97-00 Acura 1.6 EL Repair Manual

Chassis and Paint Codes 1-2Identification Number locations 1-3Warning/Caution label locations 1-4Lift and Support PointsLift and Safety Stands 1-7Floor Jack 1-8

Towing 1-9

General Information

Vehicle Identification Numberand Canadian Motor VehicleSafety Standard Certification

COLORB-73M

Paint Code

B-73MG-82PNH-503PR-97RP-27M

Cyclone Blue MetallicCypress Green PearlGranada Black PearlRoma RedPrimrose Mist Metallic

ColorPaint Code

r- Paint Code

APBA - 1000001

Transmission Type T--JAPBA: 4-speed Automatic TransmissionS40 : 5-speed Manual Transmission

Seriai Number __J

APBA: 1000001 ..S40 : 1000001 ..

r- Transmission Number

D16Y8 - 2750001

Engine Type T__;D16Y8: 1.6 e SOHC VTEC 16-valves

Sequential MultiportFuel-injected Engine

Seriai Number _J

Engine Number

1-2

Body Type and Transmission Type -5: Sedan/5-speed Manual6: Sedan/4-speed

AutomaticVehicle Grade -----------'

4: Standard5: Standard with ABS6: Sport7: Premium

Check Digit ---1

ModelYear -----------~V: 1997

Factory Code -------------'H: Alliston Plant, Ontario, Canada

Seriai Number --------------'

Manufacturer, Make andType of Vehicle

2HH: HONDA OF CANADAMFG.,INC.ACURA Passençer car

line, Body and Engine TypeMB4: 1.6ELJD16Y8

JVehicle Identification Number

2HH MB45 4 *V H 900001

Chassis and Paint Codes1

1-3

Engine Number

Vehicle IdentificationNumber (VIN)

Vehicle IdentificationNumber (VIN)

Identification Number Locations

NOTICE ;SRS'• NO SERVICEABLEPARTSINSIDE.• REFERTO SERVICEMANUAl FORDETAILEDINSTRUC

TIONS.

G: MONITORCAUTION

NOTICETO PREVENTSRS DAMAGE, REMOVE STEERINGWHEElBEFORE REMOVING STEERING SHAFT CONNECTINGBOLT.

F:STEERINGCOLUMNNOTICE

& WARNINGTHE AIRBAG INFLATOR IS EXPLOSIVEAND, IF ACCIDENTAllY DEPLOYED,CAN SERIOUSLYHURT VOU. FOllOWSERVICEMANUAl INSTRUCTIONSCAREFULLY.

SUPPlEMENTAl RESTRAINTSYSTEM(SRS)THIS VEHIClE IS EOUIPPEDWITH DRIVER AND FRONTSEATPASSENGERAIRBAGS.All SRS ELECTRICALWIRING AND CONNECTORSARECOLOREDYEllOW.TAMPERINGWITH, DISCONNECTINGOR USING ELECTRICAL TEST EOUIPMENTON THE SRSWIRING CAN MAKETHE SYSTEM INOPERATIVEOR CAUSE ACCIDENTAl FIRINGOFTHEINFlATOR.

E:SRSWARNING (HOODI

1 SRS 1

~ AlWAYSWEARYOURSEATBElT• THIS CARIS EOUIPPEDWITH A DRIVERAIRBAGAND A

FRONTSEAT PASSENGERAIRBAG AS A SUPPlEMENTAL RESTRAINTSYSTEM(SRS).

• IT IS DESIGNEDTOSUPPLEMENTTHESEATBel T.• BEFOREDRIVING, READ lABEL INSIDE THE GLOVE

BOX.

0: DRIVERINFORMATION:(SUNVISOR)

1-4

& DANGEREXPlOSIVE/FlAMMABlECONTACTWITH ACID, WATEROR HEAVY METAlS SUCHAS COPPER.lEAD ORMERCURYMAY PRODUCEHARMFUlAND IRRITATING GASES OR EXPLOSIVE COMPOUNDS.STORAGE TEMPERATURES MUST NOT EXCEED 200°F(100°C).FORPROPERHANDlING, STORAGEAND DISPOSAl PROCEDURESREFERTO SERVICEMANUAl, SRS SUPPLEMENT.POISONCONTAINSPOISONOUSSODIUM AZIDEAND POTASSIUMNITRATE.FIRSTAID:IF CONTENTSARESWAllOWED, INDUCEVOMITING. FOREYECONTACT,FLUSHEYESWITHWATERFOR15MINUTES.IFGASES(FROMACIDORWATERCONTACT)AREINHALED,SEEKFRESHAIR. IN EVERYCASE,GETPROMPTMEDICALATTENTION.KEEPOUTOFREACHOFCHILDREN.

C:DRIVERMODULEDANGER

& WARNINGTHE AIRBAG INFlATOR IS EXPLOSIVEAND IF ACCIDEN·TAllY DEPlOYED,CANSERIOUSlY HURTORKill VOU.• DO NOT USEElECTRICAl TESTEQUIPMENTOR PROBe

INGDEVICES.THEYCANCAUSEACCIDENTAl DEPlOYMENT.

• NO SERVICEABlE PARTSINSIDE. DO NOT DISASSEMBLE.#. PLACEAIRBAGUPRIGHTWHENREMOVED.

• FOllOW SERVICEMANUAllNSTRUCTIONSCAREFUllY.

B: DRIVERMODULEWARNING

-SRSINSTALLATION OF THE SRS CABLEREel IS CRITICALTOTHEPROPEROPERATIONOFTHESRSAIRBAGSYSTEM.REFERTO SERVICEMANUAl FORDETAILED INSTALLA·TION INSTRUCTIONS.

A: CABLEREel CAUTION

Warning/Caution label locations

1-5

& WARNINGTHE AIRBAG INFLATOR IS EXPLOSIVE AND, IF ACCIDENTALLY DEPLOYED, CAN SERIOUSLY HURT OR KILL VOU.• DO NOT USE ELECTRICAL TEST EQUIPMENT OR PROB

ING DEVICES.THEY CAN CAUSE ACCIDENT AL DEPLOYMENT.

• NO SERVICEABLE PARTS INSIDE. DO NOT DISASSEMBLE.

• PLACE AIRBAG UPRIGHT WHEN REMOVED.• FOLLOW SERVICE MANU AL INSTRUCTIONS CAREFULLY.

& DANGEREXPLOSIVE/FLAMMABLECONTACT WITH ACID, WATER OR HEAVY METALS SUCHAS COPPER, LEAD OR MERCURY MAY PRODUCE HARMFUL AND IRRITATING GASES OR EXPLOSIVE COMPOUNDS. STORAGE TEMPERATURES MUST NOT EXCEED200°F (100°C). FOR PROPER HANDLlNG, STORAGE ANDDISPOSAL PROCEDURES REFER TO SERVICE MANUAL,SRS SUPPLEMENT.POISONCONTAINS POISONOUS SODIUM AZIDE AND POTASSIUMNITRATE.FIRST AIDIF CONTENTS ARE SWALLOWED, INDUCE VOMITING. FOREVE CONTACT, FLUSH EYES WITH WATER FOR 15 MINUTES. IF GASES (FROM ACID OR WATER CONTACT) AREINHALED, SEEK FRESH AIR IN EVERY CASE, GET PROMPTMEDICAL ATTENTION.KEEP OUT OF REACH OF CHILDREN.

1:FRONT SEAT PASSENGER MODULE DANGER

(cont'dl

G

H

AIRBAG INFORMATIONSUPPLEMENTAL RESTRAINT SYSTEM (SRS)• THE SRS MUST BE INSPECTED TEN YEARS AFTER IT IS

INST ALLED. THE DATE OF INSTALLATION IS SHOWNON THE CERTIFICATION PLATE, LOCATED ON THEDRIVER'S DOORJAMB.

• DIAGNOSTIC CHECKS AND REPLACEMENT OF SRSCOMPONENTS MUST BE DONE BY AN AUTHORIZEDDEALER.

• SEE YOUR OWNER'S MANUAL FOR ADDITIONAL SRSINFORMATION.

H: SRS INFORMATION LABEL (GLOVE BOX)

E

1-6

TIRE INFORMATION

BATTERV CAUTION

1)'-----nil

---------/ 1 \(~q i

See page 1-4

COOlANT INFORMATION

SRSWARNING

SEflVICEINFORMATION

(cont'd)

Warning/Caution label Locations

1-7

REAR SUPPORT POINTLIFT BLOCKSFRONT SUPPORT POINT

3. Raise the hoist to full height and inspect lift points for solid support.

2. Raise the hoist a few inches (centimeters) and rock the vehicle to be sure it is firmly supported.

1. Place the lift blocks as shown.

NOTE:• Since each tire/wheel assembly weighs approximately 30 lbs (14 kg), placing the front wheels in the luggage area can

assist with the weight distribution.• Use the same support points to support the vehicle on safety stands.

i·'#i;MIdN When heavy rear components such as suspension, fuel tank, spare tire, and trunk lid are to be removed,place additional weight in the luggage area before hoisting. When substantial weight is removed from the rear of thevehicle, the center of gravit y may change and can cause the vehicle to tip forward on the hoist.

Lift and Safety Stands

Lift and Support Points

1-8

LIFT PLA TFORM

Center the jackbracket in the middleof the jack lift platform.

REAR:LIFT PLA TFORM

Center the jackingbracket in the middleof the jack lift platform.

'MhMMN• Always use safety stands when working on or under

any vehicle that is supported by only a jack.• Never attempt to use a bumper jack for lifting or

supporting the vehicle.

FRONT:

4. Adjust and place the safety stands so the vehiclewill be approximately level, then lower the vehicleonto them.

3. Raise the vehicle high enough to insert the safetystands.

2. When lifting the rear of the vehicle, put the gearshiftlever in reverse (Automatic transmission in Œl position).

1. Set the parking brake and block the wheels that arenot being lifted.

Floor Jack

Lift and Support Points

1-9

TOWING HOOK

Rear:

TIE DOWN HOOKS

Front:

CAUTION:• Improper towing preparation will damage the trans

mission. Follow the above procedure exactlv. If voucannot shift the transmission or start the engine(automatic transmission), vour vehicle must be transported on a flat-bed.

• It is best to tow the vehicle no farther than 50 miles(80 km), and keep the speed below 35 mph (55 km/h).

• Trying to lift or tow vour vehicle bV the bumpers willcause serious damage. The bumpers are not designedto support the vehicle's weight.

Manual Transmission• Release the parking brake.• Shift the transmission to neutral.Automatic Transmission• Release the parking brake.• Start the engine.• Shift to ,D~;position, then [ffi position.• Turn off the engine.

If the vehicle cannot be transported by flat-bed, it shouldbe towed with the front wheels off the ground. If due todamage, the vehicle must be towed with the frontwheels on the ground, do the following:

Sling-type Equipment - The tow truck uses metal cableswith hooks on the ends. These hooks go around parts ofthe frame or suspension, and the cables lift that end ofthe vehicle off the ground. The vehicle's suspension andbody can be seriously damaged if this method of towingis attempted.

Wheel lift Equipment - The tow truck uses two pivotingarms that go under the tires (front or rear) and lifts themoff the ground. The other two wheels remain on theground.

Flat-bed Equipment - The operator loads the vehicle onthe back of a truck. This is the best way of transporting thevehicle.

Emergency TowingThere are three popular methods of towing a vehicle:

If the vehicle needs to be towed, cali a professional towing service. Never tow the vehicle behind another vehicie with just a rope or chain. It is very dangerous.

Towing

Standards and Service Limits 2-2Design Specifications 2-11Body Specifications 2-14

Specifications

specs

2-2

r-- ym er ea a ve ram- ec IonMEASUREMENT STANDARD (NEW) j SERVICE LlMIT

Compression 250 rpm and wide open throttlekPa (kgf/cm2, psi) Nominal 1,270 (13.0, 184)

Minimum 930 (9.5, 135)Maximum variation 200 (2.0, 28)

Cylinder head Warpage -- 0.05 (0.002)Height 92.95 - 93.05 (3.659 - 3.663) --

Camshaft End play 0.05 - 0.15 (0.002 - 0.006) 0.5 (0.02)Camshaft-to-holder oil clearance 0.050 - 0.089 (0.002 - 0.004) 0.15 (0.006)Total runout 0.03 (0.001) max. 0.04 (0.002)Cam lobe height IN Primary 37.065 (1.4592) --

Mid 38.274 (1.5068) --Secondary 36.778 (1.4479) --

EX 38.008 (1.4964) --Valve Valve clearance (Cold) IN 0.18 - 0.22 (0.007 - 0.009) --

EX 0.23 - 0.27 (0.009 - 0.011) --Valve stem 0.0. IN 5.48 - 5.49 (0.2157 - 0.2161) 5.45 (0.2146)

EX 5.45 - 5.46 (0.2146 - 0.2150) 5.42 (0.2134)Stem-to-guide clearance IN 0.02 - 0.05 (0.001 - 0.002) 0.08 (0.003)

EX 0.05 - 0.08 (0.002 - 0.003) 0.11 (0.004)

Valve seat Width IN 0.85 - 1.15 (0.033 - 0.0451 1.6 (0.063)EX 1.25 - 1.55 (0.049 - 0.061) 2.0 (0.079)

Stem installed height IN 53.17 - 53.64 (2.093 - 2.112) 53.89 (2.122)EX 53.17 - 53.64 (2.093 - 2.112) 53.89 (2.122)

Valve spring Free length IN 58.0 (2.28) --EX 58.7 (2.31) --

Valve guide 1.0. IN 5.51 - 5.53 (0.217 - 0.218) 5.55 (0.219)EX 5.51 - 5.53 (0.217 - 0.218) 5.55 (0.219)

Installed height IN 17.85 - 18.35 (0.703 - 0.722) --EX 18.65-19.15 (0.734-0.754) --

Rocker arm Arm-to-shaft clearance 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)

6S tlTc r d H dIV 1

": When using a new belt, adjust deflection or tension to new values. Run the engine for 5 minutes then turn it off.Readjust deflection or tension to used belt values.

r- nglOe ectnca - ec IonMEASUREMENT STANDARD (NEW)

Ignition coil Rated voltage V 12Primary winding resistance at 68°F (20°C) n 0.63 - 0.77Secondary winding resistance at 68°F (20°C) kn 12.8 - 19.2

Ignition wire Resistance at 68°F (20°C) kn 25 max.

Spark plug Type See section 4Gap 1.0 - 1.1 (0.043 -~.oo,)

Ignition timing At idle 12° ± 2°° BTOC (Red)

Alternator belt· Oeflection with 98 N (10 kgf, 22 Ibfl 8.0 - 10.5 (0.31 - 0.41) with used beltbetween pulleys 6.0 - 8.5 (0.24 - 0.33) with new belt

Belt tension N (kgf, Ibf) 340 - 490 (35 - 50, 77 - 110) with used beltMeasured with belt tension gauge 540 - 740 (55 - 75, 121 - 165) with new belt

STANDARD (NEW) SERVICE LlMIT

Alternator Output 12 V at hot A 75(MITSUBISHI) Coil resistance (rotor) at 68°F (20°C) kn 3.4 - 3.8 --

Slip ring 0.0. 22.7 (0.89) 22.2 (0.87)Brush length 19.0 (0.75) 5.0 (0.20)Brush spring tension 9 (oz) 300 - 450 (10.6 - 15.9) --

Starter motor Type Gear reduction(MITSUBA Commutator mica depth 0.4 - 0.5 (0.Q16 - 0.020) 0.15 (0.006)1.0 kW Commutator runout o - 0.02 (0 - 0.0008) 0.05 (0.002)1.2 kW) Commutator 0.0. 28.0-28.1 (1.102-1.106) 27.5 (1.083)

Brush length 15.8 - 16.2 (0.62 - 0.64) 11.0 (0.43)Brush spring tension (new) 15.7 - 17.7 --N (kgf, Ibfl (1.60 - 1.80, 3.5 - 4.0)

4S fElE

1Standards and Service Limits

2-3

,- ngme u rlca lon- ec IonMEASUREMENT STANDARD (NEWI 1 SERVICE LlMIT

Engine oil Capacity e (US qt, Imp qt) 4.0 (4.2, 3.5) for engine overhaul3.6 (3.8, 3.2) for oil change, including filter3.3 (3.5, 2.9) for oil change, without filter

Oil pump Inner-to-outer rotor radial clearance 0.02 - 0.14 (0.001 - 0.0061 0.20 (0.008)Pump housing-to-outer rotor radial clearance 0.10 - 0.18 (0.004 - 0.007) 0.20 (0.008)Pump housing-to rotor axial clearance 0.03 - 0.08 (0.001 - 0.003) 0.15 (0.006)

Relief valve Pressure setting with oil temperature 176cF (80°C)kPa (kgf/cm2, psi) at idle 70 (0.7. 101min.

at 3.000 rpm 340 (3.5, 50) min.

8S tlLb" t"E

- ngme OC - ec IonMEASUREMENT STANDARD (NEW) SERVICE LlMIT

Cylinder block Warpage of deck surface 0.07 (0.003) max. 0.10 (0.0041Bore diameter 75.00 - 75.02 (2.953 - 2.954) 75.07 (2.9561Bore taper -- 0.05 (0.002)Reboring limit -- 0.5 (0.021

Piston Skirt 0.0. at 5 mm (0.2 in) 74.980 - 74.990 (2.9520 - 2.9524) 74.970 (2.9516)from bottom of skirt

Clearance in cylinder 0.D10 - 0.040 (0.0004 - 0.00161 .0.05 (0.002)Groovè width (for ring) Top 1.020 - 1.030 (0.0402 - 0.0406) 1.05 (0.041)

Second 1.220 - 1.230 (0.0480 - 0.0484) 1.25 (0.049)Oil 2.805 - 2.820 (0.1104 - 0.1110) 2.85 (0.112)

Piston ring Ring-to-groove clearance Top 0.035 - 0.060 (0.0014 - 0.0024) 0.13 (0.005)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 0.30 - 0.45 (0.012 - 0.018) 0.70 (0.028)Oil 0.20 - 0.70 (0.008 - 0.0281 0.80 (0.031)

Piston pin 0.0. 18.994 - 19.000 (0.7478 - 0.7480) --Pin-to-piston clearance 0.D10 - 0.022 (0.0004 - 0.0009) --

Connecting Pin-to-red interference 0.014 - 0.040 (0.0006 - 0.00161 --rod Small end bore diameter 18.96 - 18.98 (0.746 - 0.747) --

Large end bore diameter Nominal 48.0 (1.891 --End play installed on crankshaft 0.15 - 0.30 (0.006 - 0.012) 0.40 (0.016)

Crankshaft Main journal diameter 54.976 - 55.000 (2.1644 - 2.1654) --Rod journal diameter 44.976 - 45.000 (1.1707 - 1.1717) --Taper 0.0025 (0.0001) max. 0.005 (0.0002)Out-of-round 0.0025 (0.0001) max. 0.005 (0.0002)End play 0.10 - 0.35 (0.004 - 0.014) 0.45 (0.018)Total ru no ut 0.03 (0.001) max. 0.04 (0.002)

Bearings Main bearing-to-journal oil clearanceNo. 1 and 5 journals 0.D18 - 0.036 (0.0007 - 0.0014) 0.05 (0.002)No. 2, 3 and 4 journals 0.024 - 0.042 (0.0009 - 0.0017) 0.05 (0.002)

Rod bearing-to-journal oil clearance 0.020 - 0.038 (0.0008 - 0.00151 0.05 (0.002)

Unit of length: mm (in)7S tiBI kE

2-4

- u c - ec IonMEASUREMENT STANDARD (NEW) SERVICE LlMIT

Clutch pedal Pedal height to floor 165 (6 1/2) --Stroke 130- 140(5.12-5.51) --Pedal play 12 - 21 (0.47 - 0.83) --Disengagement height to floor 83 (3.27) --

to carpet 44 (1.73) min. Reference --Flywheel Cluteh surface runout 0.05 (0.002) max. 0.15 (0.006)

Clutch dise Rivet head depth 1.3 - 1.9 (0.05 - 0.07) 0.2 (0.01)Thiekness 8.5 - 9.1 (0.33 - 0.36) 5.5 (0.22)

Pressure plate Warpage 0.03 (0.001) max. 0.15 (0.006)Diaphragm spring fingers alignment 0.6 (0.02) max. 1.0 (0.04)

12S fCI t h

r-- ue an mlSSlon- ec JonMEASUREMENT STANDARD (NEW)

Fuel pressure Pressure with fuel pressure regulator vacuum hose 260 - 310 (2.7 - 3.2,38 - 46)regulator disconnected kPa (kgf/cm2, psi)

Fuel tank Capacity f (US gal, Imp gal) 45(11.9,9.9)

Engine Idle speed rpm MIT (neutral) 1 NT (ffi] or ~ position)

750 ± 50 1 750 ± 50Id le CO % 0.1 max.

11S fdEF

r-- 00IOg- ectronMEASUREMENT STANDARD (NEWI

Radiator Engine coolant capacity f (US qt, Imp qt) MIT 4.2 (4.4, 3.7) for overhaulincluding engine, heater, cooling 3.8 (4.0, 3.3) for coolant changeline and reservoir NT 4.3 (4.5, 3.8) for overhaul

Reservoir capacity: 3.9 (4.1, 3.4) for coolant change0.4 f (0.42 US qt, 0.35 Imp qt)

Radiator cap Opening pressure kPa (kgf/cm2, psi) 93 - 123 (0.95 - 1.25, 13.5 - 17.8)

Thermostat Start to opening oF (OC) 169 - 176 (76 - 80)Fullyopen oF (OC) 194 (90)Valve litt at fully open 8.0 (0.31) min.

Cooling fan Thermoswitch "ON" temperature oF (OC) 196 - 203 (91 - 95)Thermoswitch "OFF" temperature OF(OC) Subtract 5 - 15 (3 - 8) from actual "ON" temperature

10sC rStandards and Service Limits

2-5

;- anua ransmlsslon - ec IonMEASUREMENT STANDARD (NEW)

1 SERVICE LlMIT

Transmission oil Capacity e (US qt, Imp qt) 1.9 (2.0,1.7) for overhaul1.8 (1.9, 1.6) for oil change

Mainshaft End play 0.11 - 0.18 (0.004 - 0.007) AdjustDiameter of bail bearing contact area A 21.987 - 22.000 (0.8656 - 0.8661) 21.930 (0.8634)(Transmission housing side)Diameter of 4th, 5th gear contact area B 26.980 - 26.993 (1.0622 - 1.0627) 26.930 (1.0602)Diameter of 3rd gear contact area C 33.984 - 34.000 (1.3380 - 1.3386) 33.930 (1.3358)Diarneter of bail bearing contact area 0 25.977 - 25.990 (1.0227 - 1.0232) 25.920 (1.0205)(Clutch housing side)Runout 0.02 (0.001) max. 0.05 (0.002)

Mainshaft 3rd and 1.0. 39.009 - 39.025 (1.5358 - 1.5364) 39.07 (1.538)4th gears End play 3rd 0.06 - 0.21 (0.002 - 0.008) 0.33 (0.013)

4th 0.06 - 0.19 (0.002 - 0.007) 0.31 (0.012)Thickness 3rd 30.22-30.27 (1.190-1.192) SO.15 (1.187)

4th 30.12 - 30.17 (1.186 - 1.188) 30.05 (1.183)

Mainshaft 5th 1.0. 37.009 - 37.025 (1.4570 - 1.4577) 37.07 (1.459)gear End play 0.06 - 0.19 (0.002 - 0.007) 0.31 (0.012)

Thickness 28.42 - 28.47 (1.119 - 1.121) 28.35 (1.116)

Countershaft Diameter of needle bearing contact area A 30.000-30.015 (1.1811-1.1817) 29.950 (1.1791)Diameter of lst gear contact area B 35.984 - 36.000 (1.4167 - 1.4173) 35.930 (1.4146)Diameter of bail bearing contact area C 24.980 - 24.993 (0.9835 - 0.9840) 24.930 (0.9815)Runout 0.02 (0.001) max. 0.05 (0.002)

Countershaft 1st 1.0. 41.009 - 41.025 (1.6145 -1.6152) 41.07 (1.617)gear End play (When tightened by the specified torque) 0.03 - 0.10 (0.001 - 0.004) 0.22 (0.009)

Thickness 30.41 - 30.44 (1.197 - 1.198) 30.36 (1.195)

Countershaft 2nd

1

1.0. 44.009 - 44.025 (1.7326 - 1.7333) 44.07 (1.735)gear End play (When tightened by the specified torque) 0.04 - 0.12 (0.002 - 0.005) 0.24 (0.009)

Thickness 31.92 - 31.97 (1.257 - 1.259) 31.85 (1.254)

Spacer collar 11.0. 32.988 - 32.998 (1.2987 - 1.2991) 33.04 (1.301)(Countershaft 2nd ; 0.0. 38.989 - 39.000 (1.5350 - 1.5354) 38.93 (1.533)gear) length 32.03 - 32.06 (1.261 - 1.262) 32.01 (1.260)

Spacer collar 1.0. 27.002 - 27.012 (1.0631 - 1.0635) 27.06 (1.065)(Mainshaft 4th 0.0. 4th 33.989 - 34.000 (1.3381 - 1.3386) 33.93 (1.336)and 5th gear) 5th 31.989 - 32.000 (1.2594 - 1.2598) 31.93 (1.257)

length 4th 22.83 - 22.86 (0.899 - 0.900) 22.81 (0.898)5th 23.53 - 23.56 (0.926 - 0.928) 23.51 (0.926)

Reverse idler gear 1.0. 15.016 - 15.043 (0.5912 - 0.5922) 15.08 (0.594)Gear·to-reverse gear shaft clearance 0.032 - 0.077 (0.0013 - 0.0030) 0.14 (0.006)

Synchro ring Hinq-to-qear clearance (Ring pushed against gear) 0.73 - 1.18 (0.029 - 0.046) 0.4 (0.016)

Shift fork Fork finger thickness lst/2nd 6.2 - 6.4 (0.244 - 0.252) --3rd/4th 7.4 - 7.6 (0.291 - 0.299) --

Fork-to-synchro sleeve clearance 0.35 - 0.65 (0.014 - 0.026) 1.0 (0.04)

Reverse shift fork Fork pawl groove width 12.7 - 13.0 (0.50 - 0.51) --Fork-to-reverse idler gear clearance 0.5 - 1.1 (0.020 - 0.043) 1.8 (0.07)l-groove width 7.05 - 7.25 (0.278 - 0.285) --Fork-to-5th/reverse shift piece pin clearance 0.05 - 0.35 (0.002 - 0.014) 0.5 (0.02)

Shift arm A Inner diameter of shift arm C contact point 13.005 - 13.130 (0.5120 - 0.5169) --Shift arm A-to-shift arm C clearance 0.005 - 0.230 (0.0002 - 0.0091) 0.35 (0.014)

Shift arm B Inner diameter of shift arm B shaft contact point 13.973 - 14.000 (0.5501 - 0.5512) --Shift arm B-to-shaft clearance 0.013 - 0.070 (0.0005 - 0.0028) 0.16 (0.006)Shift arm B-to-shift piece clearance 0.2 - 0.5 (0.008 - 0.020) 0.62 (0.0244)Diameter of shift piece contact point 12.9 - 13.0 (0.508 - 0.512) 12.78 (0.5031)

Final driven gear Backlash 0.07 - 0.130 (0.0028 - 0.0051) 0.180 (0.0071)

Differentiai carrier Pin ion shaft bore diameter 18.010 - 18.028 (0.7091 - 0.7098) --Carrier-to-pinion shaft clearance 0.023 - 0.057 (0.0009 - 0.0022) 0.095 (0.004)Driveshaft bore diameter 26.025 - 26.045 (1.0246 - 1.0254) --Carrier-to-driveshaft clearance 0.045 - 0.086 (0.0018 - 0.0034) 0.14 (0.006)

Differentiai pinion Backlash 0.05 - 0.15 (0.002 - 0.006) --gear Pinion gear bore diameter 18.042 - 18.066 (0.7103 - 0.7113) --

Pinion gear-to-pinion shaft clearance 0.055 - 0.095 (0.0021 - 0.0037) 0.15 (0.006)

Set ring-to-bearing outer race o - 0.1 (0 - 0.004) Adjust with shim

Unit of length: mm (in)13S fITM

2-6

,....- u orna IC ransrnlsslon - ec IonMEASUREMENT STANDARD (NEW)

1SERVICE LlMIT

Transmission Capacity f (US qt, Imp qt) 5.9 (6.2, 5.2) for overhaulfluid 2.7 (2.9,2.4) for fluid change

Hydraulic Line pressure at 2,000 rpm in ffil or ® position 830 - 880 (8.5 - 9.0, 120 - 130) 780 (8.0, 110)pressure 1st clutch pressure at 2,000 rpm in lQ4~positionkPa 2nd clutch pressure at 2,000 rpm in ~ position 800 - 850 (8.2 - 8.7, 120 - 124) 760 (7.7, 1101(kgf/cm2, psi) with linear solenoid connector with linear sole no id

disconnected connector disconnected0- 150 (0 - 1.5, 0 - 21) 150 Il.5, 21)with linear solenoid connected to with linear solenoidbattery voltage connected to battery

voltage

3rd and 4th clutch pressure at 2,000 rpm in ~ posi- 810 - 860 (8.3 - 8.8, 118 - 125) 760 (7.8,110)tion with linear solenoid connector with linear solenoid

disconnected connector disconnected0-150(0-1.5,0-21) 150 (1.5, 21)with linear solenoid connected to with linear solenoidbattery voltage connected to battery

voltage

Stail speed rpm (Check with vehicle on level groundl 2,700 2,550 - 2,850

Clutch Clutch initial clearance lst,2nd 0.65 - 0.85 (0.026 - 0.033) --3rd,4th 0.40 - 0.60 (0.016 - 0.024) --

Clutch return spring free length 1st 32.0 (1.26) 30.0 (1.18)2nd, 3rd, 4th 30.5 (1.20) 28.5 (1.12)

Clutch disc thickness 1.88 - 2.00 (0.074 - 0.079) Until grooves worn outClutch plate thickness lst 1.55 - 1.65 (0.061 - 0.065) Discoloration

2nd, 3rd, 4th 1.95 - 2.05 (0.077 - 0.081)

Clutch end plate thickness Mark 1 2.05 - 2.10 (0.081 - 0.083) DiscolorationMark 2 2.15 - 2.20 (0.085 - 0.087) ~Mark 3 2.25 - 2.30 (0.089 - 0.091)Mark 4 2.35 - 2.40 (0.093 - 0.094)Mark 5 2.45 - 2.50 (0.096 - 0.098)Mark 6 2.55 - 2.60 (0.100 - 0.102)Mark 7 2.65 - 2.70 (0.104 - 0.106)Mark 8 2.75 - 2.80 (0.108 - 0.110)

1 Mark 9 2.85 - 2.90 (0.112 - 0.114) Discoloration

14S ff TA t

Standards and Service Limits

2-7

(cont'd)

r- U orna IC ransrnlsslon - ec IonMEASUREMENT STANDARD (NEW) SERVICE LlMIT

Transmission Oiameter of needle bearing contact areaOn mainshaft stator shaft bearing 22.980 - 22.993 (0.9047 - 0.9052) Wear or damageOn mainshaft 2nd gear 35.975 - 35.991 (1.4163 -1.4169)On mainshaft 4th gear collar 31.975 - 31.991 (1.2589 - 1.2595)On mainshaft 1st gear collar 30.975 - 30.991 (1.2195 - 1.2201)On countershaft (left side) 36.004 - 36.017 (1.4175 -1.4180)On countershaft 3rd gear collar 35.980 - 35.996 (1.4165 -1.4172)On countershaft 4th gear 27.980 - 27.993 (1.1016 - 1.1021)On countershaft reverse gear collar 31.975 - 31.991 (1.2589 - 1.2595)On countershaft 1st gear collar 31.975 - 31.991 (1.2589 -1.2595)On reverse idler gear shaft 13.990 - 14.000 (0.5508 - 0.5512) Wear or damage

Inside diameter of needle bearing contact areaOn mainshaft 1st gear 35.000 - 35.016 (1.3780 - 1.3786) Wear or damageOn mainshaft 2nd gear 41.000 - 41.016 (1.6142 -1.6148)On mainshaft 4th gear 38.000 - 38.016 (1.4961 - 1.4967)On countershaft 1st gear 38.000 - 38.016 (1.4961 - 1.4967)On countershaft 3rd gear 41.000 - 41.016 (1.6142 - 1.6148)On countershaft 4th gear 33.000 - 33.016 (1.2992 - 1.2998)On countershaft reverse gear 38.000 - 38.016 (1.4961 - 1.4967)On reverse idler gear 18.007 - 18.020 (0.7089 - 0.7094)On stator shaft (ATF pump side) 29.000 - 29.013 (1.1417 - 1.1422)On stator shaft (stator side) 27.000 - 27.021 (1.0630 - 1.0638)

Reverse idler gear shaft holder LO. 14.416 - 14.434 (0.5676 - 0.5683) Wear or damageEnd playMainshaft 1st gear 0.08 - 0.19 (0.003 - 0.007) --Mainshaft 2nd gear 0.05 - 0.13 (0.002 - 0.005) --Mainshaft 4th gear 0.075 - 0.185 (0.003 - 0.007) --Countershaft 1st gear 0.1 - 0.5 (0.004 - 0.020) --Countershaft 3rd gear 0.05 - 0.17 (0.002 - 0.007) --Countershaft 4th gear 0.10 - 0.18 (0.004 - 0.007) --Reverse idler gear 0.05 - 0.18 (0.002 - 0.007) --Countershaft reverse gear 0.10 - 0.25 (0.004 - 0.010) --

Selector hub 0.0. 51.87 - 51.90 (2.042 - 2.043) Wear or damageMainshaft 4th gear collar length 45.00 - 45.03 (1.771 - 1.773) --Mainshaft 4th gear collar flange thickness 4.435 - 4.525 (0.1746 - 0.1781) Wear or damageMainshaft 1st gear collar length 27.00 - 27.15 (1.063 - 1.069) --Countershaft distance collar length 38.87 - 38.90 (1.530 - 1.531) --

38.92 - 38.95 (1.532 - 1.533) --38.97 - 39.00 (1.534 - 1.535) --39.02 - 39.05 (1.536 - 1.537) --39.07 - 39.10 (1.538 - 1.539) --39.12 - 39.15 (1.540 - 1.541) --39.17 - 39.20 (1.542 - 1.543) --39.22 - 39.25 (1.544 - 1.545) --39.27 - 39.30 (1.546 - 1.547) --

Countershaft 3rd gear collar length 21.15 - 21.20 (0.8327 - 0.8346) --Countershaft reverse gear collar length 14.5 - 14.6 (0.571 - 0.575) --Countershaft reverse gear collar flangethickness 2.4 - 2.6 (0.094 - 0.102) Wear or damageCountershaft 1st gear collar length 14.5 - 14.6 (0.571 - 0.575) --Countershaft 1st gear collar tlange thickness 2.4 - 2.6 (0.094 - 0.102) Wear or damage

Unit of length: mm (in)14S fti TA t

2-8

~ u orna IC ransrmssron con - ec IonMEASUREMENT STANDARD (NEW) SERVICE lIMIT

Transmission Mainshaft 2nd gear thrust washer thickness 3.97 - 4.00 (0.156 - 0.1571 Wear or damage4.02 - 4.05 (0.158 - 0.159)4.07 - 4.10 (0.160 - 0.161)4.12 - 4.15 (0.162 - 0.163)4.17 - 4.20 (0.164 - 0.165)4.22 - 4.25 (0.166 - O. 167)4.27 - 4.30 (0.168 - 0.169)4.32 - 4.35 (0.170 - 0.171)4.37 - 4.40 (0.172 - 0.173)4.42 - 4.45 (0.174 - 0.175) Wear or damage

Thrust washer thicknessMainshaft bail bearing left side 2.95 - 3.05 (0.116 - 0.120) Wear or damageMainshaft lst gear 2.43 - 2.50 (0.096 - 0.098) 4,Countershaft 3rd gear splined washer 4.45 - 4.50 (0.175 - 0.177) Wear or damage

One-way clutch contact area 1.0.Countershaft 1st gear 83.339 - 83.365 (3.2810 - 3.28211 Wear or damageParking gear 66.685 - 66.698 (2.6254 - 2.6259) Wear or damage

Mainshaft feed pipe A. 0.0. (at 15 mm from end) 8.97 - 8.98 (0.353 - 0.354) 8.95 (0.352)Mainshaft teed pipe 8. 0.0. (at 30 mm trom end) 5.97 - 5.98 (0.2350 - 0.2354) 5.95 (0.234)Countershaft feed pipe 0.0. (at 15 mm from end) 7.97 - 7.98 (0.3138 - 0.3142) 7.95 (0.313)Mainshaft sealing ring thickness 1.87 - 1.97 (0.074 - 0.078) 1.80 (0.071)(29 mm and 35 mm)

Mainshaft bushing 1.0. 6.018 - 6.030 (0.2369 - 0.2374) 6.045 (0.2380)Mainshaft bushing 1.0. 9.000 - 9.015 (0.3543 - 0.3549) 9.03 (0.356)Countershaft bushing 1.0. 8.000 - 8.Q15 (0.3150 - 0.3156) 8.03 (0.316)Mainshaft sealing ring goove width 2.025 - 2.075 (0.0797 - 0.0817) 2.08 (0.082)

Regulator Sealing ring contact area 1.0. 35.000 - 35.025 (1.3780 - 1.3782) 35.050 (1.3799)valve body

Shifting device and Reverse shift fork finger thickness 5.90 - 6.00 (0.232 - 0.2361 5.40 (0.213)parking brake con- Parking brake pawl -- 1Wear or other defecttrol Parking gear --Servo body Shift tork shaft bore 1.0. 14.000 - 14.010 (0.5512 - 0.5516) --

Shift fork shaft valve bore 1.0. 37.000 - 37.039 (1.4567 - 1.4582) 37.045 (1.4585)

ATF pump ATF pump gear side clearance 0.03 - 0.05 (0.001 - 0.002) 0.07 (0.003)ATF pump gear-to-body clearance Drive 0.1050 - 0.1325 (0.0041 - 0.0052) --

Driven 0.0350 - 0.0625 (0.0014 - 0.0025) --ATF pump driven gear 1.0. 14.016 - 14.034 (0.5518 - 0.5525) Wear or damageATF pump driven gear shaft 0.0. 13.980 - 13.990 (0.5504 - 0.5508) Wear or damage

Differentiai Pinion shaft contact area 1.0. 18.000 - 18.018 (0.7087 - 0.7094) --carrier Carrier-to-pinion clearance 0.Q16 - 0.052 (0.0006 - 0.0020) 0.1 (0.004)

Driveshaft contact are 1.0. 26.005 - 26.025 (1.0238 - 1.0246) --1 Carrier-to-driveshaft clearance 0.025 - 0.066 (0.0010 - 0.0026) 0.12 (0.005)

Differentiai 8acklash 0.05 - 0.15 (0.002 - 0.006) --pinion gear 1.0. 18.042 - 18.066 (0.7103 - 0.7113) --

Pin ion gear-to-pinion shaft clearance 0.059 - 0.095 (0.0023 - 0.0037) 0.1510.006)

Set ring-to-bearing outer race clearance 0- 0.15 (0 - 0.006) Adjust

14S t"t'dltl TA t

Standards and Service Limits

2-9

MIS: Manual steenng, PIS: Power steenng": When using a new belt, adjust deflection or tension to new values. Run the engine for 5 minutes then turn it off.

Readjust the deflection or tension to used belt values.

- eermg - ec IonMEASUREMENT STANDARD (NEW)

Steering wheel Play at steering wheel circumference 0- 10 (0 - 0.4)Starting load at steering wheel circumferenceN (kgf, IbnManual steering 15 (1.5, 3.3)Power steering Engine running 29 (3.0, 6.6)

Gearbox1

Angle of rack guide screw loosened 20° Maxfrom locked positionPreload at pin ion gear shaft N·m (kgf·cm, lbf-in) 0.6 - 1.2 (6 - 12, 5.20 - 10.42)

Pump Pump pressure with valve closed 6,400 - 7,400 (65 - 75,920 - 1,070)(oil temp./speed: 40°C (105CF) min./idle.Do not run for more than 5 seconds).kPa (kgf/cm2, psi)

Power steering Recommended power steering fluid HONDA Power Steering Fluid (V or S)fluid Fluid capacity e (US ct, Imp qt) 0.85 (0.90, 0.75) at disassembly

Reservoir 0.4 (0.42, 0.35)

Power steering Deflection with 98 N (10 kgf, 22 Ibn 10.5 - 14.0 (0.41 - 0.55) with used beltbelt" between pulleys 7.5 - 10.0 (0.30 - 0.39) with new belt

Tension measured with belt tension gaugeN (kgf, lbf) 340 - 490 (35 - 50, 77 - 110) with used belt

640 - 780 (65 - 80, 143 - 176) with new belt

17S tiSt

r- -STANDARD (NEW)

MEASUREMENTWire Dia. 0.0. Free length No. of Coils

Springs Regulator valve spring A 1.8 (0.071) 14.7 (0.584) 87.8 (3.457) 16.5Regulator valve spring B 1.8 (0.071) 9.6 (0.381) 44.0 (1.732) 11.0Stator reaction spring 4.5 (0.177) 35.4 (1.407) 30.3 (1.193) 1.9Modutator valve spring 1.4 (0.055) 9.4 (0.374) 35.0 (1.378) 10.9Torque converter check valve spring 1.0 (0.039) 8.4 (0.334) 33.8 (1.331) 8.2Cooler relief valve spring 1.0 (0.039) 8.4 (0.334) 33.8 (1.331) 8.2Relief valve spring 1.1 (0.043) 8.6 (0.342) 37.1 (1.461) 13.42nd orifice control valve spring 0.7 (0.028) 6.6 (0.262) 34.8 (1.370) 22.01-2 shift valve spring 0.9 (0.035) 7.6 (0.302) 41.3 (1.626) 16.32-3 shift valve spring 0.9 (0.035) 7.6 (0.302) 57.0 (2.244) 26.83-4 shift valve spring 0.9 (0.035) 7.6 (0.302) 57.0 (2.244) 26.81st accumulator spring 2.1 (0.083) 16.0 (0.636) 89.1 (3.508) 16.24th accumulator spring B 2.3 (0.091) 10.2 (0.402) 51.6 (2.031) 13.84th accumulator spring A 2.6 (0.102) 17.0 (0.676) 87.0 (3.425) 14.22nd accumulator spring A 2.4 (0.094) 29.0 (1.152) 39.0 (1.535) 2.93rd accumulator spring A 2.8 (0.110) 17.5 (0.695) 89.3 (3.516) 15.62nd accumulator spring B 1.6 (0.063) 9.0 (0.358) 20.7 (0.815) 6.13rd accumulator spring B 2.2 (0.087) 31.0 (1.220) 35.1 (1.382) 2.42nd accumulator spring C 2.2 (0.087) 14.5 (0.576) 68.0 (2.677) 13.9lock-up shift valve spring 0.9 (0.035) 7.6 (0.302) 73.7 (2.902) 32.0lock-up timing valve spring 0.9 (0.035) 8.1 (0.319) 80.7 (3.177) 45.8lock-up control valve spring 0.7 (0.028) 6.6 (0.262) 38.0 (1.496) 14.13-4 orifice controt valve spring 0.7 (0.028) 6.6 (0.262) 37.5 (1.476) 24.6Servo control valve spring 1.0 (0.039) 8.1 (0.322) 52.1 (2.051) 20.8CPC valve spring 0.6 (0.024) 5.6 (0.223) 12.2 (0.480) 5.5CPB valve spring 0.9 (0.035) 8.1 (0.322) 47.2 (1.858) 18.34th exhaust valve spring 0.9 (0.035) 6.1 (0.242) 36.4 (1.433) 19.5

Unit of length: mm (in)Section 14Automatic Transmission

2-10

*: When using a new belt, adjust deflection or tension ta new values. Run the engine for 5 minutes then turn it off.Readjust deflection or tension ta used belt values.

- Ir on Ilonm9- ec IonMEASUREMENT i STANDARD (NEW)

Air Lubrieant type: SP-l0 (P/N 38899 - P13 - AOl or 38897 - P13 - A01AH) (For refrigerant: HFC-134a (R·134a))Conditioning Lubricant eapaeity Condenser 20 (2/3 0.7)system me (fi oz, Imp oz) Evaporator 45 (1 1/2, 1.6)

Line or hase 10 (1/3, 0.4)Receiver 10 (1/3,0.4)

Compressor Lubricant type: SP-l0 (PIN 38899 - P13 - AOl or 38897 - P13 - A01AH) (For refrigerant: HFC-134a (R-134a))Lubricant capacity me (fi oz, Imp oz) 130 - 150 (41/3 - 5,4.6 - 5.3)Field coil resistance at 68°F (20°C) n 3.05 - 3.35Pulley-to-pressure plate clearance 0.5 ± 0.15 (0.020 ± 0.006)

Compressor Deflection with 98 N (10 kgf, 22 Ibf) 7.5 - 9.5 (0.30 - 0.37) with used beltbelt* between pulleys 5.0 - 6.5 (0.20 - 0.26) with new belt

Belt tension N (kgf, Ibf) 340 - 490 (35 - 50, 77 - 110) with used beltMeasured with belt tension gauge 690 - 830 (70 - 85, 154 - 187) with new belt

22S tiA" C diti

....- ra es- ec IonMEASUREMENT STANDARD (NEW) SERVICE LlMIT

Parking brake Play in stroke at 196 N (20 kgf, 44 Ibf) lever force Ta be locked when pulled --lever 6 - 9 notchesFoot brake Pedal height (with floor mat removed) MIT 156.5 (6.16) --pedal AIT 161 (65/16) --

Free play 1 - 5 (1/16 - 3/16) --Master cylinder Piston-to-pushrod clearance 0- 0.4 (0 - 0.02) --Dise brake Dise thickness Front 20.9 - 21.8 (0.82 - 0.86) 19.0 (0.75)

Dise runout Front -- 0.10 (0.004)Dise parallelism Front -- 0.Q15 (0.0006)Pad thickness Front 9.5 - 10.5 1.6 (0.06)

Rear brake 1.0. 200 (7.87) 201 (7.91)drum Lining thiekness 4.0 (0.16) 2.0 (0.08)

19S tlB k

- uspenslon - ec IonMEASUREMENT STANDARD (NEW) SERVICE lIMIT

Wheel Camber Front 0°00' :!: ,. --alignment Rear -, ° :!: , ° --

Caster Front ,040' :!: ,. --Total toe Front ln 2 :!: 2 (0.08 :!: 0.08) --

Rear ln 2 ~~(0.08 'gg! ) --Front wheel turning angle Inward wheel 35°50' --

Outward wheel 35°50' (Reference) --Wheel Rim runout Aluminum wheel Axial 0- 0.7 (0 - 0.03) 2.0 (0.08)

Radial 0- 0.7 (0 - 0.03) 1.5 (0.06)Steel wheel Axial 0- 1.0 (0 - 0.04) 2.0 (0.08)

Radial 0- 1.0 (0 - 0.04) 1.5 (0.06)

Wheel bearing End play Front o - 0.05 (0 - 0.002) --Rear 0- 0.05 (0 - 0.002) --

18S tlsStandards and Service limits

2-11

(cont'd)

Gear reduction/MITSUBA1.0 kW, 1.2 kW

12 V30 seconds

Clockwise as viewed trom gear end

125 e (132 US qt, 110 Imp qt)/minuteUNLEADED gasoline with 86 Pump

Octane Number or higher

Belt driven, SOHC 4 valve per cylinderForced and wet sump, trochoid pump33.4 e (35.3 US qt, 29.4 Imp qt)/minute

9.6

Water-cooled, 4-stroke SOHC VTECgasoline engine

Inline 4-cylinder, transverse75.0 x 90.0 mm 1 2.95 x 3.54 in1,590 cm- (mi) 97.0 cu-in

1,600 kg

Five

Type/MakeNormal OutputNominal VoltageHour RatingDirection of Rotation

Cylinder ArrangementBore and StrokeDisplacementCompression RatioValve TrainLubrication SystemOil Pump Displacement at 6,800 engine rpmWater Pump Displacementat 6,000 engine rpmFuel Required

Type

Gross Vehicle Weight Rating (GVWR)

Ground ClearanceSeating Capacity

176.3 in67.1 in54.9 in

103.1 in58.1/58.1 in

5.9 in

4,478 mm1,705 mm1,395 mm2,620 mm

1,475/1,475 mm150 mm

Front/Rear

Overall LengthOverall WidthOverall HeightWheelbaseTrack

STARTER

ENGINE

WEIGHT

DIMENSIONS

NOTESENGLISHMETRICITEM

Design Specifications

2-12

- conITEM METRIC

1ENGLISH NOTES

STARTER (cont'd) Weight MITSUBA 1.0, 1.2 kW 3.4 kg 1 7.51bf

CLUTCH Clutch Type MIT Single plate dry, diaphragm springAIT Torque converter

Clutch Facing Area MfT 160 cm' 1 25 sq-in

TRANSMISSION Transmission Type MfT Synchronized 5-speed forward, 1 reverseAIT 4-speed automatic, 1 reverse

Prirnarv Reduction Direct 1 : 1

TRANSMISSION Manual transmissionGear Ratio lst 3.250

2nd 1.9093rd 1.2504th 0.9095th 0.702Reverse 3.153

Final Reduction Gear ratio 4.250

Gear type Single helical gear

Automatic transmissionGear Ratio lst 2.722

2nd 1.5163rd 0.9754th 0.638Reverse 1.954

Final Reduction Gear ratio j 4.357

Gear type Single helical gear

AIR Cooling Capacity 3,530 Kcal/h 1 14,000 STU/hCONDITIONING Compressor Type/Make Scroll/Sanden

No. of Cylinder --Capacity 85.7 mÎ Irev 1 5.22 cu-in/rev

1Max. Speed 10,000 rpmLubricant Capacity 130 mÎ

1

4 1/3 fi oz. SP-l04.61mp oz

Condenser Type Corrugated fin

Evaporator Type Corrugated fin

Siower Type Sirocco fanMotor Input 200 W/12 VSpeed Control 4-speed variableMax. Capacity 460 m3/h l 16,200 cu-ft/h

Temperature Control Air-mix type

Compressor Clutch Type

1

Dry, single plate, poly-V-belt drivePower Consumption 40 W max./12 V at 68°F (20°C)

Refrigerant Type1

HFC-134a (R-134a)Quantity 650 -gog

122.9 _~80Z

Design Specificationst'd)

2-13

ITEM METRIC1

ENGLISH NOTES

STEERING Type Power assisted, rack and pinionSYSTEM Overall Ratio 17.7

Turns, l.ock-to-Lock 3.6Steering Wheel Dia. 380 mm 1 15in

SUSPENSION Type Front and Rear Independent double wishbone, coil springShoek Absorber Front and Rear Telescopie, hydraulie nitrogen gas-filled

WHEEL Camber Front 0°00'ALlGNMENT Rear _1°

Caster Front 1°40'Total Toe Front In2mm l 0.08 in

Rear In2mm ln 0.08 inBRAKE SYSTEM Type Front Power-assisted self-adjusting

ventilated diseRear Power-assisted self-adjusting solid dise

Pad Surface Area Front 37.5 cm- x 2 1 5.8 sq-in x 2Parking Brake Type Mechanical aetuating, rear two wheel brakes

TIRE Size Front and Rear P195/55R1584VSpare Tire T125170D14

ELECTRICAL Battery 12 V - 38AH/5HRStarter 12 V - 1.0 kW, 1.2 kWAlternator 12V-75AFuses ln Under-dash Fuse/Relay Box 7.5 A, 10 A, 15 A, 20 A

ln Under-hood Fuse/Relay Box 7.5 A, 10A. 15 A, 20 A, 30 A, 40 A, 80 Aln Under-hood ABS Fuse/Relay Box 7.5 A, 20 A, 40 A

Headlights High/Low 12V-60/55WFront Turn Signal 12V-50CPRear Turn Signal Lights 12V-21WBrakefTailiights 12 V - 21/5 WTaillights 12 V - 5 WHigh Mount Brake Light 12V-21 WBack-up Lights 12V-21Wlieense Plate Lights 12 V-8WCeiling Light 12 V - 8 W (With moonroof)

!12 V - 5 W (Without moonroof)

Trunk Lights 12V-3.4WGauge Lights 12 V - 1.4 W. 3 W. 3.4 WIndieator Lights 12 V - 1.12 W. 1.4 W, 3 WIllumination and Pilot Lights 12V-0.84W,l.4W

DloQ.<en-c(1)n-.~-.nCU~-.o:::JVI

33

C::J~;

1,475 (58.11

4,478 (176.3)

2,620 (103.11

- ...(/1..w• U)~U'I

1,705 (67.11

1,475 (58.11

Lubrication Points 3-2Maintenance ScheduleNormal Conditions 3-4Severe Conditions !. 3-6

Maintenance

3-2

*1: Always use Genuine Honda Manual Transmission Fluid (MTF). Using motor oil can cause stiffer shifting because itdoes not contain the proper additives.

