 2'1,35, 36, 3A,42
N o e n g i n eb r a k i n g . 9,20,21,35,36,38
in lll position.
Vehicledoes not accelerate 9, 17, 18,19,20. 35,36,38
Vehiclemovesin E position.
(Shiftcableadjustmentis proper). 1 0 ,2 2 , 2 3
Lateshiftfrom N positionto E position,and from E '10,1 1 ,1 2 , 2 24, 1

positionto E position.
Lateshift from E positionto E position.and from E
positionto N position. 1 l , ' t 2 , 1 7 ,1 8 , 2 2 4
,1
Enginestopswhen shiftedto E positionfrom E position. 9, 10,20,35,37,34,

42
Enginestopswhen shiftedto E positionfrom I position. 9, 18,19,20,25,26,35,37,38,42
Noisefrom transmissionin @ position.rl 5, 17, 18,'t9,25,26
Excessive
idle vibration. 2,3,4,21,24
Noisefrom transmissionin @ and @ positions. 2,3,19,24,25,2A
Huntingenginespeed. 16,35,37,38
Vibrationin all position. 8, 2a
Shift leverdoes not operatesmoothly. 11,29,4'l
Transmissionwill not shift into lll positionor transmis-
11, 29,30, 31,32,33
sion cannotbe removedfrom E position.
Vehicledoes not accelerate
to more than a certainspeed. 9 , 1 0 ,1 4 ,1 5 , ' t 6 , 2 0 , 3 5 , 3 7
Excessive
shockon startingoff. 38,42
Flareson accelerating
at low speed. 20,21,38, 42
Excessive in E, E, tr, E positions.
vibration 20,21,38,42
Lowenginespeedin E. E. tr. E positions. 20,21,38,42
Stall speed high. 10,20,38
Stallspeedlow. 9, 20,27,37, 38
Judderon startingoff. 20,43
*1: Somegear noiseis normalin the Lll positiondue to planetarygearaction.
14-294
t . CAUSELIST
PROBABLE
Low CVTfluid level

ATF pump worn. AT gearsworn or damaged.Foreignmaterialin ATF pump.
ATF pump chain/ATFpump sprocketworn or damaged.
Inputshaftworn or damaged.
5 S u ng e a rw o r n o r d a m a g e d .
6 Finaldrivenoearworn or damaqed,
1 drivengearworn or damaged-
Secondarydrive gear/secondary
8 plateworn or damaged.
Flywheel/drive
9 housingassemblyworn or damaged.
Intermediate
'10 Forwardclutchdefective.
1'r Shift cablebroken/outof adiustment.
't2 M"nu"t
t"uffi
13 ATFfeed pipe (pulleypressure)worn or damaged.
14
Vchiclcspeedsensordefective.
16 TCM or PCMdefective.
'11 Reversebrakedetective.
'18
rl, 1q
20
t't
Planetarygearworn or damaged.
Start clutchdefective.
ATFfeed pipe (startclutchpressure)worn or damaged
brakeclearanceincorrect.
Clutchclearance/reverse
23 worn or damaged
Reversebrakereturnspring/retainer
24 Needlebearingon input shaftworn or damaged.
25 Thrustneedlebearingon carrierworn or damaged.
Thrustwasheron carrierworn or damaged.
27 Enoine outout low.------------------------
Flvwhcelassemblvdefective.
29 Controlleverworn or damaged.
30 Parkpawl/parkpawl shaftworn or damaged
Detentlever/parkbrakerod assemblyworn or damaged
32 Parkgearworn or damaged.
33 Parkpawl springworn or damaged.
34 filter clogged.
ATFstrainer/ATF
Lower valve body assemblydefective.
50 Lowervalvebodv assemblvdefective(PLregulatorvalvebody assemblydefective)'
Lowervalvebodv assemblydefective(shiftvalvebody assemblydefective).
Lowervalve bodv assemblvdefective(startclutchcontrolvalvebody assemblydefective)'
39 Lowervalve bodv assemblvdefective{inhibitorsolenoiddefective}
fl, 40
41
Solenoidharnessworn or damaged.
Manualvalvebody worn or damaged.
PBfeedbacksystem defective.
43 CVTfluid deteriorated.
14-295
RoadTest
NOTE:Warm up the engineto normaloperatingtemperature(the radiatorfan com6son).
1. Apply the parkingbrakeand blockthe wheels.Start the engine,then shift to the E positionwhile depressingthe
brakepedal.Depressthe accelerator
pedaland releaseit suddenly.The engineshouldnot stall.
2. Testin E position
Parkthe vehiclein a slope (approx.16'). apply the parkingbrake,and shift into E position.Releasethe brake;the
vehicleshouldnot move.
3. Test-drivethe vehicleon a flat road in the positionshown in the table.Checkthat the enginespeedsmeetthe approx-
imatevehiclespeedsshown in the table.
NOTE: Throttle position sensor voltage representsthe throttle opening. To monitor the throttle position sensor volt-
age,useone of the followingmethods:
A. Connectthe HondaPGMTester,and go to the PGM-FIDataList.

OBDll SCANTOOLor
HONOAPGMTESTER
A 1 For road testing on '96 - 98 models, remove the drive/s side kick panel to exposethe TCM; on '99 - OOmodels,
removethe passenger'sside kick panel to exposethe PCM (see page l,[-236),
Set the digital multimeter to checkthrottle position sensor voltage betweenterminals:

. '96 - 98 modols: TCM 84 {+} and Aa (-) or A17 (-1.
. '99 - 0Omodels: FCM C27 {+l and 820 (-l ot 822 l-1.
DIGITALMULTIMETER
(Commerci.llyrvrilabl.l
KS-AHM-32-003
or oquivalant
BACKPROBE
ADAPTER
'96 - 98 Models:
BRN/BLK D{16Pt
A {26P1
TPS {BED/BLK}
BRN/BLK
14-296 Waresideot femaleterminals

o @ position: EnginoSpeed rPm
VehicloSpeed
Throttle Opening -
25 mph l/() km/h) | 37 mph {60km/h) | 62 mph {100km/h}
Throttlepositionsensorvoltage:0.75V 1,250- 1,650
2,500- 3,100 2,650- 3,250 2,700- 3,300
Throttlepositionsensorvoltage:2'25V
Throttlepositionsensorvoltage;4 5 V 3,950- 4,550 4,650- 5,250 5,200- 5,800
Fullthrottleposition
o $l position:EngineSpeedrPm
VehicleSpoed
Throttle Oponing
2s mph(40km/hl | 37 mph(60km/hl | 62 mph{r00km/h}
- 2,200
1,800 2,200- 2,800 3,550- 4,150
Throttlepositionsensorvoltage:0.75V
2,950- 3.550 3,250- 3,850 4,050- 4,650
ThrottleDositionsensorvoltage:2.25V
Throftlepositionsensorvoltage:4.5v 4,100- 4,700 5,100- 5,700 5,900- 6,500
Fullthroftleposition
o E position: Engin€Sp6ed rPm
Vehiclo Spoed
Throttle Oponing
25 mph (40km/hl | 37mPh{60km/h) J 62 mph 1100km/h}
3,100- 3,700 3,650- 4,250 4,450- 5,050
ThrottleDositionsensorvoltage:0.75V
3,500- 4,100 4,050- 4,650 4,800- 5,400
Throttlepositionsensorvoltage;2.25V
Throttlepositionsensorvoltage:4.5V 4,100- 4,700 5,100- 5.700 5,900- 6,500
Fullthrottleposition
14-297
Stall Speed
Test
CAUTION:
. To prevent transmission damage,do not test stall sp€€d for mole than 10 secondsat a time.
. Do not shift the lsver whils raising the engine speod.
. Be sure lo remove the pressuregauge before tosting stall speed.
. Stall speed tssts should be used tor diagnostic purposesonly,
1. Engagethe parkingbrake,and blockthe tront wheels.
2. Connecta tachometerto the engine,and stan the engine.
3. Makesurethe A/C switchis OFF.
4. After the enginehaswarmed up to normaloperatingtemperature(the radiatorfan comeson), shift into E position.
5. Fullydepressthe brakepedaland accelerator

for 6 to 8 seconds,and note enginespeed,
6. Allow two minutesfor cooling,then repeatthe test in E, E, and E positions.
Stall SpeedBPM in E poshion:

Specification:2,500rpm
Servic€Limit: 2,350- 2.650rpm
Stall Speed RPM in E, E and E positions:

Specitication:3,000rpm
ServiceLimit: 2,800- 3,100rpm
TROUBLE PROBABLECAUSE
Stallrpm high in @. p. [, and @ positions Low fluid levelor ATF pump output
CloggedATF strain€r
PH regulatorvalve stuck closed
Slippageof forwardclutch
Faultystartclutch
Stallrpm high in E position . Slippageof reversebrake
. Faultystartclutch
Stallrpm low in E, P, [, and @ positions Engineoutput low
Faultystan clutch
Stuckshiftvalve
14-294
FluidLevel
l . Checking/Changing
CAUTION: while chscking and changing, be sure not to Changing
allow dust and other toreign particles to ent€l inlo the
transmission. 1. Bringthe transmissionup to normaloperatingtem-
perature(the radiatorfan comeson) by driving the
Checking vehicle.Parkthe vehicleon the level ground, and
NOTE: Checkthe fluid level with the engine at normal turn off the engine.
operatingtemperature(theradiatorfan comeson).
2. Bemovethe drain plug,and drainthe CVTfluid.
' 1 . P a r kt h e v e h i c l eo n t h e l e v e lg r o u n d .T u r n o f t t h e
engrne. NOTE| lf a coolerflusheris to be used,see page14-
352and 14-353.
2. Removethe dipstick(yellow loop) from the trans-
mission,and wipe lt with a cleancloth.
Reinstallthe drain plug with a new sealingwasher,
NOTE: Checkthe transmissionfluid 50 to 90 sec- t h e n r e f i l l t h e t r a n s m i s s i o nw i t h G e n u i n eH o n d a
onds aftershuttingoff the engine. CVTFluidto the uppermarkon the dipstick.
3. Insertthe diDstickinto the transmission. Automatic TransmissionFluid CaPacity:

3.9 i (4.r US qt. 3.4 lmp qt) 8t chlnging
DIPSTICK(YELLOWLOOPI 6.4 I (6.8 US qt, 5.6 lmp qt) 8t ov€lhaul
RscommendedAutomatic TransmissionFluid:
GenuineHonda CVT Fluid-
Use GenuineHondaCW fluid only. Usingotherflu-

i d s c a n a f f e c t t r a n s m i s s i o no p e r a t i o n a n d m a y
reducetransmissionliJe.
ChangeInterval:
Normal Condition: 30, 000 miles 148,000km)
SevereCondition: 30,000 miles (48,000km), but it
you drive at high sPeedsin high
R e m o v et h e d i p s t i c ka n d c h e c kt h e f l u i d l e v e l . t90"F (32'C) and abovol temper-
shouldbe betweenthe uDDerand lower mark. atures, the ttansmission fluid
DIPSTICK
should be changed evsrY 15,000
miles 124,000km).
5. lf the level is below the lower mark, add fluid into {-]lr
t h e f i l l e r h o l e t o b r i n g i t t o t h e u p p e r m a r k .U s e
G e n u i n eH o n d aC W F l u i do n l y . ORAINPLUG SEALINGWASHER
18 x 1.5mm Replace.
6. Insertthe dipstickinto the transmission. a9 N.7n(5.0kgl.m, 36 lb{'ftl
14-299
PressureTesting
. While testing, be careful of the rot8ling front wheels.

. M8k6 suro lifts, iacks, and satety stands are placed properly lsee section 11.
CAUTION:
. Beforetesting, be sur. the transmb3ion fluid is fillod to the propor lcvel.
. Warm up the engin€ to nolmal operating tsmperature bofore testing
. While t€sting, be 3ure not to allow dust and other loreign particles to onler into the transmi$ion.
1. Raisethe front of the vehicle,and supportit with safetystands(seesection1).
2. Setthe parkingbrake.and blockboth rearwheelssecurely.
3. Allow the front wheels to rotate freely.
4. Warm up the engine(the radiatorfan comeson),then stop aridconnecta tachometer.
5. Connectthe specialtool to eachinspectionhole.
TOROUE:18 N.m (1.8 kgt'm, 13 tbtfr)
GAUTION:
. Connectthe oil pressurogauge !!€curoly,bs sur6 not to allow dust and other foroign particlG3to ontar the inspsc-
tion hole.
. Whon troubleshooting by tho E indicltor light indic.t6 a problam. you mu3t u3e an oil p.essure gluge that moa,
sures 4,9(X)kPa (a.90MPa,50.0 kS cr*,771psi) or more when molsuring driv. pulley pressureand driven pullcy
pre33ure.
NOTE:
. D.ive pulley pressuremay be above 3,430kPa (3.i8 MPa,35.0 kgf/cmr,498 psi) wh€n there is a transmissionprob-
lem that causesthe TCM or PCMto go into the fail-safemode,
. Use a commerciallyavailableoil pressuregauge that measures4,900kPa {4.90MPa, 5O.Okgf/cmr,711 psi) or
more,and the Ay'TOil PressureHose,2210mm (07MAJ- PY4011A).
A/T OIL PRESSURE A/T PRESSURE HOSE A/T PRESSUBE HOSE

GAUGE A/T LOW PRESSURE ADAPTER 2210mm
SETW/PANEL GAUGEW/PANEL 07MAJ- PYar'120 07MAJ- PYitollA
0ta{r6 - oO2Oi|(Xt 0706 - qt7o:t{ro lil R.qulr.d) la R.quir.d)
FORWARDCLUTCHPRESSURE DRIVEPULLEYPRESSURE
INSPECTIONHOI.E REVERSEBRAKEPRESSURE
INSPECTION (Markedwith "DR") INSPECTION
"F") I.IOLE
lMarkedwith
ATF DIPSTICK
CLUICH PRESSURE
DRIVENPULLEYPRESSURE INSPECNONHOLE
INSPECTION HOLE
(Markedwith "LUB") INSPECTION HOLE (Markedwith "SC")
lMarkedwith "DN")
14-3 0 0
Startthe engine.
pressuresat 1'500rpm'
1 . Shiftto the respectiveshift leverpositionsin the table,and measurethe following
. ForwardClutchPressure
. ReverseBrakePressure
. DrivePulleyPressure
. DrivenPulleyPressure
8. Shiftto E posltion,and measurethe lubricationpressureat 3,000rpm'
FLUIDPRESSURE
SHIFTLEVER PROBABLECAUSE
PBESSURE POSmON SYMP{OM
Standard/SsrviceLimit
Forward E No or low for- ForwardClutch 1 . 4- 1 . 7 5M P a

ward clutch (14.3- 17.8kgtcm' , 203- 253Psi)
Clutch
pressure
Reverse ts No or low ReverseBrake 1 . 4- 1 . 7 5M P a

reversebrake (14.3- '17.8kg7cm' ,203- 253Psi)
Brake
pressure
Drive N No or low ATF pump, PH reg- 0.2- 0.7 MPa
Pulley drive pulley ulatorvalve,PL (2 - 7.1 kgflcm' ,28 - 101Psi)
pressure regulatorvalve,
Shiftvalve
Drivepulley PH regulatorvalve,
pressure
roo PL regulatorvalve,
high Shift valve.Shift
controllinear
solenoid
Driven No or low ATF pump, PH reg- 1 . 5- 2 . 3M P a
drivenpulley ulatorvalve,Shift (15.3- 23.5kg?cm' ,218- 334 Psi)
Pulley
pressure valve,Shift control
linearsolenoid
Drivenpulley PH regulatorvalve
pressuretoo
hi g h
Lubrication No or low ATF pump, Above0.2 MPa
lubrication Lubricationvalve (Above 2 kgf/cm'. 30 Psi)
pressure
the specialtool afterpressuretestlng

9 . Disconnect
the bolts to the specified
1 0 . Installthe sealing boits in the jnspectionholes with new sealingwashers,and tighten
toroue.
TOROUE:18 N.m {1.8 kgf'm, 13 lbf'ft}
CAUTION: Keepall foreign particles out of the transmission'
14-301
LowerValveBodyAssembly
Replacement
@ Make sure lifts, iacks, and saf€ty stands 7. Removethe ATFcooleroutlet line.
are placsd prop€rly {seasection 1). 8. Removethe ATFcoolerline bracketbolt.
9. Removethe ATF pan (fourteen bolts).
CAUTION: While removing and installing th6 lower 10. Removethe ATF strainer(two bolts).
valve body asssmbly, b€ sule not to allow dust and 1l. Removethe one bolt securingthe solenoidharness
other for€ign particlesto entsr inio the transmksion. connector,
1 2 . R e m o v et h e l o w e r v a l v e b o d y a s s e m b l y( e i g h t
1. Raisethe front of the vehicle,and support it with bolts). LINEBOLT
safetvstands(seesection1). 28 N.m (2.9kgtm,21 lbtft)
SEALING
Replace.
2. Set the parking brake,and block both rear wheels
securetv. ATF COOI.-ER
OUTLET
R e m o v et h e d r a i n p l u g , a n d d r a i n t h e C V T f l u i d .
Reinstallthe drain plug with a new sealingwasher
(seepage 1+299).
CAUTION: Keop all of other toreign parliclos out of O.RING

Feplace.
the transmission.
SOLENOIOHARNESS
4. Disconnectthe 8P connectorfrom the solenoidhar- CONNECTOR
ness connector.
OOWELPIN
Remove the ATF cooler hoses at the ATF cooler 5x1.0mm
lines.Turn the ends of the ATF cooler hosesup to 12 N.m 11.2kgt.m,
O.RING 8.7 tbt.ftl
preventATF from flowing out, then plug the ATF ATF Replace.
coolernoses. STNAINER VALVE
BODYASSEMBLY
CAUTION: Keep all of other foroign particlo3out of
6x1.0mm
tho transmission. 12 N.m 11.2kgf.m,
8.7 rbf.ft)
6. Removethe right front mounvbracket.
6x1.0mm ATF PAN GASKET
10 x 1.25mm 12 N.m 11.2kgt m, Replace.
ila N.m (,1.5kgf.m,33 lbtft) E.7 tbt'ft)
ATF COOLERINLET
OOWELNN UNE BRACKETBOLT
RIGHTFRONT 8 x 1,25mm
MOUNT/BRACKET 26 N.m {2.7 kgf.m,
20 tbf.frl
ATF COOLERLINE x 1.0mm

ATF PAN
12 N.m 11.2kgf.m,E.7lbf.ftl
1 3 . Install the new lower valve bodv in the reverse

ordgrof the removalorocedure.
CAUTION: Koep all ot other fo.oign particles out of
ths transmission.
NOTE:
10x 1.25mm . Replacethe followingparts:
sil N.m 15.5kgf.m, - O - r i n g so n t h e s o l e n o i dh a r n e s sc o n n e c t o r
40 rbr.ft)
and the ATFstrainer
- ATF pan gasket
- Sealingwashers
. l f t h e A T F c o o l e r i n l e t l i n e b r a c k e ti s b e n t o r
ATF COOLERHOSE warped,put it backto the originalposition.
1 4 . Perform the start clutch calibrationorocedureon
page14-293.
14-302
ATFFilter
l . Removal/lnstallation
Make sure lifts, lEcks, snd safoty stands 6. Removethe ATF cooleroutletline.
!@
ara pl8ced properly {saesection 1). 7. Removethe ATF coolerline bracketbolt.
8. Removethe ATF pan (fourteen bolts)
CAUTION: While removing and installing the ATF tilier, 9. Removethe ATF cooler inlet line from the ATF pan
be sure not to allow dust or other for6ign particle3 to (threebolts).
enter thg transmission. 10. Removethe ATFfilter,and cleanit.
11. Checkthat the ATFfilter is in good condition.
1. Raisethe front of the vehicle,and support it with 12. Replacethe ATFfilter if it is clogged.
safetystands(seesection1).
LINEBOLT
2. Set the parking brake,and block both rear wheels 28 N.m {2.9 kgf.m,21 lbt.ft)
securely.
3. R e m o v et h e d r a i n p l u g , a n d d r a i n t h e C V T f l u i d .
Reinstallthe drain plug with a new sealingwasher ATF COO1TROUTIET
{seepage 14-299). ATF COOLERINI-ET
6x1.0mm LINEERACKETBOLT
12 N m (1.2kgf m, 8 x 1.25mm
CAUTION: Keep all toreign particles out ot the 26 N.m (2.7kgt.m,
transmission. 20rbtftt
Remove the ATF cooler hoses at the ATF cooler

lines.Turn the ends of the ATF cooler hosesup to
preventATF from flowing out, then plug the ATF
coolernoses.
fl, 5.
CAUTION: Keep all foreign particles out of the
transmission.
Removethe rightfront mounvbracket.

O.RING
Replace.
ATF FILTER
10 x 1.25mm ATF
4{ N.m {i1.5kgf.m,33 lbf ft) GASKET
Replace.
ATF PAN
ATF COOLERLINE
6x1.0mm
12 N.m (1.2 kgt'm,8.7 lbl'ft)
'13. l n s t a l lt h e A T F f i l t e r i n t h e r e v e r s eo r d e r o f t h e
removalprocedure.
10 x 1.25mm
GAUTION: Keep all foreign particles out ot the
54 N.m {5.5 kgt'm,
40 rbl.ft) transmission,
NOTE:
R e p l a c et h e O - r i n g s ,t h e A T F p a n g a s k e ta n d
sealingwashers.
(|'t ATF COOLERHOSE l f t h e A T F c o o l e r i n l e t l i n e b r a c k e ti s b e n t o r
warped.put it backto the originalposition
14-303
Transmission
Removal
@
. Mako
4, Disconnect the solenoidharnessconnector,
the drive
suro lifts. iacks, and satety stands are placod pulleyspeedsensorconnector,and the groundcable
properly, and hoi3t bracket are attached to lhe cor- terminals.
rect position on the engine {seesoction 1}.
. Apply parking brake and block r€ar wheels so tha GROUNDCABLE
vehicle will not roll off stands and fall on you while GROUNDCAELE
working undor it.
CAUTION:Use tender coversto avoid damaging painted

surfaces.
1. Disconnectthe battery negative(-) terminal from

the battery,then removethe positive(+)terminal.
Removethe intakeair duct and air cleanerhousing

assembly.
3. Removethe starter cables and cable holder from

the starter motor. DRIVEPULI.-EY
SPEEDSENSOR
CONNECTOR
STARTERMOTOR SOLENOIOHARNESS
CONNECTOR
Removethe clip, then separatethe shift cablefrom

the controllever,
CAUTION: Take care not to bend the shift cable.

S}IIFT CABLE
WASHER
WASHER
STARTERCABLE
CONTROLLEVER
14-304
I R e m o v et h e d r a i n p l u g , a n d d r a i n t h € C V Tf l u i d
6. Disconnectthe vehiclespeedsensor(VSS)connec- 8.
tor, the driven pulley speed sensorconnector,and Reinstallthe drain plug with a new sealingwasher.
the secondarygearshaftspeedsensorconnector.
CAUTION:While installing the drain plug' bo 3ur.
SECONDARYGEAR ORIVENPULLEY nol io allow du3l 8nd other toreign particles to
SHAFTSPEED SPEEDSENSOR
SENSOR enter into th€ trsnsmi$ion.
CONNECTOR
DRAINPLUG SEALINGWASHER
18 x 1.5rnm Replaco.
(, N.m (5.0 kgfm, 36 lbf'ft|
7. Removethe transmissionhousingmountingbolts.
9. Removethe splashshield.
14-305
Transmission
Removal(cont'd)
10. Removethe cotte. pins and castlenuts,then separate '16,
Removethe rightfront mounvbracket,
the balljointsfrom the lowerarm (seesection1g).
-=V,
SELF-LOCKING
NUT
\
\ /\<,\
CASTLEI{UT COTTER
Replace. oitupea rOax
Replac6.
ATFCOOLER
HOSE
't1. Remove
the right damper fork bolt, then separate 17. Remove the ATF cooler hoses at the ATF cooler
right damperfork and damper. lines.Turn the ends of the ATF cooler hosesuo to
preventCVT fluid from flowing out, then plug the
't2. Pry the right
and left driveshaftsout of the differen- ATF coolerhosesand lines,
tial.
NOTE: Checkfor any sign of leakageat the hose
tJ. Pullon the inboardjoint to removethe right and left joints.
driveshafts(seesection16).
18. Removethe engine stiffenersand the flywheel cover.
1 4 . Tie plasticbagsoverthe driveshaftends.
NOTE:Coatall precisionfinishedsurfaceswith clean

e n g i n eo i l .
Removethe exhaustpipe A.
q.
ENGINESTIFFENER
SELF.LOCKING
NUT 1 9 . Removethe eight drive plateboltsone at time while
Replace. rotatingthe crankshaftpullev.
SELF.LOCKING
NUT
EXHAUSTPIPEA
Replace.
1 4- 3 0 6
Removethe distributor' 2 3 . R e m o v et h e t r a n s m i s s i o nh o u s i n gm o u n t i n gb o l t
and rearenginemountingbolts
Atach a hoistingbracketto the engine,then lift the
e n g i n es l i g h t l y . REARENGINEMOUNTING
TRANSMISSIONHOUSING
MOUNTINGBOLT
WASI{ER
Pull the transmissionaway from the engine until it

clearsthe l4 mm dowel pins, then lower it on the
22. Placea iack under the transmission.and raisethe
transmissionjust enoughto take weight off of the transmissionjack
mounts,thenremovethe transmissionmountbracket
MOUNT
TRANSMISSION
TRANSMISSIONMOUNT
14-307
lllustratedIndex
Transmission/Lower
ValveBodyAssembly
14- 3 0 8
O ATF DIPSTICK
O o-RINGReplace.
.' SOLENOIDHARNESSCONNECTOR
@ LOWERVALVEBODYASSEMBLY
O DOWELPIN
O LINEBOLT
.i ATTfCOOUR IruIETLINEB8ACKETBOLT
€] lrr cooua truler LINEASSEMBLY
O SEALINGWASHERRePIACE'
G, ATF COOLEROUTLETPIPE
6) o-RINGReplace.
@ ATF FILTER
fO o-RINGReplace.
@ ATF PAN
(3 DOWELPIN
(D O-RINGReplace.
E) ATF STRAINER
@ ATF MAGNET
(9 ATF PAN GASKETRePIACE'
O ATF MAGNET
€t oRAIN PLUG
@ SEALINGwAStlER Replace.
Torque Value Size Remarks

Bolt/Nut No.
12 N.m {1.2kgf m, 8.7 lbf'ft} 6x1.0mm
8F 26 N.m (2.7kgim,20 lbf'ft) 8 x 1 . 2 5m m
28 N.m (2.9kgf'm,21lbf'ft) 1 2x 1 . 2 5m m Linebolt
12J
49 N.m (5.0 kgf'm, 36 lbf'ft) 1 8x 1 . 5m m Drainplug
18D
14-309
lllustratedIndex
Transmission
Housing/Flywheel
Housing
8G
I
)
H
14-310
6) o-RING Replace.
C O-RINGReplace.
€) STARTCLUTCHATF FEEDPIPE
e) OIL SEALRePlace
HOUSING COO-RINGReplace.
.' FLYWHEEL
€I FEEOPIPEFLANGE
O flVWneel }|OUSttttGGASKETReplace
@ SNAPRING
6 DIFFERENTTALASSEMELY BRACKET
O' CONNECTOR
@lrr plsslce uruEASSEMBLY @ BALLBEARING
O O-RING Replace
PIN 6} SNAPRING
@ DOWEL 64 COTTERRETAINER
€) ATFPUMPASSEMBLY 6DCoTTERS,25.5mm selectivePart
(ODowELPlN,18x 10mm
Replace.
6t stlnt cLutcHasseMsLv
O O-RING @secoruomvontvEGEAR ASSEMBLY
o DowELPlN,22x 10mm
@ o-RINGSReplace
lrr puup oRve cxltttt 6) DIFFERENTIALCOVER
iA SNAPRING rO ttaUSr SntU, zs t 35 mm Selectivepart
part
f3 fxaUst St|t|l, zz t 28 mm Selective
@ SECONDARY GEARSHAFT
Gtlrr punpontvespaocxer @ PARKPAWLSHAFT
O PITOTFLANGE
@ PARKPAWLSPRING
itonTFpurrap HUB
ontveSPRoGKET .1i PARK PAWL
(O THRUSTWASHERS
@ TONGUEDWASHERREPIACE,
@ PITOTPIPEBRACKET @ PARKROOHOLDER
O PITOTLUBRICATION PIPE
@ BALLBEARING
@ PITOTPIPE @ o-RINGReplace.
t3 OIL SEALReplace.
@ VEHICLESPEEDSENSOR
OaSEt AtitC, SOmm SelectivePart
@ OIL SEALReplace.
o3lrr passlce ltnE HoLOER
ASSEMBLY
12 N.m (1.2kgnm,8.7lbf'ft) 6x1.0mm

22 N.m (2.2kgf'm.16lbf'ft) 8 x 1 . 2 5m m
26 N.m (2.7 kgf'm, 20 lbf'ft) 8 x 1 . 2 5m m
29 N.m {3.0 kgf'm, 22 lbift) 8 x 1 . 2 5m m
ft,
14-311
)
lllustratedIndex
RightSideCover/lntermediate
Housing
88
I
.Fi.

6) TRANSMISSION HOUSING GASKET Replace'
O ENDCOVER PIN
@ DOWEL
O ATF FEEDPIPE @)ATFFEED PIPE
O DOWELPIN Replace.
@ o-RING
@ O-RINGReplace. 60o-RINGReplace.
G) FEEDPIPEFLANGE SPEED SENSOR
@reeopperurucepuru @)DRIVEPULLEY
@ TRANSMISSION HANGER
O] ROLLER @ SNAPRING
O IruTENMEDNTE ASSEMBLY
XOUSING part
sxlrr lsseugLv
aocorutnoL @ txaust Sxtfu,zs t 31mm selective
ttoustt'tc @ SALLBEARING
@tnlrusmtsstottt 6J RINGGEAR
@ SHIFTCABLEBRACKET 6DSNAPRING
c) BREATHER CAP part
Selective
@ aevenseaRlxe rND PLATE
@ oll- SEALReplace. @ REVERSE BRAKE DISC
@ CONTROL LEVER BRAKE PLATE
G LoCKWASHER Replace. @ REVERSE
(D secololaY ceaR SHAFTSPEED sENsoR @ DISCSPRING
6} THNUSTWASHER
o) onvel put-uv sPEEDSENSOR eelnNc
@}finusr NeeoLr
@ O-RING Replace. WASHER
(OSNAPRING @ THRUST
ASSEMBLY
@ GARRIER
6 rnmrsutsstoru xouslNc oRlvENPULLEY WASHER
SHAFTROLLER BEARING @ THRUST
@ THRUSTNEEDLE BEARING
@ ENDCOVER GASKETREPIACE'
Replace @}SUNGEAR
@ o-RING RINGREPIACE'
6omnruulL vnLVe goDYLINEA @ SEALING
@ NEEDLEBEARING
64 MANUALVALVEBODYLINEB @ INPUTSHAFT
@ O-RING Replace. BEARING
SPRING @ NEEDLE
@ DETENT @ SEALINGRINGFEPIACE'
O ATFFEEDPIPE Replace'
.1,
@ SEALINGRING{RUBBERI
@ O-RING Replace. PIPE
@ ATFFEED
@ MANUALVALVEEODY
@ DOWEL PIN
goDYSEPARAToR PLATE
@ r'rllull valve
6DSNAPRING
@troRwlno cturcx ASSEMBLY
@ o-RINGReplace
@ SNAPRING
o3spnlrucaetlrupn/RETURNSPRING ASSEMBLY
@ nevenseennr eBtottt
@ o-RING Feplace.
@ SNAPRINGRE'AINER
@ ATFFEEDPIPE
12 N.m (1.2kgf'm,8.7lbf'ft) 6x1.0mm

6B 14 N.m {1.4kgf'm,10 lbift) 6x1.0mm
8B 37 N.m (3.8 kgf'm, 27 lbf'ft) 8 x 1 . 2 5m m
8F 26 N.m (2.7kgf'm,20lbf'ft) 8 x 1 . 2 5m m
8G 29 N.m (3.0 kgf'm, 22 lbf'ft) 8 x 1 . 2 5m m
rl,
14-313
TransmissionHousing/LowerValveBodyAssembty
Removal
NOTE:
. Cleanall partsthoroughlyin solventor carburetorcleaner,
and dry with compressedair.
. When removingthe lowervalvebody,replacethe followingl
- O-rings
- ATF pan gasket
- Sealingwashers
O.RING
Replace.
SOLENOIOHARNESSCONNECTOR
DOWELPIN 6 x'1.0mm BOLT
LOWERVALVEBODYASSEMBLY
6 x 1.0mm BOLT
ATF PAN GASKET

Replace.
ATF COOLERINLET LINE

ATF STRAINER BRACKETBOLT
8 x 1.25mm
ATF COOI..ERINLET LINE
6 x 1.0mm BOLT
6 x 1.0mm EOLT
14-314
l . '1. Removethe ATFcoolerinlet iine bracketbolt'
2. Removethe ATFcooleroutlet line
Removethe ATF pan (fourteenbolts).
Removethe ATFstrainer{two bolts)
5. Removethe one bolt securingthe solenoidharness

connector,then pushthe connector.
6. Removethe lowervalvebody (eightbolts)
7. Cleanthe inletopeningof the ATFstrainerthoroughly

with compressedair, then checkthat it is in good
condition,andthe inletopeningis not clogged'
ATF STRAINER
2 c '
c;2 ar\
INLETOPENING
the ATFstrainerif it is cloggedor damaged

Replace
NOTE:The ATF strainercan be reusedit it is not

clogged.
14-315
TransmissionHousing/Flywheel
Housing
Removal
NOTE:
. Cleanallpartsthoroughlyin solventor carburetorcleaner,and dry with
compressedair.
. When removingthe transmissionhousing/flywheel housing,replacethe following:
- O-rings
- Secondarydrive gear assembly
- Start clutch assemblv
- Flywheelhousinggasket
ATF PASSAGELINE
HOLD€RASSEMBLY 8 x 125 mm BOLT
VWHEELHOUSING
IX)WEL PIN
OIFFERENTIAL
ASSEMBLY EYWIIEELHOUSINGGASKET
SNAPRING Roolace.
COTTER
RETAINER
ATF PA$gAGE
COTTERS, 25.5 mm UNE ASSEMBLY
Selectivepart O.RING
STARTCLUTCH Rsplaco. 6 x 1,0 mm BOLT
ASSEMBLY
Replace. O.RING
Replace.
THRUSTSHIM, ATF PUMP DRIVECHAIN
25x35mm
Seloctivepart SNAP RING
THRUSTSHIM,22 r 28 mm
part
Seloctive
GRII{GS
SECONDARY Replac€. 6 x 1.0 mm BOIT
GEARSHAFT ATF PUMP DRIVE
SPROCKET
SECONDARYDRIVE
GEARASSEMBLY PfTOTFLANGE
Replace.
ATF PUMP DRTVE
PARK SPROC|(ETHUB
PAWL SHAFT
THRUSTWASHERS
PARKPAWL
SPRING
INPUTSHAFT
InANSMISS|O]{ HOUSTNG
DRIVENPULLEYSHAFT
14-316
)
10. Setthe specialtool on the startclutch'and attachthe
1 . Removethe ATF passageline holderassembly'
oawl of the specialtool to the parkgear securelyas
Removethe flywheelhousing(twentybolts)' shown.
Removethe ATF passageline assembly(onebolt) CAUTION:

. Do not place tho pawl of the spocial tool on the
start clutch guidc. ll the pawl ot the spocial tool
Removethe ATF pump drive sprocket (three bolts),
contacts the 3tart clutch guid€, the start clutch
then removethe ATF pump drive chaan.
guido may be damaged.
. Be sure not to allow dust and other foreign par-
Move the pitot flange toward its cutout, then remove
ticles to enter into the drivon pull6y shaft'
the pitot flange.
STARTCLUTCH
REMOVER
07TAE- P4V0120
STARTCLUTCH
ASSEMBLY
Replace.
PAWL
PITOTPIPE
1 1 .Removethe start clutch and the secondarydrive
gear assemblyusing the specialtool, then remove
the secondarygearshaft.
Removethe snap ring securingthe ATF pump drlve STARTCLUTCH
sprockethub. then remove the 22 x 28 mm thrust REMOVER
07TAE- P4V0120
shim, the ATF pump drive sprockethub and the thrust
wasners,
7. Removethe differentialassemblY.
Removethe park pawl shaft,the park pawl spring,

and the parkPawl' STARTCLUTCH
ASSEMBLY
9. Removethe snap ring securingthe startclutch,then
remove the cotter retainerand the cotters.
14-317
End Cover/lntermediate
Housing
Removal
NOTE:
. Cleanallpartsin solventor carburetorcleansr,and drywith compressedair,
. When removing the end cover/intermediatehousing, replacsthe following parts:
- O-rings
- End cover gasket
- Transmissionhousinggasket
- Sealingrings
- Sealingwashers
8 x 1.25 mm BOLT
6 x 1.0mm BOLT
REVERSEBRAKE
END PLATE
Dtsc { u
PLATE
DISCSPRING
SNAP
ENDCOVER
THRUST GASXET
2 5 x 3 1m m Feplac€.
Selectivepart
RINGGEAR
THRUSTWASHER
THRUSI NEEDLE
BEARING 8 x 1.25mm BOLT
THRUSTWASHER
CARRIER
ASSEMBLY sNAP / INIERMEDIATE
R|NG I HOUSINGASSEMSLY
THRUSTWASHER
THRUSTNEEDLE
BEARING
SUN GEAR
TRANSMISSTON
o.BING
INPUTSHAFT HOUSINGGASKET
Replace.
Replace.
SNAPRING
CLUTCHEND
PLATE
FORWARDCLUTCH
ASSEMBLY
SEALINGRING(RUBBER}
Replace. DOWELPIN
SNAPRING
SPRINGRETAINER/ HOUSING
RETURNSPRINGS
SNAPRING
RETAINER
14-318
l . 11. Compressthe returnsprings.then removethe snap
1 . Removethe end cover {three6 mm bolts,eleven8
mm bolts). ring
2. Removethe manualvalvebody linesA and B C A U T I O N :l f t h e s p r i n g r e t a i n e r t a b i s o n t h e

rsverse braks piston, tho spting letainer may be
3. Removethe snap ring securingthe ring gear,then damaged. Be surs the spring letainer tab is not on
removethe thrustshim and the ring gear' the piston.
SPECIALTOOL
4. Removethe snap ring securingthe reversebrake
discsand plates,then removethe reversebrakeend
plate.brakediscs,brakeplates,and discspring'
5. Removethe carrierwith the thrust washersand the

thrust needlebearingfrom the forwardclutch
6. Removethe sun gear and the input shaft as a sub

assemblybY Pullingit
The sun gear is pressfittedtightly into input shaft' SPfiINGFETAIiGR
TAB
7. Removethe snap ring securingthe forward clutch, 12. Removethe specialtool, then remove the spring
springassembly.
retainer/return
and removethe snapring securingthe forwardclutch
end plate,then removethe forward clutchend plate' 1 3 . Removethe sealingbolt securingthe reversebrake
pressureinsPectionhole.
8 . R e i n s t a ltl h e c a r r i e ro n t h e f o r w a r d c l u t c h ,t h e n 1 4 . Apply air pressureto the inspectionholeto remove
the reversebrakePiston
securethe carrierwith the snap ring on the forward
clutchend Plate. SPBINGREYAINER/
RETURiI SPRIiIG
ASSEMALY
9. Remove the forward clutch and carrier assembly
together. REVERSEBNAXE
PISTON
' 1 0 .l n s t a l lt h e s p e c i a lt o o l t o r e m o v e t h e s n a p r i n g
securingthe reversebrakereturnspring retaineras
snown. o-Rrllcs
Replace.
REVERSE BBAKE
SPRING COMPRESSOR
07TAE- PaV0110
FCVERSEBRAKE
PRESSUREINS?ECTK)N
HOtl
SEALING
WASHER
Replace.
8 x 1.25mm
18 N.m 11.8kgf.m, 13 lbf.ttl
Removethe snap ring retainerfrom the drive pulley

shaft.
1 6 . Removethe manualvalvebody (fivebolts)'
't7 Removethe rollerand pushthe controlshaftassem-
bly toward the outsideof the transmissionhousing,
then removethe intermediate housing(fourbolts)'
14-319
ManualValveBody
NOTE:
. Cleanall partsthoroughlyin solventor carburetorcleaner,and dry with compressedair. Elow out all passages.
. Coatall partswith CVTFluidduringassembly.
SPRINGSEAT
REVERSEINHIBITOR
VALVESPRING
REVERSE
INHIBITOR
VALVE
MANUAL VALVE
MANUAL VALVEBODY
Inspectfor wear, scratches
and sconng,
14-320
ForwardClutch
l . lllustrated Index
CLUTCHORUM
\
\ DISCSPRING
\_
CLUTCHEND PLATE
CLUTCHPISTON
SNAPRING
14-321
ForwardClutch
Disassembly
1. Removethe snap ring, then removethe clutchend 3. Installthe specialtoolsas shown.
plate,clutchdiscs,and plates.
CLUTCHSPRING
COMPRESSOR
ATTACHMENT
07LAE- PX40100
SNAPRING
CLUTCHSPRING
COMPRESSOR
ATTACHMENT
07LAE- PXa0100or
07HAE- P150100
2. Removethe disc spring. CLUTCHSPRING
COMPRESSOR
BOLT ASSEMBLY
o7R{E-PG402OO
OISC SPRING
CAUTION: lf €ither ond of the sp€cial tool is sst over
an aroa of the spring retainer which is unsupported
by th€ retum spring, the rotainer may be damaged.
Be sure the spccialtool is adiustedto hava tull con-
taqt with the sp.ing retainer.
t
CLUTCHDRUM
Do not B€t here.
SPECIALTOOL
SPRINGRETAINES
14-322
4. Compressthe returnsprlng. 6. Wrap a shop rag aroundthe clutchdrum, and apply
air pressureto the fluid passageto removethe piston.
Placea fingertip on the otherend while applyingair
pressure.
OSHA-APPROVED
30 psi NOzzLE
Removethe snapring.Thenremovethe specialtools,

and returnspring.
springretainer,
SPBINGRETAIT{€R
14-323
ForwardGlutch
Reassembly
NOTE: 3. Installthe pistonin the clutchdrum. Apply pressure
. Clean all parts thoroughly in solvent or carburetor and rotateto ensureproperseatang,
cleaner,and dry them with compressedair.
. Blow out all passages. NOTE: Lubricatethe piston O-ring with CVT Fluid
. Lubricateall partswith CW Fluidbeforereassembly. beforeinstalling.
1. Inspectthe checkvalve;if it's loose,replacethe pis- CAUTION: Do not pinch thc O-ring by installing the
ton. pistoo with too much torqo.
CHECKVALVE CLUTCHDRUM
on theclutchpision.
InstallnewO-rings
Install the return spring and spring retainer,and
positionthe snap ring on the retainer.
CLUTCHDRUM
PISTON
14-324
l .
5. lnstallthesDecialtoolsas shown. 6. Compressthe returnsPrlng'
CLUTCHSPRING
COMPRESSOR
ATTACHMENT
07LAE- PX40100
CLUTCHSPNING
COMPRESSOR
ATTACI{MENT
07LAE- Pxil010oo.
CLUTCI{ SPRING 07HAE- P150100 7. Installthe snap ring.
COMPRESSOR
BOLT ASSEMBLY
oTGAE-PG40200
CAUTION: lf either end of the specialtool is set ovel

an area of lhe spring retain€r which is unsupported
by the return spring, tho retainsr may be damaged'
Be sure the speciallool is adiusted to have full con-
tact with the spring tetainer.
SIIAP RING
8. Removethe specialtools.
Sgt h6r6.
Do not sat hore.
SPECIALTOOL
(cont'd)
RETAINER
14-325
ForwardClutch
Reassembly
{cont'd)
9. Installthe discspring. 12. Installthesnap ring.
NOTE:Installthediscspringin the directionshown.
DISC SPRING
SNAPRING
-\
"arr"" o"u*
1 0 . Soakthe clutchdiscsthoroughlyin CW Fluid for a

minimumof 30 minutes.
1 1 . Starting with a clutch plate. alternatelyinstall the

clutch platesand discs.Installthe clutch end plate
with flat sidetoward the disc. 13. Verify that the snap ring end gap is correct.
NOTE:Beforeinstallingthe platesand discs,make

sure the insideof the clutch drum is free of dirt or CLUTCH
other toreign matter.
CLUTCHENDPLATE
Installin this dir€ction.
Minimum7.9mm (0.31ini
14-326
14. Measurethe clearancebetweenthe clutchend plate 15. It the clearanceis out of tolerance,selecta new ciutch
and toDdiscwith a dial indicator,Zeroth€ dial indica- end platefrom the followingtable,thenrecheck.
tor with the clutch end plate lowered,and lift it up to
the snap ring. The distancethat the clutch end plate NOIE: lf ihe thickestclutchend plateis installedbut
moves is the clearancebetweenthe clutch end plate the clearanceis still over the standard,replacethe
andtoDdisc. clutchdiscsand clutchPlates.
NOTE:Take measurements in at leastthree places,

and usethe averageas the actualclearance. PTATEI{UMBEN
Clutch End Plate-to-TopDisc Clesranc€:
STANDARD:0.6 - 0.8 mm 10.024- 0.031inl
FORWARDCLUTCHEND PLATE
Plate No. Part Number Thickn€ss
1or15 22561- P4V- 003 3 . 5m m ( 0 . 1 3 8i n )

2or16 22562- P4V -OO3 3 . 6m m ( 0 . 1 4 2 in)
3or17 2 2 5 6 3 - P 4 V - 0 0 33 . 7m m ( 0 . 1 4 6i n )
4or18 22564- P4V- 003 3 . 8m m ( 0 . 1 5 0i n )
5or19 2 2 5 6 s - P 4 V - 0 0 33 . 9m m ( 0 . 1 5 4i n )
6ot20 2 2 5 6 6 - P 4 V - 0 0 34 . 0m m ( 0 . 1 5 7i n )
7 ot 21 22567-P4V -003 4 . 1m m ( 0 . 1 6 1i n )
8ot22 2 2 5 6 8 - P 4 V - 0 0 3 4 . 2m m ( 0 . 1 6 5i n )
9ot23 2 2 5 6 9 - P 4 V - 0 0 3 4 . 3m m { 0 . 1 6 9i n )
1 0o r 2 4 22570-P4V-OO3 4 . 4m m ( 0 . 1 7 3 in)
'll 2 2 5 7 1 , P 4 V - 0 0 34 . 5m m ( 0 . 1 7 7i n )
or 25
12ot 26 2 2 5 7 2 - P 4 V - O O 34 . 6m m ( 0 . 1 8 1i n )
1 3o t 2 7 22573-P4V-OO3 4 . 7m m { 0 . 1 8 5i n )
1 6 . After replacingthe clutchend plate,makesure thal

the clearanceis within tolerance.
14-327
SecondaryGearShaft
25 x 35 mm ThrustShim Selection
1. Measurethe distancebetweenthe flywheelhousing Calculate25 x 35 mm thrust shim thicknessbv fol-
surfaceand the ball bearing as shown, then note lowingformula.
the measurement(Measurement A).
FLYWHEEL FORMULA;
HOUSING 25 x 35 mm Thrust Shim Thicknoss
>dt?' = Measurement A - Measurement B + Flywheel
Housing GasketThickness:0.5 mm {0.020in}
Example:
MeasurementA: 32.7 mm (1.287in)
Moasurem.nt B: 30.! mm {1.185in}
25 x 35 mm Thrust Shim Thickness

O = 32.7mm (1.287in) - 30.1mm (1.185in)
+ 0.5 mm {0.020in)
= 3.1 mm (0.122inl
BALLBEARING
Select 25 x 35 mm Thrust Shim D.
A
MeasuringDistance Selectthe 25 x 35 mm thrust shim from the follow-
ing the table.
THRUSTSHIM, 25 x 35 mm
EALL
BALL FLYWHEEL
BEARING HOUSTNG No. Part Number Thickne3s
Installthe secondarygear shatt in the transmission 90551- P4V- 000 2 . 8m m ( 0 . 1 1 0i n )

housing. B 9 0 5 5 2 - P 4 V - 0 0 02 . 9m m ( 0 . 1 1 4i n )
c 9 0 5 5 3 - P 4 V - 0 0 03 . 0m m ( 0 . 1 1 8i n )
Measure the distance between the transmission
housing surface and the thrust washer mounting D 9 0 5 5 4 - P 4 V - 0 0 0 3 . 1m m ( 0 . 1 2 2
in)
surfaceof the secondarygear shaft as shown,then E 9 0 5 5 5 - P 4 V - 0 0 0 3 . 2m m ( 0 . 1 2 6i n )
notethe measurement(Measurement B).
9 0 5 5 6 - P 4 V - 0 0 0 3.3 mm (0.130in)
G 9 0 5 5 7 - P 4 V - 0 0 0 3 . 4m m ( 0 . 1 3 4i n )
H 9 0 5 5 8 - P 4 V - 0 0 0 3 . 5m m ( 0 . 1 3 8i n )
9 0 5 5 9 - P 4 V - 0 0 03 . 6m m { 0 . 1 4 2i n )
9 0 5 6 0 - P 4 V - 0 0 0 3 . 7m m ( 0 . 1 4 6i n )
K 90561- P4V- 000 3.8 mm (0.'150 in)
14-328
Differential
l . lllustratedIndex Bacl(lashInspection
1. Placethe differentialassemblyon V-blocks,and install
BOLTS
both axles.
1 0x 1 . 0m m
98 N.m 110.0kgf.m,
72 tbl.ltl 2. Checkthe backlashof both piniongears.
Left-handthreads
Standard (Newl: 0.05- 0.15 mm 10.002- 0.006in)
PINIONGEARS
FII{AL ORIVENGEAR
BAIT EEANIM;
SET RING. 8() tnm lf the backlashis out of tolerance,replacethe differ-

Soloctivopan entialcarrier.
14-329
Differential
BearingReplacement DifferentialCarrierReplacement
NOTE:Checkthe bearingsfor wear and rough rotation. 1. Removethe final driven gear from the differential
lf the bearingsare OK, removalis not necessary. carner.
'1. Removethe ball bearingsusinga
bearingpuller. NOTE: The final driven gear bolts have left-hand
threads.
BOLTS
1 0x 1 , 0m m
98N'm 110,0 kgf.m,
72 tbl.ttl
Left-hand threads
BAI-LBEARING
Installthe new ball bearingsusing the special tool

with a pressas shown. DIFFERENTIAL
CARRIER
Installthe final driven gear with its chamferedside
on the innerborefacingthe differentialcarrier.
ORIVER10 mm l.O. Tightenthe boltsto the specifiedtorque in a crisscross

07746- 0030100
Paftern.
TOROUE:98 N.m (10.0kgt.m, 72 lbf.ft)
BALLBEARING
14- 3 3 0
Clearance
Oil SealInstallation/Side
l . Oil SealRemoval
1. Removethe differentialassembly. 1. lnstall a 2.50 mm (0.098in) thick 80 mm wide set
r i n gi n t h e t r a n s m i s s i ohno u s i n g .
2. Removethe oil sealfrom the transmissionhousing.
NOTE:Do not installtheoil sealyet.
TRANSMISSION
HOUStl{G
TRANSMISSON OIL SEAL

HOUSING R€placa.
3. Removethe oil sealfrom the flywheelhousing. lnstallthe differentialassemblyinto the transmrs-

sion housingusingthe specialtoolas shown
DIFFEREI{NAL
ASSEMBLY
(cont'd)
14-331
Differential
Clearance(cont'dl
Oil SealInstallation/Side
3. Installtheflywheelhousing,and tightenthe bolts. 4. Measurethe clea.ancebetweenthe 80 mm set ring
and outer race of the ball bearingin the transmis-
sion housing.
8 x 1.25 mm
0 - 0.15mm (0 - 0.006in)
STANDARD:
29 N m (3.0kgt m,22 lbf.ttl
ug Ei
DOWELPIN
lf the clearanceis more than the standard,selecta

new set ring from the table,and installit.
SETRING,80 mm

904' r4-689-000 2.50mm (0.098in)
90415-689-000 2 . 6 0m m ( 0 . 1 0 2in)
90416-689-000 2 . 7 0m m ( 0 . 1 0 6in)
90417-689-000 2 . 8 0m m ( 0 . 1 1 0in)
90418-689-000 2 . 9 0m m ( 0 . 1 1 4in)
90419-PH8-000 3 . 0 0m m ( 0 . 1 1 8i n )
NOTE:lf the clearancemeasuredin steD4 is stan-

dard, it is not necessaryto perform steps 7 and 8.
6. Removethe flywheelhousing.
7. Replacettle 2.50mm (0.098in) set ring, 80 mm with

the one ot the correctthicknessselectedin steD5.
14-332
FlywheelHousing
Input Shaft Oil Seal
l . Replacement
1. Removethe input shaft oil seal from the flywheel
8. Installthe oil sealin the transmissionhousingusing
the sDecialtools as shown. housing.
DRIVER
07749- 0010d)0
OIL SEAL
Instalithe oil seal in the flywheelhousingusingthe

9. Installthe oil seal in the flywheelhousingusingthe soecialtoolsas shown.
soecialtools as shown.
FLYWHEEL
lmtalled depth:
2 . 5 - 3 . 5m m
PILOT,
26x30mm
ro"nri':,ilii.rl
DRIVER
ATIACHMENT,58 x 72 rnin
oTJAD- PH80200
t@
0?947- d'40201
14-333
Transmission
HousingBearings
DrivenPulleyShaft BearingReplacement
1. To removethe driven pulleyshaft b'earingtrom the Expandthe snap ring with snap ring pliers,insert
t r a n s m i s s i o nh o u s i n g ,e x p a n dt h e s n a p r i n g w i t h the new bearing part-way into the housing using
s n a p r i n g p l i e r s ,t h e n p u s h t h e b e a r i n go u t u s i n g the specialtools and a press as shown. Installthe
the specialtoolsand a pressas shown. bearingwith the groovefacingoutsidethe housing.
NOTE: Do not removethe snap ring unlessit's nec- N O T E :C o a ta l l p a n sw i t h C W F l u i d .

essaryto cleanthe groovein the housing.
R e l e a s et h e p l i e r s ,t h e n u s i n g t h e s p e c i a lt o o l s ,
push the bearingdown into the housing until the
snap ring snapsin place.
07749- 001(xDo
ATTACHMENT,
72x75mm
BEARING 07746 - OO1
0600
GROOVE
SNAP RING
After installingthe bearingverifythe following:

ATTACHMENT,
72x75mm
07746 - (x'l05U) o The snap ring is seatedin the bearingand hous-
ing grooves.
. The ring end gap is correct.
ENDGAP|0 -9 mm
l0 - 0.35 inl
077i()- 001(xrco
SNAPRING
14-334
FlywheelHousing
Bearing
SecondaryGearShaft Bearing SecondaryGear Shaft Bearing
1. Removethe secondarygear shaft bearingusingthe 1. Removethe secondarygear shaft bearingusingthe
specialtools as shown. soecialtool as shown.
3/8" - 16 SLIDEHAMMER 3/8" - 16 SLIDEHAMMER

{Comm6rciallYavailablel lCommorciallyaY.ilabl6l
GEAR
SECONDARY
ADJUSTABI.T BEARING SHAFTBEARING
PULLER.25- 40mm
07736- A01000A
Installthe new secondarygear shaft bearinguntil it 2. lnstallthe new secondarygear shaft bearinguntil it
bottomsin the transmissionhousing.usingthe spe- bottoms in the flywheel housing,using the special
cialtools as shown. tools as shown.
DRIVER
07749- (x)10000
ATTACHMENT.
62xGgmm
07745- 0010500
14-335
RingGearBearing ControlShaft Assembly
Replacement RemovaUlnstallation
1. Remove the ring gear bearing. 1. Removethe bolt and lockwasher.
CONTROLSHAFT
ASSEMBLY
TRANSMISSION
RING RINGGEAR
Installthe new ring gear bearinguntil it bottoms in

the ring gear.usingthe specialtoolsas shown,
6r1.0mm
14 N.ft 11.4kg{.m, CONTROL
10 rbf.ftl LEVER
DRIVER LOCKWASHER
07?{9 - 001(xxxt Replace.
2. Removethe control lever from the control shaft.
3. Removethe control shaft assembly.
4. Installthe controlshaftassemblyin the transmission

housing.
Installthe controlleverto the controlshaft.
Installand tightenthe bolt with a new lockwasher.
1 4- 3 3 6
Transmission
Reassembly
CAUTION:While reassembling.be sure not to sllow dust and othor foreign particlesto enter into the transmission.
NOTE:
. Coatall partswith CVTFluid.
. Replacethe followingparts:
- O-rings
- S e a l i n gr i n g s
- Sealingwashers
- Gaskets
- Startclutchassemblyand secondarydrivegear
assembly
8 x 1.25mm
37 N.m {3.8kgf.m,27 lbtftl
SNAPRING
6x1.0mm
12 N m 11.2kgf.m,8.7 lbl.ft)
MANUAL VALVE
LINES
REVERSEBRAKE
END PLATE ENDCOVEB
Dtsc DOWEL
PIN
PLATE
DISCSPRING ENDCOVERGASKET
6x1.0mm
THRUSTSHIM,25x 31 mm 12 N.m 11.2kgtm,8.7 lbtft)
Selectivepart
SNAP
RINGGEAR RING eB 8 x 1.25mm
THRUSTWASHER H^c 29 N.m 13.0kgl m, 22 lbtftl
MANUAL
THRUST VALVE
BEARING BOOY INTERMEDIATE
HOUSINGASSEMBLY
THRUSTWASHER
CARRIERASSEMBLY
THRUSTWASHER
ROLI.IR
THRUSTNEEDLE
BEARING
SUN GEAR ATF FEEDPIPE
INPUTSHAFT O-RINGS TRANSMISSION

SNAPRING HOUSINGGASKET
FORWARDCLUTCH
SHAFT
ASSEMALY
(RUBEERI
SNAPRING
SPRINGRETAINER/
RETURNSPRING
ASSEMBLY
DOWELPtN
REVERSE
BRAKEPISTON
O.RINGS
TRANSMISSION
HOUSING
SNAPRINGRETAINER
ATF FEEDPIPES
14-338
1. lnstallthe ATF feed pipe in the transmissionhous- 9 . Compressthe return springs,then installthe snap
ing, and installthe three ATF feed pipeswith new ring in the intermediatehousing above the spring
O - r i n g si n t h e t r a n s m i s s i ohno u s i n g , retainer.
Installthe two dowel pins and new transmissionhous-
ing gasketon the transmissionhousing. 1 0 . Verifythat the snap ring end gap is correct'
Pushthe controlshaft assemblytoward the outside
M i n i m u m 1 5m m 1 0 . 5 i9n )
of the transmissionhousing,then installthe inter-
mediatehousingassembly(four bolts). '-t,,,,.
lnstall the manual valve body separatorplate and ///,,- \\',r
the two dowelpins on the intermediate housing, i/
then installthe rnanualvalve body with the detent '1 ,
spring (five bolts).
Put the controlshaft assemblyback,then installthe '/.
.r' .-J?
//
SNAPR I N G
rollerin the intermediatehousing.
6 . lnstallthe reversebrakepiston in the intermediate
housing. 1 1 . S o a k t h e r e v e r s eb r a k ed i s c s t h o r o u g h l yi n C V T
springassemblyon F l u i df o r m i n i m u m3 0 m i n u t e s .
7 . Installthe spring retainer/return
the reverse brake Piston.
12. Installthedisc springon the reversebrakepiston'
NOTE:Installthereturnspringson the springguides
of the reversebrake piston securely 1 3 . S t a r t i n gw i t h a r e v e r s eb r a k e p l a t e , a l t e r n a t e l y
installthe reversebrakeplatesand discs lnstallthe
tnstallthe specialtool to compressthe returnspring reversebrakeend plate,and the snap ring'
L
as shown.
1 4 . Measurethe clearancebetweenthe reversebrake
REVERSEBRAKE end plateand the top discwith a dial indicator'Zero
1
COMPRESSOR
SPRING plate
the dial indicator with a reversebrake end
07TAE- P4V0110 the snap ring The distance
lowered, and lift it up to
that the reversebrakeand platemoves is the clear-
ance between the reverseend plate, and the top
disc.
NOTE:Take measurements in at leastthree places'

and usethe averageas the actualclearance'
-
STANDARD:0.45- 0.75 mm (0.018 0'030 in)
CAUTION:lf the spring retainertab is on the reverse

brakc piston, the spring rstainer may be damaged'
Be sure the spring retainertab is not on the piston'
SPECIALTOOL REVERSEBRAKE
rp {cont'd)
14-339
-^ from www.Manualslib.com manuals search engine
Downloaded
Transmission
(cont'dl
Reassembly
lf the clearanceis not within the standard,removethe 22. Veritythat the outsidediameterol the snap ring is
reversebrakeend plateand measureits thickness. correct.
1 6 . Select and install a new reversebrake end Dlate.
then recheck.
Msximum41.4mm11.63
in)
N O T E : l f t h e t h i c k e s tr e v e r s eb r a k ee n d o l a t e i s
installed,but the clearanceis still over the standard,
replacethe reversebrakediscsand plates.
REVERSEBRAKEEND PLATE
SI{APRIiIG
Plat6 No. Part Number Thickness
1 22551 - P4V- 003 3 . 6m m ( 0 . 1 4 2i n ) Install the input shaft and the sun gear as a sub
assemDry.
22552-P4V-003 3 . 8m m ( 0 . 1 5 0
in)
2 2 5 5 3 - P 4 V - 0 0 3 4 . 0m m ( 0 . 1 5 7i n ) I n s t a l lt h e t h . u s t n e e d l e b e a r i n ga n d t h e t h r u s t
washeron the sun gear.
4 2 2 5 5 4 - P 4 V - 0 0 3 4 . 2m m ( 0 . 1 6 5i n )
5 2 2 5 5 5 - P 4 V - 0 0 3 4 . 4m m ( 0 . 1 7 3i n )
CARRIER
ASSEMBLY
6 2 2 5 5 6 - P 4 V - 0 0 3 4 . 6m m ( 0 . 1 8 1
in)
7 22557-P4V -OO3 4 . 8m m ( 0 . 1 8 9i n )
8 2 2 5 5 8 - P 4 V - 0 0 3 5.0 mm (0.200in)
1 7 . After replacingthe reversebrake end plate, make IHruST

surethat the clearanceis within the standard.
1 8 . R e m o v et h e s n a p r i n g , r e v e r s eb r a k ee n d p l a t e ,
discs,plates.and discspring.
1 9 . I n s t a l lt h e s n a p r i n g r e t a i n e ro n t h e d r i v e p u l l e y THFUST I'IEEDI!
EEARIT{G
shaft.
20. Wrap the drive pulleyshaftsplineswith tapeto pre-
v e n t d a m a g et o t h e O - r i n g s ,t h e n i n s t a l ln e w O -
nn g s .
2 1 . Installthe forwardclutchassemblyon the drive pul-
ley shaft,then installthesnap ring.
SITAP
O-RINGS
SI{AP RIM;
BETA EB
25. Installthecarrierassemblyon the forwardclutch.
DRIVEPUI.IEY
SHAFT
14-340
30. lf the clearanceis out of tolerance,removethe 25 x
26. Installthe thrust washer,the thrust needlebearing'
31 mm thrust shim and measureits thickness'
and the thrustwasheron the carrierassembly'
THRUSTSHIM,
2 5 x 3 1m m 3 1 . Selectand install a new 25 x 31 mm thrust shim.
SNAPRING then recheck.
Selective Pan
THRUSTSHIM, 25 x 31 mm
RINGGEAR
No. Part Numb.l Thickne*3
90451- P4V- 000 1.05mm (0.041in)
THRUSTNEEDLE THRUSTWASHERS B 9 0 4 5 2 - P 4 V - 0 0 0 1.12mm (0.044in)

EEARING '1.19mm (0.047in)
c 90453-P4V-000
'l.26mm (0.050in)
D 90454- P4V- 000
9 0 4 5 5 - P 4 V - 0 0 0 1.33mm (0.052in)
F 90456-P4V-000 1.40mm (0.055in)
904s7-P4V-000 1.47mm (0.058in)
90458-P4V-000 1.54mm (0.06'lin)
'1.61mm (0.063in)
90459-P4V-000
CARRIER J 90460-P4V-000 1.68mm (0.066inl
ASSEMBLY K 9 0 4 6 1 - P 4 V - 0 0 0 1.75mm (0.069in)
21. lnstallthering gear and the 25 x 31 mm thrustshim,
90462-P4V-000 1.82mm (0.072in)
then installthesnaPrrng.
M 904a0-P4V-000 1.085mm (0.0427
in)
24. Verifythat the outsidediameterof the snap ring is N 9 0 4 8 1 - P 4 V - 0 0 0 1.155mm (0.0454in)
correct, 901a2-P4V-000 1.225mm (0.0482in)
o
Maximum30.7mm (1.21in) 90483-P4V-000 1.295mm (0.0510
in)
o 9 0 4 8 4 - P 4 V - 0 0 0 1.365mm (0.0537in)
R 904a5-P4V-000 1.435mm (0.0565in)
90486-P4V-000 1.5O5mm (0,0593in)
T 90487-P4V-000 1.575mm (0.0620in)

90488-P4V-00{) 1.645mm {0.0648in)
SNAPRING 90489-P4V-000 1.715mm (0.0675
in)
90490-P4V-000 1.785mm (0.0703in)

29. Measure the clearancebetween the 25 x 31 mm
thrustshim and the snaPrlng.
32. After replacingthe 25 x 31 mm thrust shim, make
-
STANDARD:O.O5- 0.11 mm (0.0020 0.00'8 in) sure that the clearanceis within toleranceand the
snap ring outside diameter is correct'
NOTE:Takemeasurementsin at leastthree places' 33. Installthe discspringin the directionshown'
and usethe averageas the actualclearance
34. S t a r t i n gw i t h a r e v e r s eb r a k e p l a t e , a l t e r n a t e l y
install the reverse brake plates and discs lnstall
selectedreversebrake end plate, then install the
snap nng.
RING
REVERSE BRAKE
END PLATE Dtscs
SPRING
REVERSE lnstall in this direction.
'- t PI-ATES
,**r#*,". )
RINGGEAR (cont'd)
14-341
Transmission
(cont'd)
Reassembly
35. Verifythat the snap ring end gap is correct. 39. Installthe park pawl,spring,and shaft on the trans-
missionhousing,then move the controlleverto anv
M i n i m u m1 8m m ( 0 . 7 1i n )
gear otherthan E position.
SNAPRING COTTER
,/\, THBUST
SHIM, RETAINER
25x35mm
COTTERS,
."or**ol!/' SECONDARY
GEARSHAFT
25.5mm
pan
Selective
Install the manual valve body lines A and B wkh

new O-ringson the manualvalvebody and the inter-
mediatehousing. STARTCI.UTCH
ASSEMBLY
6x1.0mm
8 x 1.25mm 12 N..n (1.2kgt m, SECONDARY
37 N.m 13.8kgf.m,27 lbf.ftl 8.7 rbtft) ORIVEGEAF
ASSEMBLY
END
COVER fl
g O.RINGS
PARK
PAWL SPRING
PARKPAWL
END
COVERGASKET
DOWELPINS
O-RINGS
,10, Install the secondary gear shaft with setected25 x

35 mm thrust shim (seepage ,14-328).
MANUAL VALVE 41. Wrap the driven pulley shaft splines with taDe to
BODYLINEA prevent damage to the O-rings, then install new O_
rings.
42, Assembleths secondarydrive goar assembly in the
start clutch assembly,then installthem on the driven
pulley shaft,
43. Pull the handle of the specialtool up, then install
the tip of it into the driven pulley shaft hole, and set
the specialtool on the stan clutch.
CAUTION:Whib in3trling thc st rt ctutch and rh.

3ocondlry driye g.!r a3sombly using lh€ special
tool, bo 3urc nol to sllow du3t or olher foraign par_
uaNYuAL
VALVE
ticlos to ontq into tho iransmbsion.
STARTCLUTCH
37. Install the two dowel pins and new end cover gas_ INSTALLER I c,rrr,unar".
ket on the intermediatehousing,then install new O_ 07TAE - P4V0r30
rings on the ATF feed pipes.
Installthe end cover (three 6 mm bolts, eleven g

mm bolts).
NOTE:Installthe nine 8 mm bolts in the end cover

( t w o 8 m m b o l t s r e m a i n i n t h e e n d c o v e r )t h e n
tightenthe eleven8 mm bolts.
14-342
44. Pushthe handleof the specialtool, then tightenthe 47. lf the clearanceis not within the standard,remove
nut to seal the secondarydrive gear assemblyon the cottersand measuretheirthickness
the drivenpulleYshaftsecurelY.
48. Selectand installnew cotters,then recheck.
STAAT CLUTCHIi'ISTALIIR
07TAE- PaV0130 COTTERS,25.5 mm
No. Part Number Thickness
9 0 4 2 9 - P 4 V - 0 0 0 2.9m m ( 0 . 1 1 4i n )
B 9 0 4 3 0 - P 4 V - 0 0 03.0m m ( 0 . 1 1i8n )
c 9 0 4 3 -1P 4 V - 0 0 0 3 . 1m m ( 0 . 1 2l2n )
D 9 0 4 3 2 - P 4 V - 0 0 0 3 . 2m m ( 0 . 1 2 6
in)
49. After replacingthe 25.5mm cotters,make surethat

the clearanceis the standard
50. lnstallthe cotterretainerand the snaprlng
Verify that the outsidediameterof the snap ring is

correct.
Minimum33.9mm (1.33in)
OF
SHAFT HA'{DI,-E
Pull the handleof the specialtool up, and remove SNAP RII{G
the specialtool.
52. l n s t a l l t h e t h r u s t w a s h e r s .t h e A T F p u m p d r r v e
46. lnstallthecotters,then measurethe clearanceDelween sprockethub and the 22 x 28 mm thrustshim on the
the cottersand the startclutchguide inDUtshaft,then installthe snap ring.
0 - 0.13mm (0 - 0.005inl
STANDARD: SNAPRING\
THFUST SHIM, 22 x 2a mm
NOTE:Take measurements in at leastthree places, Selectivepan
ATF PUMP DRIVE
and usethe averageas the actualclearance SPROCKETHUB
THRUSTWASXERS
25.5mm
COTTERS,
GAUGE
INPUTSHAFT
lilSTART 1
(il
START CLUTCH (cont'd)
GAUGC
14-343
Transmission
(cont'd)
Reassembly
53. Verifythat the outsidediameterof the snap ring is After replacingthe 22 x 28 mm thrust shim. make
correct. sure that the clearanceis within toleranceand the
M a x i m u m2 6 . 3m m ( 1 . 0 4i n ) snap ring outsidediameteris correcr.
58. Installthe pitot flange using its cutout as shown to

clearthe pitot pipes.
SNAP RING
54. Measurethe clearancebetween the 22 x 28 mm

thrustshim and the snap ring.
STANDARD:0.37- 0.65 mm (0.015- 0.026inl
NOTE:Takemeasurementsin at leastthree places,

and usethe averageas the actualclearance.
59. Install the ATF pump drive sprocket.and put the

ATF pump drive chain on the ATF pump drive and
driven sprockets,then install8nd tighten the bolts
(three bolts).
TF PUMPDRIVECHAIN
6x1.0mm
12 N.m
55. lf the clearanceis out of tolerance,removethe 22 x 11.2kg{.m,8.7 lbf.ftl
28 mm thrustshim and measureits thickness.
ATF PUMPORIVE
co. Selectand install a new 22 x 28 mm thrust shim, SPROCKET
then recheck.
PITOTFLANGE
THRUSTSHIM,22 x 28 mm
No. Part Numb€r Thicknsss ATF PUMP
c 9 0 5 7 3 - P 4 V - 0 0 01 . 1 5m m ( 0 . 0 , {i5n )
D 9 0 5 7 4 - P 4 V - 0 0 0 1.40mm {0.055in)
E 9 0 5 7 5 - P 4 V - 0 0 0 1.65mm (0.065in)
F 9 0 5 7 6 - P 4 V - 0 0 0 1.90mm (0.075in)
9 0 5 7 7 - P 4 V - 0 0 0 2 . 1 5m m ( 0 . 0 8 5i n )
9 0 5 7 8 - P 4 V - 0 0 0 2.40mm (0.095in) INPUTSXAFT
14-344
l .
60. Installthe ditferentialassembly
(oneboltl'
61. InstalltheATF passageline assemblywith new O-rings
housing'
62. Installthethreedowel pinsand new flywheelhousinggasketon the transmission
(twentybolts)'
63. Installthe flywheelhousingand connectorbracket
64. InstalltheATF passageline holderassembly(two bolts)'

8 x 1.25mm
6x1.0mm 29 N.m t3.o kg['m, 22 lbf'ttl
12 N.m {1.2 ksf'm,
8.7 tbf.ftl
/
L|NE
ATFPASSAGE I
I g
u
s
g
l l
"o.o.'o{ FLYWHEELHOUSING
d
\n
rm
\A
o-nrnc--.-..ff
BRACKET
CONNECTOR ATF PASSAGELINE
ASSEMALY
DOWELPIN 6x1.0mm
12 N.m 11.2kgd'm,
8.7tbr.tr)
ASSEMBLY
DIFFERENNAL
O.RING
DOWELPIN
DOWELPIN
FLYWHEELHOUSING
GASKET
TRANSMISSION
ItousrNG
ATF PASSAGE
LINEASSEMBLY
PASSAGELINE
TRANSMISSIONHOUSING
GUIOE
(cont'd)
14-345
Transmission
(cont'dl
Reassembly
65 lnstallthe solenoidharnessconnectorwith a new O-ring(one bolt),then installthe lower valve body assemblywith
threedowel pins (eightbolts).
66. Installthe ATFstrainerwith a new O-ring(two bolts).
67. lf necessary,
assemblethe ATF pan,ATFfilter,and the ATFcoolerinlet line (seepage14_303).
68. Installthe ATF pan with the two dowel pinsand a new ATF pan gasket(fourteenbolts).
69. Installthe ATF coolerinlet line bracketbolt.
70. InstalltheATFcooleroutletlinewith the line bolt and new sealingwashers.
6x1.0mm
12 N.m 11.2kgf.m,
8.7 rbtft)
DOWELPINS
ATF STRAINER
ATF COOLEROUTI.IT LINE
DOWELPINS
ATF PAN,/ATFFILTER/
ATF COOLERINLET
LINEASSEMELY
@
@
C4
CONNECTOE
6x1.0mm
12 N.m {1.2kgf.m,
8.7 tbtftl
6x1.0mm LOWERVALVEBODY
12Nm11.2kgl.m, ASSEMBLY
8.? tbf.ft) 6x1.0mm
12 N.m 11.2kgf.m,
8.7 tbt.ft)
ATF COOI.ERINI.IT
LINEBRACKETBOLT
I x 1.25mm
26 N.m (2.7kgt.m,20 lbf.ft)
14-346
Flywheel/DrivePlate
WASHER
DRIVEPLATE Installin this direction.
/,1 . . /
o0 vl
a9a .t
FLYWHEEL
wear'
lnspectthe teethof the ring gearfor excessive
1 2x 1 . 0m m
74 N.m (7.5kgf.m, 54lbfft)
Torque in a crisscrossPattern

Transmission
Installation
L Flushthe ATF cooleras describedon pages14-352
6. Placethe transmissionon s jack,and raiseit to the
and 14-353.
engineassemblylevel.
Removethe used greasein the flywheel hub caD 7. Anach the transmissionon the engine,then install
and flywheelsplines.
the transmissionhousing mounting bolt and rear
enginemountingbolts.
Fill the insideof the flywheelhub cap,and coatthe fly-
wheel hub splineswith SuperHighTemp Urea Grease
(P/N08798- 9002)as shown.
REARENGINEMOUNTING
TRANSMISSION HOUSING BOLT
MOUNTING BOIT Replace.
6,1N.m 16.5kgl.m, 12 x 1.25mm
47 tbtttl 59 Nrn {6.0 kgl.m. ,€ lbt ftl
SPLINES
Apply SUPEBHlcH TEMP
UREAGREASE WASHER
lPlN 08798- 90O2t
SUPERHIGHTEMP
UREAGREASE
(P/N 08798 - !)0021
1.5-2.5 g 10.05-0.t9oz)
lnstallthe transmissionmount bracket.Tightenthe

long bolt loosely,and tighten the nuts and bott on
I n s t a l la n e w s e a l i n g r i n g ( r u b b e r )o n t h e i n o u t the mount bracket to the specified torque. Then
shaft,and installtwo '14x 20 mm dowel Dinsin the tighten the long bolt to the specifiedtorque.
flywheelhousing.
Installthe flywheelsecurelyon the input shaft,then 12x 1.25mn

installthestartermotor on the flywheelhousing. 6,r N'm 16.5kgtm,47 tbtftl
4,1Nm l-".--..-,^ TRANSMISSON

MOUNT BRACKET
la.5 kgt.m,33 tbt.ft) G \ V
INPUTSHAFT
STARTER
.4;i "lrj
,i rr,"r.,., a
SEALINGRING 12 x 1.25mn
{RUEBER) MOUI{T 74N.m(7.5tstm,5a tbtftt
l4 x 20 mm DOWELptN
FLYWHEEL
14-348
l . 1 3 . Tighten the crankshaftpulley bolt, if necessary
(see
9. Installthe remainingtransmissionhousing mount-
ing bolts. section6).
PRIMARYOXYGENSENSOR 1 4 . Connectthe ATF cooler hosesto the ATF cooler lines

(seepage 14-357).
CAUTION: Whilo connecting the ATF cooltr hGes,

b€ sure not lo allow dust and other loreign parti-
cles to entg. into the transmission.
15. Installtherightfront mounvbracket'
10 x 1.25mm
a,r N.m {4.5 kgf'm,33 lbt ftl
RIGHTFRONT
MOUNT/BRACKET
ATF COOLERLINE
TRANSMISSION HOUSING
MOUNNNG BOLT
6il N.m {6.5 kgf.m,47 lbf'ftl
10 x 1.25 mm
1 0 . Removethe transmissionjack and the hoist. then 54 N.m {5.5 kgt'm,
remove the hoist bracketfrom the engine' 4{) tbl.ftt
1 1 . Attach the flvwheel to the drive plate with eight

boltsand torqueas follows:
Rotatethe crankshaftpulley as necessaryto tighten ATF COOI,TRHOSE
rhe bolts to half of the specifiedtorque,then to the
16. Installthe exhaust PiPeA.
final torque,in a crisscrosspattern.
After tightening the last bolt. check that the EXHAUSTPIPEA
crankshaftrotatesfreelY.
12. Installthe flywheelcoverand the enginestiffeners

6xl.0mm
*s$o
12 N.m
ENGINE 10x 1.25mm
-rE l12 kgf'm' STIFfENEB artN.mla.skgt.m,
DRIVE 8.7 tbf.ftl
33tbtftt
GASKET
Replace.
8 x 1.25mm
24 N.m
(2.1kgf'm, @
17 tbt.ftt
\
oor*rr-@ SELF.LOCKING NUT
Replace. Replace.
DRIVEPI.ATEBOLT 10 x 1.25mm
SELF.LOCKING
6x1.0x14mm 5/aN.m {5.5kgt m,
Replace.
12 N.m {1.2kgt m. 8 x 1.25mm irc lbf.ft)
8 x 1.25mm
8.7 lbf,ftl 26 N.m SELF.LOCKING NUT
22 N.m t2.2 kgl m, 16lbf'ftl
FLYUTHEEL 12.7kqfin, Replace.
ENGINESTIFFENER 20 rbt'ftl 8 x 1.25mm
10 x 1.25mm 16 N.m {1.6kgl'm,
8 x 1.25mm '17 r,a N.m {4,5kgf m, 12 tbl.ftt
24 N.m (2.4 kgt'm, lbf'ftl (cont'dl
33 tbf.ftl
14-349
Transmission
1 7 . InstallI new set ring on the end of eachdriveshaft. 20. Installthe splashshietd.
Installthe right and left driveshafts(seesection16).
CAUTION:While instatlingthe drive3haftsin the

differential,be sure not to allow dust and olher for-
aign particles to enter into tho transmission.
NOTE:
. Cleanthe areaswherethe driveshaftscontactthe
transmission{differential}thoroughly with sol-
vent or carburetorcleaner,and drv with com-
Dressedair.
. Turn the right and left steeringknucklefully out-
wa.d, and slide each driveshaftinto the differen-
tial until you feel its set ring clip engagethe side I
gear.
I 6 a
a
6*
1 9 . Installthe damperfork,then installthe right and left
"a,a s 6 x 1 . 0m m
ball joints to each lower arm with the castleouts 9.8 t{.m 11.0kgt.m,
and new cotter pins. 7.2 tbf.trl
2 1 . Connectthe vehicle speed senso. connector.the

10 x 1.25mm driven pulley speedsensorconnectorand the sec-
43 N.m ondary gear shaft speed sensor connector,
{4.4 kgf.m,32 lbf.ftl
6x1,0mm
12 N.m {1.2kg{.m,8.7 tbf,ft)
DRIVENPULLEY
SPEEDSENSOR
CONNECTOR
SELF-LOCKING
NUT
Replace.
12x 1.25mm CASTI.I
'12x 1.25
6l N.m mm
ksr.m.
{6.s 47tbr.ftrl! _ll - s.otet'.,
ffiteo
SECONOARYGEAR
E.
SHAFTSPEED 6 x 1.0 m.rl
'12N.m
SENSOBCONNECTOR {1.2 kg{.m,8.7tbf.fo
1 4- 350
22. Installthe shift cable end on the control lever,and 25. Connectthe startermotorcableon the startermotor.
installthe shiftcableon the shift cablebracket' and installthe cableholder.
CAUTION: Take care not to bend the shift cable' NOTE:When installingthe stanermotor cable.make
s u r e t h a t t h e c r i m p e ds i d e o f t h e r i n g t e r m i n a li s
23. lnstallthe clip in the directionshown. facingout (seesection23).
LOCKNUT
SHIFI CABLE 29 N m {3.0kg{ m, 22lblftl STARTERMOTOR
SHIFTCABLE
ERACKET
WASHER
IPLASTIC)
STARTEB
B MOUNTINGNUT
9 N.m (0.9 kgf m,7 lbf ft)
LEVER
CONTROL
26. Installall removedconnectorsand clamps'
27. Installthe distributor.
24, Connectthe solenoidharnessconnector.the drive
p u l l e y s p e e d s e n s o rc o n n e c t o r .a n d t h e g r o u n d 28. Installthe intake air duct and air cleaner housing
assemDly.
cableterminals.
29. R e f i l l t h e t r a n s m i s s i o nw i t h t h e r e c o m m e n d e d
GROUNDCABLE
GenuineHondaCVTFluid(seepage14-2991
6x1.0mm 6x1.0mm
12 N.m {1.2kgf.m. TERMINAL
8,7 rbtft)
12 N.m {1.2kgf'm, CAUTION:While filling the CvT Fluid,bs surs not io
8.7lbtfrl
allow dust and other fotoign particles to entor into
the transmission.
30. Connect the battery positive (+) terminal first, then

the negative(-l terminal to the battery'
3 1 . Checkthe ignitiontiming (seesection23).
Startthe engine.Setthe parkingbrake,and shift the
transmissionthrough all gears three times Check
GROUND shiftcableadjustment(seepage 14-355).
TERMINAL Checkthe front wheelalignment(seesection18)
DRIVEPULLEY 34. L e t t h e e n g i n e r e a c ho p e r a t i n gt e m p e r a t u r e( t h e
SPEEDSENSOR radiatorfan comes on) with the transmissionin lXl
CONNECTOR
or E position,then turn it off and checkfluid level'
Perform the start clutch calibration procedureon
page14-293.
36. Roadtest as describedon pages14-296and 14-297
SOLENOIDHARNESS
CONNECTOR
14-351
Transmission
GoolerFlushing
@ To prevent iniury to face and eyes,always 7. With the water and air valvesoff, attachthe water and
wear safety glassesor a tace shield when using the air suppliesto the flusher.(Hotwaterif available.)
transmissionflusher.
NOTE:This procedureshouldbe performedbeforerein-

stallingthe transmission.
'1.
Checkthe tools and hosesfor wear and cracksbefore
using.lf wear or cracksare found, reDlacethe hoses
beforeusing.
Usingthe measuringcup.fill the tankwith 2,1ounces

(approximately2/3 full) of biodegradableflushing
fluid (J35944- 20).Do not substitutewith any other
f l u i d . F o l l o wt h e h a n d l i n gp r o c e d u r eo n t h e f l u i d
contatner.
Securethe flusherfiller cap,and pressurize

the tank 8. Turn on the flusherwater valve so water will flow
with compressedair to between5S0- 829 kpa (5.6- throughthe coolerfor 10 seconds.
8.45kgf/cm' ,80 - 120psi).
NOTE:lf water does not flow throughthe cooler,it
NOTE:The air line shouldbe equippedwith a water is completelyplugged,cannotbe flushed,and must
trap to ensurea dry air system, be replsced.
4. Hangthe tool underthe vehicle. 9. Depressthe trigger to mix the flushing fluid into the
water flow. Usethe wire clip to hold the trigger down.
Attach the tank's dischargehose to the return line
oi the transmissioncoolerusinga clamp. '10.
While flushingwith the water and flushingfluid for
two minutes.turn the air valve on for five seconds
Connectthe drain hoseto the inlet line on the trans- every 15- 20 secondsto createa surgingaction.
missioncoolerusinga clamp. AIR PRESSURE: MAX 845 kpa (8.45kgflcmr, 120 psi)
IMPORTANT: 11. Turn the water valve off. Releasethe trigger,then

Securelyclampthe oppositeend ofthe drain hoseto a reversethe hosesto the coolerso you can flush in
bucketor floor drain, the oppositedirection.Repeatsteps8 through 10.
TRANSMISSION
12. Releasethe trigger.and rinsethe coolerwith water
only for one minute.
13, Turn the water valveoff, and turn off the water supply.
'14. Turn
the air valve on to dry the systemout with air
for two full minutesor until no moistureis visible
leavingthe drain hose.
CAUTION: Rosidual mobturo in the qooler or lines

cln damagethe transmission,
15. Removethe flusherfrom the cooler line.Attachthe

t drain hoseto a container.
16. Installthe transmission.and leave the drain hose

TRANSMISSION COOLER
FLUSHER attachedto the coolerline.
{Commerciallyavailable)
Kent-MooreJ384O5-A
or oouivalent
14-352
l .
1 7 . Makesurethe transmissionis in the E] position. TOOL MAINTENANCE
w i t h c v T F l u i d ,a n d r u n t h e
F i l lt h e t r a n s m i s s i o n
enginefor 30 secondsor until approximately0 95 { 1. Emptyand rinseaftereachuse.Fillthe canwith water
( 1 . 0U S q t . , 0 . 8l m p q t . )i s d i s c h a r g e d . and pressurizethe can. Flushthe dischargeline to
ensurethat the unit is clean.
1 8 . Removethe drain hose, and reconnectthe cooler
returnhoseto the transmission(seepage14-355) 2, lf dischargeliquiddoes not foam,the orificemay be
blocked.
'19. Refillthe transmissionwith CVTFluidto the proper
level(seepage 14-299). 3. To clean,disconnectthe plumbingfrom the tank at
the largecouPlingnut.
FILLERCAP FILTER COUPLING

NUT
\
I I
- 0--D -@q \
i
I
\
ORIFICE
O.RING
.l, Removethe in-linetilterfrom the dischargesideand

cleanif necessary'
The fluid orificeis locatedbehindthe filter. Cleanit

with the pick storedin the bottom of the tank han-
dle. or blow it cleanwith air. Securelyreassemble
all parts.
14-353
Shift Cable
RemovaUlnstallation
@ Make sure lifts, iacks and safety stands are Removethe air cleanerhousingassembly.
placedproperly(seeseqtion11,
Removethe clip from the control lever,and loosen
1. Removethe front console(seesection20). the locknut.
CLIP SHTFT
CABLE LOCKNUT
2. Shift to E position,then removethe lock pin from 29 N.m 13.0kgf m,22 lbf.ft)
the adiuster. \.
*o"ra" \
SHIFTCABI-E
BRACKET
CONTROLLEVER
Removethe shift cablefrom the control lever,the

shiftcablebracket,and the clamp.
Removethe shift cablebracketbolts and nuts,then

remove the shift cable.Take care not to bend the
shift cablewhen removing/installing
it.
SHIFTCABLEBRACKET
ADJUSTER
{1.2kgI m, 8.7lblft)
7. lnstallthe shift cable in the reverseorder of removal.
8. Checkthe cableadjustment(seepage14-355).
14-354
t Adjustment
!@ Make sure lifts, jacks and safety stands are 3. Checkthat the holein the adiusteris perfectlyaligned
placed properly (seesection 1). with the holein the shiftcable.Therearetwo holesin
the adjuster.They are positioned90" apartto allow
l. Removethe front console(seesection20). cableadjustmentin 1/4turn increments.
2. Shift to I posirion,then removethe lock pin from

the adjuster.
lf the hole is not perfectlyaligned,loosenthe lock-

nut on the adjusterand adjustas required.
Tightenrhe locknutto 7 N.m (0.7kgim,5 lbf'ft).
Installthe lock pin on the adjuster'lf you feel the

lock pin binding as you reinstallit. the cable is still
out of adjustmentand must be readjusted
7 . M a k e s u r e t h e l o c k p i n i s s e a t e di n t h e a d i u s t e r
SHIFTCAELE securery.
{ 0 . 7 k g f . m ,5 l b f ' l t l
lMovethe shift leverto eachposition,and verifythat

t h e s h i f t p o s i t i o ni n d i c a t o rf o l l o w st h e a u t o m a t l c
transaxlegear positionswitch.
S t a r t t h e e n g i n e ,a n d c h e c kt h e s h i f t l e v e r i n a l l
positions.lf any gear does not work properly,refer
to troubleshooting (seepage 14-294and 14-295).
1 0 . Insertthe ignition key into the key cylinderon the

Aff gear positionindicatorpanel,and verifythat the
shift lockleveris released.
l,
14-355
,l from www.Manualslib.com manuals search engine
Downloaded
Shift Lever
PUSHKNOESPRING
X ,l
PUSHKNOB
SHIFTLEVER
KNOB
\
\re / SCREW
tn rn
Jl / I 3 N.n l0.3xgtm, 2 lbf ftl
a,-,/ Applynon-hardening
/ Apply non-hardening th'
threadlocksealant.
./
,/ \2 I
-6r SCREW
3 N.m{0.3kgf'm,2 lbl.ft)
SILICONEGREASE
SHIFTINDICATORLAMP. A/T GEARPOSTTONINDICATORPANEL
LEVERCOVER
SHIFTLOCK
sotENolD BUSHING
-611
SII.'|CONEGREASE
SCREW
3 N.m10.3kgl.m.2lbf.ttl SHIFTI.TVEBASSEMBLY
L@KP'N
dE("""--
n2
6x1.0mm
9,8 N.m 11.0kgf.m, -<tl
7.2 tbtft) SILICONEGREASE
A/T GEARPOSITION
PLAYE A/T GEARPOSMON SWNCH
3 N.m 10,3kqf.m,
2tbfitl
SHIFTLEVENBRACKETBASE
SHIFTLEVER
BASE COLLAR
6x1.0mm
9.8 N.m {1.0 kgf.m,7.2 lbf ftl
14- 3 5 6
Shift Indicator Panel ATF Gooler/Hoses
Adjustment lnstallation
1 . C h e c kt h a t t h e i n d e x m a r k o n t h e i n d i c a t o a
r ligns 1. InstalltheATF cooler,ATF coolerline assemblyand
with the E mark on the shift indicatorpanelwhen the ATFcoolerhoses.
the transmissionis in NEUTRAL.
6x1.0mm
11 N.m ('l 1 kgf.m,8.0lbl'ftl
ATF COOLERLINEASSEMBLY
ATF COOLERHOSE
RADIATOR
6x1.0mm
9.8 N.m 11.0kgf'm, 7 8 lbf'ft)
ATF COOLER
HOSES
ATF COOI..ER
lf not aligned,removethe front console{seesection Connectthe ATF cooler hoses to the ATF cooler
20). linesand ATF cooler.and securethem with the clips
as shown.
Removethe shift indicatorpanel mounting
and adjustby movingthe panel.
NOTE: Wheneverthe shift indicatorpanel is removed,

reinstalltheDanelas describedabove.
1 l l
Tf 6-8mm
{ i
l.T 10.2- 0.3 in)
33-35mm
11.3- 1.4inl
2-1mm 2-ilmm
10.1- 0.2 in) { 0 . 1- 0 . 2 i n )
It,
14-357
There is no chapter 15 in the printed version of this manual. I
actually went to a Honda dealership and asked if I could look at
the manual. The mechanic told me Honda probably used chapter
15 for something in another market with a different transmission
option.

I

SpecialTools
Ref. No. I Tool Number Description Oty I Remark

o 07JAF- SH20400 SupportBaseAttachment 1
07LAD- PW50601 InnerRaceDriver 1
07MAC- S100200 BallJoint Remover,28 mm 1
@ 07746- 0010300 Driver Attachment,42 x 47 mm 1
,a 07746- 0010400 Driver Attachment,52 x 55 mm I
\9' 07746- 0030400 DriverAttachment,35 mm l.D. I
o 07749- 0010000
- SD90100
HandleDriver 1
@ 07965 SupportBase I
@ 07xAc- 0010100 ThreadedAdapter,22 x 1.5mm 1
@ e @
&
w
@
@
c 6
@
\r'
lo,
c[G)
8-)
g e
l..---,l
G)
16-2
Driveshafts
Inspection Removal
DriveshaftBoot 1. Loosenthe wheel nuts slightly.
Checkthe boots on the driveshaftfor cracks,damage,
leakinggreaseand loose boot bands.lf any damageis Raisethe front of the vehicle,and support it with
'l).
found,replacethe boot and boot bands, safetystandsin the properlocations(seesection
LooseSplines Removethe wheel nuts and front wheels.

Turn the driveshaftby hand and make sure the splines
a n d j o i n t a r e n o t e x c e s s i v e llyo o s e .l f a n y d a m a g ei s
found,replacethe inboardjoint.
Twisied or Cracked
Makesurethe driveshaftis not twistedor cracked.
Reolaceit if necessarv.
DRIVESHAFT
Drainthe transmissionfluid (seesection13 or 14).
R a i s et h e l o c k i n gt a b o n t h e s p i n d l en u t , t h e n
removethe nut.
nut and flangebolts.

Removethe selJ-locking
FLANGEBOLT
10 x 1.25mm
BOOTBANDS
1.
(cont'd)
16-3
Driveshafts
Removal(cont'd)
8. Remove the cotter pin from the lawer arm ball joint 1 2 . P u l l t h e i n b o a r dj o i n t , a n d r e m o v et h e d r i v e s h a f t
castle nut. and remove the nut. from the differentialcase as an assembly.Do not
pull on the driveshaft;the inboardjoint may come
apart.Use carewhen prying out the assembly,and
pull it straightto avoid damagingthe differentialoil
seat.
07MAC- SL00200
I n s t a l la 1 2 m m h e x n u t o n t h e b a l l j o i n t . B e s u r e
that the hex nut is flush with the ball joint pin end,
or the threadedsectionof the ball joint pin might be SCREWDRIVER
damagedby the specialtool.
1 0 . Usethe specialtool as shown in section18,to sepa- 13. Pullthe knuckleoutward,and removethe driveshaft
rate the ball joint and lower arm. Be carefulnot to o u t b o a r dj o i n t f r o m t h e f r o n t w h e e l h u b u s i n g a
damagethe balljoint boot. plastichammer.
NOTE: lf necessary,apply penetratingtype lubri,

cantto loosenthe balljoint.
1 1 . Pry the driveshaftassemblywith a screwdriver,as

shown, to force the set ring at the driveshaftend
pastthe groove.
SCREWDRIVER
3.5mm
DRIVESHAFT
16-4
t Disassembly
lnboard Joint Side: Crimping Type
1 . C a r e f u l l yc l a m p t h e d r i v e s h a f itn a v i s e w i t h s o f t
j a w s , t h e n r e m o v et h e s e t r i n g f r o m t h e i n b o a r d
joint.
2. Removethe boot bands.Take care not to damage

the boot.
. lf the boot band is a lockingtab type, pry up the
l o c k i n gt a b s w i t h a s c r e w d r i v e ra, n d r a i s et h e
end of the band.
. It the boot band is a welded type, cut the boot
band.
. lf the boot band is a crimping type, pry up the
end of the bandwith a screwdraver.
. lf the boot band is a double loop type, lift up the DoubleLoopType
band bend.
Locking Tab Typs
M a r k e a c h r o l l e ra n d i n b o a r dj o i n t t o i d e n t i f yt h e
locationsof rollersand groovesin the inboardjoint.
Then removethe inboardjoint on the shop towel.
Be carefulnot to drop the rollerswhen separating
them from the inboardioint.
INBOARD JOINT
Check splines forwearor damage,
Check insideboreforwear.
Inspectfor cracks.
Replace.
Welded Type
l , (cont'd)
16-5
Driveshafts
(cont'dl
Disassembly
4. Mark the rollersand spiderto identifythe locations Outboard Joint Side:
of the rollerson the sDider,then removethe rollers.
1. L i f t u p t h c t h r e e t a b s w i t h a s c r e w d r i v e r ,t h e n
B€ARING
REMOVER
available}
{Commerciallv remove the boot bands,Take care not to damage
the boot.
NOTE:
. lf the boot band is a double loop type, lift up the
band bend.
. lf the boot band is a welded type, cut the boot
band.
. lfthe boot band is a locking tabs type, pry up the
tabs with a scr€wdriv€rand lift uo the snd of the
band.
TAB
STOPRING
to '96- 98modols
(Applicable and
Erazil-produceddriveshafts)
Removethe circlip.
Mark the spiderand driveshaftto identifythe posi-

tion ot the spideron the shaft.
1 . Removethe spiderusinga bearingremover.
Removethe stop ring (Applicableto '96 - 98 models

and Brazil-produceddriveshafts).
Wrap the splineson the drivsshaftwith vinyl tapeto 2. Slide the outboard boot to the inboardioint side.
preventdamageto the boot and dynamicdamper.
DRIVESHAFT
INBOAROAOOT
VINYL TAPE Inspectfor cracking,
splitting and wear.
DYNAMIC DAMPER
Check
for damage. OUTBOABD
BOOT
R e m o v et h e i n b o a r d boot, and if necessary,the

dynamicdamper.
16-6
1 Wipe off the greaseto exposethe driveshaftand 7. Removethe driveshaftfrom the vise
the outboardioint inner race.
8. Removethe stop ring from the driveshaft.
4. Markthe driveshaftat the same positionof the out-
boardjoint end with paint.
DRIVESHAFT
Feplace.
5. Carefullvclampthe driveshaftin a vise.
ADAPTER,24 x 1.5 mm
THREADED
07xac- (x)102(x)
Removethe outboardjoint using a specialtool as

snown.
16-7
Driveshafts
Reassembly
U.S. and Canada-ProducadDriv€shafts
Notetheseitemsduring reassembly'
. Cleanthe disassembledparts with solvent,and dry them thoroughlywith compressedair, Do not wash the rubber
pans with solvent.
o ;..jl@l : Thoroughlypackthe inboardjoint and both joint bootswith the joint greaseincludedin the new driveshaft
ser,
Greasequantity:
lnboardJoint 1 1 5- 1 3 5g ( 4 . 0- 4 . 8o z )
OutboardJoint 1 1 5- 1 3 5g ( 4 . 0- 4 . 8o z )
. The'98 Canadamodel and all '99 - 00 modelsusesa TPE(Thermoplastic

PolyesterElastomerloutboardjoint boot. Use
the ear clamptype boot band in the outboardjoint boot set.
CIRCLIP
STOPRING
('96- 98 models)
INBOARDBOOT
-6l
Packcavitywith grease.
-6r EABCLAMPBAND
Packcavitywith grease.
Replace.
DYNAMICDAMPER
OOUBI.SLOOPBAND
Replace.
EARCLAMPBAND
Replace.
DRIVESHAFT
STOPRING
Replace.
OUTBOARDBOOTITPE)
-6ll
, Pack cavity with grease.
EARCLAMPBAND
Replace.
-G.1
OUTBOARDJOINT
16-8
l / Brazil-ProducedDriveshafts
Notetheseitemsduring reassembly
. clean the disassembledparts with solvent,and dry them thoroughlywith compressedajr. Do not wash the rubber
partswith solvent.
. .fut :Thoroughlypackthe inboardjoint and both joint bootswith the joint greaseincludedin the new driveshaft
ser.
Greas€quantity:
lnboardJoint 1 1 5- 1 3 5g ( 4 . 0- 4 . 8o z l
OutboardJoint 1 1 5- 1 3 5g { 4 . 0- 4 . 8o z )
INSOARDJOINT
t t
DRIVESHAFT
BOOTBANDS
Replace.
l,z -6.l
(cont'd)
Pack cavity w r t h g r e a s e ,
16-9
Driveshafts
(cont'dl
Reassembly
Japan-ProducedDriveshafts
Notetheseitemsduring reassembly.
. Cleanthe disassembledpans with solvent,and dry them thoroughlywith compressedair. Do not wash the rubber
parts with solvent.
o r@l : Thoroughlypackthe inboardjoint and both joint bootswith the joint greaseincludedin the new driveshaft
set.
Greasequantity:
1600DOHCWEC engine 130- 1409 (4.6- 4.9oz)

InboardJoint Except1600DOHCVTECengine 1 1 0- 1 2 0g ( 3 . 9- 4 . 2o z )
Splines(Al 0.5- 1.0g (0.018- 0.035oz)
'1600DOHCWEC
engine Rubberboot 90- 'l00g (3.2- 3.5oz) TPEboot;105- 1159 (3.7- 4.1oz)
OutboardJoint
Except1600DOHCVTECengine Rubberboot 70- 80 g |'2.5- 2.8 ozl TPEboot 95 - 105g (3.4- 3.7 oz)
{1600DOHCVTECangine)
SETRING
Replace. ],*"u,
,"^S
'/ t'.t$-'-,'
-6{@ INBOARD BOOT
Packcavity with grease. ,/s -6;
Packcavity with grease.
DYNAMICDAMPER
DYNAMIC
Replace.
DOUA|.I Lq)P BAND

Replace. OUTBOARDBOOT
IRUEBER)
LOOPBAND
(Rubbertypc) Replace.
tttt t*' -----_.r...-

._
Packcavity with grease-
CLAMPBAND
Replace.
16-10
lnboard Joint Side: 6. Fit the rollersonto the spiderwith their high shoul-
dersfacingoutward,and notetheseitems:
1, Wrap the splineswith vinyl tapeto preventdamage . Reinstallthe rollersin their originalpositionson
to the bootsand dynamicdamPer. the spiderby aligningthe marks
. Hold the driveshaft pointed up to prevent the
rollersfrom fallingoff.
VINYLTAPE
-\r/ INBOARDBOOT
-
-<@
Highshoulderfaces
DAMPER
DYNAMIC
Installthe dynamicdamperand inboardboot to the

driveshaft,then remove the vinyl tape. Take care
not to damagethe boots.
I n s t a l lt h e s t o p r i n g i n t o t h e d r i v e s h a f tg r o o v e
(Applicsbleto '96 - 98 modelsand Brazil- Produced
driveshafts)A . lways rotatethe stop ring in its
grooveto be sureit is fully seated. 7. Packthe inboardjoint with the joint greaseincluded
in the new driveshaftset.
@--c't"t't
Greasequantity:
Japan-Produced:
1600DOHCVTECongine:
130- 1/t0g 14.6- '[.9 oz)
STOPRING Except 1600DOHCVTECangine:
(ApplicablGto'96- 98 modob and 110- 120I {3'9 - il'2 oz}
Brrzil-Producrddrivoshaftrl Left inboard ioint splines O:
0'5 - 1.0s (0.018- 0'035oz)
U.S,,Canada,and Brazil'Produced:
1 1 5- 1 3 5g ( 4 0 - 4 . 8 o z l
Installthe spiiler on the driveshaftby aligningthe

markson the sDiderand the end of the driveshaft.
Fit the circlip into the driveshaft groove. Always 6

rotatethe circlip in its groove to be sure it is fully
seated.
-6.l
lr; (cont'd)
1 6 - 11
Driveshafts
(cont'dl
Reassembly
8. Fit the inboardjoint onto the driveshaft,and note 10. lf necessarypositionthe dynamicdamperas shown
theseitems: Detow.
. Reinstallthe inboardjoint onto the driveshaftby . Installa new dynamic damper band. and bend
aligningthe marks on the inboardjoint with the down both setsof lockingtabs.
markson the rollers. . Lightly tap on the doubled-overponjon of the
. H o l d t h e d r i v e s h a f ts o t h a t t h e i n b o a r dj o i n t bandto reduceits height.
pointsup to preventit from fallingoff.
Loft:
1600DOHCVTECmodel: 26i 2 mm (1.0t 0.1inl
All other models: 9,1t 2 mm (3.710.1 inl
With "SR1" mark: 7512 mm 12.9! 0.1inl
Right:
16dl DOHCVTECmodels:2612 mm 11.0t 0.1inl
All other modelii 5 5 1 2 m m ( 2 . 2t 0 . 1i n l
DYNAMIC
DAMPER INBOARO
JOINT
Adjust the length of the driveshaftsto the figure

below, then adjust the boots to halfway between -SR1" MARK
full comDressionand full extension.The ends of the DYNAMICDAMPERBAND
bootsseatin the grooveof the driveshaftand joint.
Left driveshaft.1600DOHCWEC model:

475- 480mm 118.7 - 18,9inl
U.S. and Canada-ProducedITPEBOOTI

Left 53612 mm {21.110.1 in}
Right:2txt12 mm {10.it1 0.1in}
Right driveshaft,1600OOHCVTECmodel:
475- 480mm (18.7- 18.9in)
Left driveshaft,all othei models:
774-779 mm (30.5- 30.7in)
Right driveshaft,all other models:
501- 506mm 119.7 -'19.9inl
OYNAMICDAMPER OUTBOARDJOINT
16-1 2
l . 11. Setthe doubleloop band onto the boot and dynam- 1 4 . Threadthe free end of the band through the nose
ic damperwith the band end toward the front ot the sectionof the boot band tool and into the slot on
vehicle. t h e w i n d i n gm a n d r e l .
1 5 . Placea wrenchon the winding mandrelof the boot

band tool, and tightenthe band until the mark you
DOUBLELOOPBANO
madeon the band meetsthe edgeof the clip.
,
(KD-3191
or equivalent) Markon band.
1') Pullup the slackin the band bY hand

-
1 3 . Mark a positionon the band 10 - 14 mm {0 4 0 6
i n )f r o m t h e c l i P . 1 6 . Lift up the boot band tool to bend the free end
the band90 degrees,then center-punch the clip'
CLIP
HAMMER
Ip (cont'd)
16-13
Driveshafts
(cont'dl
Reassembly
1 7 . Unwindthe boot bandtool, and cut off the excess5 Outboard Joint Sid.:
- 10 mm (0.2- 0.4 in) from the clip.
1. Wrap the splineswith vinyl tapeto preventdamage
to the boot.
5-10mm
10.2- 0.a inl TPE tvDe:
-.
OUTBOARO
BOOTITPE)
BOOTBAND
Replac€,
VINYLTAPE
1 8 . Securethe end of the boot band by tappingit down

with a hammer,
Rubbertyp.:
>V INYLTAPE
I n s t a l lt h e b o o t b a n d a n d o u t b o a r d b o o t , t h e n
remove the vinyl tape. Take care not to damage the
boot,
19. Installthenew set ring, Installthe stop ring into the driv€shaftgroove.
DRIVESHAFT
Note these items after reassembly:

. Make sure the band and clip does not interfere with
anythingand the band does not move.
a Removeany grease remaining on the surrounding
surfaces.
1 6- 14
4. lnsert the driveshaft into the outboard joint until the 6. Checkthe alignmentof the paint mark with the out-
stop ring is closeon the ioint. boardjoint end.
DRIVESHAFT
7. Packthe outboardjoint with the joint greaseincludsd

in th€ new ioint boot set.
Gleaso quanlity
U.S.,canada, and Brazil'Ploducod:
) J 115- 135g {4.0- 4.8oz}
To completelyseat the outboardjoint, pick up the Japan-Producod:
DOHCVTECangino:
161X,
driveshaftand joint, and drop them from about 10
cm (4 to 5 inches)onto a hard surface.Do not use a Rubborboot: 90 - 100g 13.2- 3.5oz)
TPEboot: 1tl6- 115I {3'7- tl'l oz}
hammer as excessiveforce may damagethe drive-
Excapt 1000DOHCVTECengine:
shaft.
Rubbel boot: 70 - 80 g l.2.5- 2.8 ozl
TPEboot: 95 - 105g {3.4- 3.7 oz}
DRIVESHAFT
J (cont'd)
16-15
Driveshafts
Reassembly
lcont'd)
8 . Installtheoutboardboot and the boot bands. 11. Closethe ear portion of the band with a commer-
. lf the boot is the rubber type. go to step 13. ciallyavailableboot band Dincerc.
. lf the boot is the TPEtype, go to step 9.
Fit the boot endsonto the driveshaftand outboard

ioint.
BOOTBAND PINCERS
KENT-MOORE J,35910
or eouivalent
EAR FOFNON
10, Set the ear clamp band by threadingthe tab into the
holesof the band. Chsckthe clearancabetween the closed ear oonion
of the band. lf the clesranceis not within the stan-
dard, close the ear portion of ths band further.
6.0 mm (0.24in) MAX
3.0 mm 10.t2inl MAX
EARCLAMPBAND
Reolace.
16-16
I 17. Threadthe free end of the band through the nose
13. Fit the boot ends onto the driveshaftand the
sectionof a commerciallyavaiiableboot band tool
outboardjoint
KD-3191or equivalentand into the slot on the wind-
ing mandrel.
Mark spot.
BOOTBANDTOOL
available)
lCommerciallY
or equivalent
KD-3191
MANDREL
1 4 . Fit the doubleloop boot bandsonto the boot ends'
Pullup the slackin the band by hand'

1 8 . Placea wrench on the winding mandrelof the boot
- - band tool, and tighten the band until the marked
1 6 . Mark a positionon the band 10 14 mm {0 4 0 6
spot on the band meetsthe edgeof the clip'
in,)from the cliP.
1q Lift uo the boot band tool to bend the free end of
the band 90" to the clip Centerpunchthe clip, then
CLIP fold overthe remainingtail onto the clip
lrz (cont'd)
16-17
Driveshafts
(cont'dl
Reassembly Installation
20. Unwind the boot band tool, and cut off the excess 1, Installthe new set ring onto the driveshaftgroove.
free end of the band to leave a 5 - 10 mm (0.2- 0.4 Always use a new set ring whenever the driveshaft
in.)tail protrudingfrom the clip. is beinginstalled.
INBOARD
JOiIT
21. Bendthe bandby tappingit down with a hammer.
NOTE:Maks sure the band and the clip does not

interferewith anything, and the band does not SET RII{G GR(X)VE
mov6. Removeany greaseremaining in the sur-
roundingsurtaces.
2. Installthe outboardjoint into the knuckte.
AANOEND
KNUCKI.E
OUTBOARDJOINT
16-18
3. lnsertthe inboardend of the driveshaftinto the dif- 5. lnstallthe dampertork over the driveshaftand onto
t e r e n t i a lo r i n t e r m e d i a t es h a f t u n t i l t h e s e t r i n g t h e l o w e r a r m . I n s t a l lt h e d a m p e r i n t h e d a m p e r
locksin the groove fork so the aligningtab is alignedwith the slot in
the damPerfork.
NOTE: Cleanthe areaswhere the driveshaftcontact FLANGEBOLT
the transmission(differential)thoroughlywith solvent l0 r 1.25mm
or carburetorcleaner,and dry with compressedair' rit N.m t4.akgf.m,32 lbf.ft) AIIGN|NGTAB
JOINT
INBOARD
Replace.
INBOARDJOINT
GROOVE
an SELF-LOGKING
12x 1.25mm
NUT
6,1N.m16.5kgi.m,a7 lbfftl
Replace.
Loosely install the flange bolts and the new self-

lockingnut.
1 . Apply oil to the seatingsurfaceof the new spindle
DIFFERENTIAL nut.
FRONTWHEEL
WHEELNUT 12 x 1.5 mm
lnstall the knuckieon the lower arm. then trghten 108N.m (11.0kgl'm, g) lbl ftl
the castlenut and installa new cotterpin
NOTE: wipe off the grease before tightening the

nut at the ball ioint.
CAUTION:
. Be careful not to damagothe ball ioint boot'
. Torque the castle nut to the lower torque sp€ci-
fication, thsn tighten it only far enough to align
the slot with th€ pin hol6. Do not align the nut
by loosening. SPINDLENUT 22 x 1.5 mm
181N m 118.5 kgt'm,13illbt'ftl
NOTE:Aftortightening, usea driftto
stakethespindlenutshoulderagainstthe drivoshaft'
8. Installa new spindlenut,then tightenthe nut'
9. Cleanthe mating surfacesot the brakedisc and the
wheel. then install the front wheel with the wheel
nuts.
10. Tighten the flange bolts and the new self-locking
nut with the vehicle'sweighton the damper.
11. Refillthe transmissionwith recommended fluid (see
COTTERPIN section13 or 14).
Replace. 't2. Checkthe front wheel alignmentand adjust if nec-
CASTLENUT On reassemblY,
essary(seesection18),
J 12 x 1.25 mm
i$ - 59 N.m 15.0- 6.0 kgl m,35 - 43 lbf ftl
bendthe cotterpin
16-19
IntermediateShaft
Removal Disassembly
'1.
Drainthe transmissionoil or fluid {seesection13 or NOTE: Be carefulnot to damagethe metal rings on the
r4). intermediate
shaftduringdisassembly.
2. Removethe left driveshaft(seepage 16-3). 1. Removethe set ring.
3 . Removethe threedowel bolts. 2. Removethe intermediateshaft outer seal from the

Deaflngsuppon.
OOWELBOLTS 3. Removethe externalcirclip,

'10x 1.25mm
Removethe intermediate
shaftfrom the differential.
CAUTION: Hold the intermsdiate shaft horizontal

until it is clear of lhe dilterential to prevent damage
to the differential oil seal.
INTERMEDIATE
SHAFT
16-20
Disassembly
6. Pressthe intermediate shaft bearingout ot the bear-
Pressthe intermediateshaftout of the shaft bearing
usingthe specialtools and a pressas shown. ing support using the specialtools and a pressas
shown.
Removethe internalcircliP Press
SUPPORTBASE
HANOLEDRIVER I
Press
ATTACHMENT 0?749- 00'10000
DRIVERATTACHMENT,
INTERNALCIBCLIP I 07JAF- SH20400 12x47 mm
07746- 0010300
FLOATINGRUBBEB
DAMPER
Checkfor deterioration SUPPORT BASE
BEARING SUPPORTRING and oamage.
or distortion
for damage
Check ATTACHMENT
07JAF_ SH20it00
BEARINGSUPPORT
Checkfor damage
ReassemblY
NOTE:
compressedair' Do not wash the rubber
. clean the disassembtedparts with solvent,and dry them thoroughlywith
partswith solvent.
reassembly'
. Becarefulnot to damagethe metalringson the intermediateshaftduring
DOWELBOLTS
BEARINGSUPPORTRING 1 0x 1 . 2 5m m
39 N.m 14.0kgf.m,29lbIftl
EXTERNALCIRCLIP
Packthe interior
of the outerseal.
SHAFTRING
INTERMEDIATE 2.0-35s10.07-012oz)
INTERNALCIRCLIP I sErR'NG
Reolace
A4\
SHAFTBEARING
VU
INTERMEDTATE
Replace,
OUTERSEAL
l J Replace.
(cont'd)
16-21
lntermediateShaft
(cont'd)
Reassembly
1. Pressthe intermediateshaft bearinginto the bear- Seatthe externalcirclip in the groove of the inter-
ing support using the specialtools and a press as mediateshaft.
shown.
Installthe outer seal into the bearingsupportusing
Prass the specialtools as shown.
I NOTE: Installthe seal ftush with the bearingsup-

port.
Pre$
t HANDr.r
DRTVER
DRIVER ATTACHMENT, - 0011r(x)0
52x55mm
07746- 0010(X) Packthe Interior
of the ouler seal.
2.0- 3.5g {0.07-0.12 ozl ORIVERATTACHMENT,
52x55mm
077i16- 0010/O0
OUTENSEAL
Seatthe internalcirclipin the grooveof the bearing

suppon.
Pressthe intermediateshaft into the shaft bearing

usingthe specialtools and a press.
Praa.r
I
@---
LJ
INTERMEDIATE
SHAFT
Install the new set ring in the intermediateshaft

groove.
DRIVERATTACHMENT,35mm LD.
16-22
lnstallation
1. lnsertthe intermediateshaft assemblyinto the dif-
ferential.
CAUTION:Hold the intermodiateshaft horizontal

to prevent damag€to the difterential oil seal'
NOTE:Cleanthe areaswherethe intermediate shaft

contacts the transmission (differential)
thoroughly
with solvent or carburetorcleaner,and dry with com-
air,
Dressed
2. Installthe three dowel bolts,then tightenthem'
DOWELBOLTS
10x 1.25mm
39 N.m {i1.0kgf'm, 29 lbf'ftl
l z
16-23
l .
Steering
Tools
Speciaf ....."'.....17-2 Inspection and Adiustment
17-30
SteeringOperation'......."'........'......
t ManualSteering Power Assist Check
17-30
With VehicleParked.."................
ComponentLocations
SteeringLinkageand Gearbox ....." 17-31
lndex ................ .......17-3
Pump Beft ...--."""..17-32
Inspectionand Adiustment
RackGuide Adiustment .'.......'.......'.17'33
17-4
SteeringOperation"'......"...............
17-33
FluidReplacement.....'..".................
RackGuideAdiustment................... 17-5
*SteeringWheel " 17-34
Pump PressureCheck .............'....-.
'Steering Wheel
(Seepower steering section)
*SteeringColumn Removal 17-35
.."'........'...
(Seepower steering sectionl 17-35
.............
Ir/ SteeringGearbox
Removal 17-5
.................
lnstallation
*Steering Column
17-36
......'.....'.'
Disassembly .......""17-7 Removal/lnstallation....'........... 17'37

---....
ReassemblY 17-9
..'......... lnspection 17'38
..............
lnstallation 17-13 Power Steering Hoses,Lines
.............
FluidLeakageInspeetion............'.... 17-39
PowerSteering Replacement ......"..17-39
Component Locations Power Steering PumP
lndex "......."..... """' 17-15 17-40
.'.'..'..'.............
System DescriPtion Disassembly ".........17-41
17'16
FluidFlow Diagram.........""............. fnspection 17'42
.......---'."
17-17
"........"'...--
SteeringPump ............'... Reassembly ..'.........17-44
17-20
SteeringGearbox.".................'...'.'.' SteeringGearbox
Troubleshooting Removal 17'47
....'........."'
17'22
GenerafTroubleshooting..........--.... DisassemblY ..........'17-49
17 -26
Noiseand Vibration......................... Reassembly 17-55
'...........
FfuidLeaks .............17-28 lnstallation 17-65
.............
Ball Joint Boot Replacement.......'..17-68
lp

Ref. No I Tool Number Description Oty I Pag€Reterence
o 07GAF - PH70100
- SD4010A
PilotCollar 1 11-54
@ 07GAG or PistonSealRingGuide 1 17-59
07GAG - SD40100
@ 07GAG - SD4020Aor PistonSealRingSizingTool 'I '17-59
07GAG - S040200
@ *07JGG - 00r010A BeltTensionGauge 1 17-32
@ 07MAC- 5100200 BallJoint Remover,28 mm 'I
17-6,47
fof OTNAD - SR3O2OA CylinderEndSealBemoverAttachment 1 17-51
@ 07NAG - SR3090A or PistonSealRingSizingTool I | /-ao
07NAG- SR30900
@ 07RAK - 5040110 P/SJoint Adaptor(Pump) 1 17-34
@ 07RAK - 5040121or P/SJoint Adaptor (Hose) 1 17-31
07RAK - 5040t20
@ 07406- 0010004 or P/S PressureGauge 't7-34
07406- 001000r
@ 07725- 0030000 UniversalHolder I 't7-42,16
@ 07746- 0010100 Attachment,32x 35 mm 1 17-57,58
@ 07746- 0020100 Driver,22 mm l.D. 1 17-10
@ 07746- 0030300 Attachment,30 mm l.D. I 17-44
@ 07749- 0010000 Driver 1 't7-57
@ 07916- SA50001 LocknutWrench, 40 mm 1 17-5,33
@ 07965- SA50500 FrontHub DiVAssemblyTool I 17-68
@ 07974- SA5020A or SleeveSealRingSizingTool 1 17-57
07974- SA50200
@ 07974- SA50800 BsllJoint BootClip Guide I 17-57,6A
* lncludedin the BeltTensioncauge Set,07TGG-
OO10OOA.
p
v
o @ o
€_
ts7- (o)
dysB F=1
@
@
aal @ @ @
@ @ @
17-2
ComponentLocations
t lndex
ManualSteering
NOTE:
beenfound defectiveor damageddur-
. lf an intactairbagassemblyhas been removedfrom a scrappedvehicleor has
be deployed(seesection24)'
ing transit.storageor service,it should
o Beforeremovingthe gearbox,removethe driver'sairbagassemblyand steeringwheel
. After installingthe gearbox,checkthe wheelalignmentandadjustif necessary
and proceduresin the SRS
precautions,
SRScomponentsare locatedin this area.Reviewthe SRScomponentlocations,
section124)beforeperformingrepairsor service'
STEERINGWHEEL
Page17'35
page17-36
Disassembly/FeassemblY,
DRIVER'SAIRBAGASSEMBLY
seesection24
STEERINGCOLUMN
Page17-37
page17'38
Inspection,
CABLEREEL
seesection24
IGNTTION SWITCH
See section23
STEERINGGEARBOX
RackGuideAdiustment,Page17-5
Removai,page17'5
Disassembly, Page17_7
Reassembly, page17_9
page17 13
Installation, TIE.RODEND BALLJOINT
t, page17-68
BallJoint BootReplacement,
17-3
Inspectionand Adjustment
SteeringOperation
SteeringWheelRotationalPlay Ste€ring Effort Check
Placethe front wheels in a straightaheadpositionand Raisethe front wheelsoff the ground.
measurethe distancethe steeringwheel can be turned Turn the steeringwheelwith a springscaleand checkits
without movingthe front wheels. reaorng,
PLAY:0 - 10 mm (0 - 0.4 in)

ROTATIONAL Standard:15 N (1.5kgf,3.3 lbll maximum
lf the play exceedsthe servicelimit, perform rackguide l f i t r e a d sm o r e . p e r f o r m r a c k g u i d e a d j u s t m e n (t s e e

adjustment(seepage lT-5). p a g e1 7 - 5 ) .
lf the play is still excessiveafter rack guide adjustment,
inspectthe steeringlinkageand gearbox as descrjbed
Detow.
a o -
\---------U
Steering Linkageand Gearbox
TIE.ROOLOCKNUT
Checkfor looselocknut.
BOOT
I n s p e c tf o r d a m a g e a n d d e t e r i o r a t i o n .
COLUMN
STEERING JOINTS Inspectfor loosecolumn
Checkfor loosejoint mountingboltsand nuts.
PINIONSHAFTGROMMET
for damageand deterioration.
BALLJOINT BOOT
END BALLJOINT
Inspectfor damageand deterioration.
I n s p e c tf o r f a u l t y m o v e m e n t
See pago 17-68tor replacement.
ano oamage.
GEABBOXMOUNTING
Inspectf or deterioration.
GEABBOXASSEMBLY
I n s p e c tf o r l o o s e m o u n t i n g b o l t s .
1 7-4
SteeringGearbox
RackGuideAdjustment Removal
N O T E : P e r f o r mt h e r a c k g u i d e a d j u s t m e n tw i t h t h e NOTE:Using solventand a brush,to wash any oil and
wheelsin the straightaheadposition. dirt off the gearbox.Blow dry with compressedair.
1. Loosenthe rack guide screw locknutwith the spe- 1. Raisethe front of vehicle,and supportit on satety
cialtool, then loosenthe rackguidescrew. standsin the properlocations(seesectionI ).
2. Removethe front wheels.

RACKGUIDESCREW
3. Removethe steeringwheel(seepage 17-35).
4. Removethe steeringloint cover
JOINTCOVER
STEERING
LOCKNUT WRENCH,40mm
07916- SA5000r
l.r Tightenthe rackguide screwuntil it compresses

the
springand seatsagainstthe rackguide,then loosen
rt.
Retightenthe rackguide screwto 4 N'm (0.4kgf m,

2.9 lbf.ft),then backit off to specifiedangle.
Removethe steeringjoint lower bolt, and discon-
SpeciliedReturn Angle: 30' max. nect the steeringjoint by moving the joint toward
t h ec o l u m n .
4. T i g h t e nt h e l o c k n u tw h i l e h o l d i n gt h e r a c k g u i d e
JOINT
STEERING
Checkfor tight or loose steeringthrough the com-

pleteturningtravel.
Rechecksteeringeffort(seepage17-4).
l,z LOWERBOLT
(cont'd)
17-5
SteeringGearbox
Removal(cont'd)
Removethe cotter pin from the castle nut ('96 - '97 13. Removethe mountingbracket,
models)or nut ('98- '00 models)and removethe nut.
Replace.
7 . Installthe10 mm hex nut on the ball joint.

Be sure that the 10 mm hex nut is flush with the ball
joint pin end, or the threadedsectionof the ball joint
pin mightbe damagedby the balljointremover.
NOTE:Removethe ball joint usingthe specialtool,

Refer to section 18 for how to use tho ball joint Pullthe steeringgearboxall the way down to clear
remover. th€ pinionshaftfrom the bulkhead,then removethe
pinionshaftgrommet,
Separatethe tie-rodball joint and knuckleusingthe
specialtool. t5. Move the steering gearbox to right so the left rack
end clearsthe rearbeam,then tilt the left side down
CAUTION: Avoid damaging the ball ioint boot. to remove it from the car.
Removethe left tie-rod end, then slide the rack all

the way to the right.
'10.Separatethe exhaustpipeA
or TWC (seesectiong).
PINIONSHAFTGROMMET
1 1 . Disconnectthe shift linkage(seesection13 or sec-
tion14).
12. Removethe stiffener plate.
STEENINGGEARBOX
17-6
Disassembly
)
'1.
Placethe gearboxin a vise with a soft jaws, then Pushthe right end of the rack backinto the cylinder
c l a m p t h e g e a r b o xa t t h e m o u n t b r a c k e to r g e a r housing so the smooth surfacethat rides against
housing. the sealwon't be damaged.
CAUTION: Be carcful not to distort the gear hous- L o o s e nt h e l o c k n u t ,a n d r e m o v e t h e r a c k g u i d e

in9 by clamping it too iight in the vise incorrectly. screw.
2. Removethe tie-rodend and locknut. 7. R e m o v et h e d i s c w a s h e r ,s p r i n g a n d r a c k g u i d e

from the gear housing.
Removethe boot bands and tie-rod clips. Pull the
bogtsawayfrom the ends of the gearbox.
RACKGUIOE
SPRING
DISCWASHER
LOCKNUT RACKGUIDESCREW
8. Removethe pinion dust seal and the 35 mm snap

TIE.RODCLIP
nng.
/ 9. Holdthe pinionshattwith a visesecurely

Removethe pinion by tapping evenly around the
flangedsectionof the gearboxwith a plasticham-
met.
4. H o l d t h e s t e e r i n gr a c k w i t h o n e w r e n c h , a n d
unscrewthe rackend with anotherwrench. CAUTION: Do not tap on tho steering rack.
CAUTION: Be caleful not to damagc the rack sur' NOTE| Do not reusethe removedpinion.
facs with the wrench.
STEERINGRACKENO 9._ PINIONDUSTSEAL
Replace.
ViF=\_
SNAPRING,35mm
STEERINGPINION
Feplace.
l ,
17-7
SteeringGearbox
(cont'dl
Disassembly
10. Slidethe steeringrackout of the cylinderhousing. the gearboxmountingcushionif necessary:
12. Replace
CAUTION: Be carelul not to damage the bushing in . To removethe cushion,usea sharpknifeand make
the cylinderhousing. a cut downthe lengthof the cushion.Becarefulnot
to damagethe painton the outsideof the cylinder
housing.Removethe old cushion.
. Apply weatherstripadhesiveto the insideof the
new cushion.Installthe cushiononto the cylinder
housingand positionit 20 - 22 mm (0.79- 0.87in)
from the end of the cylinderhousingas shown.
N O T E :A f t e r i n s t a l l i n gt h e c u s h i o n ,w i p e o f f a n y
e x c e s sa d h e s i v et h a t m a y h a v e d r i p p e d i n t o t h e
i n s i d eo f t h e c y l i n d e hr o u s i n g .
1 1 . R e m o v et h e r a c ke n d b u s h i n g .
GEARBOXMOUNTINGCUSHION
20 - 22 mm 10.79- 0.87 in)
Inspectinnerwall tor wear or damage.
17-8
Reassembly
NOTE:
. Cleanthe disassembled partswith solvent,and dry them with compressedair. Do not dip the rubberpartsin solvent.
. Alwavsreplacethe non reuseablepartswith new ones beforeassembly
. Do not allow dust,dirt, or otherforeignmaterialsto enterthe steeringgearbox.
PINIONOUSTSEAL
RACKENOBUSHING
-6,1 Replace.
MOUNTINGCUSHIONS
GEARBOX
\
V."^pR,NG,3smm
^lr
-6i
r@ a
^$'q0
/
t r \
")*o''o"'"'*
DISCWASHER
RACKGUIDE
t J (cont'd)
17-9
Steering Gearbox
(cont'dl
Reassembly
L Apply a thin coat of greaseto the insidesurfaceof Drivein the steeringpinion in the gear housingwith
t h e r a c ke n d b u s h i n g . the soecialtools.
Greasequantity:1 - 3 S 10.04-0.1ozl
PINIONDUST
SEAL
CAUTION:Do not till the slots with greas€;th€y Replace.
ORIVER.
must remain open to serve as air passages, 22 mm l.D.
o7716-
qr20100 SNAPRING,35 mm
I n s t a ltl h e r a c ke n d b u s h i n gb y a l i g n i n gt h e r o u n d
projectionon the bushingwith the hole in the cylin- Vinyltape
d e rh o u s i n g
STEERING
PINION
I n s t a l lt h e 3 5 m m s n a p r i n g s e c u r e l yi n t h e g e a r
housinggroove.
7 . Apply vinyl tape to the pinion shaft,then coat the

vinyltapewith grease.
Installthe piniondust sealon the gear housinguntil

it seatsproperly,then removethe tape.
Greasethe steeringrackteeth.
G r e a s et h e s l i d i n gs u r f a c eo f t h e r a c k g u i d e ,a n d
4. I n s t a l lt h e s t e e r i n gr a c k i n t o t h e c y l i n d e rh o u s i n g installit on to the gear housing.
carefullyto avoiddamagingthe rackend bushing.
1 0 . Installthe spring,discwasherand rackguide screw
on the gear housing.
NOTE:Installthe disc washerwith its convexside

facingin.
Dtscw,
a(-\
\ l 1* l
\, ,/
SPRING RACKGUTDE
RACKGUIOESCREW
LOCKNUT
CYLINDERHOUSING
11. Adjustthe rackguidescrew(seepage 17-5).
17-10
I t 12. l n s t a l lt h e n e w l o c k w a s h e r i n t h e g r o o v e i n t h e 16. Apply grease around the outside ot the rack end
steeringrack. housing.
1 3 . Installthesteeringrackend into the rack
RACKEND 54 N m ts.s kgf'm, 40 lbtft)
LOCKWASHER
Replace.
=-.
TAB .r=-q!q!!.n
SILICONEGREASE
RACK END
1 7 . Apply a light coat of silicone grease to the boot

1 4 . Hold the steering rack with a wrench and tighten
grooveson the rackends.
the rackend with another.
(l*v CAUTION: Be careful not to damage the tack sur-

fac€ with the wrench.
lnstall the boots in the rack end with the tie-rod
clips.
1 5 . After tighteningthe rack ends, stakethe four sec-
tions of the lock washer with a roll pin drift and a NOTE: Install the boot band with the rack in the
mallet. straight ahead position (right and left tie-rodsare
. Placethe wood blockon the presstable.then set equalin length).
the lock washer section of the rack end on the
wood blocksecurelY.
. Be sure the tool is alignedwith the flat sections
of the steeringrackend beforepressing
. Stakethe lock washer in the center of the flat NOTE| WiPe greaseoff
section of the steering rack end. the threadsectlon
ROLLPIN DnlFTl
(Commorci.lly.Yril.blol
Snap-OnNo. PPRSor oquival.nt
NOTE: This drift has a flat

tip, to prevent puncturing
of metalwasher.
rl, nlCr/
srEEatruG
WOODENBLOCK
TIE.ROOCLIP
(cont'd)
17-11
SteeringGearbox
Reassembly(cont'd)
'19.
Installthe boot band so that the lockingtabs of the 2 2 . S l i d et h e r a c kr i g h t a n d l e f t t o b e c e r t a i nt h a t t h e
band(stakepoints)are in the rangeshown below. bootsare not detormedor twisted.
{ T a b ss h o u l df a c eu p a n d s l i g h t l yf o r w a r o . ,
20. Bendboth setsof lockingtabs.
2 1 . Lightlytap on the doubled-overportionsto reduce

t h e i rh e i g h t .
CAUTION:Stakethe band lockingtabs firmly.
Stakepoints
+ Fronr
Lett Boot Band Right Boot Bend

(Viewedfrom the left side) (Viewedfrom the right side)
17-12
lnstallation
)
1. Slidethe rackall the way to the righl 4. I n s t a l lt h e s t i f f e n e rp l a t e w i t h t h e t w o g e a r b o x
mountingboltsand stiffenerplateattachingbolts.
2. Installthe pinion shaft grommet,and insertthe pin N O T E rI n s t a l lt h e b o l t s l o o s e l yf i r s t . t h e n t i g h t e n
i o n s h a f tu p t h r o u g ht h e b u l k h e a d . them securely.
PLATE
STIFFENER
NOTE|Align the notch in the pinion shaft grommet
w i t h t h e t a b o n t h e g e a rh o u s i n g .
ATTACHINGBOLTS
38 N.m (3.9kgf.m.28lbf.ftl
GEARBOX MOUNTING EOLTS
43N.m{4.4kgf.m,32lbf'ftl
STEEBINGGEARBOX
5. Centerthe steeringrackwithin its stroke
6. Slip the lower end ot the steeringjoint onto the pin
J 3. Installthe mountingbracketswith the two gearbox ion shaft(line up the bolt hole with the groove
m o u n t i n gb o l t so n t h e c u s h i o n . aroundthe shaft),and tightenthe lower bolt.
NOTE:
. Connectthe steeringshaft and pinion with the
steeringwheeland steeringrackcentered
B e s u r e t h a t t h e l o w e r s t e e r i n gj o i n t b o l t i s
s e c u r e l yi n t h e g r o o v ei n t h e s t e e r i n gg e a r b o x
p i ni o n .
lf the steeringwheel and rack are not centered,
r e p o s i t i o nt h e s e r r a t i o n sa t l o w e r e n d o f t h e
steeringioint.
JOINT
STEERING
{4.0 kgt.m,29 lbf.ftl

NOTE:The arrowon the bracket
pointtowardthe front. STEERING JOINT
LOWERBOLT
22 N.m
J {2.2kgf.m,16lbf'ft} (cont'd)
I t- t5
SteeringGearbox
7. Centerthe cable reel by first rotating it clockwise 9. Reconnsctthe ti€-rod ends to the steering knuckles,
until it stops.Then rotate it counterclockwise thon tightsn th€ castlenut ('96-'97 models)or nut
(approximatelytwo turns) until the arrow mark on ('98-'00 models)to the specifiedtorque,and install
the label points straight up. Reinstallthe steering new cotter pins.
wheel(seepage 17-35).
NOTE: Before connecting the tie-rod ends, wipe off
Installthe steeringjoint cov€r with the clampsand a n y g r e a s ec o n t a m i n a t i o nf r o m t h e b a l l j o i n t
clrps. tapered section and threads.
CAUTION: Torque lhe ct3tle nut to thr lowsr torque

spocification,th€n tighton it only tar anough to
align the 3lot with tho pin hob. Do not align the
nut by loosening ('96 - '97 modcls onlyl.
STEERING
JOINI COVER
TIE.ROD
COTTERPINS
R6plac6.
On rgassombly,b6nd
cotter prn as shown.
'96 - 37 model3: '98 - '00 modol3:
CAST1TNUT NUT
,O - ilt N'm 4a N.m
{4,0 - 4.8 kgf.m.
(4.5kgf.m,
29 - 35 tbtftl 33 lbr.ftl
10. Installthe exhaustpipe A or TWC (seesection9).
l l . Connectthe shift linkage (see section 13 or section

14).
Installthe front wheels.
After installation,perform the following checks.
. Adjust the front toe (seesection 18).

. Checkthe steering wheel spoke angle. Adjust by
turning the right and left tie-rods, if necessary.
NOTE:Turn the right and lefttie-rodsequally.
17-14
ComponentLocations
I lndex
Power Steering:
NOTE:
. li an intactairbagassemblyhas been removedtrom a scrappedvehicleor has beenfound defectiveor damageddur-
ing transit.storageor service,it shouldbe deployed(seesection24).
. Beforeremovingthe gearbox,removethe driver'sairbagassemblyand steeringwheel.
. After installingthe gearbox,checkthewheelalignmentandadjustif necessary.
SRScomponentsare locatedin this area.Reviewthe SRScomponentlocations.precautions,

section{24}beforeperformingrepairsor service.
STEERINGWHEEL
page17-35
page17-36
Disassembly/Feassembly,
DRIVER'SAIRBAGASSEMBLY
seesection24
STEERINGGEAREOX
RackGuideAdiustment, page17'33
Removal,page17 47
Disassembly, page17-49
Reassembly, page17-55
/ page17-65
Installation,
VALVEEODYUNIT
Overhaul,page17 52
COLUMN
page17-37
Femoval/lnstallation,
page17-38
Inspection,
CASLEREEL
see section24
IGNITIONSWITCH
Seesection23
POWEFSTEERINGPUMP TIE.RODEND BALLJOINT

PumpBeltInspection,page11-32 page17-68
BallJointBootReplacement,
PumpBeltAdiustmenl,page11'32
PumpPressureCheck,page17 34
page17'40
1,, page17-41
Disassembly/Reassembly,
17-15
System Description
FluidFlow Diagram
The system is a compactrotary-valve-type power steering,connectedto the steeringgearbox.The fluid pressureis pro-
vided by a vane-typepump which is driven by the enginecrankpulley.The amount of fluid and pressureis regulatedby
the flow controlvalvebuilt into the pump.The fluid pressurefrom the pump is deliveredto the valvebody unit aroundthe
pinionof the steeringgearbox.The valveinsidethe valvebody unit controlsthe hydraulicpressureand changesthe direc-
tion of the flow. The fluid then flows to the powercylinder.where rackthrust is generated.Fluid returningfrom the power
cylinderflows backto the reservoir,wherethe fluid is "filtered"and suppliedto the pump again.
RESERVOIR
VALVEBOOYUNIT
SUB.VALVE
FLOWCONTROLVALVE STEERINGGEARBOX
17-16
SteeringPump
)
Construction
The pump is a vane-typeincorporatinga flow controlvalve(with an integratedreliefvalve)and is drivenby a POLY-V-belt
from the crank pulley.The pump features10 vanes.Eachvane performstwo intake/discharge operationsfor every rota-
tion of the rotor.This meansthat the hydraulic
fluid pulse
pressure becomes extremely small during discharge.
FLOWCONTROLVALVE
ROTOR VANE CAM RING

/
Operation
The belt-drivenpulley rotatesthe rotor through the drive shaft.As the rotor rotates,the hydraulicpressureis appliedto
the vanechamberof rhe rotor and the vaneswill rotatewhile beingpushedonto the innercircumference of the cam ring.
The inner circumferenceof the cam ring has an extended portion with respect to the centerof the shaft, so the vanes
move downward in the axial directionas the rotor As
rotates. a resultof this roller movement. the internal volume of the
vanechamberwill change,resultingin fluid intakeand discharge
STARTOF FLUIDINTAKE: FLUIDINTAKE: FLUIDMOVEMENT: FLUIDDISCHARGE:
The vanes are pushed onto l h e v o l u m eo f t h e v a n ec h a m - T h e s u c k e d - i nf l u i d m o v e s As the vanes return to the

the inner circumferenceol the ber increasesso that fluid is towardthe dischargeport. t h e i r o r i g i n a lP o s i t i o no n t h e
cam ring, suckedin. inner side,the volume of the
v a n e c h a m b e rd e c r e a s e s o
t h e f l u i d i s d i s c h a r g e df r o m
the dischargeport.
J (cont'd)
a - t 4 -
I I- | t
SystemDescription
SteeringPump(cont'dl
The flow control valve and sub-valvein the pump per- FLOWCURVE
forms the following steps @ through @ to control the
flow of fluid, that is to increasethe dischargevolume
when enginespeedis low, and to decreaseit when the l o
engine speed increases.The assistancethrust of the
s t e e r i n gg e a r b o xc h a n g e si n c o m p l i a n c ew i t h t h e t r r
t r r
changein the dischargevolume. l o
3
J
PUMP R.P.M.
o When the engine starts,fluid dischargedfrom the To STEERING GEARBOX

SUB.VALVE
dischargeport startsto flow through oil passageA,
the fixed orificeand the variableorificeto the steer-
ing gearbox.When the engine speed is extremely
low, the return port is closed by the flow control
Fluid pressuredischargedfrom the dischargeport

is appliedto the top of the sub-valve,and the fluid
pressurethat passedthrough oil passageA is applied !rs+/f/ffih\\
to the bottom of the sub-valve.When this happens,
the pressuredifferencebetweenthe ends of oil pas-
sageA, which is causedby the resistanceoil passage o,,-i^"l^tKzYt)9
1y ul3Yl
A w h e n t h e f l u i d f l o w s t h r o u g h t h e p a s s a g e .i s
appliedto the sub-valve,However,the pressuredif-
ferenceapplied to the sub-valve.that is the force
that pushes the sub-valve down, is too small to
overcomethe spring force, and the variableorifice is
fully openwhen the enginespeedis extremelylow.
FLOW CONTNOLVALVE
Becausethe fluid volume flowing throughthe fixed To STEEnINGGEARBOX
orificeand variableorificeincreases, a pressuredif- su8-vALvE
terence is createdbetweenthe ends of these ori-
fices, and it increasesin proportionto the engine
speed.As the fluid pressurethat passedthe fixed
orificeand variableorificeis directedto the bottom
of the flow control valve. a pressuredifferenceis
created between the top and bottom of the valve,
w h i c h p u s h e sd o w n t h e f l o w c o n t r o l v a l v e a n d ORIFICE
opens the return port. As a result,pan of the fluid
dischargedfrom the dischargeport feturns to the
pump suction port, keepingthe dischargevolume
ToP
constant.
In this condition,the sub-valvedoes not move. and
the variableorificestaysfully open.
FLOWCONTROLVALVE
17-1 8
t @ The fluid volumethat flows thoroughoil passageA
To STEERINGGEARBOX
and the pressuredjfferenceappliedto the sub-valve

i n c r e a s ei n p r o p o r t i o nt o t h e e n g i n e s p e e d .T h e
sub-valvelowers overcomingthe spring force,and
it stans to closethe variableorificeto regulatethe
dischargevolume,Whenthis happens,the fluid vol-
ume flowing to the steeringgearboxdecreasesas
the engine speed increases.At the same time, the
flow controlvalvecontinuesto controlthe fluid vol-
ume to the returnPort,
To STEERINGGEAREOx
SUB.VALVE
@ As the enginespeedincreasesfunher, the pressure
differenceat the sub-valveincreasesfurtheras well.
The sub-valvethen closesthe variableorificecom-
p l e t e l y ,r e g u l a t i n gt h e d i s c h a r g ev o l u m e f u r t h e r .
W h e n t h i s h a p p e n s t, h e f l u i d v o l u m e d i s c h a r g e d
from the pump to the steeringgearboxis regulated /F
ft>..\
a n d m a i n t a i n e da t a g i v e n l e v e l u n t i l t h e e n g i n e
speedreachesthe high speedrange The flow con-
'-€/K\A/A
trol valve functions continuesto control the fluid o'.'to"5lo'#2"n
af
volumeto the returnPort. 11\D7
FLOWCONTROLVALVE
PressureRelief
P r e s s u r ea t t h e d i s c h a r g es i d e o f t h e f i x e d o r i f i c ei s
directedto the bottom of the flow control valve.When
the pressurebuilds up, the reliefvalve in the flow con-
trol valveopensto releasethe pressureat the bottomof
the valve.This allows the flow control valve to be
pushed back by the pressuredifference,and the fluid
volumeto the pump returnport increases.
As explainedabove. the system keepsthe pump dis-
c h a r g ep r e s s u r e( r e l i e fp r e s s u r ef)r o m e x c e e d i n gt h e
given level by controllingthe volume of the fluid to the
pump relurn pon,
1., DAMPINGORIFICE
{Docreasesexcessiv€
FLOWCONTROLVALVE
RELIEFVALVE {Opan)
vibration in the valv6.)
17-19
)
System Description
Steering Gearbox
The rack-and-pinion type steeringgearboxhas a valvebody unit incorporatedwith the pinionto controlthe steeringfluid
pressure.Steeringfluid from the pump is regulatedby a rotaryvalve in the valve body unit and is sentthroughthe cylin,
der line to the power cylinder,where hydraulicpressureis applied.The steeringfluid in the other side of the power cylin,
der returnsthroughthe cylinderline and valvebody unit to the reservoii.
VALVEEODYUNIT
CYLINDERLINE
To RESERVOm
+-
FromPUMP -;
POWERCYLINDER
Valve Body Unit
Insidethe valve body unit is the valve,which is coaxialwith the pinion shaft,and controlsthe steeringfluid pressure.The
valve housingis connectedwith the fluid line from the pump,the returnline to the reservoir,and the two cylinderlines
from the respectivepower cylinder.The pinion shaft is double- structuredwith the input shaft connectedto the pinion
gear,both of which are interconnected with the torsionbar.
The pin insertedin the valve and the pinion shaft grooveengage;this allowsthe pinion shaft to rotatetogetherwith the
valve.Becauseof this construction, the differencein angle in the circumferential
directionbetweenthe input shaftand the
valve becomeslargeraccordingto the torsionalstrengthof the pinionor steeringresistance. However,maximumtorsion
betweenthe shaftsis regulatedby the engagedsplinesof the shaftsat the pin engagementsectionto hold the torsionbar
within the set value,
This allowsthe steeringsystemto functionas an ordinaryrack-and-pinion type steeringif the steeringfluid is not pressur-
izedbecauseof a faulty pump,
VALVE
Difforencein angle botwoon the
input shaft and pinion shsft
PINIONSHAFT
lo
-l
INPUTSHAFT
a INPUTSHAFT
17-20
Control
Pressure
Low assistat higherspeeds:
W h e n s t e e r i n g r e s i s t a n c e I s I o w , s u c h a s w h e n d r i v i n g a t h i g h s p e e d s , o r w h e n d r i v i n g soIt rthe
a i gfeed
h t a pressure
head,theinpu
power cylinderorifices.Most
nearor in the neutralposition,so there is little or no fiow ro any of the
fromthepumpisbypassedtothereservoir.Becauseofthis,thepressurestaysthesameinbothsidesofthepo
der, resultingin low or no asslst
VALVE From PUMP

RESERVOIR RETURNPASSAGE
lTo RESERVOIRI
SECTIONA-A
POWERCYLINDER
STEERINGGEARBOX
Highassistat lower speeds:

low speeds'or when turning the wheel wirh the vehicle
When steering resistanceis high. such as when driving at
stopped,thedifference|nang|ecreatedbetweentheinputshaftandtheVa|veopensthef|uidpassageonon
c|osesthefluidpassageontheotherside,ateachpairoforifices'Thef|uidpressureincreasesinthesideo|th
c y | i n d e r | e d b y t h e | a r g e r f | u i d p a s s a g e ' T h i s i n c r e a s e d p r e s s u r e p u s h e s o n t h e r a c k p i s t o n , athe
| l osteering
wingthe s t eto
tluid eringwh
the returnpassageopensallowing
be turnedwith light effort.on the other sideof the powercylinder,
r e t u r n t h r o U g h t h e i n p u t s h a f t t o t h e r e s e r v o i r ' T h e f | u i d p a s s a g e s t o t h e p o w e r c and
y | i npower
d e r a uassist
t o m aincreases
tica||ychang
increasingas the steeringresrstance increases.In other words, the passagesbecomelarger
(for example'when parkingor makinglow speedturns)' and the pas-
when the steeringeffort would normallybe high,
sagesbecomesma||erandpowerassistdecreaseswhenthesteeringeffortwou|dnorma||ybe|ow,(forexamp|e,w
drivingat high speedsor straightahead).
FLUIOPASSAGETO
POWERCYLINDER
/t=\
\a!-4,))
=YjJ
SECTIONA-A
l' {High fluid Pressure}

Troubleshooting
GeneralTroubleshooting
Checkthe followingbeforeyou begin:
. Hasthe suspensionbeenmodifiedin a way that would affectsteering?
. Are tire sizes,tire varietyand air pressurecorrect?
. lsthe steeringwheeloriginalequipmentor equivalent?
. lsthe powersteeringpump belt properlyadiusted?
. ls steeringfluidreservoirfilledtoproperlevel?
. ls the engineidle speedcorrectand steady?
HardSteering(Checkthe poworassist.se€page17-3o.lfthe torce is over 29 N (3.0kgf,6.6lbo, Procedewith this troubleshootinq.)
Checkthe pump fluid pressure

(soepage17-34).
Abnormal
l/easure steady-state tluid pres- C h € c kt h e f e e d s n d r e t u r n c i r c u i t l i n € s a n o n o s e
lluid pressure
s!re while idling with the both betw6€n the gearbox and pump for clogging and
valvestully open. {fluid pressure
is too high) d€lormation.
It should be 1.500kPa(15 kgf/cmr,
213psi)or below.
Normallineand hose
Normal
Faultyvalve body unit
Checkthe pump fluid pressure

{seepage 17-34).
M e a s u r ep u m p r e l i e f p r e s s u r e Checkth€ flow control vslve (see page 17-42).
Reliefpres- . Chockthe valvo lor smooth movement in the hous-
while idling with the pressurecon-
sure too low ing.
trol valveIully closed.
It should be 6,400- 7,400kPa(65- . Checkthe reliefvalve for leaks.
75 kgflcm,,920- 1,070psi)
Normalrelisfpressure Abnormal
Go to page 17-23 Faultypump assembly Faultyllow control valve

(Replace the pump es an
assembly)
17-22
I
Checkthe force requiredto turn
the wheel(seePage17 30i
Startthe engineand measurethe
force requiredto turn the wheel Deformed
to the right and left.Difference of Abnormal
t h e l o r c e r e q u i r e dt o t u r n t h e
wheel to the right and to the Ieft
should be 2.9 N 103 kgf, 0.7 lbf)
or below. Faultycylinderlines
Normal Checkfor bent rack shaft

II
Compairthe steeringto another alike
vehicle. Checkrackguideadiustment(see AdiustmentOK
page17-33).
Faultyvalvebody unit
1,, (cont'd)
17 -23
Troubleshooting
GeneralTroubleshooting(cont'd)
Assist(excessively
lightsteering)at lf the problem is not correctedby
Checkthe rack guide for proper adiustingthe rack guide, adjust
high speed.
adiustment(seepage17 33). t h e f r o n t w h e e l a l i g n m e n tl s e e
section181.
Shockor vibrationwhen wheelis

Checkthe rack guide for proper
turnedto {ull lock.
adjustment(seepage17-33).
Rackguideis adjustedproperly.
lfthe problemis not correctedby

adjustingthe rackguide,replace
Checkthe belt for slippageand the gearbox.
a o l u s t a s n e c e s s a r y{ s e e p a g e
11 32).
Steeringwheelwill not return

smoothly.
A a n d B c y l i n d e rl i n e sa r e n o r -
mal, checkwheel alignment(see W h e e l a l i g n m e n ti s a b n o r m a l ,
section18). adjust as needed.
Wheelalignmentis normal.
Checkthe steeringwheel opera-
tion and power assistcheck{see
page lT-30).
It the measurementsare out of

s p e c i f i c a t i o n sa, d j u s t t h e r ac k
guide.
lf the problemis not correctedby

the gearbox.
1 7- 2 4
Unevenor roughsteering Adjustthe rac*guide(seepage17-3).
lf the problemis not correctedbY

the gearbox.
Adiustthe belttension.Feplacethe
(seePage1732).
belt,il necessary
lfthe enginestallswhenthe wheel

is turnedwhile car is stoppedor
ldle speedlow or erratic. moving at low speed,adjustthe
idlespe€d(seesection11)
Checkpower sleeringfluid level lf

Air in reservoir,or check Power the level is excessivelylow, check
steeringIluid level. lor leaksin the system.Add lluid
to the specifiedlevel.
lf ltuid level is OK, checkO-rings

a n d s e a l so n b o t h e n d s o f t h e
pump inlet hose,and the P/S
pump housing mating surfaces
/ and the pumP shaft oil seal for
suction leaks. RePlaceParts as
nocessary.
P u m p b e l t s l i P P i n go n P L r l l e Y Adjust the belt tension (see Page

Steeringwheel kicksback (pumpstopsmomentarilY) 1732)orreplace belt.
duringwide t!rns.
Checkif pump press{rreis normal

and the gaugeneedletravel is 500
Installthe power steeringpressure k P a ( 5 k g l / c m ?7, l P s i ) o r l e s s .
gauge,Closethe Pressurecontrcl Chockthe flow control valve if the
valve fully and m6ssurethe PumP needletravel exceeds500 kPa (5
pressure{s€epage17-34}. kgflcm',71 Psi).l{ the flow control
valve is normal, replacethe PumP
as an assemoly.
ll,
17 -25,
) from www.Manualslib.com manuals search engine
Downloaded
Troubleshooting
Noiseand Vibration
NOTE;Pump noisein first 2 - 3 minutesafterstartingin cold weatheris normal.
Humming Humming due to pulsationof fluid is normal, particularlvwhen the wheel is

turned with the vehicle stooDed.
lf equipped with automatictrans-

mission, the hum could be the Confirm by temporarily removing
torque conveateror pump noise. the pump belt.
High-pressureline touching the

frame. Repositionthe line.
Rattleor chattering Loose steeringshaft connector, C h e c ka n d t i g h t e n , o r r e p l a c e

tie-rod.or balljoint. paatsas necessary.
Columnshaftwobbling. Replacethe columnassembly.
Checkthe rack guide tor proper

adjustment(seepage 17,33). Adiusi,if necess€ry.
Rattlingsoundand feelingwhen turningthe steeringwheelraghtand leftwith the

engineOFFis normal.
Pump noise,though not loud.trom the valvebody unit can be heardwhon turn-
ing the steeringwheel rightor left.This is normat.
CAUTION: When imp€sting, do not hold the steering wheet a[ the way to
the right or the left.
17-26
)
Checkthe tluid level.
Cavitationcaused bY air bubbles l f l o w , f i l l t h e r e s e r v o i rt o t h e
Gratingnoise proper level,and checklor leaks.
Pumpnoase from pump in the fluid.
Tighten or replaceas nocessary.
Checklor a crushed suction hose

or a loose hose clamp allowing
air into the suction side of the
sy$em.
Tighton or roplaceas necossary.
NOTE: Pump noise uP to 2 - 3 loud,

lf pump nois€is abnormallY
m i n u t e sa l t e r s t a r t i n gi n c o l d remove and inspectthe PUmPfor
Pumpgearnois€ weatheris normal w6ar and damage(seePage 17-
ComparepumP noiseat operating 41).
temperatureto simularvehicle.
l z / Tightenor replacethe Pulley.

l f s h a t t i s l o o s e , r e P l a c et h e
Rattleor chattgring pump.
t r
17-27
Troubleshooting
FluidLeaks
Checkthe gearboxassemblyfor oil leakscarefully.Oil can leak out of various points.dependingon location
of the
faultyoil seals/seal
rings.Checkthe followingbeforeremovingthe gearboxfrom the frame_
SteeringGearbox Leakingfrom the oil seal on the Replacethe valve oil seal from
top of the valvehousing. the valvehousing.
Leakingfrom cylinder end into Replacethe valve oil seal trom

left tie rod boot. the pinionshaft.
Replacethe cylinderend sealon

the gearhousingside.
Leakinglrom cylinder end into Replacethe cylinderend seal on

right tie-rod boot. the cylinderend side.
Leakinglrom the shaftupperend

sectronor pin engagementsec, Replacethe valvebody unit.
tion ol the pinionshaft.
Leakingfrom cylinderlineA or B Tightenthe connector.lf it's still

connections{at tlare nut}. leakinO,replacethe Iine,cylinder
or valvehousingunit.
L e a k i n gc a u s e db y a d a m a g e d
cylinde.lineA or B. ReplacecvljnderlineA or B.
Leakingfrom feed line and return Tighten the connector. ll it's still
lineioint fittingon the valvebody leaking,replacethe line,,ointfit,
unit (atflarenut). ting or valv6housing.
17-2a
Replace the housingO-rings
lf the housingstill leaks,rePlace
the pumP.
Reservoiris overfilled
Pull off the hose and drain the
reservoitto the Properlevel.
Air leakin suctionsideofthe sys'

tem (reservoir,inlet hose,tront
pump seal).
Tighten the fifting. lI it's still leak-

Pumpoutletline L e a k i n ga t t h e t h r e a d e d f i t t i n g ing, replacethe O-ringor feed line.
(highpressure,
Leakingat the swaggedjoint.
/ Leakingbecauseol damage,dete_ Reolaceor rePairas necessarY.

PumpinletIine assemblY.
or imProPer
rioration,
(low-pressure)
t J
17-29
SteeringOperation PowerAssist Gheckwith
VehicleParked
Placethe front wheels in the straight ahead position,
and measurethe distancethe steering wheel can be 1. Checkthe power steeringfluid level (see page 17-
turnedwithout movingthe front wheels. 33) and pump belttension(seepage17-32).
ROTATIONALPLAY:0 - 10 mm l0 - 0.39 inl 2. Startthe engine,allow it to idle.and turn the steer-

ing wheel from lock-tolockseveraltimes to warm
lf the play exceedsthe servicelimit. perform rack guide up the fluid.
adjustment(seepage 17-33).
lf the play is still excessiveafter rack guide adjustment. 3. Attach a spring scaleto the steering wheel. With the
inspectthe steeringlinkage and gearboxas described engine idling and the vehicleon a clean,dry floor,
on the nel(t pag€. pull the scaleas shown and read it as soon as the
tires beginto turn.
ROTATIONALPLAY
D 0
The scaleshould read no more than 29 N (3.0 kgf.

6.6 lbf). lf it reads more, check the gearbox and
pump,
17-30
I SteeringLinkageand Gearbox
STEERING COLUMN
Inspectfor loosecolumn
mountingboltsand nuts
TIE-RODEND BALLJOINT
Inspectfor faultymovement
and damage.
BOOT
Inspect damageand deteriorataon
STEERING JOINTS
Checkfor loosejoint bolts.
l./ SHAFTGROMMET
I n s p e c tf o r d a m a g e a n d d e t e r i o r a t a o n .
TIE-RODLOCKNUT
for looselocknut
STEERINGGEARBOX
lnspectfor loosemountingbolts.
GEARBOX MOUNTINGCUSHIONS
Inspectf or deterioration
BALLJOINT BOOT
Inspectfor damageand deteriorataon'
Seepage17-68lorreplacement.
lrz
17-31
PumpBelt
NOTE:When usinga new belt,first adjustthe deflection Adiustment
or tensionto the valuesfor the new belt, then readjust
the deflectionor tensionto the valuesfor the used belt 1. Loosenthe powersteeringpump mountingbolts.
afterrunningenginefor five minutes.
2. Adjustthe belttension.
Inspection
'99 - '00
mod€ls: 816A2 Engin€Typo only
Attachthe specialtool to the belt and measurethe ten-
sion of the belt. . Turn the adjustingbolt by handto get the properbelt
Tension: tension,then retightenthe mountingbolts,
'99 -'00
mod€ls:B1642 Engin. Type only
Used Bsh: 390 - 540 N lao - 55 kgt.88 - 120 tbf) ADJUSNNG
BOLT
New Belt: 740- 880N {75- 90 kgf, 170- 200tbt}
'96 - '00
models:Other EngineTypes
Used Beh: 340 - 490 N (35 - 50 kgf, 77 - ilO tbfl
New Belt: 640- 780N 165- 80 ksf, 1& - 176tbf)
NOTE:
. lf thereare cracksor any damageevidenton the belt,
reDlaceit with a new one.
. Followthe manufacturer's instructionsfor the tension
gauge.
BELTTENSION GAUGE
07JGG_ 001010A
PUMP MOUNNNG BOLTS POWERSTEERING

24 N.m (2.4kgf'm, 17 tbtftl PUMP
'96 -'00
modek: Othcr Engins Typos
. Pry power steering pump away from the engine with

a wrench to get the proper belt tension, then retight-
en the mountingbolts.
Inspectthe pump beltfor cracksor any damage.
Replacethe belt with a new one if necessary. PUMPMOUNTINGBOLT
24 N.m (2,4kgf.m, 17 lbl.ftl
Measuremontwithout Beh Tension Gauga:
Apply a force of 98 N (10 kgt,22 lbfl and measurethe
deflectionbetweenthe power steering pump and the
crankshaftpulleys.
Dsflectior:
'99 -'00 model3:816A2
Engine Typ€ onty
Used Beh: 7.5 - 11.0mm t0.30- 0.43 inl
New Beh: 5.0 - 7.0 mm (0.20- 0.28 in)
'96 - '00
models:Othor Engine Typos
Used Behi 10.5- 14.0mm (0.ial- 0.59 inl
Now Beh: 7.5- 10.0mm (0.30- 0.39inl
POWERSTEERINGPULUY
PUMPMOUNTING BOLT
24N.m{2.akgtm, 17tbtftl
Start the engine and turn the steeringwheel from
lock-to-lockseveraltimes,then stop the engineand
recheckthe deflectionof the belt,
CRANKSHAFT
PULLEY
17-32
I RackGuideAdjustment FluidReplacement
Checkthe reservoirat regularintervals,and add fluid as
NOTE:Performrack guide adjustmentwith the wheels
in the straightaheadPosition. necessary.
CAUTION: Always us€ Genuine Honda Power Stearing
1. Loosenthe rack guide screw locknutwith the Fluid-V or S. Using any other type of power sto€ring
cialtool. tluid or automatic transmission lluid can cause
increasedwear and poor steering in cold weathor.
'96 - '97 models: SYSTEMCAPACITY:
Loosenthe rackguidescrew 0.85liter 10.90US' qt,0.75 lmp'qt)
at disassembly
RESERVOIR CAPACITY:
0.4 liter (0.42US. qt, 0.35 lmP.qt)
LEVEL LINE
LOWERLEVELLINE
LOCKNUTWRENCH,40 mm
1. Raisethe reservoir,then disconnectthe returnnose.

'98 - '00 models: 2. Connecta hose of suitablediameterto the discon-
Removethe rack guide screw and remove the old nectedreturn hose,and put the hose end in a suit-
sealantoff of the threadedsection. ablecontainer.
Apply new sealantall around the threads.Loosely CAUTION:Take care not to spill tho fluid on the
installtherackguidescrew body and parts. Wipe off any spill€d fluid at oncs'
Tightenthe rack guide screwto 25 N'm (2.5 kgf'm.