*2: Always use Genuine Honda Premium Formula Automatic Transmission Fluid (ATF). Using a non-Honda ATF can affectshift quality.

*3: Always use Genuine Honda DOT3 Brake Fluid. Using a non-Honda brake fluid can cause corrosion and decrease the lifeof the system.

*4: Always use Genuine Honda Power Steering Fluid (V or SI. Using any other type of power steering fluid or automatictransmission fluid can cause increase wear and poor steering in cold weather.

1 1 1 Il! 1 1 :-20 20 40 60 80 100°F

30 20 -10 0 10 20 30 40°C

Engine oil viscositv forambient temperature ranges

.'; ~ • J j t ~ + J;, 41

Recommended Engine QilAPI CERTIFICATION SEAlAPI SERVICE LABEL

No. LUBRICATION POINTS LUBRICANT

1 Engine API Service Grade: Use SH "Energy Conserving Il'' grade oil.The oil container may also display the API Certification Sealshown below. Make sure it says "For Gasoline Engines."SAEViscosity: See chart below.

2 Transmission Manual Genuine Honda MTF*'

Automatic Genuine Honda Premium FormulaAutomatic Transmission Fluid (ATF)*2

3 8rake Line Genuine Honda 00T3 8rake Fluid*3

4 Clutch Line Genuine Honda 00T3 8rake Fluid*3

5 Power steering gearbox Steering grease PIN 08733 - 8070E

6 Shift lever pivots (manual transmission) Grease with molybdenum disulfide

7 Release fork (manual transmission) Super High Temp Urea Grease (PIN 08798 - 9002)

8 Steering boots9 Steering bail joints10 Shift lever (automatic transmission)11 Pedallinkage12 8rake master cylinder pushrod13 Trunk hinges and latch14 Door hinges upper and lower

Multi-purpose grease15 Door opening detents16 Fuel filler lid17 Engine hood hinges and engine hood latch18 Clutch master cylinder pushrod19 Throttle cable end and throttle linkage20 Rear brake shoe linkages21 Steering wheel (back side)

22 Caliper piston seal, dust seal,caliper pin, piston 1 Silicone grease

23 Throttle cable end (dashboard lower panel)

24 Power steering system 1 Genuine Honda Power Steering Fluid (V or S)*425 Air conditioning compressor Compressor oil:

SANDEN: SP-l0 PIN 38899 - P13 - AOlor 38897 - P13 - A01AH(For Refrigerant: HFC-134a (R-134a))

For the details of lubrication points and types of lubricants to be applied, refer to the IIlustrated Index and various workprocedures (such as Assembly/Reassembly, Replacement, Overhaul, Installation, etc.) contained in each section.

Lubrication Points

1

3-3

/

@@ ® ®

S2 D)0

_.~ ::::J3 r+QJ CI)- ::::J0 C)0 :::s:::J nC- CI)a:0 CI):l nen ~

CI)e,c-CI)

Service at the indicated dis- miles x 1.000 15 30 45 60 75 90 105 120 SECTIONtance or time whichever km x 1.00ll 24 48 72 96 120 144 168 192 NOTE andcomes first. months 12 24 36 48 60 72 84 96 PAGE

Replace engine oil Replaceevery 7,500miles (12,000km) or 12months Capacity for change with filter: 8·43.6 f (3.8 US qt. 3.2 Imp qt)

Replace engine oil filter • • • • • • 1 • • 8-5.6Check engine oil and coolant Check ail and coolant at each fuel stop Check levels and check for leaks. 8-4. 10-4

Replace air cleaner element • • • • 11-123

Intake: 0.18 - 0.22 mm (0.007 - 0.009 in)Inspect valve clearance Inspect at 30.000 miles (48,000 km) only Exhaust: 0.23 - 0.27 mm (0.009 - 0.011 in) 6-10

Measured when cold

Replace spark plugs • • • • ZFR5F-l1 4-21Gap: 1.0 - 1.1 mm 10.039- 0.043 in)

Replacetiming belt and inspect water pump • Replace the timing belt. 6-17, 10-11Check water pump for signs of seal leakage.

Check for cracks and damage.Check deflection and tension at center of following belts 4-34

Inspect and adjust drive belts • • • • pressing with 98 N (10 kgf, 22 Ibf) tension: 17-14Alternator drive belt: 8.0 - 10.5 mm (0.31 - 0.41 in)PIS purnp belt: 10.5 - 14.0 mm (0.41 - 0.55 in) 22-37

AlC compressor belt: 7.5 - 9.5 mm (0.30 - 0.37 in)

Inspect idle speed • 750 ± 50 rpm (M!T: neutral)11-103750 ± 50 rpm (AIT: [ID or [f] position)

Capacity for change:

Replace engine coolant • • • M!T: 3.8 f (4.0 US qt. 3.3 Imp qt) 10-5,6AIT: 3.9 f (4.1 US qt, 3.4 Imp qt)Check specific gravit y for freezing point.

Manual transmission: Genuine Honda MTF 1.8 f (1.9 US

Replace transmission fluid • qt. 1.6 Imp qt) for change 13-3Automatic transmission: 2.7 t 12.9US qt, 2.4 Imp qt) for 14-95change with Genuine Honda Premium Formula ATF• Check the brake pad and disc thickness and free rnove-ment.

Inspect front and rear brakes • • • • • • • • • Check the wheel cylinder for leaks. 19-9, 11. 12.• Check the brake linings for cracking, glazing. wear. or 18.19.22contamination.

• Check the cali pers for leakage.Use Genuine Honda DOT3 brake fluid. Check that brake

Replace brake fluid • • fluid level is between the upper and lower marks on the 19-7reservoir.

Check parking brake adjustment • • • • • • • • Fullv engaged 6 to 9 notches . 19-6

Rotate tires The suggested rotation method is shown in the diagram(Check tire inflation and condition at least Rotate tires every 7,500 miles (12,000 km) --once per month) of the Owner's Manual.

W1~ Follow the Normal Conditions Maintenance Schedule if the severe driving conditions specified in the Severe Conditions Maintenance Schedule on pages 3-6 and 3-7 do not apply.

eN1(J1

For Canadamodel: Follow the Severe Conditions Maintenance Schedule on page 3-6 and 3-7.

According to state and federal regulations, failure to perform maintenance on the items marked with an asterisk (*) will not void customer's emission warranties.However, Honda recommends that ail maintenance services be performed at the recommended time or mileage period to ensure long-term reliability.

Service at the indicated miles x 1,000 15 30 45 60 75 90 105 120 SECTIONdistance or time whichever km x 1,000 24 48 72 96 120 144 168 192 NOTE andcomes first. months 12 24 36 48 60 72 84 96 PAGE

Visually inspectthe following items:

Tie-rod ends, steering gear box, and Checksteering linkage for looseness.Checkcondition of boots. 17-22boots Check for fluid leaks.

Suspension components Checkthe bolts for tightness. 18-8,9,Checkthe condition of bail joint boots. 20,21

Driveshaft boots Checkcondition of boots. 16-3Brake hoses and lines (including ABS) Check for damage or leakage. 19-4

10-4,• • • • • • • • Check levels, condition of fluids, and check for leaks. 13-3,Ali fluid levels and condition of fluid If brake fluid is low, check brake pad thickness. 14-95,19-7

1---

Cooling system hoses and connections Checkail hoses for damage, leaks, and deterioration. 10-2Check for proper fan operation.

Exhaust system* Checkthe catalyticconverter heat shield, exhaust pipe, 9-3,4and muffler for damage, leaks,and tightness. 11-126

f---

Fuel lines and connections* Checkfor leaks.Retighten looseconnectionsand 11-105replaceany damagedparts.Inspect supplemental restraint system 10years after production --

-CD

CI)Cl)<Cl)~Cl)

oo::sC-a:o::sfA

"1: Replace the timing belt at 60.000 miles (U.S.) 100.000 km (Canada) if the vehicle regularly is driven in one or more of these conditions:• In very high temperatures (over 110°F, 43CC).• In very low temperatures (under - 20°F, - 29°C).

Service at the indicated dis- miles x 1.000 15 30 45 60 75 90 105 120 SECTIONtance or time whichever km x 1.000 24 48 72 96 120 144 168 192 NOTE andcomes first. months 12 24 36 48 60 72 84 96 PAGE

Replace engine oil and oil filter Replace every 3.750 miles (6.000 km) or 6 months Capacity for change with filter: 8-43.6 l' (3.8 US qt, 3.2 Imp qt)

Check engine oil and coolant Check oil and coolant at each fuel stop Check levels and check for leaks. 8-4. 10-4Replace air cleaner elementUse normal schedule except in dusty condi- • • • • • • • • 11-123tions

Intake: 0.18 - 0.22 mm (0.007 - 0.009 in)Inspect valve clearance Inspect at 30.000 miles (48.000 km) only Exhaust: 0.23 - 0.27 mm (0.009 - 0.011 in) 6-10

Measured when cold

Replace spark plugs • • • • ZFR5F-ll 4-21Gap: 1.0 - 1.1 mm (0.039 - 0.043 in)

Replace timing belt*l and inspect water pump • Replace the timing belt. 6-17. 10-11Check water pump for signs of seal leakage.

Check for cracks and damage.Check deflection and tension at center of folfowing belts 4-34

Inspect and adjust drive belts • • • • pressing with 98 N (10 kgf. 22 Ibf) tension: 17-14Alternator drive belt: 8.0 - 10.5 mm (0.31 - 0.41 in)PIS pump belt: 10.5 - 14.0 mm (0.41 - 0.55 in) 22-37

AlC compressor belt: 7.5 - 9.5 mm (0.30 - 0.37 in)

Inspect id le speed • 750 ± 50 rpm (MIT: neutral) 11-103750 ± 50 rpm (AIT: [ffi or ŒJ position)

Capacity for change:

Replace engine coolant • • • MIT: 3.8 f (4.0 US qt, 3.3 Imp qt) 10-5.6AIT: 3.9 f (4.1 US qt. 3.4 Imp qt)Check specifie gravit y for freezing point.

Manual transmission: Genuine Honda MTF 1.8 t (1.9 US

Replace transmission fluid • • • • qt, 1.6 Imp qt) for change 13-3Automatic transmission: 2.7 f (2.9 US qt. 2.4 Imp qt) for 14-95change with Genuine Honda Premium Formula ATF• Check the brake pad and dise thickness and free move-ment.

Inspect front and rear brakes Inspect every 7.500 miles (12,000 km) or 6 months • Check the wheel cylinder for leaks. 19-9.11.13.• Check the brake linings for cracking. glazing. wear, or 18, 19. 22contamination.

• Check the calipers for leak.Use Genuine Honda DOT3 brake fluid. Check that brake

Replace brake f1uid • • fluid level is between the upper and lower marks on the 19-7reservoir.

Check parking brake adjustment • • • • • • • • Fully engaged 6 to 9 clicks. 19-6

Follow the Severe Conditions Maintenance Schedule if the vehicle is driven MAINLY under one or more of the Severe Driving Conditions (page 3-7):eN1en

eN1

--..J

NOTE: If the vehicleis drivenOCCASIONALLy undera "severe" condition,vou should follow the NormalConditionsMaintenanceScheduleon pages3-4and3-5.

SevereOrivingConditions:• Driving lessthan 5 miles (8 km) per trip or, in freezingtemperatures,driving lessthan 10miles (16km) per trip.• Driving in extremelyhot lover 90°F(32°C))conditions.• Extensiveidling or long periodsof stop-and-godriving.• Trailer towing, driving with a car-topcarrier,or driving in mountainousconditions.• Driving on muddy, dusty, or de-icedroads.

Accordingto stateand federal regulations,failure to performmaintenanceon the itemsmarkedwith an asterisk(*) will not void custorner'semissionwarranties.However,Hondarecommendsthat ail maintenanceservicesbeperformedat the recommendedtime or mileageperiod to ensurelong-term reliability.

Service at the indicated miles x 1,000 15 30 45 60 75 90 105 120 SECTIONdistance or time whichever km x 1,000 24 48 72 96 120 144 168 196 NOTE andcomes first. months 12 24 36 48 60 72 84 96 PAGE

Lubricate locks and hinges • • • • • • • • 3-2,3Clean antenna mast • • • • • • • • ---Rotate tires The suggested rotation method is shown in the dia-(Checktire inflation and condition at least Rotate tires every 7,500miles (12,000km) ---once per month) gram of the Owner's Manual.

Visually inspectthe following items:

Tie-rod ends, steering gear box, and Checksteering linkage for looseness.Checkcondition of boots. 17-22boots Checkfor fluid leaks.

Every 7,500miles (12,000km) or 6 months Checkthe bolts for tightness. 18-8,9,Suspension components Checkthe condition of bail joint boots. 20,21Driveshaft boots Checkcondition of boots. 16-38rake hoses and lines (including A8S) Checkfor damage or leakage. 19-4

Check levels, condition of fluids, and check for leaks. 10-4, 13-3,Ali fluid levels and condition of fluid If brake fluid is low, check brake pad thickness. 14-95,

19-7

Cooling system hoses and connections Checkail hoses for damage, leaks, and deterioration. 10-2• • • • • • • • Checkfor proper fan operation.

Exhaust system* Checkthe catalyticconverter heat shield, exhaust pipe, 9-3,4and muffler for damage, leaks,and tightness. 11-126

Fuel lines and connections" Checkfor leaks. 11-105Lights and controls Checkaillighting functions. ---Vehicle underbody Checkfor damageand fluid leaks. ---Inspect supplemental restraint system 10years after production ---

Chargi"ng SystemComponent Location Index 4-22Circuit Diagram 4-23Troubleshooting 4-24Alternator Replacement 4-28Alternator Overhaul 4-29Rectifier Removal 4-30Rectifier Test 4-31Rotor Slip Ring Test 4-32Alternator Brush Inspection 4-32Rear Bearing Replacement 4-33Alternator Reassembly 4-33Alternator Belt Inspection and

Adjustment 4-34Cruise Control

Component Location Index 4-35Circuit Diagram 4-36Control Unit Input Test 4-37Main Switch Test/Replacement 4-39Set/Resume Switch Test/

Replacement 4-39Actuator Test 4-41Actuator Replacement 4-42Actuator Cable Adjustment 4-42Actuator Solenoid Test 4-43Actuator Disassembly 4-44

r--:'II.!:!:I

Special Tools 4-2Starting System

Component Location Index 4-3Circuit Diagram 4-4Starter Test 4-5Starter Solenoid Test 4-6Starter Replacement 4-7Starter Overhaul 4-8Armature Inspection and Test 4-9Brush Inspection 4-11Overrunning Clutch Inspection 4-11Brush Holder Test 4-12Starter Reassembly 4-12Performance Test 4-13

Ignition SystemComponent Location Index 4-14Circuit Diagram 4-15Ignition Timing Inspection and

Setting 4-16Distributor Replacement 4-17Distributor Overhaul 4-18Ignition Control Module (lCM) Input

Test 4-19Ignition Co il Test 4-20Ignition Wire Inspection and

Test 4-20Spark Plug Inspection 4-21

Engine Electrical

-

4-2

* Included in the Belt Tension Gauge Set, TIN 07JGG - 001000A

Ref. No. Tooi Number Description aty Page Reference

CD A973X - 041 - XXXXX Vacuum Pump/Gauge, 0 - 30 in.Hg. 4-40*@ 07JGG - 001010A Belt Tension Gauge 4-33CID 07PAZ - 0010100 SCS Service Connector 4-16

Special Tools

1

4-3

STARTERTest, page 4-5Solenoid Test, page 4-6Replacement, page 4-7Performance Test, page 4-13

BATTERVTest, section 23

AIT GEAR POSITION SWITCHTest, section 14Replacement, section 14

STARTER CUT RELAV (MIT)Test, section 23

Component Location Index

~

~Starting System

: SECURITY

1 C~WR_O_l _j

BLK

~

CLUTCHSWITCH

( ON: Clutch pedal) :fully depressed

1-BLU/BlK

BLU/BLK

BLU/ORN

NO.3' UNDER-DASH(7.5A) FUSE/RELAY

BOX

BLK/RED

---_j

Arr GEARPOSITION SWITCH(ON: ln position [NJ or [Ë) )

: SECURITY1 CONTROLT

STARTER(Permanent magnet type)

BLK

~

f

B S

n---BLU/BLK

BLKIWHT

~I-- - - - - - - - - - - - - - STARTERCUT RELAY

BLK/RED

BLK/RED

BLK

4-4

IGNITIONSWITCHUNDER - HOOD FUSE/RELAy BOX

Circuit Diagram

Starting System

4-5

(cont'd)

9. Check for an open in the wire between the ignitionswitch and starter.

8. Checkthe AIT gear position switch (see section 14).

7. Check the starter cut relay and clutch interlock switch(see section 23),

6. Check the ignition switch (see section 23).

• If the starter still does not crank the engine,remove it, and diagnose its internai problem.

• If the starter cranks the engine, go to step 6.

SOlENOIDTERMINAL

BlK/WHTWIRE

- 5. Connect a jumper wire from the battery positive (+)terminal to the solenoid terminal.The starter should crank the engine.

4. Unplug the connector (BLK/WHT wire and solenoidterminal) from the starter.

3. Check the battery, battery positive cable, ground,starter eut relay, and the wire connections for looseness and corrosion. Test again ..If the starter still does not crank the engine, go tostep 4.

• If the starter does not crank the engine, go tostep 3.

• If it cranks the engine erratically or too slowly, goto "Check for Wear and Damage" on the nextpage.

2. Turn the ignition switch to START (III) with the shiftlever in [ID or (f] position (AIT) or with the clutch pedaldepressed (MIT). The starter should crank the engine.

1. Remove the No. 44 (15 A) fuse from the under-hoodfuse/relay box.

Check the Starter Engagement:

NOTE: After this test, or any subsequent repair, resetthe ECM/PCM to clear any codes (see section 11).

• Use following equipment:- Ammeter, 0 - 400 A- Voltmeter, 0 - 20 V (accurate within 0.1 volt)- Tachometer, 0 -1,200 rpm

• Hook up a voltmeter and ammeter as shown.

Alternate Procedure:

• Use a starter system tester.• Connect and operate the equipment in accordance

with the manufacturer's instructions.• Test and troubleshoot as described.

Recommended Procedure:

NOTE: The air temperature must be between 59 and100°F (15 and 38°C) before testing.

Starter Test

r:-:1~

2. Check the pull-in coil for conti nuit y between the Sand M terminais. The coil is OK if there is continuity.

S TERMINAL

STARTERCABLE

ARMATUREHOUSING(GROUND)

BTERMINALMOUNTING NUT9N'm (0.9 kgf·m,7Ib'·h)

1. Check the hold-in coil for conti nuit y between the Sterminal and the armature housing (ground). Thecoil is OK if there is continuity.

4-6

If the drive gear hangs up on the torque converter or tlywheel ring gear, check for:• solenoid plunger and switch malfunction.• dirty drive gear assembly or damaged overrunning

clutch.

With the shift lever in [ID or œJ position (NT) or with theclutch pedal depressed (MfT), turn the ignition switch toSTART (111), and release to ON (11).The starter drive gear should disengage from the torqueconverter or flywheel ring gear when vou release thekey.

Check Starter Disengagement

Check Cranking rpmEngine speed during cranking should be above 100 rpm.If speed is too low, check for:• loose battery or starter terminais.• excessively worn starter brushes.• open circuit in commutator segments.• dirty or damaged helical spline or drive gear.• defective drive gear overrunning clutch.

If cranking voltage is too low, or current draw too high,check for:• dead or low battery.• open circuit in starter armature commutator seg-

ments.• starter armature dragging.• shorted armature winding.• excessive drag in engine.

Check Cranking Voltage and Current DrawCranking voltage should be no less than 8.5 volts.Current draw should be no more than 350 amperes.

Check the drive gear overrunning clutch for binding orslipping when the armature is rotated with the drivegear held.If damaged, replace the gears.

Check for Wear and DamageThe starter should crank the engine smoothly andsteadily, If the starter enqaqes. but cranks the engineerratically, remove it, and inspect the starter drive gearand torque converter or flywheel ring gear for damage.

Starter Solenoid TestStarter Test (cont'd)

Starting System

4-7

5. Connect the battery positive cable and negative cableto the battery.

NUT

Crimped side of ringterminal

NOTE: When installing the starter cable, make surethat the crimped side of the ring terminal is facing out.

4. Install in the reverse order of removal.

3. Remove the two bolts holding the starter, th enremove the starter.

MOUNTING BOLT44 N'm (4.5 kgf·m,33Ibf.ft)

B TERMINAL

~g/

BTERMINALMOUNTING NUT9 N'm (0.9 kgf·m,7lbHt)

STARTERCABLE

2. Disconnect the starter cable from the B terminal onthe solenoid, then disconnect the BLK/WHT wirefrom the S terminal.

1. Disconnect the battery negative cable.

Starter Replacement

4-8

OVERRUNNINGCLUTCHInspection, page 4-"

GEAR HOUSINGCOVER

-~MOLYBDENUMDISULFIDE

SOLENOIDLEVER

STARTERSOLENOIDTest, page 4-6

ARMATURE HOUSINGNUT9 N'm (0.9 kgf·m, 7 IbHt)

~

ARMATUREInspection andTest, page 4-9

ENDCOVERBRUSHInspection, page 4-11

BRUSH HOLDERTest, page 4-12

OVERRUNNINGCLUTCH

~ .....~~+---SOLENOIDLEVER

CAUTION: Disconnect the battery negative cable beforeremoving the starter.

Starter Overhaul

Starting System

4-9

(cont'd)

COMMUTATOR

DIAL INDICA TOR

Standard (NEW) Service Limit

0- 0.02 mm 0.05mm(0 - 0.0008 in) (0.002 in)

Commutator Runout

• If the commutator runout is within the servicelimit, check the commutator for carbon dust orbrass chips between the segments.

• If the commutator runout is not within the service limit, replace the armature.

3. Measure the commutator runout.

VERNIER CALIPER


28.0 - 28.1 mm 27.5 mm(1.102-1.106 in) (1.083 in)

Commutator Diameter

• If the surface is dirty or burnt, resurface with emerycloth or a lathe within the following specifications,or recondition with #500 or #600 sandpaper.

• If commutator diameter is below the service limit,replace the armature.

2. Check commutator surface and diameter.

Inspect for damage.

If there is wear or damage, replace the armature.

1. Inspect the armature for wear or damage due to contact with the permanent magnet or field winding.

Armature Inspection and Test

~

~

COMMUTATORCOll CORESHAFT

7. Check with an ohmmeter that no conti nuit y existsbetween the commutator and armature coil core,and between the commutator and armature shaft. Ifthere is continuity, replace the armature.

If the blade is attracted to the core or vibrates whilethe core is turned, the armature is shorted. Replacethe armature.

ARMATURE

ARMATURE TESTER

6. Place the armature on an armature tester. Hold ahacksaw blade on the armature core.

4-10

COMMUTATOR SEGMENT

5. Check for continuity between the segments of thecommutator. If an open circuit exists between anysegments, replace the armature.


0.4-0.5 mm 0.15 mm(0.016 - 0.02 in) (0.006 in)

Commutator Mica Depth

NOT GOOO

4. Check the mica depth. If necessary, undercut themica with a hacksaw blade to achieve the properdepth. If service limit cannot be maintained, replacethe armature.

Armature Inspection and Test (cont'd)

Starting System

4-11

4. Check the condition of the flywheel or torque converter ring gear if the starter drive gear teeth aredamaged.

3. If the starter drive gear is worn or damaged, replacethe overrunning clutch assembly; the gear is notavailable separately.

~y\\DRIVE GEAR

CLUTCH GEAR

2. Rotate the overrunning clutch both ways. Ooes itlock in one direction and rotate smoothly inreverse? If it does not lock in either direction or itlocks in both directions, replace it.

1. Siide the overrunning clutch along the shaft. Ooes itmove freely? If not, replace it.

NOTE: To seat new brushes after installing them in theirholders, slip a strip of #500 or #600 sandpaper, with thegrit side up, over the commutator and smoothly rotatethe armature. The contact surface of the brushes will besanded to the same contour as the commutator.


15.8- 16.2mm 11.0 mm(0.62 - 0.64 in) (0.43 in)

Brush Length

Measure the brush length. If not within the service limit,replace the brush holder assembly.

Overrunning Clutch InspectionBrush Inspection

r:-:I~

ENDCOVER

BRUSHHOLDER

3. Install the end cover on the brush h~der.

D

1

2. lnstall the armature in the housing. Next, pry backeach brush spring again, and push the brush downuntil it seats against the commutator, then releasethe spring against the end of the brush.

1. Pry back each brush spring with a screwdriver, thenposition the brush about halfway out of its holder,and release the spring to hold it there.

NOTE: Use the illustration on page 4-8 as reference forreassembly.

4-12

18.5- 23.5 N(1.85 - 2.35 kgf, 4.1 - 5.2 Ibf)

Spring Tension

BRUSH

SPRINGSCAlE

2. Insert the brush into the brush holder, and bring thebrush into contact with the commutator, then attacha spring scale to the spring. Measure the spring tension at the moment the spring lifts off the brush.

(±) BRUSH HOLDER(±) BRUSH HOlDER

e BRUSH HOLDERe BRUSH HOLDER

1. Check that there is no continuity between the Œ> ande brush holders.If there is continuity, replace the brush holderassembly.

Starter ReassemblyBrush Holder Test

Starting System

4-13

80 A or less (Electric current), 2,600 rpm or more(Motor-speed)

Specifications:

3. If the electric current and motor speed meet thespecifications when the battery voltage is at 11.5 V,the starter is working properly.

BATTERY

A

2. Connect the starter to the battery as described inthe diagram below, and confirm that the motorstarts and keeps rotating.

1. Clamp the starter firmly in a vise.

Starter No-Ioad Test:

BATTERY

CAUTION: Do not leave the battery connected for morethan 10 seconds.

Disconnect the battery also from the body. If the pinionretracts immediately, it is working properly.

Retracting Test:

BATTERY

sM


Disconnect the battery from the M terminal. If the pin iondoes not retract, the hoId-in coil is working properly.

Hold-in Coil Test:

Disconnect the wire.

BATTERY9 e

s


Connect the battery as shown. If the starter pin ion popsout, it is working properly.

Pull-in Coil Test:

NOTE: Before starting the following checks, disconnectthe wire from terminal M, and make a connection asdescribed below using as heavy a wire as possible (preferably equivalent to the wire used for the vehicle).

Performance Test

r--:'I~

4-14

DISTRIBUTORReplacement, page 4-17Overhaul, page 4-'8Ignition Coil Test, page 4-20Ignition Control MOdule (lCM)Input Test, page 4-19

SPARK PlUGSInspection, page 4-21

IGNITION WIRESInspection and Test, page 4-20

SERVICE CHECK CONNECTOR 12P)[Wire colors: BRN and BlK]

IGNITION TIMING CONTROL SYSTEM• Troubleshooting, section 11• Idle speed Inspection/Adjustment, section 11• Inspection and Setting, page 4-16


Ignition System

4-15

ECM/PCM

SPARKPLUGS

BLU

hBLU BLU

~TESTTACHOMETERCONNECTOR

. TACHOMETER

. PCM

IGNITIONWIRES

46 238 9

BLU

...... -- WHT/BLUTOC: Top dead centerCKP: Crankshaft positionCYP: Cylinder position

BIGNITION CONTROLMODULE (ICM)

(Has built-in )norsecondenser

IGNITIONCOlL

BLK/YEL YEL/GRNBLK/YEL

OISTRIBUTOR 10

ECM/PCMyYEL/GRN

Circuit Diagram

•

Disconnect the SCS service connector from the service check connector.

8.

Tighten the distributor mounting bolts, and recheckthe ignition timing.

7.

MOUNTING BOLTS18 N'm (1.8 kgf·m, 13 Ibf·h)

To RETARD

6. Adjust the ignition timing if necessary, as follows.Loosen the distributor mounting bolts, and turn thedistributor ignition (DI) housing counterclockwise toadvance the timing, or clockwise to retard the timing.

4-16

RED MARK

WHTMARK(TOC)

POINTER

MIT12°± 2° BTDC (RED)during idling inneutral

Aff 12°± 2° BTDC (RED)during idJing in [IDorœJ

Ignition Timing:

5. Check the ignition timing in no Joad conditions:headlights, blower fan, rear window defogger, andair conditioner are not operating.

4. Connect the timing light to the No. 1 ignition wire,then point the light toward the pointer on the timingbelt cover.

3. Start the engine. Hold the engine at 3,000 rpm withno load (AIT in lliJ or [ë], MIT in neutral) untiJ theradiator fan cornes on, then Jet it idle.

2. Remove the service check connector 2P (BRN andBLK wires) from the connector holder located underthe dash on the front passenger side, then connectthe SCS service connecter (TIN 07PAZ - 0010100) toit.

1. Check the idle speed, and adjust it if necessary (seesection 11).

Ignition Timing Inspection and Setting

Ignition System

4-17

7. After setting the ignition timing, tighten the mounting bolts.

6. Set the ignition timing (see previous page).

5. Connect the connector to the distributor.

NO.4No.2

No. 1 No. 3

No. 1CYLINDERMARK

4. Connect the ignition wires to the distributor ignition(DI) cap as shown.

3. InstalJthe mounting bolts, and tighten them lightly.

NOTE: The lug on the end of the distributor and itsmating grooves in the camshaft end are both offsetto eliminate the possibility of installing the distributor 1800out of time.

2. Slip the distributor into position.

1. Coat a new O-ring with engine oil, then install it.

NOTE: Before Vou install the distributor, bring the No. 1piston to compression stroke TOC.

Installation:

CAMSHAFT ENDDISTRIBUTOR END

3. Remove the mounting bolts from the distributor,then remove the distributor from the cylinder head.

2. Disconnect the ignition wires from the distributorignition (DI) cap.

1. Disconnect the connector from the distributor.

Removal:

Distributor Replacement

r:-:'I~

4-18

TDC/CKP /CYP SENSORTroubleshooting, section 11Do not disassemble.

OISTRIBUTOR IGNITION (DI) HOUSINGCheck for cracks and damage.

O-RING

IGNITION CONTROLMODULE (lCM)Input Test, page 4-19

IGNITION COlLTest, page 4-20

BLU

OISTRIBUTOR IGNITION (DI) CAPCheck for cracks, wear,damage, and fouling.Clean or replace.

lEAK COVER

OISTRIBUTOR IGNITION (DI) ROTOR

CAP SEALCheck for damage.

Distributor Overhaul

Ignition System

4-19

9. If ail the tests are normal, replace the ICM.

.8. Check for continuity on the BLUwire to body ground.There should be no continuity.

7. Check for continuity on the BLU wire between thetest tachometer connector and the ICM.There should be continuity.

6. Check for continuity on the YEL/GRN wire to bodyground.There should be no continuity. If there is continuity(short to ground), the ICM is probably damaged.

5. Disconnect the ECM/PCM connector A (32P). Checkfor continuity on the YEL/GRN wire between theECM/PCM and the ICM.There should be continuity.

• If there is no battery voltage, check:- the ignition coil.- the WHT/BLU wire between the ignition coil

and the ICM.• If there is battery voltage, go to step 5.

4. Turn the ignition switch ON (II). Check for voltagebetween the WHT/BLU wire and body ground.There should be battery voltage.

• If there is no battery voltage, check the BLK/YELwire between the under-dash fuse/relay box andthe ICM.

• If there is battery voltage, go to step 4.

3. Turn the ignition switch ON (II). Check for voltagebetween the BLK/YEL wire and body ground.There should be battery voltage.

BLK/YEL WIRE

2. Disconnect the wires from the ICM.

1. Remove the distributor ignition (DI) cap, the distributor ignition (DI) rotor and the leak cover.

NOTE:• See section 11 if the malfunction indicator lamp (MIL)

came on.• Perform an input test for the ignition control module

(ICM) after finishing the fundamental tests for theignition system and the fuel and emissions systems.

Ignition Control Module (lCM) Input Test

3. If resistance exceeds 25 kü, replace the ignition wire.

IGNITION WIRE

Ignition Wire Resistance:25 kü max. at 68°F (20°C)

2. Connect ohmmeter probes and measure resistance.

IGNITION WIRE

Check for broken,corrodee. and bentterminais.

1. Check the condition of the ignition wire terminaIs. Ifany terminal is corroded, clean it, and if it is brokenor distorted, replace the ignition wire.

CAUTION: Carefullv remove the ignition wires bVpulling on the rubber boots. Do not bend the wires; Voumight break them inside.

4-20

TERMINAL B (-)TERMINAL A (+)

SECONDARYWINDINGTERMINAL

NOTE: Resistance will vary with the coil temperature;specifications are at 6~oF (20°C).Primarv Winding Resistance(Between the A and B terminais):0.63 - 0.77 0Secondarv Winding Resistance(Between the A and secondary winding terminais):12.8 - 19.2 kO

Using an ohmmeter, measure resistance between theterminaIs. If the resistance is not within specifications,replace the ignition coil.

Ignition Wire Inspection and TestIgnition Coil Test

Ignition System

4-21

3. Apply a srnall quantity of anti-seize compound tothe plug threads, and screw the plugs into the cylinder head finger-tight. Then torque them to 18 N'm(1.8 kgf·m, 13 lbf-ft}.

ROUNDEDELECTRODE

Spark Plugs:ZFRSF-11 (NGK)KJ16CR-l11 (NOl

• Replace the plug if the center electrode is roundedas shown below:

1.1 mm(0.043 in)

Standard 1.1 -81 mm (0.043-8.004 in)

• Adjust the gap with a suitable gapping tool,

Electrode Gap

2. Check the electrode gap.

Fouled plugs may be caused by:• Retarded ignition timing• Oil in combustion chamber• Incorrect spark plug gap• Plug heat range too cold• Excessive idling/low speed running• Clogged air cleaner element• Deteriorated ignition coil or ignition wires

Burned or worn electrodes may be caused by:• Advanced ignition timing• loose spark plug• Plug heat range too hot• Insufficient cooling

• Improper gap• Oil-fouling• Carbon deposits• Cracked centerelectrode insulator

Worn or deformed

1. Inspect the electrodes and ceramic insulator for:

Spark Plug Inspection

r:-:'I~

4-22

ALTERNATOR BELTInspection and Adjustment, page 4-34

ALTERNATORTroubleshooting, page 4-24Replacement, page 4-28Rectifier Rernoval. page 4-30Rectifier Test. page 4-31Rear Bearing Replacement, page 4-33

BATTERY

UNDER-HOOD FUSE/RELA Y BOX

CHARGING SYSTEM LlGHT(In the gauge assemblylTest, section 23


Charging System

4-23

CHARGINGSYSTEMLlGHT(1.4W)

UNDER - HOOD FUSE/RELA y BOX

,-_--a._N./'O-,41 (BOA)-....;...1_..... ---- ......

Circuit Diagram

Wire side offemale terminais

IG(BLK/Y

1:

ALTERNATOR 3P CONNECTOR

Repair the open in the BlK/YElwire between the alternator andunder-dash fuse/relay box.

NO

YES 1 Go to Alternator/Regulator Test(see page 4-26).

Check for a blown No. 15 (7.5 A)fuse and a blown charging svstem light bulb. If the fuse andbulb are OK, repair the open inthe WHT IBlU wire.

NO

4-24

(T0 next page)

YES

Is there banery voltage?

Voltage Check: •Measure the voltage at the No. 2terminal of the 3P connector withthe ignition switch ON (II).

NO

Does the charging systemlight go off?

Charging System Light Check-2: 1Start the engine.

YES

Does the charging systemlight come on?

Charging System Light Check-1:Make sure the charging systemlight comes on.

Charging System Light Test

1. Battery (see section 23)2. Charging system light3. Voltage4. Alternator/regulator

If the charging system light does not come on or does not go off, or the battery is dead or low, test the following items inthe order listed below:

Troubleshooting

Charging System

4-25

(cont'd)

~L~T/BLU'

,/-=-'"

,

Wire side ofL female terminais

WHT/BLU)

ALTERNATOR 3P CONNECTOR

Test and repair the alternator 1components.

YES

Turn the ignition switch OFF, andrepair the open in the WHT /BLU wire.

NO

Turn the ignition switch OFF, andrepair the short to ground in theWHT/BLU wire.

NO

Does the charging systemlight go off?

Check for an open in the L circuit(cont'd):Disconnect the jumper witebetween the No. 3 terminal of the3P connector and ground.

YES

Does the charging systemlight come on?

Check for an open in the L circuit:1. Turn the ignition switch OFF.2. Disconnect the 3P connector

from the alternator.3. Ground the No. 3 terminal of

the 3P connector with ajumper wire.

4. Turn the ignition switch ON (III.

1

(From previous pagel

r:-:'I-==-

Test and repair the alternator components.

Replace the voltage regulator.

NEGATIVETERMINAL

INDUCTIVEPICK-UP

NEGATIVE TESTERCABLE (BLK)

VOLTSELECTOR

VOLTMETERNEGATIVELEAD (BLK)

FULL FIELDTESTERLEAD (BLU)

LOAD ADJUSTER(CARBON PILE)

YES

4-26

To next page

2

Alternator IRegulator Test-3:Apply a load with a VAT-40 untilthe battery voltage drops tobetween 12 - 13.5V.

NO

Is the voltage less than 13.5 V?

Alternator IRegulator Test-2:1. Release the accelerator pedal,

and let the engine idle.2. Make sure ail accessories are

turned off. Turn the selectorswitch to position 2 (charging).

3. Remove the inductive pick-up,and zero the ammeter.

4. Place the inductive pick-upover the battery ground cableso that the arrow points to thebattery negative terminal.

5. Raise the engine speed to2,000 rpm, and hold it there.

NO

Is the voltage over 15.1 V?

Alternator/Regulator Test-1:1. Connect a Sun VAT-40 (or

equivalent tester), and turnthe selector switch to position1 (starting).

2. Shift to neutral (AIT in ŒJ or[ffi) position, and start theengine. Hold the engine at3,000 rpm with no load untilthe radiator fan comes on,then let it idle.

3. Raise the engine speed to2,000 rpm, and hold it there.

NOTE: Make sure the battery is sufficiently charged (see section 23).

Alternator/Regulator Test

Troubleshooting (cont'd)

Charging System

4-27

Replace the voltage regulator.

YES

Test and repair the alternator cornponents.

NOIs the alternator output 50 A ormore?

END COVER

REGULATOR(Located insidethe end cover)

NOTE: Attach a probe to a VAT-40 full field test lead, and insert the probe into the full fieldaccess hole at the back of the alternator. Switch the field selector to the" A (Ground)" position momentarily, and check the amperage reading.

Alternator IRegulator Test-4:With the engine speed still at2,000 rpm, full-field the alternator.

CAUTION: The voltage will rise quickly when the alternator is full-fielded, Do not allowthe voltage to exceed 18 V; it may damage the electrical system.

NO

The charging system is OK.Is the amperage 50 A or more?

From previous page

r:-:1-=:1

8. Adjust the alternator belt tension after installation(see page 4-34).


6. Remove the lower mount bracket, then remove thealternator from below the vehicle.

5. Pull out the through boit, then remove the alternator from the mount brackets.

LOWER MOUNTBRACKET BOLTS44 N'm (4.5 kgf·m, 33 Ibf.ft)

MOUNTING NUT44 N·m (4.5 kgf·m. 33 Ibf.ft)

ADJUSTING BOLT24 N'm (2.4 kgf·m, 17 IbHt)

4. Remove the adjusting boit, mounting nut, thenremove the alternator belt from the pulley.

4-28

3. Remove the terminal nut and the WHT wire fromthe B terminal.

TERMINAL NUT8 N'm (0.8 kgf·m, 6 IbUt)

3P CONNECTOR

2. Disconnect the 3P connector from the alternator.

1. Remove the battery negative cable, then disconnectthe positive cable.

Alternator Replacement

Charging System

4-29

REAR HOUSING

BRUSHInspection, page 4-32

VOLTAGEREGULATOR

STATORTest, page 4-32

PULlEY LOCKNUT111 N'm 111.3kgf·m, 81.7Ibf.ftl

RECTIFIER ASSYTest, page 4-31Removal, page 4-30

THROUGHBOlT

CAUTION: Do not get grease oroil on the slip rings.

To loosen the pulley locknut, use the tools as shown. Ifnecessary, use an impact wrench.

NOTE: Do not remove the pulley unless the bearingsneed replacement.

24mmBOXWRENCH

REAR BEARINGReplacement, page 4-33

ALUMINUM PLATESAlternator Overhaul

REAR HOUSING

DRIVE-END HOUSING«:>

NOTE: Separate the rear housing and drive-endhousing with the stator attached to the rear housing.

4. Separate the rear housing and drive-end housing.

DRIVE-END HOUSING

REAR HOUSING-.NOTE: Be careful not to damage the stator with thetip of the screwdriver.

3. Separate the rear housing from the drive-end housing by inserting a fIat tip screwdriver into the openings and prying them a part.

4-30

2. Heat the rear bearing seat with a 1,000W hair drierfor about five minutes (120 - 140°F, 50 - 600e).

THROUGH BOLT

DRIVE-END HOUSING

1. Remove the four through bolts.

Rectifier Removal

Charging System

4-31

2. If any of the diodes fails, replace the rectifier assernbly. (Diodes are not available separately.)

B' EB P, Pl

1. Check for continuity in each direction between- the Band P terminais.- the B' and P terminais.- E (ground) and the P terminais.Ail diodes should have continuity in only one direction.

NOTE: The diodes are designed to allow current to passin one direction while blocking it in the opposite direction. Since the alternator rectifier is made up of ninediodes, each diode must be tested for continuity in bothdirections with an ohmmeter that has diode checkingcapability; a total of 18checks.

Rectifier Test

7. Install the new rectifier in the reverse order of removal.• Apply the soldering iron only long enough to

ensure a good connection so the heat will notdamage the diodes.

• Use only a rosin core type solder or solder jointswill corrode.

RECTIFIER DIODE

6. Unsolder the rectifier from the stator leads.• To avoid damaging the diodes with heat, pinch

the stator leads between pliers to carry heat off,and apply the soldering iron only long enough toseparate the leads from the rectifier .

• Use a 100W soldering iron.

TERMINAL NUT

5. Separate the rear housing from the stator/rectifierassembly by removing the four screws and the terminai nut.

r--:1I!::=J

SOLDE RING IRON

4. If the brushes are less than the service limit, replacethem.

5.0 mm (0.20 in)19.0 mm (0.75 in)

CID Service LimitCD Standard (NEW)

Alternator Brush length:

3. Measure the length of the brushes with verniercalipers.

2. Separate the rear housing from the stator/rectifierassembly by removing the four screws and the terminai nut from the rear housing (see page 4-30).

1. Separate the drive-end housing from the rear housing as described on page 4-30.

4-32

3. If the coil fails either continuity check, replace thealternator.

2. Check that there is no conti nuit y between each leadand the coil core.

LEADS

1. Check that there is continuity between each pair ofleads.

Stator Test

3. If the rotor fails either continuity check, replace thealternator.

2. Check that there is no continuity between the sliprings and the rotor or rotor shaft.

ROTORSLIP RINGS

1. Check the resistance between the slip rings.There should be 1.8 - 3.0 ohms.• If resistance meets the specification, go to step 2.• If resistance does not meet the specification,

replace the alternator.

Alternator Brush InspectionRotor Slip Ring Test

Charging System

4-33

4. After assembling the alternator, turn the pulley byhand to make sure the rotor rotates smoothly andwithout noise.

REAR HOUSINGISTATOR ASSEMBlY

DRIVE-ENDHOUSING/ROTORASSEMBlY

BRUSH ACCESS HOlE

3. Put the rear housing/stator assembly and drive-endhousing/rotor assembly together, tighten the fourthrough bolts and pull out the pin.

2. Heat the rear bearing seat in the rear housing asdescribed on page 4-30. After heating, continueimmediately with assembling before the rear bearing seat cools completely.

BRUSHESPIN

1. Push the brushes in, then insert a pin or drill bit(about 1.8 mm diameterl to hold them there.

Press

2. Use a hand press to install the new bearing. Applypressure only on the inner race to avoid damagingthe bearing.

REAR BEARING

BEARING PUllER

• Make sure the tips of the bearing puller jaws arethin enough to fit between the bearing and theslip rings.

• Do not reuse the bearing.

1. Pull off the rear bearing.

Alternator ReassemblyRear Bearing Replacement

r:-:'I~

BELT TENSION GAUGE07JGG - 001010A

24 N·m (2.4 kgf·m.17 Ibf.ft)

NOTE: If the belt is worn or damaged, replace it.

Tension:Used Belt: 300 - 490 N (35 - 50 kgf, 77 - 110 Ibf)New Belt: 540 - 740 N (55 -75 kgf, 121 -165 Ibf)

2. Attach the belt tension gauge to the belt, and measure the tension. Follow the gauge manufacturer'sinstructions.

1. Remove the three bolts from the left end of thesplash shield, and pull it back as needed.

Belt tension gauge method:

4-34

ALTERNATORBELT

CRANKSHAFTPULLEY

24 N'm (2.4 kgf·m,17 Ibf.ft)

Measure here.

NOTE: If the belt is worn or damaged, replace it.

Deflection:Used Belt: 8.0 -10.5 mm (0.31 - 0.41 in)New Belt: 6.0 - 8.5 mm (0.24 - 0.33 in)

Apply a force of 98 N (10 kgf, 22 Ibf), and measure thedeflection between the alternator and crankshaft pulley.

Deflection method: .

NOTE: When using a new belt, first adjust the deflectionor tension to the values for the new belt, then readjustthe deflection or tension to the values for the used beltafter running engine for five minutes.

Alternator Belt Inspection and Adjustment

Charging System

4-35

ACTUATOR ASSEMBlY• Test, page 4-41• Replacement. page 4-42• Solenoid Test. page 4-43• Disassernblv, page 4-44

VACUUM TANK

ACTUATOR CABLEAdjustment, page 4-42

AIT GEAR POSITIONSWITCH• Test. section 14• Replacement, section 14

ClUTCHSWITCH (MIT)• Test. page 4-36• Clutch Pedal Adjustment.section 12

CRUISE CONTROL UNITInput Test, page 4-37

BRAKE SWITCH• Test, page 4-36• Pedal Hight Adjustment,section 19

MAINSWITCHTest/Replacement,page 4-39


~ - .+ENGiNECruise Control

G401G402

G201

PNK

GAUGEASSEMBLY

(

ArT: ~3"s~~~~SWITCH )ION: 121. 1i53I. fD4l J

MfT: CLUTéH SWiTCHBLK BLK [ON: Pedal releasedJ BLK

l l l

BLKBLK

LT GRN

G401G402

DASH LlGHTSBRIGHTNESSCONTROLLER

BLK

VEHICLE SPEEDSENSOR (VSSJ

BLU/WHT

7

RED/BLU

l 5BLK RED

YEL

HORNSWITCH

No.30 17.5A)FUSE

'7RED/BLK

No.14(7.5A)

RED/BLK

2LTGRN

MAINSWITCH

UNDER - DASH FUSE/RELA y BOX

CRUISECONTROLACTUATOR

CRUISE CONTROL UNIT

LT GRN/BLK

2

RESUME

SET!RESUMESWITCH

CABLEREEL

BRAKESWITCH

WHT/GRN

WHT/GRN

4-36

BRAKELlGHTS

GRN/WHT

7

HORN

BLU/RED

~

HORNRELAY

UNDER - HOOD FUSE/RELAY BOX

Circuit Diagram

Cruise Control

4-37

(cont'd)

RED/BlU BRN/BlK BLU/WHT l T GRN

GRN/WHT l T GRN/RED l T GRN/BlK

Wire side of female terminais

If the terminais are bent, loose, or corroded, repair them as necessarv, and recheck the system.If the terminais look OK, make the following input tests at the connector.- If any test indicates a problem, find and correct the cause, then recheck the system.- If ail the input tests prove OK, the control unit must be faulty; replace it.

3. Inspect the connector and socket terminais ta be sure they are ail making good contact.

2. Disconnect the 14Pconnector tram the control unit.

1. Remove the driver's dashboard lower caver (see section 20).

SRS components are located in this area. Review the SRS component locations, precautions, and procedures in the SRSsection (24) before performing repairs or service.

Control Unit Input Test

r:-:'I~

4-38

8 BRN/WHTUnder ail conditions Check for resistance to ground: • Faulty actuator solenoid

There should be 80 - 120 O. • Poor ground (G201)

Under ail conditions Check for resistance to ground: • An open in the wire1 BRN There should be 40 - 60 O.

10 BRN/BLKUnder ail conditions Check for resistance to ground:

There should be 70 - 110 O.

Ignition switch ON (II), Check for voltage to ground: • Faulty brake switch

2 GRYmain switch ON and There should be 0 V with the pedal • An open in the wirebrake pedal depressed, depressed and battery voltagethen released with the pedal released.

3 BLKUnder ail conditions Check for continuity to ground: • Poor ground (G40', G402)

There should be continuity. • An open in the wire

Brake pedal depressed, Check for voltage to ground: • Blown No. 52 (15 A) fuse in the

4 GRN/WHTthen released There should be battery voltage under-hood fuse/relay box

with the pedal depressed, and 0 V • Faulty brake switchwith the pedal released. • An open in the wire

LT GRN/ Set button depressed Check for voltage to ground: • Blown No. 52 (15 A) fuse in the5 RED There should be battery voltage. under-hood fuse/relay box

• Faulty horn relay

LT GRN/ Resume button • Faulty set/resume switch6 BLK depressed • Faulty cable reel

• An open in the wire

Ignition switch ON (II) Attach to ground: • Blown bulbCruise indicator light in the gauge • Blown No. 25 (7.5 A) fuse in the

9 RED/BLUassembly should come on. under-dash fuse/relay box

• Faulty dimming circuit in thegauge assembly


Ignition switch ON (II) Check for voltage between the • Faulty vehicle speed sensor (VSS)and main switch ON; BLU/WHT ® and BLKe terminais: • An open in the wire

12 BLU/WHT raise the front of the There should be 0 - 5 V or morevehicle, and rotate onewheel slowly with the -0 - 5 V or more repeatedly.other one blocked.Ignition switch ON (II) Check for voltage·to ground: • Blown No. 14 (7.5 A) fuse in the

13 LTGRN and main switch ON There should be battery voltage. under-dash fuse/relay box• Faulty main switch• An open in the wire

AIT: Shift lever in m, Check fo_rcontinuity to ground: • Faulty AIT gear position switch[Qi] or [Q;l There should be continuity. • Faulty or misadjusted clutch

14 PNK MIT: Clutch pedal NOTE: There should be no conti- switch (MIT)released nuit y when the clutch pedal is • Poor ground (G401, G402)

depressed or when the shift lever • An open in the wireis in other positions.

Possible cause if result is not obtainedTest: Oesired resultTest conditionCavity Wire

Control Unit Input Test (cont'd)

Cruise Control

4-39

(cont'd)

• If there is conti nuit y, and it matches the table,the switch is OK.

• If there is no conti nuit y in one or both positions,go to step 6.

\ Terminal1 2 3

Position \SET (ON)

RESUME (ON)

Terminal side ofmale terminais

5. Check for continuity between the terminais of thecable reel sub-harness 3P connector in each switchposition according to the table.

4. Disconnect the cable reel sub-harness 3P connectorfrom the main wire harness.

3. Remove the dashboard driver's lower coyer (see section 20).

2. Disconnect the driver's airbag connector(see section 24).

1. Disconnect the battery negative cable, then disconnect the positive cable, and wait at least three minutes.

Set/Resume SwitchTest/Replacement

If there is no conti nuit y, replace the switch.

\ Terminal1 2 3 4 5

Position \OFF

ON 0-~

4. Check for continuity between the terminais in eachswitch position according to the table.

MAIN SWITCH

5P CONNECTOR

3. Disconnect the connector from the switch.

2. Carefully push out the switch from behind the dashboard.

1. Remove the driver's dashboard lower coyer (see section 20).

Main Switch Test/Replacement

r:--:1~

11. After connecting the airbag connectors, confirmproper system operation: Turn the ignition switch ON(II); the SRS indicator light should come on for aboutsix seconds and then go off.

10. Reconnect the battery positive cable, then the negative cable.

9. Reconnect the driver's airbag connecter. and reinstallthe access panel on the steering wheel.

8. If ail tests prove OK, reconnect the cable reel andcable reel sub-harness connector, then reinstall thesteering column covers.

4-40

• If there is continuity, and it matches the table,replace the cable reel.

• If there is no conti nuit y in one or both positions,replace the switch.

1\ Terminal1 2 3

Position \SET (ON)

RESUME (ON)

7. Check for conti nuit y between the terminais in switchposition according to the table.


6. Remove the two screws, th en remove the switch.

Set/Resume Switch Test/Replacement (cont'd)

Cruise Control

4-41

9. Disconnect power and ground from the 4Pconnector.Disconnect the vent hose from the actuator. Connecta vacuum pump to the actuator vent hose port, andapply vacuum. The actuator rod should pull in cornpletely. If not, the vacuum valve is stuck open.Replacethe actuator.

8. If Vou replace the solenoid valve assembly, be sureto use new O-rings on each solenoid.

7. Repeat steps 2 through 5, and disconnect groundfrom the No. 1 terminal. The actuator rod shouldreturn. If it does not return, but the vent hose andfilter are not plugged, the solenoid valve assemblyis defective.

6. Disconnect ground from the No. 3 terminal. The actuator rod should return. If it does not return, but thevent hose and filter are not plugged, the solenoidvalve assembly is defective.

5. With voltage and vacuum still applied, try to pull theactuator rod out by hand. You should not be able topull it out. If vou can, it is defective.

ACTUATOR RaD

4. The actuator rod should pull in completely. If the rodpulls in only part-way or not at ail, check for a leaking vacuum line or defective solenoid.

Terminal side of

3.

2. Connect battery power to the No. 4 terminal andground to the No. 1, No. 2 and No. 3 terminais.

1. Disconnect the actuator cable from the actuator rodand the 4Pconnector.

Actuator Test

5. Retighten the locknut, and recheck the free play.

NOTE: If necessary, check the throttle cable freeplay (see section 11), then recheck the actuator rodfree play.

4. If free play is not within specs, loosen the locknut,and turn the adjusting nut as required.

LOCKNUT FREE PLAY: 11 ± 1.0 mm(0.43 ± 0.04 in)

ACTUATOR ROD

3. Measure the amount of movement of the actuatorrod until the cable pulls on the accelerator lever(engine speed starts to increase). Free play shouldbe 11± 1.0mm (0.43 ± 0.04 in).

2. Start the engine. Hold the engine at 3,000 rpm withno load (NT in [ffi or [f] , MfT in neutral) until theradiator tan comes on, th en let it id le.

1. Check that the actuator cable operates smoothlywith no binding or sticking.

4-42

7. Install in the reverse order of removal, and adjustthe free play at the actuator rod after connecting thecable (see next column).

6. If necessary, disconnect the cable end from the linkage over the accelerator pedal, then turn the grommet 90° in the bulkhead, and remove the cable.

4P CONNECTOR

VENTHOSE

VACUUM HOSE

5. Remove the three mounting bolts and the actuatorwith the bracket.

4. Disconnect the vacuum hose trom the vacuum tank.Pull out the vent hose.

BOOT

3. Disconnect the 4P connector trom the actuator.

ADJUSTING NUT

2. Disconnect the cable end from the actuator rod.

1. Pull back the boot, and loosen the locknut. Then disconnect the cable from the bracket.

Actuator Cable AdjustmentActuator Replacement

Cruise Control

4-43

4 3 2

NOTE: Resistance will vary slightly with temperature; specified resistance is at 70°F (20°C).

f\ Terminal

\, 2 3 4

Resistance(0)

VENTSOLENOID 0-~40-600

VACUUMSOLENOID30- 500

SAFETYSOLENOID40-600

2. Check for resistance between the terminais according to the table.


œ~

1. Disconnect the 4P connector from the actuator.ACTUATOR

Actuator Solenoid Test

r::-:1I~

4-44

VENT HOSE

FILTER COVER

ACTUATORTest, page 4-41

WIRE SUPPORT BRACKET

ACTUA TOR BRACKET

ACTUATOR CABLE

Actuator Disassembly

Cruise Control

Engine Removal/Installation 5-1Cylinder Head/Valve Train 6-1Engine Block 7-1Engine Lubrication 8-1Intake Manifold/Exhaust System 9-1Cooling 10-1

Engine

Installation 5-10Removal ~ 5-2

Engine Removai/lnstailation

ECM/PCMECM/PCMCONNECTORS

MAIN WIRE HARNESSCONNECTOR

7. Disconnect the main wire harness connector.

6. Disconnect the connectors from the ECM/PCM.

BATTERYBASE

5. Remove the battery and battery base.

5-2

BATTERY POSITIVETERMINAL

UNDER-HOODFUSE/RELAYBOX

BATTERY CABLES

4. Disconnect the battery cables from the under-hoodfuse/relay box and battery positive terminal.

3. Disconnect the battery negative terminal first, th enthe positive terminal.

2. Make sure vou have the anti-theft code for theradio, then write down the frequencies for theradio's preset buttons.

1. Secure the hood open as far as possible.

CAUTION:• Use fender covers to avoid damaging painted sur

face.• Unspecified items are common.• To avoid damage, unplug the wiring connectors

carefully while holding the connector portion.• Mark ail wiring and hoses to avoid misconnection.

Also, be sure that they do not contact other wiring orhoses or interfere with other parts.

1

"'Wi;lhi.J[;• Make sure jacks and safety stands are placed properly

and hoist brackets are attached to the correct positions on the engine.

• Make sure the vehicle will not roll off stands and fallwhile Vou are working under it.

Removal


5-3

(cont'd)

FUEL RETURNHOSE

BRAKE BOOSTERVACUUM HOSE

12. Remove the brake booster vacuum hose, fuel returnhose and vacuum hose.

FUEL FEEDHOSE

33 N·m (3.4 kgf·m,251bHt)

11. Remove the evaporative emission (EVAP) controlcanister hose and fuel feed hose.

'MhlJi!.llN Do not smoke while working on the fuelsystem. Keep open flame or spark away from thework area. Drain fuel only into an approved container.

10. Relieve fuel pressure (see section 11).

ENGINEWIREHARNESS CONNECTORS

9. Disconnect the engine wire harness connectors onthe left side engine compartment.

lAT SENSORCONNECTOR

AIR CLEANERHOUSING

INTAKE AIRDUCT

6x1.0mm9.8 N·m (1.0 kgf·m, 7.2Ibf.ft)

\

Disconnect the intake air temperature (lAT) sensorconnector, then remove the intake air duct and aircleaner housing.

8.

AIC COMPRESSORBELT

IOLER PULLEY CENTERNUTADJUSTING

BOLT

16. Loosen the idler pulley center nut and adjustingboit, then remove the air conditioning (A/C) compressor belt.

LOCK BOLT8 x 1.25mm24 N'm (2.4 kgf·m. 17 Ibf·ft)

PIS PUMPBELT

MOUNTING BOLT8 x 1.25mm24 N'm 12.4kgf·m, 17 Ibf.ftl

NOTE: Do not disconnect the PIS hoses.

15. Remove the mounting boit and lock boit, then removethe power steering (PIS) pump belt and pump.

5-4

GROMMET

14. Remove the grommet and wire harness clamps,then pull out the ECM/PCM connectors.

LOCKNUTADJUSTINGNUT

THROTTLECABLE

NOTE:• Take care not to bend the cable when removing

it. Always replace any kinked cable with a newone.

• Adjust the throttle cable when installing (see section 11).

13. Remove the throttle cable by loosening the locknut,then slip the cable end out of the accelerator linkage.

Removal (cont'd)


5-5

(cont'd)

24. Drain the engine oil. Reinstall the drain boit using anew washer (see page 8-4).

23. Drain the transmission oil or fluid. Reinstall thedrain plug using a new washer (see section 13, 14).

22. Drain the engine coolant (see page 10-5).• Loosen the drain plug in the radiator.

SPLASHSHIELD

, ,~

6 x 1.0 mm9.8 N'm (1.0 kgf·m.7.2Ibf·hl

21. Remove the front tires/wheels and splash shield.

20. Raise the hoist to full height.

'%If.WIldN Use care when removing the radiatorcap to avoid scalding by hot coolant or steam.

19. Remove the radiator cap.

8 x 1.25mm24 N'm (2.4 kgf.m,17 Ibf·hl

SLAVE CYLINDER

8 x 1.25 mm24 N'm (2.4 kgf·m,17lbf·hl~,

NOTE:• Do not disconnect the line/hose assembly.• Do not operate the clutch pedal once the slave

cylinder has been removed.• Take care not to bend the line.

18. Remove the clutch slave cylinder and line/hoseassembly (Mrr).

TRANSMISSIONGROUND CABLE

6 x 1.0 mm11N'm Il.1 kgf·m,81bHtl

17. Remove the transmission ground cable and hoseclamp.

SELF-LOCKING NUT10 x 1.25 mm54 N·m (5.5 kgf·m. 40 Ibf-ft)Replace.

8 x 1.25 mm16 N·m (1.6 kgf·m. 12 Ibf.ft)Replace.

GASKETReplace.

GASKETSReplace.

28. Remove exhaust pipe A.

6x1.0mm14 N·m (1.4 kgf·m. 10 Ibf.ft)Replace.

NOTE:• Take care not to bend the cable when removing

it. Always replace any kinked cable with newone.

• Adjust the shift cable when installing (see section 14).

8 x 1.25 mm22 Nom1202jom. 16Ibf.f.,

27. Remove the shift cable (AIT).

5-6

AIC COMPRESSOR

NOTE: Do not disconnect the AlC hoses.

26. Remove the AlC compressor.

8x1.25mm22 N·m (2.2 kgf·m. 16 Ibf.ft)

EXTENSIONROD

SHIFT ROD

25. Remove the shift rod and extension rod (MfT).

Removal (cont' d)


5-7

(cont'd)

ATFCOOLERHOSES

34. Remove the ATF cooler hoses, then plug the ATFcooler hoses and pipes (NT).

LOWER RAOIATORHOSE

HEATERHOSES

33. Remove the upper and lower radiator hoses andheater hoses.

32. Lower the hoist.

DRIVESHAFT

NOTE: Coat ail precision-finished surfaces withclean engine oil. Tie plastic bags over the driveshaftends.

CAUTION:• Do not pull on the driveshaft, the CV joint may

come apart .• Use care wh en prying out the assembly.

Pull it straight to avoid damaging the differentialoil seal or intermediate shaft dust seal.

31. Remove the driveshafts.

30. Disconnect the suspension lower arm bail joints(see section 18).

29. Remove the damper forks (see section 18).

5-8

HOISTING BRACKETInstall on the cylinder headwith a 8 x 1.25 mm boit.

35. Attach the chain hoist to the engine.

Removal (cont' d)


5-9

42. Raise the engine ail the way, and remove it from thevehicle.

41. Slowly raise the engine approximately 150 mm (6 in).Check once again that ail hoses and wires are disconnected from the engine/transmission.

40. Check that the engine/transmission is completelyfree of vacuum hoses, fuel and coolant hoses andelectrical wiring.

TRANSMISSIONMOUNTBRACKET

TRANSMISSIONMOUNT

39. Remove the transmission mount bracket, thenremove the transmission mou nt.

38. Remove the upper bracket.

BOlTSReplace.

REAR MOUNTBRACKET

37. Remove the rear mount bracket.

Replace.

Replace.NUT

lEFT FRONTMOUNT

36. Remove the left and right front mount and bracket.

5-10

10 x 1.25 mm44 N·m 14.5 kgf·m.33lbf·hl

10 x 1.25 mm44 N'm 14.5 kgf·m.33lbf·hl

8 x 1.25 mm24 N'm 12.4 kgf·m.17lbf·hl

FRONTSTIFFENERlM/TI

STIFFENER lA/TITighten the bolts on the stiffenerin the numbered sequence as shown(CD -@J.

10 x 1.25 mm54 N·m (5.5 kgf·m.40lbf·hlENGINE SIDE

MOUNT BRACKET

10 x 1.25 mm«N'm (4.5 kgf·m.33lbf·hl

Bracket Bolts Torque Specifications:

Installation


5-11

(cont'd)

CD 14 x 1.5mm83N'm (8.5 kgf·m.611bHt)Replace.

3. Install the rearmount bracket,then tighten the boltsin the numberedsequenceshown (CD - @).

CD 12 x 1.25 mm74 N'm (7.5 kgf·m.54Ibf.ft)

2. Install the upper bracket, then tighten the nuts inthe numberedsequenceshown (CD - @).

12 x 1.25 mm64 N'm (6.5 kgf·m.47Ibf.ft)

NOTE:Do not tighten the bolts/nuts on the transmissionside.

1. Install the transmission mount and bracket, thentighten the bolts on the frame side.

Install the engine in the reverseorder of rernoval.Reinstallthe mount bolts/nuts in the following sequence.Failureto tollow these proceduresmay causeexcessivenoiseandvibration, a.ndreducebushing lite.

Engine Installation:

G) 12 x 1.25 mm59 N'm (6.0 kgf·m,43 Ibf.ft)Replace.

o 10 x 1.25 mm44 N·m (4.5 kgf·m,33 Ibf·ft)

6. Tighten the bolts/nut on the left front mount in thenumbered sequence shown (CD - @).

5-12

CD 12)( 1.25mm64 N·m (6.5 kgf·m,47Ibf·ft)Replace.

f@ 10 x 1.25mm

44 N·m (4.5 kgf·m,33Ibf·ft)

5. Tighten the bolts on the right front mount/bracket inthe numbered sequence shown (CD - CID).

'2;' 12 x 1.25mm74 N·m (7.5 kgf·m,54Ibf·ft)

CD 12 x 1.25mm64 N'm (6.5 kgf'm,47Ibf.ft)

4. Tighten the bolt/nuts on the transmission mountbracket in the numbered sequence shown (CD - CID).

Installation (cont'd)


5-13

(cont'd)

• Clean the areas where the driveshaft(s) and theintermediate shaft contact the transmission (differential) thoroughly with solvent or carburetorcleaner, and dry with compressed air.

• Check that the 'set rings on the ends of the driveshaft click into place.CAUTION: Use new set rings.

• Adjust the shift cable (see section 14).• Adjust the throttle cable (see section 11).• Adjust the cruise control cable (see section 4).• Refill the engine with engine oil (see page 8-4).• Refill the transmission with fluid (see section 13,

14).• Refill the radiator with engine coolant (see page

10-5).• Bleed air from the cooling system with the heater

valve open (see page 10-5).• Clean the battery posts and cable terminais with

sandpaper, assemble them, then apply grease toprevent corrosion.

• Inspect for fuel leakage (see section 11).After assembling the fuel line, turn ON (II) theignition switch (do not operate the starter) so thatthe fuel pump runs for approximately two seconds and the fuel line pressurizes. Repeat thisoperation two or three times, then check for fuelleakage at any point in the fuelline.

• Enter the anti-theft code for the radio, then enterthe customer's radio station presets.

7. Perform the following:

5-14

RIGHT FRONTMOUNT

SIDE ENGINEMOUNT

REAR MOUNT

C

AA: 10 x 1.25 mm

64 N·m (6.5 kgf-m, 47 Ibf.ft)B: 10 x 1.25 mm

44 N·m (4.5 kgf·m, 33 Ibf·ftlC: 12 x 1.25 mm

83 N'm (8.5 kgf·m, 61 Ibf·ftl0: 12 x 1.25 mm

59 N·m (6.0 kgf·m, 43 Ibf·ftlReplace.

Mount and Bracket Bolts/Nuts Torque Value Specifications:

Installation (cont' d)


Rocker ArmsRemoval 6-26Disassembly /Reassembly 6-27

Rocker Arms and Lost Motion AssembliesInspection 6-28

Rocker Arms and ShaftsClearance Inspection 6-29

CamshaftInspection 6-30

Valves, Valve Springs and Valve SealsRemoval 6-32

Valve GuidesValve Movement 6-33Replacement 6-35Reaming 6-37

Valve SeatsReconditioning 6-34

ValvesInstallation 6-37

Camshaft/Rocker Arms andCamshaft Seal/PulleyInstallation 6-38

Special Tools ·6-2VTEC Control System

Troubleshooting Flowchart 6-3VTEC Solenoid Valve

Inspection 6-6VTEC Rocker Arms

Manual Inspection 6-7Inspection Using Special Tools 6-7

Valve ClearanceAdjustment 6-10

Valve SealsReplacement (Cylinder head removal

not required) 6-12Crankshaft Pulley and Pulley Boit

Replacement 6-14Timing Belt

lIIustrated Index 6-15Inspection 6-16Tension Adjustment 6-16Removal 6-17Installation 6-18

Crankshaft Speed Fluctuation (CKF)SensorReplacement 6-20

Cylinder HeadlIIustrated Index 6-21Removal 6-23Warpage 6-34Installation 6-39

Cylinder Head/Valve Train

6-2

:J) - 2oCV -,

@

~)

Ref. No. Tooi Number Description Qty Page Reference

CD 07HAH - PJ7010B Valve Guide Reamer, 5.5 mm 6-37CID 07JAA - 001010A Socket, 17 mm 6-14CID 07JAB - 001020A Holder Handle 6-14@ 07LAJ - PR3020B Air Stopper 6-7,8@ 07NAB - 001040A Holder Attachment, 50 mm 6-14® 07NAJ - P07010A Pressure Gauge Adapter 6-40 07406 - 0020201 Aff Pressu re Hose 6-4

or 0-' 07MAJ - PY4011A Aff Pressure Hose, 2,210 mm 6-4and 0-2 07MAJ - PY40120 Aff Pressure Adapter 6-4

@ 07406 - 0070300 Aff Low Pressure Gauge W/Panel 6-4® 07742 - 0010100 Valve Guide Driver, 5.5 mm 6-35,36

Special Tools

6-3

(cont'd)


Inspect for an open or short toground in the wire between theVTEC pressure switch and ECM/PCM (C15).If the wire is OK, substitute aknown-good ECM/PCM andrecheck.

NO

VTM(BLU/BLK)

Replace the VTEC pressure switch.

Terminal side ofmale terminaisNO

L-------{nJ-------'

VTEC PRESSURE SWITCHCONNECTOR

Intermittent failure, system is OKat this time.Check for poor connections orloose wires at the VTEC pressureswitch, VTEC solenoid valve andECM/PCM.

NO

* RoadTest:Accelerate in lst gear ta an engine speed over 6.000 rpm.Hold that engine speed for at least two seconds.If the OTC P1259 is nat repeated during the first raad test,repeat this test two more times.

1 YES

(Ta page 6-4)

Is there approx. 12 V?

Test the VTEC Pressure SwitchWire:1. Turn the ignition switch ON (II).2. Measure the voltage between

VTEC pressure switch connector No. 1 and body ground.

YES

Is there continuity?

Test the VTEC Pressure Switch:1. Turn the ignition switch OFF.2. Oisconnect the VTEC Pressure

switch connector.3. Check for continuity between

VTEC pressure switch connector terminal No. 1 and No. 2.

YES

Is OTC P1259 indicated?

Check the VTEC Control System:1. Do the engine control module

(ECM)/powertrain control module (PCM) Reset Procedure (seesection 11).

2. Start the engine.3. Warm up the engine to normal

operating temperature (cooling fan comes on).

4. Do the Road Test. *

- The MIL has been reported on.- OTC P1259 is stored,

Refer to page 11-38 through 11-55 before troubleshooting.

1 P1259 1 The scan tool indicates Diagnostic Trouble Code (DTC)P1259:A problem in the VTECPressureSwitch circuit or. . VTECSolenoid Valve circuit.

Troubleshooting Flowchart

VTEC Control System

12V

AIT LOW PRESSURE GAUGE W IPANEL~07406-0070300

j

AIT PRESSURE HOSE,2,210 mm07MAJ - PY4011A andAIT PRESSURE ADAPTER07MAJ - PY40120

or

,~,-.AIT PRESSURE HOSE07406 - 0020201

NO 1 11 Inspect the VTEC solenoid valve.

AlT PRESSURE HOSE,2,210 mm07MAJ - PY4011A andAIT PRESSURE ADAPTER07MAJ - PY40120

AIT PRESSURE HOSE07406 - 0020201

or

Inspect the VTEC solenoid valve.NO

NOTE: Keep measuring time às short aspossible because engine is running with noload (less than one minute).

AIT LOW PW/PANEL07406-0070300-,-.

Wire side of femaleterminais

"- __ ......'1}-----

VTEC PRESSURE SWITCHCONNECTOR

Repair open in the wire betweenVTEC pressure switch and A10 orA23 of the ECM/PCM.If the wire is OK, substitute aknown-good ECM/PCM andrecheck.

NO

6-4

(To page 6-5)

YES

Is the pressure above 390 kPa(4.0 kgf/cm2, 57 psi)?

Test the VTEC Solenoid Valve:1. Turn the ignition switch OFF.2. Disconnect the VTEC solenoid

valve connector.3. Attach the battery positive ter

minai to the GRN/YEL terminaI.

4. Start the engine and check theoil pressure at engine speed5,000 rpm.

YES

Is pressure below 49 kPa(0.5 kgf/cm2, 7 psi)?

Test the VTEC Solenoid Valve:1. Turn the ignition switch OFF.2. Remove the VTEC pressure

switch and install the specialtool as shown, then reinstallthe VTEC pressure switch.

3. Connect a tachometer (see section 11).

4. Start the engine.5. Warm up engine to normal

operating temperature (coolingfan comes on).

6. Check oil pressure at the following engine speeds 1,000,3,000 and 5,000 rpm.

YES


Test the VTEC Pressure SwitchWire:Measure voltage across the VTECpressure switch connecter.

1

(From page 6-3)

Troubleshooting Flowchart (cont' d)

VTEC Control System

6-5

Wire side offemale terminal

VTEC SOLENOID VALVECONNECTOR


VTS(GRN/VEl)

ECM/PCM CONNECTORA (32P)

TEC SOlENOIDALVEONNECTOR .----~ n )------,

Terminal side ofmale terminal

VTEC SOlENOID VAl VECONNECTOR


C (31PIA (32P)1

Test the VTEC Pressure Switch:1. Turn the ignition switch OFF.2. Reconnect the VTEC pressure

switch connector. l'Il]3. Start the engine. lulu 1.4. With the battery positive ter-

~minai connected to the VTECsolenoid valve. measure volt-age between C15 and A10 orA23.

1

NOIs there approx. 12 Vabove15.000 rpm?

Replace the VTEC pressure switch.

1 YES

Test the VTEC Solenoid Valve:1. Turn the ignition switch OFF.2. Disconnect the battery positive

terminal from the VTEC sole-noid valve.

3. Check for conti nuit y betweenthe VTEC solenoid valve con-nector terminal No. 1 and bodyground.

1NO

Is there 14 - 30 O? Replace the VTEC solenoid valve.

1 YES VVC

Test the VTEC Solenoid ValveWire:Check for continuity between theVTEC solenoid valve connectorterminal No. 1 and A8.

1NO Repair open in the wire between

Is there continuity? the ECM/PCM (AS) and VTEC sole-

1 YESnoid valve connector.

Test the VTEC Solenoid ValveWire:Check for continuity between theVTEC solenoid valve connector ter-minai No. 1 and body ground.

1YES Repair short in the wire between

Is there continuity? the ECM/PCM (AS) and VTEC sole-

1 NOnoid valve connector.

Substitute a known-good ECM/PCM and recheck. If symptom/indication goes away, replacethe original ECM/PCM.

ECM/PCM CONNECTORS(From page 6-4)

VTEC PRESSURESWITCH22 N'm (2.2 kgf·m, 16 IbHt)

6 x 1.0 mm12 N'm (1.2 kgf'm, 8.7 IbHtl

• If the VTEC solenoid valve is normal, check theengine oil pressure.

4. If the filter is not clogged, push the VTEC solenoidvalve with your finger and check its movement.

6-6

6 x 1.0 mm12 N'm (1.2 kgf·m, 8.7 IbHt)

!VTEC SOLENOIDVALVE FILTERReplace.

VTEC SOLENOID VALVE ASSEMBL y

\

• If there is clogging, replace the engine oil filterand the engine oil.

3. If the resistance is within specifications, remove theVTEC solenoid valve assembly from the cylinderhead, and check the VTEC solenoid valve filter forclogging.

14- 30 fl7

VTEC SOLENOID VALVEResistance: 14 - 30 n

2. Measure resistance between the terminal and bodyground.

t. Disconnect the 1P connector from the VTEC solenoid valve.

Inspection

VTEC Solenoid Valve

6-7

(cont'd)

AIR STOPPER07lAJ - PR3020B

2. Plug the relief hole with the special tool.

NOTE: Refer ta page 6-40 when installing the cylinderhead caver.

1. Remove the cylinder head caver.

CAUTION:• Before using the Valve Inspection Tool, make sure

that the air pressure gauge on the air compressorindicates over 400 kPa (4 kgf/cm2, 57 psi).

• Inspect the valve clearance before rocker arm inspection.

• Cover the timing belt with a shop towel to protectthe belt.

• Check the intake primary rocker arm of each cylinderat TOC.

Inspection Using Special Toois

• If the intake mid rocker arm does not move,remove the mid, primary and secondary intakerocker arms as an assembly and check that the pistons in the mid and primary rocker arms movesmoothly.

• If any rocker arm needs replacing, replace theprimary, mid, and secondary rocker arms as anassembly.

5. Check the intake mid rocker arm of each cylinder atTOC.

SECONDARYROCKER ARM

MID ROCKERARM

4. Check that the intake mid rocker arm moves independently of the primary and secondary intake rockerarms.

3. Push the intake mid rocker arm on the No. 1 cylinder manually.

NOTE: Refer to page 6-40 when installing the cylinder head cover.

2. Remove the cylinder head cover.

1. Set the No. 1 piston at TOC.

Manuallnspection

~

~VTEC Rocker Arms

If any intake mid rocker arm moves independently ofthe primary and secondary rocker arms, replace therocker arms as a set.

SECONDARYROCKER ARM

MID ROCKERARM

5. Make sure that the intake primary and secondaryrocker arms are mechanically connected by the pistonand that the mid rocker arm does not move whenpushed manually.

Specified Air Pressure:250 kPa (2.5 kgf/cm2, 36 psi)

4. Loosen the regulator valve on the valve inspectiontool and apply the specified air pressure to the rockerarm synchronizing piston NB.

6-8

VALVE INSPECTIONTOOl(Cornrnerciallvavailable)• Pull the dial andturn ta adjust.

INSPECTIONHOlE

10 x 1.0 mmADAPTER

AIR STOPPER07lAJ - PR3020B

10 x 1.0 mmSEALING BOLT

20 N·m 12.0k9\ Ibf.ltl

3. Remove the sealing boit from the inspection holeand connect the Valve Inspection Tool.

Inspection Using Special Tools (cont'd)

VTEC Rocker Arms

6-9

8. After inspection, check that the malfunction indicator lamp (MIL) does not come on.

lOST MOTIONASSEMBlY

7. Use a 10 mm diameter rod to depress each lostmotion assembly through its full movement.Replace any lost motion assembly that does movesmoothly.

6. Remove the special tools.

EXHAUST

No. 4 No. 3 No. 2 No. 1

No. 4 No. 3 No. 2 No. 1

INTAKE

Adjusting screw locations:

INTAKEand EXHAUSTVALVELOCKNUTS20 N'm (2.0 kgf·m, 14Ibf.ft)

5. Loosen the locknut, and turn the adjustment screwuntil the feeler gauge slides back and forth with aslight amount of drag.

6-10

Intake: 0.18 - 0.22 mm (0.007 - 0.009 in)Exhaust: 0.23 - 0.27 mm (0.009 - 0.011 in)

4. Adjust the valves on No. 1 cylinder.

"UP" MARK

3. Set the No. 1 piston at TOC. The "UP" mark on thecam-shaft pulley should be at the top, and the TOCmarks should align with the cylinder head upper surface.

2. Remove the upper cover (see page 6-17).

NOTE: Refer to page 6-40 when installing the cylinderhead.


NOTE:• Valves should be adjusted only when the cylinder

head temperature is less than 100°F (38°e).• After adjusting, retorque the crankshaft pulley boit to

181 N'm (18.5 kgf·m, 134 Ibf·ft).

Adjustment

Valve Clearance

6-11

"UP" MARK

9. Rotate the crankshaft 180° counterclockwise to bringNo. 2 piston to TOC. The "UP" mark should be onthe intake side. Adjust the valves on No. 2 cylinder.

"UP" MARK

8. Rotate the crankshaft 180° counterclockwise tobring No. 4 piston to TOC. Both TOC grooves areonce again visible. Adjust the valves on No. 4 cylinder.

"UP" MARK

7. Rotate the crankshaft 180° counterclockwise (camshaft pulley turns 90°). The "UP" mark should be onthe exhaust side. Adjust the valves on No. 3 cylinder.

FEELERGAUGE

6. Tighten the locknut, and check the clearance again.Repeat the adjustment if necessary.

OIL PASSAGES

OIL PASSAGES

NOTE: Put shop towels over the oil passages toprevent the valve keepers from falling into the cylinder head.

8. Position the lever arm under the cross shaft so thelever is perpendicular to the shaft and the compressor attachment rests on top of the retainer for thespring being compressed. Use the front positionslot on the lever as shown.

7. Insert an air adaptor into the spark plug hole. Pumpair into the cylinder to keep the valve closed whilecompressing the springs and removing the valvekeepers.

6. Select the 7/8 in diameter short compressor attachment, and fasten the attachment to the No. 4 hale 01the lever arm with the speed pin supplied.

Intake Valve Seais:

6-12

5. Insert the cross shaft through the top hole of thetwo uprights.

4. Using the 8 mm bolts supplied with the tool, mountthe two uprights to the cylinder head at the endcamshaft holders. The uprights fit over the camshaft as shown.

3. Remove the fuel injectors and the wire harness.

NOTE:• Refer to page 6-26 for rocker arm assembly

removal.• When removing or installing the rocker arm

assembly, do not remove the camshaft holderbolts. The bolts will keep the holders, springsand rocker arms on the shaft.

• Refer to page 6-40 when installing the cylinderhead cover.

2. Remove the cylinder head cover and the rocker armassembly.

1. Turn the crankshaft so that the No. 1 and the No. 4pistons are at top dead center (TOC).

'MhiJiidN Alway wear approved eye protection whenusing the in-car valve spring compressor.

The procedure shown below applies when using the incar valve spring compressor (Snap-on YA8845 withYA8845 - 2 A 7/8" attachment).

NOTE: Cylinder head removal is not required in thisprocedure.

Replacement (Cylinder head removal not required)

Valve Seals

6-13

19. Repeat steps 6 to 18 on the other cylinders.

_l8. Install the springs, the retainers and the keepers inreverse order of removal.

17. Install the valve seals (see page 6-37).

16. Remove the valve seals (see page 6-32).

15. Using a downward motion on the lever arm, compress the valve spring and remove the keepers fromthe valve stem. Slowly release pressure on thespring.

FRONTPOSITIONSlOT

IN-CARSPRING COMPRESSORYA-8845

NOTE: Put shop towels over the oil passages toprevent the valve keepers from falling into the cylinder head.

14. Position the lever arm under the cross shaft so thelever is perpendicular to the shaft and the compressor attachment rests on top of the retainer for thespring being compressed. Use the front positionslot on the lever as shown.

13. Select the 7/8 in. diameter short compressor attachment, and fasten the attachment to the No. 2 hole ofthe lever arm with the speed pin supplied.

Exhaust Valve Seals:

12. Install the springs, the retainers and the keepers inreverse order of removal.

11. Install the valve seals (see page 6-37).

10. Remove the valve seals (see page 6-32).

9. Using a downward motion on the lever arm, compress the valve spring and remove the keepers fromthe valve stem. Slowly release pressure on thespring.

6-14

~SOCKET, 17 mm07JAA - 001010A(or Commercially availablel

HOlDER ATTACHMENT, 50 mm07NAB - 001040A

TIMING BELTGUIDE PLATE

0 0 00 0 00000000=0 0

~§gg~00 00000000

0

CRANKSHAFT

HOLDER HANDLE07JAB - 001020A

NOTE: Do not use an impact wrench when installing.

Crankshaft pulley boit size and torque value:14 x 1.25 mm181 N'm (18.5 kgf·m, 134 Ibf·ft)

WASHER

TIMING BELTDRIVE PULlEY

CRANKSHAFTPULlEY

\PULLEY BOLT

Clean, remove any oil, and lubricate the points shown below.0: Cleanx : Remove any oil• : Lubricate

When installing and tightening the pulley, follow the procedure below.

Replacement

Crankshaft Pulley and Pulley Boit

6-15

6 x 1.0 mm9.8 N-m (1.0 kgf·m,7.2Ibf·ft)

TIMING BELTDRIVE PULLEYReplacement, page 6-14

ADJUSTING BOLT 6 x 1.0 mm10 x 1.25 mm Replace. 12 N'm (1.2 kgf'm,44 N·m 14.5kgf·m, 33 Ibf.ft) 8.7Ibf.ft)

PULLEY BOLT14 x 1.25 mm181 N'm 118.5kgf·m,134Ibf.ft)Replacement, page 6-14Do not use an impactwrench when installing.

Install with concavesurface facing in.

CRANKSHAFT PULLEYReplacement, page 6-14

RUBBERPLUG

6x1.0mm9.8 N'm (1.0 kgf·m,7.2Ibf.ft)RUBBER SEALSReplace when damagedor deteriorated.LOWER COVER

CRANKSHAFT SPEED FLUCTUATIONICKF) SENSOR

8 x 1.25 mm37 N'm (3.8 kgf·m, 27 Ibf.ft)Apply engine oil to the boitthreads.

TIMING BELTInspection, page 6-16Adjustment, page 6-16Removal, page 6-17iallat;on, page 6-18

HEAD COVER GASKETReplace if it is leaking,damaged or deteriorated.Apply liquid gasket atthe four corners of therecesses.

CYLINDER HEADCOVERReter to page 6-40when installing.

6 x 1.0 mmr 'O kgf·m, 7.2Ibf.ft)WASHER! Replace when damagedl or deteriorated.

@

NOTE:• Refer to page 6-18 for how to position the crankshaft and pulley before installing the belt.• Mark the direction of rotation on the belt before removing it.• Do not use the upper cover and lower cover to store removed items.• Clean the upper cover and lower cover before installing them.• Replace the camshaft seals and crankshaft seals if there is oil leakage.• Reter to page 6-14·before installing the timing belt.

lIIustrated Index

Timing Belt

8. After inspecting, retorque the crankshaft pulley boitto 181 Nrn (18.5 kgf·m, 134 Ibf·ft).

7. Tighten the adjusting boit.

6. Rotate the crankshaft counterclockwise three teethon the camshaft pulley.

ADJUSTING BOLT44 N·m (4.5 kgf'm,33Ibf.ft)

Loosen the adjusting boit 180°.5.

Set the No. 1 piston at TDC (see page 6-19).4.

Rotate the crankshaft five or six revolutions to setthe belt.

3.

Remove the upper cover (see page 6-17).2.

• Refer to page 6-40 when installing.


NOTE:• The tensioner is spring-Ioaded to apply tension to the

belt automatically after making the following adjustment.

• Always rotate the crankshaft counterclockwise whenviewed from the pulley side. Rotating it clockwisemay result in improper adjustment of the belt tension.

• Inspect the timing belt before adjusting the belt tension.

CAUTION: Always adjust the timing belt tension withthe engine cold.

6-16

4. After inspecting, retorque the crankshaft pulley boitto 181Nrn (18.5 kgf·m, 134 Ibf·ft).

Ratate pulleyand inspect belt.

Inspect thisarea for wear.

NOTE:• Replace the belt if it is oil or coolant soaked.• Remove any oil or solvent that gets on the belt.

3. Inspect the timing belt for cracks and oil or coolantsoaking.

2. Remove the upper cover (see page 6-17).

• Refer to page 6-40 when installing.


Tension AdjustmentInspection

Timing Selt

6-17

(cont'd)Replace.

LOWERCOVER

NOTE: Do not use the lower cover ta store removeditems.

8. Remove the lower caver and dipstick tube.

7. Remove the crankshaft pulley (see page 6-14).

NOTE:• Use a jack ta support the engine before removing

the upper bracket.• Make sure ta place a cushion between the ail

pan and the jack.

6. Remove the upper bracket (see page 6-25).

6x1.0mm9.8 N'm (1.0 kgf·m.J'Ohl

NOTE: Do not use the upper cover ta store removeditems.

5. Remove the dipstick, then remove the upper coverand id1erpulley bracket.

4. Loosen the mounting nut and lock boit, then removethe alternator belt (see page 6-23).

3. Loosen the idler pulley center nut and adjustingboit, then remove the air conditioning (Ne) cornpressor belt (see page 5-4).

8 x 1.25mm24 N'm (2.4 kgf·m. 17 Ibl·ftl

MOUNTING BOLT8xl.25mm24.N·m (2.4 kgf·m. 17 IbUt)

2. Loosen the mounting boit and lock boit, then removethe power steering (PIS) pump belt and pump.

1. Remove the splash shield (see page 5-5).

NOTE: If the timing belt is going to be reused, mark thedirection of rotation on the belt before removing it.

CAUTION:• Turn the crankshaft pulley so the No. 1 piston is at

top dead center (TOC)before removing the belt (seepage 6-19).

• Inspect the water pump before installing the timingbelt (see page 10-11).

• Replace the timing belt at 168,000 kmaccording to the maintenance schedule (normal conditions/severe conditions).If the vehicle is regularly driven in one or more of thefollowing conditions, replace the timing belt at100,000 km.

ln very high temperatures (over 110°F,43°C)ln very low temperatures (under -20°F, -29°C)

Removal

TOC MARK

2. Set the camshaft pulley to TOC. Align the TOCmarks on the camshaft pulley to the cylinder headupper surface.

KEYTIMING BELTDRIVE PULLEYClean.

1. Set the timing belt drive pulley so that the No. 1 piston is at top dead center (TOC). Align the groove orthe timing belt drive pulley to the pointer on the oipump.

Install the timing belt in the reverse order of removal;Only key points are described here.

6-18

11. Remove the timing belt.

ADJUSTING BOLT44 N·m (4.5 kgf·m,33Ibf·ft)

10. Loosen the adjusting boit 180°. Push the tensionerto remove tension from the timing belt, thenretighten the adjusting boit.

6x 1.0mm12 N·m (1.2 kgf·m.8.7Ibf·ft)

9. Remove the CKFsensor from the oil pump.

InstallationRemoval (cont'd)

Timing Selt

6-19

• See section 4 for alternator belt tension adjustment.

• See section 22 for AlC compressor belt tensionadjustment.

• See section 17 for PIS pump belt tension adjustment.

11. After installation, adjust the tension of each belt.

10. If the camshaft pulley is not positioned at TOC,remove the timing belt and adjust the position following the procedure on page 6-18. Then reinstallthe timing belt.

TOC MARK

CAMSHAFT PULlEV:

TOC MARK(WHITEI

CRANKSHAFT PUllEV:

9. Check that the crankshaft pulley and camshaft pulley are both at TOC.

8. Adjust the timing belt tension (see page 6-16).

7. Rotate the crankshaft pulley about five or six turnscounterclockwise so that the timing belt positionson the pulleys.

6. Install the crankshaft pulley, then tighten the pulleyboit (see page 6-14).

NOTE: Clean the upper and lower covers beforeinstallation.

5. Install the lower cover and upper cover.

4. Loosen and retighten the adjusting boit to tensionthe timing belt.

NOTE: Make sure the timing belt drive pulley andcamshaft pulley are at TOC.

3. Install the timing belt tightly in the sequence shown.CDTiming belt drive pulley (crankshaft) ~@Adjustingpulley ~@Water pump pulley ~@Camshaft pulley.

6-20

6. Install the CKF sensor in reverse order of rernoval,

6 x 1.0 mm12 N'm (1.2 kgf·m.8.7Ibf·ttl

CKF SENSORCONNECTOR

/

5. Disconnect the CKF sensor connector, then removethe CKF sensor.

4. Remove the lower coyer and idler pulley bracket(see page 6-17).

3. Remove the upper coyer and dipstick/tube (seepage 6-17).

2. Remove the crankshaft pulley (see page 6-14).

NOTE: Refer to page 6-40 when installing.

t. Remove the cylinder head coyer.

Replacement

Crankshaft Speed Fluctuation(CKF) Sensor

6-21

(cont'd)

CYLINDER HEADGASKET

Replace.

CYLINDERHEAD

DISTRIBUTORSee section 4.

HEAD COVER GASKETReplace if it is leaking,damaged or deteriorated.Apply liquid gasket atthe four corners of therecesses.

RUBBER SEALReplace when damagedor deteriorated.

<:>CYLINDER HEAD BOLT10 x 1.25 mm67 N'm (6.8 kgf·m, 49 Ibf.ft)Tightening, page 6-40Apply engine oil to the threads.

CYLINOER HEADCOVERReter to page 6-40, wheninstalling the cylinder head cover.

6x1.0mm9.8 N'm (1.0 kgf·m, 7.2Ibf.ft)Apply soapsuds to threads and cylinder headcontact surface when replacing the rubberseal, then remove any soapsuds after installing rubber seal.

WASHERReplace when damagedor deteriorated.

8 x 1.25 mm24 N'm (2.4 kgf·m,17Ibf.ft)

NOTE: Use new O-rings and gaskets when reassembling.

CAUTION:• To avoid damage, wait until the engine coolant temperature drops below 100°F (38°C) before removing the cylinder

head.• When handling a metal gasket, take care not to fold it or damage the contact surface.

lIIustrated Index

Cylinder Head

6-22

EXHAUST CVlINDER HEADVALVE Removal, page 6-23

Warpage, page 6-34Valve seat reconditioning,page 6-34Installation, page 6-39

INTAKE VALVERemoval, page 6-32Installation, page 6-37

Replace.

Clean.

Oll CONTROLORIFICE

VALVE KEEPERS

SPRING RETAINER

INTAKE VALVESPRING

ss VALVE SPRINGSEAT

INTAKE VALVEGUIDE

Replace.

6x 1.0mm12N'm (1.2 kgf·m,8.7 Ibf.ftl

CAMSHAFT

ROCKERARMASSEMBlY

6x 1.0mm12 N'm Il.2 kgf·m. 8.7 Ibf·ftlApply engine oil to thethreads.

VALVE KEEPERS-,SPRING RETAINER---"~\~

EXHAUST VALVE_____"SPRING

EXHAUSTVAlVE0&1SEAl VALVE SPRINGReplace. SEAT

EXHAUST VALVEGUIDE Replace.Inspection, page 6-33Replacement, page 6-35 Apply engine oil toReaming, page 6-37 the threads.

8 x 1.25mm20 N'm (2.0 kgf·m, 14Ibf.ft)Apply engine oil to thethreads.

lOSTMOTIONASSEMBlYHOlDER

\lOSTMOTIONASSEMBlY

., Prior to reassembling, clean ail the parts in solvent, dry them and apply lubricant to any contact parts.

lIIustrated Index (cont'd)

Cylinder Head

6-23

(cont'd)

8. Remove the PIS pump bracket (see page 5-10).

MOUNTING NUT10 x 1.25 mm44 N'm (4.5 kgf·m.JJ IbUt)

LOCK BOLT8 x 1.25 mm24 N'm (2.4 kgf·m.17 IbUt)

7. Loosen the mounting nut and lock boit, thenremove the alternator belt.

6. Loosen the idler pulley center nut and adjustingboit, then remove the air conditioning (Ne) compressor belt (see page 5-4).

5. Loosen the mounting boit and lock boit, thenrem ove the power steering (PIS) pump belt andpump (see page 5-4).

lAT SENSORCONNECTOR

AIR CLEANERHOUSING

INTAKE AIRDUCT

6 x 1.0mm9.8 N·m (1.0 kgf·m. 7.2IbUt)

\

4. Disconnect the intake air temperature (lAT) sensorconnector, then remove the air cleaner housing.

3. Drain the engine coolant (see page 10-5).• Remove the radiator cap to speed draining.

2. Disconnect the negative terminal from the battery.

1. Make sure Vou have anti-theft code for the radio,them write down the frequencies for the radio's preset buttons.

NOTE:• Unspecified items are common.• Mark ail wiring and hoses to avoid misconnection.

Also, be sure that they do not contact other wiring orhoses, or interfere with other parts.

• Inspect the timing belt before removing the cylinderhead.

• Turn the crankshaft pulley so that the No. 1 piston is attop dead center (see page 6-19).

CAUTION:• Use fender covers to avoid damaging painted sur

faces.• To avoid damage, unplug the wiring connectors

carefully while holding the connector portion.• T0 avoid damaging the cylinder head, wait until the

engine coolant temperature drops below 100°F(38°C)before loosening the retaining bolts.