18 lbf.ft),then loosenit.
Retightenthe rackguidescrewto 3 9 N'm (0.4kgim,

2.9 lbf.ft),then back it off to specifiedangle.
SpecifiedReturn Angle: 20" max.
4. T i g h t e nt h e l o c k n u tw h i l e h o l d i n gt h e r a c k g u i d e
screw.
Checkfor tight or loose steeringthrough the com-

HOSE
pleteturningtravel.
PerformfollowinginsPections: 3. Startthe engine,let it run at idle,and turn the steer-

ing wheel from lock-to-lockseveral times When
. Steeringoperation(seepage 17-30). f l u i d s t o p s r u n n i n go u t o f t h e h o s e ,s h u t o f f t h e
. Powerassistwith vehicleparked. engine,Discardthe fluid.
4. Reinstallthe returnhoseon the reservoir'
5. Fillthe reservoirto the upperlevelline.
6. Startthe engineand run it at fast idle,then turn the
steeringtrom lock-to-lock severaltimes to bleedair
trom the system.
l r 7. Recheckthe fluid leveland add some it necessary.
CAUTION: Do not fill the reservoir beYond the
upper l€vel line.
17-33
lnspectionand Adjustment
PumpPressureCheck
C h e c kt h e f l u i d p r e s s u r ea s f o l l o w s t o d e t e r m i n e Startthe engineand let it idle.
whetherthe troubleis in the pump or gearbox.
7 . Turn the steeringwheel from lock-to-lockseveral
NOTE: First check the power steering fluid level and timesto warm the fluid to operatingtemperature.
pump belttension.
Measuresteady-state fluid pressurewhile idling. If
CAUTION: Disconnectthe high pr$sure hos€ with care t h e p u m p i s i n g o o d c o n d i t i o nt,h e g a u g es h o u l d
so as not lo spill the power sieering tluid on tha frame readlessthan 1500kPa(15kgf/cmr,213 psi).
and other parts. lf it readshigh, checkthe outlet line or valve body
unit (seeGeneralTroubleshooting 17-22).
1. Disconnectthe outlet line from the Dumooutlet fit-
ting, then installtheP/Sjoint adaptor(pump)on the 9 . C l o s et h e p r e s s u r ec o n t r o l v a l v e ,t h e n c l o s et h e
Dumooutlet. shut-off valve gradually until the pressuregauge
2. Connectthe P/Sjoint adaptor (hose)to the power needleis stable.Readthe oressure.
steering pressuregauge, then connect the outlet
hoseto the adaptor. lmmediatelyopenthe pressurecontrolvalvefully.
3. Installthe power steeringpressuregaugeto the P/S
joint adaptor(pump)as shown. GAUTION: Do not keep lhe prossure control valve
clos€d more then 5 soconds or the pump could be
damagod by over-heating.
ourlErHosE
FnrNo ,t"ll lrilu"ott
lf the pump is in good condition,the gaugeshould
P/S JOINT ADAPTOBIHOSEI
07RAK- S0i10l2r
read at least 6,400- 7,400kPa (65 - 75 kgflcm,,920 -
ol 1,070psi).A low readingmeanspump outputis too
07RAK- 50{{)120 low for full assist.Repairor replacethe pump,
P/S PRESSURE GAUGE
07406- 001000A P/S PBESSURE
GAUGE
or 07{16 -@1@OA
07406- 0010001 oi
(Pa.t of tooll
11 N.m
11.1kgt m, 8 lbf.ftl
PRESSURE
CONTROLVALVE
SHUT.OFF
VALVE
PUMPOUTLET
FITTING
6 x 1.0 mm BOLT SI{UT.OFFVALVE

lPart of tool)
11 N.m
11.1kgf m, 8 lbtftl
4. Openthe shut-offvalvefully.
5. Openthe pressurecontrolvalvefully.
17-34
Steering Wheel
Removal lnstallation
S R Sc o m p o n e n t sa r e l o c a t e di n t h i s a r e a R e v i e wt h e CAUTION: Do not tap on the steering wheel or steering
SRScomponentlocations,precautions,and procedures column shaft when installing the stsering wheel.
in the SRSsection(24)beforeperformingrepairsor ser-
vice. N O T E :B e f o r ei n s t a l l i n gt h e s t e e r i n gw h e e l ,a l i g n t h e
front wheelsstraightahead.
N O T E :B e f o r er e m o v i n gt h e s t e e r i n gw h e e l .a l i g n t h e
front wheelsstraightahead. 1. B e f o r ei n s t a l l i n gt h e s t e e r i n gw h e e l , c e n t e r t h e
cable reel, Do this by first rotating the cable reel
1. R e m o v et h e d r i v e r ' s a i r b a g a s s e m b l yf r o m t h e clockwiseuntil it stops.Then rotateit counterclock-
steeringwheel(seesection24) wise approximatelytwo turns The arrow mark on
the cablereellabelshouldpointsstraightup.
2. Disconnectthe horn connectorand cruise control
switchesconnector.
CAELEREEL
CRUISE Installthe steeringwheel with the steeringwheel

l,/ SWITCHESCONNECTOR nut.
NOTE: Be sure the steering wheel shaft engages

3. Removethe steeringwheelnut the cablereeland cancelingsleeve.
STEERING WHEELNUT
Replace.
ag N.m {5.0kgt rn, 36lbfft)
Attachthe cruisecontrol switchesconnectorio the

steeringwheelcliP,
Connectthe horn connector.
I n s t a l lt h e d r i v e r ' sa i r b a ga s s e m b l y a, n d c o n f i r m
propersystemoperation(seesection24).
Removethe steeringwheelby rockingit slightlyfrom
C h e c kt h e h o r n a n d c r u i s e c o n t r o l s w i t c h e sf o r
1., as you pull steadilywith both hands.
side-to-side
properoperatrons.
17-35
Steering Wheel
STEERING
WHEEL
*@*&*W
@,
17-36
SteeringColumn
I Removal/lnstallation
S R Sc o m p o n e n t sa r e l o c a t e di n t h i s a r e a .R e v i e wt h e 9. Installationis the reverseof the removalprocedure
SRScomponentlocations,precautions,and proceclures NOTE:
i n t h e S R Ss e c t r o n( 2 4 )b e f o r ep e r t o r m i n g
r e p a i r so r s e r - . Makesurethe steeringjoint is connectedas follows:
vice. a. Insertthe upper end of the steeringioint onto the
N O T E :B e f o r er e m o v i n gt h e s t e e r i n gc o l u m nf o r S R S , steeringshaft (lineup the bolt holewith the flat on
removethe driver'sairbagassemblyand cablereel lsee the shait),and looselyinstallthe upperjoint bolt.
s e c t i o n2 4 ) . b . S l i p t h e l o w e r e n d o f t h e s t e e r i n gj o i n t o n t o t h e
1 . R e m o v et h e s t e e r i n g w h e e l( s e ep a g e1 7 3 5 ) . pinion shaft (line up the bolt hole with the groove
2 . R e m o v et h e d r i v e r ' sd a s h b o a r dl o w e r c o v e r a n d a r o u n dt h e s h a f t ) ,a n d l o o s e l yi n s t a l lt h e l o w e r
driver'skneebolster(seesection20). joint bolt.
3. Removethe combinationswitchassemblyfrom the Be sure that the lowei joint bolt is securelyin the
s t e e r i n gc o l u m ns h a { tb y d i s c o n n e c t i nt hg e c o n n e c - groovein the pinionshaft.
tors. c . P u l l o n t h e s t e e r i n gj o i n t t o m a k e s u r e t h a t t h e
4. Disconnect the ignitionswitchconnectors. steeringjoint js fully seated.Then tightenthe ioint
5 . R e m o v et h e s t e e r i n jgo i n tc o v e r . bolts.
6 . B e m o v et h e s t e e r i n jgo i n tb o l l s . . 8e sure the wires are not caught or pinchedby any
7 . D i s c o n n e ct th e s t e e r i n gi o i n t b y m o v i n gt h e j o i n t partswhen installingthe column
toward the column,and removeit from the column . Make sure the wire harnessis routed and fastened
shaft. properly.
8 . R e m o v et h e s t e e r i n gc o l u m n b y r e m o v i n gt h e . Makesurethe connectorsare properlyconnected.
attachinn g u t sa n d b o l t .
UPPER STEERINGCOLUMN
RETAININGCOLLAB COMBINATIONSWITCH
NOTE:Takecarenot to let the ASSEMBLY
retainingcollarfall out of
positionduringinstallation.
STEERING JOINTBOLTS
22 N.m {2.2kgf.m,16lbtft}
FLANGENUT
13 N.m {1.3kgl.m.9 lbf ft)
FLANGEBOLTS
22Nm12.2kgl'm,
16tbt.tr)
UPPERJOINT BOLT
COLUMNCOVER
Bolt musl line up
on shaft.
Groove.
JOINTCOVER
CLIP
LOWERJOINT BOLT
8oh must line up wrth
groovearoundon shaft.
J
17-37
SteeringColumn
Inspection
NOTE:The tilt steeringcolumn type is shown;the con-
v e n t i o n asl t e e r i n gc o l u m ni s s i m i l a re x c e p tf o r t h e t i l t
mechantsm.
Checkthe steeringcolumn ball bearingand the steer-

ing joint bearingsfor play and proper movement.lf
there is noiseor if there is excessiveplay,replacethe
steeringcolumnas an assembly.
Checkthe retainingcollar for damage.lf it is dam-
aged,replacethe retainingcollar.
Checkthe absorbingplates,absorbingplate g u i d e s
and slidingcapsulesfor distonionor breakage.
Replacethe steeringcolumn as an assemblyif they ABSORBINGPLATEGUIDES
are distortedor broken.
COLUMNBALL
BEARINGS
SLIDING
This part is attachod
to the column bracket
with the plasticinjections.
1 . Move the tilt lever from the loose positionto lock

position 3 to 5 times; then measurethe tilt lever
preloadl0 mm {0.4in) from the end ofthe tilt lever.
Preload: 70 - 90 N (7 - 9 kgf. 15 - 20 lbf)
l f t h e m e a s u r e m e n ti s o u t o f t h e s p e c i f i c a t i o n ,
adjustthe pfeloadusingthe followingprocedures. TILTLOCKBOLT
Tighten the lock bolt with
a. Loosenthe tilt lever,and set the steeringcolumn the tilt leverraised.
in the neutralposition.
b. Removethe 6 mm lockbolt and removethe stop.
c. Adjustthe preloadby turningthe tilt lock bolt left
or flgnr.
d. Pullup the tilt leverto the uppermostpositionand
install the stop. Checkthe preloadagain. lf the
measurementis still out of specification,repeat
the aboveprocedures"a" through"c" to adjust.
CAUTION:Be caretul not to loosen tho tilt lever 10 mm (0.4inl

when installingthe stop or tightening the 6 mm
lock bolt.
9.8N.m (1.0kgl.m,7lbf.ft)
1 73 a
Power Steering Hoses,Lines
Fluid LeakageInspection
HOSESand LINES
. I n s p e c th o s e sf o r d a m a g e ,l e a k s ,i n t e r f e r e n c eo r LINES
VALVEBODYUNIT-to-CYLINDER
'17N.m 12 tbl.ftl
twisting. {1.7
. Inspecttluid linesfor damage,rustingand leakage.
VALVEBODYUNIT-Io-FEED/RETURN LINES
. Inspectfor leaksat hose and line joints and connec- Feedline:14 x '1.5mm llare nut
tions. 37 N.m {3.8 kgJ.m,27 lbf'tt)
POWERSTEERING swtTcH Return Line Joint 16 x 1.5 mm flare nut
12 N.m {1.2kgt.m,9lbt.ft} 28 N m 12.7kgf.m,20lbtft)
CYLINDERHOUSING-to.CYLINDER LINES
28 N.m (2.7 kgf.m,20 lbf.ft)
8()07
Checkfor leaks.
G€AR8OX andVALVEBODYUNIT
Checkfor leaksatthematingsurface
andflarenutconnections,
OUTLETHOSE
11 N.m
( 1 . 1k g f . m , 8
tbt
PUMPASSEMBLY (Double
RingTypei
Checkfor leaksat the pump
seal,inletand outletfiftings.
Replacement
NOTE: CAUTION: Check all clamps for deterioration or delor-
. Connecteachhoseto the corresponding pipesecurely mation; replacewith the clamps new ones il necessary.
until it contactsthe stop on the line.Installthe clamp
or adiustableclampat the specifieddistancefrom the
hoseend as shown.
. Add the power steeringfluid to the specifiedlevelon
the reservoirand checkfor leaks.
ADJUSTABLEHOSECLAMP: HOSECLAMP:
. P o s i t i o nt h e a d i u s t a b l eh o s e c l a m p s a t t h e p o i n t s . Positionthe hoseclampsat the pointsindicated(b) in
indicated(a)in the drawingabove. the drawingabove.
. Slidethe hoseoverthe line until it contactsthe stop. . Slidethe hoseoverthe line until it contactsthe stop.
1., 2.5- 5.5 mm

{0.01- 0.22in)
2.0 - 4.0 mm
(0.08- 0.16in)
2.5- 5.5mm
(0.01- 0.22in)
17-39
PowerSteeringPump
RemovaUlnstallation
NOTE: Eeforedisconnectingthe hosesfrom the pump, Connectthe inlet hose and the outlet line. Tiqhten
Dlacea suitablecontainerunderthe vehicle. the pump fittingssecurely.
1. Removethe belt by looseningthe pump mounting Looselyinstallthe pump in the pump bracketwith
b o l t s a n d a d j u s t i n gb o l t ( ' 9 9- ' 0 0 m o d e l s :8 1 6 4 2 mountingbolts and adjustingbolt ('99-'00 models:
EngineTypeonly). 81642EngineTypeonly).
1. Installthepump belt.
OUTLETLINE 11 N.m {1.1kgf'm,
8
CAUTION:
. Make sure that the power steering belt is prop-
orly positioned on the pulleys.
. Do not get power stoering tluid or grease in the
power steering bsh or pulley faces.Cleanoff any
L fluid or greasebefore installrtion.
8. Adjustthe pump belt (seepage 17-32).
Fill the reservoirto the upper level line (see page
PUMPMOUNTING BOLT
24 N.m(2.4kgl.m,17lbfft)
2. Coverthe Ay'Ccompressorwith severalshop towels

to protectit from spilledpowersteeringfluid.
3. Disconnectthe inlet hose and the outlet line from

the pump,and plug them.
NOTE:Takecare not to spill the fluid on the body

or parts,Wipe off any spilledfluid at once.
4. R e m o v et h e p u m p m o u n t i n gb o l t s a n d a d j u s t i n g
b o l t ( ' 9 9 - ' 0 0 m o d e l s :8 1 6 A 2E n g i n eT y p e o n l y ) ,
then removethe pump.
NOTE:
. Do not turn the steeringwheel with the pump
removeo.
. Wrap the opening of the pump with a piece of
tape to preventforeign material from entering
thepump.
17-40
Disassembly
CAUTION: The power steering components are made of aluminum. Avoid damaging the components during assembly.
NOTE:
. Cteanthe disassembledpartswith a solvent,and dry them with compressedair. Do not dip the rubberparts in a sol-
vent.
. Alwavs replacethe O-ringsand rubbersealswith new ones beforeassembly.
. Apply recommendedpower steeringfluid to the partsindicatedin the assemblyprocedures'
. Do not allow dust,dirt, or otherforeignmaterialsto enterthe power steeringsystem.
. Replacethe pump as an assemblyifthe partsindicatedwith asterisk(*) are worn or damaged'
FLANGEBOLTS
20 N.m {2.0kgf.m,
14 rbf ft)
4.5mm ROLLER
*OUTERSIOEPLATE
5 mm ROLLER .PUMP NOTOR
}SIDE PLATE
l,/ SNAPRING 13 x 1.9mm O-RING

Replace.
*SUB-VALVE
51 x 2.4 mm O-RING
Replace.
15.2x 2.4mm O-RING PUMPSEAL

Replace. Replace.
PUMPSEALSPAC€R
INLETJOINT .PUMP DRIVESHAFT
BALL BEARING
FLANGEBOLTS lnspectionand RePlacement,
11 N m 11.1kgf.m, seepage17-43
8 rbf.ftl
10 mm CIRCLIP
*FLOWCONTROI-VALVE
and Overhaul,
Inspection
se[ pasett.tz g
mm O-RING
seatuc/
4 --{;'rX!;' PULLEYNUT
6il N.m {6.5 kgf.m,
$ 47 tbf.frl
FI-OWCONTROLVALV€ CAP
49 N.m {5.0 kgt m,
36 rb{.ft)
J (cont'd)
17-41
PowerSteeringPump
Disassembly(cont'dl Inspection
' t . Drain
the fluid from the pump. Flow Control Valve:
2 . Hold the steering pump in a vise with soft jaws, 1. Checkthe tlow control valve for wear. burrs, and
hold the pulley with the specialtool, and remove other damage to the edges of the grooves in the
the pulleynut and pulley. vatve,
FLOW
CAUTION: Be careful not to damage the pump VALVE
CONTROL
housing with the iaws of the vise and extension bar.
UNIVERSALHOLDER
for
Check
damageto edges.
Inspectthe bore the flow control valve for scratches

or wear.
Slip the valve back in the pump, and checkthat it

moves in and out smoothly.
Loosenthe flow control valve cap with a hex wrench

and removeit.
4. Removethe O-ring,flow controlvalveand spring.
5. Removethe inletjoint and O-ring.
6. Removethe pump coverand pump coverseal.
7. Removethe outer side plate,pump cam ring, pump

rotor,pump vanes,side plateand O-rings.
lf OK, go on step 4; if not, replacethe pump as an
8. Removethe snap ring, then removethe sub-valve assembly.The flow control valve is not available
from the pump housing. separately.
9. Remove the circlip, then remove the pump drive 4. Attach a hose to the end of the valve as shown.
shaft by tappingthe shaft end with the plasticham-
mer.
VALVE
FLOWCONTROL TIOSE
10. Removethe pump sealspacerand pump seal.
17-4 2
I 5, Submergethe valve in a containerof power steer- Ball Bearing:
ing fluid or solvent.and blow in the hose.lf air bub-
bles leakthrough the valve at lessthan 98 kPa 1. Inspectthe ball bearingby rotatingthe outer race
(1.0kgf/cm' ,14.2psi),repairit as follows. slowly. lf any play or roughnessis felt, replacethe
ball bearing.
, AIR PRESSURE
? BALLBEARING
i-- POWERSTEERTNG
FLUIDor SOLVENT
Hold the bottom end of the valve with a open end

wrench.
7. Unscrewthe seat in the top end of the valve. and Removeand discardthe ball bearingusing a press
removeany shims,the reliefcheckball. reliefvalve as snown.
l./ and reliefvalvespring.
RELIEFVALVE
Installthenew ball bearingusinga pressas shown.
RELIEFCHECKBALL Ball Boaring Rsplaccmont:
{W-*"' Prcrt
SEAT
9 N.m
{0.9kgf'm, 6.5 lbt'ftl
RELIEFVALVE
SPRING
Clampthis end in
a openend wrench, FLOWCONTROLVALVE
8. Clean all the parts in solvent, dry them off, then

reassembleand retest the valve. lf the flow control
valve tests OK, reinstallit in the pump. lf the flow
control valve still leaksair, replacethe pump as an lnstallwith the
assembly.The flow control valve is not available red shielded side
separatelY. facing down.
NOTE: 11necessary,relief pressureis adjustedat NOTE:Supportthe innerrace

the factorv by adding shims under the check ball with the tool securely.
1., seat.lf you found shims in your valve,be sure you

reinstallas many as Youtook out.
17-43
PowerSteeringPump
Reassembly
1 . Align the pin of the sub-valvewith the oil passage Coat the pump cover seal and the cover bushing
in pump housing.and push down the sub-valve. with the power steeringfluid, then installthe pump
Installthesnap ring properly. coverseal into the groovein the pump cover.
OIL PASSAGE
Alignthe pin of lnstallthe outer side olateover the two rollers.
the oil passage. ROL1IR
OUTERSIDEPLATE
4.5 mm ROLLER
5 mm ROLLER
PUMP HOUSING
SNAPRING
Installthe new pump seal in the pump housingby

hand,then installthepump sealspacer.
NOTE: Insertthe pump seal with its grooved side

facingin. PUMPCOVER BUSHING
Positionthe pump drive shaft in the pump housing, 7. Set the pump cam ring over the two rollerswith the
" o " markon the cam ring upward.
then drive it in usinga specialtool as shown.
Installthe 40 mm circlip with its radiusedside fac-

ing out, 40 mm CIRCLIP
PUMPCAM RING
ATTACHMENT,
30 mm
d
BALL BEARING oRrvE
sHAFr
gf'uMP
/ffi\ ROI,IIR SET HO'"ES
f.\'vj
PUMPSEALSPACER
H
n,/
/:K
/ZA\.-- PUMPSEAL
V Reptace.
ROLl.ERS
17 -44
I 8 . Assemblepump rotor to the pump cover with the
't2. Coatthe O-ringwith power steeringfluid. and posi
" " " markson the rotor facingdown. tion it into the pump housing.
9 . Setthe 10vanesin the groovesin the rotor. Installthe pump cover assemblyin the pump hous-
tng.
NOTE:Be surethat the round ends ot the vanesare FI.ANGEEOLTS
in contactwith the slidingsurfaceof the cam ring. 20 N.m (2.0 kgf.m,
14 tbf.ft)
PUMPROTOR PUMPCOVER
ASSEMBLY
0 E 51 x 2.4mm
Replace.
gn
't4. C o a t t h e f l o w c o n t r o l v a l v e w i t h p o w e r s t e e r l n g
fluid.
15. lnstall the flow control valve and spring on the

1 0 . C o a t t h e O - r i n g w i t h p o w e r s t e e r i n gf l u i d , a n d pump housing.
installit into the groovesin the side plate.
1 6 . C o a t t h e O - r i n g w i t h p o w e r s t e e r i n gf l u i d , a n d
1 1 . Installthe side plateon the cam ring by aligningthe installit on the Jlowcontrolvalvecap.
rollerset holesin the side platewith the rollers.
1 7 . Installthe flow controlvalvecap on the pump hous-
r ing, and tighten it.
SIDE PLATE
E
15.2x 2,1 mm O-RING
Replace.
ROLIIR SETHOTT
SET HOI.Ê
FLOWCONTROL
VALVECAP
49 N.m (5.0 kgj m,
36 tbf.ft)
l , ROI.I.ERS
{cont'd)
17-45
PowerSteeringPump
(cont'dl
Reassembly
C o a t t h e O - r i n g w i t h p o w e r s t e e r i n gf l u i d , a n d 21. Holdthe pulleywith the specialtool,and tightenthe
installit into the groovesin the inletjoint. pulleynut.
Installthe inletjoint on the pump housing. PULLEYNUT

UNIVERSALHOLDER 64N.m{6.5kgf.m,
15.2x 2.4
Replace.
'11N.m (1.1kgt.m, -
8 |bnft) EI Checkthat the pump turns smoothlyby turning the
pulleyby hand.
I n s t a l lt h e p u l l e y a s s h o w n b e l o w , t h e n l o o s e l y
installthe pulley nut. Hold the steeringpump in a
vise with soft jaws.
CAUTION:Be car€fulnot io damagethe pump hous-

ing with the jaws ot the vise.
17-46
SteeringGearbox
Removal
)
NOTE:Usingsolventand a brush,wash any oil and dirt 7. Removethe cotter pin from the castle nut {'96 -'97
'00 modslsl and removethe nut.
off the valve body unit its lines.and the end if the gear- models)or nut ('98-
box. Blow dry with comPressed air.
1. Drainthe power steeringfluid as describedon page TIE.RODEND
2. Raisethe front of vehicle, and support it on safety

stands in the proper locations(seesection 11.
BALLJOINTREMOVER.
28 mm
3, Removethe front wheels. 07MAC- SLqI2|X)
4. Removethe driver'sairbagassembly,and steering

wheel(seepage17-35)
5. Bemovethe steeringjoint cover.
'98 - '00 mod.b:

NUT
COTTERPINS
Repl6ce.
8 . lnstallthe t0 mm hex nut on the balljoint.

Be surethat the 10 mm hex nut is flushwith the ball
joint pin end, or the threaded section of the ball
joint pin might be damagedby the specialtool.
NOTE:Removethe ball joint usingthe specialtool.

Refer to section 18 for how to use ths ball joint
remover.
9 . Seoaratethe tie-rodball joint and knuckleusingthe

6. Removethe steeringjoint lower bolt, and loosen specialtool.
the steeringjoint upper bolt. Disconnectthe steer-
ing joint by movingthe ioint towardthe column CAUnON: Avoid damaging tho ball ioint boot.
1 0 . Removethe left tie-rod end, then slide the rackall the

way to the right.
1 1 . Separatethe exhaust pipe A or TWC (seesection 9).
12. Disconnectthe shift linkage(seesection13 or section

14).
t J (cont'd)
17-47
SteeringGearbox
Removal{cont'dl
1 3 . Loosenthe 14 mm flare nut and disconnectthe feed 17. Removethe mountingbrackets.
line.
1 4 . Loosenthe adjustablehose clamp and disconnect

the returnhose.
t9. Loosenthe 16 mm flare nut and removethe return

hosejoint trom the valve body unit.
CAUTION: After disconnecting lhe hos6 and lin6.

plug or seal the hose and line with a pioca ol tapa
or equivalent to prevenl foreign matorials trom
entsring the valve body unit.
N O T E : D o n o t l o o s e nt h e c v l i n d e r l i n e A a n d
betweenthe valve body unit and cylinder.
ADJUSTABLE
HOSE
CLAMP
1 8 . Pull the steeringgearboxall the way down to clear

the pinionshaftfrom the bulkhead.then removethe
pinionshaftgrommet.
Move the steering gesrbox to right so the left rack

end clearsthe rearbeam,then tilt the left side down
to remove it from the vehicle,
CAUTION: Be careful not io bend or damage the

fagd ling and cylindsr lin99 whgn rgmoving thg
1 6 . Removethe stiffenerDlate. ggarbox,
NOTE: Some stiffener plate attaching bolts are also

used as gearboxmounting bolts.The gearboxwill
tilt to sidewhen theseboltsare removed.
STEERINGGEANEOX
17-48,
Disassembly
)
Steering Rack DisassemblY Holdthe steeringrackwith a wrench('98-'00 mod-
els: left end only), and unscrewthe rack end with
NOTE: anotherwrench.
r Beforedisassemble the gearbox,wash it off with sol
vent and a brush. CAUTION: Be caroful not to damage the rack 3ur-
. Do not dip sealsand O-ringsin solvent. faco whh the wrench.
1. Removethe steeringgearbox(seepage 17-47].. NOTE:'96 -'97 modelsis shown.
STEERINGRACK END
2. Removethe tie-rodend and locknut. LOCKWASHER
3. Removeair tube and cliPs.
STEERINGRACK
t )
Removethe boot bands and tie-rod clips Pull the Loosen the locknut, then remove the rack guide
bootsawayfrom the endsof the gearbox. screwand O-ring('96-'97 modelsonly)
7. Removethe springand the rackguidefrom the gear

housing.
BOOT
(|-, TIE.RODCLIP
{cont'd}
17 -49
SteeringGearbox
Disassembly(cont'd)
8. RemovecylinderlinesA and B from the gearbox. 11. Drill a 3 mm (0.12in) diameterhole approximatety
2.5 - 3.0 mm (0.10- 0.12 in) in depth in the staked
point on the cylinder.
cAunoN:
o Do nol allow metal shavings to onter the cylin.
der housing.
. After romoying iha cylinder end, remova any
bur6 at the staksd point.
Dcpthi 2,5 - 3.0 mm {0.10- 0.12in}
CYLINDERLINEg CYLINOCR
LINEA
Drain the fluid from the cylinderfittings by slowly CYUNDER

moving the steering rack back and forth,
1 0 . Removethe two flange bolts, then remove the valve

body unit from the gearbox. (See page 17-52for
valve body unit disassembly.)
VALVEBOOYUNIT 1 2 . H o l d t h e s t e e r i n g g e a r b o x u s i n g a C - c l a m pa s
FLANGEBOLT
snown.
'96 - '97
mod.ls:
32 mm SHIMS
98 - '00 modok:
WAVE WASHER
13. Loosenand removethe cvlinderend.
17-50
t 14. Assemblea 12 x 1.25mm flangenut onto a 12 x 175 18, Removethe 12 mm bolt and nut from the steering
mm grade 10flangebolt as shown. rack,
1 9 . R e m o v et h e c y l i n d e re n d s e a l f r o m t h e s t e e r i n g
N O T E :W r a p t h e t l a n g e p o r t i o n o f t h e b o l t w i t h racK.
vinyl tapeto protectthe cylinder. CYLINDER HOUSING
Replace.
J__--'- ,----)t'
| ,-----'" ,-,-'-'
| fiN\\ ----'
12,
BOLT
mm FLANGE | .Wl'----
t
VINYLTAPG {p/N 90i77 - SLo- 000} 12 mm FLANGENUT
I| ^--.'--4
-'4a
t5. Installthe flange bolt into the end of the steering
r a c k u n t i l i t b o t t o m s i n t h e h o l e ,t h e n b a c kt h e
flange bolt out
'll4 turn. Hold the flange bolt, and
A
Q)
ooY-----
* \
srerhtncnact
tightenthe flangenut againstthe rackby hand. 20. lnserta 24" long,3E" drive extensionand the spe-
1 6 . Installthe bearingseparatoron the gearboxhousing cialtool into the cylinderfrom the gearboxsrcle.
a5snown. NOTE: Make sure that the specialtool is securely
12 x 175 mm Ptess positionedon the backupring edges'
FLANGEBOLT CAUTION: Be caroful not damago to inner surfaco
of the cylinder housing with the specisltool'
BEARINGSEPARATOR 21. Set the gearboxin a press,then pressout the cYlin-
0 - 1112"I
der end sealand backupring from the gearbox,
t./ lCommerciallyavailablo)
GAUTION:
. Keepthe tool sttaight to avoid damagingthe cylin'
der wall. Checkth€ tool angls, and corr€st it if nec-
€ssary,whon rsmoving the cylinder snd seal.
. Uss a pross to removs tho cylinder end seal. Do
not try to removo ths seal by striking the tool h
will br€ak the backup ring. and the cylinder snd
s€alwill lemain in tho gearbox.
Pross
STEERINGRACK
CYLINDEREND SEAL
1 7 . Set the gearboxin a pressso the gear housingpoint

upward,then pressthe cylinderend seal and steer-
ing rackout of the gearbox BACKUPRING
NOTE:Hold the steeringrackto keep it from falling

CYLINDEREND SEAL
when pressedclear.
CAUTION:
CYLINDEREND SEAL
. Be carsful not damage to inn6l surfaceot the
REMOVERATTACHMENT
cylinder housing with the flange bolt.
1., . Do not place your lingers under th€ ste€ring
rack.
07NAD- SR3020A
(cont'd)
17-51
SteeringGearbox
(cont'dl
Disassembly
22. Carelullypry the pistonseal ring and O-ringoff the Valve Body Unii Disassembly
prslonrack.
23. Eeforeremovingthe valvehousing,applyvinyl tape
CAUTION| Be caletul not to damage the inside of to splinesof the pinionshaft.
seal ring groove and piston edges when removing
the sealrin9, 24. Separatethe valve housingfrom the pinion shaft/
valveusinga press.
VALVEHOUSING
Vinylt.pe
PINIONSHAFT
Replace.
Checkthe innerwall of the valve housingwherethe

seal ring slideswith your finger.lf there is a step in
t h e w a l l , t h e v a l v e h o u s i n gi s w o r n . R e p l a c et h e
valvehousing.
NOTE:
T h e r em a y b e t h e s l i d i n gm a r k sf r o m t h e s e a l
r i n g o n t h e w a l l o f t h e v a l v e h o u s i n g .R e p l a c e
the valvehousingonly if the wall is stepped.
When the valve housingis replaced,jnstallnew
shim(s)on the bearingsurfaceof the housingto
adjustthe thickness.
Checkthe inside of valve housing
whether the wall is stepped.
17-52
I 28. Usinga cutteror an equivalenttool, cut and remove
2 6 . C h e c kf o r w e a r . b u r r s a n d o t h e r d a m a g et o t h e
the lour seal ringsfrom the sleeve'
edgesof the groovesin the sleeve'
CAUTION: Be careful not to damage the edges of
NOTE:The pinion shaft and sleeveare a precision
the slgevs grooves and outer surface whsn lemov-
m a t c h e ds e t l f e i t h e rt h e p i n i o n s h a f t o r s l e e v e
ing the seal rings.
must be replaced,replaceboth partsas a set'
SLEEVESEALRINGS SLEEVE
Checkfor Peeloff or
damage.
29. Using a cutter or an equivalenttool, cut the valve

seal iing and O-ringat the groovethe pinion shaft'
27. Removethe circliPand Pinion shaft sleevefrom the
l./ pinionshaft.
Removethe valvesealring and O-ring'
CAUTION: Be careful not to damage the edges oI

the pinion shaft gloove and outer surface when
removing the valve seal ling and O-ring'
Cutting slot Posrtlon.
VALVESEALRING
Replace.
1., (cont'd)
-r t rt .<
l r -99

SteeringGearbox
Disassembly(cont'd)
30. Bemovethe valveoil sealand backupring {'96-'97
models)or wave washer('98-'00 models)from the
oinionshaft.
NOTE:
. Inspectthe ball bearing by rotating the outer race
slowly. lf there is any excessiveplay, replacethe
pinionshaftand sleeveas an assembly.
. The pinion shaft and sleeve are a precisefit; do
not intermix old and new pinion shaftsand
steeves.
BALLBEARING
'98- '(x) mod.lr:

WAVEWASHER Replace.
3 1 . Pressthe valve oil seal and roller bearing{'96 -,97
m o d e l s lo r b u s h i n g( ' 9 8 - ' 0 0 m o d e l s lo u t o f t h e
valve housing using a hydraulicpress and special
tool shown below.
NOTE: Do not use a hammer; it will damage the

specialtool.
'96 - '97 modob:

PILOTCOLLAR
07GAF- PH70100
VAI.VE OIL SEAL

Replace.
BOI.I"ERBEARING
Replace.
'96 - '00 mod.b:
PILOTCOLLAR
07GAF- PHtoroo
VALVEOII.SEAL
Replace.
BUSHING
Beplace.
17-54
Reassembly
)
NOTE: parts in a sol-
. clean the disassembled partswrth a solvent,and dry them with compressedair. Do not dip the rubber
vent.
. Alwaysreplacethe O-ringsand rubbersealswith new ones beforeassembly'
. Applythe recommendedpowersteeringfluid to the parts+ndicated in the assemblyprocedures'
o Do not a||owdust,dirt, or otherforeignmaterialsto enterthe power steeringsystem.
a Usethe appropriatespecial tools where necessary'
CYLINDERLINE A
FLANGEBOLTS
20 N.m (2.0kgt'm, 14lbf ftl
CYLINDERLINEB
VALVEHOUSING
FLARENUTS
28 N.m (2.7ksf m,20 lbf ftl
VALVEOILSEAL
Replace.
''*^'*-1$*€-/s6-,,mode,3:
--,
fitllTllli".",'r'o,.n,ft *---
EUSHING
Replace 'P'\-- .---- BEARING
..-------......
SLEEVESEAL RINGS ",a"a,,
SS
Replace. lss-, Replace.
"o.
CYLINDEREND SEAL
Xll,Y5"l'.--r...- gY------..r.u,
Replace. ,-f-..-S: ,96 _,9? models:
l./ BACKUP
Replace.
--€l€--------=-
- 'oo ,,iod"t., -s-'---------
-.-.-r_
_
ircriip'ii.rt'-
vALvE SEALR'NG
wAvEwAsHER i"pru"".
,
I CYLINDER
,
HOUSING
d
//
AJ
-\-
-\
O.RING
/ ,S-'..- --'\- ReDtace.
_\-j GEARHouslNG l.g
\ntonsrnrr
.,_-\ t\ F
s 97 models onlY:
S_.<---,tj-
)@OOD m\ n"prac".
CYLINDEREND SEAL
/'\N,."._
nrNG I
'98- 'oo
models:
-
RACKGUIDE
\
:scREw
I
O.RING
Replace.
.98- '00 models:
CYLINDEREND
69 N.m {?.0kgt'm,51 lbl'ft)
t J (cont'd)
17-55
SteeringGearbox
(cont'd)
Reassembly
Valve Body Unit Reassembly 8. Apply power steering fluid to the surface of the
v a l v e s e a l r i n g t h a t w a s i n s t a l l e do n t h e p i n i o n
1. Apply vinyl tape to the steppedportion of the pin- shaft.
ion shaft,and coatthe surfaceof the vinyl taoe with 9. Apply power steeringfluid to the insideof the spe-
the powersteeringfluid. cial tool. Set the largerdiameterend of the special
2. Installthe backup ring ('96 -'97 models)or wave tool overthe valveseal ring.
washer ('98 -'00 models)with its taperedside as 10. Move the specialtool up and down severaltimes to
shown below. makethe valvesealring fit in the pinionshaft.
3. Coat the inside surface of the new valve oil seal 11, Removethe soecialtool.
with powersteeringfluid. 12. Turnthe specialtool over,and set the smallerdiam-
4. Slidethe valve oil seal over the pinion shaft,being eter end of the specialtool over the valve seal ring.
carefulnot to damagethe sealinglip. Move the specialtool up and down severaltimes to
Vinyl t.po m a k et h e v a l v e s e a l r i n g f i t s n u g l y i n t h e p i n i o n
{Steppedponion} '96 - '97 models: shaft.
Tap6redposition.
PISTONSEALBING
BACKUP SIZINGTOOL
Grooveside. 07NAG - SR:togoA
ol
surethe springis 07NAG - SR3|X)00
seatodin the oil seal.
lip
'98 - '00
mod.b:
CAUTION: InstEllihe valve oil seal whh its groov.d

3ide tacing opposite tho boaring.
Apply vinyl tape to the splinesand steppedportion

of the shaft, and coat the surface of the vinyl tape
with the powersteeringfluid.
Fit the new O-ringin the grooveof the pinionshaft.
(g(m
Usethe larger diameter Makethe valvesealring
Then slide the new valve seal ring over the shaft end of the special fit snuglyin the pinion
tool first to make shaftusingthe otherend
and the groovein on the pinionshaft. the valve seal ring (smallerdiameterend)of
7. Removethe vinyl tapefrom the pinionshaft, fit in the pinion the specialtool.
shaft.
VALVESEALRIiIG
Replace.
Do not over-expand.
17-56
I 18. Apply power steeringfluid to the surfaceo{ the
pin-
Apply power steeringfluid to the surfaceof the spe- pinion shaft
ion shaft.Assemblethe sleeveover the
cialtool. Setthe new sealrings over the specialtool
f r o m t h e s m a l l e r d i a m e t e re n d o f t h e t o o l , a n d b y a l i g n i n gt h e l o c a t i n gp i n o n t h e i n s i d eo f t h e
expandthe seal rings. Do two rings at a time from sleevewith the cutout in the shaft.Then installthe
eachend of the sleeve. new circlipsecurelyin the pinionshaftgroove'
NOTE; NOTE:
. Do not over-expand the sealring. Installtheresin B e c a r e f u l n o t t o d a m a g et h e v a l v e s e a l r i n g
seal rings with care so as not to damagethem' when insertingthe sleeve.
After installation,be sure to contract the seal Installthecirclipwith its radiusedsidetowardthe
rings usingthe specialtool(sizingtool). sleeve.
. There are two types of sleeveseal rings: black
and brown. Do not mix the different types of
sleevesealringsas they are not compatible
1 4 . Setthe specialtool in the groovesin the sleeve,and

set eachring in eachgroovesecurely.
NOTE: After installation,compressthe seal rings

with your fingerstemPorarilY
BALLJOINT BOOI CLIPGUIDE

07S7,1-SA50800
SLEEVE
'19. Apply power steeringfluid to the seal ring lip of the

valveoil seal.then installthe sealin the valve hous-
i n g u s i n g a h y d r a u l i cp r e s s a n d s p e c i a lt o o l s a s
shown.
CAUTION: Install the valve oil seal with its grooved

side facing the tool.
15. Apply power steeringfluid to the seal rings on the ATTACHMENT.
sleeve,and to the entire insidesurfaceof the spe- 32x35mm
cialtool. Pre3s 0774.6- q)101(x)
16. lnsertthe sleeveinto the specialtoolslowly'
1 7 . M o v e t h e s l e e v ee a c h d i r e c t i o ns e v e r a lt i m e s t o
makethe sealringssnuglyfit in the sleeve' DRIVER
I
07749- 0010000
NOTE: Be surethat the seal ringsare not turned uP.
fr SITEVESEALRING
SIZINGTOOL
0797a- SA5020A
07974- SA50200
or
VALVEOIL SEAL
Replace.
Makesurethe
springis in the
J oil seal. (cont'd)
17-57
SteeringGearbox
(cont'd)
Reassembly
20. Pressthe new bearing ('96 - '97 models) or new 2 4 . P r e s st h e p i n i o n s h a f t / s l e e v eu s i n g a h y d r a u l i c
bushing ('98 -'00 models)into the valve housing pressas shown.
usinga hydraulicpressand specialtool as shown,
N O T E : C h e c kt h a t t h e p i n i o n s h a f v s l e e v et u r n s
NOTE:Placethe rollerbearing('96-'97 models)on smoothlyby turningthe pinionshaft.
the valve housingwith the stampedletterfacingup
towardsthe valveside.
DRIVER
Pr033 ATTACHMENT,
077itg-001tXlOO
+ 3:Ix35mm
07746- 0010,t(x)
'96 - '97 models:

ROLLERBEARING
Letterstampedtace
upward.
'98 - '00 modob:
?/_vusHrNG
['---v-lt
\4)
21. Apply vinyl tape to the pinion shaft.then coat the
vinyltape with power steeringfluid.
Sealing lip face.

VALVEOIL SEAL
VALVEHOUSING
PINION
SLEEVESEALRINGS
E
Replace.
8e surethat the
sealnngs are not
turnedup, then
install.
22. Insertthe pinionshaft into the valvehousino.
CAUTION: Be careful noi to damage th€ valve seal

rings.
23. Removethe vinyltapefrom the pinionshaft.
17-5A
)
31. Wrap vinyl tape aroundthe rackteeth and rackend
Steering RackReassembly
edges,then coat the surfaceof the tape with the
powersteeringfluid
25. Coatthe pistonseal ring guide with power steering
NOTE: Make sure that the vinyl tape is wrapped
fluid,then slideit onto the rack,big end first'
carefullyso that thereis no steppedportion
26. Positionthe new O-ringand new pistonsealrlng on
the specialtool, then slide them down toward the
big end of the tool
NOTE:
. Do not over expand the resin seal rings lnstali
the resin ;eal rings with care so as not to dam-
age them. After installation,be sure to contract
the seal ring usingthe specialtool(sizingtool)
. Replacethe piston'sO-ringand sealring as a set'
27. Pull the O-ringoff into the piston groove,then pull

the pistonsealring off into the pistongrooveon top
Coatthe insidesurfaceof the new cylinderend seal
ol the O-ring
with power steeringfluid.
Installthe cylinderend seal onto the steeringrack
PISTON with its groovedsidetowardthe piston.
CAUTION:When installingthe cylinder end seal,
be caieful not damagethe sealing lip face of tho
seal with the edgss or teeth of th€ ste€ring rack'
PISTONSEALRING
GUIDE
07GAG- SD4O10Aol CYLINDEREND SEAL
07GAG- SD,ol(xt
Coatthe piston seal ring and the insideof the spe-

cialtoolwith powersteeringfluid.
Carefullyslide the tool onto the rack and over the

pistonsealring.
Move the specialtool back and forth severaltimes

to makethe pistonsealring fit snuglyin the piston'
PISTON Make sure the

Replace. sPring is in the cylinder
end soal
E
Removethe vinyl tapefrom the steeringrack
NOTE:Removeany residueoftape adhesive
(cont'dl
17-59
SteeringGearbox
Reassembly{cont'd)
3 5 . I n s t a l lt h e n e w b a c k u pr i n g o n t h e s t e e r i n gr a c k , 37. Installthe flange bolt into the end of the steerino
then placethe cylinderend sealto piston. r a c k u n t i l i t b o t t o m s i n t h e h o l e ,t h e n b a c kt h l
f l a n g e b o l t o u t 1 / 4t u r n . H o l d t h e f l a n g eb o l t a n d
BACKUPRING tightenthe flangenut againstthe rackby hand.
38. Installthe cylinderend seal into the bottom of the

c y l i n d e rb y p r e s s i n go n t h e b o l t w i t h a p r e s sa s
shown.
CAUTION: Do not push on the boh with excessive

force as it may damage tho cylinder end seal.
Preas
12 x 175mm FLANGEBOLT
{P/N 90177- SLo - 000}
36. Greasethe steeringrackteeth,then Insenthe steer-
12 mm FLANGENUT
ing .ack into the gear housing.
CAUTION: Be careful not to damage to inner sur-

face of the cylindsr housing with the rack edges.
?q R e m o v et h e f l a n g e b o l t . a n d c e n t e rt h e s t e e r i n g
rack.
W r a p v i n y l t a p e a r o u n dt h e r a c k e n d e d g e s .a n d
coatthe surfaceof the tape with the power steering
fluid.
NOTE: Make sure that the vinyl tape rs wrapped

carefully so that there is no stepped portion.
17-60
)
46. C o a t t h e i n s i d es u r f a c eo f t h e c y l i n d e re n d w i t h
4 1 . Coatthe insidesurfaceof the new cylinderend seal
power steeringfluid,then installthecylinderend by
with power steeringfluid.
screwingit into the cylinderhousang.
Installthe cylinderend seal onto the steeringrack
4 7 . Removethe C-clampfrom the steeringgearbox'
with its groovedsidetowardthe piston'
After tighteningthe cylinderend' stakethe point of
Pushin the cylinderend sealwith your finger' -'00
t h e c y l i n d e rh o u s i n gs h o w n b e l o w F o r ' 9 8
modelsgo to step51.
CAUTION:When installing the cylinder end sesl'
be carelul not damage the sealing face ot the seal
NOTE: Stakethe cylinder in the position opposite
with the threads and burrs at the staked position oI
from where the stake was removed during disas-
the cylinder housing.
semoly.
tr CYLINDES
Replace.
ENDSEAL
Makesurethe sPring
Stake point. Depth: 1 0 mm (0.04in)
end seal
is in the cylincler
CYLINDEREND
SEAL
Be carefulnot to damage
the bushingwhen inserting
Removethe vinyl tapefrom the steeringrack' the cylinderend.
-'97 model only)'
49. Selectthe 32 mm shim(s)('96
NOTE:Removeany residueoftape adhesive
N O T E :O n l y r e i n s t a ltl h e o r i g i n a l3 2 m m s h i m ( s )
Holdthe steeringgearboxusinga C-clampas shown'
when the steeringgearboxis reassembledwithout
replacingthe pinionshatt,valve housing,and gear
C-CLAMP: box housingwith new ones.
l f t h e p i n i o n s h a f t , v a l v e h o u s i n g ,a n d g e a r b o x
housingare replaced,selectthe new shim{s)as fol-
lows.
GEARBOX
Shim selection:
a. Set the four 32 mm shims on the bearingsurfaceof
t h e g e a r b o xh o u s i n g .T o t a l t h i c k n e s so f t h e f o u r
shimsshouldequalno more than 0 70 mm'
Shim set: four 32 mm shims (Thickness: 010 mm'
0.15mm, 0.20mm, 0.25mm respectivelyl
CAUTION: Th€ four 32 mm shims do not have

thickness identification marks Measure the thick-
ness of each shim using a micrometsr, and mark
the shim lor identification.
l-, (cont'd)
17-61
SteeringGearbox
(cont'd)
Reassembly
b. I n s t a l lt h e v a l v e b o d y u n i t o n t h e g e a r b o x ,a n d Example:
tighten the flange bolts to the specifiedtorque. Measurementis 0.28mm (0.011in):
VALVEBODYUNTT FLANGEBOLT 0.70- O.28= 0.42mm (0.028- 0.011= O.Ot7inl
20 N.m {2.0ksl.m, 14lbI.ftl
The selectedshims should be 0.28 mm lO.OtOin) and
0.15mm {0.006in} in thickness.
lf the r€quired shim thicknessis 0.10 mm or less, no

shims are necessarv.
50. Sot the selected32 mm shims (,96 - ,97 models

only) on the bearingsurfaceofthe gearbox housing.
FLANGEBOLT
20N.m12.0ksf.m,1l lbtftl
VALVEBODYUNIT
O-RING
Replace.
Measurethe clearancebetween the gearbox and
valvebody unit usinga feelergaugeas shown. -A-l
NOTE:Measurethe clearanceat the point midway
betweenthe two mounting bolts.
'96 - 37 modsl3
only:
32 mm SHIMS
{S.loctod numb.r of
3him!l
NEEDLEBEARING
-R1
5 1 . Coat ths new O-ring with grease,and carefully fit it
on the valvehousing.
Apply greaseto the needlebearingin the gearbox

housing.
D e t e r m i n et h e r e q u i r e dt h i c k n e s so f t h e 3 2 m m EA Installthe valve body unit on the gearboxhousing

shims by subtractingthe clearanceobtainedin the by engagingthe g€ars.
step "c" from the total thicknessof the four shims.
( T o t a lt h i c k n e s so f t h e 4 s h i m s )- ( C l e a r a n c e=) NOTE: Note the valve body unit installationposi-
Requiredthicknessof the shims tion (directionof line connection).
NOTE:Selectthe shims so that the total thickness 54. Tighten the flange bolts to the specifiedtorque.
is closeto. but lessthan,the requiredthickness,
17-62
)
55. InstallthecylinderlinesA and B. 6 0 , l n s t a l lt h e n e w l o c k w a s h e ri n t h e g r o o v e i n t h e
NOTE: steeringrack.
. C l e a nt h e j o i n t s o f t h e c y l i n d e rl i n e s A a n d B 61. Screweachrackends into the rack'
-'00 mod-
thoroughly. The joints must be free of foreign 62. Holdthe steeringrackwith a wrench('98
els:left end onlY),and tightenthe rack ends'
materlal.
. Installthe cylinderlinesA and B by tightingthe CAUTION: Bo cateful nol to damage ihe rack sur-
flare nuts by hand first, then tighten the flare face with the wranch.
'96 -'97 model is shown.
nutsto the specifiedtorque. NOTE:
STEERING RACKEND
17 N.m {1.7 kgt'm, 12 lbl.ft) 54N'm t5 5 kgtm' 40lbl'ft)
LOCKWASHER
28 N.m (2.7 kgf m,20 lbf ftl
STEERINGRACK
CYLINDERLINE8 CYLINDERLINEA
56. Greasethe sliding surface of the rack guide, and

installit onto the gear housing
'97 models: After tighteningthe rack ends, stakethe four sec-
5 7 . 36 -
Apply a thin coat of greaseto the new O-ring,and tions of lockwasherwith a drift and a mallet.
installit on the rackguidescrew. Placethe wood block on the presstable. then set
38 - '00 models: the lock washer section of the rack end on the
Remove the old sealant off of the threaded section, wood block securelY.
then apply new sealantall aroundthe threads Be sure the tool is alignedwith the flst sections
of the steeringrackend belorepressing.
58. Installthe spring, rack guide screw and locknuton
the gear housing. Stake the lock washer in the center ot the flat
Adjustthe rackguide screw(seepage17-33)' section of the steering rack end.
NOTE:After adjusting,checkthat the rack moves
smoothlyby slidingthe rackright and left'
'1 l:.
r 1
-Gl
O.BING
Replace.
NOTE:Thisdrift hasa flat,

to preventpuncturing
WOODENBLOCK
l / LOCKNUTS
{cont'd}
17-63
SteeringGearbox
(cont'dl
Reassembly
64. Apply greaseto the circumferenceof the rack end 67. Adjust the air hose fitting positionof the boots bv
housing. turningit as shown below.
LEFTBOOT RIGHTBOOT
(Viewedfrom the {Viewedfrom the
left side) right side)
RACKEND GROOVE
=^.
#-q!:s!!H
SILICONEGREASE
AIR HOSEFITTING
A p p l y a l i g h t c o a t o f s i l i c o n eg r e a s et o t h e b o o t
grooveson the rackends.
66. lnstall the boots in the rack end with the tie-rod
clips. Install new boot bands on the boot, and bend both
sets of locking tabs.
NOTE:Installthe boots with the rack in the straight
ahead position (right and left tie-rodsare equal in CAUTION: Stlke ths band locking tabs firmly.
length).
RACK END
NOTE: Wipe the greaseoff

the threadsection.
Lightlytap on the doubled-overportionsto reduce

their height.
Slide the rack right and left to be certainthat the

boots are not deformed or twisted.
TIE.RODCLIP
17-64
lnstallation
7 1 . C o n n e c tt h e a i r t u b e b e t w e e nt h e r i g h t a n d l e f t CAUTION: Be carelul not to bend or damage the feed
boot. line and cylinder lines when installing the gearbox'
lnstallthe clipson the cylinderlines'then clampthe 1, Beforeinstallingthe gearbox,slide the rack all the
air tube with the cliPs. way to right.
2. Installthe mounting cushion on the steeringgear-

DOX.
CYLINDERLINE A
Installthe pinionshaftgrommet,then insertthe pin-
ion shaft up throughthe bulkhead.
NOTE:Align the notch in the pinion shaft grommet

with the tab on the valvehousing.
CLIP
l./
I n s t a l lt h e m o u n t i n g b r a c k e to v e r t h e m o u n t t n g
cushion,then installtwogearboxmountingbolts'
MOUNTINGBRACKET
cusHroN
39 N.m
(4.0kgj m, 29 lbtftl
NOTE:Installthe bracket
l-, with the arrow Pornllng
towardthe front. (cont'd)
17-65
SteeringGearbox
(cont'dl
Installation
5. I n s t a l l t h e s t i f f e n e rp l a t e w i t h t h e t w o g e a r b o x 9 . Centerthe steeringrackwithin its stroke.
mountingboltsand stiffenerplateaftachingbolts.
1 0 . Slip the lower end of the steeringjoint onto the pin-
CAUTION: Be sure the air tube is not caught or ion shaft (lineup the bolt holewith the groove
pinched by stiffener plate, aroundthe shaft),and tightenthe upper and lower
steeringjoint bolt.
N O T E :I n s t a l lt h e b o l t s l o o s e l yf i r s t , t h e n t i g h t e n
them securely. NOTE:
. Connectthe steeringshaft and pinion with the
cablereeland steeringrackcentered.
. Be surethat the lower steeringjoint bolt is securely
in the groovein the steeringgearboxpinion.
. lf the steeringwheel and rack are not centered,
r e p o s i t i o nt h e s e r r a t i o n sa t l o w e r e n d o f t h e
steeringjoint.
STEERING JOINT
UPPERBOLT
22 N.m (2.2kgf.m,
ATTACHINGAOLTS 16 tbt.ftl
MOUNTINGBOLTS
(} N.m (4.a kgt m, 32 lbf.ftl
PINIONSHAFT
6. Installthe returnhosejoint by tighteningthe l6 mm
f l a r en u t .
7. Connectthe relurn hose securely,and tighten the

a d j u s t a b l eh o s e c l a m p f r o m t h e e n g i n ec o m p a r t -
ment.
8. C o n n e ctth e f e e d l i n e a n d t i g h t e nt h e 1 4 m m f l a r e Groove,
nut.
STEERINGJOINT
NOTE:Makesure that there is no interference LOWERBOLT
betweenthe fluid lines,the rear beam or any other 22 N.m (2.2kgt.m,16lbtttl
parts.
ADJUSTABLEHOSE 16 mm FLARENUT
CLAMP 28 N.m {2.9 ksl.m. 20 lbf.ft)
(seepage17-39) 1 1 .Centerthe cable reel by first rotating it clockwise
u n t i l i t s t o p s .T h e n r o t a t ei t c o u n t e r c l o c k w i s e
RETURN (approximatelytwo turns) until the arrow mark on
the label points straight up. Reinstallthe steering
wheel (seepage17 35).
1a mm FLARENUT
37 N.m (3.8kg{.m,27 lbt.ftl
17-66
)
12, Installthe steeringjoint coverwith the clampsand a 1 4 . Installthe exhaustpipeA or TWC (seesection9).
clrp.
1 5 . Connectthe shift linkage(seesection13 or section
14).
1 6 . lnstallthe front wheels
1 7 . Fill the systemwith power steeringfluid, and bleed

air from the system(seepage17-331
1 8 . After installation, performthe followingchecks

. S t a r t t h e e n g i n e ,a l l o w i t t o i d l e , a n d t u r n t h e
steeringwheel from lock-tolockseveraltimes to
warm up the fluid. Checkthe gearboxfor leaks
(seepage17-39).
. Adjustthe front toe (seesection18).
1? Reconnect the tie-rodendsto the steeringknuckles, . Checkthe steeringwheel spokeangle.Adjust by
tightenthe castlenut ('96-'97 models)or nut ('98
- turningthe right and lefttie-rods,if necessary.
'OOmodels)to the specifiedtorque,and installnew
cotter plns. NOTE:Turn the right and lefttie-rodsequallv
NOTE: Before connectingthe tie-rod ends, wipe off

any greasecontaminationfrom the ball joint tapered
sectionandthreads.
t r CAUTION: Torquo the castle nut to the lower torque

sp€cification, then tighten it only tar enough to align
the slot with the pin hole. Do not align the nut by
loosening{,96-'97 modelsonly).
NE-RODEND
COTTERPINS
Replace.
On reassembly,bend
\ the cotterPin6s shown.
'96 -'97 models: '98 -'00 mod€ls:
CASTLENUT NUT
40 - a8 N'm &l N.m
(4.0- 4.8 kgf'm, {a.5kgf'm,33lbl'ftl
29 - 35 lbf.ftl
(l-,
17-67
Balljoint Boot Replacement
'96 - '97 models: '98 - '00
models:
1. Removethe boot set ring and the boot. CAUTION:Do not contaminatothe boot installation sec-
tion with grease.
CAUTION:Do not contaminatethe boot installa.
tion section with grsase. 1. Removethe boot from the tie-rodend, and wiDethe
old greaseoff the ball pin.
2. Packthe interiorof the boot and lip with grease.
2. Packthe lower area ofthe ball pin with fresh grease.
3. Wipe the greaseoff the sliding surfaceof the ball
pin,then packthe lower areawith freshgrease. 3. Packthe interiorof the new boot and liD with fresh
grease.
CAUTION:
. Keep greaseoff the boot installation seciion and CAUTION:
the tapered s€ction ot the ball pin. . Keop groasc ott tho boot installalion sestion and
. Do not allow dust, dirt, or oth6r foreign materi- th. iapored s.ction if th€ ball pin.
als to 6nt8r the boot. . Do not allow dust. dirt, or other foreign materials
LIP EALLPIN TAPERED
to entor tho boot.
SECTION
Wipe off the grease. LtP .6r
J_/
ru
-6lr BOOT INSTALLA
SECTION
BOOTINSTALLATION
SECTION Wipe off the gr€ase,
SECTION
Wipeoff the grease
Wipe off the grease.
4. Installthe boot in the grooveof the boot installation
sectionsecurely,then bleedthe air from the boot.
Installthe new boot usingthe specialtool as shown
ADJUSTINGBOLT below.
Adjustthe depth
by turningthe bolt.
NOTE: The boot must not be a gap atthe boot instal
lation sections.
FRONTHUB
DIS/ASSEMBLYTOOL
07965 - SA5o500
SETRING
Adjust the specialtool with the adjustingbolt until

the end of the tool aligns with the groove on the
boot. Slidethe set ring over the tool and into posi-
UOn.
CAUTION: After installing the boot, qhsck the ball CAUTION: Aftor installing the boot, chock the batl
pin tapered section for grease contamination and pin tapgred section tor grgase cortamination. and
wipe it it necGsary. wipe it it n€ces3ary.
17-68
Suspension
SpecialTools 18-2
............. Front Damper
ComponentLocations Removal 18-17
.................
lndex ,,.............. ......f8-3 Disassembly/1nspection 18-18
..................
Wheel Alignment Reassembly ...........
18-19
Caster.............. .......18-4 lnstallation 18-19
.............
Camber ..................
l8-4 RearSuspension
Front Toe Inspection/ SuspensionArms Replacement
Adiustment ........18-5 ('96- 99 models)....................,.....
18-21
RearToe lnspection/ SuspensionArms Replacement
Adiustment ........18-5 ('992D Si and Si-Rmodels) ........1A-22
TurningAngleInspection................ 18-6 Hub BearingUnit Replacement......18-23
Wheel/HubInspection UpperArm Eushing
l8-7
BearingEnd P|ay.............................. Replacement .....18-25
) .......18-7 RearDamper
WheelRunout
Front Suspension Removal .................
18-26
SuspensionArms Replacement Disassembly/|nspection .....1A-27
.............
('96- 99 modelsl..........................
18-8 Reassembly ...........
18-28
SuspensionArms Replacement lnstallation 18-29
.............
('992D Si and Si-Rmodels) ........18-9
Knuckle/HubReplacement............. 18-10
Lower Ball Joint Replacement.......18-16
BallJoint Boot Replacement ..........
18-17
l r

SpecialTools
Ref. No. Tool Numbor Description Oty PageReteronc€
o 07GAF- SE00200 Hub AssemblyGuideAttachment ,| tdtc

07GAF- SE00401 Hub DivAssemblyBase 1 1 8 -1 4
€) 07GAG- SD40700 BallJoint BootClip Guide 1 18-17
@ 07JAF- SH201l0 Hub Dis/Assembly Pilot,38 mm 1 1 8 -1 4
07JAF- SH20120 Hub Dis/Assembly Shaft,22.4x25.4 mm 1 1 8 -1 4
\9 07JAF- SH20200 BallJoint RemoverBase 1 18-16
o 07MAC- S100200 BallJoint Remover,2Smm 1 1 8 - 1 21, 3
@ 07746- 0010500 Attachment,62 x 68 mm 1 18-14
aa\ 07749- 0010000 Driver 1 1 8 -1 4
@ 07947- 6340201 Driver Attachment 1 1 8 -1 5
o 07965- SB00100 EallJoint Remover/lnstaller 1 1 8 -1 6
@ 07965- 5800200 BallJoint InstallerBase 1 1 8 -1 6
@ 07965- SD90100 SupportBase I 18-15
@ 07974- SA50700 BallJoint BootClip Guide 1 1 8 - 1 61, 7
o @ @.@ @
o @
1a-2
ComponentLocations
lndex
)
W h e e l A l i g n m e n t ,p a g e l 8 4
Front Suspension:
FBONTDAMPER
. Removal,page18-17
. Disassembly/lnspection,
page18-18 UPPERARM
' Replscement,
page18-8
. Reassembly, page18'19
. Installation,
page18-19
KNUCKLE/HUB
. Replacement,
page18'10
. WheelBearingReplacement,
page18-14 STABILIZERBAR
. LowerEallJointReplacement,
page18-16 ' Replacement,
page18-8
LOWERARM
. Replacement,
Page18-8
Rear Suspsnsion:
REARDAMPEB
. Removai.page18-26
. Disassembly/lnspection,
page 18-27
. Feassembly, page lS-28
. Installation,
page18-29
UPPERARM
' Replacement,
page18 20
LOWERARM
. Replacement,page 18-20
ARM TRAILINGARM
l-, . Feplacement,
page18 20 ' Replacement,
page18-20
18-3
WheelAlignment
Caster
N O T E :F o r p r o p e ri n s p e c t i o n / a d j u s t m eonf t h e w h e e l
alignmentcheckand adjustthe following beforecheck-
Camber
lnspection
,f,
i n gt h e a l i g n m e n t . N O T E :U s e c o m m e r c i a l l y - a v a i l a b co l em p u t e r i z efdo u r
w h e e l a l i g n m e n te q u i p m e n t o m e a s u r ew h e e l a l i g n -
. Checkthat the suspensionis not modified. m e n t ( c a s t e rc, a m b e r ,t o e , a n d t u r n i n ga n g l e ) .F o l l o w
. Checkthe tire sizeand tire pressure. the equipmentmanufacturer's instructions.
. Checkthe runoutof the wheelsand tires.
. Checkthe suspensionball ioints.{Hold a wheel with 1 . C h e c kt h e c a m b e ra n g l e .
your hands and move it up and down and right and
leftto checkfor wobbling.) Camberangle:
Front: 0'00' j 1"
Rear:-1"11"
2. lf out ol specification,checkfor bent or damaged

suspensron components.
Inspection
N O T E :U s e c o m m e r c ilal y - a v a i l a b lceo m p u t e r i z efdo u r
m e n t { c a s t e rc. a m b e r ,t o e , a n d t u r n i n ga n g l e ) .F o l l o w
the equiDmentmanufacturer's instructions.
1 . Checkthe casterangle.
Casterangle: 1',10'I 1'
2. lf out of specification,checkfor bent or damaged

suspensron components.
18-4
Front Toe Inspection/Adiustment RearToe Inspection/Adiustment
N O T E :U s e c o m m e r c i a l l y - a v a i l a bc loem p u t e r i z efdo u r N O T E :U s e c o m m e r c i a l l y - a v a i l a b co l em p u t e r j z e Ido u r
w h e e l a l i g n m e n te q u i p m e n t o m e a s u r ew h e e l a l i g n - w h e e l a l i g n m e n te q u j p m e n t o m e a s u r ew h e e l a l i g n -
m e n t ( c a s t e rc, a m b e r ,t o e , a n d t u r n i n g a n g l e ) .F o l l o w m e n t ( c a s t e rc, a m b e r ,t o e , a n d t u r n i n ga n g l e ) .F o l l o w
the equipmentmanufacturer's instructions. the equipmentmanufacturer's instructions.
1. Checkthe tire pressure. 1. R e l e a spea r k i n gb r a k e .
Centersteeringwheel spokes. NOTE:

a M e a s u r ed i f f e r e n c ei n t o e m e a s u r e m e n tw
slth
? C h e c kt h e t o e w i t h t h e w h e e l s p o i n t e d s t r a i g h t the wheelspointedstraightahead.
ah e a d . . if the parkingbrakeis engaged,you may get an
incorrectreadang,
Fronttoe: lN 1 1 2 mm llN l/16 r 1/16 inl
Reartoe-in:2 11mm ttltollllS int
- lf adjustmentis required,go on to step 4.
- lf adjustmentis required,go to step2.
- lf no adjustmentis required,remove alignment
equrpmenr. - lf no adjustmentis required,remove alignment
equipment.
4. Loosenthe tie-rod locknuts,and turn both tie-rods
in the same directionuntil the front wheels are in 2. Beforeadjustment,note the locationsof adiusting
straightaheadposition. boltson the right and left compensatorarms
Loosenthe adjustingbolts, and slide the compen

TIE.ROD LOCKNUT satorarm in or out. as shown,to adjustthe toe
'14x 1.5mm
4,1N.m {4.5 kgf.m,33 lb{.ft)
t J ADJUSTINGBOLT
10 x 1.25mm
64 N.m 16.5ksf m, 47 lbtft)
In ARM
CoMPENSAToR
Turn both tie-rodsequally until the toe readangon
the turningradiusgaugeis correct. 4. Tightenthe adiustingbolts
6. After adjusting,tightenthe tie-rodlocknuts. . Example:

A f t e r t h e r e a r t o e i n s p e c t i o n t, h e w h e e l i s 2 m m
NOTE:Repositionthe tie-rodboot if it is twistedor (0.08in) out of the specification.
displaced. - M o v e t h e a r m s o t h e a d j u s f i n gb o l t m o v e s 2 m m
(0.08in) inwardtrom the positionrecordedbeforethe
adjustment.
- The distancethe adjustingbolt is moved should be
equalto the amountout-of-specification.
18-5
WheelAlignment
TurningAngle Inspection
N O T E rU s e c o m m e r c i a l l y - a v a i l a b co l em p u t e r i z e fdo u r
m e n t ( c a s t e rc, a m b e r ,t o e , a n d t u r n i n ga n g l e ) .F o l l o w
the equipmentmanufacturer's instructions.
'1. Turn
t h e w h e e l r i g h t a n d l e f t w h i l e a p p l y i n gt h e
b r a k e ,a n d m e a s u r et h e t u r n i n g a n g l e o f b o t h
wneets.
Turningangle:
lnward wheel: 39'50'
Outwald wheel (referencel:33'10'
2. l f t h e t u r n i n g a n g l e is not within the specifications,

c h e c k f o r b e n t o r d am a g e d s u s p e n s i o nc o m p o -
nents,
18-6
Wheel/HubInspection
BearingEnd Play WheelRunout
\
1. Raisethe vehicleoff the ground,and suppon it wjth 1. Raisethe vehicleoff the ground,and supportit with
safetystandsin the properlocations(seesection1). safetystandsin the properlocations(seesectionI I
2. Removethe wheels,then reinstallthewheel nuts 2. Checkfor bent or deformedwheels.
3. Attachthe dial gaugeas shown. 3. Attachthe dial gaugeas shown.
4. N4easurethe bearingend play by movingthe disc in 4. Measurethe wheel runoutby turningthe wheel.
or outward.
Front and RearWheel Axisl Runout:
Front/R€ar: Standard:
Standard:0 - 0.05mm l0 - 0.002inl Steel Whoel: 0 - 1.0 mm (0 - 0.0,1inl
Aluminum Wheel: 0 - 0.7 mm (o - 0.03 in)
ServicaLimit: 2.0 mm (0.08inl
t./
Measureend playat
hub flange.
Front and RearWheel Radill Runout:
Standard:
Bear: Steol Wheel: 0 - 1.0 mm (0 - 0.04 in)
AluminumWheol:0 - 0.7 mm (0 - 0.03in)
ServiceLimit: 1.5mm {0.06in}
M e a s u r e e n d P l a Ya t c e n t e r o f
the hub cap.
lf the wheel runout is more than the servicelimit,

l J lf the bearingend play measurementis more than
the standard,replacethe wheelbearing. replacethe wheel.
1A-7
FrontSuspension
('96- 99 models)
SuspensionArms Replacement
CAUTION:
. Replacethe selt-lockingnuts after removal.
. The vehicle should be on the ground betore any bolts or nuts connectedto rubber mounts or bushings are tightened.
NOTE:
. Wipe off any dirt, oil or greaseon the threadsbeforetighteningthe fasteners.
. The right and left damper forks are not interchangeable. The left damper fork is markedwith "AL" while the right
damperfork is markedwith "AR'
. The right and left upperarmsare not interchangeable. The left upperarm is markedwith "SO1-L"while the right upper
arm is markedwith "SOl-R".
. Beforetighteningthe upperand lower mountingnuts on the stabilizerlink,adjustthe locationof the link with the sus-
pensionundervehicleload.
. When installingthe radiusarm washers,the "FR" markfacesthe front ofthe vehicle.
. After installingthe suspensionarm, checkthe front wheelalignment,and adjustif necessary (seepage18-4).
FLANGEBOLTS
1 0x 1 . 2 5m m
54 N.m 15.5kgl.m,
40 tbf.ftl
BALLJOINT BOOT
STAEILIZER END . C h e c kf o r d e t e r i o r a t i o n a n d d a m a g e .
RUBBER BUSHING . S e e p a g e 1 8 - 1 6f o r b o o t r e p l a c e m e n t .
Checkfor deterioration - ---\--
-\
and damage,
STABILIZER BAR
FLANGEBOLT Checkfor bendingand damage.
1 4x 1 . 5m m /)l
103N.m{10.5kg{.m,. t,t,,"-iV
,/4,
76lb{.ft) \
FLANGEBOLT-
v:\
;iffillr-"-
ilHitffi*::,"*" LOWERARM
Checkfor
c
Jl
o.'----------- 1 4x 1 . 5m m
da TT Replace.
and damaoe, 83 N.m {8.5kgf.m, 61 lbf.ftl
1 { x 1 . 5m m
89 N.m {9.1 kgt m. 66 lbtft)
-6; DAMPERFORK
Checkfor damage.
SILICONEGREASE
RUBBERBUSHING
FLANGEBOLT
10x 1.25mm
SELF-LOCKING NUT I x 1.25 € N.m {4.6 kgt m.
22 N.m (2.2kg{.m, 16lbf.ftl 32 tbf.ft)
Replace.
SELF-LOCKING NUT
12x 1.25mm
Replace.
6it N m {6.5 kgf.m, 47 lbf.ftl
RUEBERBUSHING
. Checkfor deterioration
and damage.
.6t",.,"o".c"Ke
STAAIL|zER ENDRUBBER
EUSHINGS
Notethe direction
of the bushings.
18-8
SuspensionArms Replacement('992D Si and Si-Rmodels)
I CAUTION:
. The vehicle should be on the ground belore any bolts or nuts connectedto rubber mounts or bushings are tightened.
NOTE:
. Wipe off any dirt, oil or greaseon the threadsbeforetighteningthe fasteners "AL" while the right
. The right and ieft damper forks are not interchangeable. The left damper fork is markedwith
"AR"
damperfork is markedwith "SOl-L" while the right upper
. The right and left upperarms are not interchangeable. The left upperarm is markedwith
"SO1-R".
arm is markedwith
. Beforetighteningthe upper and lower mountingnuts on the stabilizerlink,adiustthe locationof the link with the sus-
p e n s i o nu n d e rv e h i c l el o a d .
"FR" markfacesthe front of the vehicle.
. When installingthe radiusarm washers,the
. After installingthe suspensionarm, checkthe front wheelalignment,and adjustif necessary (seepage18-4).
FLANGEBOLTS UPPERARM
10 x 1.25mm ' Checkthe balljointbootfor
sit N.m 15.5kgf.m, deterioration
anddamage.
40 tbtftl . Checkthe bushingfor deterioration
anooamage,
. C h e c kt h e b a l l i o i n t f o . f a u l t y
movement and clamage. BUSHING
STABILIZER
Alignthe stabilizermark
with the end of stabilizerbushing
FLANGEBOLT
1 4x 1 . 5m m
l./ 103N.m (10.5kgf.m,

76tbr.ftl
STABILIZER BAR
Checkfor bendingand damage.
STABILIZER LINK FLANGEBOLT8 x 1.25mm
. Checkthe balliointbootfor 22 N.m (2.2 kgf.m, 16lbf.ft)
deteriorationand damage. SELF-LOCKING NUT
. Checktheballiointtor faulty 1 4x 1 . 5m m
movementanddamage. LOWERARM
Checkfor Replace.
damage. 83 N.m 18.5kgf m, 61 lbf.ft)
FLANGEBOLT
-.6r hSHrtlrT.[*"u
srr-,co", 1 4x 1 . 5m m
6g619g Checkfor deterioration 89 N.m 19.1kgf.m,66 lbf.ft)
ano oamage.
SELF.LOCKING NUT
10 x 1.25mm 29 N m 13.0kgf m, 22 lbf ftl
Replace.
Holdthe ballioint pin usinga hex wrench, FLANGEBOLT
the self'locking
and taghten nut. 10x '1.25mm
43 N.m {4.4kgf.m,
FLANGENUT l0 x 1.25mm
32 tbtft)
29 N.m 13.0kgI m,2.2 lbf ft)
Beforetighteningthe {langenut,
positionthe balljoint Pin SELF.LOCKING NUT
in the middleof its rangeof travel, DAMP€RFORK 12 x 1.25mm
with the suspension undervehicleload Checklor damage. Replace.
64 N m 16.5kgl.m, 47 lblft)
DAMPERFORK
RU88ERBUSHING
Checkfor deterioration
and damage.
RANGE
4@lsrlrcoNE GREASE
18-9
FrontSuspension
Knuckle/Hub
Replacement
CAUTION:
. Replacotho salf-lockingnuts after romoval.
. The vehiclo should be on tho ground bsfore any bohs or nuls connectedto rubber mounb or bushings are tightened.
. Torqu€ th€ castle nut to the lowor torque specification,ihen tighton it only far enough to align th€ slot whh the pin
hole. Do not align the nut by loosening.
NOTE:
. Use only genuineHondawheel weightsfor aluminumwheels.Non-genuinewheel weights may corrodeand damage
the aluminumwheels.
. On the aluminumwheels,removethe centercap from the insideof the wheelafter removingthe wheel,
. Beforeinstallingthe brakedisc,cleanthe matingsurfacesof the front hub and brakedisc,
. Beforeinstallingthe wheel,cleanthe matingsurfacesof the brakediscand wheel.
o Wipe off the greasebeforetighteningthe nut at the ball joint.
CALIPERMOUNTINGBOLT CASTLENUT
1 2x 1 . 2 5m m 10 r 1.25mm
108N.m {11.0kgl.m,80lbf.ft) 39 - ia7N.m (4.0- 4.8 kgf.m,29 - 35 lbf,ftl
COTTERPIN
Replace.
WHEELBEARING
Replace.
page18-14
Replacement,
CIRCLIP
LOWERBALLJOINT SCREW
Inspectfor faulty 5x0.8mm
movementand wear. 5 N.m {0.5 ksl.m, 4 lbf.ftl
FRONTHUB
SETRING
Checkfor damageand
cracks.
BALLJOINT BOOT Replacement,
Checkfor deterioration page18-10
and damage. SPINDI.T]{UT
22 r 1.5 mm
CASTLE NUT lEl N.m {18.5kgf.rn,13{ lbl.ttl
12x 1.25mm Replace.
49- 59N.ml5.O- 6.0kg{.m.36- /(} lbf,ftl NOTE:
. Beforeinstellingthe spindle nut. apply
6n9ineoilto th6 seatingsurfaceofthe nut.
. Atter tightening, uso a drift to stakethe
spindle nut should6ragainstthe driveshaft.
BRAKEDISC
Checkfor wear and
rust.
lnspection,
section19.
WHEELNUT
12 x 1.5mm
'108N.m
1r1.0kgf.m, 8lt lbf.ft)
6 mm BRAKEDISCRETAININGSCREW
9.8 N.m 11.0kgf.m, 7 lbtft)
18-10
)
1. Loosenthe wheel nuts slightlY. 7. Removethe 6 mm brakedisc retainingscrews.
Raisethe front of the vehicle,and support it with safe-

ty standsin the properlocations(seesection1).
3 . Removethe wheel nutsand wheel.

6 mm BRAKEOISC
WHEEL NUT RETAININGSCREWS
'108N.m
9.8 N.m t1.0 kgf.m, 7 lbf'ft)
{11 kgf m, 80 lbl.ft)
I x 1.25mm BOLTS
8 . Screwtwo 8 x 1.25mm bolts into the discto push it

awayfrom the hub,
18'lN.m 118.5kgf m, 134lblfti NOTE: Turn each bolt two turns at a tameto prevent
Replace. cockingthe disc excessivelY.
NOTEIBeforeinstallingthe spandlenut, apply
engineoil to the seatingsurfaceof the nut After Removethe brakediscfrom the knuckle.
tightening,use a drift to stakethe spindlenut
shoulderagainslthe driveshaft
l ) Raisethe locking tab on the spindle nut, then remove
1 0 .Checkthe front hub for damageand cracks.
1 1 . R e m o v et h e w h e e l s e n s o rf r o m t h e k n u c k l e( f o r
the nut.
Remove the brake hose mounting bolts. vehicleswith ABS).
BRAKEHOSEMOUNTINGBOLT NOTE:Do not disconnectthe wheel sensorconnec-

I x 1.25mm
12 N.m (1,2kgtm,8,7 lbf'ftl tor.
N.m
CALIPERMOUNTINGBOLTS {'1.0kgf m,
12 x 1.25mm 7 tbf.ft)
108 N.m {'11.0kgtm, 80 lbt.ft)
6. Removethe caliper mounting bolts and hang the

caliperassembiyto one side MOUNTING
BOLTS
CAUTTON:To prevent accidentaldamage to the 9.8 N.m
caliper assemblyor brake hoso' use a short piece of WHEEL 11.0kgf,m, 7 lbf'ft)
(cont'd)
wire to hang the caliPertlom lhe undelcarriage.

FrontSuspension
(cont'dl
Knuckle/HubReplacement
NOTE: Use the specialtool to separatethe ball joints 17. Oncethe specialtool is in place,turn ths adjusting
from the suspensionor steeringarm, bolt as necessaryto make the jaws parallel.Then
hand-tighten the pressure bolt, and recheckthe
CAUTION: 86 careful not lo damagethe ballioint boot. jaws to makesurethey are still parallel.
12. Cleanany din or greaseoff the balljoint.
13. Removethe cotter pin from the steeringarm, and

removethe nut.
14. Apply greaseto the specialtool on the areasshown,

This will ease installationof the tool and prevsnt
damageto the pressurebolt threads.
PRESSURE
AOLT AI\IUSTING BOLT
NOTE: After making the adiustment to the adiust-

ing bolt, be sure the head of the adjusting bolt is in
this position to the allow the jaw to pivot.
1 8 . With a wrsnch, tighten the pressurebolt until the

ball joint shaft pops loose from the steering arm.
1 5 . Installa 10 mm hex nut onto the ball joint. Be sure
that the hex nut is flushwith the balljoint pin end to E@ we.r cye plotection. Thc brtt ioint
prevent damage to the threaded end of the ball cln brcrk loose suddenly and sclt'tol dirt or other
joint. d.brb inio youl .ye..
1 6 . Install the special tool as shown. Insert the jaws 10 Rsmov€the tool, then remove th€ nut from the end
carefully,makingsure you do not damagethe ball of the ball ioint and pull the ball joint out of the
joint boot. Adiust the iaw spacing by turning th6 stoering/suspensionarm. Insp€ctthe ball joint boot
pressurebolt. and replaceit if damaged.
NOTE: lf necessary,apply penetratingtype lubri-

cantto loosenthe balljoint.
COTTER.PIN
Replace.
On reassembly,
bend the cofter pin
CASTI.TNUT
10 x 1,25mm
39 - 47 N.m
14.0- 4.8 kgf.m, CASTLENUT
29 - 3s tbl.ftt 10 r 1.2smn--]*-
corrcn nn .\
Replace-
18-12
)
20, Removethe cotter pin from the lower arm ball joint Removethe cotterpin from the upper ball joint cas-
castlenut. and removethe nut. tle nut, and removethe nut.
COTTER.PIN
Replace.
On reassembly,
bend the cotter Pan
CASTLE NUT
12x 1.25mm
49- 59 N.m(5.0- 6.0kgl m,36-,13lbf'ft|
'12x 1.25mm
39 - 47 N.m
14.0- 4.8 kgf m,
29 - 35 tbf.ft)
12mm HEXNUT 07MAC- SL00200
lnstallthe 12 mm hex nut onto the balljoint

Be sure that the hex nut is flush with the ball joint
l r pin end, or the threadedsectionof the ball joint pin

mlght be damagedby the balljoint remover'
25. Usethe specialtool as shown on page l8-12to sep-

aratethe balljoint and knuckle.
NOTE: lf necessary,apply penetratingtype lubri

cantto loosenthe ball joint.
26. Putl the knuckteoutward and remove the driveshaft

BALLJOINT REMOVER,28 mm
07MAC- SL00200 outboardjoint from the knuckleby tapping the drive-
shaft end with a plastichammer,then removethe
knuckle.
KNUCKLE
Checkfor damage.
21. lnstalla 12 mm hex nut onto the ball joint. Be sure
that the hex nut is flush with the ball joint pin end'
or the threadedsectionof the ball joint pin might be
damagedby the balljoint remover.
22. Usethe specialtool as shown on page l8-12to sep-

aratethe ballioint and lowerarm.
NOTE; lf necessary,apply penetratingtype lubri-

cantto loosenthe ball joint.
l J
18-13
FrontSuspension
Knuckle/Hub (cont'dl
Replacement
NOTE: Replacethe bearingwith a new one after removal. 29. Pressthe wheel bearingout ofthe knuckleusingthe
specialtools and a Dressas shown,
27. Separatethe hub from the knuckleusingthe special
tools and a hydraulicpress. Pross
DRIVER
CAUTION:
o Take cale not to distort the splash guard.
07749- (X)l0000
t
. Hold onto the hub to keep it from falling whon ATTACHMENT,
KNUCKLE 62x68mm
pr$sed clear, 07746- 0010500
. To prevenl damage to the tool. mak€ sure the
threads are fully engagedbelore pressing.
Press
HUBDIS/ASSEMBLY
BEARTNG PILOT,38mm
t 07JAF- SH20110
SEPARATOR -
O- 1112in.
(Commercially
available)
HUB DIS/ASSEMBLYBASE WHEEL BEARING

07GAF- SEoo4Ol Replace.
Pressthe wheel bearing inner race from the hub

using the specialtools, a bearingseparator,and a
press as shown.
HUB DIS,/ASSSMBLY
PILOT,38 mm
07JAF- SH20110
KNUCKLE
HUB DIS/ASSEMALY
SHAFT.22.{x 25.4mm
07JAF- SH20120 FRONT
I{U8
28. Removethe circlip and the splash guard from the

knuckle.
Checktor bendingand damage.
HUB DIS/ASSEMBLY
SHAFT,22.4x 25.4mm
07JAF- SH20120
18-14
I N O T E :W a s h t h e k n u c k l ea n d h u b t h o r o u g h l yi n 34. lnstallthe hub on the knuckleusingthe specialtools
highflash point solventbeforereassembly. shown and a hydraulicpressas shown.
31. Pressa new wheel bearing into the knuckleusing CAUTION:Take care not to distort tho splashgusrd'
the specialtoolsand a pressas shown
N O T E :P l a c et h e w h e e l b e a r i n go n t o t h e k n u c k l e
HUB/ASSEMBLY
with the pack seal (metalcolor) toward the inside GUIDEATTACHMENT
Be careful not to damage the sleeve of the pack 07GAF-SEflt2d)
seal.
Press
KNUCKLE
HANOI.E DOUBLELIPSEAL
07749- 001
COLOR)
{BLACK
DRIVER
ATTACHMENT
58x72mm
07947- 6340201 FRONTHUB
SUPPORTBASE
07966- StXx)100 SPLASHGUARD
KNUCKLE
SUPPORT BASE
07965- SD90100
32. Installthecirclipsecurelyin the knucklegroove' tnstall the knuckle in the reverse order of removal'
and pay particularattentionto the followingitems:
33. Installthesplashguard,and tightenthe screws.
. Be careful not to damage the ball joint boots
when installingthe knuckle.
scREws . Torque all mounting hardwareto the specified
5 N.m(0.5kgdm, 4lbt'ft) torque valugs.
. Torquethe castlsnuts to the low€r torque specl-
fications,then tighten them only far enough to
align the slot with the pin hole. Do not align the
castlenut by loosening.
. lnstall new cotter pins into the castlenuts after
torquing.
. Avoid twistin0 the sensorwires when installing
the wheelssnsor.
. Beforeinstallingthe brakedisc,cleanthe mating
surfacesof the front hub and the inside of the
brakedisc.
. Beforeinstallingthe wheel,cleanthe matingsur-
faceofthe brakediscand the insideof the wheel
. Checkthe front wheel alignment,and adjustit if
l-, necessary (seepage18-4).
18-15
FrontSuspension
Lower BallJoint Replacement
L Removethe knuckle(seepage18-11). 8. Installthe ball joint boot and set ring usingthe spe-
cialtool (seepage18-16).
Removethe boot by pryingthe set ring off.
C h e c kt h e b o o t f o r d e t e r i o r a t i o na n d d a m a g e .
replaceif necessary.
ADJUSTINGBOLT
Adjustrhe depthby
Installthe specialtools onto the ball joint and tight- turningthe bolt.
en the casflenut.
P o s i t i o nt h e s p e c i a lt o o l s o v e r t h e b a l l j o i n t a s
shown. then set the assemblyin a vise. Pressthe
ball joint out of the knuckle,
BALLJOINTREMOVER/INSTALLER
07965- SB00r00
CASTLENUT
l f
BALLJOINTREMOVER
BASE
07JAF- SH20200
Placethe balljoint in positionby hand.
7. Installthe specialtools over the ball joint as shown, Installthe knucklein the reverseorder of removal,
then pressthe ball joint in. and pay particularattentionto the followingitems:
BALLJOINT INSTALLEBBASE . Be careful not to damage the ball joint boots

07965- 5800200 when installingthe knuckle,
. Torque all mounting hardwareto the specified
torquevalues.
. Torquethe castlenuts to the lower torque speci-
fications.then tighten them only far enough to
align the slot with the pin hole. Do not align the
castlenut by loosening.
. Installnew cotter pins into the castlenuts after
torquang.
. Avoid twisting the sensorwires when installing
the wheelsensor.
. Beforeinstallingthe brakedisc.cleanthe mating
surfacesof the front hub and the inside of the
brakedisc.
. Beforeinstallingthe wheel,cleanthe matingsur-
faceof the brakediscand the insideof the wheel.
. Checkthe front wheel alignment,and adjustit if
BALLJOINT HOUSINGSURFACE
necessary{seepage18-4).
18-16
FrontDamper
Removal
! BallJoint BootRePlacement
l. Removethe front wheels(seepage18-11).
1. Removethe set ring and the boot.
CAUTION:Do not contaminatethe boot installa- 2, R e m o v et h e d a m p e r p i n c h b o l t t r o m t h e t o p o f

tion section with grease. damperfork.
Packthe interiorof the boot and lip with grease

DAMPERFORK
EALLPIN TAPEREDSECTION
OAMPER
FORK
BOLT
EOOTINSTALLATIONSECTION BOOTINSTALLATIONSECTION
Wipeoff the grease. Wipe off the grease.
3. Wipe the greaseoff the sliding surfaceof the ball OAMPER

pin and packwith freshgrease. PINCH SELF-LOCKING NUT
AOLT 1 2x 1 . 2 5m m
1 0x 1 . 2 5m m Replace.
CAUTION:
. Keep greaseoff the boot installation section and
the tapeled section of the ball pin. Removethe damper fork bolt and self-lockingnut
l J . Do not allow dust, dirt, or other toreign materi-

als to enterthe boot.
from the bottom of the damper fork, then remove
damperfork.
4. Installthe boot into the grooveof the boot installa- Removethe damperby removingthe two nuts
tion sectionsecurely,then bleedthe atr.
5. Installthe upper and lower ball joint boot set rings

usingthe specialtools as follows: DAMPER
L o w e r b a l l j o i n t : A d i u s t t h e s p e c i a lt o o l w i t h t h e
adjustingbolt until the end of the tool alignswith
the groove on the boot. Slide the set ring over the
tool and into Position.
AOJUSTINGBOLT
BALLJOINT Adjust the depth by
BOOTCLIP turningthe bolt.
GUIDE
UPPEREALL
JOINT EOOT:
07GAG- SD40700
LOWERBALL
JOINT BOOT:
07974- SA50700
CAUTION: After installing the boot, check the ball

pin tapsrod section fol grease contamination and
l t wipe it if necessary.
18-17
Front Damper
Disassembly/lnspection
Disassembly
'1.
Compressthe damper spring with the spring com-
pressor accordingto the manufacturer,sinstruc-
Replace.
tions,then removethe self-lockinonut. DAMPER
MOUNTING
WASHER
CAUTION: Do not compress the spring more than

n€cessaryto remove the nut.
10 mm SELF-
LOCKINGNUT
Replace. BASE
DAMPER
MOUNTING
BUBBER
and damage.
STRUTSPRING DAMP€R SPf,ING

COMPRESSOR: Checktor weakenedcompression
(Commerci.llyavailabl.l and damage.
BRANICKO T/N MST.s8I}A, T/N 7200, SPBINGMOUNTINGRUBBER
or eouivalent Checkfor deterioration
and damage,
BUMP STOP
Releasethe pressurefrom thg spring compressor, Checkfor and
then disassemble
the damperas shown in the next damage.
column. BUMPSTOPPLATE
DUSTCOVER
PLATE
Inspostion
1. Reassemble all parts,exceptthe spring.
2. Pushon th€ damperassemblyas shown.
OUSTCOVER
Checkfor bendingand damage.
Checkfor smooth operationthrough a full stroke, DAMPERUNIT

both compressionand extension,
N O T E :T h e d a m p e r s h o u l d m o v e s m o o t h l v .l f i t
does not (no compressionor no extension),the gas
is leaking,and the dampershouldbe replaced.
Checkfor oil leaks,abnormalnoises,or bindingdur-
ing these tests.
18-18
Reassembly lnstallation
\
't. Installthe damperunit on a springcompressor. 1. Looselyinstallthe damperonto the frame with the
aligning tab facing inside.then loosely install the
2. Assemblethe damper in reverseorder of removal two flangenuts.
exceptthe damper mountingwasherand self lock-
ingnut. FLANGE NUTS
10x 1,25mm
NOTE:Align the bottom of the damper spring and 49 N.m(5.0kgt'm,36 lbf'ftl
springlower seatas shown.
DAMPERASSEMBLY
STRUTSPRINGCOMPRESSOR:
lcommercially availablel
BRANICK@ T/N MST.58OA,T/N 7200,
or 6quival€nt
l r
SPBINGLOWERSEAT
3. P o s i t i o nt h e d a m p e r m o u n t i n g b a s e o n t o t h e
damperunit as shown.
4. Compressthe damPersPring.
Installthe dampermountingrubber,dampermount-
ing washer,and a new 10 mm self-lockingnut.
Hold the dampershaft.and tightenthe 10 mm self-

lockingnut.
NUT
SELF-LOCKING
10x 1.25mm
29 N.m 13.0kgf m, 22 lbf ft) DAMPER
Replace. MOUNTINGWASHER
(l-t
{cont'd)
18-19
Front Damper
2. Installthe damperfork over the driveshaftand onto
t h e l o w e r a r m . I n s t a l lt h e f r o n t d a m p e r i n t o t h e
damperfork so the aligningtab is alignedwith the
slot in the damperfork.
ALIGNINGTAB
DAMPER
PINCH
EOLT
10 x 1.25mm
43 N.m 14.4kgf.m,32 lbtftl 12x 1.25mm
64 N.m 16.5kgl.m, 47 lbtftl
Replace.
Looselyinstallthe damperpinch bolt into the top of

the damperfork.
Looselyinstallthe damperfork bolt and a new self-

lockingnut into the bottomof the damperfork.
Raisethe knucklewith a floor jack until the vehicle

just lifts off the safety stand.
@E The ftoor ilck must be sscuroty posi-

lionsd or personal iniury may r€€uh.
Tightenthe damperpinchbolt.
7 . Tightenthe damperfork bolt and self-locking

nut.
8 . Tightenthe flangenutson top of the damper.
9 . Installthe brake hose mounts with the brakehose

mountingbolts.
1 0 . Installthe front wheel.
1a-20
RearSuspension
I SuspensionArms Replacement('96- 99 modelsl

bafore hoisting' Wh€n
tffi
- Whsn ths suspensionarms ar6 to be removed. place additionsl weight in the trunk
gravity may change causing ths cat to tip tor'
substantial weight is removed ftom th6 teal of ths vehicl6, the center of
ward.
CAUTION:
.Thgvehic|eshouldb€onthggroundboforeanybohsornutsconnectodtorubbelmountso]bughingsaretighton.
NOTE:
. Makesurethe toe adjustingboltson the compensatorarm are installedin the samedirection'
,.t UP LK,,or "t UP LS'.is stampedon the |eft upperarm and ,,t UP R" or "t UP RH G.,or
. ,,t UP 1,, or ,,t UP LH G,. or
"t UP RK" or "t UP RS" on the right upperarm'
"t UP" stampedsidefacesforward'
. The rightand left "ornp"n""to, uitt rre symmetricallnstallsothe
.Afterinsta||ingthesuspens|onarm,checktherearwhee|alignment,andadjustifnecessary(seepagelS-4).
FLANGEBOLT
10 x 1.25mm
54 N.m
(5.5kgf'm, 40 lbf'ftl
ADJUSTINGBOLT
(FLANGEBOLTI
10x 1.25mm
UPPERARM INNER
47 tbf.ftl BUSHING
Checkfor deterioration DAMPERMOUNTINGBOLT
and oamage. (FLANGEBOLT}
10 x 1.25mm
54Nm
t J (5.5kgd.m,iro lbf'ft)
l0 mm FLANGEBOLT
N.mt4.0kstm, 29lblftl
UPPERARM
Checkfor bendang
damage-
FLANGEBOL
10 x 1.25mm TRAILINGARM
FI.ANGEBOLT
COMPENSATOR ARM I 54 N.m 10 x 1,25mm
Checkfor bending (5.5ksrm, aolbf'ftl
54 N.m
ano oamage, \ (5,5ksrf.m,4{}lbf'ft}
COMPENSATOR ARM
INNERBUSHING
.- SILICONE
.@] GREASE
Checktor deteriorataon
and damage. LOWENARM BUSHING
.,- SILICONE
LOWERARM
..i@l GREASE
FLANGEBOLT Checkfor cracks
10 x 1.25mm ano damage. Checkfor deterioration
FLANGEAOLT and oamage,
64 N.m {6.5 kgt'm,
12 x 1.25mm
47 lbf.ft)
64 N.m {6.5 kgf m,
47 tbf.ftt
1A-21
RearSuspension
SuspensionArms Replacement
('gg2D Si and Si-Rmodels)
CAUTION:
. Roplacethe self-lockingnut after removal.
' The vehicle should be on the gtound before any bohs or nuls connectedto rubber
mounts or bushing are tightened.
NOTE:
' Makesurethe toe adjustingbortson the compensatorarm are insta|edin the same
direction.
. "t UP L" or "t UP LH G" or "t Up LK" or "l Up LS,,is stampedon the left upperarm and ,,t
" i U PR K " " t Up R,,or "t Up RH G,,
o r U P R S " o n t h e r i g h tu p p e ra r m .
. T h e r i g h ta n d l e f tc o m p e n s a t oarr m a r es y m m e t i c aIrn. s t a lsl o t h e " u p r " m a r k p o i n t s t o t h e f r o n t .
. After installingthe suspensionarm, checkthe wheelatignmentand adiustif necessary,
FLANGEBOLT 8 rhm BOLTS STABILIZER
BUSHTNG
'10x 1.25mm
22 N.m {2.2 kgf.m, 16 tbtfrl
54Nm155kgl.m,
,rc lbf.ftl STAEILIZER BAR
Checkfor bendingor damage.
FLANGEBOLT
10 x 1.25mm
64 N m {5.5 kgf.m,47 lbtftl
UPPERARM BUSHING
Checkfor deterioration Alignthe stabitizermark
and with the end ot the stabilizerbushing.
FLANGEBOLT
'10x 1.25mm
54 N.m 15.5kgt.m, a0 lbtftl
FLANGEBOLT
10x 1.25mm
54 N.m 15.5*gf.m,
stLrcoNE
iO lbf.ftl
UPPERARM BUSHING
EOLTS
TRAILINGARM 10x 1.25mm
Checkfor bendingand 39 N m ll kgf.m, 29 lbf.ft)
UPPERARM FLANGEBOLT
Checkfor b€ndingor damage. 10 x 1.25rnm
#@l 54 N.m {5.5 kgt m, iro lbf.ft)
stLtcoNE
COMPENSA TORARM BUSHING
FLANGENUT
r '1.25mm
29 N.m {3.0 ksl.m,22 lbtft}
COMPENSATOR Beloretightening the flange nut,
ARM BUSHING positionthe balljoint pin
Checkfor deterioration in the middleol its rangeof
and damage. travel,with the suspension under
FLANGEBOLT vehicleload.
l0 x 1.25mm
6l N.m 16.5kg{.m,a7 lbt.ftl LOWERARM
Checkfor damage-
FLANGEBOLTS
10 x 1,25mm
64 N.m {6.5kgf.m, 47 lbf.ftl LOWERARM BUSHING
SELF.LOCKNGNUT
10 x 1.25 mm 29 N.m (3.0 ksl.m, 22 tbtfrl
-Gr
stltcoNE
Replace.
Hold the ball ioinl pin using a hex w.enct. LOWERARM BUSHING
and tighten the selfjocking nut. . Checkfor deteriorationand damaoe.
' Seepage18 25 for bushingreplaciement.
STABILIZEBLINK
' C h e c kf o r b e n d i n g a n d d a m a g e .
. C h e c kt h e b u s h i n g f o r d e t e r i o r a t i o na n o
oamage.
18-22
I HubBearingUnit RePlacement
NOTE:
weightsmay corrodeand damage
o Use only genuineHondawheel weightsfor aluminumwheels Non-genuinewheel
t h e a l u m i n u mw h e e l s .
. o n t h e a | u m i n u m w h e e | s , r e m o v e t h e c e n t e r c a p f r o m t h e i n s i d e o f t h e W h e e | a f t e r r e m o v i n g t h e w h e e |(or
'
hub and the brakedisc brake
. Beforeinsta||ingthe brakedisc (or brakedrum),c|eanthe mating surfacesof the rear
orum,.
andwheel'
. Beforeinstallingthe wheel,cleanthe matingsurfacesofthe brakedisc(or brakedrum)
* 1 :Forvehicleswith drum brakes.

*2'.'99 2D Si and Si-Bmodels
12 6 mm FLANGEBOLT
9.8 N.m {1.0kgf m, 7 lbf'ft|
SPINDLEWASTIER
SPINDLENUT
22 x 1.5mm
*2 SPLASHGUARO 181N,m (18.5kgt'm.134lbfft)
Checkfor cracking Replace.
and damage. NOTE:
TRAILINGARM ' Beforeinstallingthe spindlenut,apply
Checkfor cracking
engineoil to the seatingsurfaceof the
and oamage, nut,
' Aftertightening,usea drift Punch
to lockthe spindlenut shoulderinto
the spindle.
HUBCAP
l r Beplace.
12 BRAKEDISC
Checkfor wear and
rust,
'2 6 mm BRAKEDISCRETAININGSCREW
\ 9.8 N'm 11.0kgt m, 7 lbf'ft|
*1 BACKINGPLATE
/\
*1 BRAKESHOE
r1 FLANGEBOLT
10 x 1.25mm
6,0N.m (6.5ksl.m,47 lbl'ftl '1 BRAKEORUM
REAB WHEEL NUT

HUB UNIT BEARING 1 2x 1 . 5m m
Checkfor cracking 108N.m{11.0 kgt'm.80lbt'ft)
and damage.
l-t (cont'd)
1A-23
RearSuspension
Hub BearingUnit Replacement(cont'dl
NOTE:Disctype {'992D Si and Si-Rmodets) 8 . Release
the parkingbrakelever.
1. Loosenthe wheel nuts slightly. 9 . R e m o v et h e b r a k e d r u m , h u b u n i t b e a r i n g ,a n d

spindlewasherlfor vehicleswith drum brakes).
2. Raisethe rear of vehicle,and supportit with safety
standsin the properlocations{seesection1).
3. Removethe wheel nuts and rearwheel.
4. Pullthe parkingbrakeleverup.
5. R e m o v et h e h u b c a p .
6. R a i s et h e l o c k i n gt a b o n t h e s p i n d l en u t , t h e n
removethe nut. SPINDLE NUT
22x 1.5mrn
181N.m (18.5kgf'm,134lbf.fi)
Replace. BRAKEDRUM
NOT€:
. Eeforeinstallingthe spindlenut,
lFor vehictes \ applyengineoil to the seating
\with drumbrakes;/ surfaceof the nut.
. Aftertightening,usea drift to
stakethe spindlenut shoulder
againstthe spindle.
SPINDI-E
WASHER
10. Removethe 6 mm flangeboltsand calipershield.

WHEELNUT
12x 1.5mm CALIPER
SHIELO
108N.m C h e c kf o r b e n d i n g a n d d a m a g e .
I I 1 kgt m, 80 lbf.ftl
6 mm FLANGEBOLTS
9.8 N.m {1.0kgf.m, 7 lbf,ft)
HUBCAP
Replace-
NOTE:Takecarenot to damagethe hub untt
on disassembly.
7 . Remove the 6 mm brake disc retaining screws.
6 mm BRAKEDISC
RETAININGSCBEWS
9.8 N.m 11.0kgl.m, 7 lbf.frl
1A -2 4
T UpperArm BushingRePlacement
1. R e m o v et h e u p p e r a r m b u s h i n g a n d u p p e r a r m
1 1 . Removethe two brakehose mountingbolts
j n n e rb u s h i n ga s s h o w n
1) R e m o v et h e c a l i p e rb . a c k e tm o u n t i n gb o l t s ,a n d
ARMINNERBUSHING
UPPER ARMBUSHING
UPPER
hangthe caliPerto one side
CAUTION:To prevent accidentaldamage to the

caliper or brake hose, use a short piece of wile to
hang the caliperfrom the undercarriage.
I t t
BRAKE HOSEMOUNTING BOLTS
22 N'm{2.2kgf'm,16lbt"ft}
ARM
REARUPPER
Scribea line on the upperarm innerbushingso that
it is in linewith the bolt mountingsurface
Markto pointson the upper arm so that they are In

line and make a right anglewith the arm as shown
in the drawing.
l r CALIPER 10x 1.25mm

38N'm (3.9kgf'm,28lbf'ftl
Screwtwo 8 x 1.25mm bolts into the discto push it
awayfrom the hub.
NOTE:Turn each bolt two turns at a time to pre-

vent cockingthe discexcessively. BOLTMOUNTING
SURFACE
1 4 . Removethe brakedisc. Drivein the upperarm innerbushingwith the marks
aligned.
1 5 . Removethe hub unit bearingfrom the spindle
5. Drivethe upperarm bushingintothe upperarm
NOTE: Drive in the upper arm bushingand upper

a r m i n n e r b u s h i n g u n t i l t h e i r l e a d i n ge d g e s a r e
flush with the uPPerarm
UPPER
ARM
SPINOLEWAS}IER
l t 16. lnstallin the reverseorderof removal.
1A-25
RearDamper
Removal
1. Bemovethe rearwheels(seepage1g-22). 6. Lowerthe rearsuspension,
and removethe damper.
2. Removethe speakercoverand speaker(Hatchback).

Sedanand Coupe:Removethe trunk side panel(see
section20).
3. Removethe two flange nuts.
FLANGENUTS
10x 1.25mm
4. Removethe flangebolt from the damper.
FLANGEBOLT
'10x 1.25mm
FLANGE BOLT
10x 1,25mm
Removethe flangebolt that connectsthe lower arm

to the trailingarm.
18-26
I Disassembly/lnsPection
Disassembly lnspection
1. Compressthe damper spring with the spring com- 1. all parts,exceptthe sprlng.
Reassemble
p r e s s o ra c c o r d i n gt o t h e m a n u f a c t u r e r ' isn s t r u c -
tions,then removethe self-lockingnut. 2. Pushon the damPeras shown.
GAUTION: Do not compress the spring more than

necessaryto remove the sell-lockingnut.
WOODENBLOCK
l r
Checkfor smooth operationthrough a full stroke,

STNUTSPRINGCOMPRESSOR: both compressionand extension.
lComm6rcially.vailablel
ERANICKoT/N MST-580A,T/N 7200,or equivalent N O T E :T h e d a m p e r s h o u l d m o v e s m o o t h l y l f i t
does not (no compressionor no extension),the gas
Release the pressure from the spring compressor. is leaking,and the dampershouldbe replaced.
then disassemblethe damper as shown on page 18-
CheckJor oil leaks,abnormal noises,and binding
duringthesetests.
(|-r
{cont'd)
18-27
RearDamper
(cont'dl
Disassembly/lnspection Reassembly
SELF-LOCK|NG
NUT - el
10x 1.25mm v 1. Installthe damperunit onto a springcompressor.
29 N.m{3.0kst'm,22 lbf.ftl
Replace. NOTE:Followthemanufacturer's
instructions.
DAMPEB
MOUNTING
WASHER Assemblethe rear damper in the reverseorder of
DAMPER
MOUNTING disassemblyexceptthe damper mounting washer
8U8BER and self-lockingnut.
Checktor
deterioration NOTE:Align the bottom of the damper spring and
ano oamage. springlower seatas shown.
DAMPER
COLLAR
P o s i t i o nt h e d a m p e r m o u n t i n g b a s e o n t o t h e
DAMPER
damoerunit as shown.
MOUNTINGBASE
SIRUTSPRING COMPRESSOR:
OAMPERMOUNTING DAMpERMOUNTTNG (Commerciattyavaitabtel
BUBBES BRANICKO T/N MST-580A,T/N 7200.
Checkfor or cquivalont
deterioration
ano oamage. DAMPERSPRING
Checklor weakness,
compression,and damage.
SPRINGMOUNTING
RUBBER
ano oamage.
BUMP STOP
Checkfor weakness
and damage,
OUSTCOVERPLATE
DUSTCOVER
Checklor bending
Compressthe damperspring with the spring com-

pressor.
Installthe damper mounting washer, and loosely

installa new self-locking
nut.
Holdthe dampershaftwith a hex wrench,and tight-

DUSTCOVERBOOT
en the self-locking
nut.
and damage. SELF-LOCKING
NUT DAMPER
10 x 1,25mm MOUNTING
29 N m 13.0kgt.m, 22 lbtftl WASHER
Replace. :
OAMPERUNIT
18-2A
RearDamper
I lnstallation
' 1 . L o w e r t h e r e a r s u s p e n s i o n a, n d p o s i t i o n t h e
damperwith the springstop pointedtoward the left
SPRINGSTOP
2. Looselyinstallthetwo flangenuts
FLANGENUTS
10x 1.25mm
49 N.m (5 kgf.m, 36 lbt'ft)
Tightenthesenuts in
step7.
l r
3. Looselyinstallthe flangebolts.
FLANGEBOLT
10 x 1.25mm
54 N.m {5.5 kgf m, 40 lbt'ft1
FLANGEBOLT
10 x 1.25mm
54 N.m {5.5 kgf.m,
/r0 lb{.ft|
Raisethe rear suspensionwith a floor jack until the

vehicle just lifts off the safety stand.
!@@ Tne floor iacx must be securelYPosi-

tionod or peFonal iniury may rssull
Tightenthe flangebolts.
Tightenthe two flangenuts on top of the damperto

the specifiedtorque.
7. Checkthe rearwheel alignmentand adjustif neces-

sary (seepage18-4).
1A-29
t
Brakes
ConventionalBrakes ..."...19-1
Anti-lockBrakeSystem(ABS)."......"..19-43
It-,
l t

t
Brake
Conventional
SpeciafTools .............19'2 RearBrakePads
ComponentLocations Inspectionand Replacement,,........19-24
lndex ................ ......19-3 RearBrakeDisc
Inspectionand Adiustment DiscRunoutlnspection...................19-26
BrakeSystem RubberParts DiscThicknessand Parallelism
19-4
and BrakeBooster...........,.,............. Inspection ..........19-26
BrakePedal 19-5
............ RearBrakeCaliper
ParkingBrake ........19-6 Disassembly ...........19-27
Bleeding .................
19-7 Reassembly ........."19-31
Front BrakePads RearDrum Brake
Inspectionand Replacement..........19-8 Index/lnspection 19-35
..............................
Front ErakeDisc Inspection 19-36
....,.,.......
DiscRunoutInspection................... 19-12 BrakeShoe Disassembly..............." 19-37
DiscThicknessand Parallelism BrakeShoeReassembly 19-37
...............'..
Inspection ..........
19-12 BrakeHoses/Lines
Front BrakeCaliper Inspection/TorqueSpecifications..... 19-39
Disassembly 19'13
.......... HoseReplacement 19-40
...........................
Reassembly ...........
19-16 ParkingBrakeCable
MasterCylinder/BrakeBooster lnspectionand Replacement........,.19-41
Removal/lnstallation 19-21
.......................
PushrodClearanceAdiustment ......19-22
BrakeBoosterInspection................ 19-23
l-l

SpecialTools
Ref. No. I Tool Numbo] Descriplion Oty I PageReference

o 07HAE- SG00100 BrakeSpringCompressor 19-28,
33
07JAG- SD40100 PushrodAdjustmentGauge 19-22
- SA50001
07914 SnapRingPliers
o @
19-2
ComponentLocations
lndex
I
ERAKEPEDAL BRAKEHOSES LINES

Inspectron
and Inspection/Torque
specif page19-39
ications,
page195
Adjustment, page19-40
HoseReplacement,
MASTERCYLINDER/BRAKE BOOSTER
page19 21
PushrodClearanceAdjustment,page19_22
BrakeBoosterInspection,page 19-23
l J
PARKINGBRAKECASLE
inspectionand Replacement,
p a g e1 9 4 1
BBAKE
Adiustment,page19-6 REARORUMBRAKES
FRONTBRAKES page19-36
Inspection,
NOTE: There are two types offront brakecalipers: BrakeShoeBeplacement, page19'37
"5410" REARDISCBRAKES
The calipertypescan be identitiedby the
or "2056"stampedon the caliperbody.Checkthe RearBrakePads,page19 24
type ot the brakecaliperbetore servicing. RearBrakeDisc,page19 26
FrontBrakePads RearBrakeCaliper,page19'27
5410Type:page19-8
2056Typerpage19 10
FrontBrakeDisc,page19-12
FrontBrakeCaliper
5410Type:page19-13
2056Type:page19-14
l J
19-3
BrakeSystemRubberPartsand BrakeBooster
@ Brake Boostet Brake Hoses
Checkbrakeoperationby applyingthe brakes. Visuallycheckfor damageor signsof fluid leakage.
lf the brakesdo not work properly,checkthe brake Replacethe brakehose with a new one if it is dam-
booster,Replacethe brakeboosteras an assembly a g e do r l e a k i n g .
if it does not work properlyor if there are signs of
leakage. @ CaliperPiston Seal and Piston Boots
Checkbrakeope.ationby applyingthe brakes.
€) Piston Cup and PressureCup Inspeqtion Visuallycheckfor damageor signsof fluid leakage.
. Checkbrakeoperationby applyingthe brakes. lf the pedal does not operateproperly,the brakes
Visuallycheckfor damageor signs of fluid leak- drag. or there is damageor signs of fluid leakage,
age. disassembleand inspectthe brakecaliper.Replace
R e p l a c et h e m a s t e rc y l i n d e ra s a n a s s e m b l yi f the boots and seals with new ones wheneverthe
the pedal does not work properly or if there is brakecaliDeris disassembled.
damageor signsof fluid leakage.
@ Wheol Cylindor Piston Cup and Dust Cover
. C h e c kf o r a d i f f e r e n c ei n b r a k e p e d a l s t r o k e Checkbrakeoperationby applyingthe brakes.
b e t w e e nq u i c k a n d s l o w b r a k e a p p l i c a t i o n s . Visuallycheckfor damageor signsof fluid leakage.
Replacethe master cylinder if there is a differ- lf the pedal does not operate properly,the brakes
encein oedalstroke. drag, or there is damageor signs of fluid leakage,
disassembleand inspectthe wheel cylinder.lf nec-
essary,replacethe wheelcylinderas an assembly.
19-4
BrakePedal
)
PedalHeight 4. Screw in the brake switch until its plunger is fully
1. Disconnectthe brakeswitch connector,loosenthe depressed(threadedend touching the pad on the
brakeswitch locknut,and backoff the brakeswitch pedal arm). Then back off the switch 1/4 turn to
until it is no longertouchingthe brakepedal, m a k e 0 . 3 m m ( 0 . 0 1i n ) o f c l e a r a n c eb e t w e e nt h e
threadedend and pad. Tighten the locknutfirmly.
2. At the carpetcutout,measurethe pedalheightfrom Connectthe brakeswitchconnector.
the right sidecenterof the pedalpad.
CAUTION: Make sure that the brake lights go off
PUSHROD when the pedal is released.
LOCKNUT
LOCKNUT
* 0.3mm
(0.01in)
5. Checkthe brakepedalfree play as describedbelow.
I t PedalFreePlsy
1. With the engine off, inspectthe play on the pedal
POINTICUTOUTI pad by pushingthe pedalby hand.
Standard PedalHeight (with carpet removed): FreePlay:1 - 5 mm (1/16- 3/16 inl

M/T: 156.5mm 16.16inl
A/T, CVT:161mm (5 5/16 in) 2. lf the pedal free play is out of specitication,
adjust
the brakeswitch.
3. Loosenthe pushrodlocknut,and screwthe pushrod
in or out with pliersuntil the standardpedal height CAUTION: lf the pedal free play is insufficient, it
from the floor is reached.After adjustment,tighten may result in brake drag.
the locknutfirmly.
N O T E : D o n o t a d i u s tt h e p e d a l h e i g h tw i t h t h e
Dushroddepressed.
BRAKEPEDALPAO
PUSHROOLOCKNUT
15 N.m
(1.5kgf.m. 11 lbI.ft)
19-5
ParkingBrake
Inspection Removethe rearconsole(seesection20).
1. Pullthe parkingbrakeleverwith 196N {20kgf.44 lbf)
force to fully apply the parkingbrake.The parking Pullthe parkingbrakeleverup one click,
brake lever should be locked within the sDecified
numberof clicks. Tightenthe adjustingnut until the rearwheelsdrag
slightlywhen turned.
Lever Lockedclicks: 6 - I
Pulledup w i t h 19 6 N 1 2 0k g f , 4 4 l b f )
ADJUSTING
NUT
2. Adjustthe parkingbrakeif the leverclicksare out of
specification.
Beleasethe parkingbrakeleverfully, and checkthat
Adiusiment the rear wheelsdo not drag when turned.Readjust
if necessarv.
NOTE:After servicingthe rear brakepadsor calipers,or
the rear brakeshoe, loosenthe parkingbrakeadjusting 7. Make sure that the parkingbrakesare fully applied
nut, startthe engine,and depressthe brakepedalsever- when the parkingbrakeleveris pulledup fully.
al times to set the self-adjusting
brakebeforeadjusting
the parkingbrake. 8. Reinstallthe rearconsole.
1. Raisethe rear wheels off the ground, and support

the vehicleon safetystands.
l@ Elock the front wheels bofore iacking

uDthe rear ot the v6hicle.
2. On vehicleswith rear disc brakes,make sure the

parkingbrakearm on the rearbrakecalipercontacts
the brakecalioerDin.
19-6
Bleeding
I CAUTION: FRONTT
. Always use GenuineHondaDOT3 BrakeFluid.Using 8
n o n - H o n d ab r a k € f l u i d c a n c a u s e c o r r o s i o n a n d
docrea3ethe life of the system.
. Make surs ||o dirt or other foteign matter is allowed
to contaminate the brake fluid,
. Do not spill brake lluid on the vehicle, it may damago
the paint; if brake lluid doos contac{ the paint, wash
it ofl imm€diately with water.
NOTE:The reservoiron the mastercylindermust be at

the MAX (upper)level mark at the start of the bleeding
p r o c e d u r e a n d c h e c k e da f t e r b l e e d i n g e a c h b r a k e
caliper.Add fluid as required.
1. Makesure the brakefluid levelin the reservoiris at

the MAX lupper)levelline.
REARlDrum Brakel:
MAX {UPPER)LEVEL
CYLINDER
Havesomeoneslowly pump the brakepedslseveral

times,then applysteadyPressure.
Loosenthe brakebleedscrewto allow air to escape

f r o m t h e s y s t e m .T h e n t i g h t e n t h e b l e e d s c r e w
securely.
Repeatthe procedurefor eachwheelin the sequence

shown below until air bubblesno longerappearin REAR(DiscBrake):
the fluid.
Refillthe mastercylinderreservoirto the MAX (up-

per)levelline.
ELEEDINGSEOUENCE:
O Front Right (D Bo.r Right
1,, O Front Left O Rear Left

AIEEDSCREW
9 N.m (0.9ksf m, 6.5 lbf'ft)
19-7
Front BrakePads
Inspectionand Replacement
NOTE:Therearetwo typesof front brakecalipers: 4. Removethe pad shim. pad retainers,and pads.
T h e c a l i p e rt y p e s c a n b e i d e n t i f i e db y t h e " 5 4 1 0 " o r
"2056" stamped on the caliper body as shown below. NOTE:When the caliperis equippedwith an outer
Checkthe type of the brakecaliperbeforeservicing. pad shim, replacethe shim togetherwith the pads
5i110Type:
NOTE:For 2056type disassemblyprocedures.

see page
19-'10.
Never use an air hose or dry brush lo clean brake

assgmblios.
Use an OSHA approved vacuum cleaner to avoid
breathing brake dust.
1 . Loosenthe front wheel nuts slightly,then raisethe

vehicle,and support it on safety stands.Remove
the front wheels.
2 . Removethe brakehosebracketfrom the knuckle. 5. U s i n g v e r n i e rc a l i p e r s m
, e a s u r et h e t h i c k n e s so f
Removethe caliper bolt, and pivot the caliper up each brakepad lining.The measurementdoes not
out of the wav. includethe pad backingplatethickness.
Brake PadThickno$:
Standard:9.5 - 10.5mm 10.37- 0.41 in)
SerYicoLimit 1.6 mm {0.06in}
CALIPERBOLT lf the brake pad thicknessis less than the service

limit, replacethe front Dadsas a set.
NOTE:Checkthe hosesand pin boots for damage

and deterioration.
19-8
)
'12. Pushin the pistonso that the caliperwill fitoverthe
7. Cleanthe caliperthoroughly;removeany rust,and
checkfor groovesand cracks. pads, Make sure that the piston boot is in position
8. Checkthe brakediscfor damageand cracks. to prevent damaging it when pivoting the caliper
9. lnstallthe pad retainers, down.
CALIPERBOLT
N m (3.3kgf m,2a lbf.ft)
10. Apply greaseto the points indicatedby the arrows

in the followingillustration:
NOTE:Use the pad greaseincludedin the pad set

or Molykote Nl77grease,and apply a thin coat of
greaseevenlyto the designatedpoints.
o Pistonend and innerDadcontactsurface

. Padand calioerbracketcontactsurface
I t .
.
.
Outerpad and caliperbody contactsurface
Outer pad shim and outer pad contact surface
Outerpad shim and caliperbody contactsurface
1 3 . Pivotthe caliperdown into position,then installthe
caliperbolt and tightenit.
CAUTION: Be caretul not damage the pin boot

when pivoting the caliper dowr.
1 4 . lnstallthe brakehosebracketon the knuckle
WEARINDICATOB NOTE: Inspectthe brake hose for interferenceor

twisting.
1 5 . Depressthe brakepedalseveraltimes to makesure

the brakeswork. then test-drive.
INNER PAD N O T E :E n g a g e m e n o t f t h e b r a k e m a y r e q u i r ea
greater pedal stroke immediately after the brake
pads have been replacedas a set. Severalapplica-
OUTERPAD t i o n s o f t h e b r a k e p e d a l w i l l r e s t o r et h e n o r m a l
11. Installthe brakepadsand pad shim correctly. Dedalstroke.
1 6 . After installation.checkfor leaksat hose and line

. Whon reusing the pads, always reinstall the jointsor connections,and retightenif necessary.
brake pads in their original positions to prevont
loss of braking efticiency.
. Contaminated brake discs or pads teduce stop-
ping ability. Keep greaseoft the discs and pads'
NOTE: lnstall the Dad with the wear indicator on
l.t the inside.

(cont'd)
19-9
Front BrakePads
(cont'dl
Inspectionand Replacement
2056Type: 5. U s i n g v e r n i e rc a l i p e r s m
. e a s u r et h e t h i c k n e s so f
each brake pad lining.The measurementdoes not
@
. Never use an air hose or dry brush to
includethe pad backingplatethickness.
clgan brake
assemblies. Brake PadThicknsss:
. Use an OsHA-approvedvacuum cleanor lo avoid Standard; 8.5 - 9.5 mm 10.33- 0.37 in)
breathing broke dust. ServicaLimh: 1.6 mm {0.06in}
1. Loosenthe front wheel nuts slightly.then raisethe

vehicle, and support it on safety stands. Remove
the front wheels.
2. Removethe brakehosebracketfrom the knuckle.
3. Removethe caliperbolt B, and pivot the caliperup
out of the wav,
lf the brake pad thicknessis less than the service

limit, replacethe front pads as a set,
7. Cleanthe caliperthoroughly;removeany rust. and

checkfor grooves and cracks.
EOLTB 8. Checkthe brakediscfor damageand cracks,

NOTE:Checkthe hosesand pin boots for damage
and deterioration. 9. Installthe pad retainers.
Removethe pad shim, pad retainers,and pads.
NOTE:When replacingthe pads, replac€the shim

togetherwith the padsas a set,
OUTER
PADSHIM
C h e c kf o r w e a r .
INNER PAD
PAORETAINERS
Checkfor weaknessand
damage,
OUTERPAD
19-10
)
lO. Apply greaseto the points indicatedby the arrows 12. Pushin the pistonso that the caliperwill fit over the
in the followingillustration: pads.Make sure that the piston boot is in position
t o p r e v e n td a m a g i n gi t w h e n p i v o t i n gt h e c a l i p e r
NOTE:Use the pad greaseincludedin the pad set
or Molykote M77 grease,and apply a thin coat of PISTON
greaseevenlyto the designatedpoints.
. Pistonend and innerpad contactsurface

o Padand caliperbracketcontactsurface
. Outerpad and caliperbody contactsurface
. Outerpad shim and outer pad contactsurface CALIPERBOLTB
. Outerpad shim and caliperbody contactsurface 26 N.m {2.7kgt m,
20 rbl.ftl
WEARINDICATOR
OUTERPAD
OUIER
PADSHIM 1 3 . P i v o tt h e c a l i p e rd o w n i n t o p o s i t i o n ,t h e n i n s t a l l
caliperbolt B and tightenit.
1 4 . lnstallthebrakehosebracketon the knuckle.
NOTE:Inspectthe brakehose for interferenceand

twisting.
Depressthe brakepedalseveraltimes to makesure

the brakeswork,then test-drive
N O T E :E n g a g e m e no t f t h e b r a k e m a y r e q u i r ea
I 1. Installthe brakepadsand pad shim correctly greater pedal stroke immediately after the brake
pads have been replacedas a set. Severalapplica-
t i o n s o t t h e b r a k e p e d a l w i l l r e s t o r et h e n o r m a l
@
o When reusing the pads, always reinstall the pedal stroke.
brake pads in their original positions to plevent
loss of braking etticiencY. 1 6 . After installation,checkfor leaksat hose and line
. Contaminated brake discs ol pads reduce stop- jointsand connections, and retightenif necessary.
ping ability. Keep greaseoft the discs and pads.
N O T E :I n s t a l lt h e p a d w i t h t h e w e a r i n d i c a t o ro n
the inside.
1 9 - 11
Front BrakeDisc
DiscRunoutInspection DiscThickness
and Parallelism
Inspection
L Loosenthe front wheel nuts slightly,then raisethe
vehicle,and support it on safety stands. Remove 1 . Loosenthe front wheel nuts slightly,then raisethe
the front wheels. vehicle,and support it on safety stands.Remove
the front wheels.
2. Removethe brakepads(seepage19,8).
Removethe brakepads(seepage 19-8).
I n s p e c t h e d i s c s u r f a c ef o r d a m a g ea n d c r a c k s .
Cleanthe discthoroughlyand removeall rust. U s i n g a m i c r o m e t e r ,m e a s u r ed i s c t h i c k n e s sa t
eight points, approximately45" apart and 10 mm
Use wheel nuts and suitableplain washersto hold (0.4in) in from the outeredgeof the disc.
the disc securelyagainstthe hub,then mount a dial
i n d i c a t o ra s s h o w n , a n d m e a s u r et h e r u n o u t a t
10 mm (0.4in) from the outeredgeof the disc.
Brake Disc Runout:

BrakeDbc Thickn6s:
Standlrd: 20.9- 21.8 mm (0.82- 0.86 in)
WHEELNUT ANO
PLAINWASHER Max. RefinishingLimit: 19.0mm 10.75inl
'108N.m
(11 kg{.m,80 lbf.ft) NOTE:Replacethe brakedisc if the smallestmea-
surementis lessthan the max. refinishinqlimit.
Brake Disc Parallelism:0.015mm (0.fit06 in) max.
lf the disc is beyond the servicelimit, refinishthe NOTE:This is the maximum allowabledifference
brake disc with an on-car brake lathe, The Kwik- betweenthe thicknessmeasurements.
Lathe produced by Kwik-way Manufacturing Co.
and the "Front BrakeDisc Lathe" offeredby Snap- lf the disc is beyondthe servicelimit for parallelism,
on ToolsCo.are approvedfor this operation. refinishthe brake disc with an on-car brake lathe.
The Kwik-Latheproduced by Kwik-WayManufac-
Max. RefinishLimit: 19.0mm (0.75in) turing Co. and the "Front BrakeDisc Lathe"offered
by Snap-onTools Co. are approvedfor this opera-
NOTE:A new disc shouldbe refinishedif its runout tion.
is greaterthan 0.10mm (0.004in)
NOTE:Seesection18for brakedisc reDlacement.
19-12
Front BrakeCaliper
Disassembly
NOTE:Therearetwo typesof front brakecalipers: 3. R e m o v et h e c a l i p e rp i n s a n d p i n b o o t s f r o m t h e
"5410"or calioerbracket,
T h e c a l i p e rt y p e s c a n b e i d e n t i f i e db y t h e
"2056" stamped on the caliper body as shown below. CALTPERPINB BRACKET
CAL|PER
Checkthe type of the brakecaliperbeforeservicing.
5410Type:
see page
NOTE:For 2056type disassemblyprocedures, CALIPERPIN A
19-14.
4, lf necessary.apply compressedair to the caliper
fluid inlet to get the piston out. Placea shop rag or
@
o Never use an air hose ot dry brush to clean brakg wooden blockas shownto cushionthe pistonwhen
assemblies. it is expelled.Uselow pressureair in shortspurts.
. Use an OSHA approved vacuum clganer to avoid
breathing brake dust. @
. Do not place your iingers in tront ol the piston.
CAUTION: . Do not use high air pressure; use 8n OSHA
. Do not spill brake lluid on the vehicls; it may damage approved 30 PSInozzls,
I t the paint; if brake fluid does conlact the paint, wash

it off immedistely with waier.
. To prevenl spills, covet the hose ioin$ with rags or
shop towels.
. Clean all parts in brake fluid and air dry; blow out all
passageswith compressedair.
L Removethe banjo bolt, and disconnectthe brake

hosefrom the caliDer.
CALIPER
BANJO EOLT
Removethe pistonfrom the caliper,and checkthe
pistonfor scoring.
Removethe boot clip,pistonboot and pistonseal.
CAUTION:Take care not to damage the cylindcr

PISTONSEAL
Replace.
SEALING
Replace. BOLTS BOOTCLIP
Replace.
Removethe caliperbolts,then remove the caliper \ ,
from the bracket.
,t. (
CALIPERBODY
\) Checkfor scoring
l J PISTONBOOT
Replace. (cont'd)
19-13
Front Brake Caliper
Disassembly(cont'dl
2056Type: 4. R e m o v et h e p i n b o o t , s l e e v eB a n d s l e e v eb o o t
from the caliperbody.
@Nevor u3e an air hos€ or dry brush to clgan brake CALIPER EODY
Check for scoring
on cytinder wa .
assomblios.
Use an OSHA approved vacuum cl6aner to avoid
braathing braks duet.
CAUTION:
. Do not spill brakefluid on ths vchicle; it may damage
the paint; if brako fluid does contact the p.int. wash
it olt immediately with wato..
. To prevsnt spills, cover the ho3o ioints whh rag3 or
shop towels.
. Cl€an all parts in brake fluid and air dry; blow out 8ll
passagsswith compr63€d air.
1. Removethe banjo bolt, and disconnectthe brake

hosefrom the caliper.
SLEEV€B
SEALINGWASHERS Checkfor damage.
lf necessary,apply compressedair to the csliper
fluid inlet to get the pistonout. Placea shop rag or
woodenblockas shownto cushionthe oistonwhen
it is expelled.Use low pressureair in shortspurts,
a Do not placo your lingers in ftont ol tho pkton.

a Do noi usa high air prsssure; uso an OSHA
approved 30 PSInozzle.
WOODENALOCK
Removecaliper bolt B, pivot the caliper up out of

the way,then removethe caliperfrom the bracket.
Removethe guide pin boot from sleeveA on the

caliDerbracket.
C h e c kf o r d a m a g e .
Removethe pistonfrom the caliper,and checkthe

GUIDEPIN BOOT pistonfor scoring.
Replace.
GALIPERBRACKET
Checktor cracks.
1 9- 1 4
7. Removethe boot clip, pistonboot and pistonseal.
CAUTION;Take care not to damage the cylinder

bore.
goor cLtP
Replace.
SEAL
NSTON BOOT
Replace.
l.t
19 - 1 5
Front BrakeGaliper
Reassembly
5410Type:
NOTE:For 2056type reassemblyprocedures,

see page19-18.
o Never use an air hose or dry brush to clean brako assemblies.

. Use an OSHA approved vacuum cleanerto avoid breathing brake dust.
. Contaminatedbrake discs or pads reducestopping abilhy.
. when reusing the pads, always reinstall the brake pads in their original positions to pr€vent loss of braking €fficiency.
CAUTION:
. Do not spill brake fluid on the vehicle;it may damagethe paint; if brake fluid do€s contaci the psint, wash it oft imme"
diately with water.
. Cleanall parts in brake fluid and air dry; blow out all passag€swhh comp.€ssedair.
. Betorereassembling,checkthat all parts are free ol dust and othor toreign particlos.
. Replaceparts wilh new ones whenever specifiedto do so.
. Make sure no dirt or other toreign matt€r is allowed to contaminate the brake fluid.
. Always use Genuine Honda DOT 3 Brake Fluid. Using a non.Honda brake tluid can cause corrosion and decressethe
life of th€ system.
NOTE:
. Coatthe piston,pistonseal,and caliperborewith cleanbrakefluid.
. Replaceall rubberpartswith new oneswheneverdisassembled.
z_.
.=-.q8! .9!,H:
Use recommendedrubber greasein the caliper seal set.
-.61' use recommendedsealgreasein the catipersealset.

BRAKEPADS CALIPERBRACKEIMOUNTINGBOLT
PIN BOOTS
108N.m {11.0kgt m,80lbf.ft)
"k..6
Replace.
*/
tilfliltn
1
\ *
WEAB
WEAB rNDrcAroR
INDICATOR
t w t\J fl iJI Il car-rpen
-
prr'r
e-....,-q\,
W
l n s r a l li n n e r p a d w i t h lAV
@{
irs weat indicatot !pwatd/,.
q CALIPERBRACKET
OUTERPADSHIM
-o PIN A -
CAI-IPER -'''---&@
PAD RETAINERS
PISTONSEAL
Replace. PISTONBOOT
Replace.
-6r
/ eoorcr-re
neptace.
BLEEDSCREW I
S N.m (0.9kgt.m, 6.5 tbf.ftl
CALIPERBODY
6
v o/
19-16
'1.
Cleanthe piston and caliperbore with brakefluid, Apply the recommendedseal greasein the caliper
and inspectfor wear and damage. seal set to the sliding surfaceof the pins and the
C o a tt h e n e w p i s t o n s e a l w i t h t h e r e c o m m e n d e d lnsideof the new pin boots.
rubbergreasein the caliperseal set.and installthe lnstallthe pin boots into the groovesin the caliper
sealin the cylindergroove. bracketproperly.
CALIPERERACKET
Apply the recommendedseal greasein the caliper
sealset to the sealinglips and insideof a new pis-
ton boot,and securelyinstallit in the caliperwith the CALIPER
new bootclip.
-6l
CAUTION: Be careful nol to damage the caliper CALIPEBPIN B
cylinderwall.
-6.l
PIN BOOTS
Replace.
PISTONSEAL
Replace.
--^.
,:=-qE!!!-H
RUBBER GREASE
-6l
CALIPERPIN
7. Insertpin A and pin B into the caliperbracket.

8. Install the pin boots into the grooves in the pans
I J PISYONBOOT
Replace.
propeny.
9. Installthe brakepads in their originalpositions(see
page 19-9).
j@i 10. Pushin the pistonso that the caliperwill fit overthe
SILICONEGREASE pads,and installthe caliPer.
11. Tightenthe caliperbolts.
12. Connectthe brakehoseto the caliperwith new seal-
ing washers,and tightenthe banjobolt.
BANJO EOLT SEALINGWASHERS
34 N.m (3.5kg{ m, 25 lbflt} Replace.
L u b r i c a t et h e c a l i p e ra n d p i s t o nw i t h b r a k ef l u i d ,
then installthe pistonin the cylinderwith the dished
end facingin.
CALIPERBOLT
32 N.m 13.3kgt.rn,24lblft)
'13. Fill the brakereservoitand bleedthe brakesystem

{seepage19-7).
1 4 . Performthe following checks:
. Checkfor leaksat hose and line joints and con-
nections.and retightenif necessary.
. Checkfor brakehosesfor interferenceand twisting.
(cont'd)
19-17
Front BrakeCaliper
Reassembly(cont'd)
2056Type:
I
. Never use an air hose or dry b.ush to clean brake assemblies.
. Uso an OSHA approved vacuum cleansrto avoid breathing brake dust.
. Contaminatedbrake discs or pads reducestopping ability.
t when reusing the pads, always r6instsll the brake pads in their original positioos to prevent
loss ol braking efficiency.
CAUTION:
' Do not spill brake tluid or th€ vehicle; it m8y damage the paint; if brake fluid does
contact the paint, wash it off imme-
diately with water.
. Cleanall parts in brake tluid and air dry; blow out all passageswith compr63ed air.
. Beforo reassembling,checkthat all parts are fr€e of dust and other foreign particles,
. Replaceparts with new ones wheneveaspecifiedto do so.
. Make sure no dirt or other foreign matter is allowad to contaminato the brake fluid,
' Always use Genuine Honda DOT 3 Brake Fluid. Using a non-Hondabrake fluid can
caus€ corrosior and decreasethe
life ol the system.
NOTE:
. Coatthe piston,pistonseal,and caliperborewith cleanbrakefluid.
. Replaceallrubberpartswith new oneswheneverdisassembled.
.'=5@: Use recommendedrubbergreasein the calipersealset,
-6l ' Use recommendedsealgreaseIn the calipersealset.
BRAKEPAOS
@6--i#i['i,?li"..;:l]l?Y]li"'"'
CALIPERBRACKET
OUTERIPAD
r""'"rr -/ffr
WEAR,INDICAToR.
r"""ip"autr, ,ffi \
i t s w e a r n d c a t o r u ' w\a r d \ e"6ft 'ADRETATNERS
MffiA pr
GUIDE
PIN
BOOT \\ ) {I I II ) I I
\I\d/ tt\' id 6
% '---r..'.*
caL,PER u -es
**=*t
".-,."oo*'J.l,
ru,oonW U
BLEED SCREW SLEEVE
A
9 N.m(0.9kgf.m,6.5lbf.ft)
\
o@ -"-41
q.- SLEEVE8 r{.i'""Jg*'
t\ a,t/
c'f3!@
CALIPERBOLTB PISTONEOOT
2 6 N m { 2 . 7 k g f . m20
, tbf.ftl Replace. -
CALIPERBODY .&l
PIN BOOT BOOTCLIP

Replace.
Replace.
19-18
1. Cleanthe piston and caliperbore with brakefluid, 4. Lubricatethe caliper and piston with brake fluid,
and inspectfor wear and damage. t h e n i n s t a l lt h e p i s t o n i n t h e c y l i n d e rw i t h t h e
dishedend facingin.
Coat a new Distonsealwith the recommendedrub-
ber greasein the calipersealset,and installtheseal
in the cylindergroove.

seal set to the sealinglips and insideol a new pis-
ton boot, and securelyinstallit in the caliperwith a
new boot clip.
CAUTION: Be carelul not to damage ths calipor

cylinder wall.

seal set to the sliding surfaceoJ sleeveB and the
insideof the new pin and sleeveboots.
lnstallthe new sleeveand pin boots 8nd sleeveB

on the caliDer.
I J NOTE: Makesure to installthe boots into the grooves

in the caliperand sleeveB properly.
BOOT
SI.EEVE
Replace. Replace.
=_.
-6,
SILICONEGREASE
-1!!4!!n
RUBEERGREASE
SLEEVEB
Y
P IN BOOT
Replace.
t./ (cont'd)
19-19
Front BrakeCaliper
(cont'dl
Reassembly
7 . Apply the recommendedseal greasein the caliper 1 1 .Connectthe brakehoseto the caliperwith new seal-
seal set to the sliding surfaceof sleeveA and the ing washers,and tightenthe banjobolt.
insideof a new guide pin boot.
Tightenthe caliperbolt B.
I n s t a l lt h e g u i d e p i n b o o t i n t o t h e g r o o v e i n t h e
sleeveA.
BANJOBOLT
Make sure that the brake pad retainersand brake
padsare in their originalpositions(seepage 19-10).
26 N.m (2.7 kgl.m, 20 lbtftl
1 3 . Fill the brake reservoir and bleed the brake svstem

(seepage 19-7).
1 4 . Performthe following checks.

Installthe caliperonto sleeveA, and pivot it down . Checkfor leaksat hose and line ioints and con-
into position. nectaons,and retighten if necessary.
. Checkfor brake hoses for interferenceand twist-
NOTE:Installthe guide pin boot into the groove in Ing.
the caliperproperly.
BRACKET
SLEEVEA
19-20
MasterCylinder/BrakeBooster
I RemovaUlnstallation
CAUTION: 9. Removethe four boostermountlngnuts
. Be care{ulnol to bend or damagethe brake lineswhen 10. Pull the brake booster forward until the clevis is
rsmovingthe mastsr cYlinder. clearof the bulkhead.
. Do not soill brakefluid on the vehicle; it may damage 1 1 . R e m o v et h e b r a k eb o o s t e rf r o m t h e e n g i n ec o m -
the paint; if brake fluid does contact the paint, wssh panmenr.
'12. Installthe brakeboosterand mastercylinderin the
it off immediatelYwith water'
. To prevent spill3, cover the hose ioints with rags or reverseorderof removal.
shop towels.
CAUTION:
the brakefluid levelswitchconnectors' . When connecting the brake lines. make sure
1 . Disconnect
2 . Remove reservoircap from the mastercylinder'
the that there is no inte erence between the brake
3 , The brakefluid may be suckedout through the top lines and oth6r Parts.
of the mastercylinderreservoirwith a syrlnge. r Be careful not to bend or damage the brake lines
Disconnect the brakelinesfrom the mastercylinder' when installing the master cylinder.
5 . R e m o v et h e m a s t e rc y l i n d e rm o u n t i n g n u t s a n d
washers. N O T E : l f r e p l a c i n gt h e m a s t e rc y l i n d e ro r b r a k e
6. Removethe mastercylinderfrom the brakebooster' b o o s t e r ,c h e c ka n d a d i u s tt h e p u s h r o dc l e a r a n c e
7. Disconnectthe vacuum hose trom the brakebooster' be{oreinstallingthe mastercylinder(seepage 19-221'
8. Removethe cotterpin and clevispin from the clevis'
, n d b l e e dt h e
F i l l t h e m a s t e rc y l i n d e rr e s e r v o i r a
brake svstem (see Page 19-7).
CAUTION: Do not disconnect the clevb by remov-
ing it from the operating rod of the brako booster' lf 1 4 . After installation.checkthe brakepedal height and
the clevis is loosened, adiust the pushrod length brake pedaltree play (see page l9-5) and adjust if
before installingth€ brake booster (seepage 19-221' necessary.
BRAKE BOOSTER
\l/ (WithABS:7" + 8" tandembrakebooster)
-6.4 BRAKEFLUIOLEVEL
CLEVISPIN SWITCHCONNECTORS
MASTERCYLINDER
COTTERPIN
Replace.
VACUUM HOSE
To RearWheelCylinders
t'N't'ttrnt'-''
To FrontCaliper $
(WithoutABS)
To FrontCaliper
lWithoutABSi
15 N.m {1.5kgl m,
11 tbtft)
CONTROLVALVE
PBOPORTIONING
1 5 N . m { 1 . 5 k g i f . m ,1 1 l b t f t }
l r (With ABS: To modulator unit)
19-21
MasterCylinder/BrakeBooster
Pushrod GlearanceAdjustment
NOTEr N O T E :l f t h e c l e a r a n c eb e t w e e nt h e g a u g e b o d y
. T h e m a s t e rc y l i n d e r p u s h r o d - t o - p i s t o cn l e a r a n c e and adjustingnut is 0.4 mm (0.02in), the pushrod-
must be checkedand adjustmentsmade, if neces_ to-pistonclearanceis 0 mm. However,if the clear_
sary,beforeinstallingthe mastercylinder. ance betweenthe gauge body and adjustingnut is
. ABS type is shown, conventionalbraketype is similar. 0 mm, the pushrod-to-piston clearanceis 0.4 mm
(0.02in) or more.Therefore,it must be adjustedand
1. Setthe specialtool on the mastercylinde.body;push rechecked.
in the centershaft until the top of it contactsthe end
ofthe secondarypistonby turningthe adjustingnut. 6. lf clearanceis incorrect,loosenthe star locknut,and
turn the adjusterin or out to adjust.
NOTE;
. Adjustthe clearancewhile the specifiedvacuum
is appliedto the booster.
. Holdthe cleviswhile adjusting.
7 . Tightenthe star locknutsecurely.
Removethe specialtool.
0 - 0.4mm (0- 0.02in)
STARLOCKNUT
22 N.m
{2.2kg,f.m,16lbtft)
Withoutdisturbingthe centershaft'sDosition,install
the specialtoolupsidedown on the booster.
Installthe mastercylinder nuts, and tighten to the
specifiedtorque.
Connectthe boosterin-linewith a vacuumgaugeO_
101 kPa (0 - 760 mmHg, 30 in.Hg)to the booster,s
e n g i n e v a c u u m s u p p l y , a n d m a i n t a i na n e n g i n e ADJUSTER
PUSHROD
speedthat will deliver66 kpa (500mmHg,20 in.Hg) ADJUSTMENTGAUGE
vacuum. 07JAG- SD('1(x)
With a feelergauge.measurethe clearanceDetween 9. Adjust the pushrodlength as shown if the booster
the gaugebody and the adjustingnut as shown. rs removed.
Clearance:0 - 0.4 mm {0 - 0.02 in) 11610.5 mm

{{.571 0.02in)
VACUUM GAUGE
(Comm€rciallyavaileblel
0 - 101kPa
{0 - 760 mm Hg, 30 in.Hg)
AOJUSTINGNUT
PUSHROD
LOCKNUT
FEELER
GAUGE 15 N.m 11.5kgf.m,11 tbtftl
1 0 . Install the master cylinder {see page l9-21).
19-22
BrakeBoosterInsPection
FunctionalTest Booster CheckValve Test
1. With the engine stopped,depressthe brake pedal 1. Disconnectthe brake boostervacuum hose at the
severaltimes to depletethe vacuumreservoir,then booster.
depressthe pedalhard and hold it for 15 seconds lf 2. Stan the engineand let it idle.Thereshouldbe vac-
t h e p e d a l s i n k s ' e i t h e r t h e m a s t e rc Y l i n d e ri s uum. lf no vacuum is available,the checkvalve is
bypassinginternally,or the brake system (master not working properly. Replacethe brake booster
c y l i n d e r .l i n e s .m o d u l a t o r ,p r o p o r t i o n i n gc o n t r o l vacuumhoseand checkvalve,and retest.
valve,or caliPer)is ieaking. BRAKEBOOSTER
2. Start the engine with the pedal depressed lf the VACUUMHOSE
pedalsinksslightly,the vacuumboosteris operating ( C h e c kv a l v e
n o r m a l l y .l f t h e p e d a l h e i g h t d o e s n o t v a r y , t h e built-in)
boosteror checkvalve is faultY.

3. With the engine running.depressthe brake pedal
l i g h t l y .A p p l y j u s t e n o u g hp r e s s u r et o h o l d b a c k
a u t o m a t i ct r a n s m i s s i o nc r e e p .l f t h e b r a k ep e d a l
s i n k sm o r e t h a n 2 5 m m ( 1 . 0i n . ) i n t h r e e m i n u t e s ,
t h e m a s t e rc v l i n d e ri s f a u l t y . A s l i g h t c h a n g ei n
pedal height when the A'lCcompressorcycleson
a n d o f f i f n o r m a l . ( T h e A / C c o m p r e s s o rl o a d
changesthe vacuumavailableto the booster')
LeakTest
1 . D e p r e s st h e b r a k ep e d a lw i t h t h e e n g i n er u n n i n g .
then stop the engine.lf the pedal height does not
vary while depressedfor 30 seconds,the vacuum
b o o s t e r i s O K . l f t h e p e d a l r i s e s .t h e b o o s t e ri s
faulty.
2, With the engine stopped,depressthe brake pedal
s e v e r a lt i m e s u s i n g n o r m a l p r e s s u r e W h e n t h e
Dedalis first depressed,it should be low On con-
secutiveapplications, the pedalheightshouldgrad-
uallv rise. lf the pedal positiondoes not vary, checK
the boostercheckvalve.
l./
19-23
Rear Brake Pads
Inspection
and Replacement
4. Removethe outerpad shim,pads,and pad retainers.
Never use an air hose or dry brush to clean brake
assemblies.
Use an OsHA-apptoved vacuum cl€aner to avoid
breathing brake dust,
'L PAORETAINERS
Blockthe front wheels,loosenthe rear wneet nuts
s l i g h t l y ,s u p p o r tt h e r e a r o f t h e v e h i c l eo n s a f e t y
stands,then removethe rearwheels.
Releasethe parkingbrake,and removethe calioer

s hi e l d .
OUTERPAO
SHIM
Checkfor
REARBRAKE PADS
Check
for wear.
U s i n g v e r n i e rc a l i p e r s m
, e a s u r et h e t h i c k n e s so f
CALIPER
SHIELD each brakepad lining.The measurementdoes not
anclude the pad backingplatethickness.
Removethe brakehose clamp bolt from the trailing
arm first, then remove the two caliper mounting BrakePad Thickness:
boltsand the caliperfrom the bracket. Standard: 7.0 - 8.0 mm {0.28- 0.31 in}
ServiceLimit: 1.5 mm {0.06in}
CAUTION:
. Thoroughly clean the outside of the caliDerto
prevent dust and dirt trom entering inside.
. Support the calipor with a pieco of wire so that
it does not hang fuom the brake hose.
NOTErCheckthe hosesand pin boots for damage

or deterioration.
PARKING BRAKE
CABLE ^.. ._-_ ---.
BACKINGPI-ATE
lf the pad thicknessis less than the service limit,

replacethe padsand shimstogetheras a set.
19-24
I 7 . Cleanthe caliperthoroughly;removeany rust, and 12. Rotatethe caliperpistonclockwiseinto the cylinder'
checkfor groovesand cracks. then align the cutout in the piston with the tab on
the innerpad by turningthe pistonback
Checkthe brakediscfor damageand cracks.
CAUTION: Lubricate ths boot with rubber grease
l v l a k es u r e t h a t t h e p a d r e t a i n e r sa r e i n s t a l l e di n to avoid twisting the piston boot. lf the piston boot
their correctpositions. is twisted, back it out so it sits properly.
CALIP€RMOUNTING
BOLTS
23 N,m {2.3kg{.m, 17 lbt'ft)
CUTOUT
BRAKECALIPER
PAD RETAINERS
Apply greaseto the pointsindicatedby the arrow in
the followingdrawing:
NOTE:Use the pad greaseincludedin the pad set 1 3 . Installthe brakehoseclampon the trailingarm.
or lMolykoteM77 grease,and apply a thin coat of
greaseevenlyto the designatedpoints. 1 4 . Installand tightenthe calipermountingbolts.
. Pistonend and inner pad contactsurface
. Padand caliperbracketcontactsurface 1 5 . Installthe calipershield.
. Outerpad shim and outer pad contactsurface
. Outerpad shim and caliperbody contactsurface
1 6 . After installation.checkfor leaksat hose and line

jointsand connections, and retightenif necessary.
1 1 . l n s t a l lt h e b r a k ep a d s a n d o u t e r p a d s h i m o n t h e 1 7 . Depressthe brakepedalseveraltimes to makesure

caliper bracket.Installthe inner pad with its wear the brakeswork,then test-drive
indicatorfacingdownward.
NOTE:Engagement of the brakemay requrregreater
pedaltravel immediatelyafter the brakepads have
@
iwhen reusing the pads, always reinstall the
of
been replacedas a set. Severallight applications
pedalwill restore the normalpedaltravel.
t./ brake pads in iheil original posiiions lo prevont the brake

loss ol braking efficiency Greaterthan normal pedaltravel may damagethe
. Contaminaled brake discs or pads reduce stop- mastercylinder.
ping ability. Keepgreaseoff the discs and pads.
19-25
RearBrakeDisc
DiscRunoutInspection DiscThickness
and Parallelism
Inspection
1 . Loosenthe front wheel nuts slightly,then raisethe
vehicle, and suppon it on safety stands. Remove 1. Loosenthe front wheel nuts slightly,then raisethe
the front wheels. vehicle,and support it on safety stands. Remove
the front wh6els.
Removethe brakepads(seepage 19-24).
2. Removethe brakepads(seepagej9-24).
I n s p e c t h e d i s c s u r f a c ef o r d a m a g ea n d c r a c k s .
Cleanthe discthoaoughly,and removea rust. 3. U s i n g a m i c r o m e t e r .m e a s u r ed i s c t h i c k n e s sa t
erght points, approximately45" apart and 1o mm
Use wheel nuts and suitableplain washersto hold {0.4 in) in from the outer edge of the disc. Replace
the disc securelyagainstthe hub. then mount a dial the brakedisc if the smallestmeasurementis less
i n d i c a t o ra s s h o w n . a n d m e a s u r et h e r u n o u t a t than the max. refinishinglimit.
10 mm (0.4in) from the outeredgeof the disc.
Brake Disc Runout:

ServiceLimit:0.10mm {0.00,tin)
BrakeDisc Thickness:
Standard:8.9 - 9.1 mm (0.350- 0.358in)
Max. RsfinishingLimit: 8.0 mm {0.31in}
Brake Disc Parallelirm:0.015mm

(0.0006inl msx.
5. lf the disc is beyond the servicelimit, refinishthe
brakedisc, NOTE;This is the maximum allowabledifference
betweenthe thicknessmeasurements.
Max. RetinishingLimit: 8.0 mm {0.31in)
4. lf the disc is beyondthe servicelimit for Darallelism.
NOTE:A new disc shouldbe refinishedif its runout refinishthe brakedisc.
is greaterthan 0.10mm (0.004in).
NOTE;Seesection18for brakedisc replacement.
19-26
Rear BrakeCaliper
Disassembly
5, R e m o v et h e p i n s a n d p i n b o o t s f r o m t h e c a l i p e r
@
f l',leveruse an air hose or dry brush to clean brake bracket.
assemblies.
. Use an OsHA-approvedvacuum cleaner to avoid
breathing brake dust.
. Contaminated brake discs or pads reduce stopping
ability.
CAUTION:
. Do not spill brake tluid on the cal; h may damagethe
paint; if brake fluid does contact the paint, wash ii
ofl immediatelYwith water.
. To prevent spills, cover the hose ioints whh rags or
shop tow€ls.
. Clean all parts in brake fluid and air dry; blow out all
passagsswith complessedair.
1. Removethe calipershield(seepage 19-24).
2. R e m o v et h e l o c k p i n a n d c l e v i sp i n . R e m o v et h e
cableclip,and disconnectthe cablefrom the arm
CABLECLIP
PIN A
6. Removethe pad springfrom the caliperbody
Removethe banjobolt and two sealingwashers
Removethe two calipermountingbolts and caliper

body from the bracket.
CALIPERMOUNTNG AOLTS
CALIPERBRACKET SEALING
Checkfor cracks WASHERS BANJO (cont'd)
Replace. BOLT
19-27
RearBrakeGaliper
Disassembly(cont'd)
7. Removethe piston by rotatingthe piston counter- 9. Installthe specialtool betweenthe caliperbodv and
c l o c k w i s ew i t h t h e t o o l , a n d r e m o v et h e p i s t o n spnng cover.
boot.
CAUTION: Be caretul not to damags the inside of
CAUTION: Avoid damaging the piston. the caliper cylinder during caliper disassembty.
BRAKESPRING
COMPRESSOR
PISTONBOOT 07HAE- SG00100
Replace. LOCKNUTS
Removethe pistonseal. Positionthe locknutsas shown.then turn the shaft

untilthe platejust contactsthe caliperbody.
CAUTION: Take care not to damage the cylinder
bore. N O T E : D o n o t c o m p r e s st h e s p r i n g u n d e r t h e
springcover.
CALIPERBODY 1 1 . Turn the shaft clockwise1/4-'ll2 tu.n to comoress

Check for scoring on adjustingspringB in the caliperbody.
CAUTION: To preyant damage to the inner compo-

nonts. do not turn the shaft mor€ than 1/2 turn.
SHAFT
LOCKNUTS
PISTONSEAL
Replace.
ADJUSTII{G
SPRING8
19-28
\
Lowerthe locknutsfully,and tightenthem securely. 15. Removethe adjustingbolt.
NOTE:Keepthe locknutsin this positionuntil you

r e i n s t a l l t hcei r c l i p .
1 3 . Removethe circlipwith snapring pliers.
SNAPRING
PLIERS
07914- SA50001
Removethe springcover,adjustingspringB, spacer,

't4. Hold the platewith your fingers,and turn the shaft bearingA, and cup from the adjustingbolt.
Removethe specialtool from the
counterclockwise.
'17. Removethe sleevepiston,and removethe pin from
calioer.
the cam in the caliperbody.
LOCKNUTS SLEEVEPISTON
Checklor wear and
damage,
i
I
I
6-50-a
w l \
I
O-RIITG
Repl6ce.
l./ (cont'd)
19-29
RearBrakeGaliper
(cont'dl
Disassembly
18. Removethe returnspring.
RETURN
SPRING
PARKINGLEVER/
CAM ASSEMBLY
Checklor damage.
1 9 . Removethe parkinglever and cam as an assemblv

from the caliperbody.
CAUTION: Do not loosen the parking nut with the

cam inslalled in the caliper body, lf the leyer and
shaft must be separated, hold the lever in a vise,
and loosenthe parking nut,
Removethe cam boot.
19-30
I Reassembly
HP* "n ",, hos6 or drv brush to ctoan brake assemblies.

o Use an OSHA-approvedvacuum cleanel to avoid brealhing brake dust'
. Contaminatedbrake discs or pads reducestopping sbility.
. When reusing the pads, in3tall thom in thoil original positions to prevent loss of braking efficiency'
CAUTION:
. Do not soill brake fluid on the vehicle; lt may damagelhe paint; if brake fluid does contacl the paint' wash it oft imme-
diately with water.
. Cl€anall Darts in brake fluid and air dry; blow out all passagsswith comPressedair'
. Belore rsas3embling,checkthat all parts ars free ot du3t and othor tor€ign particles'
. Replaceparts with new ones whenever spscifiodto do so.
o Make sur€ no dirt or othor foreign matter is allowed to contaminate the brake tluid'
. Always use Genuine Honda DOT 3 Brake fluid. Using a non-Hondabrake fluid can Gtuse corrosion and decreasethe
lif€ of ths system.
NOTE:
. Coatpiston,pistonseal,and caliperborewith cleanbrakefluid
. Replaceall rubberpartswith new oneswheneverdisassembled.
o .-'{@]: Userecommendedsiliconeand pin greasesin the calipersealset.
. -ffi,Use rubbergreasein thecalipersealset.

recommended
-"'9
sPRTNG
RETuRN
8 mm FLANGEBOLT
iiilji:ll;; 23 N.m (2.3kgt'm, 17lbf ftl
__X.,,..".^ BLEEDSCREW
9 N.m (0.9kgtm,6.5lbf'ft|
@
BEARINGA
PAOSPNING
=^.
PISTONBOOT
F -61
\
@@-t-. .ffi
r---
PINBOOTS
CUP
Replace.
Replace.
OUTERPAD SHIM
BRAKEPAOS PISTONSEAL
Replace.
I
"l-r,r.,"or"'*o" orr" @.,
23N.m{2.3kgtm,17lbf.ftl \@ CALIPEB PISTON
BRACKET
l / CALIPERBMCKET \
MOUNTINGEOLTS
----.-,o,
54 N.m (5.5 kgf.m,40lbl.ft) q%
(cont'd)
19-31
RearBrakeCaliper
(cont'dl
Reassembly
L Packall cavitiesof the needlebearingwith the rec, 5. I n s t a l l t h ep i n i n t h e c a m .
ommendedrubbergreasein the calipersealset,
O.RING
Coat a new cam boot with recommendedrubber Replace.
grease in the caliper seal set, and install it in the
caliperbody.
PARKINGNUT
28 N.m (2.8 kgt m,
20rbr.trt
SLEEVE
PISTON
SPRII{G
WASHEN
z. Installa new O-ringon the sleevepisron.
.-_e!!!9!.{
RUBBER 7. Installthe sleevepistonso that the hole in the bot-
GREASE tom of the pistonis alignedwith the pin in the cam,
and the two pins on the pistonare alignedwith the
holesin the calioer.
Coat a new cup with recommendedrubbergrease

in the caliperseal set, and installit with its groove
facingthe bearingA side of the adjustingbolt.
€8.--:BTif
Apply recommendedrubber greasein the caliper @'-.-3nfi""'i"
seal set to the pin contactingarea of the cam, and @--seacrn
installthe cam and lever assemblyinto the caliper
bodv. $ eeenrne
a
lnstallthe returnspring.
CAUTION:
. When the cam and lever wgre separatod.b€ surg
to assemble them bofore installing the cam in
the caliper body, Install the lev€r and spring
fi,*,*^"
GF- CUP
Replace.
=^.
#-g!!!!!Jl
washer. apply locking agent to the threads, and RUBBER
GREASE
tighten the parking nut while holding the l.vor
whh a vise,
. Avoid damaging the cam boot since it must bs
installed before thg cam.
. When installing the cam, do nol allow the cam
boot lips lo turn outside in.
o Fit the bearingA, spacer.adjustingspring B, and
springcover on the adjustingbolt, and installthem
in the caliDercvlinder.
19-32
1 0 . l n s t a l lt h e s p e c i atl o o l o n t o t h e s p r i n gc o v e r ,a n d 13. Coat a new piston sealwith recommendedsilicone
turn the shaft untilthe locknutcontactsthe plate. greasein the calipersealset,and installit in the cali-
per.
PISTONSEAL
Replace.
-6l
PISTONBOOT
Replace. RUBBER
GREASE
1 4 . Apply recommendedrubber greasein the caliper

seal set to the sealinglips and insideof a new pis-
ton boot,and installit in the caliper.
Coatthe outsideof the pistonwith brakefluid, and

i n s t a l li t o n t o t h e a d j u s t i n gb o l t w h i l e r o t a t i n gi t
clockwisewith the tool.
1 1 . Checkthat the flaredend of the springcoveris below CAUTION: Avoid damaging the piston and piston
the circlipgroove. boot.
12. Installthe circlip into the groove.then removethe

specialtool.
NOTE:Checkthat the circlipis seatedin the groove

properly.
PISTON
CIRCLIP
SPRINGCOVER
t.t (cont'd)
19-33
RearBrakeCaliper
(cont'dl
Reassembly
'16. Installthepad
springonto the caliper. 21. Installthe brakepad retainersand brakepads (see
page19-25).
PAD SPRING 22. Align the cutout in the piston with the tab on the
innerpad (seepage 19-25).
Installthe caliperonto the caliperbracket.and tight-
en the calipermountingbolts.
CALIPERMOUNTINGBOLTS
23 N.m {2.3 kg{.m. 17 lbf.ft)
BANJO BOLT
34 N.m
1 1 . Apply the recommendedpin groasein the caliper WASHERS 13.5kg{.m.
sealset to the slidingsurfaceof the pins and inside Replace. 25 rbtft)
of the new pin boots. 24. Connectthe brakehoseto the caliperwith new seal,
ing washers,and tightenthe banjo bolt,
Installthe pin boots into the groovesin the caliper Insertths cable through the arm, and connectthe
bracketproperly. cabls to the lever with the clevis pin and lock pin.
PINBOOTS Installthe cableclip securely.
Replsce.
CLEVISPIN
-t
(Bl.ck Colorl //t
LOCKPIN
Roplace.
26. Installthe caliDershield.
27. Fill the brakereservoir,and bleedthe brakesvstem
(seepage19-71.
28. Operatethe brake pedal severaltimes, then adjust
PIN the parkingbrake(seepage 19-6).
Repl6ce. 29. After installation,performthe followingchecks:
PIN GREASE
. Checkfor leaksat hose and line joints and con-
19. Insertpin A and pin B into the caliperbracket. nections,and retightenif necessary.
. Checkthe parkingbrakeleverfor operation,and
20. Installthe pin boots into the grooves in the p rn s adjust it if necessary.
propefly. . Checkfor brakehosefor interference or twistinq.
19-34
RearDrum Brake
Index/lnspection
Never use an air hose or dly brush to clean brake assemblies,

Use an OSHA approved vacuum cleanarto avoid breathing brake dust,
a Contaminatedbrake linings or drums reducestopping ability.
a Block the tront wheels before iacking up ths r€ar of lhe vehicle.
'1.
Blockthe front wheels,loosenthe rear wheel nuts slightly,supportthe rear of the vehicleon safety stands,then
removethe rearwheels.
2. the parkingbrake,and removethe rearbrakedrum.

Release
WHEELCYLINDER
Inspectfor leakage.
I N m 10.9kgtm, 6.5 lbf.ftl lf necessary,replaceas an assembly.
PARKINGBRAKELEVER
Markedleftand right.
WAVE
u-cLrP WASHER UPPERRETURNSPRING
Replace. Checkfor weakness
@
I ano oamage,
J
PIVOTPIN
/ €f-l ,.ro,".r r.*,"n

TENSIONPIN
/
10 mm BOLT
6,1Nm 15.5kgf m, .^ *'t") |
d " /
/
/
, Installsecurelyon
tensionpin.
II
47 tbf.ft)
IU
BACKINGPLATE
Markedlelt andright- ctEv'sB
/ (t
ADJUSTERBOI-T
Checkratchetteeth
for wear and damage. LOWERRETURN
SPRING
Checkfor weakness
BRAKESHOE and oamage.
seepage19-36
Inspection,
lf brakeshoes are to be SELF.ADJUSTER
r e u s e d ,m a r k a n d r e a s s e m b l e LEVEB
in same position.
SELF-ADJUSTER
SPRING
Checkfor weakness
ano oamage.
BRAKEDRUM
seepage'1936
Inspection,
19-35
RearDrum Brake
Inspection
1 . Checkthe wheelcylinderfor leakage. 6. Measure the inside diameter oJ the brake drum
usingthe insideverniercalipers.
Checkthe brakeliningsfor cracking,glazing,wear,
and contamination. Drum Inside Diameter:
Standard: 199.9- 200.0mm {7.870- 7.874in)
Measurethe brakeliningthickness. Servic€Limit: 201.0mm (7.913inl
Brake Lining Thickness: INSIDEVERNIERCALIPERS

Standard: 4.0 mm {0.157in}
WHEELCYLINDER
BRAKEORUM
7. l f t h e i n s i d ed i a m e t e ro f t h e b r a k ed r u m i s m o r e
LININGS
than the servicelimit, replacethe brakedrum.
8. C h e c kt h e b r a k ed r u m f o r s c o r i n g ,g r o o v e s ,a n d
NOTE; Measurementdoes not include brakeshoe cracks.
thickness.
4. lf the brakelining thicknessis lessthan the service

limit, replacethe brakeshoesas a set.
Checkthe bearingsin the hub unit for smooth oper-

ation. lf defective,refer to section 18
19-36
BrakeShoeDisassembly
t -
1. R e m o v et h e t e n s i o np i n s b y p u s h i n gt h e r e t a i n e r 6. Removethe wave washer,parkingbrakelever,and
springsand turningthem. pivot pin from the brakeshoe by removingthe U-
clrp.
TENSIONPINS
PARKINGERAKE
I-EVER
WAVEWASHER
/
@@
I
I
U-CLIP
Replace.
RETAINER
SPRINGS
Lower the brake shoe assembly,and remove the
lower returnspring.
BrakeShoeReassembly
NOTEi Be carefulnot to damagethe dust cover on
t the wheelcylinder. 1 . Apply brakecylindergrease(P/Nr08733- B020E)or
equivalentrubber greaseto the sliding surfaceof
3. Removethe brakeshoeassembly. the pivot pin,and insertthe pin into the brakeshoe.
4. Disconnectthe parkingbrakecablefrom the parking Installthe parkingbrakelever and wave washeron

brakelever. the pivot pin and securethem with the U-clip,
Removethe upper returnspring,self-adjuster lever, NOTE: Pinchthe U-clip securelyto preventthe pivot
a n d s e l f - a d j u s t esrp r i n g ,a n d s e p a r a t et h e b r a k e pin from comingout of the brakeshoe.
snoe5.
ADJUSTEBBOLT UPPERRETURNSPRING
Checkratchetteethfor Checkfor weakness
wearano oamage. a n oo a m a g e .
,6;::"'
N
r ll LEVER
//
,'/
t (cont'd)
19-37
RearDrum Brake
BrakeShoeReassembly
{cont'dl
C o n n e c tt h e p a r k i n g b r a k ec a b l e t o t h e p a r k i n g 5. Cleanthe threadedportionsof clevisesA and B.
brakelever. Coat the threads of the cleviseswith grease.To
shoften the clevises, tun the adjuster bolt.
Apply greaseon eachslidingsurface.
6. Hook the self-adjusterspring to the self-adjuster
!@ contaminated brake linings reduce leverfirst,then to the brakeshoe
stopping ability. Keep greaseor oil off the blake lin-
ings. Wipe any excessgreaseoff the parts, 7. Installthe clevisesand upper return spring. noting
the installationdirection.
. Apply brakecylindergrease{P/N:08733- 8020E)
o r e q u i v a l e nrt u b b e rg r e a s et o t h e s l i d i n gs u r - NOTE:Be carefulnot to damagethe wheel cylinder
facesas shown. dustcovers,
8. Installthe lower returnspring.

+a Slidingsurlace 9. Installthe tensionpins and retainingsprings.
SpRtNG
uppERRETURT{ CLEVISB
CLEVISA
Apply Molykote44MAto the brakeshoeendsand

LOWERRETURNSPRING
oppositeedgesofthe shoesas shown.
_' o Opposite edge of the shoe 't0. Installthebrakedrum.