'.s:.iWii}!; Make sure jacks and safety stands areplaced properl y and hoist brackets are attached to thecorrect positions on the engine.

Engine removal is not required for this procedure.

Removal

HEATERHOSE

UPPERRADIAT(HOSE

WATERBYPASSHOSE

14. Remove the upper radiatar hose, heater hase é

water bypass hose.

PCV HOSE

13. Remove the water bypass hose and positive crcase ventilation (PCV) hose.

12. Remove the brake booster vacuum hose, fuel rehase and vacuum hose (see page 5-3).

6-24

BREATHERHOSE

EVAP CONTROLCANISTER HOSE

11. Remove the evaporative emission (EVAP) controlcanister hose, fuel feed hose and breather hose.

'Mt.M@; Do not smoke while working on the fuelsystem. Keep open tlame or spark away trom thework area. Drain fuel only into an approved container.

10. Relieve fuel pressure (see section 11).

ADJUSTINGNUT

THROTTLECABLE

NOTE:• Take care not to bend the cable when removing it.

Always replace any kinked cable with a new one.• Adjust the throttle cable when installing (see sec

tion 11).

9. Remove the throttle cable by loosening the locknut,then slip the cable end out of the throttle linkage.

Removal (cont' d)

Cylinder Head

6-25

(cont'd)

Apply engine oit to theboit threads.

6 x 1.0 mm12 N'm (1.2 kgf·m, 8.7 Ibf.ft)

CAMSHAFTPULLEYBACK

COVER

20. Remove the camshaft pulley.

19. Remove the timing belt (see page 6-17).

CYLlNDERHEAD COVER


NOTE:• Use a jack to support the engine before remov

ing the upper bracket.• Make sure to place a cushion between the oil

pan and the jack.

17. Remove the upper bracket.

16. Remove the spark plug caps and distributor fromthe cylinder head.

15. Remove the engine wire harness connectors andwire harness clamps from the cylinder head and theintake manifold.• Four fuel in ject or connectors• Engine coolant temperature (ECT) sensor con-

nector• ECT switch connecter• ECT gauge sending unit connector• Throttle position sensor connector• Manifold absolute pressure (MAP) sensor con

nector• Primary heated oxygen sensor (primary H02S)

connector• Secondary heated oxygen sensor (secondary

H02S) connector• VTEC solenoid valve connector• VTEC pressure switch connector• Idle air control (lAC) valve connector

CAMSHAFT HOlDER BOLTS lOOSENINGSEQUENCE:

NOTE:• Unscrew the camshaft holder bolts two turns at a

time, in a crisscross pattern, to prevent damaging the valves or rocker arm assembly .

• When removing the rocker arm assembly, do notremove the camshaft holder bolts. The bolts willkeep the camshaft holders, the springs and therocker arms on the shaft.

2. Unscrew the camshaft holder bolts, then removethe rocker arm assembly.

ADJUSTING SCREWS

ADJUSTING SCREWS

1. loosen the adjusting screws.

6-26

CYlINDER HEAD BOLTS lOOSENING SEQUENCE:

CAUTION: T0 prevent warpage, unscrew the boltsin sequence 1/3 turn at a time; repeat the sequenceuntil ail the bolts are loosened.

23. Remove the cylinder head bolts, then remove thecylinder: head.

22. Remove the intake manifold (see page 9-2).

21. Remove the exhaust manifold (see page 9-3).

RemovalRemoval (cont' d)

Rocker ArmsCylinder Head

6-27

letter "A" is stampedon rocker arm.

Letter "8" is stampedon rocker arm.

EXHAUSTROCKER ARM Af

EXHAUST ROCKER SHAFT

t~----~v~------~v~----VEXHAUST ROCKERARMB

BIA

ROCKER SHAFTSPRING

AB

u~r A

ROCKER SHAFTSPRING(4 placesl

COLLAR

ROCKER ARMS

No. 5 CAMSHAFTHOLDER

INTAKEROCKER ARMASSEMBLY

RUBBER BAND

~

ROCKER SHAFTCOLLAR(4 placeslt---.....V 1N_,TA]OCKER S~A,....FT_o-0 -:=J--ROCKER SHAFT

COLLAR

NOTE:• Identify parts as they are removed to ensure reinstallation in original locations.• Inspect rocker shafts and rocker arms (see page 6-28).• Rocker arms must be installed in the sarne position if reused.• When removing or installing the rocker arm assembly, do not remove the camshaft holder bolts. The bolts will keep the

holders, springs and rocker arms on the shaft.

, Prior to reasse~bling, clean ail the parts in solve nt, dry them and apply lubricant to any contact points.

Disassembly IReassembly

LOST MOTION ASSEMBL yPush

2. Remove the lost motion assembly from the holderand inspect it. Test it by pushing the plunger withyour finger.- If the lost motion assembly plunger does not

move smoothly, replace it.

6-28

NOTE:• Apply oil to the pistons when reassembling.• Bundle the rocker arms with a band to prevent them

from separating.

SYNCHRONIZINGPISTON A

SYNCHRONIZINGPISTON B

PRIMARY ROCKER

ARM \

MID ROCKER ARM

SECONDARYROCKERARM

1. Inspect the rocker arm piston. Push it manually.- If it does not move smoothly, replace the rocker

arm assembly.

NOTE: When reassembling the primary rocker arm,carefully apply air pressure to the oil passage of therocker arm.

Inspection

Rocker Arms and Lost Motion Assemblies

6-29

4. Repeat these measurements on ail the rockers.- If the clearance is over the service limit, replace the

rocker shaft and ail over-toJerance rocker arms.

Inspect rocker armface for wear.

Rocker Arm-to-Shaft Clearance:Standard (New):

Intake: 0.017 - 0.050 mm(0.0007 - 0.0020 in)

Exhaust: 0.018 - 0.054 mm(0.0007 - 0.0021 in)

Service Limit: 0.08 mm (0.003 in)

3. Measure the inside diameter of the rocker arm andcheck for an out-of-round condition.

2. Zero the gauge to the shaft diameter.

MICROMETER

/hOUld be srnooth.

1. Measure the diameter of the shaft at the first rockerlocation.

Measure both the intake rocker shaft and exhaust rockershaft.

Clearance Inspection

Rocker Arms and Shafts

8. Install the camshaft holders, and tighten the bolts tothe specified torque.

7 Place a plastigage strip across each journal.

6 Clean the camshaft bearing surfaces in the cylinderhead, then set the camshaft back in place.

5 Lift the camshaft out of the cylinder head, wipe itclean, then inspect the lift ramps. Replace thecamshaft if any lobes are pitted, scored, or excessively worn.

4. Remove the bolts, then remove the camshaft holders from the cylinder head.

Camshaft End Play:Standard (New): 0.05 - 0.15 mm

(0.002 - 0.006 in)Service Limit: 0.5 mm (0.02 in)

3. Zero the dial indicator against the end of the camshaft.Push the camshaft back and forth, and read the endplay.

2. Seat the camshaft by pushing it toward the rear ofthe cylinder head.

@ @®

® @

6-30

CID

6 mm bolts: @, @ @, @

Specified torque:8 mm bolts: 20 N'm (2.0 kgf·m 14 Ibf.ft)Apply engine oil to the threads.6 mm bolts: 12 N'm (1.2 kgf·m 8.7 Ibf.ft)Apply engine oil to the threads.

1. Put the camshaft and the camshaft holders on thecvlinder head, then tighten the bolts to the specifiedtorque.

NOTE:• Do not rotate the camshaft during inspection.• Remove the rocker arms and rocker shafts.

Inspection

Camshaft

6-31

Check this area for wear.

PRIMIOSEe

ornJOrn]üEX IN EX

T/B ..

P-RI:Primary cam lobe, SEC: Secondary cam lobeMID: Mid cam lobe, T/S: Timing beltIN: Intake, EX: Exhaust

INTAKE EXHAUST

PRI 37.065 (1.4592)

MID 38.274 (1.5068) 38.008 (1.4964)

SEC 36.778 (1.4479)

Unit mm (in)Cam lobe height standard (New)

11. Check the cam lobe height wear.

- If the total runout of the camshaft is within tolerance, replace the cylinder head.

- If the total runout is out of tolerance, replace thecamshaft and recheck. If the bearing clearance isstill out of tolerance, replace the cylinder head.

Rotate camshaftwhile measuring.

Camshaft Total Runout:Standard (New): 0.03 mm (0.001 in) max.Service Limit: 0.04 mm (0.002 in)

10. If the camshaft-to-holder oil clearance is out of tolerance:- And the camshaft has already been replaced,

vou must replace the cylinder head.- If the camshaft has not been replaced, first check

the total runout with the camshaft supported onV-blocks.

Camshaft-to-Holder Oil Clearance:Standard (New): 0.050 - 0.089 mm


9. Remove the camshaft holders, then measure thewidest portion of the plastigage on each journal.

4. Remove the valve seal.

VALVE GUIDE SEAL REMOVERLISLE PIN 57900 or KD3350

SEAL REMOVER

3. Install the valve guide seal remover.

6-32

VALVE SPRING COMPRESSORSnap-on CF711 or KD-383wlth #32 JAWS

2. Install the spring compressor. Compress the springand remove the valve keeper.

SOCKET

PLASTIC MALLET

1. Using an appropriate-sized socket and plastic mallet, lightly tap the valve retainer to loosen the valvekeepers before installing the valve spring compressor.

NOTE: Index the valves and valve springs as they areremoved so that each item can be reinstalled in its original position.

Removal

Valves, Valve Springs and Valve Seals

6-33

Exhaust Valve Stem-to-Guide Clearance:Standard (New): 0.05 - 0.08 mm


Intake Valve Stem-to-Guide Clearance:Standard (New): 0.02 - 0.05 mm


NOTE: An alternate method of checking guide tostem clearance is to subtract the 0.0. of the valvestem, measured with a micrometer, from the 1.0. ofthe valve guide, measured with an insidemicrometer or bail gauge. Take the measurementsin three places along the valve stem and threeplaces inside the valve guide. The difference between the largest guide measurement and thesmallest stem measurement should not exceed theservice limit.

• If the measurement exceeds the service limit,recheck using a new valve.

• If the measurement is now within the servicelimit, reassemble using a new valve.

• If the measurement still exceeds the limit,recheck using the alternate method below, thenreplace the valve and guide, if necessary.

Valve extended 10 mm out from seat.

Exhaust Valve Stem-to-Guide Clearance:Standard (New): 0.10 - 0.16 mm


Intake Valve Stem-to-Guide Clearance:Standard (New): 0.04 - 0.10 mm


Measure the guide-to-stem clearance with a dial indicator while rocking the stem in the direction of normalthrust (wobble method).

Valve Movement

Exhaust Valve DimensionsA Standard (New): 25.9 - 26.1 mm"

(1.02 - 1.03 in)B Standard (New): 114.60 -114.90 mm

(4.512 - 4.524 in)C Standard (New): 5.45 - 5.46 mm

(0.2146 - 0.2150 in)C Service Limit: 5.42 mm (0.2134 in)D Standard (New): 1.05 -1.35 mm

(0.041 - 0.053 in)D Service Limit: 0.95 mm (0.037 in)

Intake Valve DimensionsA Standard (New): 29.9 - 30.1 mm

(1.18 - 1.19 in)B Standard (New): 117.42 -117.72 mm

(4.623 - 4.635 in)C Standard (New): 5.48 - 5.49 mm

(0.2157 - 0.2161 in)C Service Limit: 5.45 mm (0.2146 in)D Standard (New): 0.85 -1.15 mm

(0.033 - 0.045 in)D Service Limit: 0.65 mm (0.026 in)

Valve Guides

5. After resurfacing the seat, inspect for even valveseating: Apply Prussian Blue compound to thevalve face, and insert the valve in its original location in the head, then lift and snap it closed agains1the seat several times.

60:

Valve Seat Width:Standard (New):Intake: 0.85 -1.15 mm (0.033- 0.045 in)Exhaust: 1.25-1.55 mm (0.049- 0.061 in)Service Limit:Intake: 1.6 mm (0.063 in)Exhaust: 2.0 mm (0.079 in)

4. Make one more very light pass with the 45° cutter teremove any possible burrs caused by the other eutters.

3. Bevel the upper edge of the seat with the 30° cutteand the lower edge of the seat with the 60° cutterCheck the width of the seat and adjust accordingly.

2. Carefully cut a 45° seat, removing only enougtmaterial to ensure a smooth and concentric seat.

VALVE SEATCUTTER

NOTE: If the guides are worn (see page 6-33)replace them (see page 6-35) before cutting thsvalve seats.

1. Renew the valve seats in the cylinder head using é

valve seat cutter.

6-34

Cylinder Head Height:Standard (New): 92.95 - 93.05 mm

(3.659- 3.663 in)

Measure along edges, and three ways across center.

• If warpage is less than 0.05 mm (0.002 in), cylinder head resurfacing is not required.

• If warpage is between 0.05 mm (0.002 in) and0.2 mm (0.008 in), resurface the cylinder head.

• Maximum resurface limit is 0.2 mm (0.008 in)based on a height of 93 mm (3.66 in).

If the camshaft-to-holder oil clearances are within specifications" check the cylinder head for warpage.

NOTE: If the camshaft-to-holder oil clearances (seepage 6-30) are not within specification, the cylinder headcannot be resurfaced.

ReconditioningWarpage

Valve SeatsCylinder Head

6-35

(cont'd)

CAUTION:• Do not use a torch; it may warp the head.• Do not get the head hotter than 300°F (150°C);

excessive heat may loosen the valve seats.• To avoid burns, use heavy gloves when handling

the heated cylinder head.

3. Use a hot plate or oven to evenly heat the cylinderhead to 300°F(150°C).Monitor the temperature witha cooking thermometer.

2. Select the proper replacement guides, and chili themin the freezer section of a refrigerator for about anhour.

orVALVEGUIDEDRIVER,5.5 mm07742- 0010100

l-87mm +- 57 mm1- (3.43 in) (2.24 in)__tt-r

10.8 mm(0.42 in)

5.3 mm(0.21 in)

DI-------_L_l. 1

1. As illustrated below, use a commercially-availableair-impact valve guide driver attachment modifiedto fit the diameter of the valve guides. In most cases,the same procedure can be done using the specialtool and a conventional hammer.

Replacement

VALVESTEMINSTALLEDHEIGHT

8. If the valve stem installed height is over the servicelimit, replace the valve and recheck. If it is still overthe service limit, replace the cvlinder head; thevalve seat in the head is too deep.

Intake, Exhaust Stem Installed Height:Standard (New): 53.17- 53.64mm

(2.093- 2.112 in)Service Limit: 53.89mm (2.122in)

7. Insert the intake and exhaust valves in the head andmeasure the valve stem installed height.

NOTE: The final cut should always be made withthe 45° cutter.

6.

VALVEGUIDEDRIVERPRUSSIANBLUECOMPOUND (Commercially available)

The actual valve seating surface, as shown by theblue compound, should be centered on the seat.• If it is too high (closer to the valve stem), Vou

must make a second cut with the 60° cutter tomove it down, then one more cut with the 45°cutter to restore seat width.

• If it is too low (closer to the valve edge), voumust make a second cut with the 30° cutter tomove it up, then one more cut with the 45° cutterto restore seat width.

Valve Guides

VALVE GUIDE

"::tJ;;;~eCYLINDER HEAD

Valve Guide Installed Height:Intake: 17.85 - 18.35 mm (0.703 - 0.722 in)Exhaust: 18.65 -19.15 mm (0.734 - 0.754 in)

7. Applv a thin coat of clean engine oil to the outsideof the new valve guide. Install the guide from thecamshaft side of the head; use the special tool todrive the guide in to the specified installed height. IfVou have ail 16 guides to do, Vou may have to reheatthe head.

6-36

6. Remove the new guides from the freezer, one at atime, as vou need them.

CAUTION: Drill guides only in extreme cases; voucould damage the cylinder head if the guide breaks.

If a valve guide still won't move, drill it out with a8 mm (5/16 in) bit, then try again.

VALVE GUIDE DRIVER,5.5 mm07742-0010100

5. Turn the head over, and drive the guide out towardthe camshaft side of the head.

CAUTION:• Always wear safety goggles or a face shield when

driving valve guides.• Hold the air hammer directly in line with the

valve guide to prevent damaging the driver.

4. Working from the camshaft side, use the driver andan air hammer to drive the guide about 2 mm (0.1 in)towards the combustion chamber. This will knock offsome of the carbon and make removal easier.

Replacement (cont' d)

Valve Guides

6-37

(cont'd)

EXHAUST VALVE SEAL

VALVE GUIDE SEALINSTALLERKD2899 (Commercially available)NOTE: Use small ID end of

INT AKE VALVE SEAL

BLACKSPRING

WHITESPRING

NOTE: Exhaust and intake valve seals are not interchangeable.

3. Install the valve seals using the valve guide sealinstaller.

2. Install the spring seats on the cylinder head.

NOTE: Make sure the valves move up and downsmoothly.

1. Coat the valve stems with engine oil. Insert thevalves in the valve guides.

VALVE GUIDEREAMER, 5.5 mm07HAH - PJ7010B

Turn reamer inclockwise directiononly.

5. Check the clearance with a valve (see page 6·33).Verity that the valve slides in the valve guide without exerting pressure.

4. Thoroughly wash the guide in detergent and waterto remove any cutting residue.

3. Continue to rotate the reamer clockwise whileremoving it from the bore.

2. Rotate the reamer clockwise the full length of thevalve guide bore.

1. Coat both the reamer and valve guide with cuttingoil.

NOTE: For new valve guides only.

InstallationReaming

Valves

3. Turn the camshaft until its keyway is facing up (No. 1piston at TDC).

CAMSHAFT SEALSeal housing surface should be dry.Apply a light coat of oil to camshaftand inner lip of seal.

OIL CONTROL ORIFICE

Clean. ~ ~ O-RING

~RePI.ceCAMSHAFTKeyway up.

2. Clean and install the oil control orifice with a newO-ring.

1. After wiping down the camshaft, camshaft seal andjournals in the cylinder head, lubricate both surfaces and install the camshaft.

CAUTION:• Make sure that ail rockers are in alignment with their

valves wh en torquing the rocker assembly bolts.• Valve locknuts should be loosened and adjusting

screws backed off before installation.• To prevent the rocker arm assembly from coming

apart, leave the camshaft holder bolts in the holders.

6-38

PLASTICMALLET

NOTE: Tap the valve stem only along its axis so voudo not bend the stem.

VALVE SPRING COMPRESSOR(Commercially availablelSnap-on CF711 or KO - 383with #32 JAWS

5. Lightly tap the end of each valve stem two or threetimes with a plastic mallet to ensure proper seatingof the valve and valve keepers.

NOTE: Place the end of the valve spring with closeIy wound coils toward the cylinder head.

4. Install the valve spring and valve retainer, theninstall the valve spring compressor. Compress thespring and install the valve keepers.

InstallationInstallation (cont'd)

Camshaft/Rocker Arms andCamshaft Seal/PulleyValves

6-39

(cont'd)

DOWELPINS

CYLINDER HEADGASKET

1. Cylinder head dowel pins must be aligned.

NOTE:• Always use a new head gasket.• Cylinder head and cylinder block surface must be

clean.• "UP" mark on the camshaft pulley should be at the top.• Turn the crankshaft so the No. 1 piston is at TOC (see

page 6-18).• Clean the oil control orifice before installing.• Do not use the upper cover and lower cover to store

removed items.• Clean the upper cover and lower cover before instal

lation.

Install the cylinder head in the reverse order of removal:

Installation

7. Install the back cover, th en install the camshaft pulley.

6 mm bolts: @, @, @,@

Specified torque:8mm bolts: 20 N·m (2.0 kgf·m, 14Ibf.ft)Apply engine oil to the threads.6 mm bolts: 12 N·m (1.2 kgf·m, 8.7 Ibf.ft)Apply engine oil to the threads.

6. Tighten each boit two turns at a time in the sequenceshown below to ensure that the rockers do not bindon the valves.

5. Set the rocker arm assembly in place and looselyinstall the bolts.- Make sure that the rocker arms are properly posi

tioned on the valve stems.

No. 1No.S

4. Apply liquid gasket (Part No. 08718 - 0001 or 08718-0003) to the head mating surfaces of the No. 1 andNo. 5 camshaft holders.- Apply liquid gasket to the shaded areas.

Cylinder Head

Apply liquid gasket tothe shaded areas.

NOTE:• Use liquid gasket, Part No. 08718 - 0001 or 08718

- 0003.• Check that the mating surfaces are clean and dry

before applying liquid gasket.• Do not install the parts if five minutes or more

have elapsed since applying liquid gasket.Instead, reapply liquid gasket after removing oldresidue.

• After assembly, wait at least 20 minutes beforefilling the engine with oll.

10. Apply liquid gasket to the head cover gasket at thefour corners of the recesses.

\CYLINDER HEADCOVER

CORNERS OFTHE RECESS

HEAD COVER GASKETClean.

CORNERS OFTHE RECESS

NOTE:• Before installing the head cover gasket, thor

oughly clean the seal and the groove .• When installing, make sure the head cover gas

ket is seated securely in the corners of therecesses with no gap.

9. Install the head cover gasket in the groove of thecylinder head cover. Seat the recesses for thecamshaft first, then work it into the groove aroundthe outside edges.

8. Adjust the valve clearance (see page 6-10).

7. Install the timing belt (see page 6-18).

6-40

6. Install the exhaust manifold bracket. Install exhaustpipe A and the bracket, then install the cover.

• Always use a new exhaust manifold gasket.

5. Install the exhaust manifold and tighten the nuts ina crisscross pattern in two or three steps, beginningwith the inner nut (see page 9-3).

• Always use a new intake manifold gasket.

4. Install the intake manifold and tighten the nuts in acrisscross pattern in two or three steps, beginningwith the inner nuts (see page 9-2).

CYLINDER HEAD BOLTS TORQUE SEQUENCE:

NOTE:• We recommend using a beam-type torque

wrench. When using a preset-type torque wrench,be sure to tighten slowly and not to overtighten.

• If a boit makes any noise while vou are torquing it,loosen the boit, and retighten it from the 1st step.

1st step: CD -@ 20 N'm (2.0 kgf·m, 14Ibf.ft)2nd step: CD - @ 49 N'm (5.0 kgf·m, 36 Ibf.ft)3rd step: CD - @ 67 N'm (6.8 kgf·m, 49 IbHt)4th step: CD, CID 67 N'm (6.8 kgf·m, 49Ibf.ft)

3. Tighten the cylinder head bolts sequentially in foursteps.

2. Position the camshaft correctly (see page 6-18).


Cylinder Head

6-41

14. Enter the anti-theft code for the radio, then enter thecustomer's radio station presets.

13. After installation, check that ail tubes, hoses andconnectors are installed correctly.

NOTE: After assembly, wait at least 20 minutesbefore filling the engine with oll.

12. Tighten the bolts in two or three steps. In the finalstep, tighten ail the bolts, in sequence, to 9.8 N'm(1.0 kgf·m, 7.2 Ibf.ft).

SPARK PLUGSEAL

6 x 1.0 mm

9.8 N·mIl.0 kgl.m.~bHt'" f~ WASHER

CYlINOER HEAD ~COVER

NOTE:• Before installing the cylinder head coyer, clean

the cylinder head contacting surfaces with ashop towel.

• Do not touch the parts where liquid gasket wasapplied.

• Take care not to damage the spark plug sealswhen installing the cylinder head coyer.

• Visually check the spark plug seals for damage.• Replace the washer if it is damaged or deteriorat

ed.

11. When installing the cylinder head coyer, hold thehead coyer gasket in the groove by placing your fingers on the camshaft holder contacting surfaces(top of the semicircles).Set the spark plug seal on the spark plug tube.Once the cylinder head coyer is on the cylinderhead, slide the coyer slightly back and forth to seatthe head coyer gasket.

Cylinder BlockInspection 7-12Bore Honing 7-13

Piston PinsRemoval 7-13Installation 7-14Inspection 7-15

Connecting RodsSelection 7-14

Piston RingsEnd Gap 7-16Replacement 7-16Ring-to-Groove Clearance 7-17Alignment 7-17

Crankshaft Oil SealInstallation 7-18

CrankshaftInstallation 7-19

Oll PanInstallation 7-21

Oll Seals-Installation 7-22

Special Tools 7-2lIIustrated Index 7-3Flywheel and Drive Plate

Replacement 7-5Connecting Rod and Crankshaft

End Play 7-5Main Bearings

Clearance 7-6Selection 7-7

Connecting Rod BearingsClearance 7-7Selection 7-8

Pistons and CrankshaftRemoval 7-8

CrankshaftInspection 7-10

PistonsInspection 7-11Installation 7-19

Engine Block

7-2

®

@®

@ ) 0 )) )))]))]))))]l~W»~

»@ ® (J)

ii(Q)))))2J))))])))( @ 0

Ref. No. Tooi Number Description Qty Page Reference

CD 07lAB - PV00100 Ring Gear Holder 7-5CID 07749 - 0010000 Driver 7-18,23@ 07947 - SB00200 Seal Driver 7-22@ 07948 - SB00101 Driver Attachment 7-18,23® 07973 - PE00200 Pilot Collar 7-13, 14® 07973 - PE00310 Piston Pin Driver Shaft 7-13, 14(j) 07973 - PE00320 Piston Pin Driver Head 7-13, 14

1@ 07973 - PE00400 Piston Pin Base Insert 7-13, 14® 07973 - SB00100 Piston Base Head 7-13,14@ 07973 - 6570500 Piston Base 7-13, 14® 07973 - 6570600 Piston Base Spring 7-13,14

Special T0015

7-3

(cont'd)

BREATHING PORT COVERMOUNTING BOLT6 x 1.0mm11N'm (1.1 kgf'm, 8 Ibf·ft)Apply liquid gasket tothe boit threads.

THRUST WASHERSGrooved sides face outward.NOTE: Thrust 'washer thicknessis fixed and must not be changedby grinding or shimming./~~

CRANKSHAFT SEAl 1Installation. pages 7-22and 8-10 O-RINGReplace. Replace.

6 x 1.0 mm11 N'm (1.1 kgf-m.a Ibf.ft)

GASKET

CRANKSHAFT

MAIN BEARINGSSelection, page 7-7NOTE: New main bearings mustbe selected by matching crankand black identification markings. _

FlYWHEEL (MIT)

OllPANRefer ta page 7-21when installing.

Apply liquid gasket tathese points.

WASHERORAIN BOlT Replace.39 N'm (4.0 kqf-rn,291b1.1t)~

6 x 1.0 mm ~12 N'm (1.2 kgf·m,a.7 Ibf·ft)"',~b11x1.5mm

51 N'm(5.2 kgf·m. 38 Ihf·ft)Apply engine ail ta cheboitthreads.NOTE: After torquingeach cap, turn the crankshaftta check for binding.

Oll PUMPOverhaul. page 8-8Removal/lnspection,page 8-9Apply liquid gasketta the mating surface.

NOTE:• Apply liquid gasket ta the mating surfaces of the right side caver and ail pump case before installing them.• Use liquid gasket, part No. 08718 - 0001 or 08718 - 0003.• Clean the ail pan gasket mating surfaces before installing the ail pan.

., Lubricate ail internai parts with engine ail during reassembly.

IIlustrated Index

7-4

CONNECTING ROD CAP NUT8xO.75mm31 N·m (3.2 kgf·m,231bHt)

tS� Apply engine oil to"tO'f'-------- the boit threads.NOTE: After torquing each bearingcap. rotate the crankshaft tocheck for binding.

Inspect the top of each cylinder borefor carbon build-up or a ridgebefore removing the piston.Remove the ridge if necessary, page 7-9

CONNECTING RODBEARINGSClearance, page 7-7Selection, page 7-8

ENGINE BLOCKCylinder bore inspection, page 7·12Warpage inspection. page 7-12Cylinder bore honing, page 7-13

PISTON PINRemoval, page 7·13Installation, page 7-14______Inspection, page 7-15 ---"'0

~"-;;~:;;.'A- __ ----- PISTONInspection, page 7-'1NOTE: Before removing a piston, inspect thetop of the cylinder bore for carbon build-up or aridge. Remove the ridge if necessary, page 7-9

CONNECTING ROD BEARING CAP-----+-t'"Installation, page 7-19NOTE: Install caps so thebearing recess is on thesame side as the recessin the rod.

INTAKE

PISTON INSTALLATION DIRECTION:

EXHAUST

~ Lubricate ail internai parts with engine oil during- iii reassembly.

NOTE: New rod bearings must be selected by matching connecting rod assembly and crankshaft identification markings(see page 7-8).

(cont'd)

IIlustrated Index

7-5

NOTE: Thrust washer thickness is fixed and must not bechanged either by grinding or shimming.Thrust washers are installed with the grooved sides tacing outward.

• If end play is excessive, inspect the thrust washersand thrust surface on the crankshaft.Replace parts as necessary.

Crankshaft End Play:Standard (New): 0.10 - 0.35 mm (0.004 - 0.014 in)

• Service Limit: 0.45 mm (0.018 in)

Push the crankshaft firmly away from the dial indicator,and zero the dial against the end of the crankshaft. Thenpull the crankshaft firmly back toward the indicator; dialreading should not exceed the service limit.

• If out-of-tolerance, install a new connecting rod.• If still out-of-tolerance, replace the crankshaft (see

pages 7-8 and 7-19).

Connecting Rod End Play:Standard (New): 0.15 - 0.30 mm (0.006 - 0.012 in)Service Limit: 0.40 mm (0.016 in)

12)( 1.0 mm74 N·m (7.5 kgf·m. 54Ibf·ft)

Automatic Transmission:Remove the six drive plate bolts, then separate the driveplate trom the crankshaft tlange. After installation, tighten the bolts in a crisscross pattern.

12x1.0mm118 N·m (12.0 kgf·m, 87 fbf·ft)

RING GEARInspect ring gearteeth for wear ordamage.

ENGINE BLOCK

RING GEAR HOLDER07LAB - PV00100

Manual Transmission:Remove the six flywheel bolts, then separate the flywheel from the crankshaft flange. After installation,tighten the bolts in a crisscross pattern.

End PlayReplacement

Connecting Rod andCrankshaftFlywheel and Drive Plate

NOTE: If the proper clearance cannot be obtainedby using the appropriate larger or smaller bearings,replace the crankshaft and start over.

7. If the plastigage shows the clearance is still incorrect, try the next larger or smaller bearing (the colorlisted above or below that one), and check again.

CAUTION: Do not file, shim, or scrape the bearingsor the caps to adjust clearance.

6. If the plastigage measures tao wide or tao narrow,(remove the engine if it's still in the car), remove thecrankshaft, and remove the upper hait of the bearing. Install a new, complete bearing with the samecolor code (select the color as shown on the nextpage), and recheck the clearance.

7-6

Main Bearing-to-Journal Oil Clearance:Standard (New):No. 1,5 Journals:

0.018 - 0.036 mm (0.0007 - 0.0014 in)No. 2, 3, 4 Journals:

0.024 - 0.042 mm (0.0009 - 0.0017 in)Service Limit: 0.05 mm (0.002 in)

5. Remove the cap and bearing again, and measurethe widest part of the plastigage.

NOTE: Do not rota te the crankshaft during inspection.

1st step: 25 N'm (2.5 kgf·m, 181bf.ft)Final step: 51 N'm (5.2 kgf·m, 381bf.ft)

4. Reinstall the bearings and caps, then torque thebolts.

NOTE: If the engine is still in the car when you boitthe main cap down to check clearance, the weightof the crankshaft and flywheel will flatten the plastigage further than just the torque on the cap boit,and give you an incorrect reading. For an accuratereading, support the crank with a jack under thecounterweights and check only one bearing at atime.

3. Place one strip of plastigage across each main journal.

2. Clean each main journal and bearing haIf with aclean shop towel.

1. Ta check main bearing-to-journal ail clearance,remove the main caps and bearing halves.

Clearance

Main Bearings

7-7

NOTE: If the proper clearance cannot be obtainedby using the appropriate larger or smaller bearings,replace the crankshaft and start over.

7. If the plastigage shows the clearance is still incorrect, try the next larger or smaller bearing (the colorlisted above or below that one), and check clearance again.

CAUTION: Do not file, shim, or scrape the bearingsor the caps to adjust clearance.

6. If the plastigage measures too wide or too narrow,remove the upper haIf of the bearing, install a new,complete bearing with the same color code (selectthe color as shown on the next page), and recheckthe clearance.

PLASTIGAGE STRIP

Connecting Rod Bearing-to-Journal Oil Clearance:Standard (New): 0.020 - 0.038 mm

(0.0008 - 0.0015 in)Service limit: 0.05 mm (0.002 in)

5. Remove the rod cap and bearing half, and measurethe widest part of the plastigage.

NOTE: Do not rotate the crankshaft during inspection.

Torque: 31 N'm (3.2 kgf·m, 23Ibf.ft)

4. Reinstall the bearing half and cap, and torque thenuts.

3. Place a strip of plastigage across the rod journal.

2. Clean the crankshaft rod journal and bearing haIfwith a clean shop towel.

1. Remove the connecting rod cap and bearing half.

Smallerbearing(thicker)

Smallermainjournal

Red Pink Yellow GreenPink Yellow Green Brown

Yellow Green Brown BlackGreen Brown Black Blue

Smaller bearing (thicker)

C 0BA

Bearing IdentificationColor code is ---------- __ Larger crank boreon theedge ofthe bearing.

Main Journal Code location (Numbers)

Letters have been stamped on the end of the block as acode for the size of each of the 5 main journal bores.Use them, and the numbers stamped on the crankshaft(codes for main journal size), to choose the correct bearings.

Crankshaft Bore Code Location

CAUTION: If the codes are indecipherable because of anaccumulation of dirt and dust, do not scrub them with awire brush or scraper. Clean them only with solvent ordetergent.

ClearanceSelection

Connecting RodBearings

4. Remove the oil pump.

O-RINGReplace.

3. Remove the oil sereen.

DOWEL PIN

RIGHT SIDECOVER

/

2. Remove the right side cover.

1. Remove the oil pan assembly.

7-8

Red Pink Yellow Green

Pink Yellow Green Brown

Yellow Green Brown Black

Green Brown Black Blue

Aor 1

1B or Il

C or III

D or 1111

Smaller Smallerrod bearingjournal (thicker)

----_.. Smaller bearing (thicker)

3 42

Bearing IdentificationColor code is on the -------. Larger big end boreedge ofthe bearing.

Connecting Rod Journal Code locations (letters)

Hait of the number isstamped on bearingcap and the otherhait is stamped on therod.

Numbers have been stamped on the side of each connecting rod as a code for the size of the big end. Usethem, and the letters stamped on the crankshaft (codesfor rod journal size), to choose the correct bearings.

Connecting Rod Code Location

CAUTION: If the codes are indecipherable because ofan accumulation of dirt and dust, do not scrub themwith a wire brush or scraper. Clean them only with solvent or detergent.

RemovalSelection

Pistons and CrankshaftConnecting Rod Bearings

7-9

NOTE: The existing number on the connecting raddoes not indicate its position in the engine, it indicates the rod bore size.

13. Mark each piston/connecting rad assembly with itscylinder number to avoid mixup on reassembly.

12. Reinstall the connecting rad bearings and caps afterremoving each piston/connecting rod assembly.

11. Use the wooden handle of a hammer to drive thepistons out.

CAUTION: If the ridge is not removed, it may damage the pistons as they are pushed out.

10. If you can teel a ridge of metal or hard carbon aroundthe top of each cylinder, remove it with a ridgereamer. Follow the reamer manufacturer's instructions.

9. Reinstall the main caps and bearings on the enginein proper order.

8. Remove the upper bearing halves from the connecting rads and set them aside with their respective caps.

CRANKSHAFT

7. Lift the crankshaft out of the engine, being carefulnot ta damage the journals.

6. Remove the rad caps/bearings and main caps/beatings. Keep ail caps/bearings in order.

MAIN BEARING CAP BOLTS LOOSENING SEQUENCE

CAUTION: To prevent warpage, unscrew the boltsin sequence 1/3 turn at a time; repeat the sequenceuntil ail bolts are loosened.

5. Remove the bolts and the bearing cap.

Journal Taper:Standard (New): 0.0025 mm (0.0001 in) max.Service Limit: 0.005 mm (0.0002 in)

• The difference between measurements on eachjournal must not be more than the service limit.

• Measure taper at the edges of each rod and mainjournal.

'\

Measure taperal edges.

Measure our-ofround at middle.,

EBJournal Out-of-Round:Standard (New): 0.0025 mm (0.0001 in) max.Service Limit: 0.005 mm (0.0002 in)


• Measure out-of-round at the middle of each rodand main journal in two places.

Out-of-Round and Taper

7-10

DIAL INDICATOR

Crankshaft Total Indicated Runout:Standard (New): 0.03 mm (0.001 in) max.Service Limit: 0.04 mm (0.002 in)


• Measure runout on ail main journals to makesure the crank is not bent.

Alignment

• Check the keyway and threads.

• Clean the crankshaft oil passages with pipe cleanersor a suitable brush.

Inspection

Crankshaft

7-11

Oversize Piston Diameter0.25: 75.23 - 75.24 mm (2.9618 - 2.9622 in)0.50: 75.48 - 75.49 mm (2.9716 - 2.9720 in)

If the clearance is near or exceeds the service limit,inspect the piston and cylinder block for excessivewear.

SERVICELlMIT0.05 mm (0.002 in)~~I00011'_

Piston-to-Cylinder ClearanceStandard (New): 0.010 - 0.040 mm


3. Calculate the difference between the cylinder borediameter (see page 7-12) and piston diameter.

SKIRT DIAMETER

Piston Diameter:Standard (New): 74.980 -74.990 mm


A: 5 mm (0.2 in)

2. Measure the piston diameter at distance A from thebottom of the skirt.

NOTE: If a cylinder is bored, an oversized pistonmust be used.

1. Check the piston for distortion or cracks.

Inspection

Pistons

PRECISIONSTRAIGHT EDGE

Engine Block Warpage:Standard (New): 0.07 mm (0.003 in) max.Service Limit: 0.10 mm (0.004 in)

SURFACESTO BE MEASURED

Check the top of the block for warpage.Measure along the edges and across the center asshown.

2.

Reboring Limit: 0.50 mm (0.020 in)

NOTE: Scored or scratched cylinder bores must behoned.

• If the block ;s to be rebored, refer to Piston Clearance Inspection (see page 7-11) after reboring.

• If measurements in any cylinder are beyond theOversize Bore Service Limit, replace the block.

7-12

Bore TaperLimit: (Difference between first and third measure

ment) 0.05 mm (0.002 in)

Oversize0.25: 15.25 - 15.21 mm (2.9626 - 2.9634 in)0.50: 15.50 - 15.52 mm (2.9724 - 2.9732 in)

Cylinder Bore SizeStandard (New): 15.00 - 15.02 mm


x

El1. Measure wear and taper in directions X and y at three

levels in each cylinder as shown.

Inspection

Cylinder Black

7-13

3. Place the piston on the special tool and press thepin out with the special tools and a hydraulic press.

NOTE: Use a hydraulic press.When pressing the pin in or out,make sure that the recessedportion of the piston alignswith the lips on the coller,

in)

rL-..

PISTON PINDRIVER SHAFT07973 - PE00310

In- PILOT COLLARILl 07973 - PE00200

PISTON PIN DRIVER HEAD07973 - PE00320

2. Assemble and adjust the length of the piston pindriver and shaft to 53 mm (2.1 in) as shown.

PISTON BASE SPRING07973 - 6570600

1L--JPISTON BASE07973 - 6570500

PISTON BASE HEAD07973 - SB00100

\~~,~'~I

'-- -- J(~':l/

1. Assemble the special tool as shown.

Removal

NOTE:• After honing, clean the cylinder thoroughly with

soapy water.• Onlya scored or scratched cylinder bore must be

honed.

-_ -.....!--.J',

1(

J'

CYLINDER BLOCK

.J. ~--._~ ~ - t.. _:-1,-

NOTE: Some light vertical scoring and scratching isacceptable if it is not deep enough to catch your fingernail and does not run the full length of the bore.

4. If scoring or scratches are still present in the cylinder bores after honing to the service lirnit. reborethe cylinder block.

NOTE: Never use solvent, it will only redistribute thegrit on the cylinder walls.

3. When honing is complete, thoroughly clean theengine block of ail metal particles. Wash the cylinder bores with hot soapy water, th en dry and oilthem immediately to prevent rusting.

NOTE:• Use only a rigid hone with 400 grit or finer stone

such as Sunnen, Ammco, or equivalent.• Do not use stones that are worn or broken.

2. Hone the cylinder bores with honing oil and a fine(400 grit) stone in a 60 dagree cross-hatch pattern.

1. Measure the cylinder bores as shown on page 7-12. Ifthe block is to be reused, hone the cylinders andremeasure the bores.

Bore Honing

Piston Pins

____ PISTON PIN BASE INSERT~ 07913-PE00400

PILOT COLLAR07973 - PE00200

__ -~ PISTON PINEmbossed markfacing up.

~ PISTON PIN DRIVER SHAFT07973 - PE00310

PISTON PIN DRIVER HEAD07973 - PE00320

CONNECTING RODOIL HOLE

The arrow must face thetiming belt side of theengine and the connectingrod oil hole must face therear of the engine.

• When pressing the pin in or out, be sure you position the recessed fiat on the piston against the lugson the base attachment.

1. Use a hydraulic press for installation.

7-14

Inspect boltsand nuts forstress cracks.

CONNECTING ROD BOREREFERENCE NUMBERHalf of the number is stamped onbearing cap, the other half on theconnecting rod.

NOTE:• Reference numbers are for the big end bore size and

do NOT indicate the position of the rod in the engine.• Inspect each connecting rod for cracks and heat dam

age.

Normal Bore Size: 48.0 mm (1.89 in)

Each rod falls into one of four tolerance ranges (from a to+ 0.024 mm (0 to + 0.0009 in), in 0.006 mm (0.0002 in)increments) depending on the size of its big end bore. lt' sthen stamped with a number (1, 2, 3, or 4) indicating therange.You may find any combination of 1, 2, 3, or 4 in anyengine.

InstallationSelection

Piston PinsConnecting Rods

7-15

Piston Pin-to-Connecting Rod Interference:Standard (New): 0.014 - 0.040mm

(0.0006- 0.0016 in)

Check the difference between the piston pin diameter and the connecting rod small end diameter.

4.

Piston Pin-to-Piston Clearance:Standard (New): 0.010 - 0.022mm

(0.0004- 0.0009 in)

If the piston pin clearance is greater than 0.024 mm(0.0009 in), remeasure using an oversized pistonpin.

NOTE: Check the piston for distortion or cracks.

3. Measure the piston pin-to-piston clearance.

2. Zero the dial indicator to the piston pin diameter.

NOTE: Ali replacement piston pins are oversize.

Piston Pin Diameter:Standard (New): 18.994 -19.000 mm

(0.7478 - 0.7480 in)Oversize: 18.997 -19.003

(0.7479 - 0.7481 in)

1. Measure the diameter of the piston pin.

Inspection

PISTON RING

RING EXPANDER(Commercially available)

NOTE: Do not reuse old piston rings.

3. Install new rings in the proper sequence and position (see pages 7-17,18).

NOTE: If the piston is to be separated trom the connecting rod, do not install new rings veto

CAUTION: Do not use a wire brush to clean ringlands, or cut ring lands deeper with cleaning tool.

NOTE:• Use a squared-off broken ring or ring groove

cleaner with a blade to fit the piston grooves.• Top ring groove is 1.0 mm (0.039 in) wide.• Second ring groove is 1.2 mm (0.047 in) wide.• Oil ring groove is 2.8 mm (0.11 in) wide.• File down the blade if necessary.

2. Clean ail ring grooves thoroughly.

1. Using a ring expander, remove the old piston rings.

7-16

15-20 mm(0.6-0.8 in)

~ __---{_1

1 .•. .., .1

JL~

1

OilRingStandard (New): 0.20 - 0.70 mm


Second RingStandard (New): 0.30 - 0.45mm


Piston Ring End-Gap:Top RingStandard (New): 0.15 - 0.30 mm


• If the gap is too small, check to see if Vou havethe proper rings for your engine.

• If the gap is too large, recheck the cylinder borediameter against the wear limits on page 7-12.If the bore is over the service limit, the cylinderblock must be rebored.

2. Measure the piston ring end-gap with a feeler gauge:

1. Using a piston, push a new ring into the cylinderbore 15 - 20 mm (0.6 - 0.8 in) from the bottom.

ReplacementEnd Gap

Piston Rings

7-17

(cont'd)

MARK

TOPRING_~ MARK

SECONDRING_~

NOTE: The manufacturing marks must be facingupward.

Second Ring (Standard):A: 3.0 mm (0.12 in)B: 1.2 mm (0.05 in)

Top Ring (Standard):A: 2.6 mm (0.10 in)B: 1.0 mm (0.04 in)

A

.__--..1

Piston Ring Dimensions:

SECOND RING

NOTE:• The top ring has an A mark.• The second ring has an R mark.

1. Install the rings as shawn.

FEELER GAUGE

Second Ring ClearanceStandard (New): 0.030 - 0.055 mm

(0.0012 - 0.0022 in)Service limit: 0.13 mm (0.005 in)

Top Ring ClearanceStandard (New): 0.035 - 0.060 mm


After installing a new set of rings, measure the ring-togroove clearances:

AlignmentRing-to-Groove Clearance

NOTE: Refer to pages 7-22 and 8-10 for installationof the oil pump side crankshaft oil seal.

0.5-0.8 mm --+---.1(0.02-0.03 in)

RIGHT siosCOVER

Clearance: 0.5 - 0.8 mm (0.02 - 0.03 in)

2. Confirm equal clearance ail the way around with afeeler gauge.

part number sidefacing out.

DRIVER ATTACHMENT07948 - S800101

7-18

Oll RING GAPDO NOT position any ring gapin line with the piston pin hole.

SPACER GAPTOP RING GAP

OllRINGGAP

Approx.9O°

DO NOT position any ring gapat piston thrust surfaces. NOTE: Drive the crankshaft oil seal in squarely.

1. Drive the crankshaft oil seal into the right side coverusing the special tools.

~ The seal surface on the block should be dry.. iii Apply a light coat of oil to the crankshaft and to

the lip of the seal.3. Position the ring end gaps as shown:

2. Rotate the rings in their grooves to make sure theydo not bind.

InstallationAlignment (cont' d)

Crankshaft Oil SealPiston Rings

7-19

Line up the marks wheninstalling the connecting rodcap.

6. Install the thrust washers on the No. 4 journal. Oilthe thrust washer surfaces.

NOTE: Reference numbers on the connecting rodsare for big-end bore tolerance and do not indicatethe position of the piston in the engine.

Torque: 31 N·m (3.2 kgf·m, 23 IbHt)Apply engine oil to the boit threads.

5. Check rod bearing clearance with plastigage (seepage 7-7), then torque the capnuts.

NOTE: Install the caps so the bearing recess is onthe same side as the recess in the rod.

4. Rotate the crankshaft clockwise, seat the journalsinto connecting rods No. 1 and No. 4. Install the rodcaps and nuts finger-tight.

Grooved sides faceoutward.

3. Lower the crankshaft into the block, seating the rodjournals into connecting rods No. 2, No. 3. Installthe rod caps and nuts finger-tight.

2. Hold the crankshaft so the rod journals for cylindersNo. 2 and No. 3 are straight down.

1. Insert the bearing halves in the cylinder block andconnecting rods.

Before installing the crankshaft, apply a coat ofengine oil to the main bearings and rod bearings.

RUBBER HOSESNOTE: Maintain downward force on the ring compressor to prevent the rings from expanding beforethey enter the cylinder bore.

RINGCOMPRESSOR(Commercially available)

CONNECTING RODOll HOlE

2. If the crankshaft is not installed:• Remove the rod caps and bearings, install the

ring compressor, then position the piston in thecylinder and tap it in using the wooden handle ofa hammer.

• Position ail pistons at top dead center.The arrow must facethe timing belt side ~ 0of the engine. <';>

1. If the crankshaft is already installed:• Set the crankshaft to BDC for each cylinder.• Remove the connecting rod caps, and slip short

sections of rubber hose over the threaded endsof the connecting rod bolts.

• Install the ring compressor, check that the bearing is securely in place, then position the pistonin the cylinder, and tap it in using the woodenhandle of a hammer.

• Stop after the ring compressor pops free, andcheck the connecting rod-to-crank journal alignment before pushing the piston into place.

• Install the rod caps with bearings, and torque thenuts to:31 N·m (3.2 kgf·m, 23 IbHt)Apply engine oil to the boit threads.

Before installing the pistons, apply a coat ofengine oil to the ring grooves and cylinderbores.

InstallationInstallation

CrankshaftPistons

DaWEL PIN

6 x 1.0 mm11 N·m (1.1 kgf·m.S Ibf·ft)

RIGHT SIDEcaVER

/

NOTE:• Use liquid gasket, part No. 08718 - 0001 or 08718

- 0003.• Check that the mating surfaces are c1eanand dry

before applying liquid gasket.• Apply liquid gasket evenly, being careful to cover

ail the mating surface.• Ta prevent oil leakage. apply liquid gasket to the

inner threads of the boit hales.• Do not install the parts if five minutes or more

have elapsed since applying the liquid gasket.Instead reapply liquid gasket after removing theold residue.

• After assembly, wait at least 20 minutes beforefilling the engine with oil.

8. Apply liquid gasket ta the black mating surface ofthe right side caver, then install it on the cylinderblock.

7-20

MAIN BEARING CAP BOLTS TIGHTENING SEQUENCE

NOTE: Coat the thrust washer surfaces and boitthreads with oil.

First step: 25 N'm (2.5 kgf·m, 18 IbHt)Second step: 51 N'm (5.2 kgf·m, 381bHt)

7. Install the main bearing caps.Check clearances with plastigage (see page 7-6),then tighten the bearing cap bolts in 2 steps.


Crankshaft

7-21

(cont'd)

OIL PANGASKETReplace.