+O Brake shoe ends
1 1 . lf the wheel cylinderhas been removed,bleed the

brakesystem(seepage 19-7),and checkfor leaksat
brakeline connections,
and retightenif necessary.
12. Depressthe brake pedal severaltimes to set the

self-adjusting
brake.
1 3 . Adjustthe parkingbrake(seepage19-6).
19-38
Brake Hoses/Lines
Specifications
Inspection/Torque
L J
leaks,interference,
t. Inspectthe brakehosesfor damage,deterioration, and twisting.
2. Checkthe brakelinesfor damage,rusting.and leakage.Also checkfor bent brakelines.
and retightenif necessary'

3. Checkfor ieaksat hoseand line iointsand connections,
4. Checkthe mastercylinderand ABS modulatorunit for damageand leakage
CAUTION: Replacetho brake hose clip whenev€r the brake hose is serviced.
ABS MODULATORUNIT-Io-BRAKE l-lNE

19 N.m (1.9 kgf.m, 14lbl.ftl
REARDISGBRAKE:
PROPOBTIONINGCONTROLVALVE. BRAKEHOSE-to4ALlPER
io-BRAKELINE {BANJOBOLT}
l5 N.m (1.5 11 tbf.ftl 34 N.m (3.5kgtm,25 lbf ftl
BLEEOSCREW
MASTERCYLINDER-Io-BMKELINE
15 N.m (1.5ksrf.m,11 lbf'ft) 9 N'm (0.9kgf.m, 6.5 lM.ftl
BRAKELINE-to-WHEEL CYLINDER
15 N.m (1.5kgl.m, 11 lbf.ftl
BLEEDSCREW
7 N.m {0.7kst m, 5 lbf,ttl
J HOSE
BRAKELINE-io-aRAKE
15 N.m {1.5 11 tbtft)
BRAKELINE-Io-BRAKE HOSE
15 N.m (1.5kgt.m, 11 lbf'ft)
(BANJOBOLT}
3,1N.m 13.5kgf.m, 25 lbf.ft)
19-39
BrakeHoses/Lines
HoseReplacement
CAUTION: 6. Installthe brakehose bracketand brakehose onto
. Bgfore reagsembling,chgck that all parts are free of the knucklefirst.then connectthe brakehoseto the
dust and othor foroign particles. caliperwith the banjobolt and new sealingwashers.
. Repl8ceparts with new ones whenever specified to
do so, BRAKEHOSE
. Do not spill brake fluid on th6 vehicle; it may damage
tho paint; if brake fluid does contact the paint, wash
it off immediately with water.
1 . Replacethe brakehose if the hose is twisted,cracked,

or if it leaks.
6 mm HOSEBRACKET
Disconnect the brakehosefrom the brakeline using BOLTS
a 10 mm flarenut wrench. 9.8 N.m
{1.0kgf m, 7 lbtfr}
FLARENUT
WRENCH
lCommercially
available)
BRAKELINE
BANJOBOI.T
34N.m
{3.5kgf.m,25lbt.ftl
7 . I n s t a l lt h e b r a k eh o s e o n t o t h e u o o e r b r a k eh o s e
bracketwith a new brakehoseclip
BRAKEHOSE 15 N.m
(1.s ks{.m, 11 lbl.ftl
Removeand discardthe brake hose cliD from the
brakehose.
8 . Connectthe brakelineto the brakehose.
After installingthe brakehose,bleedthe brakesys-

tem (seepage 19-7).
Removethe banjo bolt, and disconnectthe brake
hosefrom the caliper. 1 0 . Performthe followingchecks:
. Checkthe brakehoseand line joint for leaks,and
Removethe brakehose bracketfrom the knuckle. tightenif necessary.
. Checkthe brakehosesfor interference and twist-
In g .
19-4 0
ParkingBrakeCable
and Replacement
Inspection
L
CAUTION: The parking blake cables must not be bent or distorted. This will lead to stiff operation and premature cable
failure.
PARKINGBRAKECABLE
Checkfor faultymovement.
PARKINGBRAKELEVER
Checkfor smooth
operation.
DISCBRAKETYPE:
EOUALIZER CLEVISPIN
\ i , PARKINGBRAKESWITCH
Disc BrakeType: Drum BrakeType:

Disconnect the parkingbrakecablefrom the leveron the Removethe parkingbrakecablefrom the backingplate
caliperby removingthe lockpin and clevispin, and remove usinga 12 mm offsetwrenchas shown.
the cablefrom the arm by removingthe clip
PARKINGERAKECABLE
BACKINGPLATE
CLEVISPIN
/ {tt 12 mm
OFFSETWRENCH
(Commercially
available)
19-41
L -
Anti-lockBrakeSystem(ABSI
19-44 Wheel Sensor ........19-64
ComponentLocations.........................
19-45 Solenoid .................
19-60
Anti-lockBrakeSystem (ABS) ABS PumpMotor .............................
19-68
Features/Construction..................., 19-46 Main Relay .............
19-71
Operation ...............
19-47 lgnition Voltage .... 19-73
Circuit Diagram .........19-50 CentralProcessingUnit {CPU}........19-74
ABS Control Unit Terminal Modulator Unit
Arrangement .........19-52 Removal/lnstallation.......................
19-75
TroubleshootingPrecautions............. 19-54 ABS Control Unit
DiagnosticTroubleCode (DTCI Replacement .........19-76
DiagnosticTroubleGode(DTCI Pulsers/WheelSensors
Indication ...........
19-56 Inspection ..............
19-76
t DTCErasure ...........
19-57 Wheel SensorReplacement............ 19-77
Symptom-to SystemChart ............. 19-58
Troubleshooting
ABS IndicatorLight DoesNot
ComeOn ............
19-60
ABS IndicatorLight DoesNot
Go Off ............................................
19-62
t /

SpecialTools
Ret.No. Tool Number Description O,V I pageReference

I I I
(!) I 07PM- 0010100 I SCSService
Connector t I 19_s6
19-44
ComponentLocations
t a
SERVICECHECKCONNECTOR
{2PI BIGHT.REAR
WHEEL
SENSORCONNECTOR
MOOULATORUNIT ABS CONTROLUNIT
RIGHT-REAR
WHEELSENSOR
LEFT.R€AR
WHEEL
SENSORCONNECTOR
UNDER.DASHFUSE/RELAY8OX
LEFT.FRONT
WHEELSENSOR
J
FUSE/RELAY
UNDER.HOOD BOX
lcl lilo Al FUSE
ABS INDICATORLIGHT HORN/STOPI15 A) FUSE
UNOEF.DASI{FUSE/RELAYBOX ABS FUSE/RELAYBOX

UNDER.HOOO
METEBI7.5 AI FUSE ABS +B (20 A) FUSE PUMP MOTOR{'O A} FUSE
0 00000
n
u
0 00000
0
t
PUMPMOTORBELAY
BR DEFRLY 17,5A) FUSE MTRCHECK(7.5AI FUSE
19-45
Anti-lockBrakeSystem(ABSI
Features/Construction
When the brakepedalis depressedduring driving,the wheelscan lock beforethe vehiclecomesto a stop, In such a case,
the maneuverability of the vehicleis reducedif the front wheelsare locked,and the stabilityof the vehicleis reducedif the
rearwheelsare locked,creatingan extremelyunstablecondition.The ABS preciselycontrolsthe slip rate of the wheelsto
ensurethe grip forceof the tires.and it therebyensuresthe maneuverbility and stabilityof the vehicle.
Judgingthe vehiclespeed.the ABS calculatesthe slip rateof the wheelsbasedon the vehiclespeedand the wheel speed,
then it controlsthe brakefluid pressureto attainthe targetslip rate.
Grip Force of Tire and Road Surlace Slip Rate

COEFFICIENT
OF
FRICTION
BRAKING
TARGETSLIPRATE STARTPOINT
ROTATIONAL
DIRECTION
RADIAL
DIRECTION
OF THE A: Distancewithout slio
ROTATIONAL 8: Slippsd distance
OIRECTION C: Actuel distance
SLIPRATE VEIIICLESPEED- WHEELSPEEO

sr-rrmre=f= VEHICLESPEED
19-46
t -
Operation
ABS Control Unit
Main Control
The ABS control unit detectsthe wheel speedbasedon the wheel sensorsignalit received,then it calculatesthe vehicle
speed basedon the detectedwheel speed.The control unit detectsthe vehiclespeedduring decelerationbasedon the
rateof deceleration.
The ABS control unit calculatesthe slip rate of each wheel. and it transmitsthe control signal to the modulator unit
solenoidvalvewhen the slip rateis high.
The pressurereductioncontrolis a three-modesystem,that is pressurereduction,pressureretainingand pressureintensi-
fying modes.
Self-diagnosisFunqtion
The ABS controlunit is equippedwith a main CPUand a sub CPU,and the CPUScheckeachother'
The CPUscheckthe circuitof the svstem.
"systemdown mode" or the "controlinhibitionmode"
Whenthe CPUSdetectfailure,they shiftto the
MAIN SOLENOID Restartcondition DTC

MODE LIGHT
ABS INDICATOR CPU
RELAY VALVE
SYSTEIV No Drive lgnition
ON Operation*r OFF + ON Memory
DOWN operation inhibition switch
CONTROL No Drive Memory
ON Operation Automatic
INHIBITION operalron inhibition
*1: ExceptCPUfailure
can be classifieldinto thesefour categories:
The self-diagnosis
O: Initialdiagnosis
@: ExceptABS control
@: DuringABS control
@: Duringwarning
On-board DiagnosisFunstion
The ABS controlunit is connectedto the data link connector{16P).
The ABS systemcan be diagnosedwith the HondaPGMTester.
/
(cont'd)
19-47
Anti-lockBrakeSystem{ABS)
Operation(cont'dl
ABS Modulator
The ABS modulatorconsistsof the inlet solenoidvalve, outlet solenoidvalve, reservoir,pump, pump motor and
the
dampingchamber.
The modulatorreducesthe caliperfluid pressuredirectly,and it is also referredto as a circulatingtype becausethe brake
fluid
circulatesthrough the caliper,reservoirand the mastercylinder.
The hydrauliccontrolhasthree modes:pressurereducing,pressureretaining,and pressureintensifying.
The hydrauliccircuitis the independent four channeltype, one channelfor eachwheel.
PUMPMOTOR
RF LR
Pressureintensifyingmode:Inletvalveopen,outletvalveclosed rN: INLETVALVE { N O R M A L t YO p E N I
OUT: OUTIET VALVE {NORMALIY CTOSED)
Mastercylinderfluid is pumpedout to the caliDer.
Pressureretainingmode: Inletvalveclosed,outletvalveclosed
Caliperfluid is retainedby the inletvalveand outletvalve.
Pressurereducingmode: Inletvalveclosed,outletvalveoDen
Caliperfluid flows throughthe outletvalveto the reservoir.
Motor operationmode: When startingthe pressurereducingmode,the pump motor is ON.
WhenstoppingABS operation,the pump motor is OFF.
The reservoirfluid is pumpedout by the pump,throughthe dampingchamber,to the master
cvlinder.
19-48
L
Wheel Soeed and Modulator Contlo
EELSPEED
OUTLET
VALVE
ON
OFF
t INLET
VALVE
ON
OFF
t\,40ToR
ON
OFF
pressure
when the wheelspeeddropssharplybelowthe vehiclespeed,the inletvalveclosesto retainthe caliperfluid
speed drops further,the outlet valve opens to
momentarily reducethe caliperfluid The pump
pressure.
When the wheel
motor startsat this time.
As the wheelspeedis restored,the inletvalveopensmomentarilyto increasethe caliperfluid pressure.
WheelSensoJ
The wheelsensorsare the magneticcontactless type

frequencychanges
As the gear pulserteeth rotatepastthe wheel sensor'smagneticcoil,AC currentis generatedThe AC
in accordance with the wheel speed.The ABS control unit the
detects wheel sensor signalfrequencyand therebydetects
the wheelspeed.
Thereare four wheelsensors,one for eachwheel
The gear pulserhas50 teeth.
GEARPULSEB
WHEELSENSOB at HIGHSPEED
gl
at LOWSPEED
=
o
/
19-49
GircuitDiagram
AA DEFBLYI7.5AI
- E8l{'Ytr
LEFT.FSONT
SOLENOIO
_@f_u,
n4@f-n,
UNDER.HOOOA8S FUSE,/FELAY
BOX UNDER-OASH
FUSSRELAY8OX
3P CONNECTOR(O number) MOOULATORUNIT IOP CONNECTOR
ZoPCONNECTOR(O numbe,
| 2 3 l 2 3 5 6 7 8 I zrJrF!_
t0 tl t3 / i 1 5 / l l l 2 3 l l
t8 20
UNDER.HOODAAS FUSE/RELAYBOX 14TiEltl
2P CONNECTOR(! number) UNDER.OASHFUSE,/RELAY BOX
1 8 PC O N N E C T O R( E n u m b € r ) c@4
| - l 2 3 5 6 PIMP MOTOR2P CONNECTOR
(Ll number)
9 ll 2 13)t4 / 1617 fFl
GAUGEASSEMELY5P CONNECTOR GTN
---t--
t 1 t / 1 3) / l 5 l
Wiresideot temaleterminals
19-50
t ABS CONIROLUN]T
ECM/ PCMISCS'
V
+B
Y
WHTNED
,,,+-{l-, [,b.,,,,,
B6li!
-F- ?,,]
8U(
J-
G,Ol, Ga02
SENSOR
LEFT.
RIGHT,
\EWIK
l
LEFT
-o&"^1'
;___.|-1
**1. ,I
coierou cot,croz
CHECK
SERVICE WHEELSENSOR
ABS CONTROLUNIT26P CONNECTOR (2P}
CONNECTOR 2PCONNECTOB
1O numb€r)
FRONT
1 2 3 4 6 / 8 I l 0 . / t t 1 2 r3 lrl2f
1 9 , / 21 23
/.[Ttl\
14t5 1 6 1 7
OATALINK REAR
ABSCONTROL UNIT22PCONNECTOR CONNECTORO 6P)
1! numb€r) tc-T-l z
I l
r[B'
12 13
Terminalsideof
/ Wire side of female terminals maleterminals
19-51
ABS ControlUnit TerminalArrangement
ABSCONTROL
UNIT26PCONNECTOR
Terminal Wire Terminalsign Voltage

numo0r color Terminalnamo Dgscription Conditions
teminals (lgnitionSwitch ON flt)) Output voltago
PCOM Power sourcefor the solenoid =
(Primary valve and pump motor. ON OV
1-GND ON
common) AC:3-6 V
scoM Powersourcefor the solenoid OFF
BLK/WHT (Secondary 2.GND theSCS
service\
lConnect Approx.3 V
common) \ conneclor l
tG2
ELVBLU (lgnition Detectsignitionswitch2
3-GND
2) !9nal. (systemactivatesignal) Batt€ryvoltage
RRO
BLU/YEL (Rear-right Detects right-rear wheel
0) sensorsignal. 4-17 53mVor aboveon
Whenthe wheelis (AC
digitaltester
6 GRY RLO Detectsleft-rearwheelsensor
(Rear-left
0) s r g n a l . 6-19 turned at 1 turn/second. range){Feferance)
150mvp-por above
8 GRN FRO D€tectsright-frontwheel on oscilloscope
(Front-right0) sgnsorsrgnal, a-21
Stops Approx.2.5V
STOP hects brakeswitchsignal. Brakepedaldepressed. Batteryvoltage
(Stop) (Prevents
unnecess€ryABSoperation) 9-GND
Brakepedalreleased. OV
Detectsleft-frontwheelsensor
signal. 53mVor aboveon
Whenthe wheelis (AC
digitaltester
10 FLO
BRN^/vHT (Front-left turnedat 1 turn/ range)(Referance)
0) 10-23
secono. 150mVFporabove
on oscilloscope
9!ops Approx.2.5V
Drivesleft-rear
outletsolenoid
12 YEL RLOUT ON OV
(Rearjeftoutlet) 12.GND ON -9
OFF AC:3^6V
RR]N Drivesright-rearinlet solenoid OFF
REDMHT (Rear-right valve. 13-GND theSCSservice]
inlet) lconnect Approx.3 V
i connector I
14 B1 Powersourcefor the solenoid
(Battery1) vatveandpumpmotor. 14.GND
82 Powersourcefor the solenoid Batteryvoltage
15 WHT/GRN (Baftery 15.GND
2) varveanopumpmotor.
r6 BLK GND2 Ground for the ABS control
{Ground2) unit. 16-GND Below0.3V
17 RR1
GRN/'/EL (Rear-right Detects right-rear wheel
1) sensorsignal. 17-4
53 mV or above
19 R L l
LT BLU (Rea.-left Detectsleft-rearwheelsensor on digitaltester
1) sagnal. 19-6 Whenthe wheelis turned (ACrange)
FRl
at 1 turn/second. (Referance)150
GRN/BLK(Front-right Detectsright-frontwheel
1) sensorsignal. 21-8 mVp-por above
on oscilloscope
FL1 Detectsleft-frontwheelsensor
(Front-left1) s i g n a l . 23-10
Stops Approx.2.5V
Drivesleft-r€arinletsolenoid '6
ON OV
ON -9
RED RL-IN OFF AC:3-6 V
(Rear-lett
inletl 25.GND
ut OFF
theSCS
lconnect service] Approx.3 V
\ connector l
BLK GND3 Ground for the ABS cgntrol
(Ground
3) unit. 26.GND Below0.3V
19-52
\ e UNIT22PCONNECTOR
ABSCONTROL
Volt.ge
Terminal Wiro Terminalsign De3cription ConditionE
numbel coror lTqrminalnamsl (lgnition Switch ON (ll)l
Output voltago
terminils
Drivesright-frontinlet ON OV
solenoidvalve. ON -9
FR-IN OFF AC:3-6 V
RED/BLU {Front-right I-GND
OFF
inlet) riJ
theSCSservicq Approx.3 V
/Connect
\ connector I
Detectsservicechecksignal SCSserviceconnector OV
scs troublecode connected.
BRN (Servicecheck {Diagnostic
indication)
4-GND
SCSserviceconnector Appro)(.5 V
signal) disconneded.
DrivesABSindicatorlight(The Indicatorlight ON Approx,2 V
indicatorlightgo€soff when 7-GND
7 BLU/RED (Warning
ABScontrolunitoutputsbat-
ramp) lightOFF
Indicator Batteryvoltage
tery volta9e),
8 BLU/YEL Not used.
FL.OUT Drivesleft-frontoutlet ON OV
10 YEUBLK {Front-left solenoidvalve. 10-GNO ON
outlet) OFF A C : 3 - 6V
Drives left-front inlet solenoid
t 11 RED/BLK
FLIN
inlet)
{Front-l€ft
11-GND
OFF
FR.OUT Drivesright-frontoutlet lconnect SCSservicq
the Approx.3 V
\ connector I
YEUBLU (Front-right solenoidvalve. 12-GNO
outlet)
DLC Communicates with Honda
l4 LT BLU (Datalink PGMTester. 14.GND Approx. 5 V
connector)
Detects pump motor drive Pump ON Batteryvoltage
MCK srgnal. 1 7 . G N D motor
17 BRNA/EL OV
lMotorcheck) reray OFF
Drivespumpmotorrelay. ON OV
ON
PMR OFF AC:3-6 V
19 YELRED (Pumpmotor 19-GND
OFF
reray, ponnect sewicq
theSCS Approx.3 V
\ connedor l
Drivesright-rearoutlel Pump ON OV
solenoidvalve. ON motor
RR-OUT relay OFF AC:3-6 V
BLU (Rear-right 21-GND
OFF
outletl uJ
theSCS servicq Approx.3 V
lconnect
\ connedor )
GND2 Ground for the ABS control 22-GND Below0.3v
22 BLK (Ground2) untt.
19-53
TroubleshootingPrecautions
ABS Indicator Light

I The ABS indicatorlight comeson when the ABS controlunit detectsa problemin the system.However,even
though
the system is normal,the ABs indicatorlight can come on, too, under the following conditions.To determine
the
actualcauseof the problem,questionthe customeraboutthe problem,takingthe followingconditionsinto consider-
ation.
. Signaldisturbance
. Wheelsoin
. Only drivewheelsrotate
. Batteryvoltage fluctuates
2. When a problemis detectedand the ABS indicatorlight comes on, the indicatorlight can stay on untatthe ignition
switchis turnedoff, or it can automatically go off, dependingon the mode.
. Lightstaysonuntil the ignitionswitchisturned off;Whenthe systemis inthesvstemdown mode.
o Lightautomaticallygoesoff: Whenthe systemis in the controlinhibitionmode.
(refer to symptom-to-systemchart)
3 The ABS indicator light stays on when the system is reactivatedwithout erasing the DTC,but it goes off after starting
the car.
when the wheel sensorsystem is faulty and the ABS indicatorlight comeson, the algorithm of the system automatically
turns off the ABS indicatorlight after the wheel speedsignal returnsto the normal speed.while, when the DTCis erased,
the CPUis resetand the ABS indicatorlight goes off when the systemcheck€dout normal by the initial diagnosis.
Therefore,test-drivethe car after servicingthe wheel sensor system, and be sure that the ABS indicator light does not
come on.
4. When the ABS control unit outputs battery voltage to the gauge assembty,the ABS indicator light goes off.
DiagnosticTrouble Code (DTC)

1. The diagnostictroublecode (DTC)is memorizedwhen a problemis detectedand the ABS indicatorlight does not go
off, or when the ABS indicatorlight comeson.
The DTCis not memorizedwhen the ABs indicatorrightcomeson unressthe cpU is activated.
2. The memory can hold any number of DTCs.However,when the same DTc is detectedtwice or more, the later one is
writtenover the old one.
Therefore.when the same problem is detectedrepeatedly,it is recordedas one DTC.
3. The DTCSare indicatedin the orderof ascendingnumber,not in the orderthev occur.
4. The DTCSare memorizedin the EEpROM{non-volatilememorv}.
Therefore,the memorizedDTCScannot be canceledby disconnectingthe battery. perform the specifiedoroceduresto
erase.
Solf-diagnosis
1. The self-diagnosiscan be classifieldintothesefour categories:
' Initialdiagnosis; Performedright afterthe enginestarts and untiltheABs indicatorlight goes
off.
o ExceptABS control: Performedwhen the ABS is not functioning,
. DuringABS control:Performedwhen the ABS is functioning.
. Duringwarning: Performedwhen the ABS indicatorlight is ON.
2 The system performs the following controls when a problem is detectedby the self-diagnosis:
. ABS indicatorlight ON
. Memory of DTC
. Modechangeto the "systemdown mode,,or the "controlinhibitionmode,,.
MODE ABS INDICATOR MAIN SOLENOID

LIGHT CPU Restartcondition DTC
RELAY VALVE
SYSTEM No Drive lgnition
DOWN ON Operation+r OFF- ON Memory
operal|on inhibition switch
CONTROL No Orive
ON Operation Automatic Memory
INHIBITION operat|on inhibition
*1: ExceptCPUfailure
19-54
t J
Kickback
1. The motor operateswhen the ABS is functioning,and the fluid in the reservoiris forcedout to the mastercylinder
causingkickbackat the brakepedal.
2. TheABScontrolunit operatesthe solenoidvalvewhen the brakepedalis releasedafterthe initialdiagnosisYoumay

hearthe faint solenoidvalveoperationsoundat this time. but it is normal.
Pump Motor
1. The pump motor operateswhen the ABS is functioning
2. You may hearthe faint operationsound

The ABS control unit checksthe pump motor operationduring acceleration.
at this time. but it is normal.
Brake Fluid Replacament/AirBlsading

1. Brakefluid replacement and air bleedingproceduresare the same as for conventionalbrakes
Troubleshooting
pre-
1. The troubleshootingflowchartsexplainthe procedureson the assumptionthat the causeof the problemis still
sentand the ABS indicatorlight is still on.
Notethat troubleshootingfollowingthe flowchartwhen the ABS indicatorlight does not come on can resultin incor-
rectjudgment.
2. Ouestionthe customerabout the conditionswhen the problemoccurred,and try to reproducethe same conditions
for troubleshooting.
self,diagnosisis made at varioustimes such as the initialdiagnosis,exceptABS control.during ABS control,during
acceleraiion,during the specifiedvehiclespeed,etc. Therefore,the symptom cannot be checkedunlessthe check
\ t conditionsmatchwith the problemconditions
3. When the ABS indicatorlight does not come on duringthe test drive,but the troubleshootingis performedbasedon
the DTC,checkfor the looseconnectors.poor contactof the terminals,etc,beforetroubleshooting.
4. erasethe DTCand test-drivethe car.Be surethat the ABS indicatorlight does not come on.
Aftertroubleshooting,
5. The connectorillustrationsshow the femaleconnectorswith a singleoutlineand the male connectorswith a double

ouflrne.
6. The connectorterminalcavitiescontainingfemaleterminalsare alwaysnumberedby lookingat the connectorfrom

the wire side.and the cavitiescontainingmale terminalsare alwaysnumberedby lookingat the connectorfrom the
terminalside.
r'
19-55
DiagnosticTrouble Code (DTCI
DiagnosticTroubleCode{DTC)Indication
NOTE:This operationcan also be carriedout with the HondapGM
Tesrer.
l connectthe scs serviceconnectorto the servicecheckconnectorinside

the passenger,s
side kickpanel.
2. Turn the ignitionswitchON (||).but do not startthe engine.
NOTE:Do not depressthe brakepedalwhen turningthe ignitionswitch.
3 Recordthe brinkingfrequencyof the ABS indicatorright.The brinkingfrequency

indicatesthe DTc.
4, Turn the ignitionswitchOFF,and removethe SCSserviceconnector.
NorE: The MslfunctionIndicatorLamp (MlL)will stay on after the engine
is startedif the scs serviceconnectoris
connected.
5. Erasethe DTC.
Condhionsfor DTCindication
. The vehicleis stoDDed.
. The SCSserviceconnector is connectedbefore the ignition switch
is turned ON fll).
. The brakepedalis released.
. Th€ SCSservice connectorremains connectedduring this procedure
The DTGindication stops 8nd the ABs conltol unit executesthe softwaro
tunqtion if at least one of the following condi-
tions b satisfied:
o The vehicleis not stoDoed.
' The ABS control unit receivesthe normat signal (which is for
the ABS controt unit) from a Honda pGM Tester.
. The SCSserviceconnector is disconnectedduring this procedu.e,
u.s.A.
@
CANADA
SERVICECHECK SCSSERVICECONNECTOR ABS INDICATORLIGHT

CONNECTOR {2PI 07PAZ- 0010100
DTC: 3 3
A8S INDICAIORLIGHT
swirch
Snilion
' when the ignitionswitchis turnedoN (ll),the ABs indicator

light comeson to checkthe bulb. Do not count it as a DTc.
o The ABS controlunit can memorizeany numberof DTCs.
. The new DTCis not memorizedwhen the ABS controlunit has
alreadymemorizedthe same
. l f t h e D T C i s n o t m e m o r i z e d , t h e A B S i n d i c a t o r l i g h t s t a y s O N a f t e r i t g o e s o f f f o r 3 . 6 s e cDTC,
onds.
19-56
DTGErasure
L J
side kickpanel.
1 . Connectthe SCSserviceconnectorto the servicecheckconnectorinsidethe passenger's
2. Depressthe brakepedal.
indicatorlight
Turn the ignition switch oN (ll) while holdingthe brakepedal,but do not start the engine.The ABS
goes off after two seconds.
4. Afterthe indicatorlight goes off, releasethe brakepedal The indicatorlightcomeson afterfour seconds
goes off again after four sec-

5. After the indicatorlight comeson, depressthe brakepedal again.The indicatorlight
onds. The brakepedal is still depressed.
6. Afterthe jndicatorlight goesoff, releasethe brakepedalagain'
7. Afterfour seconds,the indicatorlight blinkstwice for 0 3 secondand the DTCis erased
8. Confirmthe DTCindication,and checkthat the DTCwas erased

the brakepedal
NOTE:Always maintainthese steps.lf you disconnectthe scs serviceconnectorand/orfail to operate
accordingto the indicatorlight the
indication, DTCwill not be erased
Conditions for DTCerasure

o The vehicleis stopped.
. The SCSserviceconnectoris connectedbeforethe ignitionswitchis turnedON {ll)
. The brakepedalis depressedbeforethe ignitionswitchis turnedON (ll)'
. The SCSserviceconnectorremainsconnectedduringthis procedure
\ t The DTC erasurestops and ABS control unit executesthe software lunction it at least one ot the
following conditions is
satisfied:
o The vehicleis not stopped.
. The SCSserviceconnectoris disconnected duringthis servace'
.TheABscontro|unitreceivesthenormaIsigna|(whichisfortheAEscontro|unit)fromaHondaPGMTester'
. The brakepedalis not operatedaccordingto the indicatorlight indication
. The DTCerasureis finished
0.3sec
LIGHT
ABSINDICATOR
OFF
DEPRESS
BRAKEPEDAL
RELEASE
lqnitionswitch
oN (I)
19-57
DiagnosticTrouble Code (DTCI
Symptom-to-System
Chart
DETECTIONTIMING
o
DTC H1= DIAGNOSIS/ >=
SYMPTOM i.'s z r =t PNOBABLECAUSE
EV9
8 € E6 < _ 6
\9=
6tz
, Open in the pow€. source circ!ir ror the ABS -.ndicato;lisht
ABS indicator iighr does . Elown ABS indicalo.lighr butb
not com€ on when ignirion ' Open in rhe ABS indicaror tight drive cncuit.
swrt.h is lu.ned on (ll) .
NO Shori ro pow€r in theWALpcircuit
DTC . F a u l t y A B Sc o n t r c t ! n i t
A B S i n d i c a t o rl i g h td o e s Open in the lG2 circuit
ON nol90 oft 6frer engine is Opon in the +B circuir
Op€n andlor short ro body ground jn the WALP circuit
Faultv AAS coni.ol unn
t1
upen, snofiro bodyground and/or shodro power in rhe wh€61
13 Wheel sensor (op€n/short
oN. O o o o
ll Faulty ABS co.lrctunit
BL
12 Shortto wh6sls€n6or(O)circuir
in t'e.h;;Go-nso, trtcircuti
Faultywhsels€nsorinsra|ation
oN. (chipp€d pulser gea/noise) o a o FaultyABScont.olunir
I8
31
Op.ni shonto bodygroundand/o.shorrtopowsrin rhe
32 F8-OUT
FL.IN
op€n in lh6 coM circuit
3'l Solenoid (open/shon ro
ON a o FT.OUT FaultyABSconlrclunit
a
RF.IN
88 OUT
31 8t rN
38 RLOUT
op€n in tho motor pow€..ourco circlia
O p € ni n i h € m o r o . c N O c i r c u i t
ON o o
Faulty ABS conrrol unit
Open in rh€ COM, PMR 6nd/o. MCKcircuir

Op€n.n.Vor blown lus€ in the under hood AgS rusdretry box
52 ON o o
Faufty pump moto. rotay
faulv ABS conlrolunit
. Sho.tto bodygrou.d in the pMR circuit
53 .
ON o .
Shon to powsr in tha puhp moror pow6rsource circu
r.urty pump motor.etay
, FalltyABS contolunit
Open, rhorr ro bodygrcund and/or blown fus€ in the B1 or 82
54 ON o o c Shonto body ground.n.Vor short to powor in rhe COM circuit
Faulty modul.tor unn
Faulty ABS controt unit
. Connection ot the24 V bariorv tor enqins starr
lgnition voltage (low vott- .
ON o o o o .
Faurtycharoins system
Op€n in th6lG2 circuit
. Fa!lly ABS contrcl unil
E{€rml facior{sl en bs rhe ouse{sl ot |he probtem

F.ulty ABS conrrot unit
81 ON CPU o o o o
r: It DTcs 1 1 18
{wheel sensor codes) wore del*ted the lasr time the v6h cls wEs d riv€n, rhe a8s indicator tight
connorunit contnms rhat rhe wheet sensoB . rc OK, wi stay on u ntit lh6 ignition swirch is rurn6d oN t), and the
19-58
L e
MANAGEI\,4ENT
FEFER
CONDITIONFOR DETECTION EXCEPT TO
DUNING
ABSCONTAOL PAGE
ABS CONTFOL
19-60
19-62
The ABS indicator lighl cones on when vehicle is stopp€d and wheel sensor a given vohaqe does nol
1 96 4
The ABS indicaror comes on under th€lollowing conditions

t h e e l r e a c h e sa
. W h e n m o r e t h a n o n e o t w h e e l sa r e a s t a n d s t i l a n dt h e l e l o c i r v o t t h e f a s t e s w
' fohen th. velocityof the faslesl wheel reachesor exceds a given sped, and it there ar€ somewh@ls 1 96 4
whose velocityis slowe.lhan a cenain percenlageoi lh€ fast6t wheelsped for 3 given period
. when rhere are lemporary open or short ctcuits ol rhe wheel sonsor' chipp€d pulser gear, orsrgnal
orslJrbaaLe
The main relay repeatsON/OFFswitching atalltimes
. W h e n t h e m a i n r e l a y i s O N , a s h o r t t $ t p u l s e i s s e n t l o e a c h v a l v e l f t h e r e s s o m e d i s ' r e p an c v ,l h e
A B S i n d i c a l o rl i g h t c o m e so n .
. When rhe main relay is OFF,a shonl€sl pulse is s€nlto each valve lfth6 solenoid drive voltage rs
out ol a qiven range, the ABS ndicalor lighl comes on 19-66
'The pump nolot s activaled orc€ o' Mrce sfier every gn't'on sw'lch ON (ll) operarion whrle lte -^
v c h i c l ea c L e l e r a l e sl r e n t h e m o l o r o t i v e v o ' t a S e r s r h e c l e d W h e n l h e v o l l a 9 6r s a b n o r m a r , l r eA b s
\ .t indicaror llghl comes on.
. Afte. ABS ;onl rol com pletion, the moror isswitched ofi 6nd the main CPU checksthe molor dnve
19-68
voltase. when rhe vortase is abnormsl, the ABS indicato49!!!99!:l!:_-

D!rino an active motor lesl or AAS control,lhe main CPU checksihe supplv voltage to the motor'
whe;lhe vohage s abnofmal, the ABS indicator lightcomes on 19,68
lirhe moror drvevoltage indicates molot operalion when the main cPU does notswilch the motor
oN, rhe ABs indicaro. comes on 19-64
. Wh"" " ".1"".1d ""1r. f"llure is detecred,the CPU checksth€ voltage ofthe main rel6v output lllhe
vohaqe is lowerthan 6 given vohage, theABS indicator light comes on 1 97 1
. The ;ain r€lay repeatsON/OFFswitching ar a!ltimss when the main rel.v is ofi, a shorl l6st pulse
is sent ro €ach valve. The CPU mon tors the reJer€ncevohage ll the vohage is out ot a g iven range'
the ABS indic.tor lightcomes on
wt'",, rt'e lgnitlon rottag" is ower or higherthan a given voltage,lhe CPU inhibils ABSlonlroland
swirches oli the ma in relaY,6nd the ABS indicaror light com€s on When the ig n ilion vohage recove's 19.73
t o n o r m a lf 6 n g 6 ,A B S i n h i b i t i o ni s c a n c e l e d .
rimln CpU anO suU CeU ch€ck each other undercertain condnions. Whon rhe CPUSdstectthe fol'
lowing discrepanaies,rhe ABS indicator light comss on
. whe; rh€re is discGpancv n lhacarculated wheelspeed velocirv thar continuosJor more than a given
.i^/hen rhere is discrcoancvin the ehase informalion lhat continuesfor morerhan a given period 19 7'l
' When rhere is discrepancYin thecalculared conlfol pa.amerer'
. When thewatch dog conrrolp!lsetailslof a given penod
. W h e nt h 6 c h e c k o t t h €R O Mt a i 1 s .
. when there is disrepancy inrhe data roading.nd wriung prcledurc ot RAM
t r
19-59
Troubleshooting
ABS IndicatorLight DoesNot ComeOn
The A8S indicator light does not come on when ignition switch is turned ON ll.
Tho ABS indicator light does not

come on wh€n ignition switch is
tu.ned ON {lll.
check the METEB(7.5A) fuse in NOTE:All indicatortightsexceptthe charg,

the under-dash ing systemlight will not come on when the
fuse/relay
box.
METER17.5A) ft se is btown.
NO
Beplacethe tu3e and recheck.
YES
NOTE:
Reinstallthe
fuseif it is OK.
Checkfor an open in th6 lcl cir- GAUGEASSEMBI"Y5P CONNECTOR
cuii:
1, Disconnect the gaugeassem
bly 5Pconnector.
2. Turn the ignitjonswitch ON l).
the gauge assembly5P con-
n e c t o rt e r m i n a lN o . 5 a n d
body ground. Wiresideof femaleterminals
. Ropair opan in tho wiro

botwe€n thc METER t7.5 At
ls there bafteryvoltage? tuso and gauge .$cmbly.
. Roplacc th. und.r-dash tus./
r.l.y box. lop.r cirouit in3ido
the box.l
C h e c kt h e A B S i n d i c a t o rl i g h t
bulb in the gaugeassembly.
ls the bulb OK?
Ch€cktor a short to power in the

WALPcircuit:
Measurethe voltage betweenthe
g a u g e a s s e m b l y5 P c o n n e c t o r
terminalNo. I and bodyground.
Replir short to power in tho wiiG

ls there batteryvoltage? b.tweon the gruge rs3embly
.nd ABS control unh.
lTo page19-61)
19-60
t J
{Frompage19.60)
Checkthe geuge a$embly:

1. Turn the ignitionswitchOFF. GAUGEASSEMBLY5P CONNECTOR
2. Connectthe gauge assembly
5Pconnector. ,c? "
3. Connectthe terminalNo. 3 to |
l1t/'.lt/t5
b o d y g r o u n dw i t h a i u m p e r JUMPER
I GNDIBLK}
wrRE I
4. Turnthe ignitionswitchON (ll). -L
Replaceth€ ABS indicato. light

Doesthe ABS indicator drive circuit in the gauge ai3om-
lightcomeon? blY.
.Repair open in the wire

beiween the gauge assemblY
and body ground.
. Repair poor ground {G401,
G402t.
19-61
Troubleshooting
ABS IndicatorLight DoesNot Go Off
The ABS indicator light does not go off after the engine is started.
- With enginerunning,ABS
indicator light is ON.
- With tho SCS sewice connec-
to. connected l3oe page 19-561,
no DTCis indicated,
ChecktheRRDEFRLY{7.5A)tuse
in the under-dashfuse/relaybox.
Raphco tha furo and rochack.
YES NOTE:Feinstattthe
luse it it is OK.
Checkthe ABS +B (20 A) fuse in

the under hood tuse/relaybox.
R6pl.ce tho tu3c lnd r.ch.ck.
YES NOTE:Reinsta the fuse if it is OK.

ABS CONTROLUNIT 26PCONNECTOR
IG2IELK/BLUI
Chockfor an open in the lG2 cir-
GUrt:
1. Turnthe ignitionswitchON (lt).
the ABS controlunh 26Pcon-
n e c t o rt e r m i n a lN o . 3 a n d Wire sideof femaleterminals
body ground.
Bopair opcn in tha wir. botw.cn

th. RR DEFRLY 17.5Al tus. .nd
ABS control unit.
ABS CONTBOLUN]T 26PCONNECTOR
Checktor an opon in thG Bl end

82 circuit:
M e a s u r et h e v o l t a g e b e t w e e n
bodygroundand terminalsNo. 14 8T IWHT/GRNI
and No. 15individually.
Rrpair opsn in tha wiro t atwa,an

ls there banery voltage? the ABS +B (20 Al fu.r .nd ABS
control unh. Wiresideof temaleterminals
1Topage19-63)
19-62
t v
lFrompage19-621

Ch6ck lor . short to body ground
in ihe WALPGircuit: WALP{BLU/REDI
2 . D i s c o n n e ctth e A B S c o n t r o l
unit 22Pand gaugeassembly
5P connectors.
the ABS controlunit 22Pcon-
n e c t o rt e r m i n a lN o . 7 a n d Wire sideol femaleterminals
body ground.
Ropair short to body g.ound in

tho wire betweon the ABS con_
trol unit and gaugeaasembly.
WALP {BLU/REDI
Checkthe AgS cortrol unit:

1. Connectthe ABS control unit
22Pconnector.
2. Turnlhe ignitionswitchON (ll).
3. Measurethe voltagebetween Wire sideol femaleterminals
the ABS controlunit 22Pcon'
n e c t o rt e r m i n a lN o , 7 a n d ABS CONTROLUNIT 26PCONNECTOR
body ground. Check tor rn open in lho GND2
circuit:
1. Connectthe ABS controlunit
rt 26PconnectorterminalNo. 16
to body groundwith a iumper
ls there bafteryvoltage?
n e c t o rt e r m i n a lN o . 7 a n d wire sideol femaleterminals
body ground.
' Repairop€n in the wit€ between

the ABS control unit and body
ls there batteryvoltage? ground.
. Rep.ir poor ground lG40'1,
G1(}2t.
Checktor loo3€ ABS control unit

connector!. lf necesaary,substi_
tute a known-qood ABS control
unit and r€check,
Check lor an open in the WALP
circuit: GAUGEASSEMBLY5P CONNECTOR
Measurethe voltagebetweenthe
g a u g e a s s e m b l y5 P c o n n e c t o r
terminalNo. 1 and body ground.
.D
Ropai. opon in the wiro botween Y
ls therebatteryvoltage? the ABS control unit end gauge
assemblv.
J Replacethe ABS indicrtor light

driv6 ci.cuit in the gtuge assem-
bly.
19-63
Troubleshooting
WheelSensor
DiagnosticTrouble Gode {DTC)ll-18: Wheol S€n3ol Diagnosis
NoTE: The ABS indicatorlight comeson when only the drive wheelsare turning,signaldisturbanceis
detected,etc.Therefore,
test-drivethe car at a speedof 12 mph (20 krn/h)or more after turning the ignition:witch from OFF
to ON fll), and if the ABS
indicatorlight does not come on, the svstemis OK.
A8S CONTROLUNIT 26PCONNECTOR
- With the ignition switch ON
{ll), ABS indicator tighr doe. RRO
noi go off,
- IBLU/YELI
Aftsr driving, ABS indicatot
light comeson.
- With the SCS so.vice connac- Appropriate
Terminal
tor conn€c,ted{soepege 19-561, 0Tc (0)srDE 11)SrD€
DTCs11-18a.e indicrted. r 1, 12 (Right-front) No.8: FRo N o . 2 1 :F R I
RR1IGRN/YELI FL1IGRN/ORN}
13, 14 (Left-front) No.10:FLo N o . 2 3 :F L 1
15, 16 {Right-rear) No.{: RRo N o . 1 7 :R R l RLl (LT BLU} FRl (GRN/BLKI
Chocklhe wheol sensorci.cuit: 17,18(Left-rear) No.6: RLo No.19:RLI Wire sideol femaleterminals
unit 26Pconnector.
2. lleasure the resistance
betweenthe appropriatewheel
sensor(0)and (1)circuittermi,
. Reprir op€n in the l0l or {0 cir-

cuit wiro, or shon to thc {01cir-
ls the resistance
OK? cuit wi.o in thc {11circuit wirc
-
/Frontr750 1050o/20"C,68.F\ bctween ths ABS control unit
\Rear: 850- 1150O/20.C,
68"F/ and approprietowheel a6nsor.
. R.pl.ce th€ epp.opri.te wheal
3€nloa.
Checktoru short to body ground

in the wheel senso. circuit:
Checkfor continuity betweenthe
ABS control unit 26P connector
appropriatewheel sensor(0) cir
cuit terminaliand body ground.
. Rapair short to body ground in
th6 (0) or lll cilcuit wi..
bctwa.n th6 ABS control unit
and appropdaie whoel lonsor.
. Rep|'c6 tho appropriatc whcel
sanlor.
Chock tor a sho.t to powe. in tho

wheel3en3or circuit:
1. Reconnect the ABScontrolunit
26Pconnector,
2. Startthe engine.
nectorappropriate wheelsen-
s o r ( 0 ) c i r c u i tt e r m i n a l a n d
body ground.
Ropair rhon to powo. in the l0l
ls there4 V or more? or lll circuit wire batw.en th€
ABS cont.ol unit and .pplopriata
NO whccl !€naoa,
NOTE:
. Normalvoltage:Approx.2V
' 0 V: Replace the ABScontrotunit.
. 4 V or more indicatesa short to power.
fio page 19-65)
19-64
t
(Frompage19-64)
Checktor chippedpulsergear.
Replacethe drivesh.tt or hub

unil. (Chippedpulser g€ar)
DTC 11, 13, 15. 17: Roplacethe

ABS control unil.
\ e OfC 12, 11.16,18:The ABS con-
trol unit may have detected sig-
naldisturbance.
l r
19-65
Troubleshooting
Solenoid
DiagnosticTrouble Code {DTC}31-38: Solenoid Diagnosis ABS CONTROLUNIT 22PCONNECTOR
FL.OUT(YEL/ALK)
(lll, ABS indicator light does
nol go oft. or ABS indic.to.
light comes on while ABS i3
functioning.
- With the SCS servicoconnec- Appropriate Appropriate
tor connected ls€. pag€ 19-561, DTC
Connector Terminal
DTCa31-38 are indicstod. 3 1 :F R J N 22P No.1
32:FR-OUT 22P No.12
33i FL'IN 22P No. 11
Checkfor a short lo powor in tho 34:FLOUT 22P No.10
sol6noid circuitl 3s:RRIN 26P No.13 Wiresideof femaleterminals
1 . D i s c o n n e ctth e A B S c o n t r o l 36:RR-OUT 22P No. 21
unit 22Pand 26Pconnectors. ABS CONTROLUNIT 26PCONNECTOR
2. Start the engine. 37: RLIN 26P No.25
3. Measurethe voltage between 38:RL-OUT 26P No.12
the ABScontrolunitconnector
RL.OUTIYEL}
a p p r o p r i a t es o l e n o i dc i r c u i t
terminal*and bodyground.
Ropri. short to powor in thc

ls there batteryvoltage? appropriate solanoid ci.cuit wiro
botw6.n ths ABS cont.ol unit
and modulrtor unit.
Checkfor a short to body ground

in the 3olenoidcircuit: Wiresideof femaleterminals
Checktor continuity betweenthe
appropriate solenoidcircuittermi-
nal*and bodyground.
. Repairshort to body ground in

lhe .ppropriato solonoid circuit
wire betwoan th6 ABS control
unit and modllato. unit.
. Replacothe modul.tor unit.
DTC Appropriate
Terminal
Checkth€ ABS control unit: 31:FR-lN No.2:SCOM
'1. Turnthe ignitionswitch RL.OUT(YEL}
OFF.
32:FR-OUT No. 2: SCOM
2. Connectthe ABS control unit
22Pand 26Pconnectors. 33i FLIN No.1:rcOM
3. Connectthe SCS service con- 34:FL-OUT No. l: PCOM
35: RR{N No.1:PCOM
4. Turnthe ignitionswitchON {ll}. 36:RR-OUT No.1:rcOM
the ABS control unit 26P con- 37rRL'lN No.2:SCOM
nectorappropriateCONIcircuit 38:RL-OUT No. 2: SCOM
terminal++and bodyground.
Checkfor loos€ ABS control unh

ls thereapprox.3 V? connectora. It naceslrry, aub3ti-
tutc . known-good ABS control
YES unit tnd recheck.
(Topage19-671
19-66
t e
(Frompage19 66) ABS CONTROLUNIT 22PCONNECTOR
FL.OUT{YEL/BLK}
DTC
Conn€clor Terminal
31:FB-lN 22P No. 1
32:FR'OUT 22P No. 12
33: FL IN 22P No.1l
34:FL-OUT 22P No. 10
35: BR-lN 26P No. 13
Checktor an op€n in th€ solenoid 36:RR-OUT 22P No.2l
circuit: 3 7 :B L - l N 26P No.25
Measurethe voltage betweenthe 38:8I-OUT 26P No. 12
ABS control unit connectorappro-
priatesolenoidcircuitterminal*
and bodyground. Wiresideof femaleterminals
' Repsir opon in the appropriate
COM circuit wiro botwoon the
ABS control unit and modulatol
unit. ABS CONTROLUNIT 25PCONNECTOR
ls thereapprox.3V? ' Repair open in ihe appropriate
sol€noid ci.cuit wiro between BL.OUT(YELI
tho ABS control unit and modu-
lator unit.
. Roplacothe modulator unil.
Checkloi loGe ABS control unit

connoctors. It necessarv,substi-
tute a known-good ABS control
\ J unit and recheck.
19-67
Troubleshooting
ABS PumpMotor
DiagnosticTrouble Codo {DTC}51-53r ABS pump Motor Diagnosis

(ll), ABS indicator lighr doos
not go otf.
- With tho SCS s€rvico connee
tor conn€cted lsee page 19661,
OTCa51-53 aro indicated.
Checkthe MTRCHECK(7.5A) fuse.
NO
Repl.ce the fuse .nd recheck.
AAS CONTNOLUNIT 22PCONNECTOR
YES N O T E : S h o r t t h e P M R t e r m i n a tt o b o d y
NOTE:Reinstall groundfor a moment,and recheckthe fuse.
lf the fuse is blown,checkfor a shortto body 7 A t0 t l
the fuse if it is OK
groundin the MCKcircuit. 12 11 19 2 l 22
PMRIYEL/RED}
I JUMPER
I WIRE
NO Wiresideof femaleterminals
Replacotho tuse and rocheck.
YES N O T E :S h o r t t h e P M F t e r m i n a lt o b o o y
NOTE:Reinstall groundfor a moment,and recheckthe fuse.
thefuseif it is OK. lf the fuse is blown,checkfor a shortto body
ground in the wire between the under-hood
ABSluse/relaV box and pumDmotor.
Rcphce th€ pump motor rol6y.
Check the pump motor power

sourcecircuit:
Turnthe ignitionswitchON (ll).
Ch€ck for a short to !'ows. in tho

Doesthe pump motoroperate? pumP motor power 3ource ciacrrit:
Removeth6 purnpmotor relay,
Bopairsho.t to powsr in the wir€

Doesthe pump motoroperate? botwoen the under-hood A8S
tuse/.elay box and ABS pump
motor.
Checktor loGe ABS control unit

connoctors. lf nocessary,substi-
tute a known-good ABS control
unit and roch€ck,
(To page19-69)
19-68
t t
(Frompage19-68) UNDER.HOOD ABS
FUSE/RELAY8()X
JUMPERWIRE
Checkthe pump motor circuit:
1. Removethe pump motor relay.
3. Connectthe pump motor relay
connector+8 and MOTORter Ch€ckfor an open in the pump
minalswith a iumperwire tor moior +B circuit:
a momenr, 1. Turnthe ignitionswitchOFF.
2. Disconnectthe pump motor
2P connector,
3. Turnthe ignitionswitchON (ll). TERMINAL TERMINAL
Doesthe pump motor operate? 4. Connectthe pump motorrelay
connector+B and MOTORter- PUMPMOTOR2P CONNECTOR
minalswith a jumperwire.
5. Measurethe voltage between MOTOR+8 lWHTl,$
the pump motor 2P connector
terminal No. l and body rv) -
ground. Y
Wiresideot femaleterminals
Repaiaopen in the wire botween

ls therebatteryvoltage? tho under-hoodABS fuse/relay
box and pump motor.
Check the pump motor opgra- MOTOR+B {RED} MOTORGND (BLK)

tion:
\ lt Connectthe battery{+}terminalto
the pump motor 2P connectorter-
minalNo. 1.andthe (-)terminalto
the terminalNo. 2 for a moment.
ReDlacolho modulator unit.

Doesthe pump motoroperate? (Feultypump motor)
Chockfor a short to body ground Repail opon in ths wirg botwgen

in the PMRcircuit: tho pump motor and bodv ground,
1. Turnthe ignitionswitchOFF. or poor ground (G,!09). ABS CONTROLUNIT 22PCONNECTOR
2. Disconnectthe ABS control
unit 22Pconnector.
t e r m i n a lN o . 1 9 a n d b o d y
grouno,
Ropair 3hort to body g?ound in

tha wire between the under-
hood ABS fuse/rclay box and WiresideoI femaleterminals
ABS cortrol unit.
(cont'dl
(Topage19-70)
19-69
Troubleshooting
ABS PumpMotor (cont'dl
(Frompage19-69)
Check tor an opon in the PCOM

circuit:
1. Turnthe ignitionswitchOFF. --l
n
2 . R e c o n n e ctth e A B S c o n t r o l
unit 22Pconnector.
nector,
t h e p u m p m o t o r r e l a yc o n
n e c t o r P C O I , tI e r m i n a l a n d
body ground.
Repair opon in tha wiro bEtwoon

ls thereapprox.3 V? th. und€r-hood ABS fu3./rclsy
box and ABS control unit.
Chockfor rn op6n in tho PMRcir-

cuit:
Measurethe voltage beNveenthe
terminalNo. 19and body ground.
Ropair opon in tho wira b€twoon

ls thereapprox.3 V? tho undor-hood ABS fu.e/rel.y
wire sideoI temaleterminals
box and ABS control unit.
Chock for an opon in ths MCK

circuh:
2- Disconnectthe SCS service
connector.
3. Turn the ignitionswitchON lll).
n e c t o rt e r m i n a l N o . 1 7 a n d
body ground while connect-
ing the pump motor relay
connector+8 and MOTORter'
minal with a jumper wire for
moment.
Repeirop.n in th. wire batween

tho undor-hood ABS fu.o/rol.V
box rnd ABS control unh.
Ch6cklor loose ABS contlol unit

connoctors. lf ngc63ary, sub3ti-
tute d known-good ABS control
unit and recheck.
19-70
t f
MainRelay
DiagnosticTrouble Code {DTC}54: Msin Relay Diagnosis

{ll), ABS indic.tor light does
not go off.
- With the SCS 3ervicaconnoc-
tor connected (s€epag€ 19-561,
DTC54 is indicated.
checktheABS+B (20Alfuse.
Replaceth6 fuso and rechock.

YES
NOTER : einstall
thefuseif it is OK.
Ch€ck for an op€n in the 81, 82 B1

circuit: {WHT/GRNI
M e a s u r et h e v o l t a g e b e t w e e n
body ground and the ABS control
'14
unit26Pconnector terminalNo.
andNo. 15individually.
Repairopen in the wire betweon
the ABS control unit and under-
hood ABS tuse/relav box.
\ e Checkfor a short lo body ground

in the PMRcircuit: ABS CONTROLUNIT 22PCONNECTOR
1- Turnthe ignitionswitchOFF.
2. Removethe pump motor relay.
unit 22Pconnector.
t e r m i n a lN o . 1 9 a n d b o d y
grouno.
Repairshort to body ground in

the wire betweenthe undor- Wiresideof femaleterminals
ls therecontinuity? hood ABS fuse/relay box and
ABS control unit.
Checktor a short to body ground PCOM scoM

in the PCOM,SCOMcircuit: IGRN/WHT} {BLK/WHTI
unit 26Pconnector.
bodygroundandthe ABScon- . Bepai. short to body ground in
t r o l u n i t 2 6 Pt e r m i n a l sN o . 1
tho PCOMcircuit wire betwoen
andNo.2 individually.
the ABS control unit and under-
hood ABS fu3e/.olaybox.
. Repair3hort to body ground in
ls therecontinuity? the PCOMor SCOMcircuit wire
between the ABS control unit
and moduletor unit.
. R c p l a c et h 6 m o d u l a t o r u n i t .
(Short circuit insidotho unit)
l r { T op a g e1 97 2 )
(cont'd)
19-71
Troubleshooting
MainRelay(cont'd)
(Frompage19'71)
PCOM
Checktor a short to powor in the (GRN/WHTI scoM
PCOM,SCOMcircuit: (BLK/WHT}
1. Turn the ignition switch ON
r).
body groundand ABS control . Repair 3hoit to power in ihe
unit 26P connectorterminals
N o . l a n dN o . 2 i n d i v i d u a l l y . rcOM circuil wire bgtween the
ABS control unit end unde.-
hood ABS fuse/relaybox.
. Repair sho to powor in tha
PCOM oJ SCOM circuit wiro
betwoen the ABS control unit
and modulator unit.
' Repl.co the modul.tor unit.
Replacethe ABS control unit.
lshort to Dowcr iGido the unit)
V o l t ag e
19-72
lgnitionVoltage
DiagnosticTrouble Code (DTC)61: lgnhion Voltage Diagno3is
- With tha engin€ running, ABS

indicator lighl is ON.
- With the SCS s€rviceconnec-
to. conn€ctod ls€€ page 19-561,
DTC61 is indicated.
Problemv€rification:
1. Erasethe DTC.
2. Startthe engine.
3. Make sure that the ABS ind;
catorlight comeson and DTC
61 is indicated.
ls DTC61 indicated? The system b OK .t this time.
A8S CONTROLUNIT 26PCONNECTOR
Checkthe lG2 cilcuii: IG2IBLK/BLU}

terminalNo.3 and body ground.
] ls there18V or above? Wiresideof lemaleterminals
lf the vohage is 0 V, checklor an

opon in the lG2 circuit.
It there is 12 - 17 V. substitute a
known-goodABS colrtrolunit and
Jecheck.
I t
19-73
Troubleshooting
CentralProcessingUnit (CPUI
DiagnosticTroublo Code IDTC)81: CPU Disgnosis

{lll. ABS indicator light does
not go oft.
- With tho SCS servi@ connec-
tor conn€cted lsee page 19{6},
DTC81 is indicated.
P.oblemvedfication:
1. Erasethe DTC.
2. Test-drive the vehicle.
3. Make sure that the ABS indi,
catorlight comeson and DTC
81 is indicated.
ls DTC81 indicated? R€pllc6 th. ABS control unh.
The system k OK rt this time.
19-74
Modulator Unit
RemovaUlnstallation
\ i l
CAUTION:
. Do not spill brake tluid on the car; it may damage the paint; it brako lluid does contact the paint, wash it off immedi-
ately with wator.
a Take care not to damage or delorm the brake lin€s during removal and installation.
. To prevent the brake tluid from tlowing, plug and cover the hose €nds and ioints with a shop tow6l or equivalent
mat€rial.
N O T E |T i g h t e n t h e f l a rneu t s t o 1 5 N . m( 1 . 5k g n m .l 1 l b f . f t ) .
Removal
'1. Disconnect
the modulatorunit 10Pand Dumpmotor 2P connectors.
2. the brakelines,then removethe modulatorunit.

Disconnect
Installaiion
1. Installthe modulatorunit.then connectthe brakelines.
2. Connectthe modulatorunit 10Pand oumDmotor 2P connectors.
3. Bleedthe brakesystem.
4. Startthe engine,and checkthat the ABS indicatorlight goesoff.
Fom
J right-1461
PUMP MOTOR
2P CONNECTOR
-R
/2e' TOR UNIT
t'
t t
19-75
Pulsers/Wheel
ABS Control Unit Sensors
Replacement Inspection
1. Removethe right side kickpanel. 1 . Checkthe front and rear pulserfor chippedor dam-
aged teeth.
2. Disconnect
the ABS controlunit connecrors.
Measurethe air gap betweenthe wheel sensorand
3. Removethe ABS controlunit, pulserall the way aroundwhile rotatingthe pulser.
4. lnstallthe ABS control unit in the reverseorder of Slandard: 0.4 - 1.0 mm (0.02- 0.04 in,
removal,
N O T E ; l f t h e g a p e x c e e d s1 . 0 m m ( 0 . 0 4i n ) , t h e
p r o b a b i l i t yi s a d i s t o r t e ds u s p e n s i o na r m w h i c h
shouldbe replaced.
Dbc brake typo
0.{ - 1.0mm
(0.02- 0.04 in)
CONNECTORS Drum brake typ6
19-76
t l}
WheelSensorReplacement
NOTE:
. Becarefulwhen installingthesensorsto avoidtwistingthe wires.
. The torquevalueof the boltsis 9.8 N.m (1.0kgf.m,7 lbf.ft).
Front
\ J WHEEL
FRONT SENSOR
Rear
1. Removethe hub bearingunit (seesection18).

2. Removethe four backingplatebolts.
3, Pullthe backingplateawayfrom the trailingarm, then removethe wheelsensor.lt is not necessary
to disconnectthe
brakeline.
NOTE:This illustrationis drum braketype.The torquevalueof the disktype is same as drum type.
REARWHEELSENSOR
I t
19-77
l}
Body ('96 modell
Doors
FrontDoorIndex(4D) ...20-2
RearDoorIndex{4Dl .....20-8
DoorfndexlzDl3Dl .......20-14
Emblems
fnstallation 20-118
Exterior
ComponentLocationIndex............... 20-93
*FrameRepairChart .......... 20-120
* Interior
ComponentLocationIndex............... 20-58
\ e Mirrors
MirrorRep|acement ..................
.........
20-24
Mirror Holder/GoverReplacement... 20-25
RearviewMirrorReolacement ..........
20-25
Moonroof
lndex.......... .....................20-50
OpenerCable/Opener and Latch/
Wiperand Washer
ComponentLocationIndex.......... ...,.20-107
Seatsand Seat Belts
GomponentLocationIndex.......... .....20-73
Sub-frame ....20-119
Windshield,RearWindow and OuarterGlass
Index.......... .....................20-26
Body {'97 modell 20-123

Body ('98 modell 20-131
I t Body ('99 modell 20-135
Body ('00 model) 20-141

Doors
FrontDoor lndex
,ID:
WEATHERSTRIP
I
\ t
I
r^r f\
\ ) t \ '
\ - !
i'
ffitr6-
fud -@a,
\tEf
POWERWINDOW
swtTcH
Adjustment,page
20-23
DOOR
PROTECTOR
OOORPOCKET
J$--"**^
20-2
l}
GLASS
Replacement,
page20 6
Adiustment,
page 20-20 GLASSRUN
CHANNEL
t t \
. \ ' \
CENTERLOWER
CHANNEL
e CYLINDER REGULATOR
PBOTECTOR Replacement,
LOCKROD page20-6
PROTECTOR
ô
STRIKER
Adjustment,
page20-23
\
\
'
ll ?'2'
\ ttt[
ourERHANoLE \necuLaron
page20-5
Replacement, HANOLE
LOCK RETAINER
CYLINOER CLIP
#-l|r& / h )
- )
INNENHANDLEROD
s
POWERDOOR
LOCKSwlTCH
(driver'sonly)
//
*Nqd'
LATCH
/ Y < PROIECTOR
cYLTNoER ,/
ROD ,/
-"-/
LATCH /
Replacement,
20-6
INNER
HANDLE
I t
20-3
Doors
DoorPanelReplacement
NOTE;Takecarenot to scratchthe door paneland other 4. Releasethe clips that hold the door panel.Remove
pans. the door panelby pullingit upward.
1. Remove: NOTE:Removethe door panelwith as littlebending

. Innerhandle(seepage20-3) as possibleto avoidcreasingor breakingit.
. Mirror mount coverpanel(seepage20-24)
95 mm {3.74in.)
2. lf applicable,removethe regulatorhandleby pulling
the clip out with a wire hook. .L
12mm
HANOLE TRIM PAD (0.47in.) f
REMOVER
(Commercially
availablel
Snap-on
#A'177,o. r_
equivalenl
lmm
(0.04in.l rr-l
45 mm
(1.77in.l
>i Clip loc.tions, 5
3. Removethe door grip coverand speakercover,then l u - i

removethe screws.
J$- I
:fe i
POWER WTNOOW
>: Screwlocations,
5 swtTct{
cL,P /\ I
REMovERil
I
_ _t/
Dasconnect
the
;peakerconnector,
5. lnstallation is the reverse of the removal procedure.
20-4
\ :
OuterHandleReplacement
NOTE:Raisethe glassfully. 4. Pull out the outer handle.Pry the outer handle rod
out of its joint usingdiagonalcutters
'1. Remove:
. Door panel NOTE:
. Plasticcover(seepage2o-21 a To easereassembly, note location@ of the outer
handlerod on the joint beforedisconnecting it.
2. Pullout the retainercliP. . Takecarenot to bendthe outer handlerod.
o Use a shop towel to protectthe opening in the
CYLINDERPROTECTOR ooor.
OUTERHANDLE BUSHING
ROD Replace.
DIAGONAL
,w.
i4'
CUTTERS
LOCKCYLINDEB \
RETAINER
CLIP
C 3. Removethe bolts,then removethe cylinderprotec-

tor, lockcylinderand outer handle.
>: Boltlocaiions,2
6x1.omm I
i.eN.. tr.orgf.-, I
7.2rbr.fi)
,2
CYLINDER
SHOP
TOWEL
5. lnstallationis the reverseof the removalprocedure
NOTE:Makesurethe door locksand opensproperly.
LOCKCYLINDER
ROD
CYLINDER
20-5
Doors
Latch Replacement Glass/Regulator
Replacement
NOTE:Baisethe glassfully. ' 1 . Removel
o Door panel(seepage20-4)
1. Remove: . Plasticcover (see page 20-2l,
. Door panel(seepage20-4)
. Plasticcover(seepage20-2) Carefullymove the glassuntil you can seethe bolts,
. Outerhandle(seepage20-5) t h e n r e m o v e t h e m . C a r e f u l l yp u l l t h e g l a s s o u t
throughthe window slot.
Removethe bolt, then move the center lower channel
forwa rd. NOTE:Takecarenot to drop the glassinsidethe door.
Disconnectthe connector,and detachthe harness

clip from the door. Bemovethe latch through the >i Boltloc.tions,2
hole in the door.
fi s'r.o-. i
Clb9.8 N.m11.0
kstm,l
NOTE:Takecare not to bend the inner handlerod,
outer handlerod, cylinderrod and lockrod.
_-l't!!t ,/
>: Screwlocations,
3
GLASS
LOCKROO
REGULATOR
6 x 't.0mm
8 N.m(0.8kgtm,
6 tbf.ftl
4. Installationis the reverseof the removalprocedure.
NOTE:
. Make sure the inner handle rod and connector
are connectedproperly.
. Makesurethe door locksand opensproperly.
20-6
\ L
3. Disconnectthe connector,and detachthe harness 4. Greaseall the slidingsurfacesof the regulatorwhere
clip, then removethe regulatorthrough the hole in snown.
the door,
>: Bolt locations
a>,4 B>,3
6x1.0mm
8 N.m {0.8kgl m,
ttt*,
)
REGULATOR
REGULATOR
MOTOR
lnstallationis the reverseof the removalprocedure.
NOTE:Rollthe glassup and down to seeif it moves

freelywithout binding.Also make sure that there is
no clearancebetweenthe glassand glassrun chan-
I t nel when the glassis closed.Adjusrthe positionof
the glassas necessary(seepage20-20).
ar Nul locations,3
6x1.0mm
8 N.m 10.8kgf m,
6 rbt.ftl
Loosen.
REGULATOR
{Manualtype)
20-7
Doors
RearDoor Index
,[D:
OUTER
WEATHERSTRIP
INNER
WEATHERSTRIP
PLASTIC
COVER
DOOR
Adjustment,
page 20-23
t\ fu4 ffir",
\\
M
POWER WTNDOW
INNERMOLDING R*
/ -
\a- HINGE
sw[cH
\ \
\ € \
\ ; \ o(x)R
:-?
(=__:\
*e€
€ -*r'
\
PROTECTOR
\
/ \
/ \
/ DooR
/ GRIP
DOOn
GRIP
COVER
20-8
\ L
CHANNEL\
REAR
\fl
N\
\ \,\
\ \r\
\ iI\l l
ld 1l
6P lll
c"AN"..:
REo" | 1l
coLLAR
\ J I
)\3-
€)\IJ
\ lJ
6/
REGULATOR
HANOLE
:&
\tr \
'All
fr\
lll
OUTERHANDLE criss lLl
Page20-11
Replacement, l'A\ sroeeen
lll
STRIKER
Adjustment,
page 20'23
POWERWINDOW
MOTOR W-*d
t a)" u\
I *)u*ro* \
I LOCKROD pase20,tt
Repracement,
l5[1tf
%
grc
PROTECTOR
CHANNEL
LATCH
Replacement, PROTECTOR
page 20-12
POWEROOOR
LOCKACTUATOE
20-9
Doors
Door PanelReplacement
NOTE:Takecarenot to scratchthe door paneland other 3. Releasethe clips that hold the door panel.Remove
parts. t h e d o o r p a n e lb y p u l l i n gi t u p w a r d .
1. Remove: NOTE:Removethe door panel with as little bend-

. Innerhandle(seepage20-9) angas possibleto avoidcreasingor breakingit.
. Regulatorhandle(seepage20-4)
2. Removethe door grip cover,then removethe screws.

,L
12mm
TRIM PAD (0.47in.) T-
REMOVER
(Commercially
>: Screwlocation3.2
available) rt{-
Snap-on
#4177,or lmm l---4 ,nu"
equival€nt (o.o1in.l1 f- -l
45mm '
11.77in.l
> r C l i pl o c a t i o n sT,
4l N l
rRrMPAD---_Jl i
REMOVER .I+ ]
F/
4. Installationis the reverseof the removalDrocedure.
20-10
t Outer HandleReplacement
NOTE:Raisethe glassfullY. 4. Pull out the outer handle.Pry the outer handlerod
out of its joint usingdiagonalcutters.
1. Remove:
. D o o rp a n e l NOTE:
. Plasticcover(seepage20-8) . To easereassembly,note locationO of the outer
handlerod on the joint beforedisconnecting
it.
2. Removethe screws. . Takecarenot to bendthe outer handlerod.
. Use a shop towel to protectthe opening in the
door.
3
>: Screwlocations,
6x1.0mm
6 N.m {0.6kgf m, BUSHING
4 tbf.ftl Replace.
:"'*,w,
o
DIAGONAL \
\ a OUTER
HANDLE
ROD
3. Move the latchdown, and removethe bolts.
>: Bolt locations,2
6x1.0mm
9.8 N,m )
11.Okst.n,7.2lbiftl //
SHOPTOWEL
5. lnstallationis the reverseof the removalprocedure
surethe door locksand opensproperly.

NOTE:N4ake
20-11
Doors
Latch Replacement Glass/RegulatorReplacement
NOTE:Raisethe glassfutty. L Remove:
. Door panel{seepage20-10)
1. Remove: . Plasticcover (seepage20,8)
. Door panel(seepage20-10)
. Plasticcover(seepage20-8) 2. Carefullymove the glassuntil you can seethe bolts,
. Outerhandle(seepage2O-1,l then removethem.
2. Removethe lockcrankand clip. NOTE:Takecarenotto dropthe glassinsidethe door.
>: Screwlocation,I >: Cliplocation,I

>: Eoltlocations,
2
qn@l # | p o'r.o-,n I
@ 9.8N.m{t.okof.m.
- I
.- :'zulnt
_ __) _-__) /
LOCK
ROO
LATCH
Removethe rearchannelcollar.
NOTE:Takecare not to bendthe lock rod and inner

handlerod.
3. C a r e f u l l yl o w e r t h e g l a s s .R e m o v et h e b o l t s a n d
screwfrom the rearchannel,then removethe glass
from the rearchannel.
NOTE:Takecarenotto dropthe glassinsidethe door.

>: Bolt.screwlocations
A, 1 , c, 1
I
q)h:iT(--n,,".i m
6x1.0mm
- - illt) '/ - )
8 N.m (0.8 kgt m,
6 tbtttl Disconnect
the
connector.
B, 1
6x1.0mm
Removethe latchthroughthe hole in lne door. 8 N.m to.8 ksf.m, 6 tbt.ftt
,,<\
IDF-IIID I
5. lnstallationis the reverseof the removatproceoure.
.)
NOTE:Makesurethe door locksand opensproperly. -__,/
20-12
t}
4. Carefullyremovethe glassfrom the window slot.

c \
CLIP
7. Grease all the sliding surfaces of the regulator where
shown.
NOTE:
a lf necessary,remove the power window motor
from the regulator.
REAR . Beforeremovingthe powerwindow motor,scrloe
CHANNEL a lineacrossthe sectorgearand regulator.
COLLAR
SECTORGEAR REGULATOR
5. Removethe outer molding,then removethe quar-

Ier grass.
OUARTER
\
POWERWINDOW
MOTOR
>: Bolt locations,3
POWER
wTNDOW
MOTOR
6. Disconnectthe connector,and detachthe harness l' -... er

clip, then removethe regulatorthrough the hole in A nicuuron
the door. 8. lnstallationis the reverseof the removalprocedure.
>: Bolt locataons
NOTE:Rollthe glassup and down to see if it moves
A>,2
6x1.0mm
]
L
B> , 2
6 x 'l.0 mm I freelywithout binding.Also make sure that there is
\ t [l o t't.-to.arsl -.
fr- - - . e- -ttt- .ttt
-,/
j
)
I N.m {0.8 ksl'm,
6 tbf.ft)
)
nel when the glassis closed.Adjust the positionof
the glassas necessary(seepage20-20).
20-13
Doors
Door Index
2DI3D:
GLASSGUIDE
CLIP
I sAsH
€ * /
\ .u\\
\ Y \ I
OU?ER
WEATHERSIRIP
et'
PLASTIC MTRRORMOUNT
COVER ii\
<]<-- COVERPANEL
-it v
@
$=-!xtruce
\rre
,",
(sqjR5f"'
S
\s-l
@."
INNERHANDLE
TRIM
(withpowerdoorlocks)
h-P -Qa,
\ (l+,
eowenooon BRACKET \
\ INNEFHANOLE
rocKswrrcH TRIM DOOR
\ {without power
door locks)
dl Adjustment,
page 20-23
dD
h
\b ARMREST
W/
- p
POCKET
ARMREST
POCKET
;ril;"i-"-\ 9 Q*-BsfL-,"
lwith power
J E
dnJ.*-{
powen____-.-@.*\L'l
wtNDow
r-1*{ SPEAKER
swrrcH ,P
t SPEAKERCOVER
20-14
?
GLASS
Replacement,
page20-19
Adjustment,
page 20-20
GLASSRUN
CHANNEL
3ill,'^lri"*'"tt--.-.qq
\,
\I\
\\II REGULATOR
pagezo rs
\\\\ neptacement,
\\'l\
\ 6
trq\\\\ v.
tr
POWER
MOTOR
CYLINDER
PROTECTOR
LATCH
Replacement,
page20-18
STRIKER
Adjustment, RETAINEB
LOCK CLIP
page20-23
CYLINDER
\
fitn
\a
\.vqE
BOD PROTECTOR
INNERHANDLEROD
LATCH
PROTECTOR
20-15
Doors
Door PanelReplacement
N O T E :T a k e c a r e n o t t o s c r a t c ht h e d o o r p a n e l a n d 5. Releasethe clips that hold the door panel.Remove
other parts. the door panel by pulling it upward.Disconnectthe
'1. speakerconnector.
Remove:
. I n n e rh a n d l et r i m ( s e ep a g e2 0 - 1 4 ) NOTE:Removethe door panelwith as littlebending
. Mirror mount cover panel(seepage20-24) as possibleto avoidcreasingor breakingit.
2. l f a p p l i c a b l e r, e m o v et h e r e g u l a t o rh a n d l e b y
p u l l i n gt h e c l i po u t w i t h a w i r e h o o k .
.L
REGULATOR
HANDLE 12
fim
TRIM PAD (0.47 in.) T-
WIREHOOK REMOVER
(Commercially
available)
Snap-on
#A'177,or 1mm
equivalent {0.04in.)
11.77in.l
>: Clip locations,
l^
3. R e m o v et h e a r m r e s tp o c k e t ,t h e n d i s c o n n e ctth e
powerwindow switchconnector. J[
=l$
ll,\*
,,)
atr-
REMoVERtl
-)
DOORPANEL
ARMREST
POCKET
4. Removethe speakercover,then removelhe screws.
>: Screwlocations,
3
I
| 6b:a,'
L"_
O) CONNECTOR
6. lnstallation is the reverse of the removat oroceoure.
COVER
20-16
b Outer Handle Replacement
NOTE:Raisethe glassfully. 4. Pull out the outer handle.Pry the outer handlerod
out of its joint usingdiagonalcutters.
1. Remove:
. Door panel NOTE:
. Plasticcover(seepage20-14) . To easereassembly, note location@ ot the outer
handlerod on the joint beforedisconnecting it.
2. Pullout the retainerclip. . Takecarenot to bendthe outer handlerod.
. Use a shop towel to protectthe opening in the
CYLINOER
PROTECTOR door.
EUSHING
Replace.
,pr,
LOCKCYLINDER
DIAGONAL
CUTTERS \
RETAINER
CLIP
\ e 3. Removethe bolts,then removethe cylinderprotec-

tor, lockcylinderand outer handle.
>: Boltlocations,2
6x1.omm ]
9.8N.m {1.0kgf.m,
1.2tbl,ttl )
_, _-_-,/
CYLINDER
PROTECTOR
SHOP
TOWEL
LOCKCYLINOER
CYLINOER
ROD
20-17
Doors
Latch Replacement
NOTE:Raisethe glassfully. 3. Removethe boltsand movethe centerlowerchannel.
1. Remove: NOTE:Takecare not to bend the inner handle rod

. Door panel(seepage20-16) and lock rods.
. Plasticcover(seepage20-14)
. Outerhandle{seepage20-17}
2. Removethe rod protector. >: Screw locations
A>,3 8>,3
6x1.0mm
LATCH
_"
ffu 6 N.m{0.6kef.m,
11111 )
l
q )
CENTERLOWEB
CHANNEI CBANK
HOLDER
PROTECTOR
Disconnect
the connector,
6x1.0mm
8 N.m 10.8kgt.m,
6 tbtft)
Remove the inner handle, then remove the latch

throughthe hole in the door.
5. lnstallationis the reverseof the removalprocedure.
20-18
L Glass/RegulatorReplacement
1. Remove: 3. Disconnectthe connector,and detach the harness
. Door panel(seepage20-'16) clip, then removethe regulatorthrough the hole in
. Plasticcover(seepage20-14) the door.
2. Carefullymove the glassuntil you can seethe bolts, NOTE:Scribea line aroundthe rearrollerguidebolt
then loosenthem. Slidethe guide rearward,remove to showthe originaladjustment.
t h e g l a s s t r o m t h e g u i d e , a n d c a r e f u l l yp u l l t h e
glassout throughthe window slot.
>: Boltlocations
NOTE:Takecarenot to dropthe glassinsidethe door.
a >,4
6xL0mm
B> , 2
I
'-1
6x1.omm I
8 N.m (0.8 kgt m, i I N.m {0.8 kgt.m,
>: Bolt localions,2
l*
E
6x1.0mm
9.8N.m{1.0kgtm,I
7.2tbrfil I
) 6lbrft
Loosen.
,/
]
\3 Loosen ,/
ROLLER REGULATOR
t J
BOLTS
GUIDE
(cont'd)
20-19
Doors
Glass/Regulator (cont'dl
Replacement GlassAdjustment
Greaseall the slidingsurfacesof the regulatorwhere NOTE:
shown. . Placethe vehicleon a firm, levelsurfacewhen adjust-
ing the glass.
NOTE: . Checkthe weatherstrips and glassrun channelfor dam-
. lf necessary,remove the power window motor age or deterioration,and replacethem if necessary.
from the regulator.
. Beforeremovingthe powerwindow motor,scribe 1. Remove:
a line acrossthe sectorgearand regulator. . Door panel(seepages20-4,10, 16)
SECTORGEAR . Plasticcover(seepages20-2,8,14)
2. Adjustthe glass.
REGULATOR
4D:
a. Raisethe glassfully.
b. Loosenthe glass mounting bolts (front door)

and regulatormountingbolts.
Push the glass rearward (front door glass)or

iorward (reardoor glass).
d. Tighten the glass mounting bolts (front door)

and regulatormountingbolts.
A >: Gl.3s mountingbolt

locations.
B >: Regulrtor mouting
bolt loc.tions.
Front:
5. Installationis the reverseof the removalorocedure.
NOTE:Rollthe glassup and down to seeif it moves

freely without binding.Also make sure that there is REGULATOR
nel when the glass is closed.Adjustthe positionof
the glassas necessary.
20-20
b
Rear:
GLASS
+" +
REGULATOR
e. Loosenthe front channelmountingbolts (front 2DI3D:

\ J d o o r ) o r r e a r c h a n n e lm o u n t i n g b o l t l r e a r
ooor,, Raisethe glassas far up as possible,and hold
it againstthe glassrun channel.
f. Lowerthe glass.
b. L o o s e nt h e r o l l e rg u i d e b o l t s ,a n d a d j u s tt h e
g. P u s h t h e f r o n t o r r e a r c h a n n e l sa g a i n s tt h e glassso it is parallelwith the glassrun channel.
glass,then tightenthe mountingbolts.
GLASSRUN
>: Frontandrear CHANNEL
channel mounting
bolt locations
Front:
ROLLER
GUIDEBOLTS
\
(cont'd)
20-21
Doors
GlassAdjustment {cont'd)
c. Tightenthe rollerguide bolts. 6. Checkfor water leaks.
d. Loosenthe front channelbolts. Spray water over the roof and on the sealingarea
as shown.
e. Lowerthe glass.
NOTE:
f. Pushthe front channelagainstthe glass,then . Adjustthe water pressureas shown.
tightenthe mountingbolts. . Do not squeezethe tip of the hose.
GLASS
0.5 m {1.6ft)
HOSE
HOSE
U
- \ , 300 mm {11.8in)
MOUNTING
BOLT
3. Checkthat the glassmovessmoothly.
4. Raisethe glassfully and checkfor gaps.
5. Checkthe glassoperation. 1. Attachthe plasticcover,then installthe door panel

(seepages20 4, 10, 16).
NOTE:Checkthat the glass contactsthe glass run
channelevenly. Installthe regulatorhandleso it pointsforwardand
up at a 45 degreeanglewith the glassclosed.
WEATHERSTRIP
Forward -
20-22
b PositionAdjustment StrikerAdjustment
NOTE: Placethe vehicleon a firm, level surfacewhen lvlakesurethe door latchessecurelywithout slamming.
adjustingthe doors. lf it needsadjustment:
After installingthe door, checkfor a flush fit with the NOTE;The strikernuts are fixed, but the strikercan be
body,then checkfor equalgaps betweenthe front, rear, adjustedslightlyup or down,and in or out.
a n d b o t t o m d o o r e d g e sa n d t h e b o d y . T h e d o o r a n d
'L
body edgesshouldalso be parallel.Adjust at the hinges Loosenthe screws,then insert a shop towel between
as shown, the body and striker.
CAUTION:Placea shop towel on the iack to prevent

damage to the door when looseningthe door and hinge
mounting bohs for adiustment. Inserta shoptowel
DOOR MOUNTING BOLTS betweenthe body and
8 x 1.25mm
28 N.m{2.9kgf.m.21lbt'ft}
Loosen thedoormounting boltsslightly
to movethedoorlN or OUTuntil PLASTIC
it'sflushwiththebody.lf necessary,
voucaninstallashimbehindone
hingeto makethedooredges
P A R A L L E Lw i t h t h e b o d y .
HINGEMOUNTINGBOLTS
I x 1.25mm
28 N.m (2.9kgf.m,21lbtft)
Removethe innerfender,
loosenthe hingemounting
bolts,and movethe door
BACKWARD or FORWARD,
UP or DOWNas necessary sc8Ews
J to equalizethe gaps. 8 x 1.25mm
Lowerthe glass. 18 N.m (1.8kgf.m,
13 tbtftl
ifF t
2. Lightlytightenthe screws.
3. Wrap the strikerwith a shop towel, then adjustthe

strikerby tappingit with a plastichammer.
CAUTION: Do not tap the striker too hard.
4. Loosenthe screws.and removethe shoptowel.
5. Lightlytightenthe screws.
The door and body edges should be parallel- H o l d t h e o u t e r h a n d l eo u t , a n d p u s h t h e d o o r

againstthe body to be surethe strikerallowsa flush
fit. lf the door latchesproperly,tighten the screwsand
recheck.
\
NOTE:Checkfor water leaks.
20-23
Mirrors
Mirror Replacement
NOTE:Take care not to scratchthe mirror. mirror base 3. Removethe mirror mountingnuts while supporting
coverand door. the mirror.
l L o w e rt h e d o o rg l a s s .
a: Nutlocations,3
2. Carelullypry out the mirror mount cover panel by
nano.
Power mirro.:
€)CONNECTOR
(Nrirrorside)
MIRROR
(Doorharness
side)
CONNECTOR
MIRROR
MOUNT
COVEB
PANEL
Manual mirror: Installationis the reverseof the removalprocedure.
Removethe cap, screw and knob,then removethe NOTE:Make sure the connectoris connectedprop-
mirror mount cover panel. erly.
MIRRORMOUNT
KNOB
20-24
|} Mirror Holder/CoverReplacement RearviewMirror Replacement
CAUTION: Put on gloves to protecl your hands. 1. Removethe rubberdamper.
L C a r e f u l l yp r y o u t t h e m i r r o r h o l d e rw i t h a f l a t t i p 2. Pry the cover off using the end of a flat tip screw-
screwdriveras shown. drivef.
PIVOT
CAUTION: When prying with a flat-tip screwdriver,
JOINT PIN -6r wrap it with a shop towel to prgvant damage.
-G{ 3. Removethe screws,then removethe rearviewmir-
ror,
SCREW
5x0.8mm
il N.m lo.a kgf.m,
3 lbf.ftl
SHOPTOWEL
J Installationis the reverseof the removalprocedure.
NOTE:Apply greaseto the locationsindicatedby

the arrows.
>: Sc.ewlocations
A> ,3 s>,2
I
ry 6)drD
)
To remove the screws,
pull the sealaway.
SHOPTOWEL
I
20-25
Windshield,RearWindow and OuarterGlass
Index
NOTE:The numbersafterthe part namesshow the quantitiesof the partsused.
Windshieldl2Dl3D/4D):
RUBBER
UPPER
DAM
FASTENER, 2
(Sell-adhesive
type,glassside)
FASTENER, 2
body side)
lClip-type,
WINDSHIELD
Removal,page20 28
page20-29
Installation,
RearWindow (2Dl4Dl:
FASTENER, 4
(Self-adhesive-type,
glassside)
/ FASTENER,4
/ lSelf adhesive-type,
body sidel
* , /
M
SPACER,
w
/>
@
20-26
b
RearWindow l3Dl:
FASTENER,4
glassside)
SPACER,
| ,o"r.".". o
bod'side)
I
{ff*'*'YPe
DAM,2
RUBBER
tI = @
I
SEALA, 1
SEALB,2
e
OuarterGlass:
3D: 2D:
OUARTERGLASS
Removal,page20-40
page20 4l
Installation, OUARTER
GLASSTRIM
FASTENER
$( (Self-adhesave
body side)
type,
\
\
\)f\
n,
LOWERRUBBER
\il]
LOWERCLIP
FASTENER
glassside)
lSelf adhesive'type)
LOWERCLIP
(Selfadhesive-type)
DAM
20-27
Windshield
Removal
CAUTION: 4. Apply protectivetape along the edge of the dash
. Put on gloves to plotest your h8nds. b o a r da n d b o d y a s s h o w n .U s i n ga n a w l , m a k e a
. Use seat covers to avoid damaging any surfaces. h o l e t h r o u g ht h e r u b b e rd a m a n d a d h e s i v ef r o m
i n s i d et h e c a r . P u s ht h e p i a n ow i r e t h r o u g ht h e
1. To removethe windshield,first removethe: hole,and wrap eachend arounda pieceof wood-
. Rearviewmirror (seepage20-25)
. Sunvisorsand holders(seepage20-64)
PROTECTIVE
. Frontpillartrim (seepages20-59,60, 61)
! Windshieldwiper arms and cowl cover (seepage
PIANOWIRE
UPPER | '1"
RUBBER
20-1131 DAM
WINDSHIELO
Peel off the molding, and removethe glass brack-
ers. AOHESIVE
NOTE:When molding removal is difficult,cut the

moldingwith a knife.
MOLDING
WINDSHIELO
RUBBER
DAM
W i t h a h e l p e ro n t h e o u t s i d e ,p u l l t h e p i a n o w i r e
backand forth in a sawingmotion,and carefullycut
t h r o u g ht h e r u b b e rd a m a n d a d h e s i v ea r o u n dt h e
entirewindshield.
CAUTION: Hold the piano wile as closeto ihe wind-

shield as possible to prevent damage to the body
and dashboard.
3. Pull down the front of the headliner(see page 20-

64).
CAUTION: Take care not to bend the headlinet WINDSHIELD

excsssively.
6. Carefullyremovethe windshield.
20-24
Installation
t
'1. G l u e t h e r u b b e rd a m a n d f a s t e n e r st o t h e i n s i d e
Using a knife,scrapethe old adhesivesmooth to a
thicknessof about 2 mm (0.08in.) on the bonding face of the windshieldas shown.
surfacearoundthe entirewindshieldopeningflange.
NOTE:Be carefulnot to touch the windshieldwhere
NOTE: adhesivewill be applied.
. Do not scrapedown to the paintedsurfaceof the
body; damaged paint will interferewith proper
bonding. >: Faslener localions, 2
. Removethe rubberdams and tastenersfrom the FASTENER
body. ALTGNMENT, \ -o
. Maskoff surroundingsurfacesbeforepainting. MARK
2. Cleanthe body bondingsurfacewith a spongedamp-

enedin alcohol.
NOTE: After cleaning,keep oil, grease and water

ALIGNMENT
from gettingon the surface.
MABK
3 . lf the old windshieldis to be reinstalled,use a putty

knife to scrapeoff all traces of old adhesive,then
c l e a nt h e w i n d s h i e l ds u r f a c ew i t h a l c o h o lw h e r e
new adhesiveis to be applied.
13.5mm
(0.53in.)
NOTE:Make sure the bonding surfaceis kept free
of water,oil and grease. LOWERRUBBER
DAM
t C CAUTION:Avoid setting the windshield on its edges;

small chips may later deyelopinto cracks. WINOSHI€LD
NOTE: 5. Align and glue the molding to the edge of the wind-
. Cleanthe shadowedarea. shield.
o Cleanarea@ as shown.
lnside NOTE: Be caretul not to touch the windshield where
&
a4)
WINDSHIELD
MOLOING WINDSHIELO
100mm
{3.94in.l
) J WINDSHIELD Apply primer(3M N'200,or equivalent)

to edSe (cont'd)
of the windshield.
20-29
Windshield
Installation (cont'd)
Installtheglassbracketsand fastenersas shown. 9. With a sponge, apply a light coat of glass primer
around the edge of the windshieldas shown. then
NOTE:The numbersafterthe part namesshow the lightlywipe it off with gauzeor cheesecloth.
quantitiesof the oartsused.
NOTE:
>: Fastonerlocations,2 . Do not apply body primerto the windshield.and
FASTENER^ I do not get body and glassprimerspongesmixed
I
up.
. Nevertouch the primed surfaceswith your hands.
lf you do. the adhesivemay not bondto the wind-
shieldproperly,causinga leakafterthe windshield
is installed.
. Keepwater. dust, and abrasrvemateraalsaway
from the primedsurface. Applyglassprimer
t/////,
'/////l to the molding.
I Apply glass p.imer here.
GLASSBRACKETS,
2
MOLDING
7. Set the windshieldon the glassbrackets,then cen-

ter it in the opening.Make alignmentmarksacross
the windshieldand body with a greasepencilat the
four pointsshown. WINDSHIELD
10. With a sponge.apply a light coat of body primerto
NOTE:Be carefulnot to touch the windshieldwhere the original adhesiveremainingaround the wind-
adhesivewill be aDolied. shield openingflange. Let the body primer dry for
at least10 minutes.
NOTE:
. Do not apply glassprimer to the body, and be care-
ful not to mix up glassand body primer sponges.
. Nevertouch the primed surfaceswith your hands.
. Maskoff the dashboardbeforepaintingthe flange.
7////l
/////l I Apply body p mer hcre.
6mm 16mm 5mm 16 mm
(0.6:|in.) (0.2 in.l {0,63in.}
SCREW
8. Removethe windshield.
20- 3 0
3
1 1 . Thoroughlymix the adhesiveand hardenertogether 1 4 . U s e s u c t i o nc u p s t o h o l d t h e w i n d s h i e l do v e r t h e
on a glassor metal plate with a putty knife. opening,align it with the alignmentmarksmade in
step7, and set it down on the adhesiveL . ightly
NOTE: push on the windshielduntil its edge is fully seated
. Cleanthe platewith a spongeand alcoholbefore on the adhesiveall the way around.
mixing.
. Followthe instructionsthat come with the adhe- NOTE:Do not openor closethe doorsuntiladhesive
stve. ri vI Y
A L T G N M E N TM A R K
Beforefilling a cartridge.cut the end of the nozzle

as shown.
Cut nozzleend
10 mm 10.39
in.)
7 mm (0.27in.l
1 5 . Scrape or wipe the excessadhesiveoff with a putty

13. Packadhesiveinto the cartridgewithout air pockets knifeor towel.
to ensurecontinuousdelivery.Putthe cartridgein a
tu c a u l k i n gg u n , a n d r u n a b e a do f a d h e s i v ea r o u n d NOTE: To removeadhesivefrom a paintedsurfaceor
the edgeof the windshieldas shown. the windshield,wipe with a soft shop towel dampened
with alcohol.
NOTE:Apply the adhesivewithin 30 minutesafter
applyingthe glassprimer. 1 6 . Let the adhesivedry for at leastone hour, then spray
water over the windshieldand checkfor leaks.Mark
12mm (0.47in.) the leakingareas,let the windshielddry, then seal
Make a slightly thicker with sealant.
l_Z oo*.t,ut bead at each corner.
NOTE:
8 mm 10.31in.l . Let the car stand for at leastfour hours after wind-
5mm
(0.2in ) shieldinstallation. lf the car hasto be usedwithin
MOLDING
='+ the firstfour hours,it must be drivenslowly.
. Keepthe windshielddry for the first hour after
installation.
A\ulotoô
. -.\\ . Checkthat the ends of the side molding are set
underthe cowl cover.
UPPER
/
WINDSHIELD
w
't7. Reinstallall remainingremovedparts.
RUBBER
DAM LOWEB
RUBBER
FASTENER DAM NOTE:
. Installthe rearviewmirror rubber damper after
LOWER the adhesivehasdriedthoroughl',.
RUBBER . Advisethe customernot to do the followingthings
DAM
for two to three days:
lmm - Slam the doors with all the windows rolled
10.04in.l up.
- T w i s t t h e b o d y e x c e s s i v e l y( s u c h a s w h e n
) WINDSHIELD going in and out of drivewaysat an angle or
drivingover rough,unevenroads).
20-31
RearWindow
Removal
2DllDl 4. Apply protectivetape along the edge of the body as
shown. Using an awl, makea hole through the
CAUTION: adhesivefrom insidethe car. Pushthe piano wire
. Put on gloves to protect your hands. through the hole,and wrap eachend around a
. Uso ssat coversto avoid damaging any surlaces, pieceof wood.
. Do not damage thg roar window dofogggr grid linss,
window antenna grid lines, and tsrminalg.
PIANOWIRE
1. To removethe rearwindow,first removethe: ADHESIVE

. T r u n kl i d
REARWINDOW
. Rearseatcushion(seepages20-79,81)
. Rearseat side bolsters{4D,see page 20-79)
PROTECTIVE
. Rearseat-back(2D,seepage20-81) TAPE
. Rearshelf{seepages20-59,61}
. Rearpillartrim {4D,see page20-59)
. Sidetrim panel(2D,seepage20-61)
. Ouartertrim panel(2D,see page20-61)
. Rear roof trim (see page 20-65) TAPE
REARWNDOW
2, Disconnectthe rear window defogger connector
from eachside. PIANOWIRE
3. Peeloff the molding.

PROTECTIVE
NOTE:When molding removal is difficult,cut the TAPE
moldingwith a knile.
ADHESIVE
MOLDING
With a helper on the outside, pull the piano wire

backand forth in a sawingmotion,and carefullycut
F"*t, through the adhesivearound the entire rear win-
dow.
ID_HESI.VE
---, ,/,/ CAUTION: Hold the piano wiro as close to the rear
REARWINDOW window as possiblsto prcyent damageto the body.
S
MOLDING
6. Carefullvremovethe rearwindow.
20-32
lnstallation
I
1 . Using a knife,scrapethe old adhesivesmooth to a 4. Apply the double-facedadhesivetape (NITTO501,
thicknessof about 2 mm (0.08in.) on the bonding or equivalent)to the edge of the rear window, then
s u r f a c ea r o u n d t h e e n t i r e r e a r w i n d o w o p e n i n g installthe moldingaroundthe edge of the rearwin-
flange. dow as shown.
NOTE: N O T E : B e c a r e f u ln o t t o t o u c h t h e r e a r w i n d o w
. Do not scrapedown to the paintedsurfaceof the whereadhesivewill be applied.
bonding ALIGNMENTMARK
o Maskoff surroundingsurfacesbeforepainting. ADHESIVETAPE
. R e m o v e t h e f a s t e n e r sa n d s p a c e r sf r o m t h e 867mm 134.
I in.)
oooy.
5mm
2. C l e a nt h e b o d y b o n d i n g s u r f a c ew i t h a s p o n g e {0.2in.}
dampenedin alcohol. ADHESIVE
TAPE
NOTE: After cleaning,keep oil. greaseand water Thickness:
from gettingon the surface. 0.16mm (0.006in.l
MOLDING
usea putty
lf the old rearwindow is to be reinstalled, ALIGNMENT
knifeto scrapeoff all tracesof old adhesiveand the MARK
rubberdam,then cleanthe rearwindow surfacewith GLASS
alcoholwherenew adhesiveis to be applied.
NOTE:Make sure the bonding surfaceis kept free

MOLDING
of water,oil and grease.
wtNoow
)
CAUTION:Avoid setting the rear window on its
edges;small chips may later develop into cracks.
NOTE:Cleanthe shadowedarea. 5. Glue the fastenersand spacersto the insidefaceof

the rearwindow as shown.
N O T E ; B e c a r e f u ln o t t o t o u c h t h e f e a r w i n d o w
where adhesivewill be applied.
MOLOING >:Fa3l€ner, spacer

locations
A >, 4 FASTENER
(:r:^#-
T
ry
ALIGNMENT
!\raRKs
a>,2
Outside SPACER
I liGrtrrrrertrr
REARWINDOW REARWINOOW \..!44llc-''' - -
)
(cont'd)
20-33
RearWindow
Installation (cont'dl
6. Gluethe fastenersto the body as shown. 9 . W i t h a s p o n g e ,a p p l y a l i g h t c o a t o { g l a s sp r i m e r
aroundthe edgeoI the rearwindow as shown,then
Fastenerlocations,4 lightlywipe it off with gauzeor cheesecloth.
FASTENER
NOTE:
\ - . * l . D o n o l a p p l y b o d y p r i m e rt o t h e r e a rw i n d o w .
-E4,7-- ,.--
and do not get body and glass primer sponges
7 ) , / l mixed up.
4 Y l
F-LNGENY:,//
. Nevertouchthe primedsurfaceswith your hands.
lf you do, the adhesivemay not bond to the rear
w i n d o w p r o p e r l y c, a u s i n ga l e a ka t t e rt h e . e a r
window is installed.
. Keep water, dust, and abrasivematerialsaway
from the primedsurface.
'/fur1
: lppty gtassprimerhere.
MOI-DING
7. Set the rear window, then centerit in the opening.

Make alignmentmarksacrossthe rear window and FASTENER
body with a greasepencllat the four points shown. REARWINDOW
10. With a sponge,apply a light coat of body primer to

t h e o r i g i n a la d h e s i v er e m a i n i n ga r o u n d t h e r e a r
ALIGNMENTMARK
window openingflange.Letthe body primerdry for
at least10 minutes.
NOTE:
. Do not applyglassprimerto the body.and be care,
ful not to mix up glassand bodyprimersponges.
-\ /fu/
-.._s : Applyboay primerhere. 1 6m m
(0.(I, in.l
-
16 mm 7mm
(0.63in.l {0.28in.}
l
6mm r
{O.24in.}
8. Remove the rear window.
20-34
' 1 1 . Thoroughlymix the adhesiveand hardenertogether 14. Use suctioncups to hold the rear window over the
on a glassor metalplatewilh a putty knife. o p e n i n ga, l i g ni t w i t h t h e a l i g n m e nmt a r k sm a d ei n
step7, and s e t i t d o w n o n t h e a d h esiveL . ightly
NOTE: p u s h o n t h e r e a rw i n d o w u n t i l i t s e d g e sa r e { u l l y
. Cleanthe platewith a spongeand alcoholbefore seatedon the adhesiveall the way around.
mixing.
. Followthe instructionsthat came with the adhe- NOTE:Do not openor closethe doorsuntilthe adhe-
sive. siveis dry.
1 2 . Beforefilling a cartridge,cut the end of the nozzle SUCTION ALIGNMENT

a ss h o w n . CUPS MARK
1 0m m { 0 . 3 9i n . )
7 mm (0.27in.l
1 3 . Packadhesiveinto the cartridgewithout air pockets

to ensurecontinousdelivery.Put the canridgein a
c a u l k i n gg u n , a n d r u n a b e a do l a d h e s i v ea r o u n d
the edge of the rearwindow as shown.
J Scrapeor wipe the excessadhesiveoff with a putty
NOTE|Apply the adhesivewithin 30 minutesafter knifeor towel.
applyingthe glassprimer.
NOTE:To removeadhesivefrom a paintedsurface
Makea slightlythicker or the rear window, use a soft shop towel damp-
12 mm 10.,Uin.) beadat eachcorner. enedwith alcohol.
GLASS
oo*r.,u. 1 6 . L e t t h e a d h e s i v ed r y f o r a t l e a s to n e h o u r , t h e n
[/
s p r a y w a t e r o v e r t h e r e a r w i n d o w a n d c h e c kf o r
8 mm (0.31in.) leaks.Mark the leakingareas,let the rear window
dry,then sealwith sealant.
NOTE:Let the car standfor at leastfour hoursafter

rear window installation.lf the car has to be used
within the Iirst tour hours,it must be drivenslowly
MOLDING
FASTENER
1-7. Reinstallall remainingremovedparts
SPACER
NOTE:Advisethe customernot to do the following
MOLDING
thingsfor two to threedays:
. Slamthe doorswith all the windows rolledup.

. Twist the body excessively(suchas when going
i n a n d o u t o f d r i v e w a y sa t a n a n g l e o r d r i v i n g
over rough.unevenroads).
FASTENER
)
REARWINDOW
20-35
RearWindow
Removal
3D: Upper portioni
CAUTION:
. Put on gloves to ptotect your hands.
. Us€ seat cove6 to avoid damaging any surfaces.
. Do not damage the rear window defogger grid lines.
. Take carg nol scratchthe terr window molding.
'1.
To removethe rearwindow,firsr removethe:
. Rearcentershelf(seepage20-60)
. H a t c hu p p e r t r i m , h a t c ht r i m p a n e la n d h a t c h
sidetrim (seepage20-63)
TAPE
. Rearwindow wiper arm (seepage2O-115)
. Hatchspoiler(seepage20 101) Side portion:
2. D i s c o n n e ctth e r e a r w i n d o w d e f o g g e rc o n n e c t o r
GLASS
from eachside.
Apply protectivetape to the inner edge of the tail_

gate.
From insidethe hatch,usea knifeto cut throughthe

rearwindow adhesiveall the way around.
NOTE:
. lf the rear window is to be reinstalled,take care
not to damagethe molding. Lower portion;
. lf the molding is damaged,replacethe rear win_
dow and moldingas an assembly.
HATCH
ffi# ADHESIVE
Carefullyremovethe rearwindow.
NOTE;Checkthe moldingfor damage,and replace

the rearwindow if necessary.
REARWINOOW
20-36
t lnstallation
'1.
Using a knife,scrapethe old adhesivesmooth to a 4. Glue the rubberdams to the insideface of the rear
thicknessof about 2 mm (0.08in.) on the bonding window, as shown, to containthe adhesiveduring
s u r f a c ea r o u n d t h e e n t i r e r e a r w i n d o w o p e n i n g and gluethe fasteners,spacerand seals
installation,
flange. as shown.
NOTE: NOTE:
. Do not scrapedown to the paintedsurfaceol the . Gluethe rubberdams usingthe printeddots as a
body; damaged paint will interferewith proper g ui d e .
bonding. . Be careful not to touch the rear window where
a Removethe rubberdams,spacersand fasteners adhesivewill be aPPlied
from the hatch. spacorandseal
>r Fastener,
. M a s k o f f s u r r o u n d i n gs u r f a c e sb e f o r ea p p l y i n g locations
primer. A>,4 B > ,1
FASTENER SPACER
C l e a nt h e h a t c h b o n d i n g s u r f a c ew i t h a s p o n g e / l
2.
"-*^1
d a m p e n e di n a l c o h o l .
w s i
'W o.\6fif,", j
N O T E :A f t e r c l e a n i n g ,k e e p o i l , g r e a s eo r w a t e r
from gettingon the surface. A L.IGNMENT ]
IIARKS __,/ __ ,,/
ryt48rq
C>,2 S E AA
L D> '2
3. l f t h e o l d r e a r w i n d o w i s t o b e r e i n s t a l l e du, s e a 'EAL B
putty knife to scrapeoff all tracesof old adhesive,
t h e n c l e a nt h e r e a r w i n d o w s u r f a c ew i t h a l c o h o l
where new adhesiveis to be applied.
NOTE;Makesurethe bondingsurfaceis keptfree of

- \ l
O water,oil and grease. 19Pry/
CAUTION:Avoid setting the rear window on its
edges;the moldingcan be permanentlydeformed.
NOTE:Cleanthe shadowedarea
REARWINDOW FASTENER PRINTEDDOTS
REARWINDOW
MOLOING
)
(cont'd)
20-37
RearWindow
Installthe fastenersto the hatchas snown. 8. W i t h a s p o n g e .a p p l y a l i g h t c o a t o f g l a s sp r i m e r
a r o u n dt h e e d g e o f t h e r e a r w i n d o w ,t h e n l i g h t l y
>: Fastener
locations,
4 wipe it off with gauzeor cheesecloth.
NOTE:
. Do nol apply body primer to the rear window,
and do not get body and glass primer sponges
maxedup.
lf you do, the adhesivemay not bond to the rear
w i n d o w p r o p e r l y c, a u s i n ga l e a k a f t e rt h e r e a r
window is installed.
V/////f , apety st,." o.imer here.
RUBBER1 5m m
Inside I DAM {0.59in.l MOLDING
---- - -t-
tUt I 15mm
| @- L 10.59in.l
NJ-l t
rll \
,zN \
GLASS \
SPACER GLASS
REARWINOOW
Set the rearwindow uprighton the hatch,then cen-

ter it in the opening.Make alignmentmarks across
the rear window and body with a greasepencil at
the four pointsshown.
NOTE: Be carefulnot to touch the rearwindow where

adhesive
will be applied.
FASTENER
7. Remove the rear window.
20-38
3
9. With a sponge,apply a light coat of body primerto 12. Packadhesiveinto the cartridgewithout air pockets
t h e o r i g i n a la d h e s i v er e m a i n i n ga r o u n dt h e r e a r to ensurecontinuosdelivery.Put the cartridgein a
window openingflange.Let the body primerdry for c a u l k i n gg u n , a n d r u n a b e a do f a d h e s i v ea r o u n d
at least10 minutes. the edgeof the rearwindow as shown.
NOTE: NOTE:Apply the adhesivewithin 30 minutesafter

. Do not applyglassprimerto the body,and be care- applyingthe glassprimer.
ful not to mix up glassand bodyprimersponges.
//////// ' acoV boay primerhere.

ffi;fr'L/:ADHEs' vE
8mm
{ 0 . 3 1i n . l
GLASS
1 0 . Thoroughlymix the adhesiveand hardenertogether

on a glassor metalplatewith a putty knife.
NOTE:
. Cleanthe platewith a spongeand alcoholbefore
mlxlng.
. Follow the instructionsthat came with the adhe-
sive.
1 1 . Beforefilling a cartridge,cut the end oJ the nozzle MOLDING
as shown.
GLASS
---$ ,R1
Cut nozzle
10 mm {0.39in.)
f\+,,","
ffi-f in.t
to.oa
MoLD|NG/
-.17
\
I 7 mm (0.27in.)
(cont'd)
20-39
RearWindow OuarterGlass
Installation {cont'd) Removal
13. Use suctioncups to hold the rear window over the 3D:
opening.align it with the alignmentmarks made in
slep 6. and set it down on the adhesive.Lightlypush CAUTION:
on the rea. window until its edges are fully seated a Pul on gloves to protect your hands.
on the adhesiveallthe way around. . Use seat covers to avoid damaging any surfaces,
NOTE:Do not openor closethe doorsuntilthe adhe_ 1. To removethe quarterglass,first removethe:

sive is drv. . Rearseat-backand rear seat cushion (see page
20_80)
sucTtoN . Rear center shelf and rear side shelf lsee page
CUPS
20_60)
. R e a rt r i m p a n e la n d s i d e t r i m p a n e l ( s e ep a g e
20_60)
. Upper anchorbolts from the front and rear seat
belts{seepages20-86.89)
. Ouartertrim panel(seepage20-60)
2, From insidethe car, use a knifeto cut through the

quarterglassadhesiveall the way around.
NOTE:
. lf the clip on the rearedge is broken,the quarter
glasscan be reinstalled usingbutyltape(seepage
20-421.
. Apply protectivetape alongthe edgeof the entire
quarterglassopeningflange.
1 4 . Scrapeor wipe the excessadhesiveoff with a putty

knifeor towel.

or the rear window. use a soft shop towel damp-
enedwith alcohol.
1 5 . L e t t h e a d h e s i v ed r y f o r a t l e a s t o n e h o u r . t h e n
spray water over the rear window and check for
leaks,Mark the leakingareas,let the rear window
dry, then sealwith sealant.
NOTE: Letthe car standfor at leastfour hoursafter

rear window installation.lf the car has to be used
within the first four hours,it must be drivenslowly.
Reinstallall remainingremovedparts.

thingsfor two to threedays: OUARTER
GLASS
. Tr,vistthe body excessivelylsuch as when going
in and out of drivewaysat an angle or driving
over rough,unevenroads).
20-40
lnstallation
Uppcr portion: 1 . Using a knife,scrapethe old adhesivesmooth to a
thicknessof about 2 mm (0.08in.) on the bonding
s u r t a c ea r o u n d t h e e n t i r eq u a r t e rg l a s s o p e n i n g
flange.
NOTE:
. Do not scrapedown to the paintedsurfaceof the
bonding.
r Removethe rubberdams from the body.
. lf any of the clips are broken,removethem from
AOHESIVE
the body.
. Mask off surroundingsurfacesbefore applying
TAPE pnmer.
Lower oortion:
Cleanthe body bondingsurfacewith a spongedamp-
enedin alcohol.
NOTE: Afier cleaning,keep oil, greaseand water

from gettingon the surface.
PROTECTIVE
TAPE
lf the quarterglass is to be reinstalled,use a putty
knife to scrapeoff all traces of old adhesive.then
cleanthe quaner glass surfacewith alcoholwhere
ADHESIVE
adhesiveis to be apPlied.
l NOTE:Make sure the bonding surfaceis kept free

of water,oil and grease.
Pillar portion:
CAUTION: Avoid setting the quarter glass on its
edges;small chips may later devglop into cracks.
NOTE:Cleanrhe shadowedarea.
CLIP
3. Carefullyremovethe quarterglass
N O T E :C h e c kt h e q u a r t e rg l a s st r i m a n d c l i p s f o r
damage,and replacethem if necessary'
)
(cont'd)
20-41
QuarterGlass
Installation (cont'd)
4. Gluethe upperand lower rubberdams to the inside 6. lf the old quarterglassis to be reinstalled(and the
Iace of the quaner glass,as shown, to containthe c l i p o n t h e r e a r e d g e i s b r o k e no f f ) , a p p l y a l i g h t
adhesivd e u r i n gi n s t a l l a t i o n . coat of primer (3I/ C-100,or equivalent), then apply
butyl tape to the quarterglass,as shown. and seal
N O T E : B e c a r e f u ln o t t o t o u c h t h e q u a r t e rg l a s s the body holewith pieceof urethanetape.
whereadhesivewill be applied.
>: Alignment mark NOTE:
locations
GLASS . Be carefulnot to touch the quaner glasswhere
UPPER adhesivewill be applied,
RUBBERDAM . Do not peelthe separatoroffthe butyltape.
//////// '.8u'Jt tape tocarionst3M8628,or

' equivetenrl
Thickness:3.2 mm lo.t3in.l
Width:6.4mm {0.25in.)
UPPER
RUEBER BUTYL 13 mm
DAM TAPE (0.5in.l
\
\ l
*--T-
,7r--/r4--;
.. GLASS
LOWER
RUBEER
DAM
Installthe quarter glasstrim on the quarter glass,

then glue the upperand lowerclipsas shown.
N O T E : B e c a r e f u ln o t t o t o u c h t h e q u a r t e rg l a s s
where adhesivewill be applied.
UPPER OUARTER OUARTER

GLASSTRIM GLASS
GLASSTRIM
NOTE: Contactthe cljps againstthe

quarter glass trim at the areas
I n d i c a t e db y t h e a r r o w s .
20-42
t
7. With a sponge,apply a light coat of glassprimerto 8. With a sponge,apply a light coat of body primerto
the insideface of the quarterglass,as shown,then the originaladhesiveremainingaroundthe quarter
lightlywipe it off with gauzeor cheesecloth. glassopeningflange.Let the body primerdry for at
least10 minutes.
NOTE:
. Do not apply body primer to the quarter glass, NOTE:
and do not get body and glass primer sponges . Do not apply glass primer lo the body, and be
m i x e du p . c a r e f u ln o t t o m i x u p g l a s s a n d b o d y p r i m e r
. Nevertouchthe primedsurfaceswith your hands. sponges.
lf you do, the adhesivemay not bond to the quar . Nevertouchthe primedsurfaceswilh your hands.
ter glassproperly,causinga leak after the quar- . Maskoff the rearside trim panelbeforepainting
ter glassis installed. t h ef l a n g e .
///////// | apetl body erimer he,e. 16 mm
{0.63in.l
////////l : ^pptv stassprimerhe.e.
2 1m m 1 5m m
{0.83in.) (0.59in.)
l UPPER
RUBBER
DAM
9 . Thoroughlymix the adhesiveand hardenertogether

on a glassor metalplatewith a pufty knife.
NOTE:
OUARTER
GLASS BUBBEB mr x l n g .
DAM . Followthe instructionsthat came with the adhe-
sive.
1 5m m 30 mm 1 0 . Before filling a cartridge, cut the end of the nozzle

10.59in.l (r.2 in.) as shown.
C u t n o z z l ee n d
10 mm (0.39in.l
7 mm (0.27in.)
)
(cont'd)
20-43
OuarterGlass
11. Packadhesiveinto the cartridgewithout air pockets 12. Use suctioncups to hold the quarterglassover the
to ensurecontinuousdelivery.put the canridgein a opening,alignthe clips,and set it down on the adhe-
c a u l k i n gg u n , a n d r u n a b e a do f a d h e s i v ea r o u n d sive.Lightlypush on the quanerglassuntil its edges
the edgeof the quarterglassas shown. are fully seatedon the adhesiveall the way around.
NOTE: N O T E : D o n o t o p e n o r c l o s et h e d o o r s u n t i l t h e
. lf the old quarterglass is to be reinstalled,peel adhesiveis drv.
the separatoroff the butyl tape afterapplyingthe
adhesive.
. Apply the adhesivewithin 30 minutesafterapply_
ing the glassprimer.
i:.8i".,1/:ADHES,'E
8 rnm
(0.31in.l
OUARIER
GLASSTRIM
OUARTER
GLASSTFIM CLIP
Scrapeor wipe the excessadhesiveoff with a putty

knifeor towel.
BUTYI.
TAPE
or the quarter glass,wipe with a soft shop towel
dampenedwith alcohol.
1 4 . L e t t h e a d h e s i v ed r y f o r a t l e a s t o n e h o u r , t h e n
spray water over the quarter glass and check for
leaks.Mark the leakingareas,let the quarterglass
OUARTERGLASS NOTE: Letthe car standfor at leastfour hoursafter

quarterglass installation.lf the car has to be used
within the first four hours,it must be drivenslowly.
32 mm
''='I
{ 1 . 3i n . )
1 5 . Reinstallall remainingremovedparts.
[-4m,^, '"r"\
thingsfor two to three days:
GLASS . Slam the doorswith all the windows rolledup.

\ / drt". . Twist the body excessively(suchas when going
GLASS TAPE
a na n d o u t o f d r i v e w a y sa t a n a n g l e o r d r i v i n g
over rough,unevenroads).
20-44
Removal
2Oi Upper portion:
CAUTION:
. Put on gloves to protect your hands.
. Use seat covers to avoid damaging any surfaces.
1. To removethe quarterglass,first removethe:

. Rear seat-backand rear seat cushion (see page
20_81)
o Sldetrim panel(seepage20-611 ADHESIVE
. Rearshelf(seepage20-61)
o Upper anchor bolt from the front seat belt (see
page20-86) PROTECTIVE
. Ouartertrim panel(seepage20-6'l) TAPE
2. From insidethe car. use a knife to cut through the Rear edge portion:
quarterglassadhesiveallthe way around.
NOTE:
take care
. lf the quarterglassis to be reinstalled,
not to damagethe molding.
. Apply protectivetape alongthe edgeofthe entire
q u a n e rg l a s so P e n i n g
flange
Pillar portion:
TAPE
GLASS
3 . Carefullyremovethe quarterglass.
NOTE:Checkthe moldingfor damage,and replace

it if necessary.
I
20-45
OuarterGlass
Installation
1 . Using a knife,scrapethe old adhesivesmooth to a 4. Installthe molding around the edge of the quarter
thicknessof about 2 mm (0.08in.) on the bonding glassas shown.
s u r f a c ea r o u n d t h e e n t i r e q u a r t e rg l a s so p e n i n g
flange. NOTE:
. lf the old molding is to be reinstalled, scrapeoff
NOTE: t h e o l d a d h e s i v et a p e f r o m t h e m o l d i n g ,a n d
. Do not scrapedown to the paintedsurfaceof the c l e a nt h e m o l d i n gs u r f a c ew i t h a l c o h o lw h e r e
body; damaged paint will interferewith proper new adhesivetape is to be applied.Apply the
bonding. double-facedadhesivetape to the molding and
a Removethe fastenerfrom the body. quarterglassas shown.
a lf any of the clips are broken,removelhem from . Be carefulnot to touch the quarterglasswhere
the body. adhesivewill be aoDlied.
Mask off surroundingsurfacesbefore applying
pnmer. Adhesiv€tspe A (3M 4215,or equivalent)
Thicknsss:o.il mm (0.02in.l
Cleanthe body bonding surfacewith a spongedamp Widih: 5 mm {0.2 in.}
enedin alcohol. Length: /140mm {17.3in.)
NOTE: After cleaning,keep oil, greaseand water Adhesivetap6 I (NITTO501, or equivatontl

from gettingon the surface. Thickness:0.16 mm {0.006in.)
Width: I mm {0.3 in.}
lf the quarterglassis to be reinstalled,use a putty Longlh: 4it0 mm (17.3in.)
knife to scrapeoff all traces of old adhesive.then
cleanthe quarterglass surfacewith alcoholwhere Adhosiv€tape C (3M /P13. or equivalentl
adhesiveis to be applied. Thickness:0.8 mm (0.03in.l
Width: 5 mm (0.2in.)
NOTE:Make sure the bonding surfaceis kept free Length:30 mm (1.2in.)
of water.oil and grease.
ADHESIVE
CAUTION: Avoid setting the quarter glass on its
odges;small chips may later develop into cracks,
NOTE:Cleanthe shadowedarea.
20-46
t
5. lf the old quarterglassis to be reinstalled,glue the 7. With a sponge,apply a light coat of glassprimer to
upperand lowerclips and fasteneras shown the insideface of the quaner glass,as shown,then
lightlywipe it off with gauzeor cheesecloth
N O T E : B e c a r e f u ln o t t o t o u c h t h e q u a r t e rg l a s s
where adhesivewill be applied. NOTE:
. Do not apply body primer to the quarter glass,
>: Clip,fastenerlocations and do not get body and glass primer sponges
A>,2 B > ,1 mixed up.
ALIGNMENT 2.5mm
(0.m in.) lf you do, the adhesivemay not bondto the quar
ter glass properly,causinga leak after the quar-
ter glassis installed.
from the Primedsurface
t///////7, , aootva"av crimerhere'
15.5mm 10 mm
MOLDING 10.61in.l {0.39in.l
\ b
6. Gluethe fastenerto the body as shown.
location,1
>: Fastener
)
(cont'dl
20-47
OuarterGlass
8. With a sponge,apply a light coat of body primer to l'1. Packadhesiveinto the canridgewithout air pockets
the originaladhesiveremainingaroundthe quarter to ensurecontinuousdelivery.Put the cartrigein a
glassopeningflange.Let the body primer dry for at c a u l k i n gg u n , a n d r u n a b e a d o f a d h e s i v ea r o u n d
least l0 minutes. the edgeof the quarterglassas shown.
NOTE: NOTE:
. Do not apply glass primer to the body, and be . lf the old quarter glass is to be reinstalled,peel
c a r e f u ln o t t o m i x u p g l a s s a n d b o d y p r i m e r the separatoroff the butyl tape afterapplyingthe
sponges. adhesive.
. Neverlouchthe primedsurfaceswith your hands. . Peel the separator off the adhesive tape after
. Maskoff the rear side trim panel beforepainting applyingthe adhesive.
the flange. . Applythe adhesivewithin 30 minutesafterapply
ing the glassprimer.
///ffi : Appty aoay primer here.
1 6m m
10.63in.l 12mm 11
lo.tttn.lI l:ADHESIVE
8mm
{0.31in.)
CLIP
9 . Thoroughlymix the adhesiveand hardenertogeth-

er on a glassor metal platewith a putty knife.
NOTE:
mixing.
. Followthe instructionsthat came with the adhe-
sive.
1 0 . Beforefilling a cartridge,cut the end of the nozzle

as shown.
Cul nozzleend
MOLDING
10 mrn (0.39in.)
7 mm 10.27in.)
20-4A
12. Use suctioncups to hold the quarterglassover the
o p e n i n g ,a l i g n t h e c l i p s , a n d s e t i t d o w n o n t h e
adhesive.Lightlypush on the quarterglassuntil its
edges are fully seatedon the adhesiveall the way
around.
N O T E :D o n o t o p e n o r c l o s et h e d o o . s u n t i l t h e
adhesiveis dry.
} CLIP
1 3 . Scrapeor wipe the excessadhesiveoff with a putty

knifeor towel,

or the quaner glass,wipe with a soft shop towel
dampenedwith alcohol.
1 4 . L e t t h e a d h e s i v ed r y f o r a t l e a s t o n e h o u r , t h e n
spray water over the quarter glass and check for
leaks.Mark the leakingareas,let the quarterglass
NOTE:Letthe car standfor at leastfour hoursafter

quarterglass installation.lf the car has to be used
within the first four hours,it must be drivenslowly
Reinstallall remainingremovedparts-

thingsfor two to threedays:

. Twist the body excessively(suchas when going
) a i n a n d o u t o f d r i v e w a y sa t a n a n g l eo r d r i v i n g
over rough,unevenroadsl.
20-49
Moonroof
Index
SWITCHPLATE
Adjustment,page20 56
--:=::
CABLEASSEMBLY
Replacement,
page2O-55
SUNSHADE
page20-52
Replacement,
0 \
g TNNERCAELE
RAIL HOLDERB
RAIL HOLDERA
REAR
DRAIN
TUBE
Y<
/ \
u8E
?'''
ll /
LfP ll I
U 6
./w
REARDRAIN
VALVE
FRONTORAINTUBE
20-50
Troubleshooting
Symptom ProbableCause
Waterleaks 1 . C l o g g e d r a i nt u b e .
2. Gap betweenglassweatherstrjpand roof panel.
3. Defectiveor improperlyinstalledglassweatherstrip.
4. Gap betweendrainsealand roof panel.
Wind noise '1. Excessive clearancebetweenglassweatherstripand roof panel.
Motor noise 1. Loosemotor.
2. Worn gearor bearing.
3. Cableassemblydeformed.
'1.
Glassdoes not move,but motor turns Clutchout of adjustment.
2. Foreignmatterstuckbetweenguide rail and slider.
3. lnnercableloose.
4. Cableassemblynot attachedproperly.
Glassdoes not move and motor does not turn 1. Blownfuse,
{glasscan be movedwith moonroofwrench) 2. Faultyswitch.
3. Batteryrun down.
4. Defectivemotor.
5. Faultyrelay.
GlassHeightAdjustment
D The roof panel should be even with the glassweather-
s t r i p , t o w i t h i n 1 . 7 : l r 3m m ( 0 . 0 7: 3 : 3i1n . ) a l l t h e w a y
around.lf not, openthe giassfully,and:
1.7tl.8mm
{0.07:33iin.} GLASSWEATHERSTRIP
1. Removethe bracketcover.
Loosenthe nuts, and installthe shims betweenthe

glassframe and glassbracketas shown.
Shim thickness:Frontmax.3 mm 10,12in.l

Rear max. 2 mm 10.08in.) 5x1.0mm SRACKET 6x1.0mm
9.8N.m 11.0kgf m, COVEB 9.8 N.m {1.0kgtm,
Repeaton oppositesidei{ necessary. 7.2rbtft) 7.2 tbf.ft)
----------1>
20-51
Moonroof
Glass,GlassBracketand SunshadeReplacement
l. Closethe glassfully. 6. Removethe drainchannel.
2. Slidethe sunshadeall the way back. DRAINCHANNEL
3. Removeboth bracketcovers.
ERACKETCOVER
Forward
_--____->
4. Remove the nuts from both glass brackets.
GLASSEBACKET 7. R e m o v et h e h o l d e r c o v e r . t h e n r e m o v e t h e
h o l d e rB .
NUT
6x1.0mm
9 N.m {0.9 kgf.m.
? tbtftl
{i;t'm
6x1.0mm
9.8N.m(1.0kgf.m,7.2lbt.ftl
Removethe glass by lifting up and pulling forward RAILHOLDERB

as shown. Usingthe moonroofwrench,move the glassbracket
to the positionwhere the moonroofnormallypivots
NOTE:Do not damagethe roof panet. down, and removethe screws.
GLASS
scREws
20-52
b
9. Removethe rail holderA. 12. Slidethe sunshadeforward,then removeit.
NUT
6x1.0mm
I N.m(0.9kgf.m,
SUNSHAOE
GLASS BRACKET
Installationis the reverseof the removalprocedure.
NOTE:Checkthe glassheight(seepage20-51).
'14. Checkfor water leaks,

D
NOTE:Do not use high-pressure
water.
DRAIN CHANNEL
ROD
DRAINCHANNELROOSTOP
Rotateas shownto removeit from the guiderail.
10. Remove the drain channel rod slider by moving the

cable slider forward using the moonroof wrench.
I '11. Detach the drain channel rod stop from the cutout
of the guide rail as shown.
20-53
Moonroof
Motor,DrainTubeand FrameReplacement
CAUTION:
. Put on gloves to protecl your hands.
. Be careful not to damagethe seats,dashboardand other interior trim.
'1. Removethe headliner

{seepage20-64).
2. the motor connectorand glasspositionswitchconnector.

Disconnect
NOTE:When removingthe motor,detachthe connectorfrom the frame,removethe bolts and nuts,then removethe
motor.
3. Removethe glass{seepage20-52).
4. the draintubes,and detachthe ceilinglight harness.

Disconnect
5. Removethe frame mountingbolts.
NOTE;
. An assistantis helpfulwhen removingthe bolts.
. Removethe front boltslast.
6. Detachthe rearhooksby movingthe frameforward,then removethe frame.
BOLT
6x1.0mm
9.8 N.m {1.0kgt m,
7.2 tht.hl
6x1.0mm
9.8 N m (1.0kgl.m,7.2lbtft)
20-54
Assembly
GuideRails/Cable
L Replacement
7. Pullthe draintubesout the front and rearpillars.
CAUTION: Put on gloves to protect your hands,
NOTE:Beforepullingout the draintube,tie a string
to the end of it so it can be reinstalled. 1. Removethe frame.
Removethe motor and glassbracket(seepage20-52).
Removethe nuts, and lift off each guide rail, then

removethe cableassemblywith slidersattached.
NOTE:Take care not to bend the cable tubes and

guide rails.

GROMMET
NOTE:
. Beforeinstalljngthe frame,clearthe drain tubes Installationis the reverseof the removalprocedure.
and drainvalvesby usingcompressedair.
. Checkthe frameseal. NOTE:
. Cleanthe surfaceof the frame. . Oamagedpartsshouldbe replaced.
. When installingthe frame, first attach the rear . Greasethe slidingportionwith SuperHighTemp
hooksinto the body holes. UreaGrease,P/N08758- 9002.
. When connectingthe draintube, slide it over the . Fillthe groovein eachgrommetwith sealant.
frame nozzleat least10 mm (0.39in.).
. Installthe tube clip as shown.
Upward
I
I TUBECLIP
I DRAINTUBE a Installthe frame sealsecurely.

a Beforeinstallingthe motor. make sure both slid-
Checkfor water leaks. ers are parallel.
Beforeinstallingthe motor. installthe frame and
NOTE:Do not use high-pressure
water. glass,then checkthe openingdrag (seepage20-
Ity
20-55
Moonroof
Switch Plate Adjustment (Fully Closed Positionl
1. Removethe headliner{seepage20-64).
2. Usingthe moonroofwrench,closethe glassfully.
NOTE:Checkthe glassfit to the rool panel.
3. Usingan open-endwrench,loosenthe switchplatemountingbolts.
4. Adjustpositionof the switchplate(switchcam)as shown.
5. Checkthe operationof the glass(from tilt-up positionto fully closedposition,from the fully open positionto the fully
closedposition)by operatingthe moonroofswitch.
NOTE:Checkthe glassheight(seepage20-51).
SWITCHPLATE
GUIDE
PLATE
CAELEBRACKET
SWITCH CAM INNER CABLE END
While moving the switch plate little bv little, secure the switch
plate at the position where the switch cam contactsthe switch
a (a faint click is heard).
Close the glass fully, and check for water leaks.
NOTE: Do not use high-pressurewater.
2 0- 5 6
OpeningDrag Check Closing ForceCheck
{Motor Removed) (Motor Installedl
Beforeinstallingthe motor, measurelhe effort required ' 1 . A f t e r i n s t a l l i n ga l l r e m o v e dp a r t s ,h a v e a h e l p e r
to openthe glassusinga springscaleas shown. hold the switch to closethe glasswhile you mea-
sure the force requiredto stop it. Attach a spring
CAUTION: When using a spring scale, pfotest the lead- scaleas shown. Readthe forceas soon as the glass
ing edge ol the glass with a shop towel. stops moving,then immediatelyreleasethe switch
and springscale.
lf load is over 40 N (4 kgf,9 lbf),checkthe side clearance
a n dg l a s sh e i g h t( s e ep a g e2 0 - 5 1 ) . CAUTION: When using a spring scale, protect the
lerding edge ol the glasswith a shop towel.
Closing Force:200 - 290 N

SHOPTOWEL (20 - 30 kst, 44 - 66 lbfl
SCALE
lf the torce in not within specification, installa new

lockwasher,adjustthe tensionby turnangthe motor
c l u t c h a d j u s t i n gn u t , a n d b e n d t h e l o c k w a s h e r
againstthe motor clutchadjustingnut.
LOCK
WASHER
Replace.
COUNTER.
cLocKwrsE
To decrease
l,e
20-57
Interior
Component Location Index
SRScomDonentsare locatedjn the partsareasmarkedwith an asterisk(*). Reviewthe SRScomponentlocations,precau
tions,and proceduresin the SRSsection{24)beforeperformingrepairsor service.
2Dl3Dl4Dl
FRONTPILLAR
TRIM
CENTERPILLAR
UPPERTRIM { s e ep a g e s2 0 5 9 , 6 0 , 6 1 )
CENTERPILLAR {seepage20 591
LOWERTRIM PANEL REARROOFTRIM
(seepage20-59) (seepage20-65)
HEADLINER
REARPILLAR Page20'64
Replacement,
TRIM
{seepage20 59}
REAR :
lseepage20 59)
TRUNK
TRIM
(seepage 20-62)
*OASHBOARO
SEAT ComponentRemoval/lnstallation,
SIDETRIM page 20 68
{seepage20-59) Removal,page20-70
*CARPET
REARTRIM PANEL
lseepage20-62) page20 66
Replacement,
PANEL
page20-67
Replacement,
3D: OUARTER 2Dl OUARTER

TRIM PANEL TRIM PANEL
REARSIDE (see page20-60) {seepage20'61) SIDETRIM PANEL
SHEI-F (seepage20-6'l)
(seepage 20-60)
REARROOFTRIM REARROOF
(seepage 20 65)
HATCH TFIM
SIDETRIM (seepage20'65)
(seepase 20 63) HATCH
UPPER
TRIM
lseepage20 63)
CENTER
SHELF
lseepage20 60)
REAR SIDETRIM
PANEL {seepage20 60) REAR
lseepage20 60) PANEL
(seepage20 62)
HATCH
TRIM PANEL SIDETRIM
(see page 20-63) PANEL
(seepage20-60)
20-54
1
InteriorTrim
Replacement
t
CAUTION:
o When prying with a flat-tip screwdriver,wrap it with protective tape to prevent damage.
NOTE:Takecarenot to bendor scratchthe trim and panels.
4D:
>: Clip locations

a>,2 B>,6 c >,2'l o>,2 E> , 2
_tr* @,
r*'" nt-lt't
\wi,
'\tl
i
l l / CENTERPILLAR
UPPERTRIM REARPILLAR
TRIM
REARSHELF
LOCKCYLINDERTRIM
tl'
I
v Disconnectthe
E' BELTUPPER high mountbrake
ANCHOR lrghtconnector.
(seepage20-85)
T SIDE TRIM
Removethe rearseatcushionand rear
seatsidebolsterlseepage20-19]'.
k"si lnstallationis the reverseof the removalprocedure.
NOTE:
. lf necessary,replaceany damagedclips.
fEFT KICK . Beforeinstallingthe front seat belt upperanchor
PANEL
and rear shelf.make sure there are no twists or
) kinksin the seatbelts.
(cont'd)
20-59
lnteriorTrim
Replacement(cont'dl
3D:
>: Screw, bolt locations

>: Clip locations 8>,6
B>,3 c >,8 o>,3 E> , 8 A>,3
Y *"0
A>,2
N;
CLIP ^ l l - l E F \
'"'\R\
nt-.l I
I #, A@
")! c>,1
I "4"
o>,2
l@@
G>,2 H>,2
F >, lil
\ s \---
s,4, ffi;T
"x-
FRONTPILLAR e
B
V
REARSIDE
SHELF
TRIM
t SIDETRIM
PANEL
Removethe rearseat-backand
rearseatcushion(seePage20_80)
FRONTSEAT Disconnectthe rearspeaker
BELTUPPEB connector(bothsides,
ANCHOR for somemodels).
lseepage20 86)
REARTRIM
PANEL
SIDETRIM PANEL
PROTECTOR
PIVOT BRACKET
{seepage20-80)
qRIGHTKICK
PANEL
LEFTKICK
lnstallationis the reverseof the removalprocedure
NOTE:
. lf necessary, replaceany damagedclips'
PANEL . Beforeinstallingthe anchorbolts,makesurethere
are no tlvistsor kinksin the seatbelts'
20-6 0
I l
2Di
>: Clip locations >i Screw location3.4

a>,2 8>,3 c>,14 D> , 3 E>,2
CLIP
nJ
'.'rI\ZI
F>,8
1\f- G>,4
TRIM
H>,2
N 4'dr
FRONTPILLAR
SIOETRIM PANEL
Removethe rearseat-back
and
(seepage
rearseatcushaon
20-a1l.
REARSHELF
\t,
FRONTSEAT
BELTUPPER
ANCHOR
the high
Disconnect
mountbrakelight
SIDETRIM
SEATBELT
LOWERANCHOR
(seepage20-86)

€'
/>"
.h,
't6d NOTE:
RIGHTKICK . lf necessary,
replaceany damagedclips.
PANEL \ r \
) v LEFTKICK
PANEL
. Beforeinstallingthe anchorbolts and rear shelf,
makesurethere are no twists or kinksin the seat
belts.
20-61
TrunkTrim
Replacement
CAUTION:
. Put on gloves to proteci your hands.
. When prying with a flat-tip screwdriver,wrap it with protestive tap€ lo prevent damage.
NOTE:
. Takecarenot to bend or scratchthe trim and panels.
. When removingthe trunk sidetrim or trunktrim panel,fold the seat-back
forward.
Japan-produced: >: Cliplocations

REARTRIM
a>,6
PANEL
RIGHTTRUNK NOTE:Do not push
4D: the innerclip in too far.
SIDETRIM
I g cLlP ^
l#srq-'
|
' |NNER
1B
\\-
B> , 6
crLP
,- -- I J
/
/'/ \--
-- LTro
i ) :Hook locations
TRUNKMAT A i--), r
' 2D: a : - ), 2
TRUNK TRIM
(
NOTE:
. lf necessary.replaceany damagedclips.
. To installthe A clips.pull the innerclip up. install
the clip,then pushthe innerclip until it's flush.
20-62
HatchTrim
Replacement
CAUTION:
. When prying with a flat-tip screwdrivel, wrap it with protestive tape to prevent damage.
NOTE:Takecarenot to bendor scratchthe trim and panel.
>:Clip locations
a>,2
NOTE:Donotpushth
l n n e rc l i p i n t o o f a r .
& ct-tp.
54d-
g + - \
2. INNF
"
Ijy.\\ \--
.V ft - s -
- k-"i-t-;-a-
a
LEFTHATCH
SIDETRIM
HATCH
TRIM
UPPER
NOTE:
. lf necessary, replaceany damagedclips.
. T o i n s t a l l t h e A c l i p s , p u l l t h e i n n e r c l i p u p . i n s t a l l t h e c l i p , t h e n p u s h t h e i n n e ri ct 'lsi p
f luuns thi l
I
20-63
Headliner
Replacement
CAUTION: When prying with a flat-tip screwdriver, 2. Removethe sunvisorand holderfrom eachside.
wrap it with proioctiva tap€ to prevsnt damage.
>: Screwlocations,4
-A-,-
NOTE:
. Takecarenot to bend and scratchthe headliner.
. B e c a r e f u ln o t t o d a m a g et h e d a s h b o a r da n d o t h e r
i n t e r i otrr i m .
'1. Remove: 1 ^
4D:
. Frontpillartrim (bothsides.seepage20-59)
. Centerpillarlowertrim panel(bothsides,seepage
20 59)
Upper anchorbolt from the front seat belt (both
sides,seepage20-85) 3. Remove the grab handles and coat hanger.
Centerpillaroutertrim and centerpillaruppertrim
(bothsides,see page20-59)
a Ceilinglight (seesection23)
a Rearviewmirror (seepage20-25) ACCESS
Lto
3D:
. Frontpillartrim (bothsides,see page20-60)
. Right rear seat-backand rear seat cushion (see
page20-80)
. Rearcentershelf(seepage20-60)
. R e a rs i d e s h e l fa n d s i d e t r i m p a n e l( r i g h ts i d e , scREws
see page20-60)
. Upper anchorbolts from the front and rear seat
belts(rightside.see pages20-86,89)
. Ouartertrim panel(rightside,seepage20-60)
. C e i l i n gl i g h t( s e es e c t i o n2 3 ) COATHANGER
. Rearviewmirror (seepage20-25) BRACKET
2Dl
. Frontpillartrim (bothsides,see page20-51) ACCESS
. Right rear seat-backand rear seat cushion (see LID
p a g e2 0 - 8 1 ) COATHANGER
t2D/3Dl
Sidetrim panel(rightside,seepage20-61) SCBEW
a Upper anchorbolt from the front seat belt (right
side,seepage20-86)
a Ouartertrim panel(rightside,see page20-6'l)
a Ceilinglight (seesection23)
Rearviewmirror (seepage20-25)
20-64
4. Remove the rear roof trim and clips, and remove 2D:
the roof trim and socket plug (moonroof model).
>: Clip locations

'l
A> 2DllD,7 B > With moonroof,
3D.5 Without moonroof,3
[ i l ' , f E l
':: t%=,/
.l €E
_._- ,/
.l
2D l3D l4Dl
REARROOF
OUARTER
IRIM PANEL
5. 4D: Lowerthe rearpillartrim on both sides

3D: Removethe upper anchor bolts from the front
and rearseatbelts(seepages20-86,89),then lower
the quartertrim panelon left side.
2 D : R e m o v et h e u p p e r a n c h o rb o l t f r o m t h e f r o n t
seat belt (see page 20-86),then lower the quaner
trim panelon left side.
6. Lowerthe headliner.
7. Carefullyremovethe headlinerthroughthe passen-

ger'sdoor opening(2Dl4D)or hatchopening(3D).
TRIM 8. Installationis the reverseof the removalprocedure.
NOTE:
3D: . When insertingthe headlinerthrough the open-
ing, be carefulnot to fold or bendit. Also,be care-
REARROOF ful not to scratchthe bodY.
TRIM . C h e c kt h a t b o t h s i d e s o f t h e h e a d l i n e ra r e
securelyattachedto the trim.
. W h e n i n s t a l l i n gt h e r o o f t r i m , i n s t a l lt h e j o i n t
towardthe right side (moonrootmodel)
t
20-65
Carpet
Replacement
SRScomponentsare locatedin this area.Reviewthe SRS 4. Removethe tootrestand parkingbrakelevermount-
componentlocations,precautions,and proceduresin the ing bolts,and detachthe clips,then removethe car
SRSsection{24}beforeperformingrepairsor service. pet.
1. Remove: >:Clip localions,3 >: Bolt locations

A>.2 A>,2
. Frontseat(seepage2O-7 4l
:ft 3 l6x10mm
. Rearseatcushion(seepages20 79,80, 81) 9.8N.mr1.okgr'm,
o Kickpanel(seepages20-59,60,61)
\ / l e2 Y
H
::a /
) E / 7.2tbtrtl
o Centerpillarlowertrim paneli4D,seepage20-59)
. Frontseatbelt iower anchor(2Dl3D,seepage20- 2Dl3Dl4D:
86) FOOTREST
. Sidetrim (seepages20-59,60,61)
o Frontand rearconsoles
. C o n s o l ep a n e l
2. Removethe SRSunit covers.
3 . Cut areas@ and @ in the carpet,then pull it backas

snown.
>: Clip locations,2
-lM- Il
lMt
ry-l
LEFTSRS
UNITCOVER
2D I3D:
SIOETBIM
NOTE:
. Takecarenot to damage.wrinkleor twist the car-
pet.
. Makesurethe wire harnesses are routedcorrectly.
. Slip the carpet under the seat side trim (4D) or
sidetrim panel(2Dl3D)on eachside properly.
. Reattachthe cut areas@ and @ in the carpet
with wire ties.
20-66
Panel
Consoles/Console
Replacement
NoTE:Takecarenottoscratchthefrontandrealconso|es,frontseatandre|atedparts.
in numberedsequence
Disassemble
>: Screw locations >: Clip locations

a>,8 B>,4 A>,2 B>.2
' nnffir
"=)
:__) :)
€] FRONTCONSOLE
Remove the shift lever knob (M/T)
REABCONSoLE
::r_l
(witharmrest)
lnstallationis the reverseof the removalprocedure
NOTE:
. lf necessary,
. Makesurethe wire harnessesare not pinched.
. Makesurethe connectoris connectedproperly.
{ .
I 20-67
I
Dashboard
ComponentRemovaUlnstallation
CAUTION: When prying with a flat-tip screwdriver, Driver'sdashboardlower cover and knee bolster removal:
wrap it with protoctivo tape, and apply protective tape
around tho r6lat6d parts, to prevent damag6. SRScomponentsare locatedin this area.Reviewthe SRS
componentlocations,precautions.
and proceduresin the
NOTE:Takecare not to scratchthe dashboardand related SRSsection(24)beforeperformingrepairsor service.
pans.
'1.
R e m o v et h e s c r e w s ,a n d d e t a c h t h e c l i p s , t h e n
Instrument Danelremoval: r e m o v e t h e d r i v e r ' s d a s h b o a r dl o w e r c o v e r . l f
equippedwith power mirrorsand moonroof,discon-
1. Lowerthe steeringcolumn. nectthe connectors.
Removethe screws,and detachthe clips,then care-

fully removethe instrumentpanel.
>: Screw,boh loc.tions
A>.3 B>,2
>: Screwlocations,2 >: Clip locations,2 _ -rri I /a_6x1.0mm
*\Y
@{[) s 8 N'mtt o rst'm,
@sl
^ l .il | _-_- J _
\J- 7 2_rbtftl
-_
Pt)_ i_ ,/ >: Clip locations
tu
:) A>.2 B>, 1
PANEL
DRIVER'S
DASHBOARD
LOWERCOVER
Removethe bolts,then removethe kneebolster.
2 0-6 8
Glove box removal: Center dashboard lower covel:
1. Remove:
Removethe bolts,then removethe glove box.
. Driver'sdashboardlower cover
>: Bolt locations,2 . Glovebox
2. Removethe screwsand bolt, then removethe cen-

ter dashboardlower cover.Disconnectthe accesso-
ry socketconnector'
>i Boh,screwlocations
a>,1 B>'5
A s*o.e-- I A
@;*;ry'-1'-.J
_e)
Installationis the reverseof the removalproceoure
Side air vent/Side defogger trim removal:

SHOP
TRIM
SIOEDEFOGGER TOWET_
C a r e f u l l yP r Y r t a t t h e s i d e e d g e ,
then remove it,
HOOKS
SIDEAIR VENT
Removethe driver'sdashboardlower LOWERCOVER
cover,or oPenthe gloveDox,
then push the cliPsfrom each
opening by hand, and Pull it
o u t . D i s c o n n e c tt h e c o n n e d o r s HOOKS 3. Installationis the reverseof the removalproceoure'
(driver'sside).
DASHLIGHTS
BRIGHTNESS
CONTROLLER
CONNECTOR
{forsomemodels)
CFUISECONTROL
MASTERSWITCH
CONNECTOR
(forsomemodels)
(cont'd)
20-69
Dashboard
GomponentRemoval/lnstallation Removal
(cont'd)
S R Sc o m p o n e n t sa r e l o c a t e di n t h i s a r e a .R e v i e wt h e
Center panel removal: SRScomponentlocations,precautions,and procedures
in the SRSsection(24)beforepreformingrepairsor ser-
1. Remove: vice.
. Centerdashboardlowercover(seepage20-69)
. Radio{seesection23) NOTE:
. An assistantis helpfulwhen removingand installing
2. Removethe rear window defoggerswitch and haz- the dashboard.
ard warningswitch,then disconnectthe connectors. . T a k ec a r e n o t t o s c r a t c ht h e d a s h b o a r db, o d y a n d
relatedparts.
5
>: Screwlocations, >: Cliplocations
A>,4 B>,3 1. Remove:
o Frontand rearconsoles(seepage20-67)
fii* . Consolepanel(seepage2O67),
- ) . Driver'sdashboardlower coverand kneebolster
(seepage20-68)
CENTER . Glovebox (seepage20-69)
PANEI. . Centerdashboardlowercover(seepage20-69i
2. Lowerthe steeringcolumn (seesection17).
@ To avoid accidentaldeplovmentand
possible injury, always disconnect the driver's
airbag connector belore lowering the steering col-
umn lsee section 241.
rt-xR.
W "
NOTE:To preventdamageto the steeringcolumn,
wrap it with a shoptowel.
r44
HAZARD
I F.IZ
v l
Mtx
3.Disconnect the dashboardwire harnessconnectors,
remove the nuts, then move the under-dashfuse/
WARNING
swlTcH
I
I
CONTNOL
CABLE
relay box. Disconnectthe antennalead and moon-
roof relayconnectors.
REAR
wtNoow MOONROOF DASHBOARDcltPs SRSMAIN
OEFOGGER RELAY FRAME HARNESS
swtrcH CONNECTORS
(for some models)
3. Disconnectthe air mix controlcable,and removethe

screws,then pull out the centerpanel.
4. Disconnectthe connectorsfrom the heatercontrol

un i t .
NOTE:
. Makesurethe connectorsare connectedproperly.
. Adjustthe air mix controlcable(seesection21).
ANTENNA
LEAO
DATA
CONNECTOR WIREHARNESS 9.8 N.m (1.0 kgf m,
Detach. CONNECTORS 7.2lbt.ltl
20-70
Removethe followingpartsIrom the dashboard'
. Driver'sdashboardside cover
o Passenger'sdashboardlower cover
. Dashboardcenterlid
the connectorsand air mix controlcable'

Disconnect
passeneer's
rhefront
disconnect airbas
M,::;:"lx3T:iJnif:3lilH:fl"*:1::f"*'il;ili"'"
>: Bolt, screw locaiions
B > ,1 c > ,1 D > ,1
A>,7
8x125mm 6x1.0mm
8xl.25mm I ,i(\
22 N.m12.2kgt'm,I (!,@
-v, 22 N.mt2.2kstm,
@ 9.8 N.m 11.0kgl.m,
7 2'orftl
@
'"tt:___J 16tbf.ftl
- ---// _._J
>: Clip locations
A>, 1 B>,1 c>,6
,{nil Lll , ,"o
ft#5 L //Hl
lj%u|5 i//Wt
W
qT I
DASHBOARD
W72-t11 7'::--J AIR MIX CONTROL
Loosen the bolt.

CONNECTORS
FRONTPASSENGER'S
AIRBAGCONNECTOR
Remove the bolts, then lift and remove the dashboard'
pillar trim'
CAUTION: Use proteqtive plates on the bottom ot the front (cont'd)
20-71
Dashboard
Removal (cont'd)
7. lf necessary,
removethe dashboardframefrom the dashboard.
>: Screw localions a: Nut locations,3

a>,21 B>,4
l ^ 1 . / ' \ ra 6 x '1.0mm
It Shl:'
v Y /
Olb'
l Yi.!i[11"-"'".
\-]1
>: Clip locations
FRONTPASSENGER'S
OASHBOARD
DASHBOARD BRACKET
SIDECOVER
Installationis the reverseof the removalorocedure.
NOTE:
. Beforetighteningthe bolts,makesurethe dashboardwire harnessesare not pinched.
a Makesurethe connectors,antennaleadand air mix controlcableare connectedproperly.
20-72
Seatsand Seat Belts
Component Location Index
2Dl3Dl1Dl
SHOULDER ANCHOR REABSEATBELT(2DI4DI
ADJUSTER (4D) Replacement,page20-88
(seePage20-85i page20-91
lnspection,
REARSEATEELTBUCKLE/
CENTERBELTTONGUE(2DI4DI
(seep6ge 20'90)
FRONTSEATBELT
Replacement,Pages20 85,86
Page20-91
Inspection,
REARSEATt2Dl4Dl
FRONTSEA Removal,pages20-79,8'l
Removal,Page20'74 LatchReplacement,
Seat-back page20-82
Replacement,Page20 75 SeatCover RePlacement,Page20-83
HarnessWiringand Recline
Page20-77
CableLocations, FRONT SEAT
SeatCoverRePlacemenl, Page2O'77 BELTBUCKLES
{seepage20-87)
3D:
REARSEATBELTBUCKLE/
CENTERBELTTONGUE
(seePage20'90)
BEARSEATBELT
Replacement,Page20'89
page20-91
Inspection,
REARSEAT
Removal,page20 80
page20-8?
SeatbackLatchReplacement,
Page20_83
SeatCoverRePlacement,
20-73
FrontSeat
Removal
CAUTION: When prying with a flat-tip screwdriver,wrap 2. Lift the driver'sfront seat,then disconnectthe seat
it with protectivetape lo prevent damage. beltswitchconnector.
NOTE:Takecarenot to scratchthe seatcoversand body.
1. Removethe seat track end cover,then removethe

bolts.
SEATBELT
swtTcH
CONNECTOR
SEATTRACK
COVER
Removethe headrest.
4. C a r e f u l l yr e m o v et h e f r o n t s e a tt h r o u g ht h e d o o r
opening.
FRONTSEAT 5. Installationis the reverseol the removalprocedure.
NOTE:Make sure the connectoris connectedprop-

erry.
SEATTRACK
ENDCOVER
BOLT
8 x'1.25mft
22 N..n 12.2kgl.m,
16 rbf.ft)
8 x 1.25mm
22 N.rn 12,2kgl.m,
16 tbtft)
20-74
Replacement
to prevent damage'
CAUTION: When prying with a flat-tip screwdrivet,wrap it with protective tape
NOTE:
. Takecarenot to scratchthe seatcoversand body
. Removethe front seatthroughthe door openlng'
Driver's:
NOTE:Referto page2O-77for the seatbelt switchharnesswiring location'
PIVOTNUT
SEATCUSHION
8 x 1.25mm
22 N.m l.2.2
16 tbf.ft)
v
l
CENTERCOVER
1 0x 1 . 2 5m m
47 N.m {4.8kgf m, 10 x 1.25mm
35 tbt.ft) 47 N.m {i1.8kgl m,
35 tbr.ft)
INNERSEAT
TBACK
RECLINEADJUSTER
LOWERCAP
l
10 x 1.25mm
d RECLINE
47 N.m {4.8 kgf'm,

35 tbtftl
CONNECTING WIRE
To connect,twist 180'
OUTERSEAT
TRACK
8 x 1.25mm
Installationis the reverseof the removalprocedure' 20 N.m 12.0kgf.m,
RECLINE
KNOB
14 tbt.ft)
NOTE:
. M a k e s u r e t h e b u s h i n ga n d p i v o t w a s h e r a r e
installedProPerly.
. T o p r e v e n tw r i n k l e sw h e n i n s t a l l i n gt h e s e a t -
back cover, make sure the materialis stretched
evenlyoverthe Pad. (cont'd)
. Greasethe slidingPortion
20-75
FrontSeat
Replacement(cont'd)
Passenger's(with reclino cablel:
NOTE;Referto page20-77for the reclinecablelocation.
HEADREST
SEAT-BACK
PIVOTNUT
8 x 1.25mm
22 N.m 12,2kgl.m,
tbt.ftt
SEATCUSHION
PIVOT CENTERCOVER
WASHER
LOWER 10 x 1.25mm
CAP 47 N.m {4.8kgf.m,
10 x 1,25mm 3s tbt.ft)
47 N.m (4.8 kgf.m,
35 tbf.ftl INNERSEAT
TRACK
RECLINEADJUSTEB
LowER CAP
i
RECLINE
b RECLINE
COVER CABLE
x 1.25mm
47 N'm (4.7 kgf.m,
35 tbtftl
SEAT
ruf, To connect,twist 180'.
8 x 1.25mm NOTE:
20 N.m {2.0kgf.m, . M a k e s u r e t h e b u s h i n ga n d p i v o t w a s h e r a r e
14 rbf.ft) installedproperly.
. To preventwrinkleswhen installingthe seat-back
cover, make sure the material is stretchedevenly
overthe pad.
. Adjustthe reclinecable.
. G.easethe slidingponion.
20-76
HarnessWiring and Recline Seat Cover RePlacement
Cable Locations CAUTION: Put on gloves to protest yout hands'
NOTE:When installingthe seat cushion,make sure the NOTE:Take care not to tear the seamsor damagethe
seatbelt switchharness,connectorand reclinecableare seatcovers.
fastenedcorrectlyon the seatcushionframe'
Seat-backcover removal:
Driver's: >: Cliplocations 1. Release cover'
the hook,and fold backthe seat-back
HEADREST
Releaseall insidesprings,then fold back the seat-

backcover.
Passenger's(with lecline cablel: 3. Removethe headrest.

Removethe headrestguide,then removethe seat-
backcover.
TRACK lnst;llationis the reverseof the removalprocedure'

NOTE:To preventwrinkleswhen installinga seat-
backcover,makesurethe materialis stretchedevenly
over the pad beforesecuringthe insidespringsand
hook.
(cont'd)
20-77
FrontSeat
Seat Cover Replacement(cont'd)
Seat cushion cover removal: 4. Installationis the reverseof the removalprocedure.
1. Removethe seatcushion{seepages20,75,76). NOTE:

. To preventwrinkleswhen installinga seatcush-
2. Removethe clipsfrom underthe seatcushion,then ion cover, make sure the material is stretched
loosenthe seatcushioncover. evenlyoverthe pad beforesecuringthe clips.
. Replacethe releasedclipswith new ones.
>: Cliplocataons
1 - .v v vl UPHOLSTERY
RINGPLIERS
NEW CLIP
SEATFRAME
CUSHION
COVER
3. Pull backlhe edge of the seat cushioncover all the

way around,then releasethe clips,and remove the
seatcushaoncover.
>: Cliplocations
SEAT
CUSHION
COVER
20- 7 A
RearSeat
Removal
theseatcoversandbody.
NOTE:Takecarenotto scratch
4D:
>: Bolt locations

c>,1 D>' l_):Hooklocations,2
b,,***-,,.1*;iffiP-"*'piii::#r-,'-,
6x1.omm
s.aru.-tr.orer-. I
7.2lbf.ft)
] >mr
@t,
)
l1Q-
E
:-
e"r.o--
s.i N.- ir.olgr.,i
7.2'tJrftl
'/
V
.
se-ri-cusxo"[-6*
>: Cliplocations,14
"@rz, \
EE
E S /
_ _ot /
v - 2u
RIGHTSEAT
SIDEEOLSTER
2u
CENTEB
PIVOT
BRACKET
SEATCUSHION
SEAT-BACK
Pivot boll conslruction:
SLITS
PIVOTBOLT ERACKET
8 x 1 . 2 5m m
lnstallationis the reverseof the removalprocedure 22 N m (2.2kgf m, 16lbtftl
Apply liquidthreadlock
NOTE:
belts and
. Beforeattachingthe seat-backand seatcushion,make sure there are no twists or kinksin the rear seat
centerbelt.
. When installingthe seatcushion,slip the seatbelt bucklesthroughthe slits in the seatcushron'
. Makesurethe seat-backlockssecurely.
(cont'd)
adiusrthe seat-backlatch(seepage20-82)and seat-back
. lf necessary,
20-79
RearSeat
Removal(cont'dl
3D:
>: Bolt locations ,.:): Hooklocations,2 >: Clip locations,14

A>,6 B>,1 c>,1
6xr.omm I e 6x1ommI
@,
':^2(1.0
9.8 N.m ksf.h,i I 22 N.m {2.2kgf.m,l
6x1.0mm
E
qr E )
tr ,"rrr,n2 ,/
SEATCUSHION
STRIKER STRIKER
Removethe sidet.im
panel(seepage20-60).
6x1.0mm STBIKER
9.8 N.m (1.0kgI.m,
7.2 tbf.ft)
V
tt
A
CENTER
PIVOT
BRACKET
RIGHT
SEAT-BACK
\---.--- PIVOT
BRACKET
LEFT
SEAT.BACK
Pivot bolt constiuction:
-l:/*- -"
HOOK
TOOTHEO
LOCK
WASHER
BUSHING
PIVOT
Ptvor BoLT BRACKET
I x 1.25mm
22 N.m {2.2kgl.m. 16 lbf.ft)
Installationis the reverseof the removalprocedure. Apply liquidthreadlock.
NOTE:
. Beioreanachingthe seat-backand seat cushion,make sure there are no twists or kinksin the rear seat beltsand
centerbelt.
. When installingthe seatcushion,slip the seatbelt bucklesthroughthe slits in the seatcushion.
. lf necessary,
adjustthe strikerand seat-back.
20-ao
2Dt
O : Hooklocations.2 >: Cliplocation3,14

>: Bolt locations
a>,6 B>,1 c>,1
,r@.'
'----EF-|
6xr.omm ffi 6xr.omm I 8 r.'r.o-- r
]
9.8N.ml1.Okgf.m,i I \ffz
22N.m{2.2kgtm,' s.eN.mtr.o*gf.m,'
E
w ,
H/ )
,:r:2 g
It
,r:r", 7.2rbf.ftl
_) E )
SEATCUSHION
SEAT.BACKMAT
vv
PIVOTBRACKET
PIVOTBRACKET
PIVOT
RIGHTSEAT.BACK BRACKET
,^
Pivot bolt constauctaon:
TOOTHED
LOCK
WASHER
BUSXING
PIVOT
PIVOT BOLT BRACKET
I x 1.25 mm
22 N.m (2.2 kgt m. 16lblft)
Apply liquidthreadlock.
lnstallationis the reverseof the removalprocedure'
NOTE;
.Beforeattachingtheseat-backandseatcushion,makesuretherearenotwistsorkinksintherearseatbe
centerbelt.
.wheninsta||ingtheseatcushion,sliptheseatbe|tbucklesthroughthes|itsintheseatcushion.
. Makesurethe seat-backlockssecurely
adjustthe seat-backlatch(seepage20-82)and seat-back'
. lf necessary,
20-41
RearSeat
Seat-backLatch Replacement
2Dl4Dl 3D:
R e m o v et h e l o c k c y l i n d e rt r i m , t h e n r e m o v et h e r e a r Pullthe trunk mat awayfrom the seat'back(seepage20-

s h e l f( s e ep a g e s2 0 5 9 ,6 1 ) . 80).
NOTE:Takecarenot to bendeachlockrod.
>: Boll, screw locations
a>,2 B > ,1
>: Boh, screw locations
A>,4 B> , 2 6x1.0mm
/+j
9.8 N.m (1.0kgf.m, @
6x1.0mm 7.2 tbl.ft)
9.8N.m (1.0kgt.m,
7.2 rbf.ftl V
SEAT"BACK
LOCKCYLINOER
TRIM
LOCK
.i.-::
CYLINDER
LATCHCOVEB
LOCK
RODS
Installationis the reverseofthe removalprocedure.

LEFTSEAT-
EACKI-ATCH
NOTE:
Installationis the reverseof the removalprocedure. . lvlakesurethe seat-backlockssecurelyand opens
properly.
NOTE:
. Makesureeachlock rod is connectedsecurely.
. [ / a k e s u r e e a c h s e a t - b a c kl o c k s s e c u r e l ya n d
opensproperly.
. lf necessary, adjustthe seat-backlatch.
20-82
Seat Cover Replacement
CAUTION: Put on glovesto protact your hands, 4. is the reverseof the removalprocedure.
Installation
NOTE|Takecarenotto tearthe seamsor damagethe seat NOTE:

covers. . To preventwrinkleswhen installlnga seatcush-
ion cover. make sure the material is stretched
Seat-backcover removal: evenlyoverthe pad beforesecuringthe clips.
. Replacethe releasedclipswith new ones
2D l4Dl
3D:
1. Removethe seat-back(seepages20-79,8'1).
1 . Removethe seat-back(seepage20-80).
2. L o o s e nt h e s e a t - b a c kc o v e r b y r e l e a s i n ga l l t h e
clrps. 2. coverby releasingall the clips.
Loosenthe seat-back
>: Cliplocations
NOTE:Removethe lock knob, lock collar and latch
cover.
>: Cliplocations
o o
o o
o o
o o
RIGHTSEAT.EACK SEAT-BACK
LEFTSEAT-BACK
COVER
COVER COVER
3. Pull back the edge of the seat-backcover all the way
around. then releasethe clios.
>: Clip locations
3. coverall the way
Pull backthe edgeof the seat-back
around,then releasethe cliPs.
>: Cliplocations
SEAT.BACK
COVER
RIGHTSEAT.BACK
NOTE:
. To preventwrinkleswhen installinga seat-back
cover,makesurethe materialis stretchedevenly
overthe pad beforesecuringthe clips.
(cont'd)
20-a3
RearSeat
SeatCoverReplacement(cont'dl
Seat side bolstor cover removal {,lDl 2DI3D:.
1. Removethe seatside bolster(seepage20-79).
2. Loosenthe seat side bolstercover by releasingall

t" I FEF4+#€ a
'J) \
the clios,then removeit.
>: Clip locations

,.oflU m
R-U
r_rolJr
------)
SEATCUSXION
SEATSIDE COVER
BOLSTER
COVER Pull backthe edge of the seat cushioncover all the
way around,releasethe clips,and removethe seat
cusntoncover.
>: Cliplocation3
/tD:
NOTE:
. To preventwrinkleswhen installinga seat side
bolstercover,makesurethe materialis stretched
evenlyoverthe pad beforesecuringthe clips. 2Dl3Dl
. Reolacethe releasedcliDswith new ones,
S€at cushion covgr r6moval:
1. Removethe seatcushion(seepages20-79,80, 81).
2. Loosenthe seat cushioncover by releasingall the

clips.
COVER
>: Cliplocrtion3
4. Installationis the reverseofthe removalprocedure.
4D:
NOTE:
. To preventwrinkleswhen installinga seat cush-
ion cover. make sure the material is stretched
evenlyoverthe pad beforesecuringthe clips.
a Replacethe releasedclipswith new ones.
- -I ./a
l--lt___)l ) ( .) UPHOLSTERYRINGPLIERS
Ll!!l^t!!l 1", available)
{Commerciallv
NEWCLIP
COVER
SEATFRAME
20-a4
Front Seat Belt
Replacement
CAUTION: Check the front seat belts for damage, and Removethe centerpillaruppertrim (seepage20-59)
replacethem it necessary.Be carolul not to damage
them during removal and installation. 6. Removethe shoulderanchoradjuster.
Front seat belt removal (4Dl:
1. Slidethe front seatforwardfully.
2. Removethe centerpillar lowertrim panel (seepage

20-59).
8 x 1.25mm
3. Removethe upper anchorcover and lower anchor 23 N.m {2.3 kgt'm,
cap. 17 tbf.ft)
UPPERANCHORBOLT
7/16-20UNF
32 N.m (3.3kgitm, ANCHOR
SHOULDER 24 lbf.ft)
ANCHOR ADJUSTER
7. Installationis the reverseof the removalprocedure
NOTE:
. Checkthat the retractorlockingmechanismfunc-
FRONTSEAT tions as describedon page20-91.
BELT . Makesureyou assemblethe washersand collars
RETRACTOR on the uDDerand lower anchorbolts as shown.
MOUNTINGBOLT . Beforeinstallingthe anchorbolts,makesurethere
6x1.0mm are no twists or kinksin the front seat belt.
9.8Nm(1.0kgf.m.
7.2 tbf.ftl
Upper anchorboh construciion:
UPPER UPPERANCHOR
RETRACTOR BOLT
COLLAR Apply liquidthread
7/1&20UNF
32 N.m (3.3kgl.m.
24 rbl.ftl
1
I
7/16-20UNF
32 N.m {3.3 kgf.m,24lbf.ft} I
LOWER ANCHOR
SUSHING
CAP
Remove all the anchor bolts and the retractor bolt,

remove the retractor mounting bolt, then remove
the front seat belt and retractor.
(cont'd)
20-85
Front Seat Belt
Replacement(cont'dl
Lower anchor bolt construction: Front seat belt removal (2Dl3Dl:
SPRING 1. Sljdethe front seatforwardfully.

WASHER
LOWERANCHOR
2. Removel
. Rearseat-backand rear seatcushion(seepages
20-80,81)
. R e a rc e n t e rs h e l f a n d r e a r s i d e s h e l f ( 3 D . s e e
page20'60)
. Reartrim panel(3D,seepage20-60)
. Sidetrim panel(seepages20'60,61)
3. Removethe upperanchorcoverand loweranchorcap.