OIL PAN

NOTE:• Use liquid gasket, part No. 08718 - 0001 or 08718

- 0003.• Check that the mating surfaces are clean and dry

before applying liquid gasket.• Apply liquid gasket as an even bead, centered

between the edges of the mating surface.• To prevent oil leakage, apply liquid gasket to the

inner threads of the boit holes.• Do not install the parts if five minutes or more

have elapsed since applying the liquid gasket.Instead, reapply liquid gasket after removing theold residue.

• After assembly, wait at least 20 minutes beforefilling the engine with oil,

1. lnstallthe oil pan gasket on the oil pan.

Installation

O-RINGReplace.

6 x 1.0 mm11 N'mIl.1 kqf-m, 8 Ibf·ftl

GASKET

6 x 1.0 mm11 N·m (1.1 kgf·m,

8lbf.ftl \

e

10. Install the oil pump and oil screen.6 x 1.0 mm11 N-m Il.1 kqf-rn.81bHtl

i

NOTE:• Apply a light coat of oil to the crankshaft and to

the lip of the seal.• Use new O-rings, and apply oil when installing

them.

OIL PUMP HOUSING

Apply liquid gasketalong the brokenline.

Apply grease to the lips of the oil seals.Then, install the oil pump while aligning the innerrotor with the crankshaft. When the pump is inplace, clean any excess grease off the crankshaft,then check that the oil seal lips are not distorted.

9. Apply liquid gasket to the oil pump mating surfaceof the block, th en install the oil pump on the cyl inder block.

Oil Pan

SEAl DRIVER07947 - S800200Install seal with thepart number sidefacing out.

1. Using the special tool, drive in the timing pulley-endseal until the driver bottoms against the ail pump.When the seal is in place, dean any excess greaseoff the crankshah and check that the oil seal lip isnot distorted.

NOTE:• Engine removal is not required .• The crankshaft ail seal housing should be dry.

Apply a light coat of grease ta the crankshaft and tathe lips of the seals.

7-22

Torque: 12 N'm (1.2 kgf·m, 8.7 Ibf·ft)

NOTE: Excessive tightening can cause distortion ofthe ail pan gasket and oil leakage.

4. Tighten ail bolts and nuts, starting from nut CD, dockwise in three steps.

3. Tighten the nuts finger-tight at six points as shawnbelow.

ou PAN

2. Apply liquid gasket ta the black mating surfaces,then install the ail pan. Apply liquid gasket ta theshaded areas.

InstallationInstallation (cont' d)

Oil SealsOil Pan

7-23

DRIVER ATT ACHMENT07948 - S800 101Install seal with thepart number sidefacing out.

DRIVER07749-0010000

NOTE: Align the hale in the driver attachment withthe pin on the crankshaft.

2. Measure the flywheel-end seal thickness and the ailseal housing depth. Using the special tool, drive theflywheel-end seal into the rear caver ta the pointwhere the clearance between the bottom of the ailseal and the right side caver is 0.5 - 0.8 mm (0.02 -0.03 in) (see page 7-18).

Oil PressureTesting 8-7

Oil PumpOverhaul 8-8Removai/lnspection/instailation 8-9

Testing 8-7

Special Tools - 8-2lIIustrated Index 8-3Engine OilInspection 8-4Replacement 8-4

Oil FilterReplacement 8-5

Oil Pressure Switch

Engine Lubrication

8-2

CD

1

8-108-108-6

Attachment, 52 x 55 mmDriverOil Filter Wrench

07746 - 001040007749 - 001000007912 - 6110001

Page ReferenceOtyDescriptionTooi NumberRef. No.

Special Tools

8-3

DRAINBOlT39 N'm (4.0 kgf·m, 29 Ibf·ftlDo not overtighten.

\

®»:"6 x 1.0 mm12N·m (1.2 kgf·m. 8.7 Ibf·ft)

r------Oll PANRefer ta page 7-21when installing.

Replace.

BAFFLEPLATE

Replacement, page 8-5

,1

6 x 1.0 mm11N'm (1.1 kgf·m.8lbHt)

6xl.0mm /1~11N·m (1.1 kgf.m. 6",8lbHt) 0

o

1GASKETReplace.

OllSCREEN

6x1.0mm11N'm (1.1 kgf·m,8Ibf·ft)

Oll BREATHERCHAMBER

O-RING

:~roper liquid sealant.

Oll PUMPOverhaul, page 8-8Inspection, page 8-9Apply liquid gasketta the mating surfaceof the black.

ENGINEOll PRESSURE SWITCH18 N'm Il.8 kgf·m. 13 IbHt)1/8 in. BSPT (BritishStandard Pipe Taper)28 Threads/inch. Use

CAUTION: Do not overtighten the drain boit.NOTE:• Use new O-rings when reassembling.• Apply oil to O-rings before installation.• Use liquid gasket, Part No. 08718 - 0001 or 08718 -

0003.• Clean the oil pan gasket mating surfaces before install

ing the oil pan.

IIlustrated Index

NOTE: Under normal conditions, the oil filter should bereplaced at every other oil change.Under severe conditions, the oil filter should be replacedat each oil change.

Requirement API Service Grade: Use "Energy Con-serving Il'' SH grade oil. SAE 5W-30preferred.Vou can also use an oil that bears theAPI CERTIFICATIONmark.

Capacity 3.6 f (3.8 US qt, 3.2 Imp qt)at change, including filter.3.3 f (3.5 US qt, 2.9 Imp qt)at change, without filter.4.0 f (4.2 US qt, 3.5 Imp qt)after engine overhaul.

Change Every 7,500 miles (12,000km) or12months (Normal Conditions).Every 3,750 miles (6,000 km) or6 months (Severe Conditions).

3. ReinstaIJ the drain boit with a new washer, and refiIJthe engine with the recommended oil.

DRAIN BOLT39 N'm (4.0 kgf'm, 29 IbHt)Do not overtighten.

WASHERReplace.

2. Drain the engine oil.

1. Warm up the engine.

CAUTION: Remove the drain boit carefully while theengine is hot; the hot oil may cause scalding.

8-4

CAUTION: Insert the dipstick carefully to avoid bending it.

3. If the level has dropped close to the lower mark,add oil until it reaches the upper mark.

2. Make certain that the oil level indicated on the dipstick is between the upper and lower marks.

1. Check the engine oil level with the engine off andthe car parked on level ground.

ReplacementInspection

Engine Oil

8-5

(cont'd)

Inspect threads andrubber seal surface.

~ Apply oil to rubber seal- fil before installing.

NOTE: Use only filters with a built-in bypass system.

2. Inspect the threads and rubber seal on the new filter.Wipe off the seat on the engine black, then apply alight coat of oil ta the new filter's rubber seal.

1. Remove the oil filter with the ail filter wrench.

,%if.i@!ha• After the engine has been run, the exhaust pipe will

be hot; be careful when working around the exhaustpipe.

• Be careful when loosening the drain boit while theengine is hot. Burns can result because the oil temperature is very high.

Replacement

4. Run the engine for more than three minutes, thencheck for ail leakage. Recheck the ail level, and addail if necessary.

API CERTIFICATION MARKAPI SERVICE LABEL

An ail with a viscosity of 5W-30 is preferred for improvedfuel economy and year-round protection in the car. Youmay use a 10W-30 ail if the climate in your area is limitedta the temperature range shawn on the chart.

2010o 30-20 -10-30

o-20

1

Ambient Temperature

The numbers in the middle of the API Service label tellVou the oil's SAE viscosity or weight. Select the ail foryour car according ta this chart:

Oil Filter

5. Aft r installation, fill the engine with ail up ta the specifi d level, run the engine for more than three minutes,the n check for oil leakage.

CAUTION: Using any procedure other than thosesh( wn cou Id result in serious engine damage dueto il leakage.

823 4 5 6 7

2 3 4 567 8

Number after tightening.

7/8 turnclockwise.

2) ighten the filter by turning it clockwise sevenumbers from the marked point. For example, if a

mark is made under the number 2 when the rubber seal is seated, the filter should be tighteneduntil the number 1cames up ta the marked point.

1)

Use 1 his procedure ta tighten the filter if eight numbers (1 ta 8) are printed on the surface of the filter.

8-6

Oll Fil TERWRENCH07912 - 6110001

4. After the rubber seal seats, tighten the ail filter clockwise with the ail tilter wrench.

3. Install the ail tilter by hand.

ake a mark on the ail tilter base under the numer that shows at the bottom of the filter when

Tighten: 7/8 turn clockwise. he rubber seal is seated.Tightening torque: 22 N'm (2.2 kgf·m, 161bHt)

Replacement (cont'd)

Oil Filter

8-7

• If ( il pressure is NOT within specifications, inspectth oil pump (see page 8-9).

Engine Oïl Temperature: 176~F (SOCe)Engine Oïl Pressure:At Idl : 70 kPa (0.7 kgf/cm2, 10 psi)

minimumAt 3, 00 rpm: 340 kPa (3.5 kgf/cm2, 50 psi)

minimum

4. Allo the engine to reach operating temperature (fancome on at least twice). The pressure should be:

3. Start he engine. Shut it off immediately if the gaugeregis ers no oil pressure. Repair the problem beforeconti uing.

~Oll PRESSURE GAUGE{Commerciallyavailablel

AD· PTER'1' "-28,BSPT)(Co merciallyavailablel

E Oll PRESSURE SWITCHTING HOlE

2. Rem ve the engine oil pressure switch, and install anoil pressure gauge.

ect a tachometer.1.

If the oil 1ressure warning light stays on with the enginerunning, heck the engine oil level. If the oil level is correct:

3. If the switch fails to operate, check the engine oillevel. If the engine oil level is OK, check the engineoil pressure.

Oll FllTER

YEl/REDWIRE

• There should be continuity with the enginestopped .

• There should be no continuity with the enginerunning.

2. Check for continuity between the positive terminaland the engine (ground).

1. Remove the YEL/RED wire from the engine oil pressure switch.

Testing

Oil Pressure Switch

8-8

alve must slide freelyi housing bore.eplace if scored.

Replace.Installation. page 8-10 ~

/'11 1

SPRING ~

~~ ASHER

~ __.-SEA INGBOLT~ 39 N m (40 kgf·m,

29 lb ·ft)

~\ail SEAl

1

-.DOWEL PIN

INNER ROTORInspection, page 8-9

OU ER ROTORIns ection, page 8-9

NOTE:• Use new O-rings when reassembling.• Apply oil to O-rings before installation.• Use liquid gasket, Part No. 08718 - 0001 or 08718 - 0003.• The rotors must be installed in the same direction.• After reassembly, check that the rotors move without binding.

Overhaul

Qil Pump

6xl.0mm7 N·m 10.7kgf·m, 5 IbHt)

PUMP HOUSINGInspection, page 8-9Apply liquid gasketto mating surface ofthe cylinder blockwhen installing.

6x1.0mm11N'm (1.1 kgf·m, 8lbHt)

8-9

(cont'd)

ROTORS

Hous ng-to-Rotor Axial ClearanceStan ard INew): 0.03 - 0.08 mm

10.001- 0.003 in)0.15 mm (0.006 in)

9. Remove the oil pump.

OIL SCREEN

/~ INNER ROTOR

12. the housing-to-rotor axial clearance on therotor. If the housing-to-rotor axial clearance

exce ds the service limit, replace the set of innerand uter rotors and/or the pump housing.

OU ER ROTOR

Inner Rotor-to-Outer Rotor Radial ClearanceStan ard INew): 0.02 - 0.14 mm

10.001 - 0.006 in)0.20 mm 10.008 in)

11. Chec the inner-to-outer rotor radial clearance onthe p mp rotor. If the inner-to-outer rotor clearanceexce ds the service limit, replace the inner andouter rotors.

10. Rem ve the screws from the pump housing, thenseparate the housing and cover.

O-RINGReplace.DOWELPIN

8. Remove the oil pan and oil screen.

7. Remove the drive pulley.

6. Rernove the timing belt.

5. Remove the crankshaft pulley and remove the lowercover.

4. Remove the power steering pump belt, air conditioner belt and the alternator belt.

3. Remove the cylinder head cover and upper cover.

2. Turn the crankshaft and align the white groove onthe crankshaft pulley with the pointer on the lowercover.

1. Drain the engine oil.

Removai/lnspection/instailation

PUM HOUSING

Apply liquid gasketalong the broken line.

NOlE:• L se liquid gasket. Part No. 08718 - 0001 or 08718

- 0003• heck that the mating surfaces are c1eanand dry

efore applying liquid gasket.• pply liquid gasket evenly, in a narrow bead cen

t red on the mating surface.• 0 prevent oil leakage, apply liquid gasket to the

i ner threads of the boit holes.• 0 not install the parts if five minutes or more

ave elapsed since applying liquid gasket.1 stead reapply liquid gasket after removing thec Id residue.

• fter assembly, wait at least 20 minutes beforefdling the engine with oil.

21. App y liquid gasket to the cylinder block mating surface of the oil pump.

20. Inst "the two dowel pins and new a-ring on the oilpump.

19. Applya light coat of oil to the seallip.

k that the oil pump turns freely.18.

17. Reassemble the oil purnp. applying thread lock tothe ump housing screws.

8-10

ATTACHMENT.52 x 55 mm07746 - 0010400

DRIVER07149 - 0010000

NOTE: The oil seal alone can be replaced withoutremoving the oi! pump.

16. Using the special tool, gently tap in the new oil sealuntil the driver bottoms against the pump.

15. Remove the old oil seal from the oil pump.

OUTER ROTOR

14. Inspect both rotors and the pump housing for scoring or other damage. Replace parts if necessary.

Housing-to-Outer Rotor Radial Clearance:Standard (New): 0.10 - 0.18 mm


HOUSING

13. Check the housing-to-outer rotor radial clearance.If the housing-to-outer rotor radial clearance exceedsthe service limit, replace the set of inner and outerrotors and/or the pump housing.

Removai/lnspection/instailation (cont' d)

Oil Pump

8-11

NOTE: Clean the ail pan gasket mating surfaces.

24. Install the ail pan (see page 7-21).

23. Install the ail screen.

, : O-RI:\Replace.

OIL SCREEN6 x 1.0mm

6)( 1.0mm 11N'm (1.1kgf·m.11N'm (1.1kgf·m. 8 IbHt)8Ibf·ft)

6 x 1.0mm11N'm 11.1 kgf·m.8Ibf·ft)

22. Install the ail pump on the cylinder black.Apply grease ta the lip of the ail pump seal.Then, install the ail pump onto the crankshaft.When the pump is in place, clean any excess greaseoff the crankshaft and check that the ail seal lip isnot distorted.

Replace.

Intake ManifoldReplacement 9-2

Exhaust ManifoldReplacement 9-3

Exhaust Pipe and MufflerReplacement 9-4

Intake Manifold/Exhau t System

9-2

8 x 1.25mm22 N'm (2.2 kgf·m.16 'bf·ft)

INTAKE MANIFOLDBRACKET

8 x 1.25mm22 N·m (2.2 kgf·m.16Ibf·ft)

THROTTLEBODY

CAUTION:• Check for folds or scratches on the surface of the gasket.• Replace with a new gasket if damaged.

NOTE: Use new O-rings and gaskets when reassembling.

Replacement

Intake Manifold

GASKET

INTAKE MANIFOLDReplace if cracked orif mating surfaces aredamaged.1

9-3

10 x 1.25 mm44 N'm (4.5 k9f·m. 33 Ibf.ft)

EXHAUST MANIFOLDBRACKET

8 x 1.25 mm31 N'm (3.2 kgf·m.231bHt)Replace.

8 x 1.25 mm24 N'm (2.4 kgf·m.17 IbHt)

CAUTION:• Check for folds or scratches on the surface of the gasket.• Replace with a new gasket if damaged.

NOTE: Use new gaskets and self-Iocking nuts when reassembling.

Replacement

Exhaust Manifold

EXHAUSTMANIFOLD

PRIMARY HEATEDOXYGEN SENSOR(PRIMARY H02S)44 N'm (4.5 kgf·m. 33 IbHt)

Replace.

GASKET

SElF-lOCKING NUT10 x 1.25mm33 N'm (3.4 kgf·m.25lbf·ftl

9-4

8 x 1.25mm16 N'm (1.6 kgf·m, 12 Ibf·ft)Replace.

SElF-lOCKING NUT --~10 x 1.25mm54 N'm (5.5 kgf.m. 40 IbUt)Replace.

SECONDARY HEATEDOXYGEN SENSOR(SECONDARY H02S)44 N-m (4.5 kgf-m, 33 Ibf.ftl

HEATSHIElD ~~ ®6xl.0mm ~ ~y9.8 N-m (1.0 kgf·m, 7.2 Ibf.ft)

1-------8 x 1.25 mm22 N·m (2.2 kgf·m.16Ibf.ft)Replace.Tighten the bolts insteps. alternatingside-to-side.

EXHAUST PIPE TIP

® ®d®.

'6X 1.0mm9.8 N'm (1.0 kgf·m. 7.2 Ibf.ft)

MUFFlER

\GASKET

NOTE: Use new gaskets and self-Iocking nuts when reassembling.

Replacement

Exhaust Pipe and Muffler

lIIustrated Index 10-2RadiatorReplacement 10-4Engine Coolant Refilling ar dBleeding 10-5

Cap Testing 10-7Testing 10-7

ThermostatReplacement 10-8Testing 10-9

Water PumplIIustrated Index 10-10Inspection 10-11Replacement 10-11

Fan ControlComponent Location Inde 10-12Circuit Diagram 10-13Fan Motor Testing 10-14Engine Coolant Temperat re (ECT)Switch Testing 10-14

Engine Coolant Temperatur (ECT) GaugeGauge Testing 10-1,5ECT Sending Unit Testing 10-15

Cooling

Replace.ORAlPLUG

10-2

Refer to section 14when installing.

RADIATORFANFAN MOTOR

6x 1.0mm7.2 N'm (0.73 kgf·m,5.3Ibf.ftl

5)( 0.8mm5.4 N'm (0.55 kgf·m, 4.0 IbHt)

UPPERRADIATORHOSE

RADIATOREngine coolant refilling and bleedinç r

page 10-5Leak test, page 10-7Inspect soldered joints andseams for leaks.Blow out dirt from betweencore fins with compressed air.If insects, etc., are clogging \radiator, wash them off withlow pressure water.

6 Je 1.0 mm9.8 N'm (1.0 kgf·m.7.2Ibf.ftl

/

UPPER BRACKET

a, /AND CUSHION

V COOLANT~ RESERVOIR~; e~f

Pressure test, page 10-7RADI. TOR CAP

NOTE:• Check ail cooling system hoses for damage, leaks or

deteri ration and replace if necessary.• Check ail hose clamps and retighten if necessary.• Use n w O-rings when reassembling.

CAUTIO : If any engine coolant spills on painted portions oft e body, rinse it off immediately.

1AIT 4.3 f (4.5 US qt, 3.8 Imp qt)

MfT 4.2 f (4.4 US qt, 3.7 Imp qt)

Total Cooling System Capacity [Including heater andreservoir (0.4 f (0.42US qt, 0.35 Imp qt))):

','i,ihMW; System is under high pressure when theengine is hot. To avoid danger of releasing scaldingengine coolant, remove the cap only when the engine iscool.

IIlustrated Index

10-3

THERMOSTATHOUSING

HEATERHOSES

lAC VALVE(A/T)

Engine Hose Connections:

10-4

FAN MOTORCONNECTOR

LOWER RADIATOR HOSE

RADIATOR

6 x 1.0mm7.2 N·m (0.73 kgf·m,5.3IbUt)

ATF COOLERHOSES (AITIRefer ta section 14

,!

6x 1.0mm

VfiRADIA TOR CAP

• S t the upper and lower cushions securely.• Fi" the radiator with engine coolant and bleed

th air.4. Remove the radiator upper bracket, then pull up the

radiator.

3. Oisconnect the fan motor connector.

2. Remove the upper and lower radiator hoses, andATF cooler hoses. Install the radiator in the reverse order of removal:

t. Drain the engine coolant. 5. Remcve the tan shroud assemblies and other partstrom he radiator.

Replacement

Radiator

10-5

(cont'dl

MAX MARK

7. Re ove, drain and reinstall the reservoir. Fill thetank halfwav to the MAX mark with water, then upto AX mark with antifreeze.

6.

5. Ap IV liquid gasket to the drain boit threads, thenrei stail the boit with a new washer and tighten itse urelv,

DRAIN BOlT78 N·m (8.0 kgf·m. 58 IbHt'

WASHERReplace.

4. Remove the drain boit from the cvlinder block.

DRAIN PlUG

3. Loosen the drain plug, and drain the coolant.

2. Remove the radiator cap.

1. Siide the heater temperature control lever to maximum heat. Make sure the engine and radiator arecool to the touch.

CAUTION: When pouring engine coolant, be sure toshut the relay box lid and not to let coolant spill on theelectrical parts or the paint. If any coolant spills, rinse itoff immediately.

Engine Coolant Refilling and Bleeding

10. Start the engine and let it run until it warms up (theradiator fan comes on at least twice).

1

11. Turnloff the engine. Check the level in the radiator,add rOlant if needed.

12. Put tlhe radiator cap on tightly, then run the engineagair and check for leaks.

1

i

9. Pour c~oolant into the radiator up to the base of thefiller rreCk,and install the radiator cap loosely.

10-6

Aff 3.9 f (4.1 US qt, 3.4 Imp qt)

3.8 r (4.0 US qt, 3.3 Imp qt)MfT

Engine Coolant Refill Capacity [including reservoir(0.4 e (0.42 US qt, 0.35 Imp qt))):

CAUTION:• Do not mix different brands of antifreeze/coolants.• Do not use additional rust inhibitors or anti-rust

products; they may not be compatible with thecoolant.

NOTE:• Always use Genuine Honda Antifreeze/Coolant.

Using a non-Honda coolant can result in corrosion, causing the cooling system to malfunctionor fail.

• For best corrosion protection, the coolant concentration must be maintained year-round at50% minimum. Coolant concentrations less than50% may not provide sufficient protectionagainst corrosion or freezing.

• Coolant concentrations greater than 60% willimpair cooling efficiency and are not recommended.

8. Mix the recommended antifreeze with an equalamount of water in a clean container.

Engine Coolant Refilling and Bleeding (cont'd)

Radiator

10-7

!

RemtrVe the tester and reinstall the radiator cap.

NOT~: Check for engine oil in the coolant and/orcoo'4nt in the engine oil.

4.

InsPE!ctfor engine coolant leaks and a drop in pressure.

3.

ADAPTOR(for 32 mm neck, low profile)

;

RADIA~OR PRESSURETESTE(Comrn rciallyavailable)

! \

4. If the pressure drops, replace the cap.

3. Check for a drop in pressure.

2. Applya pressure of 93 - 123 kPa (0.95 - 1.25 kgf/cm2,

14-18psi).

ADAPTOR(for 32 mm neck, low profile)

RADIA TOR PRESSURE TESTER(Commercially availablel

1. Remove the radiator cap, wet its seal with enginecoolant, then install it on the pressure tester.

Cap Testing Testi~9

1. waitfuntil the engine is cool, then carefully removethe adiator cap and fill the radiator with enginecool nt to the top of the filler neck.

2. Aua;h the pressure tester to the radiator and applya pr ssure of 93 - 123 kPa (0.95 - 1.25 kgf/cm2, 14-18 p. il.

10-8

6)( 1.0 mm12 N'm 11.2 kgf·m. 8.7 Ibf.ft)

O-RING!Replace.!

ENGINE COOLANTTEMPERATURE (ECT)SWITCH24 N'm (2.4 kgf·m. 17 Ibf.ft)

RUBBER SEAL

PIN

THERMOSTATHOUSING

THERMOSTATInstall with pin up.

NOTE: Use a new O-ring when reassembling.

Replacement

Thermostat

10-9

STANDARDTHERMOSTATLift height: above 8.0 mm (0.31 in)Starts opening: 169° - 176°F (76° - 80°C)Fullyopen: 194°F(90°C)

3. Measure lift height of the thermostat when fullyopen.

CAUTION: Do not let the thermometer touch thebottom of the hot container.

2. Heat the water, and check the temperature with athermometer. Check the temperature at which thethermostat first opens, and at which it is fully open.

1. Suspend the thermostat in a container of water asshown.

T0 test a closed thermostat:

Replace the thermostat if it is open at room temperature.

Testing

10-10

CONNECTING TUBE(AIT)

O-RINGReplace.

CONNECTING TUBE(MIT)

O-RINGReplace.

ECT SWITCH24 N'm (2.4 kgf·m.17Ibf.ft)

O-RINGReplace.

O-RINGReplace.

WATER PUMP

ENGINE COOLANTTEMPERATURE IECT)SENSOR18 N'm 11.8 kgf·m.13Ibf.ft)

WATER OUTLETCOVERApply liquid gasketto mating surface.

Beplacel

ECTGAUGESENDING UNIT9 N·m (0.9 kgf·m,7lbHt)Apply Iiquid gasketto the threads.

NOTE:• Use new O-rings when reassembling .• Use liquid gasket, Part No. 08718 - 0001 or 08718 - 0003.

lIIustrated Index

Water Pump

10-11

NOT~:• K+ep the O-ring in position wh en installing.• Clean up the spilled engine coolant.

3. Installl the water pump in the reverse order of removal.

10 x 1.25 mm44 N'm (4.5 kgf·m,33Ibf.ft)

Replace.)6x1.0mml12 N·m (1.~ kgf·m,8.7 Ibf.ft) ,

NOT~: Inspect, repair and clean the O-ring grooveand rhating surface with the cylinder block.

2. Herneve the water pump by removing five bolts.

1. Rernéve the timing belt (see page 6-17).

NOTE: A small amount of "weeping" from the bleedhole is normal.

3. Check for signs of sealleakage.

BlEED HOlE

BlEEDHOlE

2. Turn the water pump pulley counterclockwise.Check that it turns freely.

1. Remove the timing belt (see page 6-17).

Replatj:ementInspection

10-12

RADIATOR FAN MOTORTest. page 10-14Test. page 10-14

RADIATOR FANIRElAY


Fan Control

10-13

UNDER-DASHFUSE/RELAY BOX

No.17 (7.5A)._r-I-

G101G201

BLKBLK

ECMtPCM

RADIATORFANMOTOR

ENGINECOOLANTTEMPERAlIuRE (ECT)SWITCH

[ON : Abové J93'C (1991 F )

GRN

~

GRN

GRNBLK/RED

RADIATORFANRELAY

UNDER - HOOD FUSE/RELAY BOX IGNITION SWITCHBATTERY --§-NO.41 (80A) NO.42 (40A)+ )---+-----<J"\.J>- ....-O""'\...~---------_+_ WHrrBLK 2 YELlBLK

_-+--+-------- BLK/YEL ------ ...

Circuit Diagram

Fan Control

~.Terminal

\ A BOperation Temperature

ON196° - 203°F 0-~(91° - 95°C)

S'WITCH 5° - 15°F (3° - 8°C) lowerOFF than the temperature

when it goes on

Me~sure the continuity between the A and B terminal~ according to the table.

r

4.

CA\~TION: Do not let the thermometer touch thebottorn of the hot container.

3. Heat the water and check the temperature with athelimometer.

WAllER

ECTSWITCH

2. Suspend the ECT switch in a container of water asshown,

1. Rernove the ECT switch from the thermostat cover(see jpage 10-8).

NOTE: Bleed air from the cooling system after installingthe ECT slwitch (see page 10-5).

Removing the ECr switch while the engineis hot ca cause the coolant to spray out, seriously scalding you. Iways let the engine and radiator cool downbefore rer/noving the ECT switch.

10-14

3. If the motor faits to run or does not run smoothly,replace it.

2. Test the motor by connecting battery power to theB terminal, and ground to the A terminal.

View from terminal side

RADIATOR FAN MOTOR

1. Disconnect the 2P connectors from each fan motor.

ECT Slvvitch TestingFan Motor Testing

Fan Control

10-15

3. If the obtained readings are substantially differentfrom the specifications above, replace the sendingunit.

Temperature 133°F (56°C) 185°F (85°C) -212°F (100°C)

Resistance (Ü) 137 46- 30

2. Using an ohmmeter, measure the change in resistance between the positive terminal and the engine(ground) with the engine cold and with the engineat operating temperature.

YEL/G.RN WIRE

ECT SENDING UNIT

1. Disconnect the YEL/GRN wire from the ECT sendingunit.

• If the pointer of the gauge does not move at ail,check for an open in the YEL/GRN wire.If the wires are OK, replace the ECTgauge.

• If the ECT gauge works, test the ECT sendingunit.

CAUTION: Turn the ignition switch OFFbefore thepointer reaches "H" on the gauge dial. Failure to doso may damage the gauge.

3. Turn the ignition switch ON (II).Check that the pointer of the ECT gauge starts moving toward the "H" mark.

YEL/GRN WIRE

ECT sENDING UNIT

2. Make sure the ignition switch is OFF, then disconnect the YEL/GRN wire from the ECT gauge sendingunit, and ground it with a jumper wire.

1. Check the No. 13 (15 A) fuse in the under-dash fuselrelay box before testing.

ECT Sending Unit TestingGauge Testing

Engine Coolant Temperature (ECT) Gauge

Emission Control SystemSystem Description , 11-126Tailpipe Emission 11-126Three Way Catalytic Converter 11-126Positive Crankcase Ventilation System 11-128Evaporative Emission Controls 11-129

Intake Air SystemSystem Description 11-122Air Cleaner 11-123Throttle Cable 11-123Throttle Body 11-124

Fuel Supply SystemFuel Lines 11-105Fuel Tube/Oulck-Connect Fittings 11-107System Descripticln 11-110Fuel Pressure 11-110Fuel lnjectors 11-111Fuel Pressure Regulator 11-113Fuel Filter 11-114Fuel Pump 11-115Fuel Gauge/Fuel Gauge Sending Unit 11-116Low Fuellndicator System 11-117PGM-FI Main Relay 11-118Fuel Tank 11-121

Idle Control Sy'stemSystem Descriptio1n 11-90Troubleshooting Flowcharts

Idle Control System 11-92Idle Air Control Valve 11-94Starter Switch Signal 11-98Air Conditioning Signal 11-99Alternator FRSignal 11-101Brake Switch Signal 11-102

Idle Speed Setting 11-103

PGM-FISystemSystem Description 11-42

Troubleshooting FlowchartsEngine Control Module/Powertrain

Control Module 11-44Manifold Absolute Pressure Sensor 11-48Intake Air Temperature Sensor 11-53Engine Coolant Temperature Sensor 11-56Throttle Position Sensor 11-59Primary Heated Oxygen Sensor (Sensor 1) 11-64Secondary Heated Oxygen Sensor

(Sensor 2) 11-68Heated Oxygen Sensor Heater 11-71Fuel Suppl y System 11-73Misfire Detected in One Cylinder 11-75Random Misfire 11-78Knock Sensor 11-79CKP/TDC/CYP Sensor 11-80Vehicle Speed Sensor 11-82Barometric Pressure Sensor 11-83CKFSensor 11-85ECM/PCM Internai Circuit 11-88

Heated Oxygen Sensor Replacement 11-89

Special Tools 11-2Component Locations

Index 11-3System Description

Vacuum Connections 11-6Electrical Connections 11-8System Connectors 11-17

TroubleshootingTroubleshooting Procedures 11-26Engine Control Module/Powertrain

Control Module TerminalArrangement 11-33

Diagnostic Trouble Code Chart 11-37How to Read Flowcharts 11-41

Fuel and Emissions

11-2

1

Special TaalsRef. No. Tooi Number Description Qty Page Reference

CD A973X - 041 - XXXXX Vacuum Pump/Gauge, 0 - 30 in.Hg 11-132,133(ID 07JAZ - 001000B Vacuum/Pressure Gauge, 0 - 4 in.Hg 11-132,133CID 07PAZ - 0010100 SCS Service Connector 11-26,45,67, 127,

130@ 07SAZ - 001000A Backprobe Set 2 11-28® 07406 - 0040001 Fuel Pressure Gauge 11-110,113

Special Toois

11-3

\SECONDARY HEATED OXYGENSENSOR(SECONDARY H02S) (SENSOR 2)Troubleshooting, page 11-68

THREE WAY CATALYTICCONVERTER (TWC)Inspection, page 11-126Troubleshooting, page 11-127

Troubleshooting, page 11-82

CRANKSHAFT SPEEDFLUCTUATION (CKF) SENSOR

\

Troubleshooting, page 11-85

KNOCK SENSOR (KS)Troubleshooting, page 11-79

IOLE:AIR CONTROL (lAC) VALVE(A/T)Troubleshooting, page 11-96

PRIMARY HEATED OXYGEN SENSOR(PRIMARY H02S) (SENSOR 1)Troubleshooting, page 11-64

ENGINE COOLANTTEMPERATURE(ECT) SENSORTroubleshooting, page 11-56

EVAPORATIVE EMISSION(EVAP) PURGE CONTROLSOLENOID VALVE

\Troubleshooting, page 11-130

CRANKSHAFTPOSITION/TOP DEAD CENTER/CYLINDERPOSITION(CKP/TDC/CYP) SENSOR(Built into the distributor)

INTAKE AIR TEMPERATURE MANIFOLD ABSOtUTE(lAT) SENSOR PRESSURE (MAP) SENSORTroubleshooting, page 11-53 Troubleshooting, page 11-48

THROTILE POSITION (TP) IOLE AIR CONTROL (lAC) VALVESENSOR (M/T)

Index

Component Locations

11-4

DATA UNK CONNECTOR (OLC)(16P)Self-diagnostic Procedures,page 1'-26

ENGINE CONTROL MODULE(ECMI/POWERTRAINCONTROL MODULE (PCMITroubleshootîng, page 11-44

SERVICEICHECK CONNECTOR12PISelf-diagnostic Procedures,page 11-26

PGM-FI MAIN RElAYRelay Testing, page l' -,18Troubleshooting, page 11-119

EVAPORATIVE EMISSION(EVAPI TWO WAY VALVETesting, page 11-133

FUEl TUBE/QUICK-CONNECTFITTINGSPrecautions, page 11-'07Disconnection, page 11-'07Connection, page 11-108FUEL RETURN PIPEReplacement, page 11-111

FUel FillCAP

FUel PUMPTesting, page "-"5Replacement, page 11-115

FUEL GAUGE SEN[)ING UNITTesting, page "-"6

FUel VAPOR PIPE

FUEL PRESSUREREGUlATORTesting, page" -"3Replacement, page' , -, '3

Index (cont'd)

Component Locations

11-5

\.

\\

RESONATORInspection, page 11-128

I~li '

THROTTLE CABLEInspection/Adjustment, page 11-123Installation, page 11-123

AIR CLEANER (ACL)

THROTTLE BODY (TB)Inspection, page 11-124Removal, page 11-125Disassembly, page 11-125

11-6

(with cruise control)

"C'C~JC

FRONT OF VEHICLE

/EVAPORATIVEEMISSION (EVAPIPURGE CONTROL SOLENOIDVALVE

MANIFOLD ABSOLUTE~PRESSUREIMAPISENSOR

~û

To EVAPORATIVE EMISSION(EVAP)TWO WAV VALVE

Vacuum Connections

System Description

11-7

@FUELPRESSUREREGULATOR@ FUEL PUMP (FP)@ FUEL TANK@ FUEL TANK EVAPORATIVE EMISSION (EVAP) VALVE@ AIR CLEANER@ RESONATOR@ POSITIVE CRANKCASE VENTILATION (PCV) VALVE@ EVAPORATIVE EMISSION (EVAP) PURGE CONTROL

SOLENOID VALVE® EVAPORATIVE EMISSION (EVAP) CONTROL CANISTER@ EVAPORATIVE EMISSION (EVAPI TWO WAY VALVE@ THREE WAY CATALYTIC CONVERTER (TWC)

CD PRIMARY HEATED OXYGEN SENSOR (PRIMARY H02S.SENSOR 1)

@ SECONDARY HEATED OXYGEN SENSOR (SECONDARYH02S. SENSOR 2)

CID MANIFOLD ABSOLUTE PRESSURE (MAPI SENSOR@ ENGINE COOLANT TEMPERATURE (ECTI SENSOR® INTAKE AIR TEMPERATURE (lAT) SENSOR® KNOCK SENSOR (KS)(j) CRANKSHAFT SPEED FLUCTUATION (CKF) SENSOR(8) IOLE AIR CONTROL (lAC) VALVE® THROTTLE BODY (TB)@ FUEL INJECTOR@ FUEL FILTER

l '~CD: .

(A/T)('_"----_-'_",IENGINECOOLANT 1

)

-, /;"!l:::':iC/=0)~3 CD

_;

(M/T)('_"--"_"_"~

Ilimi. ~===;_. _._._._ (

~================;f[§]'@

GAUGEASSEMBLY

11-8

l®BA TIERY (BOA) *<S> IGl (40A) *@FI E/M OSA)(j)No.13 FUEL PUMP SRS UNIT (1sA)@No.25 CLOCK METER (7.sA)<ID No.1SALTERNATOR SP SENSOR (7.sA)® No.10 STARTER SIGNAL (7.sA>*: in the under-hood fuse/relay box

,1

~~

0 :~'W~IGNInON SWITCH Jf) 1)--, !(5) IG, o FUEL.B

j 1 1PUMP

i 9ST 1 10 1 +1 i!). i if~.-;~ ~ 1 1

cv 1 11

!1-v"

1

1 J1

1 l 1 riJ1 BATTERY 1~

l :A11IGPl 1 PG1A'O

TA241GP2 PG2 A23 Hja - L 11 C6STS FLR A16 r-e'D V8U J-I ,AIILC1 1

L !A22 LG2 1 i

.l. ! FUEL INJECTORS1 No. 1 ,....

Cyp 8 T C4 CYPP , INJI A4 ,__~SENSOR

, No. 2CI4 CYPM INJ2 A3 ~~

......... No. 3TOC

~ T........ .... Cl TOCP ; INJ3 A2 ~--O---'T:"'

SENSOR 1 No. 4, C'3TOCM INJ4A' >--~.... C2 CKPP lAC VALVE .1

CKP 8 1 ;

SENSOR·'IACVPAI4C12CKPM -=0 1.....•~ C, CKFP ·2IACVNA'3CKF

~ l ~~SENSOR1cu CKFM

! lAC VALVE .,0'IACVAI2 >-. v'

VSS MIL

l€p CU VSS MIL A" --o@ct J

C----___J ACC AH --. Ta COMPRESSOR CLUTCH RELA

j._--~---- ca K-L'NE ACS CS -_ Ta AJC PRESSURE SWITCH

,_.__ :; ~.~:A

~ _ CONNECTORCJ

ALT Gn:;C7 SCS ~-D0)1 ::1-:::,

c ;$ TSERVICECHECK ALTFC17 .-

1CONNECTOR 1

B25 ATPNP ·2 02 041NOBI3

1 B16ATPR ·20 ! 1_____. 1 B24 ATP04 .1 !ŒJ i 1° i Ba ATP03 ·2 iŒJ 1

0[Q2 I~ ! ~ 817 AlP2 ·1 11

~ ,l1.J 1

iB1AIT GEAR

'TPOSITION

~

IIISWITCH lFUSES:

<D INTERIOR LlGHT (7.sA) * 0 leS(%) BACK UP (RADIO) (7.sA) *(3) HORN STOP (1SA) *

PGM-FIMAIN RELAY

Electrical Connections

System Description

11-9

TERMINAL LOCATIONS

- To INTERLOCK CONTROL UNIT ~

/" - , /"J ---- -- l-! ·Z SHA 83r r-!1 "SH8811 C1

11 "SLU 8t2

1

----'\ 'yAA1 T, ASS02SHTC

~I~ .~ 014 SH02S

~- Dt3S02SG1

SECONOARYH02S(SENSOR 2)

!- 1

~'C-r,I i,

! 1

1

~

_1 8_K_S_W_D_5~r---® :

i 02NM 815 ,.,..,-,-:--:-:.,...,..,..-,..,."...,.,.,..,.,.."....,..,...,.• -r-..,.,..,.,~~ MAINSHAFT

02 NMSG 8t4 r.,..,..,...,--,..,..,..,..,..,...."..,.-,.,.,..,..,. ....I~ SPEED SENSOR----~ ·11 02 NC 823 ~ COUNTERSHAFT

1 02 NCSG 822 ~ ~ SPEEO SENSOR~-----r··········.LIN'EARSOLENOIOVALVE

1

oZ LS. 82 1---0-- ..-~----. '2LS_8t y"-----------------------------_._--

_J . '.'.~------------l-A-'PO-2-S-H-TC---------.-I-lC-A--B5~·1-~ CONTROL SOLENOIO VALVE A.,~l f l LOCK·UP CONTROL SOLENOIO VALVE 811'''/ 07 PH02S .llC8 84 --:~SHIFT CONTROL SOLENOIO VALVE A

--~y-~)------------_.SHIFT CONTROL SOLENOID VALVE 8--o-~---.

PRIMARYH02S(SENSOR tl

~

~ !010VCC2 T ICM A20 ICMTP .>. lSENSOR 'f 1 i01 TPS

DU SG2 l~

! PCS AIS r-~EVAP PURGE CONTROL SOLENOIOVALVE

-... 1 ~

04 VCCI VTS AI )-~

MAP T VTEC SOLENOIO VALVE 1

SENSOR1 03MAP- _._

012SGI1-

<,

1-.... 02ECT A

ECTSENSOR T

1

'(TEC PRESSURE SWITCH

<, r--@-.. DI lAT VTM C15

1

IATSENSOR

BRAKE SWITCH -

DATALINKCONNECTOR

omes CONTROLUNIT

SERVICECHECKCONNECTOR

TPSENSOR

[~

ATSENSOR

[~ECTSENSOR

G401

ç:= BLK1L BLK

WHT/RED-------1LT BLU -----------1

GRN/BLK

C129L2

GRN/BLK"

1

Cl30

GRN'BLK)K

1

Cl07 r---

J/C

23 r- C442'-

- BRN'=-C _r-B::'~--

G402- LTBLU Fr-- A

Cl

)-T_P_S__ RED/BL

lAT)-'----- RED/YE

enzRED/WHT----------------------------------------.-----__,[~

ECT

VCCl C13lYELIRED [~MAP REDIGRN~ MAPSENSOR

SGlGRN/WHr

11-10

Electrical Connections

System Description

11-11

(cont'd)

i..D_

G101

J~'G"NiWHrl4I'~ ~L C412

WHT /GRN--[f=::===:ï)-B_K_S_W GRN/WHr ,---------- GRN/WHr--i.~

BRAKE SWITCH

~---BLK2_---~--------------------------------------~-4 J/C

VTEC PRESSURESWITCHf-P_G_1__ BLK1-~

r-BLK1=-r~

1

! C1~L.__

.----

PRIMARYH02S (SENSOR 1)

~t,C l

T~

f-

014 ~~-Q~!?- - - WHT/REOC- - - - - ", ~r

A5 SO'SHTC BLK/WHT'n a <l'dl <44, «":fi <71, cm

G"N/BLK'-c:~~LJ:::~~I~i[~JÉ!~fft~l~J~ SECONOARY

1 1 H02S (SENSOR 2)C101 C30S BRN/BLK

IB"N/BLK'~ 1 ~C442

~ B"N'~~

~

::::~~_~:H; J-_ ,...--_-_-_--_-_-_--_-_-_-_--_-_-_--_-_-_--4--,----= u i~i~i'.C11'm

G552

fUELGAUGESENOINGUNIT

-1 ---BlK

!....Q_

LOWFUELmSENSORli)

1

Fl.(LGAUGEUNIT

GAUGEASSEMBLY1!

1 C504 C557

~! -n-- VELle'K

ij-GAN'VEL

---- YEl!BlK ------1

.....1--~L...- -'

AlT

)-A_l_T_f__ WHTiRE01---------------------------iTr----'I:

Cl03.-...-----_,r-

KS

~., ~ 1

~ ClOS

06 )--K_S RED/BlU ---------z:-------------_;_-------------------------------lT'----- -~---- '----- -- ----- ----- -- ----- ----- ----- -- --'---J' -[ 8Q8-~J

PCSt-- .. AISr------ RED/YEl'

',--::--.i: 0 il'A.- cm1 :~: --- BLK/YEL==rm! : r EVAPPURGE

CONTROLSOLENOIOVALVE

VTEC __._SOLENOIDVALVE

C121

BLK/==IEL ~;---- BLU/wHTI~r------------------t-- BLU/WHT I~

C122 L.uBLK'

1J/C VSS

C128

r----- GRN/YEL'---------------------------l[Eij-1

11-12

Electrical Connections (cont'd)

System Description

11-13

(cont'dl

......(Topage11-14)

No.4FUELINJECTOR

No.3FUELINJECTOR

No_2FUELINJECTOR

C136YELlBLK' ~

~----RED'----------------------------------_+~------------------L~

C137YELlBLK'==lŒJ

NO_1FUELINJECTOR

G101

1

BRN' 1BLK'

1 BRNI

~~

~---- BRN,BLK2---._--------------------------------4~_I

J/C

~L-G-1---- BRN/BLK'-

::;:--:~:/:::-r --- ----------------~~::~1 ~ ~ ~ :~:( :~:( ;;2 BLK CKFSENSOR

BRNI I,i 1 BRNI 1 IL._ -iBLK' BRNIBLK': BRNIBLK' IL- _Ii BLK'l l~ ~

}--------- YEL/GRN----------------------+--------------------__,

~----RED4--.-----------------------------+------------------------4

1-:-:-:-:--::-:-:-:-:BLU4. . ••.• ~ .. __

~TOC~ SENSOR

~C-Y-P-M---_BLKl-------------------------------+------------------------1

)--------- GRN2.•• _ ....•.••• - •.•..•• - ••....•.••.....

[9;~SOR

B'-'--------'DISTRIBUTOR

~CYP___::::J SENSOR

}-~-.Y-.~-~-.-_.-.-.-_YEL4.. _ _.. __._ _ .

C119r- r--------,

11-14

*1: MIT*2: Aff

UNEARSOlENOIDVALVE·2

C117RE02 ~

WHT'-------------------------Lb;U

NCSG·2>-----GRN1

C120

-----------------------DJCOUNTERSHAFTSPEEOSENSOR·2

)-:_:_:_:_:__ BlU/VEL • -lF~,:"

GRN/WHT!... L~SHIFTCONTROL 'SOlENOID VAlVE.2 _A_

C115

------------------------DJMAINSHAFTSPEEDSENSOR·2

>----- BlK/BlUIACVP·2

r------ BLK/BlU

C132

YEUBLK1=rmlAC VALVE .1

L_ YEU.~' ~ËI8]lAC VALVE·2

IACV·1

J/C

C122

(From p.g. 11-13)

t•........1 Iii ClOS

~J~

YEL/BLK1)-'_GP_' YEUBL.K1

Electrical Connections (cont'd)

System Description

11-15

(cont'd)

ToAlC SWITCHSLU/.'O'--O-- SLU/••O'

C123 C442

C424

'-{ INTERLOCKWHT/RED ~ __ C_O_N_TR_O_l__U_N_IT _4

Cl02 C306

~~ _4

AIT GEARPOSITIONSWITCH

N------;

D------;

KlBlU

1"'---------1

GAUGEASSEMBly

r-i--- GRN/ORN---iORN

C415 _

Bl~ r---

~LTG.N

r--

N- i-r- r---

;.....

11

- 1-

GRN

BlU2

Bl1

WH

RE

YEl

GR! --BlU

---

'REO'_j

'--

.__ ------GRN/BlK2---

'-

-2 _ -2

WHTI

C442C123

!1 C40S CSSS C5680<_< - YEL/GRN---Qf------- YEUGRN-f P

iBlK--{_

_o_ FUELPUMP

GS52

UNDER-DASHFUSEIRELAYBOX

C4l1

11-16

BlU/ORN

Gl

UNDER-HOODFUSE/RELAYBOX

PGM-FIMAINRELAY

~--~~---r-~-~---YEL/GRN

C442

WHT/GRN

BlK/RED ----1---1---- BlK/RED

C123

\_ -- .. GRN/YEl2

INTERIORUGHT SATTERYC7.SA) (BIlA)LWHT/RE:j351

WHT/BlU ---------- WHT/BLUo

...--+--WHT/BLKC352

...--1---+--WHT/BLK

BLK/RED

veuCt23

WHT/BLU

Electrical Connections (cont' d)

System Description

11-17

NOTE: • Different wires with the same color have been given a number suffix to distinguish them (for example, YEUBLK'and YEUBLK2are not the same).0: Related to Fuel and Emissions System.

• - Connector with male terminais (double outline): View from terminal side- Connector with female terminais (single outline): View from wire side

C569C568

FlOORWIREHARNESS

C569

System Connectors (Fuel Pump)

11-18

*1: MIT*2:A/T

C136

ENGINE WIREHARNESS

C101C30S

C130

System Connectors (Engine Compartment)

System Description

11-19

(cont'd)

NOTE: - Different wires with the same color have been given a number suffix to distinguish them (for example, YEUBLK'and YEUBLK2are not the same).0: Related to Fuel and Emissions System.

.. - Connector with male terminais (double outline): View trom terminal side- Connector with female terminais (single outline): View from wire side

C134

ClOS

C133

Cl04

C137

C132*2

Cl03

C136C135

C132*'C130

CD GRN/BLK2 ® WHTl@ WHT/RED' ® BLUl3 -- 7 --4 -- 8 --

CD BLKlYEL 6 WHT/BLU(!) BLK' 7 YEUGRN3 YEURED 8 BLU@ BRN/BLK' 9 BLK/WHT~ YEUBLK' 10 BLKlYEL

Cl02*2Cl0l

11-20

C121C1l5

Cl13

C120

-,

~.

Gl01

\\ .r:'~"--,-~}

\,

Cl19

ClOSC131

ENGINEWIRE HARNESS

System Connectors (Engine Compartment) (cont'd)

System Description

11-21

NOTE:. Different wires with the same color have been given a number suffix to distinguish them (for example, YEUBLK'and YEUBLK2are not the same).0: Related to Fuel and Emissions System.