COLLARS WASHEBS LOWER BUSHING
ANCHOB UPPERANCHORBOLT
7/16-20UNF
32 N.m (3.3kgI.m,
24 tbf.ftl
Retractorbolt construqtion:
TOOTHED RETRACTOR @<-'-.-.-.- ,PPERaNcHoR

LocK W\HER BOLT
)r
I
llo1r",ffi)
RETRACTOR
MOUNTINGBOLT
tv-\y -"\s\,/
tnl 6x1.0mm
9.8 N.m (1.0kgt m,
7.2 tbtft)
I
RETBACTOF
LOWEB
ANCHOR
CAP
I
I
t
o
RETRACTOR BOLT
7/16-20UNF LOWERANCHORBOLT
32 N m 13.3kgf m, 7/16-20UNF
24 tbf.ftl 32 N.m (3.3kgl m, 24lbtft)
4. Removeall the anchorbolts and the retractorbolt,

removethe retractormountingbolt,then removethe
front seatbeltand retractor.
20- 8 6
5. Installationis the reverseof the removalprocedure. Seat belt buckle removal:
NOTE: 1. R e m o v et h e f r o n t s e a tt h r o u g ht h e d o o r o p e n i n g
. Checkthat the retractorlockingmechanismfunc- {seepage20-74).
tions as describedon page20-91.
. Makesureyou assemblethe washersand collars 2. Removethe centercover(seepages20-75,76).
on the uoDerand lower anchorboltsas shown.
. Beforeinstallingthe anchorbolts,makesurethere 3. Removethe centeranchorbolt,then removethe seat
are no twistsor kinksin the front seatbelt. beltbuckle.
SEATBELT
BUCKLE
INNERSEAT ANCHORBOLT
SPRING BUSHING
TRACK HARNESS 7/16.20 UNF
WASHER 32 N m (3.3 kgt m, 24 lbf'ft)
CLIP
Lower anchor bolt construction:
SPRING 4. Driver's:Detachthe seat belt switch connectorand
WASHER BUSHING harnessclip from the seatcushion(seepage20 77).
Removethe seat cushion mounting bolts from the
COLLARS innerseattrack{seepage20-75),and movethe inner
seattrack,then pull the seatbeltswitchharnessout.
NOTE:Takecarenot to damagethe hingebracket.
Centsr anchor bolt construction:
TOOTHEO CENTER
ANCHOR
LOCKWASHER BOLT
WASHERS LowER LOWERANCHOR

LOCKWASHER ANCHOR BOLT
Reiractor bolt construction:
TOOTHEO RETRACTOB
LOCKWASHER
SPRING WASHER
WASHER
Installationis the reverseof the removal procedure.
NOTE: Make sure you assemblethe washers and

bearingon the centeranchorbolt as shown.
20-47
RearSeat Belt
Replacement
CAUTION:Chack the rear seat belts for damage,and 3. Installationis the reverseof the removalprocedure.
replacethem if necessary,8e carolul not to damage
lhem during removal and installation. NOTE:
Rearseat belt removal {2Dl4D}: tions as describedon page20-91.
. lvlakesure you assemblethe washersand collar
1. Remove: on the upperanchorbolt as shown.
. Rearseatcushion(seepages20-79,81) . Beforeinstallingthe anchorbolt.make surethere
. Rearseat-back(2D,seepage20-81) are no twistsor kinksin the rearseatbelt.
. Rearshelf(seepages20-59,61) Upper anchorboh condruqtion:
. Reartrim panel{seepage20-62}
(seepage20-62)
. Trunksidetrim, Japan-produced
. Trunktrim panel,USA-produced(seepage20-62)
2. Remove all the anchor bolts and retractor bolt, then

remove the rear seat belt and retractor.
UPPERANCHORBOLT
7/16-20UNF
32 N.m (3.3kgf.m,2,1lbtft)
SPRING
WASHER
RETNACTOR BOLT
7/1F20 UNF
32 N.m {3.3kgf.m,
24 tbt.ft) Lower anchor bolt construction:
LOWERANCXOR
EOLT
LOWERANCHOR
Retractorbolt construction:
7/16-20UNF
32 N.m {3.3 kgf.m,24lbt.ft)
t7\ /7--^,
l/rn\ .----. A -nrfi|lH \
/
tr\7-\ \ \
TOOTHED R€TRACTOB RETRACTOR
LOCKWASHER BOLT
20-88
Rearseal belt removal (3Dl: 4. Installationis the reverseof the removalprocedure.
1. Remove: NOTE:
. Rear seat-backand rear seat cushion (see page . Checkthat the retractorlockingmechanismfunc
20_80) tions as describedon page20-91.
. Rear center shelf and rear side shelf (see page . Makesureyou assemblethe washersand collars
20_60) on the upperanchorbolt as shown.
. Reartrim paneland sidetrim panel(seepage20 . Betoreinstallingthe anchorbolt, makesurethere
60) are no twistsor kinksin the rearseatbelt.
2. Removethe upperanchorcover Upper snchor boh construction:
COLLARS
UPPERANCHORBOLT
7/16-20UNF
32 N.m {3.3 kgf.m,2it lblft)
UPPER
ANCHOR
RETRACTOR
RETRACTOR BOLT
7/16-20UNF
32 N.m 13.3kgl.m.
24 tbf.ft)
Lower anchorbolt construction:
REARSEAT
BELT
LOWERANCHOR
LOWEF
7/r6-20UNF
32 N.m {3.3kgl.m. 24 lbf.ftl
3. Removeall the anchorboltsand retractorbolt.then

removethe rearseatbelt and retractor.
TOOTHED
LOCKWASHER
(cont'd)
20-89
RearSeat Belt
Replacement(cont'dl
Soai belt buckle/Centerbolt tongue removal: Center anchor bolt construction:
1. Removethe rear seat cushion(seepages20-79'80,

81).
Removethe center anchor bolts, then remove the

seatbelt bucklesand centerbelttongue.
2Dl4Dl
BELT
CENTER
BUCKLE
TOOTHED
LOCKWASHES
Installationis the reverseof the removalprocedure
NOTE: Beforeattachingthe seat-backand seat cush-

ion,makesurethereare no twistsor kinksin the cen
ter belts.
CENTERBELTTONGUE
3D:
CENTERANCHORBOLTS
7/1$20 UNF
32 N.m (3.3kgt.m,
2/r bl.ftl
CENTENEELT
20-90
Seat Belts
Inspection
Retractor InsDection 3D:
t. Beforeinstallingthe retractor,checkthat the seatbelt

can be pulledout freely.
ao" 40'- -+ -40.
-
..'' 15' 15'
Makesurethat the seat belt does not lockwhen the
(. .-j-
retractoris leanedslowlyup to 15'from the mounted
\ ,
,)
position.The seatbeltshouldlockwhen the retractor
is leanedover40'.
CAUTION:Do not attempt to disassemblethe retrac-

tor. RETRACTOR
*: Mounted Position
Front:
4D:
* 10-
3. Replacethe seat belt with a new one if there is any
abnormality.
15 15'
i-Tl On-lhe-CarSeat Belt Inspeqtion
I ],f
1. Checkthat the seat belt is not twisted or caughton
anyrnIng.
2. A f t e r i n s t a l l i n gt h e a n c h o r s c, h e c kf o r f r e e m o v e
Forward Inside ment on the anchorbolts. lf necessary,removethe
anchorbolts and checkthat the washersand other
2D l3D. partsare not damagedor improperlyinstalled
3. Checkthe seatbeltsfor damageor discoloration.

C l e a nw i t h a s h o pt o w e li l n e c e s s a r y
CAUTION: Use only soap and water to clean.
NOTE:Dirt build-upin the metal loops of the upper

anchorscan causethe seat belts to retractslowly.
Wipe the insideot the loopswith a cleanclothdamF
enedin isopropylalcohol.
ForwaJd lnside
4. Checkthat the seat belt does not lock when pulled
Rear: o u t s l o w l y .T h e s e a t b e l t i s d e s i g n e dt o l o c k o n l y
during a suddenstop or impact.
2Dl4Di
5. Makesurethat the seatbeltwill retractautomatically
when released.
6. For each passenger'sseat belt, make sure that the

l o c k i n gm e c h a n i s mi n t h e s e a t b e l t r e t r a c t o rw i l l
engagewhen the seatbelt is pulledall the way out.
7. Replacethe seat belt with a new one il there is any

abnormality.
20-91
Seat Belts
Child Seat Anchor Plate
Attachment points are provided for a rear seat mounted
child restraintsystemwhich usesa top tether.The attach-
ment points are locatedon the rear shelf or rear trim
panel,just behindthe rearseat-back. When usinga child
seatwith a top tether,installthe child seatanchorplates
securely.
2Dl4Di
NOTE; Remove the plug covers from the attachment

pointsof the rearshelf.
TOOTHEDWASHEB
PLUGCOVERS
NOTE:
Do not removethe toothedwasherfrom the childseat
anchorplate.Usethe child seatanchorplatewith the
toothed washer attachedto it.
When installinga child seat on the rear seat,follow
of the childseat
the instructionsof the manufacturer
Additionalanchorolatesare available.
@
r Do not us6 the child seat anchor plate for any othel
purposs; it is designedexclusivelytor installation of a
child 3eat.
. Make suro the rear seat-back is locked firmly when
installing8 child seat.
REARSHELF
3D:
NOTE: The reartrim panel has perforationsat eachattach-

ment point. Cut the rear trim panel along the perforations
to makea hole.
REARTRIM
PANEL
POINTS
20-92
Exterior
ComponentLocationIndex
'1996Model
NOTE:Referto the CivicBodVRepairManual, Series,P/N.6150330,forthehood,trunk lid and hatchremoval.
2Dl30llDl
SIDEWINDOW LICENSEPLATE
MOLDINGS TRIM TRUNKLID
ROOFMOLOING Replacement, Replacement, Adjustment,page20-97
Replacement, page 20-102 page 20-100 TolsionBarRemoval,
page 20-102 20 99
HOOD
Adiustment, page 20 96 TRUNKLID
Hood Edge protector WEATHERSTRIP
Replacement, page20 99 Replacement,
page20-100
REARBUMPER
Replacement,
page2O-95
REARAIR OUTLET
Replacement,
page20-106
FUELPIPE
PROTEfiOR
Replacement,
page20-106
FENDERWELLTRIM
page20-106
Replacement,
SILLPANEL
R e p l a c e m e n t ,p a g e 2 0 1 0 5
Replacement,
page 20-106
3D:
HATCH
WEATHERSTRIP
HATCH
Adjustment,
page20-98
20-93
Front Bumper
Replacement
CAUTION:Puton glov$ to protectyour hands.
NOTE: >: golt, screw locations >: Clip

a>,2 B>,2 locations,
7
. An assistant
is helpfulwhenremovingthefrontbumper.
. Takecarenotto scratchthefrontbumDerandbodv.
i A e r r : o'n'
o r-'e .A l m
L.'*
c>,4
fl'T;Ll' \€5>_JI ,D>,4
| -.6a 8 x 't.25mm l,Rt o x 1.0mm
l(Dl[m j(Qll@ s.eN.mrr.orsf.m,
22N.n'.t2.2kstnf'.
-ll
t'KJ) 16 tbf.ft, |. 7.2 tbf.hJ
FRONTBUMPERBEAM
FRONTBUMPER
SIDESNFFENER
:l
I ir
ABSORBER
FRONTEUMPER
BEAM
lnstallationis the reverseof the removalorocedure.

FRONTBUMPER
NOTE: SIDESTIFFENER
. Make sure the front bumper engagesthe front
bumperside stiffeneron eachside securely.
. lf necessary,adjustthe front bumper side stiffener
to obtainthe propergap.
20-94
RearBumper
Replacement
CAUTION: Put on gloveslo protect your hands.
NOTE:
. An assistant
is helpfulwhen removingthe rearbumper.
. Takecarenot to scratchthe rearbumperand body.
. 2D and 4D shown here;3Dremovalproceduresare the sameas 4D.
>: Screw, boll locations
A>,2 B>,4 >: Clip locations,7
rtn ,/_-\ E
. -*E]s-
.A IVilIdfIT*ff
\r*,r/ \ \7
REARBUMPERBEAM
REARBUMPER
Installation of the removalDrocedure.

is the reverse
NOTE:
. lf necessary,
replace
anydamaged
clips.
. Makesuretherearbumperengagesthesideclipon eachsidesecurely.
20-95
Hood
Adjustment
NOTE:Beforeadjustingthe hood,looseneachbolt slightly.
1. Adjustthe hood hingesright and left,as well as fore and aft, by usingthe elongatedholes.
2. to makethe hood fit flush with the body at front and side edges.
Turn the hood edgecushions,as necessary.
3, Adjustthe hood latchto obtainthe properheightat the forwardedge.
4. After adjustment,tighteneachbolt securely.
)
6x1.0mm
9.8 N.m {1.0 kgt.m,
7.2 tbt.tll
NOTE: Move the hood latch right or left until the striker
is centeredin the hood latchas shown.
6x1.0mm
9.8 N.m {1.0kgf.m,
7.2 tbf.ftl
20-9 6
TrunkLid
Adjustment
NOTE;Beforeadjustingthe trunk lid, looseneachbolt slightly.
1. Adjustthe trunk lid hingesright and left,as well as fore and aft, by usingthe elongatedholes'
2. to makethe trunk lid fit flush with the body at the rearand side edges.
Turn the trunk lid edgecushions,as necessary,
3. Adiustthe fit betweenthe trunk lid and the trunk lid openingby movingthe striker'
4. After adjustment,tighteneachbolt securely

TRUNKLIOEDGE
CUSHION
TRUNK LID
TRUNKLIO
NOTE:Takecarenot
to hit the rearwindow
when looseningthe
bolts.
NOTE:Move the strikerright or left until it's centeredin

the trunk lid latchas shown.
9.8 N.m {1.0kgf.m,

7.2lbl.ltl
STRIKER
20-97
Hatch
Adjustment
NOTE:
. Beforeadjustingthe hatch,looseneachbolt and nut slightly.
a The suDportstrutsshouldbe removed.
. To adjust,removeboth hatchsidetrim (seepage20-63)and the rearroof trim (seepage20-65).
1. Adjustthe hatchhingesright and left,as well as fore and aft. by usingthe elongatedholes
2. to makethe hatchfit flush with the body at eachside.

Turn the hatchedgecushions,as necessary,
3. Adjustthe hatchfit to the hatchopeningby movingthe striker.
4. After adiustment,tighteneachbolt and nut securely.

HATCH
6x1.0mm EDGECUSHION
9 . 8 N . m ( 1 . 0k g f . m ,
HATCH
HINGE
Rearward
HA
EDGE
CUSHION
j ... 22 N.m (2.2 kgf.m,
\ \,_1q tbf.ftl
\ HATCH
HINGE STRIKER
l0x1 coVER
38Nm(3.9kgfm,
HATCH
2.8 rbf.ft)
EDGE
CUSHION
NOTE:Move the strikerright or left until it's centeredin

the hatchlatch.as shown.
6x1.0mm
9.8 N.m 11.0kst.m,
HATCH 7.2 tbf.ft)
LATCH
20-98
Front Grille/HoodEdge TrunkLid Torsion
Protector Bars
Replacement Removal
Front grille: CAUTION:Pui on gloves to protect your hands.
NOTE:Takecarenot to scratchthe front bumper' NOTE:Takecarenot to damagethe body
Removethe front bumper(seepage20-94)Bemovethe Removethe torsion barswith the torsion bar assembly
clips and screws,then slide the front grille forward by t o o l w h i l eh o l d i n gt h e t r u n kl i d a s s h o w n .
detachingthe hooks.
4
>: Screwlocations,
" q L
A
\t+lt /
FRONTBUMPER
CENTERCLIP
Hood edge Ploteetor: E

NOTE: lnstallationis the reverseof the removalprocedure'
. When removingthe clips,usea cllp remover.
. lf necessary, NOTE:
. Adjust the torsion bars fore or aft with the tor-
18 sion bar assemblYtool as shown
>:Cliplocations,
HOODEDGE
ll = NormalPosrtlon
a = Highertensron
'-l o[_]
/A.- -----,_ ,,, \- . Make sure the trunk lid opens properly.
20-99
TrunkLid/Hatch
Weatherstrip LicensePlateTrim
When installingthe trunk lid/hatchweatherstrip.align it CAUTION: Put on glov€s to plotest your hands.
with the alignmentmarkon the trunk lid/hatchopening.
NOTE:Takecarenot to scratchthe trunk lid/hatch.
NOTE:
. Makesurethereare no wrinklesin the weatherstrip. 1. Removethe licenseplate.
. Checkfor water leaks.
2, 3D: Removethe hatchtrim panel(seepage20-63).
2DllDi
3. Removethe nuts and clips,and detachthe clip,then
ALIGNMENTMARK
removethe licenseplatetrim.
NOTE:Takecarenot to drop the nutsinsidethe trunk

lid/hatch.
a: Nut locations,2 >: Cliplocations,

I
6fi\5x0.8mm I nA
rvr?//1,8N.m{0.18
-
j llrftl
kst.m,l aa# )
,/ - , /
WEATHERSTRIP
3D:
ALIGNMENTMARK
Installation
is the reverseof the removalorocedure.
STEEI. NOTE:lf necessary,

CORE
ALIGNMENT
MARK (2Dl4D)
BODY
20-100
HatchSpoiler
Removal
NOTE:Takecarenot to scratchthe hatchand body 4. removethe spoilertrim from the spoiler
lf necessary.
frame.
1. Removethe hatchuppertrim (seepage20-63)
NOTE:The hatchspoilertrim for Canadaproduced
2. Removethe nuts, and detachthe clip, then lift the carscannotbe disassembled.
hatchspoileruP.
>: Cliplocations
A>,4
a: Nut locations,4
1 2lbt.ftl j/
_ >: Scr€w
GROMMET
HIGHMOUNTBRAKE
LIGHTCONNECTOR
------,*;)
5. Installationis the reverseof the removalprocedure'
NOTEi
a M a k e s u r e t h e c o n n e c t o ra n d w a s h e rt u b e a r e
connectedProPerlY.
Disconnectthe high mount brake light connector and

rear window washer tube, then remove the hatch
spoiler.
20-101
SideWindow Moldings RoofMolding
CAUTION:Put on glovos to protect your hands. CAUTION: When prying with a flat-tip screwdriver, wrap
it with protestive taps to prevent damage, and use pro-
NOTE: toctiv€ tape on the body.
. Takecare not to scratchthe body
. Removethe screw,and pull th€ sidewindow molding NOTE: Take care not to scratchthe bodv.
by hand.
>: Cliplocations
A>,13
K
PIN
lBody side)
WINDSHIELO
MOLDING I
)
>: Screw locations, 1 l

*@ )
NOTE:
. Takecarenot to damagethe windshieldmolding.
MOLOING
. Makesurethe roof moldingis installedsecurely.
NOTE:lf necessary,
20-102
Doorand SideMoldings
Replacement
prevent damags'
CAUTION: When prying with a flat-tip scr6wdrivgr,wrap it with protective tape to
NOTE;
. To removethe front side molding,removethe innerfender(seepage20-106)'
. To removethe door moiding,removethe door panel(seepages20-4,10,16)and plasticcover.
. To removetherearsidemolding,removethe sidetrim panel(seepages20-60,611'
. Takecarenot to bendthe door moldings.
. Beforereassembling, cleanthe door bondingsurfacewith a spongedampenedin alcohol'
. After cleaning,keepoil, greaseand water from gettingon the surface'
4D:
FRONTDOOR Adhesiveareas.
MOLDING
2Dl3Dl
REARSIDE
MOLOING
>: Cliplocations a: Plasticnut loc€tion. 1

A >: 4D,11 B>,3 c>,2
2')13D,7
@)
(cont'dl
20-103
Doorand SideMoldings
Replacement(cont'dl
Door molding removal: Door molding installation:
The following materialsand tools are requiredto repair 1. G l u e t h e n e w a d h e s i v et a p e t o t h e m o l d i n g sa s

the door moldings. snown.
NOTE:Followthemanufacturer's [\\\\\\l : Adhesive tape tocations

instructions. 60 mm
4D: t2 t i^l
Materials:(Reference)
. Striperemover
3M 08907
Stripeadhesiveremover
3M 08908
Adhesivetape
40 mm
3M SuperAutomotiveAttachmentTape 1 1 . 6i n )
Tools;
a Protectivetape . Film
. Knifeor Cutter . Putty knife Forward L
. Spongeor Shoptowel . Alcohol REARDOOR CLIP
. Infrareddryer
HOLDER
2Dl3Dl 100mm
CAUTION: Put on gloves to protect your hands, (3.94inl
1,050mm 141.34
inl
1 . Removethe door panel, and pull back the plastic
cover,
Forward !
Apply protectivetape on and aroundthe molding. DOORMOLDING
DOORMOLDING
5 mm {0.2inl
ADHESIVETAPE
Thickness:1.2 mm 10.05in)
3. Releasethe clips from insideof the door. Carefullv Installthe

c l i p so n t h e m o l d i n g .
cut the adhesivetape with a knife or cutter while
pullingthe edgeof the moldingaway trom the door H e a t t h e b o n d i n g s u r f a c eo f t h e d o o r a n d d o o r
as shown. moldingwith an infrareddryer.
Door: 104- 140"F(40- 60.C)
NOTE:Take care not to scratchor bend the mold- Molding:68 - 86"F(20- 30.C)
Ing.
KNIFE NOTE:Use carewhen heatingto preventdeforma-

tion of the molding.
Align the molding with the clip locations,and set

the molding. Lightly push on the molding until its
edgeis fully seatedon the adhesivetape.
NOTE: Do not spray water on the motding within

the first 24 hoursafterinstallation.
DOORMOLDING
Reassemble
all removedpans.
20-104
SideSill Panel
Replacement
NOTE:
. Takecarenot to scratchthe body
. 4D shown here;2Dand 3D removalprocedureis the sameas 4D'
>: Screw locations,4
W_1
NOTE:Loosenthe screw, SIDECLIP
then removethe lowercliP Removethe sidecliPsfrom the body
usinga clip remover. by turningthem 45"
NOTErWhen removingthe side

sill panel,the sideclipswill
stayin the body.
SIOESILLPANEL
Removethe lowercliPs,
then removethe sidesill Panel
by sliding it forward.
panel,then installthe sidesill

To installthe side sill panel,removethe sideclipsfrom the body. installthem on the sidesill
panelon the car.
NOTE:
. Takecarenot to twist the sidesill panel.
replaceany damagedsideand lowerclips'
. lf necessary,
20-105
Inner Fender,Fenderwellrrim, FuelPipeprotectorand Rear
Air Outlet
Replacement
NOTE:lf necessary,
Innertender:
>: Screwlocations,4
r\
tllpo"
: , /
l
>: Cliplocations,7
Fenderwelltrim/Fuel pipe protector/Rea. air outlet:
NOTE:
. Takecarenot to bendthe fenderwelltrim. >: Clip locations
. Beforelnstallingthe fenderwelltrim, cleanthe body A>,4 B>,4 c>,2
b o n d i n gs u r f a c e I
w i t h a s p o n g ed a m p e n e di n a l c o h o l .
. Aftercleaning,keepoil, greaseor waterfrom gettingon
the surface. l;1A t'frv
Ah +
. To removethe fuel pipe protector,first removethe rear
wheel(seesection18).
. To remove the rear air outlet, first remove the rear
!--l1! \:
bumper(seepage20 95).
STEEL FENDERWELL
20-106
and Latch/Wiperand Washer
OpenerCable/Opener
ComponentLocationIndex
2Dt3DItD' o*t"
y"Tl,"nll,ib?*'r.* LOCKCYLINDER
Replacement,Page20_113 TRUNKLIOLATCH
Adiustment,Page20'117 { s e ep a g e2 0 1 1 2 )
WINDSHIELD
WASHERNOZZLES
A d j u s t m e n t , P a g e 2 0 _ 11 7
HOODLATCH
{seepage20-110)
FUELLIDOPENER
CABLE
(seepage20-108i
LID OPENER
CABLE
(seepage20 108)
LID/FUEL
LIDOPENER
( s e ep a g e2 0 1 1 1 )
RELEASEHANDLE
(seepage20-110)
3D: REARWINDOW
WASHERTUBE
REARWINDOWWIPER REARWINDOW (seepage20-116)
ARM and MOTOR WASHER NOZZLE
page20-1
Adiustment, 17
Replacement,Page20-115 WASHERRESERVOIR
Adjustment,page20 117 Page20-115
Replacement,
HATCH/
FUELLIDOPENER
(seepage20 1'11)
FUELLIDOPENER
CABLE
(seepage20 110)
HATCHOPENER
( s e ep a g e 2 0 1 1 1 )
CABLE
(seepage20 110)
LOCKCYLINDER
(seepage20 113)
20-107
OpenerCables
Replacement
NOTE: Tlunk lid/Fuel lid opener cabte (2Dl4D):
t When removingthe clips.use a clip remover.
. Takecarenot to bendthe openercables. NOTE:Removethe following partsfrom rhe Ieft side of
the vehicle,then pull the carpetback,as necessary{see
Hood op€ne. cable: page20-66).
NOTE;Removethe front bumper (see page 20-94)and . Rearseatcushion(seepages20-79,81)

innerfender(seepage20-106). . Rearseatside bolster(4D,seepage20,79)
. Rearseat-back(2D,seepage20-81)
. Centerpillarlowertrim panel(4D,seepage20-59)
g
>: Clip loc.tions
A>,5 B >, 1 o Lower anchor bolt from the front seat belt {2D. see
page20-86)
ry) Sidetrim (seepages20-59,61)

.
. Seatsidetrim (4D,see page20-59)
. Trunk mat and sparetire lid
. Reartrim panel(seepage20-62)
HOODREI.TASE . Trunksidetrim, Japan-produced (seepage20-62)
HANDI.I . Trunktrim panel,USA-produced (seepage20-62)
(seepage20-110)
>r Clip, cable cushion locations

A >,4 B > , 4 D _1 c >, 1 l4D)
t@
2D,2
_
#lB : _/ _-___)
D>,3 E > , 4 D ,1
2D,2
@ i
_ _,, -/
cablethroughthe
hotein th6body.
NOTE:
a Make sure the hood openercable is routed and
connectedproperly.
. Makesurethe hood opensproperly.
20-10a
TRUNK LID LATCH
(seepage20'112)
?e-=....-
4D:
To trunklid
latch.
TRUNKLID/FUEL
LID OPENER
( s e ep a g e2 0 1 1 1 )
latch.
a
A
'--! TRUNKLID
- OPENERCABLE
\- -l
N"La FUELLID
OPEN€RCAELE
TRUNKLID/FUEL
LID OPENER
FUEL (seepage20-111)
LATCH
(seepage 20'112)
(cont'd)
20-109
OpenerCables Openerand Latch
Replacement(cont'dl Replacement
Hatch/Fuellid opener cable l3Dl: NOTE:Takecarenot to bendthe openercables.
NOTE:Removethe following parts,then pull the carpet Hood releasehandle:

backas necessary(seepage20-66).
NOTE:Removethe kickpanel(seepages20-59,60.61).
. Rearseatcushionand rearseat back(seepage20-80)
. Lower anchorbolt from the front seat belt (seepage >: Bolt locations, 2
]
I
20 86) 6 x 1 . 0 m mj
. Sidetrim {seepage20-60) HOOOOPENER
9.8Nm CABLE
. Sparetire lid {1.0kgf.m, i (seepage20-108)
. Rearcentershelfand rearsideshelf{seepage20-60)
. Reartrim panel(seepage20-60)
. Sidetrim panel(seepage20,60)
>: Clip,cablecushionlocations
a>.9 B > ,1 c>,1 D> , 5
#, W#)
Hood latch:
Routethe opener
cablethroughthe NOTE:Removethe front bumper(seepage20-94).
hole in the body. FUEL LID LATCH
page20-112)
>: Eoltlocations,
3
I
6 x '1.0mm
9.8N.m
11.0kgf.m,
HATCH/FUEL
LIO
OPENER

NOTE:
. Make sure each openercable is routed and con- NOTE:
nectedproperly. . Makesurethe openercableis connectedproperly.
. Makesurethe hatchand fuel lid open properly. . M a k e s u r e t h e h o o d o p e n s p r o p e r l ya n d l o c k s
securely.
20-110
Trunk lid or Hatch/Fuellid opener: Striker(3Dl:
N O T E :R e m o v et h e s i d et r i m ( s e ep a g e s2 0 5 9 , 6 0 . 6 1 ) NOTE: Removethe reartrim panel(seepage20-60)
>: Boll locations,2

OPENERLOCK >: Bolt locations, 2
a@-\ CYLINDER
6xl.0mm
9.8Nm Ya//t2't4Dl
11.0kgf.m,
7.2 tbl.ttl
ti 6xl.0mm
HATCH
OPENER CAELE
(seepage20-110)
l:'.j
TBUNK LID/HATCH
OPENERCABLE
(see 2 0 - 1 0 81,1 0 )
To trunklid latch
or striker.
To fuel lid latch. \
lnstallation is the reverse of the removal procedure.
NOTE:
FUELLID
. N4ake sure each openercableis connectedProP-
OPENERCABLE
(seepages20-108,'110) erlY.
. M a k e s u r e t h e hatch opens properly and locks
securelY.
Installationis the reverseof the removalprocedure
NOTE:
. lvakesurethe openercableis connectedproperly.
. M a k es u r et h e t r u n kl i d o r h a t c ha n df u e l l i d o p e n
properly.
(cont'd)
20-111
Openerand Latch
Replacement(cont'd)
Fuel lid latch: Trunk lid latch/Lock cylinder:
NOTE:Removethe followingpa(s.
2Dl4Dl >: Bolt locations

A>,3 8>, 1
. Reartrim panel(seepage20-62J
. Rear edge of the trunk side trim or trunk trim panel 6x1.omm
(leftside,see page20-62) 9.8 N.m (1.0kgf.m,
i f f er t . o m m
(1.0
I
ZS 9.8N.ln kgt m,
.ty 7.2-tbr.ftt
:::^ _=) ,/
3D:
CYLINOER
. Accesspanelon the sidetrim panel
>: Eolt locations,2

|
r'-\ 6x10mm TRUNK LID
9.8 N.m (1.0kgf.m, I FUEL I-IO LATCH OPENER
TRUNKLID
LATCH
CYLINDER
ROD
FUELLID
After installingcheckfor
a flushfit with the body.
CONNECTOR
Disconnect.
-\
I
I TRUNK LID
OPENER
CABLE
FUELLID OPENER
CABLE
(seepages20,108,1'10)
FUELLID LATCH
Removethe fuel lid latch
by turningit 90o

Installation
is the reverse
of the removalprocedure.
NOTE:
NOTE; . Greasethe trunk lid latch.
o Makesureeachopenercableis connected
prop- . Makesurethe trunk lid opensproperlyand locks
elty securely.
. Make sure the fuel lid opens properlyand locks a M a k e s u r e t h e c o n n e c t o ra n d c y l i n d e rr o d a r e
securely. connectedproperty.
20- 1 1 2
WindshieldWiperArms
and Linkage
Replacement
Hatch latch/Lock cylinder: CAUTION: Pul on gloves to protect your hands
NOTE:Removethe hatchtrim panel(seepage20-63). NOTE:Takecarenot to scratchthe hood and body.
1. Removethe windshield wiper arms, then remove

>: Bolt locations the hood sealand cowl cover.
A>,3 B>,1
6x1.0mm I >: Clip locations

E
6;:il;l,lr'.", 'cr 9.8N.mi1.0
6 ksfm,l
1.2lbl.trl
A>,9 B>,9
Hw
/ WINOSHIELD
WIPERABMS
10 x 1.25mm
CYLINDER 18 N.m ll.8 kgf m,
u
\j:_
.r\
cowl covER
- LOCK
r€\
L^\
cYLTNDER
! ./
rAs<.L ,/
\faa"El
Disconnectthe connector,then remove the wind-
rl shieldwiper linkageassemblY.
Japan/Canada-produced:
NOTE:
. Greasethe hatchlatch.
. Make sure the hatch opens properly and locks
securely.
. Makesurethe cylinderrod is connectedproperly.
(cont'd)
20-113
WindshieldWiperArms and Linkage
Replacement(cont'dl
USA-produced: USA-produced:
>r Bolt locations,3 NOTE:Scribea line acrossthe link and windshield

wiper motor to show the originaladjustment.
>: Bolt locations,2
6 J (1 . 0m m NUT
R 1 0x 1 . 2 5m m
Y 8 N.m to.skgtm, I '18N.m
{1.8kgf.m.
.E-7Y.nt ) 13 tbtft)
3. S e p a r a t et h e w i n d s h i e l dw i p e r l i n k a g ea n d w i n d -
shieldwiper motor.
Japan/Canada-produced:
N O T E :S c r i b ea l i n e a c r o s st h e l i n k a n d w i n d s h i e l d
wiper linkageto show the originaladjustment.
>: Bolt locations,3 WINDSHIELD

WIPERMOTOR
O 6r1.0mm NUT
EF 8 N.m {0.8kstm,i 10 x 1.25mm
g 5.8 tbf.ft) ) l8 N rn (1.8kgtm,
13 tbtftl
NOTE:
. l n s t a l lt h e w i n d s h i e l dw i p e r a r m s a s d e s c r i b e d
o n p a g e2 0 - 1 ' 1 7 .
. Checkthe windshieldwiper motor operation.
. Greasethe moving parts.
WIPERLINKAG€
20-114
RearWindow Wiper
Arm and Motor WasherReservoir
' t . Removethe hatchtrim panel(seepage20 63). L Removethe front bumper(seepage20-94).
2. R e m o v et h e r e a r w i n d o w w i p e r a r m a n d w i p e r 2. Disconnectthe connectorsand washer tubes from

motor as shown. the washermotors.
>: Bolt locations,3
/)^ 6xt.omm
Ql(S) s.eru.-tt.oret'".
\./ 7.2 tbf.ft)
/
Routethe washer tubes

10the washe. reservoir
NUT
6x1.0mm
9.8 N.m 11.0kgf.m,
7.2 tbf.ft)
WIPERMOTOR
wtNDow
WASHERMOTOR
3. Installationis the reverseof the removalprocedure (3D,for somemodels)
NOTE:
. Makesurethe connectoris connectedproperly 3. Removethe bolts, then remove the washer reser-
.Install the rearwindowwiper arm as describedon voir.
p a g e2 0 - 1 1 7 .
. Checkthe rearwindow wiper motor operation. 4. Installationis the reverseof the removalprocedure.
. Greasethe moving parts.
NOTE:
a M a k e s u r e t h e w a s h e r m o t o r c o n n e c t o r sa n d
washertubesare connectedproperly.
. Checkthe washermotor operation.
20-1 1 5
WasherTube
Replacement
>: W.sher nozzle,clip and cushion locations
NOTE: a>,2 B>,3 c > ,1
. To removethe windshieldwashertube, removethe wttrtosnteLo6}
left innerfender(seepage20-106), usxea =-d "J>)
. To removethe rearwindow washertube {3D),remove
the followingpartsfrom the leftsideof the vehicle.
-
-
Innerfender(seepage20-106)
Kickpaneland sidetrim (seepage20-60)
lNozzrE cv
i
!$e
D>,1
q
E > ,1
@"[q F>, 11
- Rearseat-backand rearseatcushion(seepage20-
NtW)€
80)
- Sparetire lid
- Rearcentershelf and rearside shelf (seepage20-
60)
- Reartrim panel and side trim panel (seepage 20
60) WINDSHIELD
TUBE
Ouartertrim panel(seepage20-60)
- Rearrooftrim {seepage20-65) A
REARWINDOW
- Hatchspoiler(seepage20-101) WASHERTUBE
washernozzle.
WIRE
HARNESS
Rootethe washertube
underthe wire harness.
Routethe washertubes
to the washer reservoir
washernozzle
(seepage20-101).
REABWINDOW
WASHERTUBE
(Ior some models)
oo\
NOTE:
. Takecarenot to pinchthe washertubes.
. After installing,adjustthe aim of the washernoz-
zles(seepage20-117).
20-116
Wiper Arms/WasherNozzles
Adjustment
Windshieldwiper/Washer: RearWindow wiper/Washer (3Dl:
1. Adjust the wiper arms so that their park positions 1. Adjust the rear window wiper arm so that its park
matchthe illustration. positionmatchesthe illustration.
View trom tront to rear View trom raar to front
-.4 .// \
---..J_.__11,:l
,'l r-
A
x i A'
x x . .
REARWINOOW
WIPERARM CERAMIC
EDGE
WINDSHIELD
WIPER
ARMS B y i n s e r t i n ga t a c k a n d m o v i n g i t a s n e c e s s a r y ,
adjustthe washer nozzleso that it aims at position
C as shown in the illustration.
2. B y i n s e r t i n ga t a c k a n d m o v i n g i t a s n e c e s s a r y , NOTE:The fluid jet should hit within a 50 mm (2.0

adjustthe washer nozzlesso that they aim at posi- in,) radiusaroundpoint C.
tions A, A', B, and B'shown in the illustration.
NOTE:The fiuid jets shouldhit within a 50 mm (2 0

in.) radiusaroundeachof pointsA, A', B, and B'.
\ Distance from center from black

M;r.";-lll lrne ceramrceoge
A and A' 400mm (15.7in.) 255mm (10.0in.)

B and B' 1 1 5m m ( 4 . 5i n . ) 322mm \12.7in.)
20-117
Emblems
Installation
Apply the emblemswhere shown.
NOTE:
. Beforeapplying,cleanthe body surfacewith a spongedampenedin alcohol.
. After cleaning,keepoil, greaseand water from gettingon the surface.
Aftachment Points (Reterence): U n i t :m m ( i n . )
CIVICEMBLEM
CIVICemblem CIVICemblem
TFUNK LID TRUNKLID
Vorsion emblem Version emblem Versionemblsm
20-114
Sub-frame
Sub-frameTorque Sequence:
CAUTION: After loos€ningthe sub-frame mounting bolts, be sure to replacethem with new ones.
BOLTS
1 4x 1 . 5m m
90 N m (9.1ks{ m,
1 0x 1 . 2 5m m 66 rbf.ft)
38Nm{3.9kg{.m: Replace.
28 tbf.ft)
20-119
FrameRepairChart
U n i t :m m ( i n . )
o: Innerdiameter
DETAILAREA.Y
CVT:
(5.121
177{6.971
20-120
I t:3D
SECTIONAA
012 {0.47)UpperArm
@20{0.8)Locat. Hole
LowerArm Center
Damoer Lower Bush Center
20-121
Body ('97 model)
FrontSeat Belt
Removal/lnstallatlon ....20-128
RearSeat
RemovaUlnstallation ....20-126
WasherTube
Windshield
fndex .......... 20-124
'97 Model Changes

Outline of
The molding side seal was added.
The method of installing the rear seat cushion was changed (2Dl3D).
A middle floor gusset was added and the method of detaching the seat belt retractor was changed (2Dl3D)
The installation position of the washer tube was changed.

Windshield
lndex
NOTE:The numbersafterthe part namesshow the quantitiesof the partsused.
UPPERRUBBER
wlNDSHIELD DAM
MOLDING
FASTENER, 2
glass side)
FASTENER,2
{Clip-type,body sido)
WINDSHIELD
20-124
L-
Molding Side Seal
lnstallation
Glue the molding side seal to the windshield molding on
each side.
20-125
RearSeat
RemovaUlnstallation
3D:
i_): Hook locations
4i.,,2 Bt-;,1
>: Bolt locations

a>,6 B>,'t c > ,1
I
iI
6x1.Omm -@e ' t.o.- |
9.8N.m {1.0*nt.] S=222 N.m12.2kg{.m,I
7.2 tbt.trl j g 16tbf.ft) j T=ttJX,.)
MIOOLEFLOOR
: , / CENTERGUSSET
STRIKER
Removethe side trim I
panel (seepage 20 60).
I STNIKER
6x1.0mm I
9.8 N.m {1.0fgf..,i
.2 tb,f.ft)
l
)
--::......... VV
PIVOT ;*... 1
BRACKET
>: Clip locations,14

SEATCUSHION
HOOK l@n
I F F
A ( E E
\ q t
c
Pivot boft con3truction:
TOOTXED
LOCK
WASHER
SEAT.BACK
A
PIVOTBOLT BRACKET
8 x 1.25mm
Instailationis the reverseof the removalprocedure. 22 N.m 12,2kgf,m, 16 lbl.ftl
NOTE:
. Beforeattachingthe seat-backand seatcushion,make sure there are no twists or kinks in the rear seat belts and
centerbelt.
. When installingthe seatcushion,slip the seatbelt bucklesthroughthe slits in the seat cushion.
. lf necessary,
adjustthe strikerand seat-back.
20-126
,-.): Hooklocations
^(:).z B() ' t
2D:
>: Bolt locations

A>,6 B>.1 c>,1
6 l e 6x1.omm i
9rJ*'Ll-",-,
H
iV
16rbr'frl ) g
9.8N.m11.0
7.2rbf.ft)
ksf.m,l
i
, / v
>: Cliolocations,14 SEAT-AACKMAT
PIVOTBRACKET
V V
V
CENTER
RIGHTSEAT-BACK PIVOTBRACKET
LEFT
SEAT-BACK
TOOIHED
LOCK
WASHER
BUSHING
PIVOTBOLT BRACKET
SEATCUSHION 8 x 1.25mm
22 N.m {2.2kgf.m, 16 lbIft)
NOTE:
. Beforeattachingthe seat-backand seatcushion,make surethere are no twists or kinksin the rear seat belts and
centerbelt.
. When installingthe seatcushion,slip the seatbelt bucklesthroughthe slitsin the seatcushion.
. Makesurethe seat-backlockssecurely
adjustthe seat-backlatchand seat-back
. lf necessary,
20-127
FrontSeat Belt
RemovaUlnstallation
2D l3Dl 4. Removethe upper anchorcover and lower anchor
cap.
1. Slidethe front seatforwardfully.
UPPERANCHOREOLT
7/16-20UNF
2. Remove: 32 N.m {3.3 kgf.m,
. Rearseat-backand rear seatcushion(seepages 24 tbf.ftt
20-126,127l.
. R e a rc e n t e rs h e l f a n d r e a r s i d e s h e l f ( 3 D ,s e e
page20-60) UPPERANCHOR
. Resrtrim panel(3D,seepage2G60) COVER
. Sidetrim panel(seepages20-60,61)
3. Pull back the carpet as necessary,and removethe RETRACTOR

MOUNTINGBOLT
bolts,then removethe middlefloor gusset. 6x1.0mm
9.8 N.m (1.0kgf.m.
7.2 tbl.hl
>: Boh locations,8
LOWER
10x 1.25mm ANCHOB
38 N.m (3.9kgf'm, CAP
28 rbtftl I
I
i
o
RETRACTORAOLT
7/16-20UNF LOWERANCHORBOLT
32 N.m 13.3kgf.m, 7/16-20UNF
24 tbttrl 32 N.m (3.3kgt.m, 24 lbf.ft)
Removeall the anchorbolts and the retractorbolt.

removethe retractormounting bolt, then removethe
Iront seat belt and retractor.
6. Installationis the reverseof the removalorocedure.
NOTE:
tions as describedon page 20-91
o Makesuri vou assemblethe washersand collars
on the upperand lower anchorboltsas shown.
. Beforeinstallingthe anchor bolts, make sure there
are no twists or kinksin the front seat belt.
20-124
WasherTube
Replacement
NOTE:To removethe windshieldwashertube, removethe left innerfender(seepage20-106).
>: Washarnozzle,clipandcushionlocations
a>,2 B>,1 c>,1 D>,'t E > ,1 F > ,1 G>,1
n,i#,T<g
l_<. l_N.j
lw)*)
W ) e 9)
) I
ECM/PCM
BRACKET
c-------.-
WIRE
HARNESS Routethe washertube Routethe washertube
underthe wire harness behindthe EcM/PcMbracket.
WINOSHIELD
TUBE REARWINDOW
WASHERTUBE
A
\/
Routethe washertubes
RESERVOIR to the washer reservolr Routethe washertubes
underthe wire harness.
is the reverseof the removalprocedure.

Installation
NOTE:
. Takecarenot to Dinchthe washertubes.
. After installing,adjustthe aim of the washer nozzles(seepage20-117l'
(cont'd)
20-129
WasherTube
Replacement(cont'dl
NOTE:To removethe rearwindowwashertube (3D),removethe followingpartsfrom the leftsideof the vehicle.
- Innerfender(seepage20-'106)
- Kickpaneland sidetrim (seepage20-60)
- Rearseat-back and rearseatcushion(seepage20-80)
- Sparetire lid
- Rearcentershelfand rearsideshelf(seepage20-60)
- Reartrim paneland sidetrim panel(seepage20-60)
- Ouartertrim panel(seepage20-60)
- Rearroof trim (seepage20-65)
- Hatchspoiler(seepage20-1011
>: Washer nozzle, clip and cushion locations

A> . 9 B>,2 C > ,1
I sl - . . . _1,
a j \ < j Q i
_ ____/
_>_t _ _/
(seepage20 101).
REARWINDOW
WASHER TUBE
(forsomemodels)
Installationis the reverseofthe removalprocedure. motor.
NOTE:
. Takecarenot to pinchthe washertubes.
adjusttheaim ofthe washernozzles(seepage2O-1111.
. Afterinstalling,
20-130
Body ('98 model)
Openerand Latch
HoodLatchCoverReplacement""'.' 20-132
HatchHandleReplacement 20-132
..'.'....'...'
HatchLatch/LockCYlinder
Replacement "...'.."..'.'... 20-133
'98 Model Changes

Outline of
. The hood latch cover was added
. The hatch handle was added (3D)

Openerand Latch
Hood Latch Cover Replacement HatchHandleReplacement
NOTE:Takeca.e not to the hood latchcoverand body. '1.
Removethe hatchtrim panel{seepage20-63).
Removethe hatchhandlebolts,
>: Boltlocations,2
HOOOLATCHCOVER
|
HOOD LATCH 6x1,0mm
9.8N.mtl.Okgf.m,I
7'2tbt':---J)
20-132
Hatch Latch/LockCYlinder
Replacement
4. Note the positionof the ioint on the handlerod (A)'
Prv the handlerod ol the joint using diagonalcut- 1. Removethe hatchtrim panel(seepage20-63)'
t e r s ; t a k e c a r e n o t t o b e n d t h e r o d R e m o v et h e
hatchhandle. 2. Removethe hatchlatchscrews
>: Screw locations,3
6x1,0mm
9.8 N.m 11.0kgf'm,
7.2 tbt f0
HATCH
LATCH
BUSHING
Replace.
Disconnectthe lock rod, the handle rod, the lock
l n s t a l li n t h e r e v e r s eo r d e r o f r e m o v a l ,a n d n o t e cylinder rod. and the connector,then remove the
theseitems: hatchlatch.
Makesure
the handlerod is connectedproperly
Beforeinstallingthe hatchtrim panel,makesure
the hatchopensProPerlY.
LOCKCYLINDER
ROD
''---t
CONNECTOR
HANDLE
ROD
(cont'd)
20-133
Openerand Latch
Hatch Latch/Lock Cylinder Replacement(cont'd)
4. P u l l t h el o c kr o d o u t .
lf necessary,
removethe lockcylinder.
>: Boltlocelion.1
6xr.omm I
9.8 N.m (1.0kq .m, I
,:!!_J
ry*)*,,
\""<,/ .z ,/\
6. I n s t a l li n t h e r e v e r s eo r d e r o f r e m o v a l ,a n d n o t e
theseatems:
. Apply greaseto the hatchlatch.

. Beforeinstallingthe hatchtrim panel,makesure
the hatchopensproperlyand lockssecurely.
20-134
Body ('99 model)
Dashboard
CenterPanelRemovaland
lnstallation 20-136
Bumpers
FrontGrilleRemovaland
lnstallation 20-136
FrontAir SpoilerReplacement ."'.....20-137
Seats
FrontSeatDisassemblY and
ReassemblY 20-138
FrontSeatTorsionBar
Replacement '.'...".'....'... 20-139
Emblems
tnstallation 20-140
'99 Model Changes

Outline of
The centerDanelremovaland installationproceduresare different'
The front grille removaland installationproceduresare different'
The front air spoilerhas beenaddedfor some modelsof 2D'
A height-adjustable driver'sseatwas addedto some models'
Emblemswere addedfor some modelsot 2D'

Dashboard Bumpers
CenterPanelRemovaland FrontGrilleRemovaland
Installation Installation
1. Removethe dashboardcenterlowercover. NOTE:Takecarenot to scratchthe front bumper.
2. Removethe screws,then pull out the centerpanel. Remove the front bumper. Remove the screws. then
slidethe front grilleforwardby detachingthe hooks.
>: Sc.ewlocationi,4 >: Cliplocations
A> , 3 B>,4
r l >: Scrowlocltion3,6
@Y, dbp i
I
UPPER
VENTI(NOB
FRONTBUMPER
Disconnectthe connectorsfrom the heatercontrol

unit and hazardwarningswitch.
NOTE: Make sure the connectorsare connected

propefly.
a&
I
20-136
FrontAir SPoilerRePlacement
CAUTION: Put on glovesto protect your hands'
NOTE:
. An assistantis helpfulwhen removingthe front bumper'
. Takecarenot to scratchthe front bumperand body'
>: Bolt, screw localions
A>,9 B>,4
@l s*i BUMPER
lnstallationis the reverseof the removalprocedure'

FRONTAIR SPOILER
NOTE:
. Make sure the front bumper engagesthe front
bumpersidestiffeneron eachsidesecurely'
adjustthefront bumpersidestiffener
o lf necessary.
to obtainthe Propergap.
20-137
Seats
FrontSeat Disassembly
and Reassembly
CAUTION: When prying with a flat-tip screwdriver,wrap it with protective tape to prevent damage.
NOTE: SEAT-BACK
. Takecarenot to scratchthe seatcoversand body.
. Removethe front seatthroughthe door openlng. HEADREST
Driver's:
SEATCUSHION
PIVOTNUT
I x 1.25mm
22 N.m 12.2kgf,m,
16 tbf.ft)
CENTERCOVER RECLINEADJUSTER
8 x 1.25mm
20 N.m 12.0kgf.m, EUSHING
lil lbtftl LOWERCAP
10x 1.25mm
47 N.m (4.8kgf.m,
3s rbl.ft)
WASHERS
INNERSEAT
TRACK RECLINE
COVER
WASHER WASHER
LOWERCAP
I
8 x 1.25mm
20 N.m (2.0kg,f.m,
14 tbf.fit 8 x 1.25mm
20 N.m {2.0 kgI.rn,
l4 tbf.ft)
i\",-,"
HEIGHTHANDLE
20-13A
FrontSeatTorsionBar
Replacement
Reassemble in the reverseorderof disassembly'and
notetheseitems: NOTE|Takecarenot to tear the seamsor damagethe
seatcovers.
. Makesurethe bushingand pivot washerare installed
properly. 1. Removethe seatcushlon
. To connectthe connectingwire,twist it 90'.
. Replacethe backcoverclipswith new ones 2. Removethe torsionbar from the hookwith a flat tip
then pull out the torsionbar from the
screwdriver,
. To preventwrinkleswhen installingthe seat-back
cover,makesurethe materialis stretchedevenly seatcushionframe Put on glovesto protectyour
overthe pad. h an d s .
TORSION
. Apply multipurposegreaseto the moving portionof SAR
the seattrack.
SEATCUSHIONFNAME
TORSIONBAR SEATCUSHION
FLATTIP SCREWDRIVER
3. lnstall in the reverse order of removal'
20-139
Emblems
Installation
Align the applicationtape with the taillightand body,as shown,then pressthe emblem into place.
Removethe apptication
tape.
NOTE:
o Beforeapplying,cleanthe body surfacewith a spongedampenedin alcohol.
. After cleaning,keepoil, greaseand waterfrom gettingon the surface.
. Whenapplying,makesurethereare no wrinklesin the emblem.
Attschment Point:
VERSIONEMBLEM
DOHCVTECaid€ omblom: Vsrsion emblem:
20-140
Body {'00 model}
SeatBelts
ChildSeatAnchorPlateRemoval/
fnstallation 20-142
Emblem
fnstallation 20-144
Outline of '00 Model Changes

The childseatanchorplateremovaland installationproceduresare different'
An emblemwas addedfor some model of 3D.

Seat Belts
ChildSeatAnchorPlateRemoval/lnstallation
2DllDl
Attachmentpoints are providedfor a rear-seal-mounted child restraintsystem that uses a top tether.The attachment
pointsare locatedon the rearshelf,tust behindthe rearseat-back.
The child seatanchorplatesare installedin the middle and on both sidesof the rearshelf.Eachchild seatanchorplate
is
coveredwith the child seatanchorolatecover.
NOTE:
' Do not removethe toothedwasherfrom the child seat anchor plate, Use the anchor plate
with the toothedwasher
attachedto it.
. When installinga child seaton the rearseat,follow the instructionsof the manufacturer
of the child seat.
. When installingthe anchorplates,the one with the shonerspacergoes in the middle.
. Makesurethe rearseat-backs are lockedfirmly when installinga childseat.
U n i t :m m ( i n . )
ATTACHMENTPOINTS
REARSHELF
CIIILDSEATANCHOR CHILOSEAT
PLATECOVER ANCHOR
PLATECOVER
MIDOLECHILD
SEATANCHOR
PLA
I x 1.25mm
22 N.m 12.2kgl.m,
16 tbt.ftt
8 x 1.25mm
22 N.m 12.2kgl.m,
16 tbf.ft)
17 {0.67)
torward . 15{0.s9)
rl)
WASHER .t
CHILDSEAT
ANCHOR
TOOTHEO PLATECOVER
I x 1,25mm
N.m {2.2 kgf.m. 8 x 1.25mm
ll ff*,".rd,',i"'"o* 16tbtftl 22 N.m 12.2kgl m,

16 tbf ftl
12lO.47l
SIDE SEAT 19 (0.75)
SIDE
ANCHORPLATE
SEATANCHOR
PLATE
TOOTHED
20-142
3D:
a top tether' The attachment
Attachmentpoints are providedfor a rear-seatmounted child restraintsystem that uses
pointsare locatedon the reartrim panel.
panel Eachchild seat anchor
The child seat anchorplatesare rnstalledin the middle and on both sidesof the rear trim
p l a l ei s c o v e r e dw i t ht h e c h i l ds e a t
a n c h o p
r l a t ec o v e r '
NOTE:
plate with the toothedwasher
. Do not removethe toothedwasherfrom the child seat anchorplate. use the anchor
attachedto it.
child seat'
. when installinga child seaton the rearseat,follow the instructionsol the manufacturerof the
. Makesurethe rearseat-backs are lockedfirmly when installinga childseat'
gn;16rn (in.)
ATTACHMENTPOINTS
CHILOSEAT
ANCHORPLATE
;x?',rff{-*.
CHILDSEAT
ANCHOBPLATE
COVER
8 x 1.25mm
22 N..n (2.2 kgl'm.
16 tbfft)
20-143
Emblem
Installation
Applythe emblemwhere shown.
NOTE:
. Beforeapplying,cleanthe body surfacewith a spongedampenedin alcohol.
. Aftercleaning,keepoil, greaseand water from gettingon the surface.
Attachment Point (ReferencG): U n i t :m m ( i n , )
CIVICEMBLEM
SpecialEMBLEM
3D: Specialemblem {for CanadaSoscielEditionl
20-144
Heaterand Air Conditioning
Heater '.'..""" 21'1
Air Conditioning......."'.. "' 22-1
SYSTEM(SRS}
RESTRAINT
SUPPLEMENTAL
models (exceptsome
The civic sRs includesa driver'sairbag locatedin the steeringwheel hub ln addition,all
airbaglocatedin the dashboard above the glove box'
modelsfor canada)havea passenger's (*)
Informationnecessary to safelyservicethe sRS is includedin this serviceManual ltemsmarkedwith an asterisk
or replacingthese
on the contentspage include,or are locatednear, sRs components.servicing,disassembling
will requirespecialprecautionsand tools,and shouldtherefore be done by an authorizedHonda dealer'
items
@ rendsring the SRS inoperative, which could lead to personal iniury or deaih in the svent of a
sev€re
-";;il
frontal collision. all SRSservicework must be pertormed by an authorized Honda d€aler'
personal
. lmploper service procedures, including incorrest removal and instsllation of the sRs, could lead to
iniury causedby unintentional deployment of the airbags'
deploy
o Do not bump the SRS unit. Otherwise. the system may fait in case of a collision. or the airbags may
when the ignition switch is ON {ll}'
in lhe
. sRs electrical wiring harncssesare id€ntified by yellow colol coding. Related components ale located
panel, and in the dashboard above the glove box'
steering column, front console, dashboard,dashboald lowet
Do not use electricaltest equipment on these circuits.

Heater
lllustratedIndex * HeaterUnit
'96 - 98 Models ................................
21'2 Replacement ....'....21-39
'99 - 00 Models ................................
21'3 overhaul """" """' 21-4'l
CircuitDiagram HeaterControl Panel
'96 - 98 Models .....21-4 Repfacement .........21'42
'99 - 00 Models ................................
21-5 Overhaul-'96 - 98 Models ........... 21-43
'96
Troubleshooting- - 98 Models Temperature Control
'96 - 98 Models """" 21-44
21-6
SymptomChart ............................... Adjustment -
'99 - 00 Models .......21-45
HeaterControl PanelInput/ Adiustment-
21-7
OutputSignals..............,.............. Air Mix Control Motor
Flowcharts Test- '99 - 00 Models ...........' .......21'46
BlowerMotor Speed ................... 21-8 - '99 - 00 Models ....21'46
Replacement
Bfower Motor ,...21'10 Mode Control Motol
Mode ControlMotor ...............,.'.'21-13 Test ................, .,...'.21'47
Recirculationcontrol Motor .......21-16 Replacement '.'."...21-47
... 21
HeaterControl Panel ................ -14 RecirculationControl Motor
- '99 - 00 Models
Troubleshooting Test ................. .......21-48
21-19
SymptomChart ............................... Repfacement ......."21-48
Seff-diagnosisFunction............,,,....21-20 Relays
Flowcharts Test ................. .......2'l-49
Air Mix ControlMotor 21-21
......,.......... Heater Fan Switch
Mode ControlMotor ....................21-25 Test- '96 - 98 Models............. .......21-49
RecirculationControl Motor .......21-27 Mode Control Switch
Bfower Motor Speed ...................21'29 Test-'96 - 98 Models..........."....... 21-50
Bfower Motor ....21-31 Power Transistor
HeaterControlPanel................,.. 21-35 Test - '99 - 00 Models ....'........ ....".21-50
HeaterControl PanelInput/
21-36 *: ReadSRSDrecautions
OutputSignals............................. beforeworkingin this area.
Blower Unit
Repfacement .........21-37
Overhaul 21-38
................

lllustratedIndex
'96 - 98 Models
SRScomponentsare locatedin this area.Reviewthe SRScomponentlocations,precautions,

section{24)beforeperformingrepairsor service.
BLOWERUNIT
Overhaul,page21-38
HEATERUNIT
page21-39
Beplacement, BLOWER
page21-41
Overhaul, RESISTOB
Test,
CONTROLMOTOR
Test,page21-48
page21'48
Replacement,
a/c swtTcH
{wirhA/c)
MOO€
MOTOR
Test, page21 47
HEATERFAN
swtTcH
AIR MIX CONTROLCABLE Test,page2l'49
Adjustment,page2'1-44
Replacement,page21'43
MODE HEATERCONTBOL
swrTcHEs PANEL
Test,page 21 50 R g p l a c e m e n t ,p a g e 2 ' l - 4 2
Overhaul,page 21-43
TEMPERATURE CONTROL
LEVER
Adiustment,page21 44
Detroster-aqtivatedA/C System
Turningthe defrosteron activatesthe A,/Cand sets the air flow mode to FRESH.lt is possibleto turn the A,/Coff or to
changethe air flow to RECIRCULATE by pressingthe A/C bunon or the FRESH/RECIRCULATE button.
21-2
'99 - 00 Models
SRScomponentsare locatedin this area,Reviewthe SRScomponentlocations,precautions,
section(24)betoreperfomingrepairsor service.
BLOWEBUNIT RECIRCULATION
Replacement,page21-37 CONTROLMOTOR
Overhaul,page21 38 Test,page21-48
HEATER UNIT page21-48
Beplacement,
O v e r h a upl ,a g e2 1 - 4 1
AIR MIX CONTROLMOTOB POWERTRANSISTOR
Test,page21-46 Test,page21 50
page21 46
Replacement,
BLOWER HIGH RELAY

Test, page 21-49
MODECONTROL
HEATERVALVECABLE DIAL
Adjustment,page21 45 TEMPERATURE CONTROL
DIAL
Adjustment,page21-45
REARWINDOW
DEFOGGER
swtrcH
MODE See section 23
MOTOR
Test, page 21 47
R e p l a c e m e n t ,p a g e 2 l - 4 7
A/C SWTTCH
lwith A/cl
HEATERFAN
swtTcH
CONTROLSWITCH
21-3
CircuitDiagram
'96 - 98 Models
LINDEF
NoODFUSETFELAY
30x
No1l lS0Al Ni42 (40A)

WNTTBLK
+WFT
8L|(YEi
LIGHT
Y
I
crca(.-A-o\
S;rt'| | lieti{,**i'-t
! 9 [ 1 ' ? _ ? _L-:}
_ ? ' ?_[:]
\1 \-r.\
t _ _ ?|_ _h
t
\-r-1 \'\
21-4
'99 - 00 Models
UNDEFDASH
FUSE/RELAY
UNDER,HOOO 8OX IGNTIONSWTCH FUSElRELAY
BOX
**",@
**,',,* ",.@f u,n,",,
ELUAVHT
I
Y
BLOWER
MOTOR
PUSN
SWITCH BLUi
BtK
BLUiBLK
1
ELOWER
MOTOR
HIGH
RELAY
tic
GRY
PNK/BLK
FED''WHT
RED,YEL
BRN
YEL/FEO VENT
lHce
nvosrar
F)- neo
aLu 6RNiYEL
(WirhIVC) MOOE
8LU/!VHT HEAT CONTFOL
MOTOF
YEL - M.COM
YEL/BLU DEF
BRNfiHT
DASH
LIGHTS-/1
BBTGNTNESS
< -! l- FEo GFNM/HT
CONTROLLER
GRNiFED
[[f&H,,4*,",, BLK
O :8PCONNECTOR
! :20PCONNECTOF
PANEL
HEATERCONTROL
E : 12PCONNECToR

Troubleshooting-'96 - 98 Models
SymptomChart
NOTE;
. Checkthe enginecoolantlevel.and allow the engineto warm up beforetroubleshooting.
. Any abnormalitymust be correctedbeforecontinuingthe test.
. Becauseof the precisemeasurements needed.use a multimeterwhen testing.
o Beforeperformingany troubleshooting procedurescheck:
- FusesNo. 41 11.5Al, No. 55 (40A) in the under-hoodfuse/relaybox. and No. 17 (7.5A) in the under-dashfuse/relay
box
- GroundsNo. G401,G402
- Cleanlinessand tightnessof all connectors
Symptom Romedy
Hot air flow is low. Blowermotor runs.but one or more Performthe proceduresin the flowchart (seepage 21-8).
speedsare inoperative.
Blowerruns properly. Checkfor the following:
. Cloggedheaterduct
. Cloggedheateroutlet
. Incorrectdoor position
No hot air flow. Blowermotor does not run at all, Performthe proceduresin the flowchart(seepage21-10).
Blowermotor runs. Checkfor the following:
. Clogged heater duct
. Clogged blower outlet
. Cloggedheatervalve
. Faultvair mix door
. Heatervalvecableadjustment(seepage21-44)
. Air mix control cable adiustment (see page 2'l-441
. Faultycoolingsystemthermostat(seesection10)
. Cloggedevaporator(with air conditioning)
. Frozenevaporator{with air conditioning)
Mode controlmotor does not run, or one or more modes Performthe proceduresin the flowchart (seepage 21-13).
are inooerative.
controldoor does not chanqebetween
Recirculation Performthe procedu.esin the flowchan(seepage21-16).
FRESHand RECIRCULATE.
Both heaterand A,/Cdo not work. Performthe proceduresin the flowchart(seepage21-18),
21-6
HeaterControlPanelInput/OutputSignals
HEATERCONTROLPANELlilP CONNECToR
Wiresideof lemaleterminals
Terminal Wire Terminal Wire

Signal Signal
No. color No. color
1 YEL HEAT/DEF INPUT 8 YEVRED VENT INPUT
BLfiEL INPUT 9 GRNI/EL HEATIr'ENT INPUT
'10 BLK GROUND OUTPUT

WHT/BLU +B INPUT
4 YEUBLU DEF INPUT 11* BLU/RED A./CTHERMOSTAT INPUT

DASHLIGHTS FRESH INPUT
5 RED OUTPUT 12 GRN/WHT
CONTROLLER
BRIGHTNESS
LIGHT
COMBINATION INPUT
6 RED/8LK INPUT 13 GRN/RED RECIRCULATE
SWITCH
1 BLUMHT HEAT INPUT 14 GRN HEATERFAN SWITCH OUTPUT
21-7
-'96 - 98 Models
Troubleshooting
Blower Motor Speed
Blower motor runs. but one or

rnore speedsare inoperative,
Chsck for a short or an open in

the wire{s}:
Turn the ignitionswitch ON {ll),
and the heaterfan switchOFF.
Doesthe blowermotor run? To page21 9
HEATERFAN SWITCH6P CONNECTOR

Checkfor a shon in th6 wirels):
2. Disconnectthe blower motor
2P connector,
3. Removethe center dashboard
lower cover (see section20),
and disconnect the heaterlan
switch6Pconnector,
4. Disconnectthe blower resis
tor 4Pconnector,
t h e N o .2 , 3 , 4 a n d 5 l e r m i n a l s
o f t h e h e a t e rf a n s w i t c h 6 P
connectoa r nd bodyground
individually.
ls there continuity? Reolace the heater fan switch,
Repair short in the wire(s)

beiween the blower resistor,the
heatertan switch and the blower
motor,
21-a
Check the blower resislor:
BLOWERRESISTOR
1. Turn the ignitjon switch OFF.
2. Disconnect the blower resis
tor 4P connector.
3, N4easure the resistance
between the No. 2 and No. 4
terminals of the blower resis-
tor,
ls thereapprox.2 - 3 ohms?
Checkfor an openin the wire(s): HEATERFAN SWITCH6P CONNECTOR

1. Reconnect the blowerresistor
4Pconnector, BLU/WHT
2. Removethe centerdashboard
lower cover (seesection20), BLU/BLK
and disconnect the heaterfan 2
switch6P connector. JUMPER
3. Turnthe ignitionswitchON (ll). 1 6
WIRE
4 . G r o u n de a c ho f t h e s et e r m i - BLU BLU/YEL
nalsindividuallyin the tollow_
ing order:No.4, 2, 5 and 3.
Does the blower motor run at

Reolace the hoater fan switch.
p r o g r e s s i v e l yh i g h e r s p e e d s ?
Repairopen or causeol excessive

r e s i s t a n c ei n t h e a p p r o p r i a t e
wire{sl between the blower resis-
tor and the heater{an switch.
21-9
-'96 - 98 Models
Troubleshooting
BlowerMotor
glower motor does not run at all.
Checkthe No.55(40A)lusein the

under hood fuse/relaybox, and
t h e N o . 1 7 ( 7 . 5A ) l u s e i n t h e
undeFdashluse/relaybox.
Repl.ce th. fuse{rl, .nd rochack.
BLOWERMOTOR2P CONNECTOR
Checkthe blower motor:

1. Connectthe No. 2 terminalof
the blower motor 2P connoc f=
tor to body ground with a l 1 l
lumperwrre.
2. Turnthe ignitionswitchON (ll). r,l
**'I
ruumifalulau
Doesthe blowermotor run? T o p a g e2 1 - 1 1
Wi.e sideof fernaleterminals
Chockfor an opsn in the wire:

1 . D i s c o n n e ctth e , u m p e rw i r e gr-urwnr
and the blowermotor 2P con- Fl
nector, l1|_-_-l
the No. 1 terminal and body t4 ,t
ground.
I
Ch6cktha blower motor relay:

2 . R e m o v et h e b l o w e r m o t o r
relayfrom the under-hood
fuse/relaybox, and test it (see
page21-49).
Replace tha blower moior reley.
fo page21'12
2 1-1 0
Frompage2l 10
Checkfor an open in the wire: HEATERFAN SWITCH5P CONNECTOR

1. Turn the ignitionswitch OFF,
and disconnecthe iLrmPer
2. Removethe center dashboard

and disconnect the heaterfan
switch6P connector.
the No. 3 terminal and body
ground.
WiresideoI femaleterminals
Repairop.n in th6 wiro betw€en

the blower motor and tho heater
fan switch.
Checkfor an open in the wire:

the No. 1 terminalof the heater
tan switch 6P connectorand
bodyground.
Reolacotho heaterfan iwitch
Check tor an op€n in the wire

betw.en the heater tan switch
and body ground. ll th€ wilo b OK,
check tor poor ground at G401and
G102.
(cont'd)
21-11
-'96 - 98 Models
Troubleshooting
BlowerMotor (cont'dl
F r o mp a g e2 1 - 1 0
BLOWERMOTORRELAY'P SOCKET
Checkthe under-hoodfuse/relay 1 2 1 1
DOX:
N/leasure the voltagebetweenthe
t_T
t-l
N o . 3 t e r m i n a lo f t h e b l o w e r t
motor relay 4P socketand body rv)
ground,
i
ls therebafteryvoltage?
Checklor an open in th€ wire:

the No. 4 terminalof the blow-
er motor relay 4P socketand
body ground.
Repairopen in tho wire between

the No. 17 fuss and tho blowel
motor rclay,
Checkfor en opon in the wire:

the No. 2 terminalof the blow-
er motor relay 4P socketand
bodyground.
Check foi an open in the wire

betwe€n the blower motor relav
ls therecontinuity? and body glound. lf the wiro is
OK, check fo. poor ground at
G{01 and G4O2.
R e p a i ro p e n i n t h e B L U / W H T
wire b€tween the blower motor
relav and the blower motor.
21-12
ModeControlMotor
Mode control motor does not run,

or one of more modes are inoPela-
'17(7.5A) fuse in
Checkthe No.
fuse/relaY
the under-dash box.
Reolacethe fuse, and recheck. MODECONTROLMOTOR7P CONNECTOR
'1
Checklor an open in the wire: I 2 I 5 7

1. Disconnectthe mode control
motor7P connector. BLK/YEL
the No. l terminaa l nd body
ground.

ls therebatterYvoltage? the No. 17 tuse and the mode
control motor.
Check {or an open in the wire:

I 3 4 5 6 1
2. Check for continuity between BLK
the No. 7 terminal of the mode
conlrol motor 7P connector []
and body ground.

batwe€n the mode contrcl motol
ls therecontinuity? and body ground.lf the wir€ is OK,
checkfor poor gtound at G/U)land
G402.
Testthe modecontrolmotor (see

page21-471.
Check the mod€ control linkage
and doors:
1. Bemove the mode control
ls the mode control motor OK? motor (seepage 21-47).
2 . C h e c kt h e m o d e c o n t r o l l i n k a g e
and doors for smooth move
T o p a g e2 1 - 1 4
Dothe modecontrollinkage
anddoorsmovesmoothlY?
Reolace the mode control motor,
(cont'd)

-'96 - 98 Models
Troubleshooting
Mode ControlMotor lcont'dl
F r o mp a g e2 l - 1 3
HEATERCONTROLPANELlilP CONNECTOR
Checktor a short in the wi.e(s):

lower cover (seesection20),
and disconnectthe heatercon-
trol panel14Pconnector.
the No. 1, 4, 7, 8 and 9 termi-
nalsand body groundindivid-
Wiresideof lemaieterminals
Raprir.ny short in the wire(s)

betw€en the mode control motor
and the heatercontrol panel.
Checkfor a shon to power:

Checkthe samewires {or voltage.
Repair short to pow6r in the

wiro(3) betwoen the mode con-
lrol motor .nd tha heate. control
ls thereany voltage? prnel, This short also damag.s
tho heater cont.ol prnel. Repail
the short to power b€{ore replac-
ing the heeterconlrol pan6l.
T o p a g e2 1 1 5
2 1- 1 4
F r o mp a g e2 1 - 1 4
HEATERCONTROLPANEL14PCONNECTOR
Checktor an open in the wire{s}:

Checkfor continuitybetweenthe Wire sideof {emaleterminals
followingterminalsof the mode
control motor 7P connectorand
the heatercontrolPanel14Pcon-
nector-
7P: 14P:
N o . 2- N o . 4
N o . 3- N o .1
N o . 4- N o . 7
N o . 5- N o . 9
No.6- No.8
MODECONTROLMOTOR7P CONNECTOR
Repair any opsn in the wirels)

ls therecontinuitY? bctwoan the mode control motor
and the hoator conlrol Panol
Check Io. loo3. wires or Poor

connoctionsat lhe hoat€r control
Danel 14P connactor, and 3t the
mod6 conilol motot 7P connec-
tor. It tho connoctionsara good.
rsDlacothe heat€r coilttol panel.
2 1-1 5
-'96 - 98 Models
Troubleshooting
RecirculationControlMotor
Becirculationcontrol door does

not change between FRESHand
RECIBCULATE.
c h e c kt h e N o - 1 7 ( 7 . 5A ) f u s e i n
the under-dash fuse/relay box.
Reolacethe tuse. and recheck.
RECIRCULATION
CONTROLMOTOR
4P CONNECTOR

1 . 0 i s c o n n e ctth e r e c i r c u l a t i o n
controlmotor4P connector.
2. Tu.nthe ignitionswitchON (ll).
3. Measurethe voltagebetween BLK/YEI-
the No. l terminal and body
ground.
Repairopen in the wir6 between

ls there batteryvoltage? the No. 17Iuseand the recircula- Wiresideof temaleterminals
lion conlrol motor.
Check lhe recirculation control

2. Test the recirculation control
motor {see page 21 48).
Checkthe recirculationcontrol
linkageand door:
1. Removethe recirculation con'
trol motor {seepage21 48}.
2. Checkthe recirculationcontrol
linkageand door for smooth
I o p a g e2 1 1 7
Do the recirculation
controllink Reoairthe r€circulationcontrol
age and door move smoothly? linkageor door.
2 1-1 6
F r o mp a g e2 1 - 1 6 HEATERCONTROLPANEL14PCONNECTOR
5
I ;-? 4
Check{or a short in the wire(s): 7 8 9 'olx 11 1 2 13 14

1. Removethe centerdashboard GRN/WHT GRN/BED
and disconnect the heatercon_ 0) (0
trol panel14Pconnector'
t h e N o . 1 2 a n d N o . 1 3t e r m i -
nalsand body groundindivid-
Repair5hort in the wire{sl between

the recirculationcontrolmotor and
the heatercontrolPanel
1 5
I 2 3
i--? 6
CheckIor a short to Power:

7 8 I 'olx 11 12 13 14
Checkthe samewiresfor voltage GRN/WHT GRN/RED
V)(v
Repair short to Power in the

wire {s) between the recirculation
control motor and the heater
control panel. This short also
ls there any voltage? damages the heater control
panel. Repair the short to Power
betore replacing the heater con-
trol panel. 1 4 5
Check lor an open in the wire(s): 7 I I rol\l rr 12 1 3
following terminals of the recircu GRN/RED
lation control motor 4P connector
and the heater control Panel 14P
4P. 14P:
N o . 2- N o .1 2
No.4 N o .1 3
GRN/WHT
r zl/lt
Repair open in the wirelsl
between the recirculation control
ls there continuitY? motor and the heater control
CONTROLMOTOR
RECIRCULATION
panel.
4P CONNECTOR
Wire sideof femaletetminals

Check for loose wires or Poor
connections at the heater control
Danel 14P connector, and at the
recirculation control motor 4P
connector. lf the connections are
good, replace the heater control
Danel,
21-17
-'96 - 98 Models
Troubleshooting
HeaterControlPanel
Both heater and A/C do not work.
Checkthe No. 17{7.5A) fusein the

underdashfuse/relaybox, and the
No. 47 (7.5A) fuse in the under
hoodfuse/relaybox.
R.phce the fuso{s),.nd rccheck.

HEATER
CONTROL
PANEL1,lPCONNECTOR
Chacktor an open in the wi.e:

a n d d i s c o n n e c tt h e h e a t e r
controlpanel14Pconnector.
2. Torn the ignitionswitchON {ll).
the No. 2 terminal of the
heatercontrolpanel 14Pcon-
nectorand bodyground. Wiresideof femaleterminals
Rcpair opGnin th€ wiro betwoon

ls there bafteryvoltage? the No. 17 tuse and the hoatcl
control panel.
Checkfor an opon in the wiro:

2. Measurethe voitage between
t h e N o . 3 t e r m i n a lo f t h e
heatercontrolpanel 14Pcon-
nectorand body ground.
Rgprii open in th6 wira b€twacn

ls there batteryvoltage? the No. il7 tui. and the heat.t
cont.ol p.nal.
Checkfoi an open in the wi.e:

No. 10terminalot the heatercon-
t r o l p a n e l 1 4 Pc o n n e c t o a
r nd
body ground.
Check lor an opon in tho wire

b€{w6on the hoator control oanel
and body ground. lI the wirc is
OK, check tor poor ground at
G401.nd G4O2.
Check for looae wiaos or oool

connectionsat the hoater control
panol 14P connector. lf the con-
nactions dre good. 3ubstitute t
known-9ood heater control
panel, and rech6ck.It tho symp-
tom/indication 9oe3 .wry,
replacethe original heatel con-
trol oanol.
21- 1 8
Symptom Chart
function (see next
system,refer to self-diagnosis
For electricalmalfunctionswhich are indicatedby the self-diagnostic
page).
Notetheseitemsbeforetroubleshooting a symptom'
. Checkthe enginecoolantlevel,and allow the engineto warm up beforetroubleshooting'
. Any abnormalitymust be correctedbeforecontinuingthe test
.Becauseoftheprec|semeasurementsneeded,UseadigitaImu|timeterwithanoutputoflmAor|essatthe20k
rangewhen testing
. Beforeperformingany troubleshooting procedurescheck:
fuse/relav
- FusesNo. 41 115 Al,No 55 (40 A)]n the under-hoodfuse/relaybox' and No 17 (7 5 A) in the under-dash
box
- GroundsNo. G401,G402
- and tightnessof all connectors
Cleanliness
Symptom See pags

a1_tq
Mode controlmotor does not run, or one or more modesare inoperat've'
21-21
controldoor doesnot changebetweenFreshand Recirculate'
Recirculation
any other speedpositions 21-29
Blowermotor only runson high speedposition;it does not run in
21-31
Blowermotor does not run at all.
2 13 5
Both heaterand Ay'Cdo not work
21-19
Self-diagnosis
Function
The heatercontrolpanelhasa self-diagnosis
function.
Runningthe Self-diagnosis Funqtion

Set the mode controldial to the Vent position,and turn the ignitionswitchON fll).Withinsix seconds
afterturnangthe igni_
tion switchon. pressthe recirculation controlswitchthe requirednumberof times dependingon the recirculation indicator
lightstatus:
.lftheindicatorlightisON,presstherecirculationcontrolswitchfivetrmes.
. l f t h e i n d i c a t o r l i g h t i s O F F , p r e s s t h e r e c i r c u l a t i o n c osnwt irtoclhs i xr r m e s .
The recirculation indicatorlight will come on for two seconds.then blinkthe DiagnosticTroublecode
{DTc}to indicatea
faultycomponent.lf no DTc'sarefound,the indicatorlightwill not blinkafterthe initialtwo second
liqht.
DTCIndicationPattern(S6eDTC2l:
Recirculation
indicato.
light on
Recirculation
indicator
light off 2 sec ' 0,3sec
W i t h i n s i x s e c o n d sa t t e r t h e ,/ t
ignition switch is turned ON (lll, 1.5soc 0.3 sec
pross the recirculationcontrol
switch the required number ot VENTPOSITION
MODECONTROLDIAL
times dependingon the rocircu-
lation indicetor light status
@
At
RECIRCULATION
CONTROLSWTCH
V'
DTCTroubleshootingIndex
Diagnostic
Rgcirculation
trouble Component with problem Possible cause
indicator light See page
code (DTCI
O n eb l i n k Air mix control motor Obstructeddoor, laulty motor 21-21

2 Two blinks Air mix control motor Openor shortcircuit 21-23
ln caseof multipleproblems,the recirculation

indicatorlight will indicateonly one DTc with the leastnumberof blinks.
Resettingthe Self-diagnosisFunction
Turningthe ignitionswitchOFFwill cancelthe self-diagnosis
function,Aftercompletingrepairwork, run the setfdiagnosis
functionagainto makesurethat thereare no other malfunctions.
21-20
Air Mix GontrolMotor
door and
indicatorlight indicatesDiagnosticTroublecode (DTC)1l A problemin the air mix controllinkage,
Recirculation
motor.
heatercontrolpanel'
The air mix controlmotor regulatesthe mixtureof cool/hotair accordingto outputsfrom the
Self-diagnosiscircuit check indi'

cates a Problem in the air mix
conlrol motor circuit,
Checkth6 aii mix conirol motor:

1. Disconnect the air mix control
motor 5Pconnector.
2. Testthe air mix controlmotor
(seepage21-46).
check the air mix control linkage

and doors:
1 . R e m o v et h e a i r m i x c o n t r o l
ls the air mix controlmotorOK? motor (seePage21-46)
2. Checkthe air mix controllink-
age and doors lor smooth
movement.
Do the air mix control linkageand

doors move smoolhlY?
R€olacethe air mix control motor'
HEATERCONTROLPANEL2OPCONNECTOR
RED/WHT
RED/YEL
Check tor a short in the wiles:

1. Disconnectthe heater control
panel 20Pconnector-
2. Check for continuitY between
body ground and the heater
control panel 20P connector
t e r m i n a l sN o . 3 a n d 4 i n d i v i d '
uaIY.
Ropairany short in th€ wire{s}

betweon the heatercontrol Panel
and the air mix control motor'
(cont'd)
fo page21-22
21-21
Troubleshooting-'gg - 00 Models
Air Mix ControlMotor (cont'dl
F r c mp a g e 2 1 - 2 1
Checkfo..n open in the wires:

Checkfor continuity betweenlol-
l o w i n g t e r m i n a l so f t h e h e a t e r
controlpanel20P connectorand
the air mix controlmotor 5P con-
20P: 5P:
No3 _ N o .1
No.4 - No.5
AIRMIX CONTROL MOTOR

5PCONNECTOR
Wiresideot femaleterminals
Repairany open in the wiro(s)

bdtwoon tha hoator control panal
and air mix control motor.
Check for loo3e wires or poor

conneclionsat the heater control
panol 20P connoctor and at the
air mix control motor 5P connoc-
to.. It the connections.rc good,
substitute a known-good hoaier
control panel, and rech6ck.lf the
symptom/indicrtion goes away,
replac6 the original heater con-
trol panel.
21-22
RecirculationindicatorIightindicatesDiagnosticTroublecode(DTc)2:AprobIemintheairmixcontro|motorcircuit
from the heatercontrolpanel'
The air mix controlmotor regutatesthe mi)dureof cool/hotair accordingto outputs
Self-diagnosiscircuit check indi-

crl6s a problgm in tho air mix
contiol motor circuit.
Checkth6 rir mix control motor:

1. Disconnect the air mix control
motor5P connector'
2. Testthe air mix controlmotor
(seepage21-46).
Checkthe air mix control linkage

and doors:
1 . R e m o v et h e a i r m i x c o n t r o l
ls the air mix controlmotor OK? motor(seepage21'46).
2. Checkthe air mix controllink-
age and doors for smooth
Do the air mix controllinkageand

doorsmovesmoothlY?
Roglacethe air mix conlrol motor.
BEO/WHT
REO/YEL
Checkfor r short in the wiresl

1. Disconnect the heatercontrol
panel20Pconnector.
2. Checkfor continuitybetween PNK/BLK
body ground and the heater
control panel 20P connector
s o . 3 , 4 . 1 2 , 1 5a ^ d
t e r m i n a fN
20 individually
Bep.ir any short in the wire{s)

ls therecontinuity? between the h€rter control panel
and th6 air mix control motor.
(cont'd)
Io page 21-24
21-23
-'99 - 00 Models
Troubleshooting
Air Mix ControlMotor (cont'dl
Frompage21-23 HEATERCONTROLPANEL2OPCONNECTOR
Checktor a short to power:

C h e c kt h e s a m et e r m i n a l sf o r
voltage.
Rapair short to pow6r in the

wirelsl botween the heater con-
trol panel and the ai. mix control
ls there any voltage? molor. This short also damag.s
the heater control panel. Ropair
the short to power betoro replac-
ing the heater control panel.
Checkfor an open in the wire3:

Checkfor continuitybetweenfol
l o w i n g t e r m i n a l so f t h e h e a t e r
controlpanel20Pconnectorand
the air maxcontrolmotor 5P con
nector.
20Pt 5P:
No3 _ N o .1
No 4 _ N o .5
N o _1 2 - N o .2
N o .1 5 - No.4
No 20 - No.3
AIR MIX CONTROLMOTOR
5P CONNECTOR
Bepair any open in the wire(s) Wire sideof lemaleterminals
between the heator control panel
and air mix control motor,
Check tor loose wires or poor

connectionsat the heator control
oanel 20P connector and at th.
air mix control motor 5P connec-
tor, ll the connectionsrre good,
substitute a known-good heater
control oanel. and recheck.lf the
symptom/indication goes awry,
replacethe original heater con-
trol oanel,
21-24
Mode control motor does not run.
or one or more modesarc inope]a-
tive.
C h e c kt h e N o . 1 7 ( 7 . 5A ) f u s e i n
the under-dash fuse/relay box.
Replace the Iuse. and recheck.
MODECONTROLMOTOR7P CONNECTOR
1. Disconnectthe mode control
motor7P connector, t 2 3 1 5
2. Turnthe ignitionswitchON (ll)-
3. MeasLrre the voltagebetween BLK/YEL
mode control motor 7P con
nectorand body ground
ls therebatteryvoltage? the No. 17 luse and lhe mode
control motor.
Check the mode control motor:

1- Turn the ignition switch OFF
2, Test the mode control motor
(see page 21 47).
Checklhe mode control linkage
and doors:
1 . R e m o v et h e m o d e c o n t r o l
ls the modecontrolmotor OK? motor (seepage21 47).
2. Checkthe modecontrollinkage
and doors for smooth move
Do the mode control linkage

and doors move smoothlY?
ReDlace the mode control motor'

HEATERCONIROLPANEL2OPCONNECTOR
Check for a short to Power in the

wires:
1. Iurn the,gnitjon switch ON
(ll).
2, Disconnectthe heater control
panel20P connector.
3. Check for voltage between
the No. 2, 5, 6, 7, I and 9 ter'
minals of the heatercontrol
panel 20P connector and Wire side of female terminals
body ground individuallY.
Repair shorl to power in the
wire{sl between the heater con-
trol oanel and the mode control (cont'd)
ls lhere any voltage? motor. This short also damages
the heater control Pan6l. RePair
NO the short to power before replac'
ing the heater control Panel
Io page 21 26 21-25
Troubleshooting-'gg - 00 Models
ModeGontrolMotor (cont'dl
Frompage21-25
Chocktor a short to ground:

2. Checkthe sameterminalsfor
continuityto bodyground.
Repairany 3hort in the wirelsl

ls therecontinuity? between the heater control panel
and ihe mode control motor.
Checklor.n open in tho wires:

1, Disconnectthe mode control
motor7P connector.
the followingterminalsof the
heatercontrolpanel20Pcon
nectorand the mode control
motor 7Pconnector.
2OP: lPi
N o . 2- N o . 7
No.5- No.2
No.6- No.6
N o . 7- N o . 5
No.8- No.4
No.I- No.3
MODECONTROLMOTOR?P CONNECTOR
Wiresadeof lemaleterminals
Repair any opon in the wire(s)

ls therecontinuity? t€tween the h€ater control panel
and tha modc contol motor.
Check for loose wiaes or ooor

connectionsat the heater control
panel 20P connector rnd at the
mode control motor 7P connec-
toa, lf the connoctionsere good,
substitute a known-good heater
control panol, and recheck.lf the
syfiptom/indication goes away,
replac€the original hoatercontrol
panel.
21-26
Recirculation control door does
not chango betwe€n Fresh and
Recirculate.
Checkthe No. l7 (7.5A) fuseanthe

underdashfuse/relaybox.
Replace the fuse, and recheck.
RECIRCULATIONCONTROLMOTOR
CONTRC
,lP CONNECTOR
Checklor an oPenin the wite:

q-?
--T--T--T-|
1 . D i s c o n n e ct th e r e c i r c u l a t i o n 1l2l/l1l
controlmotor 4Pconnector.
2. Turnthe ignitionswitchON (ll) f( v )BLK/YEt
the No. 1 terminalof the recir !
culation control motor 4P
connectorand body ground.
sideof temaleterminals
ls there batteryvoltage? the No. 17 luse and lhe recircula-
tion control motor.
Check the rccirculationcontrol

motorr
'] Turn the ignitionswitchOFF.
2. Test the recirculationcontrol
motor (seePage21 48i
Check the recirculationcontrol
linkageand door:
1. Removethe recirculation con_
trol motorlseePage2l 48).
2. Checkthe recirculationcontrol
linkageand door for smooth
movement.
page
controllink_
Do the recirculation Reoairthe recirculationconlrol
age and door movesmoothlY? linkag€ or door.
(cont'd)

ControlMotor (cont'd)
Recirculation
Frcm page21-27
HEATERCONTROLPANEL8P CONNECTOR
Checkfor a short to power in the

panel8P connector.
3. Checkfor voltagebetweenthe
No.2 andNo.3 terminals ofthe
heatercontrol panel 8P con,
nectorand body ground indi
vidually.
R e p a i r3 h o r t t o p o w e . i n t h e
wire{a) b.tween tho haetor con-
trol paneland the recirculation
ls thereany voltage? Gontrol moto.. This short also
damagosthe heate. control
panel. Repairthe short to power
b€tore .eplecing the h€ater con-
trol panel.
Checkto. a short to ground:
2- Checkthe sameterminalsfor
continuityto ground.
Roprir lhon in tho wir.{s) b€tweo

the horter control panel and the
racircr alion conhol motoa.
Checkfor an open in the wires:

1 . D i s c o n n e ct th e r e c i r c u l a t i o n
control motor 4P connector.
the followingterminalsof the GRN/WHT
recirculation controlmotor 4P GRN/RED
connectorand the heatercon,
trol panel8P connector.
8P: 4Pi
N o . 2- N o . 2
N o . 3- N o . 4
Repairopen in ths wirolsl betw€€n

the heate. co.rkol panol and the I 1
recirculationcontrol motor .
RECIRCULATION CONTROLMOTOR
Check lor loo3a wires or poot 4P CONNECTOR
conn€ctionsat the hoatercontrol Wiresideof femaleterminals
panel 8P connector and at the
aecirculationcontrol motor ilP
connector,It tho connectionsare
good. substitut€ e known-good
heateicontrol panel,and aecheck.
lf th€ symptom/indication goes
away, replacethe original hedter
contrclDanel.
21-28
BIowerMotor Speed
Blower motor only runs on high N O T E :l f t h e b l o w e rm o t o r d o e s n o t

speed position; it does not run in run at all, referto page21-31.
any other speedPositions
POWEBTRANSISTOR
3P CONNECTOR
Checkfor an open in lhe wire:

1. Disconnect the powertransis 3
tor 3P connector, BLK
t h e N o . 3 t e r m i n a lo f t h e o
powertransistor3P connector
and body ground.
Check tor an open in the wire Wire sideol femaleterminals

between the Power ttansistor
l s t h e r ec o n t i n u i t y ? and body gtound. lf the wire is
O K , c h e c kf o r p o o r g r o u n d a t
G401and G402.
JUMPER
Check tor an open in the wire: WIRE
1 . C o n n e c tt h e N o . 1 a n d N o 3
terminals of the Power tran_
s i s t o r 3 P c o n n e c t o rw l t h a
jumperwire.
2 . T u r n t h e i g n i t i o ns w i t c h O N { l l )
Repair open in the wire belween

the blower motor and the Powet
tranststor.
Check tor an open in the wire:
1. Turn the ignition switch OFF LT GRN/8LK
2 . D i s c o n n e c tt h e i u m P e r w i r e .
3. Disconnectthe heater control
panel 20Pconnector.
the No. 1 terminal of the
heater control panel 20P con-
nector and the No. 2 terminal
of the Power transistor 3P
Repair open in the wire between

ls there continurty) the heater control Panel and tho
oower transistor,
To page 21 30
(cont'd)
21-29
BlowerMotor Speed(cont'dl
Frcm page21.29
Checktor a short in the wi.a:

No. 1 terminalof the heatercon
trol panel20Pconnector and body LT GRN/BLK
ground.
Wire sideoJfemaleterminals
Repairshort in ths wire betwsen

the hoater control panel and the
oower transastoa.

panel8P connector,
2. Turnthe ignjtionswitchON 1ll).
t h e N o . ' l t e r m i n a lo f t h e
heatercontrol panel 8P con HEATERCONTNOLPANEL8P CONNECTOR

Repeiropen in the wiio between
the heater control panel and the
blower motoa.
Checkthe power transistor:

2. Reconnectthe heatercontrol
panel8P and 20Pconnectors.
3. Test the power transistor {see
page21 50).
ls the powertransistorOK?
Checkfor loos€ wiras or poor con-

nections at the h€at€r control
panel 8P and 20P connectolsand
at th6 power transistor 3P conn€c-
tor. lf the connectionsare good,
substituto a known-good hoater
control panel, and recheck.It the
symptom/indication goes away,
replacethe originalheater control
oanel,
21-30
BlowerMotor
Blower motor does not run at all.
Checkthe No. 55 (40 A) Iuse in

the under-hoodfuse/relaybox,
and the No. 17 (7.5A){use in the
undeFdash fuse/relay box.
Boplaceth€ fuse(3),and rechock.
MOTOR2PCONNECTOR
BLOWER
Check th€ blow€r motor Powel
supply circuit:
1. Disconnectthe blower motor
2P connector.
3, Measurethe voltage between
the No. 1 terminaloI the blow
e r m o t o r 2 P c o n n e c t o ra n d
bodyground.
ls there batteryvoltage? fo page 21-32
Checktha blower motor:

2. Reconnectthe blower motor
2P connector.
3. Connectthe No.2 terminalo{
the blower motor 2P connec JUMPER
t o r t o b o d v g r o u n dw i t h a WIRE
tumperwire.
4. Turnthe ignitionswitchON {ll}
Doesthe blowermotor run?
To page21-33
(cont'd)
21-31
Frompage21-31
Checkthe blower motor relay:

relayfrom the under hood
fuse/relaybox, and test it- (see
page21'49).
Replace the blower motor relay.