• - Connector with male terminais (double outline): View from terminal side- Connector with female terminais (single outline): View from wire side

1 ' WHTfBLK2WHT/BL-U--S-WHTisLÜ-- -3; Vi/HT/GR-N----9 -WHT/GRN -

---- .. - --.-_ .. ------- .._-4 BLK 10 --5' WHTfREO~-1--' -'SLütWHT -,

1; WHTfREO 1

C~tS2

mIl2ffiTIC3S1

C121 C128 C129 C131r:::=1

31 rTI c0J @1 1 2 1

Il 1 GRNIYEL'

LW,' G:_R_N_'---1[I[sLUl

! YELlGRN ~ WHT'~ BLU' t: REO'~ GRNl 8 BLKl'4 YEL' 9 BLU5 -- 10 BLK!YEL

Il 1 REDl~ WHT'

C120*lC119C116*ZC11S*Z

,i WHP~ GRNfBLKl'1: BLK!YEL~ BLK/WHP

8 BLK'~ YELlBLK' BLK'1:' YELlBLK' 19 BLK'~ YELlBLK' il- BLK'I YELlBLK' i~ BLK''f YELlBLK' 13

'7/ YELlBLK' l,i BLK'

1_, BLK!YEL 8 GRNfBLKl2 BLK!YEL t GRNfBLKl

'~ BLK!YEL 1§ GRN/BLKl4 -- H GRNfBLKlt BLK!YEL 12 --~' BLK!YEL 13 GRNfBLKl7 -- 14 --

C114*Z

dTIJC113

rTIzlŒTIJ

C110 C112

8 8C108C107

11-22

*2:AIT

C419C503

C423

C412

C411

C511C510C414

C502

C405C555

C504C557

C512*2

System Connectors (Dash and Floor)

System Description

11-23

(cont'd)

NOTE:. Different wires with the same coter have been given a number suffix to distinguish them (for example, YEL/BLK'and YEL/BLK2are not the same).0: Related to Fuel and Emissions System .

• - Connector with male terminais (double outline): View trom terminal side- Connector with female terminais (single outline): View from wire side

1 YEl 8 BlK2 RED/BlK tj) GRN/BlK'3 RED ~ GRN1.; BLU' E! RED5 -- ~ WHT'6 -- "if BlKlBlU7 -- if} lTGRN

1 -- 9 --2 BlK If YEUBlK3 BlU/BlK 11 BLU/WHT, GRN/YEl 12 YEL/GRN5 GRN/RED 13 --6 RED/BlU 14 --7 -- 15 BlKIWHT

• GRN/YEl 16 WHT/BLU

1 -- 8 BlU

2 -- 9 _-3 YEURED la --~ YEl 11 --5 GRN/ORN 12 RED

6 RED/GRN 13 RED/BLK

7 GRN/RED

171213141s16 [21 a 11711011111217171151161vI71 3141 S Fsl71al717171121131CS121A/TICSllCS10

1 RED 9 GRY/wHT2 -- la --3 GRN/RED 11 BRN/WHT, YEUBlK 12 RED/YEl5 GRN/YEl 13 GRY/BlK6 BlU/BlK l' BlU7 BLU/YEl 15 BRN/BlK

• YEL/BlK 16 RED/GRN

1 REDGRN 11 YEUBLK2 -- 12 BlKIYEL3 WHT/BLU 13 YEUGRN, BlK 14 --5 GRN/WHT 15 RED/BLK6 GRN/RED 16 --7 GRN/ORN 17 --8 -- 18 BlKIWHT9 GRN/YEl 19 YEL/RED10 YEl 20 --

1 -- 9 --2 -- la --3 -- 11 --, -- 'l BlK5 -- Il BlK6 l T BLU U --7 -- Il cr BlU

• WHT/RED 16 --

CS04CS03C436

.: Securoty Alarm System

1 RED/YEl la GRN/YEl2 BlK/BlU 11 --3 RED/GRN 12 --, GRN/BlK IJ BlKIWHT5 RED/BLU 14 GRN/RED6 WHT/BlU 15 --7 -- 16 GRN/RED8 -- 17 RED/BlK9 RED/WHT 18 RED/BlK

1 RED/BlU IJ BlU/ORN2 -- 12 --3 BlK 13 --e -- le --5 -- 15 --6 WHTiBlU 16 BlKIWHT7 -- 17 --~ YEUGRN 118 WHT/GRN"9 BlKIYEl 119 --t_g BlU/ORN 20 WHT/RED

1 -- t. BlKlBlU2 -- 8 --3 -- , BlU', -- 1]1 GRN5 WHT' t} GRN/BlK'6 RED "

ir GRN

C423C419C41SIA/TI

• : Securoty Alarm System

1 BlU/RED 7 GRY2 RED/GRN 8 GRN3 YEURED· 9 rr GRN/RED, i.r BlU la GRN/BlK5 RED/BlU 11 GRN/WHT6 WHT/GRN Il YEUGRN .

. ABS

1 YEURED 11 BlU/WHT2 RED/BlU 12 BLU3 WHT/BlU 13 WHT/BlK, -- 14 --5 -- 15 --6 YEURED· 16 --7 BlU 17 --~. GRN/ORN 18 YEUGRN9 RED/BLU 19 REDla lTGRN 20 BlU/RED·..

1 lTGRN2 GRY

1 GRN/WHT'.- WHT/GRN

1 BlKIWHT2 BlU/RED~ WHT/BlK, BlK5 WHT"6 WHT/BlU·7 WHT/GRN'.: ABS

',',',: l,: 1~k1',: l,: 1 ::,

C414C412C411C40S

11-24

*2: AIT

C123C442

C438C782

C127

C126C430 /C781,

SECONDARY HEATEDOXYGEN SENSORSUB-HARNESS

C427

C443

C122

MAINWIRE HARNESSC424

System Connectors (Dash and Floor) (cont'd)

System Description

11-25

NOTE:. Different wires with the same color have been given a number suffix ta distinguish them (for example, YEL/BLKland YEL/BLK2are not the same),0: Related ta Fuel and Emissions System.

• Connector with male terminais (double outline); View tram terminal side- Connector with female terrninals (single outline): View from wire side

C782

. BAN/BlK' 111 GAN/RED

BRNlBlK' 12 --Il GAN/RED

BlUIWHT

BlUIWHT 156 BLUIWHT 16r GRIIIIWHT' 17. GRNIWHT' 18 BlU9 GANIWHT 19 BlU10 GRNIWHT' 20 BlU

S IBRN'BlK

CUl

~~

CU8

• Crull. control, WH! RED

8 WH' BlK

r vEl' ,,, RED6 BLI(. BLU 1 GRN !'l WHT'

5 WHT s BlU' 1'1 BLI(;BlU

• BlK

l YEI.RED ! 10 OAN

2 -- -T9 PIIIK'1 WHT BlU

2 YEl

, RED,BLK 9i --2 RED,WHT ,q 1YELIBlUl RED/GRN "1 GRN/BlK'· YEI.RED 'l, GRN,W'H'S GRIIIIWHT' "i GRIII/BLK'

• REDBLU " IWHT,~ED'1IWHT' 151Il RED,VEL' '61 --

1 BlK ; 8

coo

ŒL----~~~

BlU/RED' '1 AED' 25~ BlU' ,~BlK' 26

GAN' ij BlU/BlK 27'. YEL' '6 -- 28

BlU/RED' ir WHT,'RED' 291 BlU/ORN " BlU.WHT )07 BAN' '9 )1, cr BlU 20

9 -- 21'4 WHT/BlU 22

" WHT/RED' 21'1 WHT' '2'

C.z.(SKurity Allarm SystemlC127 (ECM/PCM·DI

· YEl' '.1 OAN" 25~ BlU' ~ Bll(f8lU" 261 AED' i' AEDIVEl' 27! BRN' IJ GRNIVEl' 28, BlKIWHT' ,t BlK/RED 291 BLKlWHT' " GANIORN 307 -- 19 -- 3', GANIVEl' JO YELIGAN 32, BAN/BLK' 21 -- "_ MfT;q BlK' Il BRN/BlK' '2: AIT

YElIBLK' n BlK'

'1 BlK.9lU" ze YElIBlK'

. WHT' 1" GANIWHT' 2' --2 RED' Il WHT/RED' Il GRN'

~ BLUIVEl 'l GRN/BlK' n elU'GAN/BlK' " WHl' Z, YEl'YELI I! RED' Z! rr GRN

IlIWHT' '2: AIT7 -- Ir 1 BLU'1 PNK 18i--9 -- 191--'0 -- 201 --

" BRNlBlK' Il ", BlK/RED 12 -- ,; BRNlBlK' GRN/BlK" 'l BlKIWHT' nlGRNIVH' 13 -- Il BRNlBlJ(' WHTIREO' 13 -- ljjlTBlU l._ YElIBlK' ,( BRNlBlK' !: lTGRN"' " YEl'·1 ~IBlU/ORN 15 YElIBlK' I! BRN/BlJ(' 5 ,. GRN/elK" ":MfT

1 YElIBlK' " BANlBlK' 6 GRN 'l PNKe, '2: AIT7, YElIBlK' vr BRNlBlK' t BlU/RED' 15 YEl"

1 BlUIWHT 18 -- GRN/ORN '6 --· BlUIWHT " BRN/BlJ('" t BRN' I! GRNIWHl'

'0 BlUIWHT JO BRN/9lK'" 'f WHT/BlU 18 BlUIWHT

C12lC122

SCS SERVICE CONNECTOR07PAZ - 0010100

SERVICE CHECKCONNECTOR (2P)

11-26

DATA lINK CONNECTOR (16P)

OBO " SCAN TOOl orHONDA PGM TESTER

C. OTCswill be indicated by the blinking of the Malfunction Indicator Lamp (MIL) with the SCS service connector connected.Connect the SCS service connecter to Service Check Connector as shown (The 2P Service Check Connector islocated under the dash on the passenqer's side of the vehicle). Turn the ignition switch ON (II).

B. When the MIL has not come on , but there is a driveability problem, refer to the Symptom Chart on page 11-30.

NOTE:• See the OBD Il scan tool or Honda PGM Tester user's manuals for specifie operating instructions.• The scan tool or tester can read the Diagnostic Trouble Codes (OTC), freeze frame data, current data, and other

Engine Control Module (ECM)/Powertrain Control Module (PCM) data.• Freeze frame data indicates the engine conditions when the first malfunction, misfire or fuel trim malfunction

was detected. It can be useful information when troubleshooting.

MAlFUNCTIONINDICATORlAMP(MIL)3. Honda PGM Tester: Begin troubleshooting as

indicated by the tester. The OTC troubleshootingflowcharts are not needed with the tester; followthe tester's prompts.OBD Il scan tool: Check the OTC and note it. Alsocheck and note the freeze frame data.Refer to the Diagnostic Trouble Code Chart andbegin troubleshooting.

2. Turn the ignition switch ON (II).

1. Connect the Honda PGM Tester or an OBO JI scan tool to the 16P Data Link Connector (OLC) located near the leftkick panel.

A. When the MIL has come on:

1. How To Begin TroubleshootingWhen the Malfunction Indicator Lamp (MIL) has been reported on, or there is a driveability problem, use the appropriate procedure below to diagnose and repair the problem.

Troubleshooting Procedures

Troubleshooting

11-27

(cont'd)3. Turn the ignition switch OFF.

2. Do the ECM/PCM Reset Procedure.

NOTE: If the SCS service connector is connected and there are no DTCs stored in the ECM/PCM, the MIL will stayon when the ignition switch is turned ON (II).

1. Remove the SCS Service Connector if it is connected.

III. Final Procedure (this procedure must be done after any troubleshooting)

UNDER·HOODFUSE/RElAV BOX

V~I------ BACK UP IRADIOI

(7.5 Al FUSE

NOTE: Removing the BACK UP (RADIO) (7.5 A) fuse cancels the clock and the radio presets. Make note of the eustomer's presets so vou can reset them.

• Turn the ignition switch OFF. Remove the BACK UP (RADIO) (7.5 A) fuse from the under-hood fuse/relay box for 10seconds.

NOTE: See thé OBD Il scan tool or Honda PGM Tester user's manuals for specific operating instructions .

• Use the OBD Il scan tool or Honda PGM Tester to clear the ECM's/PCM's memory.

Either of the following actions will reset the ECM/PCM.

II. Engine Control Module (ECM)/Powertrain Control Module (PCM) Reset Procedure

11-28

DIGITAL MUL TIMETER~ ICommercially availablel or

KS - AHM - 32 - 003

BACKPROBE SET07SAZ - 001DODAITwo requiredl ...............

ECM/PCM

Backprobe Adapter '"

Connect the backprobe adapters to the stacking patch cords, and connect the cords to a multimeter. Using the wire insu lation as a guide for the contoured tip of the backprobe adapter, gently slide the tip into the connector trom the wire sideuntil it comes in contact with terminal end of the wire.

How to Use the Backprobe Sets

KICK PANEL

9.8N·mIl.0 kgf·m.7.2IbUt)

If the inspection for a particular code requires voltage or resistance checks at the ECM/PCM connectors. remove the rightkick panel. Pull the carpet back to expose the ECM/PCM. Remove the ABS control unit if so equipped. Unbolt the ECM/PCM boIt. Turn the ignition switch OFF, and connect the backprobe sets and a digital multimeter as described below.Check the system according to the procedure described for the appropriate code(s) listed on the following pages.

Troubleshooting Procedures (cont'd)

Troubleshooting

11-29

(cont'd)

TERMINAL

TESTER PROBERUBBER SEAL

CAUTION:• Puncturing the insulation on a wire can cause poor or intermittent electrical connections.• Bring the tester probe into contact with the terminal from the terminal side of wire harness connectors in the engine

compartment. For female connectors, just touch lightly with the tester probe and do not insert the probe.

11-30

Probable Cause Page System

1 11-44 Engine Control Module (ECM)/Powertrain Control Module (PCM)

2 11-110 Fuel pressure

3 11-118 PGM-FI main relay

4 Section 23 Ignition system

5 11-80,85 Crankshaft Position/Top Oead Center/Cylinder Position sensor circuit, CKF sensorcircuit

6 11-53 Intake Air Temperature (lAT) sensor circuit

7 11-94, 96 Idle Air Control Valve (lACV)

8 11-103, 104 Idle speed adjustment

9 11-124 Throttle body

10 11-123 Throttle cable

11 11-48 Manifold Absolute Pressure (MAP) sensor

12 11-59 Throttle Position (TP) sensor

13 11-83 Barometric pressure (BARD) sensor

14 Section 14 AIT gear position signal

15 11-102 Brake switch signal16 11-123 Air Cleaner17 -- lntake air pipe18 11-126 ThrE!eWay Catalytic Converter (TWC)19 11-130 Evaporative emission (EVAP) control

20 -- Contaminated fuel

Probable Cause List (For the OTCChart, see page 11-37)

Other Probable Causes for an engine that will not start:- Compression - Starting system- Intake air leakage - Dverheating- Engine locked up - Battery- Timing belt

SYMPTOM PROBABLECAUSE

Engine will not start 4,2,3,5,20,14, 1

Hard starting 2,4, 11, 16, 13, 19

Cold fast idle tao low 7,8,6,16

Cold fast idle too high 7,8,10,9

Idle speed fluctuates 7,8, 10,9

Misfire or rough running Troubleshoot for misfire on pages 11-75,78

Low power 2,9, 10, 12, 17, 16, 18,20Engine stalls 2,4,11,7,20,8,5,15

Symptom ChartListed below are symptoms and probable causes tor problems that DO NOT cause the Malfunction indicator Lamp (MIL) tocome on. If the MIL was reported on, go to page 11-26.Troubleshoot each probable cause in the order listed (trom left to right) until the symptom is eliminated.The probable cause and troubleshooting paqe reference can be found below.


Troubleshooting

11-31

(cont'd)

Data Description Operating Value Freeze Data

Diagnostic If the ECM /PCM detects a problem, it will store it as a If no problem is detected,Trouble Code code consisting of one letter and four numbers. there is no output.(DTC) Depending on the problern, an SAE-defined code (POxxx) 0

or a Honda-defined code (Plxxx) will be output to thetester.

Engine Speed The ECM/PCM computes engine speed from the signais Nearly the same assent from the Crankshaft Position sensor. tachometer indication. 0This data is used for determining the time and amount offuel injection.

Vehicle Speed The ECM/PCM converts pulse signais from the Vehicle Nearly the same as 0Speed Sensor (VSS) into speed data. speedometer indication

Manifold The absolute pressure caused in the intake manifold by With engine stopped:Absolute engine load and speed. Nearly the same as atmo-Pressure (MAP) spheric pressure 0

At idle speed:24 - 37 kPa (180 - 280mmHg, 7.1 - 11.0 inHg)

Engine Coolant The ECT sensor converts coolant temperature into volt- With cold engine:Temperature age and signais the ECM/PCM. The sensor is a thermistor Same as ambient temper-(ECT) whose internaI resistance changes with coolant tempera- ature and lAT 0

ture. The ECM/PCM uses the voltage signaIs from the With engine warmed up:ECT sensor to determine the amount of injected fuel. 176 - 194°F (80 - 90°C)

Heated Oxygen The Heated Oxygen Sensor detects the oxygen content 0.0 - 1.25 VSensor (H02S) in the exhaust gas and sends voltage signaIs to the At idle speed:(Primarv, ECM/PCM. Based on these signais, the ECM/PCM con- about 0.1 - 0.9 VSensor 1) troIs the air/fuel ratio. When the oxygen content is high(Secondary (that is, when the ratio is leaner than the stoichiometric

x

Sensor 2) ratio), the voltage signal is lower.(Sensor 1)

When the oxygen content is low (that is, when the ratiois richer than the stoichiometric ratio), the voltage signalis higher.

NOTE:• The "operating values" given below are approximate values and may be different depending on the environment and

the individual vehicle .• Unless noted otherwise, "at idle speed" means idling with the engine completely warmed up, Aff in position œ or lli],

MIT in neutral, and the AlC and ail accessories turned off.

ECM/PCM DataBy connecting the OBO Il scan tool or the Honda PGM Tester to the 16P data link connector (DLC), various data can beretrieved from the ECM/PCM. The items Iisted in the table below conform to the SAE recommended practice.The Honda PGM Tester also reads data beyond that recommended by SAE.Understanding this data will help to find the causes of intermittent failures or engine problems.

11-32

Data Description Operating Value Freeze Data

H02S Loop status is indicated as "open" or "closed". At idle speed: closedFeedback Closed: Based on the H02S output, the ECM/PCM deter-Loop Status mines the air/fuel ratio and controls the amount of inject-

ed fuel. 0Open: Ignoring H02S output, the ECM/PCM refers to sig-nais trom the TP, MAP, and ECT sensors to control theamount of injected fuel.

Short Term The air/fuel ratio correction coefficient for correcting the ±20%Fuel Trim amount of injected fuel when H02S feedback is in the

closed loop status. When the signal from the H02S isweak, short term fuel trim gets higher, and the ECM/PCMincreases the amount of injected fuel. The air/fuel ratio 0gradually gets richer, causing a higher H02S output.Consequently, the short term fuel trim is lowered, andthe ECM/PCM reduces the amount of injected fuel.This cycle keeps the air/fuel ratio close to the stoichio-metric ratio when in closed loop status.

Long Term Long term fuel trim is cornputed from short term fuel ±20%Fuel Trim trim and indicates changes occurring in the fuel supply

system over a long period. 0If long term fuel trim is higher than 1.00, the amount ofinjected fuel must be increased. If it is lower than 1.00,the amount of injected fuel must be reduced.

Intake Air The lAT sensor converts intake air temperature into volt- With cold engine:Temperature age and signais the ECM/PCM. When intake air tempera- Same as ambient temper- 0(lAT) ture is low, the internai resistance of the sensor ature and ECT

increases, and the voltage signal is higher.

Throttle Based on the accelerator pedal position, the opening At idle speed: 0Position angle of the throttle valve is indicated. approx. 10 %

Ignition Ignition timing is the i9nition advance angle set by the At idle speed: 120 ± 20Timing ECM/PCM. The ECM/PCM matches ignition timing to the BTDCwith the SCS ser- x

driving conditions. vice connector connected.

CaJculated CLV is the engine Joad calculated from the MAP data. At idle speed:Load Value 15 - 35 % 0(CLV) At 2,500 rpm with no load:

12 - 30%


Troubleshooting

11-33

(cont'd)

*1: MfT*2:A!T

Terminal Wire Terminal Description Signalnumber color name

1 YEL INJ4 (No. 4 FUEL INJECTOR) Drives No. 4 fuel injector. With engine running: pulses2 BLU INJ3 (No. 3 FUEL INJECTOR) Drives No. 3 fuel injector.3 RED INJ2 (No. 2 FUEL INJECTOR) Drives No. 2 fuel injector.4 BRN INJl (No. 1FUEL INJECTOR) Drives No. 1 fuel injector.

S02SHTC(SECONDARY Drives secondary heated oxygen With ignition switch ON (II): battery voltage5 BLKJWHT HEATED OXYGEN SENSOR sensor heater. With fully warmed up engine running: dut y

HEATERCONTROL) controlledP02SHTC (PRIMARY Drives primary heated oxygen sensor With ignition switch ON (II): battery voltage

6 BLKJWHT HEATED OXYGEN SENSOR heater. With fully warmed up engine running: dut yHEATER CONTROL) controlledVTS (VTEC SOLENOID Drives VTECsolenoid valve. With engine at low engine speed: 0 V

8 GRN/YEL VALVE) With engine at high engine speed: batteryvoltage

9 BRN/BLK LG1 (LOGIC GROUND) Ground for the ECM/PCM control Less than 1.0 V at ail timescircuit.

10 BLK PG1 (POWERGROUND) Ground for the ECM/PCM powercircuit.

11 YElIBLK IGPl (POWERSOURCE) Power source for the ECM/PCM With ignition switch ON (II): battery voltagecontrol circuit. With ignition switch OFF:0 V

12*' BLKJBLU IACV (IOLEAIR CONTROL Drives IACV. With engine running: pulsesVALVE)

13*2 ORN IACV N (IOLEAIR CONTROL Drives the lAC valve (negative side).VALVE NEGATIVE SIDE)

14*2 BLKJBLU IACV P (IOLEAIR CONTROL Drives lAC valve (positive side).VALVE POSITIVE SIDE)PCS (EVAP PURGE Drives EVAP purge control solenoid With engine running, engine coolant below

15 RED/YEL CONTROL SOLENOID valve. 154°F (68°C): battery voltageVALVE) With engine running, engine coolant above

154°F (68°C): 0 V

16 GRN/YEL FLR (FUEL PUMP RELAY) Drives fuel pump relay. o V for two seconds after turning ignitionswitch ON (II), then battery voltage

17 BLKJRED ACC (AIC CLUTCH RELAY) Drives AlC clutch relay. With compressor ON: 0 VWith compressor OFF: battery voltage

18 GRN/ORN MIL (MALFUNCTION Drives MIL. With MIL turned ON: 0 VINDICATORLAMP) With MIL turned OFF: battery voltageICM (IGNITION CONTROL Sends ignition pulse. With ignition switch ON (II): battery voltage

20 YElIGRN MODULE) With engine running: about 10V (dependingon engine speed)

22 BRN/BLK LG2 (LOGIC GROUND) Ground for the ECM/PCM control Less than 1.0V at ail timescircuit.

23 BLK PG2 (POWERGROUND) Ground for the ECM/PCMpower circuit.

24 YElIBLK IGP2 (POWER SOURCE) Power source for the ECM/PCM With ignition switch ON (II): battery voltagecontrol circuit. With ignition switch OFF:0 V

NOTE: Standard battery voltage is 12V.ECM/PCMCONNECTORA (32P)


1 2 3 4 5 6 ,/ 8 9 10 11INJ4 INJ3 INJ2 INJ1 SOlSHTC POlIMTC VTSOl LG1 PG1 IGP112 13 14 15 16 17 18 l/ 20 V 22 23 24

IACV IACVN IACVP PCS FLR ACC MIL ICM LG2 PG2 IGP2

V/'V ~ VVV /

ECM/PCM CONNECTOR A (32PI

Engine/Powertrain Control Module Terminal Arrangement

11-34

*2:Aff


1 WHT lS- (lINEAR SOLENOID Ground for linear solenoid valve. With ignition switch ON (Il): pulsesVALVE - SIDE)

2 RED ts- (lINEAR SOLENOID Drives linear solenoid valve. With ignition switch ON (II): pulsesVALVE + SIDE)

SHA (SHIFT CONTROL Drives shift control solenoid valve A. With engine running in 2nd, 3rd gears:

3 BLUIYEl SOlENOID VALVE AI battery voltageWith engine running in 1st, 4th gears:about 0 V

4 GRN/BlK lC B (lOCK-UP CONTROL Drives lock-up control sole no id With lock-up ON: battery voltageSOlENOID VALVE BI valve B. With tock-up OFF: 0 V

5 YEL lC A (lOCK-UP CONTROL Drives lock-up control solenoid With lock-up ON: battery voltageSOlENOID VALVE AI valve A. With lock-up OFF: 0 V

8 PNK ATPD3 (AIT GEAR POSI- Detects AIT gear position switch ln ~ position: 0 VTION SWITCH) signal. ln any other position: battery voltageSHB (SHIFT CONTROL Drives shift control solenoid valve B. With engine running in 1st. 2nd: battery

11 GRN/WHT SOlENOID VALVE BI voltageWith engine running in 3rd, 4th: about 0 V

12 WHT/RED SlU (INTERLOCK CON- Drives interlock control unit. With ignition switch ON (II) and brakeTROl UNIT) pedal depressed: 0 VD41ND (D4INDICATOR Drives 04 indicator light. With ro.: indicator light turned ON: battery

13 GRN/BLK LlGHT) voltageWith [Oc! indicator light turned OFF: 0 V

14 WHT NMSG (MAINSHAFT Ground for mainshaft speed sensor.SPEEDSENSOR GROUND)

15 RED NM (MAINSHAFT SPEE,D Detects mainshaft speed sensor With engine running: pulsesSENSOR) signal.

16 WHT ATPR (AIT GEAR POSI- Detects AIT gear position switch ln [fi] position: 0 VTION SWITCH) signal ln any other position: battery voltage

17 BlU ATP2 (AIT GEAR POSI- Detects AIT g~ar position switch ln œ position: 0 VTION SWITCH) signal. ln any other position: battery voltage

22 GRN NCSG (COUNTERSHAFT Ground for countershaft speedSPEEDSENSOR GROUI\IDI sensor.

23 BLU NC (COUNTERSHAFT Detects countershaft speed sensor With ignition switch ON (11), and frontSPEED SENSORI signal. wheels rotating: pulses

24 YEl ATPD4 (AIT GEAR POSI- Detects AIT gear position switch ln [Q;J position: 0 VTION SWITCH) signal. ln any other position: 5 V

25 LTGRN ATPNP (AIT GEAR POSI- Detects AIT gear position switch ln [ID or Œl position: 0 VTION SWITCH) signal. ln any other position: battery voltage

NOTE: Standard battery voltage is 12V.PCM CONNECTOR B (25P)*2


1 2 3 4 5 VV 8lS- lS+ SHA LCB LCA ATPDJ

/ L~ '1 12 13 14 15 16 17 VSHB SLU O.'NO NMSG NM ATPR ATP2

V //// V 22 23 24 25NCSG NC ATPD. ATPNP

PCM CONNECTOR B (25PI

Engine/Powertrain Control Module Terminal Arrangement (cont'd)

Troubleshooting

11-35

(cont'd)

*1: M/T*2:NT


1 BlU/RED CKFP (CKF SENSOR P SIDE) Detects CKF sensor. With engine running: pulses

2 BlU CKPP (CKP SENSOR P SIDE) Detects CKP sensor. With engine running: pulses

3 GRN TDCP (TOC SENSOR P SIDE) Detects TOC sensor. With engine running: pulses

4 YEl CYPP (CYP SENSOR P SIDE) Detects CYP sensor. With engine running: pulses

5 BlU/REDACS (AiC SWITCH SIGNAL) Detects AlC switch signal. With AlC switch ON: 0 V

With AlC switch OFF: battery voltage

6 BlU/ORNSTS (STARTER SWITCH Detects starter switch With starter switch ON (III): banery voltageSIGNAL) signal. With starter switch OFF: 0 VSCS (SERVICE CHECK Detects service check connector With the connector connected: 0 V

7 BRN SIGNAL) signal (the signal causing a DTC With the connector disconnected: 5 Vindication)

8 lT BlU K-LiNE (DlC) Sends and receives scan tool sig- With ignition switch ON (II): about 5 Vnal.

VBU (VOLTAGE BACK UP) Power source for the ECM/ PCM con- Banery voltage at ail times10 WHT/BlU trol circuit. Power source for the DTC

memory

11 WHT/RED CKFM (CKF SENSOR M Ground for CKF sensor signal.SIDE)

12 WHT CKPM (CKP SENSOR M Ground for CKP sensor signal.SIDE)

13 RED TOCM (TOC SENSOR M Ground for TOC sensor signal.SIDE)

14 BlK CYPM (CKP SENSOR M Ground for CYP sensor signal.SIDE)

VTM (VTEC PRESSURE Detects VTEC pressure switch With engine at low engine speed: 0 V15 BlU/BlK SWITCH) signal. With engine at high engine speed: banery

voltageAlTF(AlTERNATORFR Detects alternator FR signal. With fully warmed up engine running:

17 WHT/RED SIGNAL) o V - banery voltage (depending onelectrical load)

la BlU/WHT VSS (VEHIClE SPEED Detects VSS signal. With ignition switch ON (II) and frontSENSOR) wheels rotating: cycles 0 V - 5 V

NOTE: Standard battery voltage is 12 V.ECM/PCM CONNECTOR C (31P)


CKFP CKPP rocp CVPP

43 652

11 12 13 14

ECM/PCM COI\INECTOR C (31PI

11-36

*1: MIT*2:A/T


1 RED/BLKTPS (THROTILE POSI- Detects TP sensor signal. With throttle fully open: about 4.8 VTION SENSOR) With throttle fullv closed: about 0.5 V

ECT (ENGINE COOLANT Detects ECT sensor signal. With ignition switch ON(I!): about 0.1 -2 REDtWHT TEMPERATURE 4.8 V (depending on engine coolant

SENSOR temperature)

MAP (MANIFOLD Detects MAP sensor signal. With ignition switch ON(II): about 3 V3 RED/GRN ABSOLUTEPRESSURE At idle: about 1.0 V

SENSOR) (depending on engine speed)

4 YEL/REDVCC1 (SENSOR Power source for MAP sensor. With ignition switch ON (II): about 5 VVOLTAGE) With ignition switch OFF: 0 V

BKSW (BRAKE Detects brake switch signal. With brake pedal released: 0 V5 GRNtWHT SWITCH) With brake pedal depressed: battery

voltage

6 RED/BLU KS (KNOCK SENSOR) Detects KS signal. With engine knocking: pulses

PH02S (PRIMARY Detects primary heated oxy- With throttle fully opened from idleHEATED OXYGEN gen sensor (sensor 1) signal. with fully warmed up engine: above

7 WHT SENSOR, SENSOR '1) 0.6 VWith throttle quickly c1osed: below0.4 V

lAT (INTAKE AIR Detects lAT sensor signal. With ignition switch ON (II): about 0.18 RED/YEL TEMPERATURE - 4.8 V (depending on intake air tern-

SENSOR) perature)

10 YEL/BLUVCC2 (SENSOR Provides sensor voltage. With ignition switch ON(II): about 5 VVOLTAGE) With ignition switch OFF: 0 V

11 GRN/BLKSG2 (SENSOR Sensor ground. Less than 1.0 V at ail timesGROUND)

12 GRNtWHTSG1 (SENSOR Ground for MAP sensor. Less than 1.0 V at ail timesGROUND)

SH02SG(SECONDARY Ground for secondary heated

13 GRN/BLKHEATED OXYGEN oxygen sensor (sensor 2).SENSOR, SENSOR :2GROUND)

S02S (SECONDARY Detects secondary heated With throttle fully opened from idleHEATED OXYGEN oxygen sensor (sensor 2) with fully warmed up engine: above

14 WHT/RED SENSOR, SENSOR 2) signal. 0.6 VWith throttle quickly closed: below0.4 V

NOTE: Standard battery voltage is 12 V.ECM/PCM CONNECTOR D (16P)


,..,-- 2 3 .- 5TPS ECT MAP VCCI BKSW6 7 8 V 10 " 12KS P02S lAT VCC2 SG2 SG113 14 / L...." ... SOlS

ECM/PCM CONNECTOR0 116P)

Engine/Powertrain Control Module Terminal Arrangement (cont'd)

Troubleshooting

11-37

(cont'd)

*: These DTCs will be indicated by the blinking of the Malfunction Indicator Lamp (MIL) with the SCS service connectorconnected.

DTC Detection Item Probable Cause Page(MIL indication*)

Manifold Absolute • Open or short in MAP sensor circuit

P0107 (3) Pressure Circuit • MAP sensor 11-48Low Input • ECM/PCM

Manifold Absolute • Open in MAP sensor circuitP0108 (3) Pressure Circuit • MAP sensor 11-50

High Input

Intake Air Temperature • JAT sensorPOll1 (10) Circuit 11-53

Range/Performance Problem

Intake Air • Short in lAT sensor circuitPOl12 (10) Temperature Circuit • lAT sensor 11-54

Low Input • ECM/PCM

Intake Air • Open in lAT sensor circuitP0113 (10) Temperature Circuit • lAT sensor 11-55

High Input • ECM/PCMEngine Coolant • ECT sensor

P0116 (86) Temperature Circuit • Cooling system 11-56Range/Performance Problem

Engine Coolant • Short in ECT sensor circuitP0117 (6) Temperature Circuit • ECT sensor 11-57

Low Input • ECM/PCMEngine Coolant • Open in ECT sensor circuit

P0118 (6) Temperature Circuit • ECT sensor 11-58High Input • ECM/PCM

Throttle Position • Open or short in TP sensor circuitP0122 (7) Circuit • TP sensor 11-59

Low Input • ECM/PCM

Throttle Position • Open in TP sensor circuitP0123 (7) Circuit • TP sensor 11-61

High Input • ECM/PCMPrimary Heated Oxygen Sensor • Short in Primary H02S (Sensor 1) circuit

P0131 (1) Circuit Low Voltage • Primary H02S (Sensor 1) 11-64(Sensor 1) • Fuel supply system• ECM/PCM

Primary Heated Oxygen Sensor • Open in Primary H02S (Sensor 1) circuitP0132 (1) Circuit High Voltage • Primary H02S (Sensor 1) 11-66

(Sensor 1) • ECM/PCMPrimary Heated Oxygen Sensor • Primary H02S (Sensor1)

P0133 (61) Slow Response • Exhaust system 11-67(Sensor 1)

Primary Heated Oxygen • Open or short in Primary H02S

P0135 (41 ) Sensor Heater (Sensor 1) heater circuit 11-71Circuit Malfunction • ECM/PCM(Sensor 1)

Diagnostic Trouble Code (DTC) Chart

11-38

*1: MIT*2:A!T

DTC Detection Item Probable Cause Page(MIL indication)Secondary Heated Oxygen Sensor • Short in Secondary H02S (Sensor 2) circuit

P0137 (63) Circuit Low Voltage • Secondary H02S (Sensor 2) 11-68(Sensor 2) • ECM/PCMSecondary Heated Oxygen Sensor • Open in Secondary H02S (Sensor 2) circuit

P0138 (63) Circuit High Voltage~ • Secondary H02S (Sensor 2) 11-69(Sensor 2) • ECM/PCMSecondary Heated Oxygen Sensor • Secondary H02S (Sensor 2)

P0139 (63) Slow Response 11-70(Sensor 2)Secondary Heated Oxygen Sensor • Open or short in Secondary H02S (Sensor

P0141 (65) Heater 21heater circuit 11-71Circuit Malfunction • ECM/PCM(Sensor 2)System T00 Lean • Fuel supply system

• Primary H02S (Sensor 11P0171 (45) • MAP sensor 11-73• Contaminated fuel

• Valve clearance• Exhaust leakage

System T00 Rich • Fuel supply system• Primary H02S (Sensor 1)

P0172 (45) • MAP sensor 11-73• Contaminated fuel• Valve clearance

P0301 r- Cylinder 1 • Fuel lnjector

P0302 72 - Cylinder 2 • Fuel lnjector circuitP0303 73 - Cylinder 3 • Ignition system 11-75P0304 74 - Cylinder 4 • Low compression

Misfire Detected • Valve clearanceKnock Sensor (KSI Circuit • Open or short in Knock Sensor (KS) circuit

P0325 (23) Malfunction • Knock Sensor (KS) 11-79• ECM/PCM

Crankshaft Position • Crankshaft Position SensorP0335 (4) Sensor Circuit • Crankshaft Position Sensor circuit 11-80

Malfunction • ECM/PCMCrankshaft Position • Crankshaft Position Sensor

P0336 (4) Sensor • Timing belt skipped teeth 11-80Range/Performanc:eCatalyst System • Three Way Catalytic converter

P0420 (67) Efficiency Below • Secondary H02S 11-127Threshold

Diagnostic Trouble Code (DTC) Chart (cont'd)

Troubleshooting

11-39

(cont'd)

*: The [p] indicator light and the Malfunction Indicator Lamp (MIL) may come on simultaneously.*1: MIT*2:A/T

DTC Detection Item Probable Cause Page(MIL indication)

Evaporative Emission Control • EVAP Purge Control Solenoid ValveSystem Insufficient • Open or short in EVAP Purge Control

P0441 (92) Purge Flow Solenoid Valve circuit11-130• EVAP Control Canister

• Vacuum lines• ECM/PCM

Vehicle Speed • Vehicle Speed SensorP0500*1 (17) Sensor Circuit • Vehicle Speed Sensor circuit 11-82

Malfunction • ECM

Vehicle Speed • Vehicle Speed SensorP0501*2 (17) Sensor Circuit • Vehicle Speed Sensor circuit 11-82

Range/Performance • PCM

P0505 (14) Id le Control System • lAC valve 11-92Malfunction • Throttle Body

P0700*2 Automaticand some of TransaxleP0715P0720 Section 14--P0730 (70)*P0740P0753P0758

Barometric Pressure • ECM/PCM (Baro sensor)P1106 (13) Circuit 11-83

Range/Performance Problem

Barometric • ECM/PCM (Baro sensor)P1107 (13) Pressure Circuit 11-84

Low Input

Barometric • ECM/PCM (Baro sensor)P1108 (13) Pressure Circuit 11-84

High Input

P1121 (7) Throttle Position Lower Than • TP sensor11-62

Expected

P1122 (7) Throttle Position Higher Than • TP sensor 11-63Expected

P1128 (5) Manifold Absolute Pressure • MAP sensor 11-51Lower Than Expected

P1129 (5) Manifold Absolute Pressure • MAP sensor 11-52Higher Than Expected

11-40

*: The D. indicator light and the Malfunction Indicator Lamp (MIL) may come on simultaneously.*1: MIT*2:A/T

DTC Detection Item Probable Cause Page(MIL indication)VTEC System Malfunction • VTECSolenoid Valve

• Open or short in VTEC SolenoidValve circuit

P1259 (22) • VTECPressure Switch Section 6• Open or short in VTEC Pressure Switchcircuit

• ECM/PCMP1300 Random Misfire • Ignition systemor • Fuel supply systemsome of • Contaminated fuelP0301 71 • Lack of fuel 11-78P0302 72P0303 73P0304 74

Crankshaft Speed • CKFsensorP1336 (54) Fluctuation Sensor 11-85

Intermittent InterruptionCrankshaft Speed • CKF sensor

P1337 (54) Fluctuation Sensor • CKFsensor circuit 11-85No Signal • ECM/PCMCrankshaft Position/Top • CKPfTOCsensor circuit

P1359 (8) Oead Center Sensor 11-87OisconnectedTop Oead Center • TOC sensor

P1361 (8) Sensor Intermittent 11-80InterruptionTop Oead Center • TOC sensor

P1362 (8) Sensor No Signal • TOC sensor circuit 11-80• ECM/PCM

P1381 (9) Cylinder Position Sensor • CYP sensor 11-80Intermittent InterruptionCylinder Position Sensor • CYP sensor

P1382 (9) No Signal • CYP sensor circuit 11-80• ECM/PCM

Idle Air Control Valve • lAC valveP1508*' (14) Circuit Failure • lAC valve circuit 11-94

·ECMIdle Air Control Valve • Open or short in lAC valve circuit

P1509*2 (14) Circuit Failure • IAC'valve 11-96• PCM

Engine Control • ECM/PCMP1607 (-) Module/Powertrain Control Module 11-88Internai

Circuit Failure AP1705 Automatic TransaxleP1706P1753P1758P1768P1785P1790P1791P1793 (70)* -- Section 14P1870P1873P1879P1885P1886P1888P1890P1891

Diagnostic Trouble Code (DTC) Chart (cont'd)

Troubleshooting

11-41 .

LOOSE

~J]

TIGHT

NOTE:• The term "Intermittent Failure" is used in these charts. It sim ply means a system may have had a failure, but it checks

out OK at this time. If the Malfunction Indicator Lamp (MIL) on the dash does not come on, check for poor connectionsor loose wires at ail connectors related to the circuit that you are troubleshooting (see illustration below).

• Most of the troubleshooting flowcharts have you reset the Engine Control Module (ECM)/Powertrain Control Module(PCM) and try to duplicate the Diagnostic Trouble Code (DTC). If the problem is intermittent and you can't duplicate thecode, do not continue though the flowchart. To do so will only result in confusion and, possibly, a needlessly replacedECM/PCM.

• "Open" and "Short" are cornmon electrical terms. An open is a break in a wire or at a connection. A short is an accidentai connection of a wire to ground or to another wire. In simple electronics, this usually means something won'twork at ail. In complex electronics (Iike ECIVI's/PCM's),this can sometimes mean something works, but not the way it'ssupposed to.

The end of a series of actions and decisions, desèribes a final repair action and sometimes directs you toan earlier part of the flowchart to confirm your repair.

Asks you about the result of an action, then sends you in the appropriate troubleshooting direction.

Asks you to do something; perform a test, set up a condition etc.

Describes the conditions or situation to start a troubleshooting flowchart.ISTARTI(bold type)

IACTIONI

< DECISION>

1 STOP 1

(bold type)

A flowchart is designed to be used from start to final repair. It's like a map showing you the shortest distance. But beware:If you go off the "map" anywhere but a "stop" symbol, you can easily get lost.

How to Read Flowcharts

11-42

PGM-FI SystemThe PGM-FI system on this model is a sequential multiport fuel injection system.Fuel injector Timing and OurationThe 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 signais sent from various sensors to obtain the final discharge duration.Idle Air ControlIdle Air Control Valve (lAC Valve)When the engine is cold, the AlC compressor is on, the transmission is in gear, the brake pedal is depressed, or the alternator is charging, the ECM/PCM controls current to the lAC Valve to maintain the correct idle speed.Ignition Timing Control• The ECM/PCM contains memories for basic ignition timing at various engine speeds and manifold air flow rates.

Ignition timing is also adjusted for engine coolant temperature.• A knock control system was adopted which sets the ideal ignition timing for the octane rating of the gasoline used.Other Control Functions1. 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 oh, the ECM/PCM supplies ground to the PGM-FI main relay that supplies current to the fuel pump for two seconds to pressurize the fuel system.

• When the engine is running, the ECM/PCM supplies ground to the PGM-FI main relay that supplies current to the fuelpump.

• When the engine is not running and the ignition is on, the ECM/PCM cuts ground to the PGM-FI main relay whichcuts current to the fuel pump.

*: AIT

CKPrrOC/CYP SensorCKF SensorMAP Sensor Fuel ln jectorsECT SensorlAT Sensor 1 Fuel ln je ctor Timing and Ouration 1

PGM-FI Main Relay (Fuel Pump)

TP SensorMIL

Primary H02S lAC Valve

Secondary H02S 1 Electronic id le Control 1AlC Compressor Clutch Relay

VSS~

~

ICM

BARO Sensor1 Other Control Functions 1

EVAP Purge Control Solenoid

KS~;

Valve

Starter Signal Primary H02S Heater

ALT FR Signal 1 Ignition Timing Control 1Secondary H02S Heater

Air Conditioning Signal VTEC Solenoid ValveOLCAIT Gear Position Signal*

1 ECM/PCM Back-up Functions 1 Lock-up Control Solenoid Valve*Battery Voltage (IGN.1)Brake Switch Signal Shift Control Solenoid Valve*

VTEC Pressure Switch Linear Solenoid Valve*

Countershaft Speed Sensor*Mainshaft Speed Sensor*

OUTPUTSENGINE CONTROL MODULE (ECM)/POWERTRAIN CONTROL MODULE (PCM)INPUTS

System Description

PGM-FI System

11-43

ECM/PCM Fail-safe/Back-up Functions1. Fail-safe Function

When an abnormality occurs in a signal from a sensor, the ECM/PCM ignores that signal and assumes a pre-programmed value for that sensor that allows the engine to continue to run.

2. Back-up FunctionWhen an abnormality occurs in the ECM/PCM itself, the fuel injectors are controlled by a back-up circuit independentof the system in order to permit minimal driving.

3. Self-diagnosis Function (Malfunction Indicator Lamp (MIL)]When an abnormality occurs in a signal from a sensor, the ECM/PCM supplies ground for the MIL and stores the DTCin erasable memory. When the ignition is initially turned on, the ECM/PCM supplies ground for the MIL for two seconds to check the MIL bulb condition.

4. Two Trip Detection MethodTo prevent false indications, the Two Trip Detection Method is used for the H02S, fuel metering-related, id le controlsystem, ECT sensor and EVAP control system self-diagnostic functions. When an abnormality occurs, the ECM/PCMstores it in its memory. When the same abnormality recurs after the ignition switch is turned OFF and ON (II) again,the ECM/PCM informs the driver by lighting the MIL. However, to ease troubleshooting, this function is cancelledwhen vou jump the service check connector. The MIL will then blink immediately when an abnormality occurs.

5. Two (or Three) Driving Cycle Detection MethodA "Driving Cycle" consists of starting the engine, beginning closed loop operation, and stopping the engine. If misfiring that increases emissions is detected during two consecutive driving cycles, or TWC deterioration is detected during three consecutive driving cycles, the ECM/PCM turns the MIL on. However, to ease troubleshooting, this functionis cancelled when vou jump the service check connector. The MIL will then blink immediately when an abnormalityoccurs.

3. Fuel Cut-off Control• During deceleration with the throttle valve closed, current to the fuel injectors is cut off to improve fuel economy at

speeds over the following rpm:• MfT: 1,000 rpm• Aff: 990 rpm

• Fuel eut-off action also takes place when engine speed exceeds 7,000 rpm, regardless of the position of the throttlevalve, to protect the engine from over-revving.

4. NC Compressor Clutch RelayWhen the ECM/PCM receives a demand for cooling from the air conditioning system, it delays the compressor frombeing energized, and enriches the mixture to assure smooth transition to the NC mode.

5. Evaporative Emission (EVAP) Purge Control Solenoid Valve -When the engine coolant temperature is above 154°F (68°C), the ECM/PCM controls the EVAP purge control solenoidvalve which controls vacuum to the EVAP purge control canister.

:-Wire side of female terminais

MILIGRN/ORN)

I/VV 1/ VVV ~112113 '4 15 16 17 18V 20V 22 23

111 1 r 2 3 4 5 6 V 8 9 10

JUMPERWIRE

24


Repair open in the wire(s)between ECM/PCM and Gl0l(located at the thermostat housing) that had more than 1.0 V.

NO

Wire side of female terminaIs

ECM/PCM CONNECTORA (32PlPG1( BLK)

f1 1 r 2 3 4 5 6 V 8 9 10 11

1'2113 14 15 16 17 uV 20V22 23 24

1/VV I/Vl/V ~PG2 V V(BLKI -:-

- Repair open in the wiresbetween ECM/PCM (A181andgauge assembly.

- Replace the Mil bulb.

NO

Substitute a known-good ECM/PCM and recheck. If symptom/indication goes away. replacethe original ECM/PCM.

YES

Is there less than 1.0V7

Check for an open in the wires(PG1. PG2linesl:1. Turn the ignition switch ON (JI).2. Measure voltage between

body ground and ECM/PCMconnector terminais A 10 andA23 individually.

NO

- Repair short or open in thewire between No. 25 CLOCKMETER (7.5 Al fuse andgauge assembly.

- Replace No. 25 CLOCK MElER(7.5 Al fuse.

NO

NOTE: If this symptom is intermittent, check for a loose No. 25 CLOCK METER (7.5 A)fuse in the under-dash fuse/relay box, a poor connection at ECM/PCM terminal A 18, oran intermittent open in the GRN/ORN wire between the ECM/PCM (A 18) and the gaugeassembly.

11-44

Substitute a known-good ECM/PCM and recheck. If symptom/indication goes away. replacethe original ECM/PCM.

YES

Is the MIL on?

Check for an open in the wire orbulb (MIL line):1. Turn the ignition switch OFF.2. Connect the ECM/PCM con

nectar terminal A 18 ta bodyground with a jumper wire.


YES

Ooes the engine start?

Try ta start the engine. 1

YES

Is the low oil pressure light on?

Turn the ignition switch ON (II).

The Malfunction Indicator lamp(MIL) never cornes on (even fortwo seconds) after ignition switchis turned ON (III.