BLOWERMOTORRELAY4P SOCKET
Check the under-hoodtuse/relay

box:
N o . 3 t e r m i n a lo f t h e b l o w e r
motor relay 4P socketand body
ground.
Checktor an open in the wire:

blower motor relay 4P socket
and bodyground.
Repairopon in lhe wire between

ls therebatteryvoltage? the No. 17 fuse and the blowet

blower motor relay 4P socket
and body ground.
Check lor an ooen in the wire

between the blowor motor relay
ls there continuityl and body ground. It the wiie is
G401and G402.
R e p a i ro p e n i n t h e B L U / W H T
wiae between the blower motor
relay and the blower motor,
21-32
Frompage21 31
C h e c kt h e b l o w e r m o t o r h i g h
relay:
1. Turn the ignitionswitchOFF,
and disconnecthe iumPer
h i g h r e l a y ,a n d t e s t i t . { s e e
page21 49).
BLOWERMOTORHIGHRELAY4P CONNECTOR
Check lor an open in the wire:

1. Connect the No. 1 terminal of
the blower motor high relay JUMPER
4P connector to body ground WIRE
with a jumPer wire.
2 . T u r n t h e i g n i t i o ns w i t c h O N ( l l ) .
Repairopen in the wire belween
Doesthe blowermotor run? the blower motor and the blower
motor high rolay.
Checkfor an op6n in the wir6:

a n d d i s c o n n e ct th e i u m P e r

b l o w e r m o t o r h i g h r e l a y4 P

ls there batteryvoltage? the No. 17 fuse and the blowor
motor high relay.

1. Turnthe ignitaon switchOFF.
t h e N o . 3 t e r m i n a ol f t h e
b l o w e r m o t o r h i g h r e l a y4 P
Ch6ck lor an op.n in the wire

botween the blower motor high
ls there continuity? relay and body ground. ll the wire
is OK, ch6ck for poot ground at
YES G401 end G402.
(cont'd)
To page 21 34
21-33
-'99 - 00 Models
Troubleshooting
BlowerMotor {cont'dl
Frompage21-33
BLOWERMOTORHIGHRELAY4P CONNECTOR
Checktor an opgn in the wiro:
panel8P connector. BLU/BLK
2
2. Checklor continuitybetween 3 4
heatercontrol panel 8P con- o
nectorand the No. 1 terminal
ot the blower motor high BLU/ALK
relay4P connector.
t 2
a 5 6 8
Repsi. op€n in the wir. betw.en HEATEROONTROLPANEL8P CONNECTOR

the h..t.r contrcl p.ncl .nd tho wir€ sido ot f€male torminals
blowar motor high rahy.
Ch€ckfor an opon in the wir6:

panel20Pconnector.
t h e N o . 1 3 t e r m i n a lo f t h e HEATERCONTROLPANCL2OPCONNECTOR
heatercontrolpanel20Pcon- Wire sideof femaleterminals
nectorand the No. 4 terminal
of the blower motor high
relay4P connector. I 2 3 a 5 0 7 8 I 10
11 12 13 15 ,/1,/1,/m
ORN/WHT
o
Ropairopon in tho wiro botwoon
tha hartor cor rol pangl rnd tha 1 2
blower motor high .elay. 3 4
OBN/WHT
Ch.ck for looso wiros or poor

conn€dions at th6 heato. control
panel 8P and 20PconnectoB and
at the blowol motor high relty
4P connoctor. It tho connoctions
are good, substitute a known-
good heatcr control panel, and
recheck. It the symptom/indica-
tion goos away, rgplacothe oiigi-
nal heatercontrol oanol.
21-34
Both heater and A/C do nol work.
checktheNo.47(7.5A)fusein the
under-hoodfuse/relaybox, and the
N o . 1 7 { 7 . 5A ) f u s ei n t h e u n d e r -
dashfuse/relaybox.
ReDlacethe tuse{s),and recheck.

HEATERCONTROLPANEL8P CONNECTOR
Check lor an open in the wire:

1. Disconnectthe heater control 1
panel 8P connector,
2 . T u r n t h e i g n i t i o ns w i t c h O N ( l l ) . 4 I
3. Measure the voltage between
the No. I terminal of the BLK/YEL
heatercontrol panel 8P con-
nector and body ground. v
Repairopen in the wire between Wire side of female terminals
ls there batteryvoltage? the No. '17luse and th6 heater
control oanel,
HEATER CONTROL PANEL 2OP CONNECTOR

panel20Pconnector.
3. Measurethe voltagelletween
t h e N o . 1 0 t e r m i n a lo f t h e
heatercontrolPanel20Pcon-
Repairop6n in the wir€ between

ls therebatteryvoltage? the No. il7 tuse and the heater Wire sideof temaleterminals
controloanel,
Check for an open in the wite: I 2

1 5 7 8
No. 6 terminal of the heater con
trol panel 8P connector and body BLK
ground.
Ch6ck tor an open in lhe wire o

betwoen the heator control Panel
ls there continuity? and bodv ground. lf the wire is
G401and G402.
Check for looso wires or Pool

conneciions at the heater control
oanel 8P and 20P connectors. lf
the connections are good, substi'
tute a known-good heat€r con-
trol Danel, and recheck. lI the
symptom/indication goes awaY,
r6place the original h€ater con-
troloanel.

-'99 - 00 Models
Troubleshooting
HeaterControlPanelInput/OutputSignals
HEATERCONTROLPANELCONNECTORS
8P CONNECTOR 2OPCONNECTOR 12PCONNECTOR
8P CONNECTOR(O qn Circuit Diagram)
Cavity Wire color Signal Cavily Whe color Signal

DASHLIGHTSBRIGHTNESS
BLU/8LK BLOWER
FEEDBACK INPUT 5 RED OUTPUT
CONTROLLER
2 GRN/lVHT FRESH INPUT 6 BLK GBOUND OUTPUT
REARWINDOWDEFOGGER
3 GRN/RED RECIRCULATE INPUT 7 BLU/YEL RELAY
OUTPUT
COMBINATION LIGHTSWITCH
4 RED/BLK (ViaNo.30 (7.5A) fuse) INPUT 8 8LfiEL lG2{Power) INPUT
20PCONNECTOR{D on circuit Diagram}
Cavity Wire color Signal Cavity Wirecolor Signal

LT 't1
POWERTRANSISTOR
EASE OUTPUT BLU/RED Ay'CTHERMOSTAT INPUT
GRN/BLK
MODECONTROL
MOTOR AIR MIX CONTROLMOTOR
2 BRNMHT INPUT 12 BRN INPUT
GROUND GROUND
BLOWER MOTORHIGH
3 RED/YEL AIR MIX HOT OUTPUT 13 ORNAA/HT INPUT
RELAY
RED,ryvHI AIR MIX COOL OUTPUT 14
5 YEUBLU MODEDEF INPUT PNK,/BLK AIR MIX POTENTIAL OUTPUT
6 YEURED MODEVENT INPUT 16
7 GRNI/EL MODEHEAT/r'ENT INPUT 11
I BLUAVHT MODEHEAT INPUT 18
9 YEL MODEHEAT/DEF INPUT 19
10 WHT/BLU +B (Power) INPUT 20 GRY AIRMIX POTENTIAL
+5 V OUTPUT
*: with Ay'c
(tr on CircuitDiagraml
12PCONNECTOR
Cavity Wilecolor Signal Cavity Wi.e colol Signal

l SWITCHLEDCOMMON OUTPUT 1 SWITCHLIGHTS+ OUTPUT
2 I SWITCHLIGHTS- INPUT
3 9 SWITCHCOMMON INPUT
RECIRCULATION
CONTROL
4 INPUT 10 A,/CSWITCH OUTPUT
SWITCHLED
RECIRCULATION
CONTROL
5 A./CSWITCHLED INPUT 11 OUTPUT
SWITCH
REARWINDOWDEFOGGER REARWINDOWDEFOGGEB
6 INPUT 12 OUTPUT
SWITCHLED SWITCH
21-36
Blower Unit
Replacement
NOTE:The blowermotor,recirculation controlmotor Wrth Air Conditioning
and blower resistorcan bs replacsdwithout rsmoving 4-b. Removoth6 ev8porator(sss pago 22-28).
th€ blowerunit (seeneldPage).
controlto "HOT."
6x1.0m|n
1. Movethetemperature 9.8 N'm
'96-98:Slidethetemperature controllever.
'99-00:Turnthe ignitionswitchON (ll),thenturn
the temperaturecontolknob. Turnthe ignition
switchoff,
Removethe glovs box (ses ssction 20),
R€moveths s6lf-tappingscrew and ths passsng6r's

dashboardlow€r cover. Removothe bolt, the nut
and the kn€ebolst€r,then removethe fiv€ boltsand
the glove box trame,
KNEE
6x1.0mm
9.8 N'm lt'o tgf'm, t.2 lb{'ttl
Disconnoctthe connectorstrom th€ blower motor,

blowor r6sistor {'96 - 98 models), power transiator
('99 - 0Omodsls), blowor motor high telay ('99 - 00
models) and recirculationcontrol motor.
R€mov€ths wiro harnossclip from tho recirculation
control motor, and releasethe wir6 harnsssfrom ths
clamo on the blowor unit. Remove the two mount-
ing bolts,tho mounting nut and ths blowor unit'
6x1.0mm
GLOVEBOXFRAME 9,t N'm 11.0lgi.m,
7.2 tbf.fil
Without Air Condhioning

4-a. Removethe wiro harnessfrom the h68t€rduct, then
remove the two self-tapping scrsws and the heatsr
duct.
9.8 .m 11.0tgfm,
1.2tblfrl
lnstall in ths reverso order of removal. Mako surs
HEATERDUCT that thsre is no air leaka96.
21-37
BlowerUnit
Overhaul
NOTE:
controldoor and linkagemove smoothlywithout binding.
makesurethat the recirculation
a Beforereassembly.
When attachingthe recirculation controlmotor, make sure its positioningwill not allow the recirculation
controldoor
to be pulledtoo far.
control motor,connectpower and ground,and watch the movementof the recircula-
After aftachingthe recirculation
tion controldoor.
RECIRCULATION
CONTROLMOTOR
Test,page21-48
BLOWER {'96 - 98 modebl

Test,page 2'l 9
POWERTRANSISTOR l'99 - 00 modebl
Test,page21-50
MOTOR
Test,page21'10('96 98 models)or
page21'31('99 00 models)
2134
HeaterUnit
Replacement
SRS componentsare located in this area. Reviewthe 4. the heaterhosesfrom the heaterunit.
Disconnect
SRScomponentlocations,precautions,and procedures
in the SRSsection{24}beforeperformingrepairsor ser- CAUTION:Enginecoolant will damagep8int.
Ouickly rinse any spilledengins coolant from painted
su aces,
L the negativecablefrom the battery.
Disconnect
NOTE:Enginecoolantwill run out when the hoses
2. Frcm underthe hood,open the clamp,then discon- drain it into a cleandrip pan.
are disconnected;
nect the heatervalve cable from the heater valve
arm. Turn the heatervalve arm to the fully opened
positionas shown.
CLAMP
HEATERVALVCCABLE
When the engine is cool. drain the engine coolant 5. Removethe mountingnut from the heaterunit.
from the radiator(seesection10).
NOTE:When removingthe mountingnut, takecare
Do not remove the radiator cap when n o t t o d a m a g eo r b e n d t h e f u e l l i n e s ,t h e b r a k e
!@
the engine is hot; the ongine coolant is under pres' lines,etc.
surg and could severelyscald you.
I x 1.25 mm
22 N.m {2.2kgl.m, 16lblftl
21-39
HeaterUnit
(cont'dl
Replacement
6. Removethe dashboard(seesection20).
7. Removethe heaterduct (seepage 21-37)or evapo-

rator (seepage 22-28).
8. Disconnectthe connectorsfrom the mode control

motor and air mix control motor ('99 - 00 models),
then remove the wire harnessclips and wire har-
nessfrom the heaterunit. Removethe clip from the
heater duct, then remove the two mounting nuts
and the heaterunit.
6x1.0mm
9.8N.m11.0kgl.m,7.2lbf.ftl
HEATER
UNIT
9. lnstallin the reverseorderof removal.Makenote of

the followingitems.
Apply sealantto the grommets.

Do not interchangethe inlet and outlet heater
hoses.Makesurethat the clampsare secure.
R e f i l lt h e c o o l i n g s y s t e mw i t h e n g i n ec o o l a n t
(seesection10).
Connectall cables,and makesure they are prop-
erly adjusted(see page 21-44(96 - 98 models)
or page21-45('99- 00 models)).
Makesurethat there is no air leakage.
21-40
Overhaul
'1. Removethe two self-tappingscrewsand the heater Pullout the heatercorefrom the heaterunit.
corecover.
NOTE: Be careful not to bend the inlet and outlet
2. Pullout the grommetfrom the heatercore pipes. pipesduring heatercore removal.
3. Removethe self-tappingscrewand the clamp. Assemblein the reverseorderof disassembly.
HEATERCORECOVER
GROMMET
21-41
HeaterControlPanel
Replacement
'95 - 98 modolsi '9!,- 00 modols:
1 . Remove the driver's dashboard lower cover, the 1 . Removethe center panel together with the heater
glove box and the center dashboardlower cover control panel (seesection 20).
(seesection 20).
Disconnect the air mix controlcablsfrom the heater Removethe self-tappingscrews and the heatercon-
unit {seepage21-44). trol panelfromthe centerDanel.
Removethe rearwindow defoggerswitch,the hazard
warning switch and the audio unit (seesection23).
Disconnectthe connectorsfrom the heatercontrol
panel.Removethe five self-tappingscrewsand the
centerpaneltogetherwith the heatercontrolpanel.
NOTE: The lockingtabs are on the bottom of the

connecrors.
Removethe four self-tappingscrews and the heater
Install in the reverseorder of removal.After installa-

tion, operatethe heatercontrol panel to see
whether it works properly.
Install in the .everseorder of removal.Adjust the air

mix control cable and the heatervalve cable {see
page 21-44)..
21-42
Overhaul-'96 - 98 Models
HEATERFAN SWITCH
Test,page21-49
Air Mix Control CableReplacomenl
1. Cutthe innercableon the leversideof the cableholder,then removeboth piecesof the innercable.
2. Usinga sharpknife,cut completelythroughthe end of the cablehousingat the two locations.
3. Slidethelargesectionofthecable housingoutofthe cableholder,beingcarefulnot to damagethe cablestops.
4. Carefullyremovethe cut piecesof the cablehousingwith a smallflat tip screwdriver.
5. Hookthe tip of the new air mix control cableto the temperaturecontrol lever,then push the cable housinginto the
cableholderuntil it locksinto place.
controlleverslidessmoothlythroughthe full strokelrom rightto left.

checkthatthe temperature
NOTE:Afterassembly,
21-43
TemperatureControl
Adjustment-'96 - 98 Models
1. From under the hood, disconnectthe heatervalve 6. From underthe hood.move the heatervalvearm to
cablefrom the heatervalve. t h e f u l l y c l o s e d p o s i t i o n .t h e n a t t a c ht h e h e a t e r
valvecableto the heatervalvearm.
TER
VALVE
HEATERVALVE ARM CABLE
HEATERVALVE ARM
2. From underthe dash,disconnectthe air mix control
cablehousingfrom the cableclamp,
AIR MIX
CONTROL 7. Hold the heatervalve arm in the closed position,
ARM and gentlypull on the heatercableouter housingto
take up any slack.then installthe heatervalvecable
housinginto the cableclamp.
3. Set the temperaturecontrolleverto MAX. COOL.
With the air mix control cable attachedto the air

m i x c o n t r o la r m , g e n t l y p u l l o n t h e o u t e r c a b l e
housingto fully closethe door and to removeany
. o n ' tp u l l t o h a r d ,o r t h e t e m p e r -
s l a c ki n t h e c a b l e D
aturecontrolleverwill move.
Hold the air mix control arm againstthe stop. then

s n a p t h e a i r m i x c o n t r o l c a b l e h o u s i n gi n t o t h e
c a b l ec l a m p .
21-44
Adjustment-'99 - 00 Models
1. From under the hood, open the cable clamp, then 5. From under the hood.turn the heatervalve arm to
disconnectthe heatervalve cable from the heater t h e f u l l v c l o s e d o o s i t i o na s s h o w n , a n d h o l d i t ,
valvearm. Attach the heater valve cable to the heater valve
arm, and gently pull on the heatervalvecablehous-
ing to take up any slack,then installthe heatervalve
cablehousinginto the cableclamp.
HEATERVALVEARM
From under the dash. disconnectthe heatervalve

cablehousingfrom the cableclamp,and disconnect
the heatervalvecablefrom the air mix controlarm.
HEATERVALVE ARM
VALVECABLE
HEATER
Setthe temperaturecontroldial on MAX COOLwith

the ignitionswitchON {ll).
Attachthe heatervalve cableto the air mix control

arm as shown above. Hold the end of the heater
valvecable housingagainstthe stop, then snap the
heatervalvecablehousinginto the cableclamp.
21-45
Air Mix GontrolMotor
Test-'99 - 00 Models -'99 - 00 Models
Replacement
't. Disconnectthe 5P connectorfrom
the air mix con- 1, Disconnectthe 5P connectorfrom the air mix con-
trol motor. trol motor. Removethe self-tappingscrews,the air
mix controlmotor and the flangecollar.
Connectbatterypower to the No. 1 terminalof the
air mix control motor, and ground the No. 5 termi, 5P OONNECYOB
nal; the air mix control motor should run, and stop
at MAX HOT.lf it doesn't,reversethe connections;
the air mix control motor should run, and stop at
MAX COOL.
lf the air mix controlmotor does not run, remove

i t , t h e n c h e c kt h e a i r m i x c o n t r o l l i n k a g ea n d
doorsfor smooth movement.
lf they move smoothly,replacethe air mix con-
trol motor.
AIR MIX CONTROLMOTOR
CONTROL
MOTOR
Measurethe resistance betweenthe No.2 and No.3 Install in the reverseorder of removal.After installa-
terminals.lt shouldbe approximately4.8to 7.2 kO. tion, makesure the air mix control motor runs
smoothly.
Measurethe resistancebetweenthe No. 2 and No. 4
terminals.lt shouldbe approximately
3.84to 5.76kO
at MAX HOT and approximately0.96to 1.44kO at
MAX COOL.
21-46
Mode Control Motor
Test Replacement
the 7P connectorfrom the mode control
1 . Disconnect 1. the 7P connectorfrom the mode control
Disconnect
motor. motor,
2. Connectbattery power to the No, 1 terminal, and

7P CONNECTOR
g r o u n dt h e N o . 7 t e r m i n a l ,
CAUTION: Never connecl the battery in iho oppo-

site direction.
U s i n ga j u m p e r w i r e , c o n n e c t h e N o . 7 t e r m i n a l
i n d i v i d u a l ltyo t h e N o . 2 , 3 , 4 , 5 a n d 6 t e r m i n a l si n
that order. Eachtime the connectionis made, the
mode controlmotor shouldrun smoothlyand stop.
NOTE:lf the modecontrolmotor doesnot run when

jumpingthe first terminal,jump that terminalagain
afterjumpingthe otherterminals.The mode control
motor is OK if it runs when jumping the first termi-
n a la g a i n .
MODECONTROLMOTOR
Removethe rod from the arm of the mode control

motor.
Remove the tyvo self-tapping screws and the mode

control motor.
lnstallin the reverseorderof removal.After installa'

t i o n , m a k e s u r e t h e m o d e c o n t r o lm o t o r r u n s
smoothly.
4. lf the mode control motor does not run in step 3,

removeit. then checkthe mode control linkageand
doorsfor smoothmovement.lf they move smoothly,
reolacethe modecontrolmotor,
21-47
RecirculationControl Motor
Test Replacement
L Disconnectthe 4P connectorfrom the recirculation L Disconnectthe 4P connectorfrom the recirculation
controlmotor. c o n t r o l m o t o r , a n d r e m o v et h e w i r e h a r n e s sc l i p
from it.
Connectbattery power to the No. I terminal, and
groundthe No.2 and No. 4 terminals;the recircula-
tion controlmotor shouldrun smoothly. 4P CONNECTOR
CAUTION: Never connest ths battery in the oppo-

site direction.
Disconnect the No. 2 or No. 4 terminalsfrom ground;

the recirculation
controlmotor shouldstop at FRESH
or RECIRCULATE.
NOTE: Don't cycle the recirculationcontrol motor

for a long time.
RECIRCULATION
CONTROLMOTOR
CONTROLMOTOR
Remove the two self-tapping screws and the recir-

culationcontrolmotor.
Install in the reverseorder of removal.After installa,

tion, make sure the recirculation controlmotor runs
smoothly.
4. lf the recirculationcontrol motor does not run in step

2, removeit, then checkthe recirculation controllink-
age and door for smooth movement.lf they move
smoothly,replacethe recirculation controlmotor.
21-48
Relays Heater Fan Switch
Test Test-'96 - 98 Models

Thereshouldbe continuitybetweenthe No 1 and No. 3 Checkfor continuitybetweenthe terminalsaccordingto
terminalswhen power and ground are connectedto the the table below.
No.2 and No. 4 terminals,and thereshouldbe no conta-
nuitywhen poweris disconnected. lerminal 4 2 5 3
1
Position
OFF
,I I 1 I rJ
t ; € 2 o -o
'Y
) 3 o- a
4 c)- {
Blowermotor relaY
. Blowermotor high relay('99 00 models)
21-49
Mode Control Switch PowerTransistor
Test-'96 - 98 Models Test-'99 - 00 Models
Checkfor continuitybetweenthe terminalsaccordinqto 1. Disconnsctthe 3P connectorfrom the oower tran-
the table below. stsror.
Terminal 't0 2, Carefullyreleasethe locktab on the No. 2 terminalin

7 1
Position the 3P connector,then removethe terminal and insu-
Heat o -o late it from body glound.
HeaVDef o- --o
Def o- -o 12V1.2-3,1W
Vent G -o
HeaVVent o- -o
1 4
7 8 9 ;l t
No.1 laLU/aLK)
Connecta 1.2- 3.4 W bulb betweenthe No. 1 and

the No. 2 cavityon the 3P connector.
Reconnect
the 3P connectorto the powertranslstor.
Turn the ignitionswitch ON fll), and checkthat the

blowermotor runs.
21-50
Air Conditioning
SpeciafTools 22-2
......'.....' Evaporator
Replacement .....",'22'24
fffustratedfndex ......................... 22-3
".......'
Wiring/Connector Locations'.........'....22'4 Overhauf .....-.....""'22'29
Description Compressor{SANDEN}
Outfine ............ .......22-s Repfacement ......'.'22-30
fffustrated 22'32
fndex ......"..................'....
Circuit Diagram
'96 - 98 Models ......"..........".......'....
22-6 ......22-33
"............
Cfutch Inspection.........
'99 Modef """""""' 22-7 ClutchOverhau .......22-34
I ........................
Troubleshooting Thermal Protector Replacement .... 22-36
SymptomChart ".'......""................. 22-8 ReliefValve Replacement......'..."".22-36
Flowcharts Compressor(DENSO)
22-9
Fan .........".................,..'. Repfacement ..""',' 22-37
Condenser
.....""" 22-12 22-39
lflustratedIndex ...............................
Compressor
.........'.22'17 "'....22-40
Clutchlnspection............."'......
A/C System
22-41
Cfutch Overhaul.....................'.........
A/C Thermostat
"""'22'21 Refief Valve Replacement'..'......"'.. 22-42
Test ........'.......'
Relays A/C Compressor Belt
Test ....."'......... ..""'22-21 Adiustment ............22'43
A/C ServiceTips and Precautions......22-22 Condenser
Repfacement .......,,22'44
A/C System Torque Specifications'...22-23
A/C System Service A/C System Service
Performance "........'..22-24
Test ...'."......... Evacuation ...,,,.......22-45
PressureTest Chart ......................"' 22-26 Charging '..........--'..22'46
Recovery 22-27
...".........," Leakrest """""""'22-46

SpecialTools
Bef. No. Tool Number Description Qty PageReference

I
o * 0 7 J G G- 0 0 l 0 l 0 A BeltTensionGauge 1 22-43
07sAz - 0010004 BackprobeSet 22-14,16
07947- 6340300 DriverAttachment '1
22-34
@ 07965- 6920500 Hub AssemblyGuldeAttachment 1 22-35
' Includedin the BeltTensioncauge Set,07TGG-0010004.
a 6r
L
3r
2 2-2
lllustrated Index
A/C PRESSURE SWITCH

Whenthe refrigerant pressureis below200kPa{2 0 kg7cm' ,
(32kgf/cm' '
28 psi)due to ;frigerant leakageor above3200kPa
EVAPORATOR 455 psi) due to blockage,
refrigerant the lVC pressure
swrtch
openslhe circuitto ihe AVCswitchand stopsthe air condilioning
Overhaul,page22 29 to protectthe comPressor'
SERVICEVALVE
{LOW.PRESSURESIDE)
A/C THERMOSTAT
Test,page22 21
RECEIVER/DRYER
B e p l a c e m e n t ,P a g e 2 2 ' 4 4
COMPRESSOR
SANDENI
Replacement,Page22 30
Page22 33
CIutchInspection,
page22 33
ThermalProtectorInspection,
ClutchOverhaul,Page22'34
ThermalProtectorReplacement, page22 36
RefiefVafveReplacemenl,page 22'36
DENSO:
Replacement,Page22-37
Page22-40
ClutchInspection,
ClutchOverhaul,Page22_41
ReliefValveReplacement,page22-42
22-3
Wiring/GonnectorLocations
A/C DIODE.
CONDENSER FAN RELAY,
COMPRESSOR CLUTCHRELAY
(Locatedin the under,hoodfuse/relaybox)
COND€NSERFAN
CONNECTOR
COMPARTMENT
WIREHARNESS
CONNECTOR
22-4
Description
Outline
refrigerantthroughthe system
The air conditionersystemremovesheatfrom the passengercompartmentby circulating
as shown below.
EVAPORATOR
(Absorption
of heati
BLOWERFAN
EOUALIZINGTUBE
(Meterspressureand
EXPANSIONVALVE improvesthe expansion
(Metersthe required THERMOSTAT valvereactiontime)
amountof refrigerant \ / CAPILLATYTUBESENSINGBULB
intothe evaporator) lControlsthe temPerature of the
refrigerantleavingthe evaporator
by meteringthe expansionvalve)
THERMALPROTECTOR
A/C PRESSURE SWITCH {Opensthe comPressor
Whenthe refrigerant is below clutchcircuitwhen the
200kPa(2.0kgtcm' ,28Psi) compressor temPerature
or above 3,200kPa132kgflcm', becomestoo high)
455 psi),the Ay'Cpressure
switchopensthe circuitto RELIEFVALVE
the A,/Cswitch and stops the pressureat the
(Relieves
airconditioning to Protectthe compressorwhenthe
compressor. pressureis too high)
S]
(Suctionand comPression,
RECEIVER/DRYER
(Trapsdebris,and
I VAPOR
HIGHPRESSURE
removesmorsturel
f-r--; I LIOUID
HtGHPRESSUBE
LIOUID
LOW PRESSURE
(Radiation
of heat)
(R-134a)refrigerantwhich does not containchlorofluorocarbonsPay attentionto the following

This car uses HFC-134a
serviceitems:
. Do not mix refrigerants CFC-12(R-12)and HFC-134a (R-134a)'

They are not compatible'
. Useonlythe recommendedpolyalkyieneglycol (PAG)refrigerantoil designedfortheR-134acompressor(SANDEN:SP-
10; DENSO:ND_OIL8). Intermixingihe re-commended (pAG)refrigerantoil with any other refrigerantoil will resultin
compressorfailure.
dischargeline,suctionline,evaporator,condenser,receiver/dryer, expansionvalve'
. All A,,icsystemparts{compressor,
with R-l2 parts'
O-ringsfor joints)haveto be properfor refrigerantR-134a Do not confuse
. Usea halogengas leakdetectordesignedfor refrigerantR-134a
station
. R-12and R-134arefrigerantservacingequipment are not interchangeable.Use only a recovery/recycling/charging
is certifiedto meet the of
requirements sAE J2210 to serviceR-134aair conditioningsystems'
that is u,L.-listedand
. Always recover the refrigerant R-134awith an approved recovery/recycling/charging station before disconnectingany
A,/Cfitting.
22-5
CircuitDiagram
'96 -
98 Models
UNDER.HOOD
FUSEi
BELAYBOX UNDEDRASH
GNITON
SWITCH FUSE/RELAY
8OX
N0.41(8rA) N0.42(40A) N 0 . 1 (77 . 5 4 )
COMPBESSOR
CLUTCH
BELAY
BLUMHT
,l
( E i)
,T'
BLUiBED
A/c I
THERMOSTAI
BLU/REO WHT/SLU BLKYEL
CONDENSEF 3
FANMOTOR
*F,.X,
2 3
F A Nr l
HEATER
swrlcH 'o
I
+
BLK BLK 8LK
G751
{
G401
I
G40l
G402 G402
22-6
'99 - 00 Models
UNDERDASH
8OX
UNDERHOODFUSE/RELAY G N I T OSNW T C H BOX
FUSE/BELAY
N0.42(404) N o . l 7( 7 . 5 4 )
N0.41(P,0A)
COMPRESSOR
CLUTCH
FELAY
$*"
O :8PcoNNEcToF HEATER PANEL

CONTROL
n :20PCONNECToF
BLK
BLK E 12P coNNEcroR
I
G751
d
-
G401
G402
22-7
Troubleshooting
SymptomChart
NOTE:
. Any abnormalitymust be correctedbeforecontinuingthe test.
. Becauseof the precisemeasurements needed.usea multimeterwhen testinq.
. Beforeperformingany troubleshooting procedurescheck:
- FusesNo. 47 l7-5 Al, No. 56 (20 A) in the under-hoodfuse/relay
box, and No. 17 (7.5A) in the under_dash
fuse/relav
box
- GroundsNo. c401, c402, G751
- Cleanlinessand tightnessof alt connectors
Symptom Remedy
Condenserfan does not run at all. Performthe proceduresin the flowchart {see page 22-9).
Compressorclutchdoes not engage. Performthe proceduresin the flowchart lsee page 22-12).
Ay'Csystem does not come on (compressorand fan), Performthe proceduresin the flowchan (seepage 22-17).
Both heaterand A,/Cdo not work. . '96 - 98 models-Performthe proceduresin the flowchart
{seepage21-18).
. '99 - 00 models-Performthe proceduresin the flowchart
(seepage21-35).
22-8
CondenserFan
Conden3erfan does not run at all.
Checkthe No. 56 (20A) fuse in the

box, and the
unde.hood frJse/relaY
No. 17 (7.5A) fuse in the under-
dashfuse/relaybox.
Reolacethe fuse{s),and techeck
Removethe condenserlan rclaY'

andtest it (seepage22 21i
Replacethe condenseifan relav.

FAN RELAY4P SOCKET
CONDENSER
Checkthe under-hoodtus6/relaY
Measurethe vohagebetweenthe
No.2 terminalofthecondenserfan
relav4Psocketand bodv ground.
JUMPER
wlRE
Check the condenser lan Power
supply circuit:
Connectthe No. 1 and No. 2 teF
minalsof the condenserfan relay
4Psocketwith a jumperwire
Doesthe condenserfan run? T o p a g e2 2 - 1 0
Io page 22 11
(cont'd)
22-9
Troubleshooting
CondenserFan(cont'd)
CONDENSER
FAN RELAY4P SOCKET
Checktor an opon in the wi.o:
1. Disconnect the jumperwire.
2. oisconnectthe condensertan
2P connector.
the No. 1 terminalof the con-
denserfan relay4Psocketand
the No. 1 terminalof the con-
denserfan 2P connector.
Rapairop6n in the wirs bgtwcon

ls therecontinuity? the condcnsor tan rclay and the CONDENSEB FAN 2P CONNECTOR
condgnlar fan. Wire side of female terminals
Checkto. en open in the wire: -=F_

No. 2 terminalot the condenser
l ! . Ilslx
fan 2P connector and body
ground. @
I
Check Ior rn opon in th6 wire

ls there continuity? bctwoen the condcnser tan and
body ground, lf iho wirc ii OK,
chcck for poor ground at G751.
Replacothe condense.fan motor.
22-10
Checkthe diode:
1. Disconnect the iumPerwire
2 . R e m o v et h e A / C d i o d ef r o m
the underhoodfuse/relaY box
3. Checkfor currentflow in both
directionsbetweenthe A and
B terminals.
B()-=iFA
ls therecurrentflow in onlY
one direction?
A/C DIOOE2P SOCKET
Chockfor an open in the wire:

(ll).
the No. 2 terminalof the AJC
d i o d e 2 P s o c k e ta n d b o d y
ground.
Repairopon in the wire betwe€n

ls there battery voltage? the No. 17 luse and the A/c
diode.

Troubleshooting
Compressor
checkthe No. 56 (20A) fuse in the

under'hoodfuse/relaybox, and the
No. 17 (7.5A) fuse in the under,
dashfuse/relaybox.
Replacethe fussls),and .echeck.
Removethe compressorclutch
relay,and test it {seepage22 21).
COMPRESSORCLUTCHRELAY
.P SOCKET
Checkth6 und€r-hoodtu3e/reby
No. 2 terminalof the compressor
clutch relay 4P socketand body
ground.
C h e c k t h e c o m p r e s s o rc l u t c h JUMPER
pow€r supply circuit: WIRE
Connectthe No. 1 and No. 2 termi-
nalsof the compressorclutchrelay
4Psocketwith a jumperwire.
Doesthe compressor
clutchclick? fo page 22-13
To page 22 14
22-12
Ftom page22 12
COMPRESSOR RELAY
CLUTCH
iaPSOCKET
Checkto. an opon in tho wire: r--------t RED

1. Disconnect the jumperwire
2 . D i s c o n n e ctth e c o m P r e s s o r
L-r-]-_l
l 2 l I
clutch1Pconnector. --r- |
3. Checklor continuitybetween l 1 l 3 l I
the No. 1 terminalo{ the com_
pressorclutchrelaY4P socket @
and the terminalof the com-
pressorclutch1Pconnector'
I
H I
1___J-RED
COMPRESSOR CLUTCH1P CONNECTOR
Repeiropen in the wiro between

ls there continuity? the compressoaclutch relaY and
the comDres3orclulch.
Inspect the comPre3sorclutch

clo.rance, lhe tharmal Protgdor
ISANDENI,and tha compr6ssor
clutch field coil {SANDEN:Soe
pag. 22-33; DENSO: See Pag.
22-10t.
(cont'd)
22-13
Troubleshooting
Compressor
lcont'dl
Frcm page22-12
CheckIor an open in the wire; COMPRESSORCLUTCHRELAY

1. Disconnecl the jumperwire. 4P SOCKET
2. Turnthe ignitionswatch ON (ll).
3. l\4easure the voltagebetween
the No. 4 terminalof the com- l--;l
pressorclutchrelay4P socket
and body ground. 1 2 |
---r--]
l . l 3|
L-J--J
BLK/YEL
Repairopen in the wire betw€en ]
A
the No. 17 fuso and the compres- (v)
sor clutch relav.
!
Checkfor an open in the wira:

then reinstallthe compressor
clutchrelay.
2 . M a k es u r e t h e A / C s w i t c hi s ECM/PCMCONNECTOR
A I32P}
O F F ,t h e n t u r n t h e i g n i t i o n
switchON (ll).
3. Using a *BackprobeSet (T/N
0 7 S A Z 0 0 1 0 0 0 4 )m , easure
the voltage betweenthe No.
1 7t e r m i n aol I the ECM/PCM
connectorA (32P)and body
ground with the ECM/PCM
connectors connected.
Wire side of female terminats

Repairopen in the wirc betweon
ls there batteryvoltage? the compressor clutch relay and
the ECM/PCtvt.
To page22-15
*Howto use the backprobe

sets
C o n n e c t t h e b a c k p r o b e a d a p t e r s t o t h e s t a c k a n gp a t c h c o r d s , a n d
connect the cords to a multimeter. Using the wire insulation as a
g u i d e f o r t h e c o n t o u r e d t i p o f t h e b a c k p r o b ea d a p t e r , g e n t l y s l i d e
the tip into the connector from the wire side until it comes in con-
t a c t w i t h t h e t e r m i n a l e n d o f t h e w i r e ( s e es e c t i o n 1 1 ) .

Frcm page22-14
SWITCH2P CONNECTOR
A/C PRESSURE
Checklor an open in the wire:

switch2Pconnector.
3. Turnth ignitionswitchON lll).
the No. 1 terminalof the AJC
pressureswitch2P conneclor
and body ground.
wire sideof {emaleterminals

ls therebatteryvoltage? the condenserfan relay tnd the A/C PRESSURE
SWITCH
A/C oressureswitch.
Check the A/C pressure switch:

the No. 1 and No. 2 terminals
of the Ay'Cpressure switch.
ls there continuity? 1o page22-16
Checkfor A/Csystemptessure.
l s t h e p r e s s u r ew i t h i n s P e c i _ Repair the A/C pressure Problem

f cations?
(cont'd)
22-15
Troubleshooting
Gompressor(cont'dl
Frompage22-15
'96 -98 models:
Checkfor an open in thg wire:

'1. Reconnectthe A"/Cpressure ECM/PCMCONNECTOR
C 13lPI
switch2P connector.
2. Make sure the A/C switch is
O F F ,t h e n t u r n t h e i g n i t i o n
switchON (ll).
3. Using a *BackprobeSet {T/N
07SAZ- 001000A),measure
the voltagebetweenthe No. 5
terminalof the ECM/PCM con-
n e c t o r C ( 3 1 P )a n d b o d y
ground with the EcM/PcM
connectorsconnected('96 -
98 models), or between the
No. 27 terminal of the
ECM/PCMconnectorA (32P)
and body ground with the
E C M / P C Mc o n n e c t o r sc o n
nected('99- 00 models).
'9!t - 00 mod.bi
ECM/PCMCONNECTOR
A I32P)
3 1 5 0 1 E 9 10 11
ta t6 l 1 1E 19 21 22 23 21
BLU/RED
Rapdiropen in tho wi?e botwaon

the A/C pr..-ruro lwitch rnd th.
ECM/PCM.
Check lor loo3e wires or oool

connections at the ECM/PCM
connectoBA l32P)and at the A/C
pressure switch 2P connector, lf
the connectionsare good, substi-
tute a known-good ECM/PCM,
and recheck. lf the svmptom/
indicationgoos away, repbce the
originalECM/PCM.
*How to use the backprobesets

Connectthe backprobeadaptersto the stackingpatch cords, and
connectthe cordsto a multimeter.Usingthe wire insulationas a
guidefor the contouredtip of the backprobe adapter,gentlyslide
the tip intothe connectorfrom the wire sideuntil it comesin con-
tactwith the terminalend ofthe wire {seesection11}.
22-16
A/C System
A/C system does not come on

{comDressorand fan).
C h e c kt h e N o . 5 6 f u s e i n t h e
u n d e r ' h o o df u s e / r e l a yb o x a n d
the No. 17fuse in the under-dash
fuse/relay box.
ReDlacethe fus6{s},and recheck.
CONDENSER
FAN RELAY4P SOCKET
Checkfor tn open in the wire:

1 . R e m o v et h e c o n d e n s e rl a n
relayfrom the underhood
luse/relaybox.
2. Turnthe ignitionswitchON {lli.
3- Measurethe voltagebetween
the No. 4 terminalof the con
d e n s e rf a n r e l a v 4 P s o c k e t
and body ground.

the No. 17 fuse and the con-
denserfan r6lay,
Checkthe under-hoodfus€/r6lay
box:
No. 2 terminal of the condenser
f a n r e l a y 4 P s o c k e ta n d b o d y
ground,
YES
Io page 22-18
(cont'd)

Troubleshooting
A/C System(cont'd)
Frompage22-11
A/C THERMOSTAT
3PCONNECTOR
Checktor an open in the wire:
2. Disconnectthe A/C thermo
stat 3P connector.
the No. 3 terminalof the Ay'C
thermostat3P connectorand
body ground.
Wire side oI femaleterminals
Repai. open in the wire between

tho No. 17 tuso and the A/C the.-
mostat.
Checkloi an open in the wi.e:

No. 1 terminalof the A,/Cthermo
stat 3P connector and body
ground,
Ropairopen in the wire betwoen

ls there batteryvoltage? the condedlo. lan rolay and the
A/C thormostat.
Checkthe A/C th6rmostat:

2. Reconnectthe A,/Cthermostat
3Pconnector.
3. Connectthe No. 2 terminalto . _Ff,, __
groundwitha iumperwire. I 1 1 2 1 3 [
4. Startthe engine.
,r,il*"-T",-.r-'..o
wrRE I
Do the fan run and the com-
pressorclutchengage?
To page22-191'96- 98 models)
To page22-20('99- 00 models)
22-18
r'oA - qe m^.lalal
Ftom page22 18 HEATERCONTROLPANELlilP CONNECTOR
Checktor an open in the wire: a 6

t r
t h e n d i s c o n n e ctth e i u m p e r 7 I I 'olx 't1 12 1 3 1 4
BLU/RED
lower cover lsee section20),
and disconnect the heatercon'
trol panel14Pconnector.
4. Measurethe voltagebetween Wire sideof femaleterminals
the No. 11 terminaland body
ground.
Repairop6n in the wire bstween

the A/C th€rmostat and th6 hoater
controlpanel.
HEATERCONTROLPANEL1'P CONNECTOR
Checklor an open in the wire:
1. Turnthe ignitionswitchOFF. Wiresideof femaleterrninals
2 . D i s c o n n e ctth e h e a t e rI a n
switch6P connector,
3. Checkfor continuitybetween 1 2 ;--? 4 5
heatercontrolpanel14Pcon_
nectorand the No.6 terminal
7 I 10 X 'll
12 13 1 4
GRN
of the heaterfan switch6P con-
nector.
Repairopen in the wiro betweGn 1 2 3

the heal.r control Panel and the GRN
heaterfan switch. a 5 6
Checkfor an open in thGwire: HEATERFAN SW]TCH6P CONNECTOR

No. 1 terminalof the heaterlan Wire sideof femaleterminals
s w a t c h6 P c o n n e c t o ra n d b o d Y
ground.
Chock tor an open in tho wir€

between the heater lan switch
ls therecontinu;ty? and body ground. lf the wire is OK,
checkfor poor groundat G401snd
G402.
ls the heaterfan switchOK? ReDlacethe heater tan switch.
Check for loose wiaes or poor

connections at the heater control
oanel 14P connoctor and hoeter
tan 3witch 5P conn€clor and at
the A/C thermostet 3P connec- (cont'd)
tor. ll the connections are good,
raplace the heator control Panel.
22-19
Troubleshooting
('99 00 models)
Frompage22 18
Checklor an open in the wire: HEATERCONTROLPANELanPCONNECTOR

t h e n d i s c o n n e ctth e j u m p e r

panel20Pconnector.
3. Turn the ;gnition switch ON
{ i.
heatercontrolpanel20Pcon-
Ropai. opan in tho wira batwaon
ls there batteryvoltage? the A/C thermostat and the
hoater control oanol.
Checkthe push switch: PUSHSW]TCH12PCONNECTOR

2. Disconnectthe push switch
12Pconnector.
,/1,/ 1 5 6
the No. I and No. 10terminals 7 8 1 9 t 0 1 1 12

of the push switch 12Pcon-
nectorwith the A/C switch ON. II
I
Check for loose wi.es or poor

connectionsel the hgater control
panel 20P connector and push
switch 12Pconnector and at the
A/C thermostat 3P connector. It
tha connectionsare good, substi-
tute a known-good heatea con-
trol pan€|, and recheck. lf the
symptom/indication goe3 away,
replacelhe original healer con-
trol oan€|,

A/C Thermostat Relays
Test Test
1. thermostat(seepage22-29).
Removethe Ay'C Thereshouldbe continuitybetweenthe No, 1 and No.2
terminalswhen power and ground are connectedto the
Connectbafterypowerto the No. 3 terminal,ground No.3 and No. 4 terminals,and thereshouldbe no conti-
the No. 2 terminal,and connecta test light between nuitvwhen Doweris disconnected.
the No. 1 and No.3 terminals.
N O T E rU s ea 1 2V , 3 W - l 8 W t e s tl i g h t .
Dip the IVCthermostatinto a cup filled with ice water,

andcheckthe testlight. ,I I
b
Serp6ntine-typeevaporator 'r
In Io
I
The light shouldgo off at 36 - 39'F{2 - 4"C}or less,and
shouldcome on at 39 - 41"F(4 - 5"C)or more 2
Laminale-typeevaporator
The light shouldgo off at 39 - 43'F (4 - 6'C) or less,and fan relay
a Condenser
shouldcome on at 43 - 45"F(6 - 7'C) or more a Compressorclutchrelay
l f t h e l i g h t d o e s n ' tc o m e o n a n d g o o f f a s s p e c i f i e d ,
replacethe PVCthermostat.
12V,3W-18W
t\----,'
t:n
,,l[4..-.
22-21
A/C ServiceTips and Precautions
The air conditionersystemusesHFC-134a (R-134a)

refrigerantand polyalkyleneglycol (PAG)refrigerantoil*, which are not
compatiblewith CFC-12(R-12)refrigerantand mineraloil. Do not use R-12refrigerantor mineraloil in this system,and do
not attemptto useR-12servicingequipmenUdamageto the air conditionersystemor your servicingequipmentwill result.
*SandenSP-10: *DENSOND-OlL8l
. P/N38897- P13- A0lAH: 120ml 14ll.oz,4.2lmp.oz) . P/N38897- PR7- A01AH:120ml (4 fl.oz)
. P/N38899- P13- A0l | 40 mf 111/3ll.oz,1.4lmp'oz) . P / N3 8 8 9 9 P R 7 - A 0 1 : 4 0 m f ( 1 1 / 3 f l ' o z )
Use only serviceequipmentthat is U.L. listedand is certifiedto meet the requirementsof SAE J2210to removeR 134a
from the air conditionersystem.
CAUTION:Exposureto air conditioner ref;ige;ant and lubricant vapol or mist can irritate syes, nose and throat, Avoid
breathing the air conditioner refrigerant and lubricant vapor or misl.
lf accidentalsystemdischargeoccurs,ventilatework areabeforeresumingservice.
serviceequipmentor vehicleair conditionersystemsshouldnot be pressuretestedor leaktestedwith compressed

R-'134a
ai.
!@@ some mixtures of air and R-t3ila have been shown to be combustible at elevated pressuresand can result
in tire or explosion causing iniury or property damage. Never use compressedair lo pressuretesl R-134aservice equip-
ment or vehicle 8ir conditioner systoms.
Additionalhealthand safetyinformationmay be obtainedfrom the refrigerantand Iubricantmanufacturers.
L Alwaysdisconnectthe negativecablefrom the batterywheneverreplacingair conditioningpans.
2. Keepmoistureand dust out of the system.When disconnecting any lines,plug or cap the fittingsimmediately;don't
removethe capsor plugsuntiljust beforeyou reconnecteachline.
3. Beforeconnectingany hoseor line,applya few dropsof refrigerantoilto the O-ring.
4, Whentighteningo. looseninga fitting,usea secondwrenchto supportthe matchingfitting.
5. When dischargingthe system,use a R-134arefrigerantrecovery/recycling/charging station;don't releaserefrigerant
into the atmosphere,
6. Add refrigerantoil after replacingthe followingparts:
NOTE:
. To avoidcontamination, do not returnthe oil to the containeroncedispensed,and nevermix it with other refriger-
ant oils.
. lmmediatelyafter usingthe oil, replacethe cap on the container,and sealit to avoid moistureabsorption.
. Do not spill the refrigerantoil on the vehicle;it may damagethe paint;if the refrigerantoil contactsthe paint,wash
it off immediately.
Condenser .......2oml (2/3fl.oz,0.7 lmp.ozl
Evaporator .,.,.,.i[5 m{ 11213tl.oz,1,6lmp.ozl
Lineor hose .....10 mf (1/3fl.oz,0.4 lmp.ozl
Receiver/Dryer 10 m{ (1/3fl.oz,0.'llmp.ozl
Leakagerepair 25 m{ (5/6 fl.oz, 0.9 lmp.ozl
Comptessor ... For compressor replacement. subtract the volume of oil drained trom the
removed compressorfrom A, and drain the calculatedvolume of oilfrom the new
compressor:A - Volume of removed compressor: Volume to drain from new
comoressor.
A: SANDEN 130 mf l/t 113ll.oz, 4.6 lmp'ozl; DENSO140 mf {4 213 ll'oz, 1.9
lmp.oz),
NOTE:Even if no oil is drainedfrom the removedcompressor,don't drain more
t h a nS 0m { 1 1 2 E l l . o z , 1 .l8m p . o zf)r o m t h e n e wc o m p r e s s o r .
REMOVED NEW
rere
COMPRESSOR COMPRESSOR
W W
0 0 0 0
-0_!- -0_a
Tol l00l
| | lffi 1onrrrutrcI
LEvEr...+jEf,voLUME
^
fi+-sAME J
22- 2 2
A/C SystemTorqueSpecifications
O Dischargehoseto the compressor(6 x 1.0mml ............... .. ...................' 9.8 N'm {1.0kgf'm,7.2lbf'ftl

@ Dischargehoseto the condenser{6 x 1.0mm1................... '... ....... ......... 9.8 N'm 11.0kgf'm,7.2 lbf'ft}
O Condenserpipeto the condenser16x 1,0mm)...............'. . . . ...........'..... 9.8 N'm (1.0kgl'm, 7.2 lbt'ft)
@ Condensel pipe (5
to the receivel/dryer x 1.0mml......... ..... . ... . '.......... 9.8 N'm (1.0kgl'm, 7.2 lbt'ft)
O Receiverpipe A to the leceiver/dryer {6 x 1.0 mm)......... ... .......... .. . . ....9.8 N'm 11.0kgf'm.7.2 lbl'ft)
@ Receiverpipe B to the receiverpipe A 13 N m (1.3 kgf'm, 9.'l lbf'ft)
O Receiverpipe C to the receiverpipe B 13 N m (1.3 kgf'm, 9.4 lbnftl
@ Receiver pipe C to the evaporator{6 x 1.0 mm) ....... 9.8 N'm (1.0kgf'm,7.2 lbtftl
O Suction pipe B to the evaporator (6 x 1.0 mml................ . .........'......'....... 9.8 N'm (1.0kgf m, 7.2 lbf'ftl
e0 Suctionpipe A to the suctionpipe B ...'. . ...... . ... ......31 N'm (3.2kgt'm,23 lbf'ftl
O Suctionhoseto the suctionpipe A... ............ . . '......... 31 N'm (3.2kgl'm, 23 lbf'ft|
@ Suctionhoseto the compressor(6 x 1.0mm)................... .. . ... .. ............ 9.8 N'm (1.0kgf'm' 7.2 lbf'ft|
@@ Compressor to the compressor bracket (8 x 1.25mm)... ..-........'.'......-.......24 N'm (2 'l kgf'm, 17 lbf ftl
@ Compressorbracket to the cytinder block (10 x 1.25mml 44 N'm l'1.5kgf'm, 33 lbf ftl
@ Compressorbracketto the left front enginemounl {12x 1.25mm}...... . . . .. ................. ... ... 59 N'm (6.0kgf'm,'|i} lbf ftl
22-23
A/C System Service
Test
Performance
The performancetest will help determineif the air con-
ditionersystemis operatingwithin specifications. Recovery/Rocycling/Charging
Station
Useonly serviceequipmentthat is U.L.-listed and is cer-

tified to meet the reouirementsof SAEJ2210to remove
HFC-134a (R-134a) from the air conditionersystem.
CAUTION: Exposure to air conditionor rofrigerant and

lubricant vapor or mist can irrilalo €yes, nose and
throat. Avoid breathing tho air conditioner rstrigerrnt
and lubricant vapor or mist,
lf accidentalsystem dischargeoccurs, ventilate work

areabeforeresumingservice.
R-134aserviceequipmentor vehicleair conditionersys-

tems should not be pressuretested or leak tested with
compressedair.
@ some mixtur$ of air and R-134ahave been

shown lo b9 combustible rt glgvatadpr€ssur63and can
resull in tire 01 oxplosion causing inlury ot property
damage. Never uao compre33edair to pressure t99t R-
134a ssrvico 6quipmsnt or vohicla air conditioner sys-
tems.
Additional health and safety information may be obtained

from the refrigerantand lubricantmanufacturers.
'1. Connect a R-134a refrigerant recover/recycling/
chargingstationto the vehicle,as shown,following
the equipmentmanufacturer's instructions.
2. l n s e r t a t h e r m o m e t e ri n t h e c e n t e r v e n t o u t l e t .
Determinethe relative humidity and air tempera-
ture,
Testconditions:
. Avoid directsunlight.
. Openhood.
. Open front doors.
. Set the temDerature controlleveror dial to MAX,
COOL,the mode control switch or dial on VENT
and the recirculationcontrolswitchon RECIRCU-
LATE.
. Turn the A,/Cswitch on. and the heaterfan switch
on MAX.
. Runthe engineat 1,500rpm.
. No driveror passengers in vehicle
After running the air conditioningfor 10 minutes

under the above test conditions,read the delivery
temperaturefrom the thermometerin the dash vent
and the high and low system pressurefrom the A,/C
gauges.
22-24
5. To completethe charts:
. Markthe deliverytemperaturealongthe venicalline.
. Markthe intaketemperature (ambientair temperature) alongthe bottomline.
. Drawa line straightup from the air temperatureto the humidity.
. Marka point 10%aboveand 10%belowthe humiditylevel.
. Fromeachpoint.draw a horizontalline acrossthe deliverytemperature.
. The delivervtemperatureshouldfall betweenthe two lines.
. Completethe low side pressuretest and high side pressuretest in the sameway.
. Any measurements outsidethe line may indicatethe needfor furtherinspection.
kPa
lkgf/cm'l
lpsil aoy.
30io
2900 -
(30)
I€OI
2500 -
(25)
DELIVERY
13601 PRESSURE
2000 - 80%
t20l
kPa
t280t
{kgf/cm')
lpsil rct
1500- 400 - 86 -l
{151 {4) r3ol
12101 t571
DELIVERY I
PRESSURE
980 -
(101
300
{3} A,-] INTAXE
I
lr40l I€I PRESSURE
200 6 8 -
l2l {20r I
t28l
INTAKE
100
tll
1141
"'l
,r-]
PRESSURE
0 uo --]
''o'
I
nt
DELIVERY
TEMPERATURE
10il 'F
68 77 86 95
(2ot t2sl t3o) 135) l4ol {"c)
INTAKETEMPERATURE
22-25
A/C System Service
PressureTestChart
Test is on page22-24,
NOTE:Performance
Test results Relatedsymptoms Probabl€cause Remedy

D i s c h a r g(eh i g h ) After stoppingcompressor.pres- Air in system Recover,evacuate,and
pressureaDnor- suredropsto about200 kPa rechargewith specifiedamount.
m a l l yh i g h {2.0kgflcm,,28psi)quickly,and Evacuation:see page 22-45
then fallsgradually. Charging:see page 22-46
Reducedor no air flow through . Cloggedcondenserfins Clean.
condenser . Condenserfan not work- Checkvoltageand fan rpm.
ing properly Checkfan direction.
Lineto condenseris excessively Restrictedflow of refriger- Restricted
lines
hot. ant in system
Dischargepres- Highand low pressuresare bal- . Faultycompressordis- Replacethe compressor.
sureabnormally ancedsoon afterstoppingcompres- chargevalve
sor,Lowsideis higherthannormal. . Faultycompressorseal
Outletof expansionvalveis not . Faultyexpansionvalve . Replace,
frosted,low pressuregaugeindi- . Moisture in system . Recover,evacuate,and
calesvacuum. rechargewith specified
amount.
Suction(low) Expansionvalve is not frosted,and . Frozenexpansionvalve the exoansionvalve.
ReDlace
pressureabnor- low oressureline is not cold. Low . Faultyexpansionvalve
mally low pressuregaugeindicates vacuum.
Dischargetemperatureis low. and Frozenevaporator Runthe fan with compressor
the air flow from vents is restricted. off. then checkA,/Cthermostat.
Exoansionvalveis frosted. Cloggedexpansionvalve Cleanor replace.
Receiver/dryer outletis cool,and Clogged receiver/dryer Replace.
inlet is warm (shouldbe warm
duringoperation).
Suctionpres- Low pressurehoseand check . Expansionvalveopentoo Repairor replace.
sureabnormally joint are coolerthan the tempera- long
h i gh ture aroundevaporator. . Looseexpansioncapillary
tube
Suctionoressureis loweredwhen Excessiverefrigerantin sys- Recover.evacuate,and
condenseris cooledbv water. tem rechargewith specifiedamount.
High and low pressureare equal- Faultygasket Replacethe compressor.
izedas soon as the compressoris Faultyhigh pressurevalve
stopped,and both gaugesfluctu- Foreignparticlestuckin
atewhile running. high pressurevalve
Suctionand dis- Reducedair flow throughcon- . Cloggedcondenserfins Cleancondenser.
chargepres- denser. . Condenserfan not work- Checkvoltageand fan rpm.
suresabnormally ing properly Checkfan direction.
hi g h
Suctionand dis- Low pressurehoseand metalend Cloggedor kinkedlow pres- Repairor replace.
chargepressure areasare coolerthan evaporator. sure hose parts
a b n o r m a l llyo w Temperaturearoundexpansion Cloggedhigh pressureline Repairor replace.
valveis too low comparedwith
that aroundreceiver/dryer.
Refrigerant leaks Compressorclutchis diny, Compressorshaftsealleaking Replacethe compressor.
Compressorbolt{s)are diny. Leaking around bolt(s) Tightenbolt(s)or replacecom-
pressor.
gasketis wet with oil.
Compressor Gasketleaking Replacethe compressor.
22-26
Recovery
Useonly serviceequipmentthat is U.L.-listed and is cer-
tifiedto meetthe requirements of SAEJ2210to remove
HFC-134a (R-134a)from the air conditionersystem
g/Cha19ingStation
R€covery/Recyclin
CAUTION: Exposure to air conditioner relrigerant and
lubricant vapor or mist can illitate eyes, noss and
throat. Avoid breathing the ail conditioner refrigerant
and lubricant vapor or mist.
lf accidentalsystemdischargeoccurs,ventilatework
areabeforeresumingservice.
R-134aserviceequipmentor vehicleair conditionersys-

tems shouldnot be pressuretestedor leaktestedwith
compressedair.
!@@ some mixtures ot air and R'13'[ahavo been

strown to be combustiblg at elevated pressuresand Gan
resuh in fire or explosioncausinginiury or property dam-
age, Never use compressed air to pressuretest R-134a
serviceequipment or vehicleair conditionersystems.
Additionalhealthand safetvinformationmay be obtained

and lubricantmanufacturers.
from the refrigerant
1, Connect a R-'134arefrigerant recoverylrecycling/

chargingstationto the vehicle,as shown.tollowing
the equipmentmanufacturer's instluctions.
2. Measurethe amountof refrigerantoil removedfrom

the A/C svstem after the recoveryprocessis com-
pleted.
NOTE: Be sure to installthe same amount of new

refrigerantoil backinto the Iy'Csystem beforecharg-
tno.
22-27
Evaporator
Replacement
1. Movethe temperaturecontrolto "HOl" 7. Disconnectthe connector from th€ Ay'Cthermostat,
'96-98: Slidethe temoeraturecontrollever.
and r€movs the wire harnessfrom the ovaporator.
'99-00: Turnthe ignitionswitch ON (ll),then turn
Remov6tho four self-tappingscrews,tho mounting
the temperaturecontol knob. Turn the ignition bolt and ths mounting nut. Disconnectth€ drain
switch off. hose,then remov€th6 avagorator.
Removethe battsry.
Rgcover the refrigerant with a rocovery/recycling/
charging station (see page 22-271.
4. Remove the bolts, then disconnectth6 suction 8nd
receiverlines from th6 evaoorator.
NOTE: Plug or cap the lines imm€diatoly after dis-

connectingthem to avoid moisture and dust con-
tamination.
srrcrrc u E
6xl.0mm
9.8 n*ln ll.0 tg6m.
7.2lbtfrl
6 x l.0.nm
9.8l$m lt.o ldm, 7.2bl.tt)
RECEiVER
UNE
Removethe glov6 box (seesection 20). Install in the reverseorder of removal. Make note of
6. Removothe self-tappingscr€w and the passeng€r's th€ following items.
dashboardlower cover. Removsthe bolt. the nut
8nd the kn€e bolst6r,th6n r6mov6 th6 fiv6 bolts and o lf you'r6 installinga new evaporator,add rofriger-
the glove box frame. ANtOiI {SANDEN,SP-10Or DENSO,ND-OIL8)
lsas page 22-221.
. Replacethe O-ringswith now ones 8t 68ch titting,
and apply 8 thin coat of r€frlgersd oil before
installingthem.
NOTE: Be sure to use the right O-rings for HFC-
134a(R-134a)to avoid loakago.
. Apply s€alantto tha grommets.
. Mske sure that ther€ is no air leakage.
. Chargs ths system {s€€ page 22-161,and tost its
performance(see pags 22-211.
22-28
Overhaul
1 . Pull out the A,/Cthermostatsensorfrom the evapo- 5. Assemblein the reverseorderof disassemblyMake
ratorfins. noteof followingitems.
Removethe self-tappingscrews and clamps from . Replacethe O-ringswith new onesat eachfitting,
the housings. and apply a thin coat of refrigerantoil before
installingthem.
3. Carefullyseparatethe housings,then remove the NOTE:Be sure to use the right O-ringsfor HFC-
evaporator. 134a(R-134a) to avoid leakage.
. Installthe expansionvalvecapillarytube so that
removethe expansionvalve.
lf necessary, it is in direct contactwith the suctionline. Then
wrap wathtaPe.
NOTE:Whenloosening the expansion valvenuts,use . Reinstallthe Ay'Cthermostatsensorto its original
a secondwrench to hold the expansionvalve or the location.
evaporatorpipe.Otherwise,they can be damaged
TAPE
6th tin lrom inld side HOUSING Replace.
lvakesurethereis no foreignmatterstuckbetween
Serpentinetype:
%
Laminatetypo: EVAPORATOR
60t5mm blow din out of lins
l'2.1! O.2inl with compressed air, 8 N.m 10.8kgt m,
6 tbf.ftl
6th fin lrom outle'tside TUAE

CAPILLARY
N
u'
ll N.m (2.itkgt.m,
VALVE
6\ 1l 17 tbtftl
A/C THERMOST
fesr page22 21
EVAPORA
LOWER
22-29
Compressor(SANDENI
Replacement
1. lf the compressoris marginallyoperable,run the 7. Loosenthe center nut of the idler pulley and the
e n g i n e a t i d l e s p e e d ,a n d l e t t h e a i r c o n d i t i o n e r adjusting bolt. then remove the A,/Ccompressorbelt
work for a few minutes.then shut the engineoff. from the pulleys.Removethe two mounting bolts
from the left front mount, then remove the ly'C com-
Disconnectthe negativecable from the battery. pressor belt by passing it through the gap befiiveen
the bodv and the left front mount.
Recoverthe refrigerantwith a recovery/recycling/
charging station (see page 22-27l.. ADJUSTINGBOLT
Removethe bolts,then disconnectthe suctionand CENTERNUT

dischargelinesfrom the compressor.
NOTE:Plug or cap the lines immediatelyafter dis-

connectingthem to avoid moisture and dust con-
tamination.
6xl.0mm
1.0x 1.25mm
aa N.m 14.5kgf,m, 33 bnft)
8. Remove the four mounting bolts and the compressor.
COMPRESSOR
Removethe condenser(seepage22-44).
NOTE:Do not disconnectthe dischargehose from

the condenser.
Removethe power steeringpump belt (seesection

1 7t .
24 N.m l2.iakgt.m, 17 lbf.ftl
22-30
9. removethe compressorbracketas fol-
lf necessary, 10. lnstallin the reverseorderof removal.Makenote of
lows. the followingitems.
. Removethe nut and the washer. . lf you're installinga new compressor,drain all
the refrigerantoil from the removedcompressor,
NOTE:When tighteningthe nut of the left front and measureits volume.Subtractthe volume of
'130m? 1/3 tl'o2,4 6 lmp'oz);
mount, make sure the washeris set properlyon drainedoil from 14
the left front enginemount as shown. the result is the amount of oil you should drain
from the new compressor(through the suction
. Removethe four mounting bolts and the com- fifting).
pressorbracket. . Replacethe O-ringswith new ones at each fit-
t i n g , a n d a p p l y a t h i n c o a t o f r e f r i g e r a n to i l
beforeinstallingthem
NOTE: Be sure to use the right O-ringsfor HFC-
134a(R-134a) to avoid leakage
12 x 1.25rrirn . Use refrigerantoil (SP-10) for R-134aSandenand
59 N.m 16.0kgt'm, Hadsysspiraltype compressorsonly'
43 tbf.ft) o To avoid contamination,do not returnthe oil to
the containeronce dispensed,and never mix it
with other refrigerantoils.
COMPRESSOR . lmmediatelYafter using the oil, replacethe cap
BRACKET
on the container,and seal it to avoid moisture
absorption.
. Do not spill the refrigerantoil on the vehicle;it
may damagethe painu if the refrigerantoil con-
tactsthe paint,wash it off immediately
. Adjust the Ay'Ccompressor belt (see page 22-43)
and the power steeringpump belt (seesection17)'
. Chargethe system(seepage 22-46),and test its
WASHER
oerformance(see Page22-241
LEFTFRONT
1.0x 1.25mm MOUNT
44 N.m (i1.5kg{.m,33 lbl.ft)
22-31
Gompressor(SANDEN)
lllustratedIndex
CENTER
NUT
Replace.
<-- ARMATUREPLATE
lnspection,page22-33
sHrM(s)
Replace.
SNAPRINGB
Replace.
ROTORPULLEY
Inspection,
page22-33
SNAPRINGA
Replace.
FIELDCOIL
lnspection,page 22-33
Replacement.
page22,36
COMPRESSoR ]
(Donot disassembte) ---------------->l
THERMALPROTECTOR
Replace.
page22-33
Inspection,
t v
i -
22-32
ClutchInsPection
Checkthe platedpartsof the armatureplatefor color . Releasethe field coil connectorfrom the holder'then
changes,peelingor other damage lf there is dam- disconnectit. Checkthe thermal protectorfor conti-
age.replacethe clutchset. nuity. lf there is no continuity.replacethe thermal
protecror,
Checkthe rotor pulleybearingplay and drag by rotat-
ing the rotor pulley by hand Replacethe clutch set
with a new one if it is noisy or has excessiveplay/drag
NOTE:The thermal protectorwill have no continuity

above251.6to 262.4oF 1122lo128'C).When the tem-
peraturedrops below 2408 to 219.8"F(116to 104"C),
Measurethe clearancebetweenthe rotor pulleyand the thermalprotectorwill havecontinuity
the armature plate all the way around lf the clear-
. of the field coil
Checkresistance
ance is not within specifiedlimits,the armatureplate
must be removed and shims added or removedas
Field Coil Resistance:3.05to 3.35 O at 68"F (20"C)
required,followingthe procedureon page22-34
replacethe
lf resistanceis not within specifications,
Cl€arance:0.5 ! 0.15 mm {0.020t 0.006in)
field coil.
NOTE:The shims are availablein four thicknesses:
0 . 1m m , 0 . 2m m , 0 . 4m m a n d0 . 5m m
22-33
Compressor{SANDEN)
Clutch Overhaul
1. Removethe center nut while holding the armature 3. Removesnap ring B with snap ring pliers.
platewith the tool.
CENTERNUT NOTE:
17.6N.m {1.8kg{.m,'t3tbnft} . Be careful not to damage the rotor pulley and
compressorduring removal/installation.
A/C CLUTCHHOLDER . Once snap ring B is removed,replaceit with a
{Commerciallvaveilable)
Robinair:P/N 10204 new one.
Kent-Moore:P/N J37872
A
\ /
G::.
. r\t \\:g2rl -/ /
. - ! L ; j ' /
2. Removethe armatureplateby pullingit up by hand.
Removethe rotor pulleyfrom the shaftwith a puller

ARMATURE
PLATE and the specialtool.
NOTE:Placethe claws of the puller on the back of

the rotor pulley,not on the belt area;otherwisethe
rotor pulleycan be damaged.
TWOJAW PULLER
{Commercially
22-34
5. Removethe screwfrom the field coil groundtermi- 7. A s s e m b l ei n t h e r e v e r s eo r d e r o f d i s a s s e m b l y
nal,then disconnecthe field coil connector. Makenote of the followingitems.
R e m o v es n a p r i n g A w i t h s n a p r i n g p l i e r s ,t h e n
removethe field coil . lnstallthe fieldcoilwith the wire sidefacingdown.
. C l e a nt h e r o t o r p u l l e ya n d c o m p r e s s o sr l i d i n g
NOTE: surfaceswith non-petroleum solvent.
. Be carefulnot to damagethe field coil and com- . Make sure the snap rings are fully seatedin the
pressorduringremove/installation. groove.
. Once snap ring A is removed,replaceit with a . Make sure that the rotor pulley turns smoothly
new one. after it's reassembled
. When installingthe field coil, align the boss on . Routeand clamp the wires properlyor they can
the field coil with the hole in the compressor. be damagedbYthe rotor Pulley.
SNAP RINGA
Replace.
Positionthe rotor pulleysquarelyover the field coil.

Pressthe rotor pulley onto the compressor boss
with the specialtool. lf the rotor pulley does not
press on straight, remove it, and check the rotor
pulleyand compressorbossfor burrsor damage.
CAUTION: Maximum press load: 39,200 kPa

(,[00kgf/cm', 5,590Psi)
Press
T HUB ASSEMBLY
GUIDEATTACHMENT
07965 - 6920500
ROTOR
PULLEY
t'l
i,'
22-35
Compressor(SANDENI
ThermalProtestorReplacement ReliefValveReplacement
1. Removethe bolt,the groundterminaland the hold- '1.
Removethe reliefvalveand the O-ring.
er. Disconnectthe field coil connector.then remove
the thermal Drotector. NOTE:
. Do not let the compressoroil runout.
7.{ N.m 10.75ksf.m,5lbtfr)
. Make sure that no foreign matter enters the sys-
GROUND tem,
/ IERMINAL
HOI.I'ER
PNOTECTOR
o o RELIEF
VALVE
9.8 N.m {1.0kgl.m,
7.2 tbl.lrl
O.RING
Replace.
Cleanthe matingsurfaces.
Replace the O-ringwith a new one at the reliefvalve.

Replacethe thermal protectorwith a new one. and a n d a p p l y a t h i n c o a t o f r e f r i g e r a n to i l b e f o r e
apply siliconesealantto the top of the thermalpro- installingit.
tector.
NOTE:
. To avoid contamination.do not returnthe oil to
the containeronce dispensed,and never mix it
with other refrigerantoils.
o lmmediatelyafter using the oil, replacethe cap
on the container,and seal it to avoid moisture
absorption.
. Do not spill the refrigerantoil on the vehicle;it
may damagethe paint; if the refrigerantoil con-
tactsthe paint,wash it off immediately.
Installand tightenthe reliefvalve.
SILICONESEALANT Charge the system {see page 22-461,and test its

performance1se6page 22-241.
3. Install in the reverse order of removal.
22-36
Compressor(DENSO)
Replacement
1 . l f t h e c o m p r e s s oirs m a r g i n a l l yo p e r a b l er, u n t h e 7. Loosenthe pivot bolt of the idler pulleybracketand
engineat idlespeed,and let the air conditioning work the adjusting bolt. then remove the A,/Ccompressor
for a few minutes,then shutthe engine off beltfrom the pulleys.lf necessary,removethe mount-
ing bolts from the left front mount. then remove the
the negativecablefrom the battery'
Disconnect fuC compressorbelt through the gap betweenthe
bodv and the left front mount.
Recoverthe refrigerantwith a recovery/recycling/
charging station lsee page 22-271
PIVOTBOLT
10x 1.25mm
Removethe each bolt, then disconnectthe suction 4,1N.m(4.5kgt'm,33lbfft)
and dischargelines from the compressor'Plug or
them
cap the lines immediatelyafter disconnecting
to avoid moistureand dust contaminatlon.
6 x '1.0mm
9.8 N.m (1.0kgf m,7.2 lbfft)
'10x 1,25mm
4,0N.m (,1.5kgf'm. 33 lbt ftl
Disconnectthe compressorclutch connector,then

removethe mountingboltsandthe compressor'
COMPRESSOR
Removethe condenser, the dis-

but do not disconnect
chargehosefrom the condenser(seepage22-441'
Removethe power steeringpump belt (seesectron

17]-.
24 N.m (2.4 kgf m, 17 lbf ftl
(cont'd)
22-37
Compressor(DENSOI
(cont'd)
Replacement
9. Removethe bolts,the suctionservicevalveand the 11. Installin the reverseorder of removal,and note these
O-ringfrom the compressor, rtems:
2s.5N.m{2.6kgf.m.18.8tbtttl lf you'reinstallinga new compressor. drainall the

refrigerantoil from the removedcompressor.and
m e a s u r ei t s v o l u m e . S u b t r a c tt h e v o l u m e o f
drainedoil from '140ml (4 28 fl{,z, 4.9 lmpoz); the
resultis the amountof oil you shoulddrainfrom
the new compressor(throughthe suctionfifting).
Replacethe O-ringswith new onesat eachfining,

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com manuals search engine

This manual contains information for the 1996- 2000 ClVlC. lt is

!@ Indicates a sttong possibility of sover. perconal iniurY

GAUTION: Indicaiqs a possibility ot p€lsonal injury or 6quipm.nt

All intormationcontainedin this manual is basedon the latestprod

FirstEdition8/99 1848Pages HONOAMOTORCO.,LTD.

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L: EastLiberty,Ohio Plant,U.S.A. B-73M CycloneBlueMetallic

4: DX with A'lC,HX with A,,/C,

Vehicleldentification Number EngineNumber !)

O ' L: EastLiberty,Ohio Plant,U S.A.

Manufacturer,Make and ] '1600SOHC16-valves

ao VehicleldentificationNumbel NH-503P GranadaBlackPearl

Line, Body and EngineType

Manufacturer,Make and EngineType

5: EX with ABS and IVC

Manulacturet, Make and

VehicleldentificationNumber Paint Code

G-82P Cypress Green Pearl

Manufacturel,Make and EngineType

Manufacturer,Make and EngineType

Manufaclurer,Make and EngineType

Manufacturer,Make and EngineType

Manufacturer,Makg and EngineType

VehicleldentificationNumber Paint Code

Manufaqturer, Makg and EngineType

5: Sedan/s-speed Manual TransmissionType

'96 -99 model C: DRIVERMODULEOANGER

Llo BEFOREREMOVINGSTEERINGSHAFT CONNECTING

SUPPLEMENTAL RESTRAINT SYSTEMISRS}

CALIFORNIA+ NLEV{RESTRICTEDI TLEV:

50 STATELEV+ CFFV+ NLEV {UNRESTRICTED}:

50 STATETLEV + NLEV (UNRESTRICTED):

EvaporativeFamily: Y HNX R OO99

CALIFORNIA+ NLEV (RESTR|CTEDt

50 STATELEV + CFFV+ NLEV {UNRESTRTCTED):

50 STATETLEV+ NLEV (UNRESTRICTED}:

1 . Placethe lift blocksas shown.

and rockthe vehicleto be sure it is firmly supported'

3 . Raisethe hoistto full height,and inspectlift pointsfor solidsupport

Raisethe vehicle high enough to insert the safety

4. Adjust and place the safety stands so the vehicle

lf the vehicleneedsto be towed,call a professional tow- Front:

Flat-bedEquipment- The operator loads the vehicle on

Wheel Lift Equipment- The tow truck usest\ivopivoting

Sling-type Equipment- The tow truck uses metal cables

lf the vehiclecannotbe transportedby flat-bed.it should

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StandardsandServiceLimits "'.".'.""' 3-2

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Compression 250rpm and wide openthroftle

Endplay 0.05- 0.15(0.002- 0.006)

Fuelpaessure wilh fuel pressureregulatorvacuumhose

Capacity I (USgal,lmp gal) 4 5 { 1 1 . 99, . 9 )

016Y5 670 1 50 700t 50

Clutch- Serr tion12

Mainshaft End play

T r a n s m i s s i ooni l Capacity | (US qt, lmp qt) 2 . 3( 2 . 4 , 2 . 0f o) r o v e r h a u l

Transmission Capacity f (US qt, lmp qti 5.9(6.2,5.2)Ioroverhaul

Clutch end plate thickness M"*l 2.3- 2.4{0.091 0.094) Discoloration

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Mainshaft feedpipeB,O.D.(at30 mm {1.2in)from end) 5.97 5.9810.2350- 0.2354i 5 . 9 5( 0 . 2 3 4 )