Engine Control Module/Powertrain Control Module (ECM/PCM)

PGM-FI System

11-45

(cont'd)


t--+---+--+-+~>I----+___,_.,t-+~®

~

SCS tBRNI

ECM/PCM CONNECTOR C (31PI

M Tester user's manuals for specifie operating

een the ECM/PCM (04) and the MAP sensorween the ECM/PCM (010) and the TP sensor.

between the ECM/PCM (A 181 and the gauge

ode (DTC) stored, the MIL will stay on if the SCSgnition switch is on.r:er-hood fuse/relay boxT (15 AI fuse in the under-dash fuse/relay boxtween the ECM/PCM (C71 and the service check

(To page 11-46)

NOTE:The Malfunction Indicator Lamp o\Nhen there is no Diagnostic Trouble C(MILl stays on or cornes on after service connecter is connected and the itwo seconds. o If this symptom is intermittent, check fo

-- A loose FI E/M (15 AI fuse in the und-- A loose No. 13 FUEL PUMP SRS UNI-- An intermittent short in the wire be

connector-- An intermittent short in the wire

Check the Diagnostic Trouble assemblyCode (DTCI: -- An intermittent short in the wire betw1. Connect a scan tool or Honda -_ An intermittent short in the wire bet

PGM Tester. - PGM-FI main relay2. Turn the ignition switch ON (III. oSee the OBO Il scan tool or Honda PG3. Read the OTC with the scan instructions.

tool or Honda PGM Tester.

YES Go to Diagnostic Trouble CodeAre any OTC(s) indicated? (DTCI chart (see page 11-371.

NO

Check the DTC by MIL indication:1. Turn the ignition switch OFF.2. Connect the SCS service con-

nector to the service checkconnector.


- Repair open or short in wireYES between the ECM/PCM (CSI

Ooes the MIL indicate any DTC? and Data Link Connector.- Go to Diagnostic Trouble Code

NO (DTCI chart (see page 11-371.

Try to start the engine.

NODoes the engine start?

*YES

Check for a short in the wire (To page 11-46)(SCS linel:1. Disconnect the SCS service

check connector.2. Stop the engine and turn the

ignition switch ON (II).3. Measure voltage between the

ECM/PCM connector terminalC7 and body ground.

NO Repair short to body ground inIs there approx. 5 V? the wire between ECM/PCM (C71

and service check connector.YES

11-46

(Ta page 11-471

rInspect FI E/M (15 A) fuse in theunder-hood fuselrelay box.

1 - Repair short in the wireNO between FI E/M (15 AI fuseIs the fuse OK?

and PGM-FI main relay.

1 YES - ReplaceFI E/M (15 AI fuse.

Inspect No. 13 FUel PUMP SRSUNIT (15 A) fuse in the under-dashfuse/relay box.

1- Repair short in the wire

between No. 13 FUEL PUMPNO SRS UNIT (15 Al fuse andIs the fuse OK?

PGM-FI main relay.

f YES - Replace No. 13 FUEL PUMPSRS UNIT (15 AI fuse.

Check for a short in a sensor:1. Turn the ignition switch ON (11).2. Disconnect the 3P connector

from each sensor one at time:• MAP sensor• TP sensor

1

(From page 11-45)

1

Check for a short in the wire (Milline):1. Turn the ignition switch OFF.2. Disconnect the ECM/PCM con-

nectar A (32P).3. Turn the ignition switch ON (II).

1 Repair short to body ground inYESIs the MIL ON? the wire between the ECM/PCM

1 NO(A181and MIl.

Substitute a known-good ECMIPCM and recheck. If symptomlindication go es away, replacethe original ECM/PCM.

(From page 11-45)

Engine Control Module/Powertrain Control Module (ECM/PCM) (cont'd)

PGM-FI System

11-47

LG2(BRNIBLKI

LGl(BRNIBLK)


IGP2(YEL/BLK)

IGP 1(YEL/BLKI



VCC2 (ffi=(YEL/BLUI rnu

VCC1 (YEL/RED)

ECM/PCM CONNECTOR 0 (16P)

Repair open in the wire(s) Jbetween ECM/PCM (A9, A22) andGl01 that had more than 1.0 V.

~--------------------------_.-

- Repair open in the wire(s)between ECM/PCM (A 11,A24) and PGM-FI main relay.

- Check for poor connectionsor loose wires at the PGM-FImain relay.

- Test the PGM-FI main relay(see page 11-118).

- Repair short to body groundin the wire between ECM/PCM (04) and MAP sensor.

- Repair short to body ground inthe wire between ECM/PCM(010) and the TP sensor.

Replace the sensor that caused ]the light to go out.

NO

NO

YES

YES


1 YES

Is there less than 1.0 V?

1

Check for an open in the wires(LG lines):1. Reconnect ail sensor connec

tors.2. Reconnect the ECM/PCM con

nector D (16P).3. Turn the ignition switch ON (II).4. Measure voltage between

body ground and ECM/PCMconnector terminais A9 andA22 individually.

1 YES

Is there battery voltage?

1

Check for an open in the wires(lGP lines):1. Disconnect the fuel in ject ors

and lAC valve connectors.2. Turn the ignition switch ON (II).3. Measure voltage between

body ground and ECM/PCMconnector terminais A 11 andA24 individually.

1 NO


1

Check for a short in the wires(VCC lines):1. Turn the ignition switch OFF.2. Disconnect the ECM/PCM

connector D (16P).3. Check for continuity between

body ground and ECM/PCMconnector terminais D4 and010 individually.

Does the MIL go OFF momentarily?

1

(From page 11-46)


MAP SENSOR 3P CONNECTOR (C131)

11-48

(To page 1'-49)

- The MIL has been reported on.- DTC P0107 is stored.

1Problem verification:1. Turn the ignition switch ON (II).2. Check the MAP with the scan

tool.

1 Intermittent failure, system is 0Is approx. 0 kPa (0 mmHg, NO at this time. Check for poor coo in.Hg) indicated? nections or loose wires at C13

1 YES(MAP sensor) and ECM/PCM.

Check for an open or short in theMAP sensor:1. Turn the ignition switch OFF.2. Disconnect the MAP sensor

3P connector.3. Turn the ignition switch ON (II).4. Check the MAP with the scan

tool,

1

NOIs approx. 0 kPa (0 mmHg, 1o in.Hg) indicated? 1

Replace the MAP sensor.

1 YES

Check for an open in wire (VCC1line):Measure voltage between theMAP sensor connector No. , ter-minai and No. 2 terminal

1

1NO Repair open in the wire betweeIs there approx. 5 V?

1ECM/PCM (04) and MAP sensar.

1 YES

1 P01071 The scan tool indicates Diagnostic Trouble Code (DTC) P0107: A low voltage (high vacuum) problem in theManifold Absolute Pressure (MAP) sensor.

o ,5, 10 , 15, ~O 25 30 (in. Hg) GAUGE----1o-o---2·oo---3~OO---4~OO---5~0-O--6~~-O--7~0~O-- READING

ImmHg)

OUTPUTVOLTAGE

(V) 3.5

3.0

2.5

2.0

1.5

1.0

0.5

The MAP sensor converts manifold absolute pressure into electrical signais and inputs the ECM/PCM.

Manifold Absolute Pressure (MAP) Sensor

PGM-FI System

11-49

(cont'd)

Wire side of female terminaisJ

MAP SENSOR 3P CONNECTOR (C131)

1

Check for a short in the wire(MAP line):1. Turn the ignition switch OFF.2. Disconnect the ECM/PCM

connector D (16P).3. Check for conti nuit y between

the MAP sensor connector No. 3terminal and body ground.

YES 1Is there conti nuit y? Repair short in the wire between

1ECM/PCM (031 and MAP sensor.

NO

Substitute a known-good ECM/PCM and recheck. If normal MAPis indicated. replace the originalECM/PCM.

(From page 11-48)

]Wire side of female terminais

JUMPERWIRE

ECM/PCM CONNECTOR 0 Il6P']

]


JUMPERWIRE

MAP SENSOR 3P CONNECTOR (C131'

1

11-50

- The MIL has been reported on.- OTC POlOSis stored.

Problem verification:1. Start the engine. Hold the

engine at 3,000 rpm with noload (Aff in ffi] or œJ position,MfT in neutral) until the radia-tor fan cames on, then let it idle.

2. Check the MAP with the scantool.

Intermittent failure, system is OKIs 101 kPa (760 mmHg, 30.0 in.Hg) NO at this time. Check for poor con-or higher indicated? nections or loose wires at C131

1 YES(MAP sensor) and ECM/PCM.

Check for an open in the MAPsensor:1. Turn the ignition switch OFF.2. Oisconnect the MAP sensor

3P connector.3. Install a jumper wire between

the MAP sensor 3P connectorterminais No. 3 and No. 2.

4. Turn the ignition switch ON (II).5. Check the MAP with the scan

tool.

NOIs 101 kPa (760 mmHg, 30.0 in.Hg)or higher indicated? Replace the MAP sensor.

, YES

Check for an open in the wireISG1Iine):1. Remove the jumper wire.2. Measure voltage between the

MAP sensor 3P connector ter-minais No. 1 and No. 2.

NO1 Repair open in the wire betweenIs there approx. 5 V? l ECM/PCM (012) and MAP sensor.

1 YES

Check for an open in the wire(MAP line):1. Turn the ignition switch OFF.2. Install a jumper wire on the

ECM/PCM connectors between03 and 012.

3. Turn the ignition switch ON (II).4. Check the MAP with the scan

tool.

Is 101 kPa (760 mm Hg, 30.0 in.Hg) NO Repair open in the wires betweenor higher indicated? ECM/PCM (03) and MAP sensor.

1 YES

Substitute a known-good ECM/PCM and recheck. If normal MAPis indicated, replace the originalECM/PCM.

1 p010al The scan tool indicates Diagnostic Trouble Code (DTC) P0108: A high voltage (Iow vacuum) problem in the. Manifold Absolute Pressure (MAP) sensor.

Manifold Absolute Pressure (MAP) Sensor (cont'd)

PGM-FI System

11-51

(cont'd)

Replace the MAP sensor.

Intermittent failure, system isOK]at this time.

YES 1

1

Is 54.1 kPa (406 mmHg, 16.0in.Hg) or higher indicated?

1

Problem verification:1. Turn the ignition switch ON (II).2. Check the MAP with the scan

tool.

lThe Mil has been reported on.OTe Pl128 is stored.

!P1128! The scan tool indicates Diagnostic Trouble Code (OTC) Pl128: Manifold Absolute Pressure (MAP) lower thanexpected.

11-52

Replace the MAP sensor. j

YES 1

1

Is 43.3 kPa (325 mmHg, 12.8in.Hg) or less indicated?

Intermittent failure, system is OKlat this time. J

1


engine at 3,000 rpm with noload (AIT in [ill or [f] position,Mrr in neutral) until the radiator fan comes on, then let itidle.

2. Check the MAP with the scantool.

1

- The MIL has been reported on.OTe Pl129 is stored.

1 P11291 The scan tool indicates Diagnostic Trouble Code (DTC) Pl129: Manifold Absolute Pressure (MAP) higher thanexpected.

Manifold Absolute Pressure (MAP) Sensor (cont'd)

PGM-FI System

11-53

(cont'd)

INTAKE AIR TEMPERATURE

- 4 32 68 104 178 212 248 '0"-20 0 20 40 eo 10 100 120 'oc,

70 ,.....---r-----r---r--....,

,o~~-~---+--~,+-_.~~---+--~

Intermittent failure. system is OK]at this time.

YES

THERMISTOR

RESISTANCE (km

Replace the lAT sensor.

NO

Did the lAT rise 2c~F(1 'Cl or morefrom the ambient temperature?

Check the lAT sensor output:1. Warm the lAT sensor with a

hair dryer.2. Check the lAT with the scan

tool.

YES

Is ambient tempe rature indicated?

Problem verification:1. Turn the ignition switch OFF.2. Disconnect the lAT sensor 2P

connector.3. Remove the lAT sensor.4. Reconnect the lAT sensor 2P

connector.5. Leave the lAT sensor exposed

to ambient temperature.6. Turn the ignition switch ON (II).7. Check the lAT with the scan

ta 01.

- The MIL has been reported on.OTCPOlll is stored.

- Or from Probable Cause List.

The lAT Sensor is a temperature dependant resistor (thermistor). The resistance of the thermistor decreases as the intakeair temperature increases as shown below.

1 P0111 1 The scan tool indicates Diagnostic Trouble Code (OTC) PO",: A range/performance problem in the Intake AirTemperature (lAT) Sensor circuit.

Intake Air Temperature (lAT) Sensor

11-54

]Wire side of female terminais

lAT SENSOR 2P CONNECTOR (C129)]Is 302:F (150=C) or higher indi- NO

1

cated? 1Replace the lAT sensor.

1 YES

Check for a short in the wire (lATline):1. Turn the ignition switch OFF.2. Disconnect the ECM/PCM con-

nector D (16P).3. Check for continuity between

the lAT sensor 2P connector ter-minai No. 2 and body ground.

1

1YES Repair short in the wire betweenIs there continuity?1

ECM/PCM (08) and lAT sensor.

1 NO

Substitute a known-good ECM/PCM and recheck. If normal lATis indicated, replace the originalECM/PCM.

]•. If the engine is warm, it will be higher

than ambient temperature.

~J/---1 Replace the lAT sensor.~--------------------------~

.. 104 171 212 248 ,."

20 4() 10 10 100 120 COCI

:E AIR TEMPERATURE

- The Mil has been reported on.RESISTANCE (km

- DTC P0112 is stored. :~,,Problem verification: ,1. Turn the ignition switch ON (II). 0.52. Check the lAT with the scan

tool.0.1

- 4 32

- 20 0

INTAI<

Is 302cF (150°C) or higher indi- NOcated?

1

YES Is the correct ambient ternper-ature indicated*?

1 YES

Intermittent failure, system is OKat this time. Check for poor con-nections or loose wires at C129(lAT sensor) and ECM/PCM.

Check for a short in the lAT sen-sor:1. Disconnect the lAT sensor 2P

connector.2. Check the lAT with the scan

tool.

!P0112! The scan tool indicates Diagnostic Trouble Code (DTC) P0112: A low voltage (high temperature) problem in theIntake Air Temperature (lAT) sensor circuit.

Intake Air Temperature (lAT) Sensor (cont'd)

PGM-FI System

11-55

Wire side of female terminaisJlAT (RED/VELl

JUMPERWIRE

13 14

ECM/PCM CONNECTOR 0 (16PI


SG2 ~IAT(GRN/BL~ (RED/VELl

JUMPERWIRE

lAT SENSOR 2P CONNECTOR (C129)

- The MIL has been reported on.- oTC POl13 is stored.

1

Problem verification:1. Turn the ignition switch ON (II).2. Check the lAT with the scan

tool.

1

NOIntermittent failure, system is 01at this time. Check for poor conIs -4°F (-20°C) or less indicated? nections or loose wires at C12~

1 YES(lAT sensor) and ECM/PCM.

Check for an open in the lAT sen-sor:1. Disconnect the lAT sensor 2P

connector.2. Connect the lAT sensor 2Pcon-

nector terminais No. 1 andNo. 2 with a jumper wire.

3. Check the intake air tempera-ture with the scan tool.

)NO j

Is -4 F (-20"C) or less indicated?1

Replace the lAT sensor.

1 YES

Check for an open in the wires(lAT, SG2Iines):1. Turn the ignition switch OFF.2. Connect ECM/PCM connector

terminais D8 and Dl1 with ajumper wire.

3. Turn the ignition switch ON (II).4. Check the lAT with the scan

tool.

)NO Repair open in the wires betweei

Is -4'F (-20'C) or less indicated? ECM/PCM (08, 011) and lAT sen

1 YESsor.

Substitute a known-good ECM/PCM and recheck. If normal lATis indicated, replace the originalECM/PCM.

1 P01131 The scan tool indicates Diagnostic Trouble Code (DTC) P0113: A. high voltage (Iow temperature) problem in theIntake Air Temperature (lAT) sensor circuit.

11-56

- The MIL has been reported on.- OTC P0116 is stored.

1


engine at 3,000 rpm with noload (Aff in [!il or [fJ position,MIT in neutral) until the radia-tor fan cames on, then let itidle.

2. With the scan tool, check theECT.

1

Is 176 - 200°F (80 - 93°C) YES Intermittent failure, system is 01

indicated? at this time. Check the coollnsystem.

j NO

Check the cooling system. If thecooling system is OK, replace theECT sensor.


Possible Cause• ECTsensor deterioration• Malfunction in the cooling system

NOTE: If OTC P0117 and/or P0118 are stored at the same time as OTC POl16, troubleshoot those OTCs first, then troubleshoot OTC PO116.

o. 1 "'r-4--.--+-~-+-........::1111~ J1 68104'401762'2248 ('F)-20 0 20 40 10 10 100 120 1 'CI

ENGINE COOLANT TEMPERATURE

THERMISTOR

2O-r:--,----r---,.----.

10~~-_r-_+-~

~+-~~_r-_+-~

RESISTANCE(km

1 P01161 The scan tool indicates Oiagnostic Trouble Code (OTC) P0116: A range/performance problem in the EngineCoolant Temperature (ECT)Sensor circuit.

The ECTSensor is a temperature dependant resistor (thermistor). The resistance of the thermistor decreases as the enginecoolant temperature increases as shown below.

Engine Coolant Temperature (ECT) Sensor

PGM-FI System

11-57

(cont'd)


J

ECT SENSOR 2P CONNECTOR (C112)

]

J

- The Mil has been reported on.

1- OTC P0117 is stored.

1

Problem verification:1. Turn the ignition switch ON (II).2. Check the ECT with the scan

tool.

1Intermittent failure, system is O~

Is 302°F (1S0°C) or higher indi- NO at this time. Check for poor con·cated? nections or loose wires at C11~

J YES(ECT sensor) and ECM/PCM.

Check for a short in the ECT sen-sor:1. Disconnect the ECT sensor 2P

connector.2. Check the ECT with the scan

tool.

1

NOIs 302°F (1S0°C) or higher indi-cated? Replace the ECT sensor.

1 YES

Check for a short in the wire(ECT line):1. Turn the ignition switch OFF.2. Disconnect the ECM/PCM con-

nector D (1SP).3. Check for continuity between

the ECT sensor 2P connector ter-minai No. 1 and body ground.

1YES Repair short in the wire betweenIs there continuity?

ECM/PCM (02) and ECT sensor.

1 NO

Substitute a known-good ECM/PCM and recheck. If normal ECTis indicated, replace the originalECM/PCM.

1 POl171 The scan tool indicates Diagnostic Trouble Code (DTC) P0117: A low voltage (high temperature) problem in theEngine Coolant Temperature (ECT)sensor circuit.

11-58


13 14

SG2 (GRN/BLKIECT(REO/WHT)

f::t;:::;:::::t

JUMPERWIRE

~ ECM/PCM CONNECTOR 0 (16P)


ECTO/WHT)

JUMPERWIRE

2(GRN/BLK)

ECT SENSOR 2P CONNECTOR (Cl12)

- The MIL has been reported on.- OTC POl18 is stored.

1

Problem verification:1. Turn the ignition switch ON (II).2. Check the ECT with the scan

tool.

tNO

Intermittent failure, system is 01

Is -4°F (-20°C) or less indicated? at this time. Check for poor CO",nections or loose wires at Cll

1 YESIECT sensor) and ECM/PCM.

Check for an open in the ECT sen-sor:1. Disconnect the ECT sensor

2P connector.2. Connect the ECT sensor 2P

connector terminais No. 1 andNo. 2 with a jumper wire.

3. Check the ECT with the scantool.

1NO

15 -4CF (-20CC) or less indicated? Replace the ECT sensor.

1 YES

Check for an open in the wiresIECT, SG2Iines):1. Turn the ignition switch OFF.2. Connect ECM/PCM connector

terminais D2 and D11 with ajumper wire.

3. Turn the ignition switch ON (II).4. Check the ECT with the scan

tool.

1NO Repair open in the wires betwee

15 -4°F (-20°C) or iess indicated? ECM/PCM (02, 011) and ECT sen

1 YESsor.

Substitute a known-good ECMIPCM and recheck. If normal ECTis indicated, replace the originalECM/PCM.

1 P01181 The scan tool indicates Diagnostic Trouble Code (DTC) POl18: A high voltage (Iow temperature) problem in theEngine Coolant Temperature (ECT) sensor circuit.

Engine Coolant Temperature (ECT) Sensor (cont'd)

PGM-FI System

11-59

(cont'd)

Terminal side of male terminais




TP SENSOR 3P CONNECTOR (C130)

23471 - THROTTlE

OPENINGO~I-D-lE--------~F~U-l~l

THROTTlE

5

OUTPUT VOLTAGE (V)

Substitute a known-good ECM]PCM and recheck. If prescribedvoltage is now available, replacethe original ECM/PCM.

NO


Check for an open in wire (vcc:Jline):Measure voltage between ECM/PCM connector terminais 010 and .011.

NO

Intermittent failure, system ism]at this time. Check for poor connections or 1005e wires at C130(TPsensor) and ECM/PCM.

YES

BRUSHHOlDER

(Ta page 11·60)

Check for an open or short in TPsensor:1. Turn the ignition switch OFF.2. At the sensor side, measure

resistance between the TP sensor terminais No. 1 and No. 2with the throttle fully closed.

YES


Check for an open in the wire(VCC2Iine):1. Turn the ignition switch OFF.2. Oisconnect the TP sensor 3P

connector.3. Turn the ignition switch ON (II).4. Measure voltage between

the TP sensor 3P connector terminais No. 1 and No. 3.

NO

Is there approx. 10% when thethrottle is fully closed andapprox. 90% when the throttleis fully opened?


engine at 3,000 rpm with noload (AIT in [ID or lE] position,Mrr in neutral) until the radiator fan cornes on, then turnthe ignition switch OFF.

2. Turn the ignition switch ON (II).3. Check the throttle position with

the scan tool,

- The Mil has been reported on.- DTC P0122 is stored.

1 P0122 1 The scan too.1 in~icates Diagnostic Trouble Code (DTC) P0122: .A.. low voltage problem in the Throttle Position(TP) sensor crrcuit.

The TP Sensor is a potentiometer. It is connected to the throttle valve shaft. As the throttle position changes, the throttleposition sensor varies the voltage signal to the ECM/PCM.

Throttle Position (TP) Sensor


13

SG2 IGRN/BLK)TPSIREO/BLK)

]


Terminal side of male terminais]

TPSENSOR3PCONNECTOR]

11-60

1NO JIs there approx. 0.5 - 0.9 km

1Replace the throttle body.

l YES

Check for an open or short in theTP sensor:Measure resistance between theTP sensor terminnals No. 2 andNo. 3 with the throttfe fuffy cfosed.

1NO JIs there approx. 3.6 - 5.4 km

1Replace the throttle body.

J YES

Check for an open in the ECM/PCM (TPS lineJ:1. Reconnect the TP sensor 3P

connector.2. Turn the ignition switch ON (II).3. Measure voltage between 01

terminal and 011 terminal onthe ECM/PCM connector.

1

Is there approx. 0.5V when theYES ! Repair short in the wire betweenthrottle is fully closed and

approx. 4.5V when the throttle1

ECM/PCM (Dl) and TP sensor.is fully opened?

1 NO

Substitute a known-good ECM/PCM and recheck. If prescribedvoltage is now available, replacethe original ECM/PCM.

(From page 11-59)

Throttle Position (TP) Sensor (cont' d)

PGM-FI System

11-61

(cont'dl


SG2 (GRN/BlKI

13 ,. /

VCC2 (YEL/BLUI

6 7 8

ECM/PCM CONNECTOR 0 (16PI


VCC2(YEL/BLUI

SG2(GRN/BLKI

TP SENSOR 3P CONNECTOR (C130)

- The MIL has been reported on.- OTCP0123 is stored.

1


engine at 3,000 rpm with noload (AIT in [ID or Œl position,Mrr in neutral) until the radia-tor fan comes on, then turn theignition switch OFF.

2. Turn the ignition switch ON (II).3. Check the throttle position with

the scan tool.

1

Is there approx. 10%when theYES

Intermittent failure, system is 0throttle is fully closed and at this time. Check for poor conapprox. 90%when the throttle nections or loose wires at C13is fully opened? (TPsensor) and ECM/PCM.

1 NO

Check for an open in the TP sen-sor:1. Turn the ignition switch OFF.2. Disconnect the TP sensor 3P

connector.3. Turn the ignition switch ON (11).4. At the harness side, measure

voltage between the TP sensor3P connecter terminais No. 1and No. 3.

1YES

Is there approx. 5 V? Replace the throttle body.

1 NO

Check for an open in the wire(SG2Iinel:Measure voltage between ECM/PCM connector terminais Dl0 and011.

1YES Repair open in the wire betweeIs there approx. 5 V?

ECM/PCM (0111 and TP sensor.

1 NO


1 P0123! The scan tool indicates Diagnostic Trouble Code (DTCl P0123: A high voltage problem in the Throttle Position(TPl sensor circuit.

11-62

Replace the TP sensor.

NO

Intermittent failure, system is OI<J.at this time.

Is TP 12.2% or higher indicatedwhen the throttle is fully opened?

Problem verification:1. Turn the ignition switch ON (II).2. Check the throttle position

with the scan tool.

- The MIL has been reported on.- OTe P1121 is stored.

1 P1121 1 The scan tool indicates Diagnostic Trouble Code (DTC) P1121:Throttle Position (TP) lower than expected.

Throttle Position (TP) Sensor (cont'd)

PGM-FI System

11-63

Intermittent failure. system is OI<J.at this time.

YES 1

1

Replace the TP sensor.

Is TP 16.5% or less indicatedwhen the throttle is fully closed?

1

Problem verification:1. Turn the ignition switch ON (11).2. Check the throttle position

with the scan tool.

1

- The MIL has been reported on.OTCP1122 is stored.

!P1122! The scan tool indicates Diagnostic Trouble Code (DTC) P1122: Throttle Position (TP) higher than expected.

l Repair fuel supply system.NO

Intermittent failure, system is (~Kat this time. Check for poor eonnections or loose wires at Cl13(Primary H02S, sensor 1) andECM/PCM.

NO

11-64

1 YES

(To page 11-65)

15 it normal?

Check the fuel pressure.

1 YES

Does the voltage stay at 0.1 Vor less?

1

Problem verification:1. Do the ECM/PCM Reset Pro

cedure.2. Start the engine. Hold the

engine at 3.000 rpm with noload (AIT in [ID or Œl position,MIT in neutral) until the radiator fan comes on.

3. Test-drive with the AIT in œposition (MIT in 4th gear)

4. Check the Primary H02S(Sensor 1) output voltage withthe scan tool during acceleration using wide open throttle.

1

- The MIL has been reported on.- OTC P013l is stored.

1 P0131 1 The scan tool indicates Diagnostic Trouble Code (DTC) P0131: A low voltage problem in the Primary HeatedOxygen Sensor (H02S) (Sensor 1) circuit.

HEATERTERMINALS

HEATER RICH +- AIR- - LEANFUelRATIO

ZIRCON lAELEMENT

~~

VOLTAGE (V) STOICHIOMETRICAIR-FUEL RATIO

SENSORTERMINALS

The Heated Oxygen Sensor (H02S) detects the oxygen content in the exhaust gas and signais the ECM/PCM. In operation,the ECM/PCM receives the signais from the sensor and varies the duration during which fuel is injected. To stabilize thesensor's output, the sensor has an internai heater. The Primary H02S (Sensor 1) is installed in the exhaust manifold.

Primary Heated Oxygen Sensor (Primary H02Sl1 (Sensor 1)

PGM-FI System

11-65

(cont'd)


PHO~S(WHT) 1 1 2

® 314~

]

PRIMARY H02S (Sensor 1) 4P CONNECTOR (C113)

]

1

Check for a short in the PrimaryH02S:1. Turn the ignition switch OFF.2. Oisconnect the Primary H02S

(Sensor 1) 4P connector.3. Start the engine and let it idle.4. Check the Primary H02S

(Sensor 1) output voltage withthe scan tool.

1

1NO Replace the Primary H02S (Sen-Ooes it stay at 0.1 V or less? l sor 1) (see page 11-89).

1 YES

Check for a short in the wire(PH02S line):,. Turn the ignition switch OFF.2. Oisconnect the ECM/PCM con-

nector 0 (16P).3. Check for continuity between

the Primary H02S (Sensor 1)4P connector terminal No. 1and body ground.

1 Repair short in the wire betweenYES15 there continuity? ECM/PCM (07) and Primary H02S

1 NO(Sensor 1).

Substitute a known-good ECM/PCM and recheck. If symptom/indication goes away. replace theoriginal ECM/PCM.

(From page 11-64)

11-66


ECM/PCM CONNECTOR0 (16P)

JUMPERWIREPH02S (WHT) SG2 (GRN/BLK)

J


JUMPERWIRE

PH02S~SG2(WHT) :. (GRN/, BLK)

1 1 2

314

PRIMARY H02S (Sensor 1) 4P CONNECTOR]

- The MIL has been reported on.- OTCP0132is stored.

1

Problem verification:1. Do the ECM/PCM Reset Pro-


engine at 3,000 rpm with noload (An" in [ffi or Œl position,MfT in neutral) until the radia-tor fan cames on.

3. Test-drive with the AfT in œposition (MfT in 4th gear).

4. Check the Primary H02S(Sensor 1) output voltage withthe scan tool during decelera-tion using completely closedthrottle.

1 Intermittent Iallure, system is OK

Ooes the voltage stay at 1.0 V NO at this time. Check for poor con-or more? nections or loose wires at C113

(Primary H02S. Sensor 1) andr YES ECM/PCM.

Check for an open in the PrimaryH02S:1. Turn the ignition switch OFF.2. Disconnect the Primary H02S

(Sensor 1) 4P connector.3. Connect the Primary H02S

(Sensor 1) 4P connector termi-nais No. 1 and No. 2 with ajumper wire.

4. Turn the ignition switch ON (II).5. Check the Primary H02S


1NO Replace the Primary H02S (Sen-Is there 1.0 V or more?

sor 1) Isee page 11-89).1 YES

Check for an open in the wires(PH02S. SG2 line):1. Turn the ignition switch OFF.2. Connect ECM/PCM connector

terminais 07 and 011 with ajumper wire.

3. Turn the ignition switch ON (II).4. Check the Primary H02S


1 Repair open in the wire betweenNOIs there 1.0 V or more? ECM/PCM (07. 011) and Primary

1 YESH02S (Sensor 1).

Substitute a known-good ECM/PCM and recheck. If symptom/indication go es away. replacethe original ECM/PCM.

1 P0132! The scan tool indicates Diagnostic Trouble Code (OTe) P0132: A high voltage problem in the Primary HeatedOxygen Sensor (Prirnarv H02S) (Sensor 1) circuit.

Primary Heated Oxygen Sensor (Primary H02S) I{Sensor 1) (cont'd)

PGM-FI System

11-67

1

Intermittent failure, system is C[]Kat this time. Check for poor connections or loose wires at C113(Primary H02S, Sensor 1) andECM/PCM.

NO

1

Replace the Primary H02S (Sensor 1) (see page 11-89).

1 YES

Is OTCP0133 indicated?

j

2. Connect the scan tool.3. Start the engine. Hold the

engine at 3,000 rpm with noload (AIT in CH] or ~ position,MIT in neutral) until the radiator fan cames on.

4. Connect the SCS service connectar.

5. Test-drive under f o ll owin qconditions.- 55 mph (88 km/hl steady

speed- AIT in _~ position (MIT in

5th gear)- Until readiness code cornes

on

cedure.

Problem Verification:1. Do the ECM/PCM Reset Pro-

1



Possible Cause• Primary H02S (Sensor 1) Deterioration• Primary H02S Heater (Sensor 1) Deterioration• Exhaust system leakage

NOTE: If DTC P0131, P0132 and/or P0135 are stored at the same time as DTC P0133, troubleshoot those DTCs first, thentroubleshoot DTC P0133.

DescriptionSy controllinq the air/fuel ratio with a Primary H02S (Sensor 1) and a Secondary H02S (Sensor 2), the deterioration of thePrimary H02S (Sensor 1) can be evaluated by its feedback period. When the feedback period of the H02S exceeds a certain value during stable driving conditions, the sensor will be judged as deteriorated.When deterioration has been detected during two consecutive trips, the MIL cornes on and DTC P0133will be stored.

1 P0133! The scan tool indicates Diagnostic Trouble Code (DTC) P0133: A slow response problem in the Primary HeatedOxygen Sensor (Prirnarv H02S) (Sensor 1) circuit.

11-68


3 ..

il

2

SH02S(WHT/REO)

SECONOARY H02S (Sensor 214P CONNECTOR (C782)


1



engine at 3,000 rpm with noload (A[T in [ill or [f) position,MfT in neutral) until the radia-tor fan comes on.

3. With the scan tool, check theSecondary H02S (Sensor 2)output voltage at 3,000 rpm.

1

Intermittent failure, system is OKat this time. Check for poor con-

Does the voltage stay at 0.3 V NO nections or 100se wires at C128

or less? (located under right side of dash),C430 (located under middle of

1 YESdash). C782 (Secondary H02S)(Sensor 2) and ECM/PCM.

Check for a short in the SecondaryH02S:1. Turn the ignition switch OFF.2. Disco nnect the Secondary

H02S (Sensor 2) 4Pconnectar.3. Start the engine.4. Check the Secandary H02S

(Sensor 2) output with the scantaol.

1

NO~

Does the valtage stay at 0.3 V Replace the Secondary H02S Jar less? (Sensor 2) (see page 11-89).

IVESCheck for a short in the wire(SH02S line):1. Turn the ignitian switch OFF.2. Di sco nn ect the ECM/PCM

connectar 0 (16P).3. Check far continuity between

the Secondary H02S (Sensor2) 4P connector terminal Na. 1and body ground.

1Repairshort in the wire betweer]YES

Is there continuity? ECM/PCM (DU) and Secondary

1 NO

H02S (Sensor 2).


1 P0137 1 The scan tool indicates Diagnostic Trouble Code (DTC) P0137: A low voltage problem in the Secondary HeatedOxygen Sensor (Secondary H02S) (Sensor 2) circuit.

Secondary Heated Oxygen Sensor (Secondary H02S) (Sensor 2)

PGM-FI System

11-69

(cont'd)


JUMPERWIRE

SH02S (WHT/REO)SH02SG(GRN/BLK)



3 : 4

JUMPERWIRE

SH02S ~ SH02SG(WHT/REO) L7~J (GRN/WHT)

SECONOARY H02S (Sensor 2)4P CONNECTOR C782


1

Problem verification:1. 00 the ECM/PCM Reset Pro-


engine at 3,000 rpm with noload (AIT in lE] or Œl position,MfT in neutral) until the radia-tor fan cames on.

3. With the scan tool, check theSecondary H02S (Sensor 2)output voltage at 3,000rpm.

1Intermittent failure, system is OKat this time. Check for poor con-

Ooes the voltage stay at 0.6 V NO nections or loose wires at C1~:3

or more? (located under right side of dash),C430 (located under middle of

1 YES dash}, C782 (Secondary H02S,Sensor 21and ECM/PCM.

Check for an open in the SecondaryH02S:1. Turn the ignition switch OFF.2. Oisconnect the Secondary

H02S (Sensor 2) 4Pconnector.3. Connect the Secondary H02S

(Sensor 2) 4P connector ter-minais No. 1 and No. 2 with ajumper wire.

4. Turn the ignition switch ON (11).5. Check the Secondary H02S


1NO Replace the Secoridarv H02S 1Is there 0.6 V or more?

(Sensor 2) (see page 11-89).

1 YES

Check for an open in the wire(SH02S, SH02SG lines):1. Turn the ignition switch OFF.2. Connect ECM/PCM connector

terminais 014 and 013 with ajumper wire.

3. Turn the ignition switch ON (II).4. Check the Secondary H02S

(Se nsor 2) output voltagewith the scan tool.

1NO

1 Repair open in the wire betwee]Is there 0.6 V or more?

1

ECM/PCM (013 and/or 014) and

1 YESSecondary H02S (Sensor 2).

Substitute a known-good ECM/ !

PCM and recheck. If symptomlindication goes away, replacethe original ECM/PCM.

1 P0138 1 The scan tool indicates Diagnostic Trouble Code (DTC) P0138: A high voltage problem in the Secondary HeatedOxygen Sensor (Secondary H02S) (Sensor 2) circuit.

11-70

- The MIL has been reported on.- OTC P0139 is stored.



engine at 3.000 rpm with noload (AIT in lliJ or [El position,MIT in neutral) until the radia-tor fan cornes on.

3. Check the Secondary H02S(Sensor 2) output at 3.000 rpmwith the scan tool.

Interminent failure, system is OKat this time. Check for poor con-

Does the voltage stay within NO nections or loose wires at C123

0.3 - 0.6 V for two minutes? (Iocated under right side of dash),C430 (located under middle of

YES dashl, C782 (Secondary H02S,Sensor 2) and ECM/PCM.

Replace the Secondary H02S(Sensor 2) (see page 11-89).

1 P0139! The scan tool indicates Diagnostic Trouble Code (DTC) P0139: A slow response problem in the Secondary HeatedOxygen Sensor (H02S) (Sensor 2) circuit.

Secondary Heated Oxygen Sensor (Secondary H02S) (Sensor 2) (cont'd)

PGM-FI System

11-71

Wire side of female terminais(cont'd)

(To page 11-72)*: P0141(To page 11-72)

Cl1 1 1

S02SHTC ,1 1 2 IIGl(BLK/WHTI 1 ! Î (BLK/WHTI

~

SECONDARV H02S (SENSOR 214P CONNECTOR (C7821*


IGl(BLK/ 2 P02SHTCVELl (BLK/WHTI

RIMARY H02S (SENSOR 1) 4P CONNECTOR (Cl13)


PRIMARV H02S (Sensor 114P CONNECTORSECONDARV H02S (Sensor 2) 4P CONNECTOR*

- The MIL has been reported on.- OTC P0135, and/or P0141 are

stored.

1


cedure.2. Start the engine. Intermittent failure, system is OK

1at this time. Check for poor con-nections or loose wires at C123

Is OTC PO135 or P0141 indi- NO (Iocated under right side of dash],cated? C430 (located under middle of

1 YESdashl. C113 (Primary H02S,Sensor 11. C782 (SecondaryH02S, Sensor 2)* and ECM/PCM.

Check for an open or short in theH02S:1. Turn the ignition switch OFF.2. Oisconnect the H02S (Primary

or Secondary*) (Sensor 1 orSensor 2*) 4P connector.

3. At the H02S side, measureresistance between the H02S4P connector terminais No.3and No. 4.

1

1

1

NO Replace the H02S (Primary orIs there 10 - 40 fl?1

Secondary*) (see page11·89).

1 YES

Check for continuity betweenbody ground and the H02S 4Pconnector terminais No. 3 and PNo. 4 individually.

1

1

1

YES Replace the H02S (Primary orIs there continuity? l Secondary*) (see page11-89).

1 NO

Check for an open or short in thewire (P02SHTC, S02SHTC* line):1. Turn the ignition switch ON (II).2. At the harness side, measure

voltage between the H02S 4Pconnector terminais No. 3 andNo. 4.

1YES


~

J NO

\fi

The scan tool indicates Diagnostic Trouble Code (DTC) P0135: An electrical problem in the Primary HeatedOxygen Sensor (Primary H02S) (Sensor 1) Heater system.The scan tool indicates Diagnostic Trouble Code (DTC) P0141: A problem in the Secondary Heated Oxygen Sensor(Secondary H02S) (Sensor 2) Heater circuit.

!P013S!

!P0141 1

Heated Oxygen Sensor (H02S) Heater

S02HTC (BLK/WHT)* P02SHTC (BLK/WHT)


ECM/PCM CONNECTOR A (32P)

,...------{VP02SHTC -(BLK/WHT),...-----rJ)


SECONDARY H02S(SENSOR 2) 4P CONNECTOR(C782)*


3 4

2

IGl(BLK/ VYEL)

PRIMARY H02S (SENSOR 1) 4P CONNECTOR(C113)

11-72

*: P0141

TCheck for a short in the wire(P02SHTC, S02SHTC* line):1. Turn the ignition switch OFF.2. Disconnect the ECM/PCM con-

nector A (32P).3. Check for conti nuit y between

the ECM/PCM connector termi-nai AG (AS)* and body ground.


15 there continuity? ECM/PCM (AG, A5*) and H02S

1 NO(Primary, Secondary*).


(From page 11-71)

rCheck for an open or short in thewire (lG1 line):Measure voltage between theH02S 4P connector terminaisNO.3 (No. 4*) and body ground. - Repair open or short in the wire

1between Primary H02S (Sensor

NO 1), No. 15 ALTERNATOR SPIs there battery voltage? SENSOR (7.5 A) fuse and

1 YESSecondary H02S (Sensor 2)*.

- Replace the No. 15 ALTERNA-TOR SP SENSOR (7.5 A) fuse.

Check for an open in the wire(P02SHTC, S02SHTC* line):1. Turn the ignition switch OFF.2. Reconnect the H02S 4P con-

nector.3. Disconnect the ECM/PCM con-

nector A (32P).4. Turn the ignition switch ON (II).5. Measure voltage between the

ECM/PCM connector terminaisAS and A10 (A5 and A10)*.

1 Repair open in the wire betweenYESIs there 0.1 V or less? ECM/PCM (AG, A5*) and H02S

1 NO(Primary, Secondary*).


(From page 11-71)

Heated Oxygen Sensor (H02S) Heater (cont'd)

PGM-FI System

11-73

(cont'd)

• Fuel Pressure Regulator clogged, stuck closed• Fuel Return Pipe clogged• Fuel ln jector leaking• Gasoline doesn't meet Owner's Manual spec.

Primary H02S (Sensor 1) deterioratedMAP Sensor range/performance

• EVAP Purge Control Solenoid Valve leaking, stuck opened• Valve Clearance

OTe P0172S stem too rich

• Fuel Pump insufficient flow/pressure• Fuel Feed Line clogged, leaking• Fuel Pressure Regulator stuck open• Fuel Filter clogged• Fuel ln jector clogged, air inclusion• Gasoline doesn't meet Owner's Manual spec.

Primary H02S (Sensor 1) deteriorated• MAP Sensor range/performance• Valve Clearance• Exhaust leak

OTCP0171S stem too lean

Possible Cause

P0107-8, P1128-9: MAP SensorP0135: Primary H02S HeaterP0137-8: Secondary H02SPO141: Secondary H02S HeaterP0441: EVAP System Insufficient Purge FlowP1259: VTEC System

NOTE: If some of the OTCs listed below are stored at the same time as OTC P0171 and/or P0172, troubleshoot those OTCsfirst, then troubleshoot OTC P0171 and/or P0172.

DescriptionSy monitoring the Long Term Fuel Trim, long term malfunctions in the fuel system will be detected.If a malfunction has been detected during two consecutive trips, the MIL will come on and OTC P0171 and/or P0172 will bestored.

1 P0171 1 The scan tool indicates Diagnostic Trouble Code (OTC) P0171: The fuel system is too lean.

1 P0172 1 The scan tool indicates Diagnostic Trouble Code (OTC) P0172: The fuel system is too rich.

Fuel Supply System

11-74

- TheMilhas been reported on.- OTC P0171 and/or P0172 are

stored.

1

Check the fuel pressure.

1NO

Is the fuel pressure OK7 J1 VES Is the fuel pressure tao high HIGH 1 Check the fuel pressure regulator

.or tao low? l and fuel return pipe.

Check the Primary H02S:1 LOW1. Start the engine. Hold the

engine at 3.000 rpm with no

1

load (AIT in [RJ or [El position. Check the fuel pump. fuel feedMfT in neutral) until the radia- pipe, fuel filter, and fuel pressuretor fan cames on. regulator.

2. Check the Primary H02S(Se nso r 1) output with thescan tool.

1

Ooes it stay at less than 0.3 V YES Replace the Primary H02S (Sen-

1or more than 0.6 V? sor 1) Isee page 11-89).

1 NO

Check for a sticking or leakingEVAP purge control solenoidvalve:With a vacuum pump, apply vacu-um to the EVAP purge controlsolenoid valve from the intakemanifold side.

1

1

NO Replace the EVAP purge contro1Does it hold vacuum?solenoid valve.

1 VES

- Check the valve clearance.- If they are OK, replace the fuel

injectors.


Fuel Supply System (cont' d)

PGM-FI System

11-75

(cont'd)

Possible Cause• Fuel injector clogging, fuel leakage, air leakage• Fuel injector circuit open or shorted• Spark plug carbon deposits, fouling, malfunction• Ignition wires open, leaking• Distributor malfunction• Compression low• Valve clearance out of spec• VTEC system malfunction

P0106: MAP sensorP017l, POl72: Fuel supply systemP0335, P0336: CKF sensorP044l: EVAP Insufficient purge flowP1359, P136l, P1362: TOC sensorP138l, P1382: CYP sensor

NOTE: If some of the oTCs listed below are stored at the same time as a mistire oTC, troubleshoot those D'I'Cs tirst, thentroubleshoot the misfire oTC.

DescriptionMisfire detection is accomplished by monitoring the crankshaft speed with the crankshaft speed fluctuation (CKFI sensorwhich is attached to the crankshaft.If misfiring strong enough to damage the catalyst is detected, the MIL will blink during the time of its occurrence, and oTCP0301, P0302, P0303 and/or P0304 will be stored. Then, after the misfire has ceased, the MIL will come on.If misfiring that increases emissions is detected during two consecutive driving cycles, the MIL will come on, and oTCP0301, P0302, P0303 and/or P0304 will be stored.

1 P0301 1 The scan tool indicates Diagnostic Trouble Code (OTCI P0301: Cylinder 1 misfire detected.

1 P03021 The scan tool indicates Diagnostic Trouble Code (oTC) P0302: Cylinder 2 misfire detected.

1 P03031 The scan tool indicates Diagnostic Trouble Code (OTC) P0303: Cylinder 3 misfire detected.

1P03041 The scan tool indicates Diagnostic Trouble Code (oTC) P0304: Cylinder 4 misfire detected.

Misfire Oetected in One Cylinder

NOTE:• If there is no freeze data of misfiring,just clear the OTC.

• If there is no freeze data of misfiring,test drives under various conditionsare necessary.

Replace the fuel injector.Substitute a known·goodECM/PCM and recheck. Ifsymptomlindication goesawav, replace the original ECM/PCM.

YES

Repair open or short in the wire.Are the wires OK7

Check for an open or short in theharness between ECM/PCM andthe fuel injector.

NO

11-76

(Ta page 11-77)

Problem verification:1. Check and record the freeze

data, then do the ECM/PCMReset Procedure.

2. Exchange the spark plug fromthe problem cylinder with oneof another cylinder.


4. Test-drive the vehicle severaltimes in the range of the freezedata.

YES

Does it click?

Check the fuel injector function:Start the engine. and listen for aclicking sound at the fuel in je ct orin the problem cylinder.

The Mil has been reported on.OTC P0301. P0302. P0303. orP0304 is indicated.


Misfire in Detected One Cylinder (cont'd)

PGM-FI System

11-77

1

Is OTe P0301, P0302, P0303, NO Intermittent misfire due to spark

or P0304 indicated?plug fouling, etc. (firing is OK atthis time).

YES

Ooes the misfire occur in the YESother cylinder whose spark plug

1Replace the faulty spark plug.

was exchanged?

NO

Check for fuel inject or malfunc-tion:1. Exchange the fuel injector

from the problem cylinderwith one from another cylin-der.

2. Let the engine idle for two min- NOTE: If there is no freeze data of mis-utes. firing, test drives under various condi-

3. Test-drive the vehicle several tions are necessary.times in the range of the freezedata.

Is OTe P0301, P0302, P0303, NO Intermittent misfire due to bad

or P0304 indicated? contact in the fuel inject or con-nector (firing is OK at this time).

YES

Ooes the misfire occur in the YESother cylinder whose fuel injector Replace the faulty fuel inject or.was exchanged?

NO

Check following items- Cylinder leak-down- Compression- Crankshaft speed fluctuation

(CKF)sensor

(From page 11-76)

11-78

NOTE: If misfire doesn't recur, some possible causes are fuel that doesn't meet owner's manualspec, lack of fuel, carbon deposits on spark plug, etc.

1\ Possible causeCrankshaft

F 1 j Distributor and Valve---------------------'\ position (CKP) ue pressure l' . . ICM Clearance

Page " sensor qrunon wrres------------------- ---------------- --------------------- ---------------- -----------------

Condition \ section 6 11-110 section 4 section 4 section 6

Only low rpm and load @ G) @

Onlyaccelerating @ CD CID

Only high rpm and load @ CD @ CID @

Not specifie @ CD @ CID @

TroubleshootingBy test-driving, determine the conditions during which misfire occurs. Oepending on these conditions, test in the orderdescribed in the table below.

Possible Cause• Fuel pump insufficient fuel pressure, amount of flow• Fuelline clogging, blockage, leakage• Fuel filter clogging• Fuel pressure regulator stuck open• Oistributor malfunction• Ignition coil wire open, leakage• Ignition control module malfunction• Valves carbon deposit• Compression low• VTEC system malfunction• Fuel does not meet Owner's Manual spec., lack of fuel

1 P1300 1or 1 P0301 through P03041 The scan tool indicates Oiagnostic Trouble Code (OTC) P1300 or some of P0301 -P0304: Random misfire.

DescriptionMisfire detection is accomplished by monitoring the crankshaft speed with the crankshaft speed fluctuation (CKF) sensorwhich is attached to the crankshaft.If misfiring strong enough to damage the catalyst is detected, the MIL will blink during the time of its occurrence, and OTCP1300 or some of OTCs P0301 through P0304 will be stored. Then, after misfire has ceased, the MIL will come on.If misfiring that increases emissions is detected during two consecutive driving cycles, the MIL will come on, and OTCP1300 or some of OTCs P0301 through P0304 will be stored.NOTE: If some of the OTCs listed below are stored at the same time as a misfire OTC, troubleshoot those OTCs first, thentroubleshoot the misfire OTC.

P1128-9 MAP sensorP0171, P0172: Fuel meteringP0505: Idle Control SystemP1253: VTEC SystemP1361, P1362: TOC sensorP1381, P1382: CYP sensorP1508: lAC valve

Random Misfire

PGM-FI System

11-79

'1 12

5KS(RED/BLU)


KS 2P CONNECTOR (C105)

KS(RED/BLU)


11 12

5


TERMINAL

OIAPHRAGM

- The Mil has been reported on.- OTCP0325 is stored.

1

Problem verification:1. Do the ECM/PCM Reset Proce-

dure.2. Start the engine. Hold the

engine at 3,000 rpm with noload (NT in llil or [f] position,MIT in neutral) until the radia-tor fan comes on, then let itidle.

3. Hold the engine at 3,000 -4,000 rpm for at least 60 sec-onds.

1

Intermittent failure, system is OK

NOat this time (test drive may be

Is DTC P0325 indicated? necessarv).Check for poor connections or

1 YESloose wires between C105 (knocksensor (KSI) and ECM/PCM.

Check for a short in the wire (KSline):1. Turn the ignition switch OFF.2. Disconnect the knock sensor

2P connector.3. Disconnect the ECM/PCM

connector D (16P).4. Check for continuity between

ECM/PCM connector termi-nais D6 and body ground.


Is there continuity? ECM/PCM (06) and knock sen-

1 NOsor.

Check for an open in the wire(KS line):Check for conti nuit y betweenECM/PCM connector terminal D6and knock sensor 2P connectorterminal No. 1.


Is there conti nuit y? ECM/PCM (06) and knock sen-

1 YESsor.

Substitute a known-good knocksensor and recheck.

1NO

jIs DTC P0325 indicated? Replace the original knock sensor.

1 YES


1 P0325! The scan tool indicates Diagnostic Trouble Code (DTC) P0325: A malfunction in the circuit of the Knock Sensor. . (KS).

Knock Sensor (KS)

SENSOR DTC SENSOR ECM/PCM WIRETERMINAL TERMINAL COLOR

CKP P0335 2 C2 BLU

P0336 6 C12 WHT

TDC P1361 3 C3 GRN

P1362 7 C13 RED

CYP P1381 4 C4 YEL

P1382 8 C14 BLK

TOCM (RED)Terminal side ofmale terminais

CVPM (BLK)

OISTRIBUTOR lOPCONNECTOR

CKPP(BLU)

CKP CVPSENSOR SENSORROTOR ROTOR

TOCSENSORROTOR

11-80

(Ta page 11-81)

- The MIL has been reported on.- OTC P0335, P0336, P136l,

P1362, P138l and/or P1382 arestored.

J


dure.2. Start the engine.

Intermittent failure, system is OKIs OTC P0335, P0336, P1361, P1362, NO at this time. Check for poor con-P1381 and/or P1382 indicated? nections or loose wires at Cl19

1 YES(distributor) and ECM/PCM.

Check for an open in the CKP/TOC/CVP sensor:1. Turn the ignition switch OFF.2. Oisconnect the distributor 10P

connector.3. Measure resistance between

the terminais of the indicatedsensar (see table).

1

NO Replace the distributor ignition• Is there 350 - 700 mhousing (see section 4).

1 YES

NOTE: If DTC P1359 is stored at the same time as DTC P0335, P0336, P1361, P1362, P1381 and/or P1382, troubleshoot DTCP1359 first, then troubleshoot those DTCs.

DescriptionThe CKP Sensor determines timing for fuel injection and ignition of each cylinder and also detects engine speed. The TDCSensor determines ignition timing at start-up (cranking) and when crank angle is abnormal. The CYP Sensor detects theposition of No. 1 cylinder for sequential fuel injection to each cylinder. The CKP/TDC/CYP Sensor is built into the distributor.

1 P1382! T.he ~can tool indicates Diagnostic Trouble Code (OTC) P1382: No signal in the Cylinder Position (CYP) sensorcrrcuit.

1 P1381 ! The scan tool .indi.cates Diagnostic Trouble Code (DTC) P1381: Intermittent interruption in the Cylinder Position'-----' (CYP) sensor circutt.

, P1362! T.he ~can tool indicates Diagnostic Trouble Code (DTC) P1362: No signal in the Top Dead Center (TDC) sensorcircuit.

1 P1361 ! The scan tool .indi.cates Diagnostic Trouble Code (DTC) P1361: Intermittent interruption in the Top Dead Center'------' (TDC) sensor Circuit.

1 P0336 \ The. ~can tool indicate~ Di~gnostic Trouble Code (DTC) P0336: A range/performance problem in the Crankshaft'----'--~-' Position (CKP) sensor circutt.

1 P033S! The sca~ to~1 indicates Diagnostic Trouble Code (DTC) P0335: A malfunction in the Crankshaft Position (CKP)sensor ctrcuit.

Crankshaft Position/Top Oead Center/Cylinder Position (CKP/TOC/CYP) Sensor

PGM-FI System

11-81

TOCP(GRN)


Repair short in the indicated sensor wires (see table).

ECM/PCM CONNECTORS C (31P)

CKP P TOC P(BLU) (GRN)

Repair open in the indicated sensor wires (see table).


Replace the distributor ignitionhousing (see section 4).

TOC P (GRN)CKPP(BLU)

OISTRIBUTOR10P CONNECTOR


NO

Is there conti nuit y?

Check for a short in the wires(CKP/TOC/CYP lines):Check for conti nuit y betweenbody ground and ECM/PCM connector terminais C2, C3 and/or C4individually.

YES

Is there 350 - 700 n?

Check for an open in the wires(CKP/TOC/CYP lines):1. Reconnect the distributor 10P

connector.2. Disconnect the ECM/PCM con

nector C (31Pl.3. Measure resistance between

the terminais of the indicatedsensor on the ECM/PCM connector (see table).

NO


Check for a short in the CKP/TOC/CYP sensor:Check for conti nuit y to bodyground on both terminais of theindicated sensor individually (seetable).

(From page 11-80)

VSS (BLU/WHTI

l' 12 3 , 5 6 1/ 8 9 10 11 1Lulu U 15 16 17 181/ 20 '/ 22 23 2' 1/ Vl/1 V1/:// ~

V

1.' 2 3 , S 6 7 al/ 10

(11 12 13 U is V 17 187/ ://l/ / ~ V/ % / / /

LGl(BRN/BLK)


VSS (BLU/WHTI

1

l' 12 3 , 5 6 l/ 8 9 10 11 1l'2ln U 15 16 17 18V 20V 22 23 2' 1

l// / LV VV ~

VC (31P)

(1 2 3 , 5 6 1 8V 10

ln 12 13 U lS / 17 18V././VL'Vl/ lL:~ lJ! V / /

LGl(BRN/BLK)

ECM/PCM CONNECTORS

A (32P)

11-82

- The MIL has been reported on.- OTCP0500 or POSOlis stored.

1

Problem verification:1. Test-drive the vehicle.2. Check the vehicle speed with

the scan tool.

1YES

Intermittent failure. system is OKat this time. Check for poor con-Is the correct speed indicated? nections or loose wires at C121

1 NO(VSS) and ECM/PCM.

Check for an open in the ECM/PCM:1. Turn the ignition switch OFF.2. Block the rear wheels and set

the parking brake.3. Jack up the front of the vehicle

and support it with safetystands.

4. Turn the ignition switch ON (II).5. Block the right front wheel and

slowly rotate the left frontwheel.

6. Measure voltage between theECM/PCM connector termi-nais C18 and A9.

1 Substitute a known-good ECM/Does the voltage pulse 0 V YES PCM and recheck. If symptom/and 5 V? indication goes away. replace the

1 NOoriginal ECM/PCM.

Check for a short in the ECM/PCM:1. Turn the ignition switch OFF.2. Disconnect the ECM/PCM

connector C (31Pl.3. Turn the ignition switch ON (11).4. Block the right front wheel

and slowly rotate the left frontwheel.

5. Measure voltage between theECM/PCM connector terminaisC18and A9.

1 Substitute a known-good ECM/Does the voltage pulse 0 V YES PCM and recheck. If symptom/and 5 V? indication goes away. replace

1 NOthe original ECM/PCM.

- Repair short in the wirebetween ECM/PCM (C18) andVSS.

- Repair open in the wirebetween ECM/PCM (C18) andVSS.

- If wire is OK. test the VSS(see page 23-60).

1 P0501 1 The scan tool indicates Diagnostic Trouble Code (OTC) P0501: A range/performance problem in the VehicleSpeedSensor (VSS) circuit (AIT).

1 P0500 1 The scan tool indicates Diagnostic Trouble Code (OTC) P0500: A malfunction problem in the Vehicle SpeedSensor (VSS) circuit (Mm.

Vehicle Speed Sensor (VSS)

PGM-FI System

11-83

(cont'd)


1

Problem verification:1. Do the ECM/PCM reset proce-

dure.2. Sta rt the engi ne. Hold the

engine at 3,000 rpm with noload (Aff in [HJ or ~ position,MIT in neutral) until the radia-tor fan cornes on, then let itidle.

3. Test-drive with the Arr in œposition (MIT in 4th gear).

4. Accelerate for five secondsusing wide open throttle.

1

1

1

NO Intermittent failure, system is OKIs OTCPll06 indicated?1

at this time.

1 YES

Substitute a known-good ECM/PCM and recheck. If symptom/indication 90es away, replacethe original ECM/PCM.

1P11061 The scan tool indicates ~iag~ostic Trouble Code (OTC) Pll06: A range/performance problem in the BarometricPressure (Baro) Sensor circuit.

Barometric Pressure (Baro) Sensor

11-84

- The Mil has been reported on.- OTCPll07 or Pll08 is stored.

1

Problem verification:1. 00 the ECM/PCM Reset Pro-

cedure.2. Turn the ignition switch ON (II).

11

1

NO Intermittent failure, system is OKIs oTC Pl107 or Pl108 indicated?1

at this time.

1 YES

Substitute a known-good ECM/PCM and recheck. If svmptorn/indication goe5 away, replacethe original ECM/PCM.

1 P110a/ The scan tool indicates Diagnostic Trouble Code (OTe) P1108: A high voltage problem in the Baro sensorcircuit.

!P1107! The scan tool indicates Diagnostic Trouble Code (DTC) P1107: A low voltage problem in the Baro sensor circuit.

Barometric Pressure (Baro) Sensor (cont'd)

PGM-FI System

11-85

(cont'd)

Replace the CKF sensor (see section 61.

YES

CKFM CKFP(WHT) (BlUI

""'.:'" -_.


Replace the CKF sensor (see section 61.

NO

CKFSENSOR3PCONNECTOR

NOIntermittent failure. system is OKat this time. Check for poor connections or loose wires at C104(CKFsensorl and ECM/PCM.

CKF SENSOR

(To page 11-86)

Is there conti nuit y?

1

Check for a short in the CKF sensor:Check for conti nuit y betweenbody ground and the CKF sensor3P connector terminais No. landNo. 3 individually.

1 YES

Is there 1.6 - 3.2 km

1

Check for an open in the CKF sensor:1. Turn the ignition switch OFF.2. Disconnect the CKF sensor 3P

connector.3. Measure the resistance

between the CKF sensor 3Pconnector terminais No. 1 andNo.3.

1 YES

Is OTC P1336 and/or P1337indicated?

1

Problem verification:1. Do the ECM/PCM Reset Proce

dure.2. Start the engine.

1

- The MIL has been reported on.- OTC P1336 and/or P1337 are

stored.

DescriptionThe diagnostic system has a pulser rotor on the crankshaft and a pulse pick-up sensor on the engine block. The ECM/PCMmonitors the crankshaft speed fluctuation based on the CKF sensor signal, and judges that an engine misfire occurred ifthe fluctuation goes beyond a predetermined limit.

1 P1337! The sca~ to~1 indicates Diagnostic Trouble Code (DTC) P1337: No signal in the Crankshaft Speed Fluctuation (CKF)sensor circuit.

1 P1336! The scan. tool indicates Dia~no.stic Trouble Code (DTC) P1336: Intermittent interruption in the Crankshaft SpeedFluctuation (CKF) sensor circuit.

Crankshaft Speed Fluctuation (CKF) Sensor

11-86

CKF PIBLU/RED)


ECM/PCM CONNECTOR C 131P)

CKFPIBLU/RED)

1

Check for an open in the wiresICKF lines):1. Reconnect the CKF sensor 3P

connector.2. Disconnect the ECM/PCM con-

nector C (31P).3. Measure resistance between

ECM/PCM connector termi-nais Cl and cu.

_1NO Repair open in the wire between

15there 1.6 - 3.2 km ECM/PCM IC1. C11) and the CKF

1 YESsensor.

Check for a short in the wireICKF line):Check for conti nuit y betweenbody ground and ECM/PCM con-nector terminal Cl.

J Repair short in the wire betweenYESIs there continuity? ECM/PCM IC1) and the CKF sen-

1 NOsor.


(From page 11-85)

Crankshaft Speed Fluctuation (CKF) Sensor (cont'd)

PGM-FI System

11-87

- The MIL has been reported on.

1- OTC P1359 is stored.

1


dure.2. Start the engine. If the engine

won't start. crank it for at least10 seconds.

1NO

Intermittent failure. system is OKat this time. Check for poor con-Is DTC P1359 indicated?nections or loose wires at C119

1 YES(distributor) and ECM/PCM.

Check for poor connections orloose wires between the distribu-tor and the ECM/PCM.

1NO

Are the connections OK? Repair as necessary.

1 YES

Substitute a known-good ECM/ 1

PCM and recheck. If symptomlindication goes away. replace theoriginal ECM/PCM.

, P1359 1 The scan tool indicates Diagnostic Trouble Code (DTC) P1359: A problem in the Crankshaft Position/Top DeadCenter/Cylinder Position (CKPfTDC/CYP) sensor circuit.

Crankshaft Position/Top Dead Center/Cylinder Position (CKP/TDC/CYP) Sensor

11-88


1


cedure.2. Turn the ignition switch ON (II).3. Wait 10 seconds.

1

1

1

NO Intermittent failure, system is OKIs DTC P1607 indicated?1

at this time.i YES

Substitute a known-good ECM/PCM and recheck. If symptom/indication goes away, replace theoriginal ECM/PCM.

1 P1607 , The scan tool indicates Diagnostic Trouble Code (DTC) P1607: An ECM/PCM InternaI Circuit Problem.

ECM/PCM Internai Circuit

PGM-FI System

11-89

3. Install the secondary Ha2S (sensor 2) in reverse orderof removal.

SECONDARV H02S (SENSOR 2)44 N·m (4.5 kgf·m, 33 Ibf·ft)

02 SENSOR WRENCHSNAP-ON or SP ToolsPIN 88750 or 93750(Commercially available)

2. Remove the secondary Ha2S (sensor 2).

SECONDARV H02S (SENSOR 21CONNECTOR

1. Remove the grommet, pull out the secondary Ha2S(sensor 2) connector, then disconnect the secondaryHa2S (sensor 2) connector.

Secondary Heated Oxygen Sensor (Secondary H02S)(Sensor 2):

2. Install the primary Ha2S (sensor 1) in reverse orderof removal.

PRIMARV H02S (SENSOR 1144 N·m (4.5 kgf·m, 33 lbf-ft)

PRIMARV H02S (SENSOR 11CONNECTOR

02 SENSOR WRENCHSNAP-ON or SP TooisPIN 88750 or 93750(Commerciallyavailable)

1. Disconnect the primary Ha2S (sensor 1) connector,then remove the primary Ha2S (sensor 1).

Primary Heated Oxygen Sensor (Primary H02S) (Sensor 1):

Replacement

Heated Oxygen Sensor (H02S)

11-90

BLK

~

_.~ VARIOUS~J SENSORS

~, BLKIBLU

_~A_ From PGM-FI~ MAIN RELAV

r---------+---- VELlBLK

AIT:

MIT:

The id le speed of the engine is controlled by the Idle Air Control (lAC) Valve.The valve changes the amount of air bypassing into the intake manifold in response to electric current controlled by theECM/PCM. When the lAC Valve is activated, the valve opens to maintain the proper idle speed.

System Description

Idle Control System

11-91

If the idle speed still cannot be adjusted to specification (and the scan tool does not indicate DTC P0505 or P1508)after lAC valve replacement, substitute a known-good ECM/PCM and recheck. If symptom goes away, replace theoriginal ECM/PCM.

4. If the above items are normal, substitute a known-good lAC valve and readjust the idle speed (see page 11-103).

3. When the idle speed is out of specification and the scan tool does not indicate Diagnostic Trouble Code (DTC) P0505or P1508, check the following items:• Adjust the id le speed (see page 11-103)

Starter switch signal (see page 11-98)• Air conditioning signal (see page 11-99)• ALT FR signal (see page 11-101)

Brake switch signal (see page 11-102)• AIT gear position signal (see section 14)

Hoses and connectionslAC valve and its mounting O-rings

-20 80

ENGINEL_----~----------~--------~-------1-4~0---------1-76--COOLANTTEMPERATURE- 4 32 68 104 (OF)

o 20 40 60

IOLE SPEEO(rpm)

2. When the coolant temperature is low, the lAC valve is opened to obtain the proper fast idle speed. The amount ofbypassed air is thus controlled in relation to the engine coolant temperature.

1. After the engine starts, the lAC valve opens for a certain time. The amount of air is increased to raise the idle speedabout 150 - 300 rpm.

(T0 page 11-93)

8

NO

Intermittent failure, system is OKat this time.

11-92

(To page 11-93)

A

YES

Is it 550 rpm or Jess?

NO

Is the idle speed (750± 50 rpm) OK?

Problem verification:t. Start the engine. Hold the

engine at 3,000 rpm with noload (M in [ffi or [f] position,MfT in neutral) until the radiatorfan comes on, then let it idle.

2. Check the engine speed atidJe with no-Ioad conditions:headlights, blower fan, reardefogger, radiator fan, and airconditioner are not operating(see page "-'03).



Possible Cause• lAC valve mechanical malfunction• Throttle body clogged port, improper adjustment• Intake manifold gasket leakage• Intake air hose loose leakage• Vacuum leak• ECTsensor range/performance problem• Throttle Position sensor range/performance problem

NOTE: If DTC P1508 or P1509 is stored at the same time as DTC P0505, troubleshoot DTC P1508 or P1509 first, th en troubleshoot DTC P0505.

1pososl The scan tool indicates Diagnostic Trouble Code (DTC) P0505: Idle control system malfunction.

Idle Control System

Idle Control System

11-93

TPut your tinger on the upper portin the throttle body.

1 Check for vacuum leaks, makeNO sure the throttle valve is corn-Ooes the engine speed drop?

pletely closed, and repair as nec-

1 YESessary.

Adjust the idle speed (see page11-103). If it's impossible. replacethe lAC valve.

-',NO J jReplace the lAC valve.IL_ ~

1

1

L._._._._._._

1

1

1

1L. . ._._.__,

NO 1 J>-----11 Replace the lAC valve.

(From page 11-92)

Adjust the (base) idle speed (seepage 11-103). If it's impossible,clean the ports in the throttlebody.

1_._._._._._._._._.~1 YESL._._._._._._.~._._._._._._._._._._._._

Ooes the engine speed drop orthe engine stail?

Check the lAC valve:Oisconnect the 2P connectortrom the lAC valve.

YES

Ooes the engine speedincrease?

Check the lAC valve:Oisconnect the 3P connector fromthe lAC valve.

(From page 11-92)

~~._._._._._~_._._._._._.,


IACV(BlK/BLU)

ECM CONNECTOR A (32P)

Repair open in the wire betweenlAC valve and PGM-FI main retav.


lAC VALVE 2P CONNECTOR (C1321

Intermittent failure, system is OKat this time. Check for poor connections or loose wires at C132(lAC valve) and ECM.

NO

VALVE

11-94

(To page 11-95)

Check for an open or short in thewire (lACV line):1. Turn the ignition switch OFF

and reconnect the lAC valveconnector.

2. Disconnect the ECM connectorA (32P).

3. Turn the ignition switch ON (II).4. Measure voltage between

body ground and ECM connector terminal A 12.

YES


Check for an open in the wire(lGP1Iine):1. Turn the ignition switch OFF.2. Disconnect the lAC valve 2P

connector.3. Turn the ignition switch ON (II).4. Measure voltage between body

ground and the lAC valve 2Pconnector terminal No. 2.

YES

Is DTC P1508 indicated?

Problem verification:1. Do the ECM/PCM Reset Pro

cedure.2. Start the engine, and warm it

up to normal operating temperature.

- The Mil has been reported on.- OTC P1508 is stored.

The lAC Valve changes the amount of air bypassing the throttle body in response to a current signal from the ECM inorder to maintain the proper idle speed.

!P150S! ~he ~can tool indicates Diagnostic Trouble Code (DTC) P1508: A problem in the Idle Air Control (lAC) valveCircuit.

Id le Air Control (lAC) Valve (MIT)

Idle Control System

11-95


JUMPERWIRE

ECM CONNECTOR A (32P)1

NO Repair open or short in the wireIs there battery voltage? between ECM (A12) and lAC

1 YESvalve.

Check the lAC valve function: IACVMomentarily connect ECM con- (BLK/nector terminais A12 and Al0 BLU)with a jumper wire several times.

'--

1NO

Ooes the lAC valve click? Replace the lAC valve.

1 YES

Substitute a known-good ECMand recheck. If symptom/indica-tion qoes away, replace the origi-nal ECM.

(From page 11-94)

IGPTerminal side of maleterminais

Replace the lAC valve.

IACVPIACVN

lAC VALVE 3P CONNECTOR

IACV N (ORNI·

10 1153 4

(To page 11-97)


Repair open in the wires betweenPCM and G101 (Iocated at thethermostat houslnql,

YESv

PG1 (BLK)

Intermittent failure, system is OKat this time. Check for poor connections or loose wires at C132(lAC valve) and PCM.

PCM CONNECTOR A 132P}

NO

STOPVALVESHAFT

BIMETAL

11-96

*: IACV N line

Substitute a known-good PCMand recheck. If symptom/indication goes away. replace the original PCM.

YES

Is there 16 - 28 fl?

Check the lAC valve:1. Turn the ignition switch OFF.2. Oisconnect the lAC valve 3P

connector.3. Measure resistance between

lAC valve 3P connector terminai No. 2 and terminais No. 1and 3 individually.

YES


Check the PCM input voltage:1. Turn the ignition switch OFF.2. Oisconnect PCM connector A

(32P) trom the PCM.3. Turn the ignition switch ON (II).4. Measure voltage between

body ground and PCM connector terminais A 14 andA13* individually.

NO

15 there more than 1.0 V?

Check for open in the wires (PGlines):Measure voltage between bodyground and PCM connector terminais A10 and A23 individually.

YES

Is OTC P1509 indicated?


dure.2. Turn the ignition switch ON (II).

- The Milhas been reported on.- OTCP1509 is stored.

The lAC Valve changes the amount of air bypassing the throttle body in response to a current signal from the PCM inorder to maintain the proper idle speed.

1 P15091 The scan tool indicates Diagnostic Trouble Code (DTC) P1509:A problem in the idle Air Control (lAC) valve circuit.

Id le Air Control (lAC) Valve (AIT)

Idle Control System

11-97

*: IACV N line


IACVP(BLK/BLU)

PCMCONNECTORA (32P)

r lAC VALVE 3P CONNECTOR (C132)Check for an open in the wire

~

(IGPline):1. Turn the ignition switch OFF.2. Disconnect the lAC valve 3P

connector.3. Turn the ignition switch ON (II).

IGP IYEl/Bl ~

4. At the wire harness, measurevoltage between lAC valve 3Pconnector terminal No. 2 and Wire side of female terminaisbody ground.

NO Repair open in the wire betweenIs there battery voltage? the lAC valve and PGM-FI main

relay.YES

Check for an open in the wires(IACV P, IACV N* lines):1. Turn the ignition switch OFF.2. Disconnect the PCM connector

A (32P).3. Check for continuity between

lAC valve 3P connector termi-nai No. 3 and PCM connectorterminal A14 (between lACvalve 3P connector terminalNo. 1 and PCM connector ter-minai A13)*.

NO Repair open in the wire betweenIs there continuity? the lAC valve and PCM (A 14,

A13*).YES

Check for a short in the wires Il(lACV P, IACVN* lines): IlCheck for continuity betweenbody ground and PCM connectorterminais A14 and A13* individu-ally.

YES Repair short in the wire betweenIs there continuity7 the lAC valve and PCM (A 14,

A13·).NO

1Substitute a known-good PCM and Ilrecheck. If symptom/indicationgoes away, replace the original IACV N (ORNPCM.

(From page 11-96)

- Repair short in the wirebetween the ECM/PCM (CG)and the No. 31 STARTER SIGNAL (7.5 Al fuse or the PGM·FI main relay.

- Replace the No. 31 STARTERSIGNAL (7.5 A) fuse.

NO

Repair open in the wire betweenthe ECM/PCM (CG)and the No. 31STARTER SIGNAL (7.5 A) fuse.

YES

Is the fuse OK?

Inspect the No. 31 STARTER SIGNAL (7.5 A) fuse in the under-dashfuse/relay box.

NO


v C (31PI(BRN/BLKII 1 STS (BLU/ORN)

l' 12 1 3 4 l 5 6 V 8 9 10 11 Il' 2 3 14 567 8 / 10

1'2/'3/ 14 '51'6 17 18 ~/ 20V 22 23 24 J L11 12 131'4 151/ 17 18VV/ V1//Vi V/ VV ~ l//1/ V //.: ~ / V

ECM/PCM CONNECTORS

A (32PI LG1

NOTE:• AIT: Transmission in [ill or ŒJ position.• MIT: in neutral

11-98

Starter switch signal is OK.

YES


Check for an open or short in thewire (STS line):Measure voltage between ECM/PCM connector terminais A9 andC6 with the ignition switch in thestart (III) position.

Inspection of Starter Switch Sig"nal.

This signaIs the ECM/PCMwhen the engine is cranking.

Starter Switch Signal

Idle Control System

11-99

(cont'd)

JUMPER WIRE

ACC(BLK/RED)

LGl (BRN/BLKI

Repair short in the wire betweenthe ECM/PCM (CS) and the AICpressure switch.

YES

ACS (BLU/RED)

Substitute a known-goodECM/PCM and recheck. If prescribed voltage is now available, replace the original ECM/PCM.See the air conditioner inspection (see section 22).

NO

15 there continuity?

Check for a short in the wire (ACSline):1. Turn the ignition switch OFF.2. Disconnect the ECM/PCM con

nector C (31Pl.3. Check for continuity between

body ground and ECM/PCMconnector terminal C5.

NO


C (31PIECM/PCM CONNECTORS

A (32PI

(To page 11-100)

Check for an open in the wire(ACC line):1. Turn the ignition switch OFF.2. Reconnect the A/C pressure

switch 2P connector.3. Turn the ignition switch ON (II).4. Momentarily connect ECM/

PCM connector terminais Agand A17 with a jumper wireseveral times.

YES


Check for a short in the wire(ACS tine):1. Turn the ignition switch OFF.2. Disconnect the A/C pressure

switch 2P connector (see section 22).

3. Turn the ignition switch ON (II).4. Measure voltage between

ECM/PCM connector terminais C5 and Ag.

Inspection of Air ConditioningSignal.

This signais the ECM/PCM when there is a demand for cooling from the air conditioning system.

Air Conditioning Signal

Repair open in the wire betweenthe ECM/P.CM (C5) and the A/Cswitch.

NO


ECM/PCM CONNECTORS

C (31P)

See air conditioner inspection(see section 22).

ACC (BLK/RED)Wire side of femaleterminais

JUMPERWIRE

UNDER-HOOD FUSE/RElAYBOX 9P CONNECTOR (C352)

Substitute a known-goodECM/PCM and recheck. Ifsymptom/indication goesaway. replace the originalECM/PCM.

- See the air conditioner inspection (see section 22).

YES

Is there less than 1.0 V?

Check for an open in the wire(ACS line):Measure voltage between ECMIPCM connector terminais A9 andC5.

A (32PI

LG1(BRN/BLK),..----_,

Repaîr open in the wire betweenthe ECM/PCM (A17) and theunder-hood fuse/relay box 9Pconnector (C352).

YES

Is there a clicking noise fromthe AlC compressor clutch?

Check for an open in the wire(ACC line):Momentarily connect under-hoodfuse/relay box 9P connector terminai No. 5 ta body ground witha jumper wire several times.

11-100

Air conditioning signal is OK.

YES

Ooes the Ale operate?NO

Check the A/C operation:1. Start the engine.2. Turn the blower switch ON.3. Turn the Ale switch ON.

YES

NOIs there a clicking noise fromthe Ale compressor clutch?

(From page 11-99)

Air Conditioning Signal (cont'd)

Idle Control System

11-101

Repair short in the wire betweenthe ECM/PCM (C17)and the ALT.


NO


Ooes the voltage decrease when YES !

1headlights and rear detogger are

1ALT FRsignal is OK.

turned on?

1

ALT 3P CONNECTOR (C103)NO

Check for an open in the wire (ALTF line):1. Turn the ignition switch OFF.2. Oisconnect the 3P connector ALT F

from the ALT. (WHT/RED)3. Turn the ignition switch ON (11).4. Measure voltage between the

ALT 3P connector terminalNo. 1 and body ground. Wire side of female terminaIs

1

1

1

NO Repair open wire between theIs there approx. 5 V?1

ECM/PCM (C17) and the ALT.

1 YES

See the ALT inspection (see sec-tion 4).

Check for a short in the wire (ALTFline):1. Turn the ignition switch OFF.2. Oisconnect the negative bat

tery cable from the battery.3. Oisconnect the ECM/PCM con

nector C (31P).4. Check for continuity between

body ground and ECM/PCMconnector terminal C17.


,/110

NO

C (31P)ECM/PCM CONNECTORS

A (32P)

Check the operation of the ALT:1. Turn the ignition switch OFF.2. Reconnect the AL T 3P con

nector to the ALT.3. Start the engine. Hold the

engine at 3,000 rpm with noload (AIT in llil or ~ position,MIT in neutral) until the radiator tan comes on, th en let itidle.

4. Measure voltage betweenECM/PCM connector terminaisC17and A9.

YES


Check for a short in the wire (ALTFline):1. Oisconnect the 3P connector

trom the ALT.2. Turn the ignition switch ON (II).3. Measure voltage between

ECM/PCM connector terminais C17 and A9.

Inspection of ALT FRSignal.

This signais the ECM/PCM when the Alternator (ALTl is charging.

Alternator (ALT) FR Signal

11-102

Brake switch signal is OK.

YES


Wire side of female terminaisRepair open in the wire betweenthe ECM/PCM (05) and the brakeswitch.

NO

1215

A 132PI

ECM/PCM CONNECTORS

- Repair open in the wirebetween the brake switch andthe HORN STOP (15 A) fuse.

- Inspect the brake switch (seesection 19).

Check for an open in the wire(BKSW li ne):1. Depress the brake pedal.2. Measure voltage between

ECM/PCM connector terminaisA9 and 05 with the brake pedaldepressed.

LGl 0 (16P) BKSW(BRN/r V r--------......,l (GRN!BLKI WHTI~~~----~--~ ~

r 1 1 2 3 4 5 6 V 8 9 10 11 1 1 2 3 4

'-------r---------' r 12113 14 15 16 17 18l/ 20L 22 23 24 1 6 7 8 ~/ 10 11

I/V/ /I//'~ L::::: 13 14V ~

YES

Is the fuse OK?

- Repair short in the wirebetween the brake switch andthe HORN STOP (15 A) fuse.

- Replace the HORN STOP (15 A)fuse.

NO

YES

00 the brake lights come on?Inspect the HORN STOP (15 A)fuse in the under-hood fuse/relaybox.

NO

Oepress the brake pedal.

NO

Inspect the brake switch (see section 19).

YESAre the brake lights on withoutdepressing the brake pedal?

Inspection of Brake Switch Signal. J

This signais the ECM/PCM when the brake pedal is depressed.

Brake Switch Signal

Idle Control System

11-103

(cont'd)

NOTE: If the id le speed is not within specification,see Symptom Chart on page 11-30.

Idle speed should be:810 ± 50 rpm

10. Turn the headlights off. Idle the engine for oneminute with heater fan switch at HI and air conditioneron, then check the idle speed.


9. Idle the engine for one minute with headlights (Low)ON, and check the idle speed.


NOTE: Pull the parking brake lever up. Start theengine, then check that the headlights are off.

8. Restart and id le the engine with no-Ioad conditionsfor one minute, then check the idle speed.

7. Reconnect the 2P connector on the lAC valve, thendo the ECM reset procedure.

6. Turn the ignition switch OFF.

NOTE: After adjusting the id le speed in this step,recheck the ignition timing (see section 4).If it is out of spec, go back to step 4.

IOLEAOJUSTINGSCREW

Adjust the id le speed, if necessary, by removing thecap and turning the idle adjusting screw.


5. Check idling in no-Ioad conditions: headlights, blowerfan, rear defogger, radiator fan, and air conditionerare not operating.

4. If the engine stalls, restart the engine with the accelerator pedal slightly depressed. Stabilize the rpm at1,000, then slowly release the pedal until the engineidles.

3. Disconnect the lAC valve connector.

2. Connect a tachometer.

1. Start the engine. Hold the engine at 3,000 rpm withno load (transmission in neutral) until the radiatorfan comes on, then let it idle.

NOTE:• Before setting the idle speed, check the following

items:- The MIL has not been reported on.- Ignition timing- Spark plugs- Air cleaner- PCVsystem

• Pull the parking brake lever up. Start the engine, thencheck that the headlights are off.

M/T:

Inspection/ Adjustment

Id le Speed Setting

NOTE:• Do not turn the idle adjusting screw when the air

conditioner is on.• If the id le speed is not within specification, see

Symptom Chart on page 11-30.

Idle speed should be:810 ± 50 rpm (in [ffi or ŒJ position)

6. Idle the engine for one minute with heater fanswitch at HI and air conditioner on, then check theidle speed.

NOTE: Do not turn the idle adjusting screw morethan 1/2-turn without checking the idle speed.

5. After turning the id le adjusting screw 1/2-turn,check the idle speed again. If it is out of spec, turnthe idle adjusting screw 1/2-turn again.

IOLEAOJUSTINGSCREW

11-104

4. Adjust the idle speed, if necessary, by removing thecap and turning the id le adjusting screw 1/2-turnclockwise or counterclockwise.

Idle speed should be:750 ± 50 rpm (in [ffi or [Ë] position)

3. Check the idle speed with no-Ioad conditions: headlights, blower fan, rear defogger, radiator fan, andair conditioner are not operating.

2. Start the engine. Hold the engine at 3,000 rpm withno load (transmission in [ffi or ŒJ position) until theradiator fan comes on, then let it idle.


NOTE:• Leave the lAC valve connected.• Before setting the id le speed, check the following

items:- The MIL has not been reported on.- Ignition timing- Spark plugs- Air c1eaner- PCVsystem

Adjust the idle speed using a Honda PGM Tester if possible. If not, use the following procedure:

AIT:

Id le Speed Setting (cont'd)

Idle Control System

11-105

(cont'd)

22N·m(2.2 kgf·m, 16 Ibf.ft)

37 N·m(3.8 kgf·m,271bUt)

33N·m(3.4 kgf·m, 25 IbHt)

NOTE: Check fuel system lines, hoses, connections, fuel filter and other components for damage, leaks and deterioration,and replace if necessary.

Fuel Unes

Fuel Supply System

11-106

10 - 15mm(0.39 - 0.59 in)

~ ~::::~~Iii,0iIII ~,

Clamp in the middle"-- .....!~

BA

Clamp in the middle

BASEGASKETReplace.

Replace.

FUELPUMP

FUELTANK -----+-!,

FUel GAUGESENDING UNIT

t!

~t!

~~Ch ~

EVAPORATIVE c>EMISSION (EVAPI ~CONTROL ~ ...~CANISTER /

~

FUEL ~FILTER

B

V

To FUELPRESSUREREGULATOR

FUel TUBEIaUICK-CONNECTFITTINGS

NOTE: Check ail hose clamps and retighten if necessary.

Fuel Unes (cont'd)

Fuel Supply System

11-107

(cont'd)

PIPE

RETAINER

CONTACT AREA

/

4. Check the contact area of the pipe for dirt and damage.• If the surface is dirty, clean it.• If the surface is rusty or damaged, replace the

fuel pump or fuel feed pipe.

NOTE:• Be careful not to damage the pipe or other parts.

Do not use tools.• If the connector does not move, keep the retainer

tabs pressed down, and alternately pull and pushthe connector until it comes off easily.

• Do not remove the retainer from the pipe; onceremoved, the retainer must be replaced with anewone.

3. Hold the connector with one hand and press downthe retainer tabs with the other hand, then pull theconnector off.

2. Check the fuel quick-connect fittings for dirt, andclean if necessary.

1. Relieve fuel pressu re (see page 11-110).

'%:d;!.l@; Do not smoke while working on the fuelsystem. Keep open flames away from your work area.

Disconnection

ACCESS PANel

A disconnected quick-connect fitting can be reconnected,but the retainer on the mating pipe cannot be reusedonce it has been removed from the pipe. Replace theretainer when• Replacing the fuel pump.• Replacing the fuel feed pipe.• It has been removed from the pipe.• It is damaged.

• When connecting or disconnecting the fuel tube/quick-connect fittings assembly, be careful not tobend or twist it excessively. Replace it if damaged.

• The fuel tube/quick-connect fittings assembly is notacid-proof; do not touch it with a shop towel whichwas used for wiping battery electrolyte. Replace thefuel tube/quick-connect fittings assembly if it cameinto contact with electrolyte or something similar.

• The fuel tube/quick-connect fittings assembly is notheat-resistant; be careful not to damage it duringwelding or other heat-generating procedures.

The fuel tube/quick-connect fittings assembly connectsthe in-tank fuel pump with the fuel feed pipe. For removing or installing the fuel pump and fuel tank, it is necessary to disconnect or connect the quick-connect fittings.Pay attention to following:

'%:np@; Do not smoke while working on the fuelsystem. Keep open flames away from your work area.

Precautions

Fuel Tube/Quick-Connect Fittings

the connector.)(lnsert intoNew RETAINER

2. Insert a new retainer into the connector if the retaineris damaged, or after• replacing the fuel pump.• replacing the fuel feed pipe.• removing the retainer from the pipe.

CONTACT AREA

1 PIPE

~

Check the pipe contact area for dirt and damage,and clean if necessary.

1.

'WhpiidN Do not smoke while working on the fuelsystem. Keep open flames away from your work area.

Connection

11-108

NOTE: The retainer cannot be reused once it hasbeen removed from the pipe.Replace the retainer when- replacing the fuel pump.- replacing the fuel feed pipe.- it has been removed from the pipe.- it is damaged.

5. To prevent damage and keep out foreign matter,cover the disconnected connector and pipe endwith plastic bags.

Fuel Tube/Quick-Connect Fittings (cont'd)

Fuel Supply System

11-109

5. Reconnect the battery negative cable, and turn theignition switch ON (II). The fuel pump will run forabout two seconds, and fuel pressure will rise.Repeat two or three times, and check that there isno leakage in the fuel supply system.

RETAINER PIPE

4. Make sure the connection is secure and the pawlsare firmly locked into place; check visually and bypulling the connector.

Reconnection to existing retainer:

_ ~ PIPE

C" /.~

RETAINER

Connection with new retainer:

NOTE: If it is hard to connect. put a small amountof new engine oil on the pipe end.

3. Align the quick-connect fittings with the pipe, andalign the retainer locking pawls with the connectorgrooves. Then press the quick-connect fittings ontothe pipe until both retainer pawls lock with a clicking sound.

New FUel TUBEIaUICK-CONNECTFITTING ASSEMBL y

With thetabs pulledapart, remove anddiscard the retainer.

Before connecting a new fuel tube/quick-connect fittingassembly, remove the old retainer from the mating pipe.

• If the fuel pressure is higher than specified.inspect for:- Pinched or clogged fuel return hose or line.- Faulty fuel pressure regulator (see page 11-

113).• If the fuel pressure is lower than specified. inspect

for:- Clogged fuel filter.- Faulty fuel pressure regulator (see page 11-

113).- Fuel line leakage.

If the fuel pressure is not as specified, first check thefuel pump (see page 11-115). If the fuel pump is OK,check the following:

Pressure should be:200 - 250 kPa (2.0 - 2.5 kgf/cm2, 28 - 36 psi)

4. Reconnect vacuum hose to the fuel pressure regulator.

Pressure should be:260 - 310 kPa (2.7 - 3.2 kgf/cm2, 38 - 46 psi)

3. Start the engine. Measure the fuel pressure with theengine idling and the vacuum hose of the fuel pressure regulator disconnected from the fuel pressureregulator and pinched. If the engine will not start,turn the ignition switch ON (II), wait for two seconds, turn it off, then back on again and read thefuel pressure.

FUEL PRESSUREADAPTER BOlT, 12 mm(90008 - PD6 - 0101

FUELPRESSUREGAUGE07406 - 0040001

CLAMP

2. Remove the 12 mm banjo boIt from the fuel filterwhile holding the fuel filter with another wrench.Attach the fuel pressure adapter boit, 12 mm, andspecial tool.

1. Relieve fuel pressure.

Inspection

11-110

NOTE: Replace the washers whenever the 12 mmbanjo boit is loosened or removed.

12 mm BANJOBOlT33 N'm (3.4 kgf·m.251bf.ftl

6. Slowly loosen the 12 mm banjo boIt one completeturn.

5. Place a rag or shop towel over the 12 mm banjo boit.

4. Use a box end wrench on the 12 mm banjo boit atthe fuel filter while holding the fuel filter with another wrench.

3. Remove the fuel fil! cap.

2. Disconnect the battery negative cable from the battery negative terminal.

1. Write down the frequencies for the radio's presetbuttons.

'8W';@ibN• Do not smoke while working on the fuel system.

Keep open flames or sparks away from your workarea.

• Be sure to relieve fuel pressure while the ignitionswitch is off.

RelievingBefore disconnecting fuel pipes or hoses, release pressure from the system by loosening the 12 mm banjoboit on top of the fuel filter.

Fuel Pressure

The fuel supply system consists of a fuel tank, in-tankhigh pressure fuel pump, PGM-FI main relay, fuel filter,fuel pressure regulator, fuel injectors, and fuel deliveryand return lines. This system delivers pressure-regulated fuel to the fuel injectors and cuts the fuel deliverywhen the engine is not running.

System Description

Fuel Supply System

11-111

(cont'd)

7. Siide new cushion rings onto the fuel injectors.8. Coat new O-rings with clean engine oil, and put them on the fuel injectors.9. Insert the fuel injectors into the fuel rail first.10. Coat new seal rings with clean engine oil, and press them into the intake manifold.

EVAPPURGE CONTROLSOLENOID VALVE

12N·m(1.2 kgf.m,8.7Ibf·ft)

4. Remove the retainer nuts on the fuel rail.5. Disconnect the fuel rail.6. Remove the fuel injectors from the intake manifold.

NOTE: Place a rag or shop towel over the hoses before disconnecting them.

1. Relieve the fuel pressure (see page 11-110).2. Disconnect the connectors from the fuel injectors.3. Disconnect the vacuum hoses and fuel return hose from the fuel pressure regulator. Disconnect the vacuum hoses

and 2P connector from the EVAP purge control solenoid valve.

'%id;i.'iidN Do not smoke wh en working on the fuel system. Keep open flames away from your work area.

Replacement

Fuel Injectors

11-112

15. Turn the ignition switch ON (II), but do not operate the starter. After the fuel pump runs for approximately two seconds,the fuel pressure in the fuel line rises. Repeat this two or three times, then check whether there is any fuel leakage.

14. Install the connectors on the fuel injectors.

13. Connect the vacuum hoses and fuel return hose to the fuel pressure regulator. Connect the vacuum hoses and 2Pconnector to the EVAP purge control solenoid valve.

12. Install and tighten the retainer nuts.

CAUTION: To prevent damage to the O-rings, install the fuel injectors in the fuel rail first, then install them in theintake manifold.

11. Install the fuel injectors and fuel rail assembly in the intake manifold.

Fuel ln je ct ors (cont' d)

Fuel Supply System

11-113

NOTE:• Replace the O-ring.• When assembling the fuel pressure regulator,

apply clean engine oil to the O-ring and assemble it into its proper position, taking care not todamage the O-ring.

12 N'm(1.2 kgf·m,8.7Ibf·ft)

O-RINGReplace.

FUELPRESSUREREGULATOR

2. Disconnect the vacuum hose and fuel return hose.

3. Remove the two 6 mm retainer bolts.

1. Place a shop towel under the fuel pressure regulator,then relieve fuel pressure (see page 11-110).

'Mi.Wii.i[; Do not smoke while working on fuel system. Keep open flame away from your work area.

Replacement

If the fuel pressure did not rise, replace the fuelpressure regulator.

3. Check that the fuel pressure rises when the vacuumhose from the fuel pressure regulator is disconnectedagain.

2. Reconnect the vacuum hose to the fuel pressureregulator.

FUEL PRESSUREREGULATOR

CLAMPFUELPRESSUREGAUGE07406 - 0040001

Pressure should be:260 - 310 kPa (2.7 - 3.2 kgf/cm2, 38 - 46 psi)(with the fuel pressure regulator vacuum hosedisconnected and pinched)

1. Attach the special tool and the fuel pressure adapterboit, 12 mm, (90008-PD6-010) on the fuel filter (seepage 11-110).

'Mhl.'lIb; Do not smoke during the test. Keep openflames away from your work area.

Testing

Fuel Pressure Regulator

12mmBANJOBOlT33N·m13.4 kgf·m,251bHt)

11-114

NOTE: Clean the tlared joint of high pressure hosesthoroughly before reconnecting them.

5. When assembling, use new washers as shown.

4. Remove the fuel filter clamp and fuel tilter.

3. Remove the 12 mm banjo boit and the fuel feedpipe from the fuel filter, while supporting it with theanother wrench, as shown.

2. Relieve fuel pressure (see page 11-110).

1. Place a shop towel under and around the fuel filter.

The fuel filter should be replaced whenever the fuelpressure drops below the specified value [260 - 310 kPa(2.7 - 3.2 kgf/cm2, 38 - 46 psi) with the fuel pressure regulator vacuum hose disconnected and pinchedJ aftermaking sure that the fuel pump and the fuel pressureregulator are OK.

'MhWW;• Do not smoke while working on fuel system. Keep

open flame away from your work area.• While replacing the fuel filter, be careful to keep a

safe distance between battery terminais and anytools.

Replacement

Fuel Filter

Fuel Supply System

11-115

ACCESS PANel

6. Install parts in the reverse order of removal.

5. Remove the fuel pump from the fuel tank.

4. Remove the fuel pump mounting nuts.

.3. Disconnect the 2P connector from the fuel pump.

2. Remove the access panel from the floor.

1. Remove the seat cushion (see section 20).

'Mhpiih; Do not smoke while working on fuel system. Keep open flames away from your work area.

Replacement

• If battery voltage is available, check the fuel pump·ground. If the ground is OK, replace the fuel pump.

• If there is no voltage, check the wire harness (seepage 11-119).


FUEL PUMP(VEl/GRN)

FUEL PUMP2P CONNECTOR (CS68)

5. Check that battery voltage is available between thefuel pump 2P connector terminal No. 2 and bodyground when the ignition switch is turned ON (II).


JUMPER WIRE

FUel PUMP(VellGRN)

PGM-FI MAIN RELAY 7P CONNECTOR (C443)

4. Connect the PGM-FI main relay 7P connector terminai No. 4 and No. 5 with a jumper wire.

CAUTION: Be sure to turn the ignition switch OFFbefore disconnecting the wires.

3. Disconnect the fuel pump 2P connector.

2. Remove the access panel from the tloor.

1. Remove the seat cushion (see section 20).

If you suspect a problem with the fuel pump, check that thefuel pump actually runs; when it is ON (li), you will hearsome noise if you hold your ear to the fuel fill port with thefuel fill cap removed. The fuel pump should run for twoseconds when ignition switch is first turned ON (II). If thefuel pump does not make noise, check it as follows:

,%it.i;wm; Do not smoke during the test. Keep openflame away from your work area.

Testing

Fuel Pump

Replace.

5.9N·m

/

(0.6 kgf·m.4.3Ihf·ft)

~FUEL GAUGESENOING UNIT

9. Remove the fuel gauge sanding unit as shown.

• If the pointer of the fuel gauge does not move atail, replace the gauge.

• If the gauge is OK, inspect the fuel gauge sending unit.

NOTE: The fuel gauge is a bobbin (cross-coil) type,hence the fuel level is continuously indicated evenwhen the ignition switch is OFF, and the pointermoves more slowly than that of a bimetal type.

CAUTION: Turn the ignition switch OFF before thepointer reaches "F" on the gauge dial, Failure to doso may damage the fuel gauge.

8. Check that the pointer of the fuel gauge starts moving toward the "F" mark.

11-116

7. Attach a jumper wire between the No. 1 and No. 2terminais, then turn the ignition switch ON (II).


• If the voltage is as specified, go to step 5.• If the voltage is not as specified, check for:

- an open in the YEL/BLK or BLK wire.- poor ground (G552).

5. Connect the voltmeter positive probe to the No. 2terminal and the negative probe to the No. 1 terminai, then turn the ignition switch ON (II).There should be between 5 and 8 V.

4. Disconnect the 3P connector from the fuel gaugesending unit.


FUEL GAUGESENDING UNIT3P CONNECTOR(C569)

ACCESS PANEL

3. Remove the access panel from the floor.

2. Remove the rear seat cushion (see section 20).

1. Check the No. 25 CLOCK METER (7.5 A) fuse in theunder-dash fuse/relay box before testing.

'MhhiildN Do not smoke while working on the fuelsystem. Keep open flame away from your work area.

Testing

Fuel Gauge/Fuel Gauge Sending Unit

Fuel Supply System

11-117

8. Add 4 l' of fuel (1.1 U.S. Gal. 0.9 Imp. Gai). The lightshould go off within five minutes.


• if the light comes on, check the sending unit.• If the light does not come on, check for:

- an open in the GRN/YEL wire between thefuel unit and fuel gauge assembly.

- blown bulb.- poor ground (G552).

FUEL GAUGE SENDING UNIT 3P CONNECTOR (C569)IBlKe JUMPER WIRE

(GRN/YEL)

7. Connect the No. 1 and No. 3 terminais with a jumperwire.

6. Remove the access panel from the floor, and disconnect the 3P connector from the fuel gauge sendingunit.

• If the light comes on within four minutes, go tostep 8.

• If the light does not come on within four minutes, go to step 5.

5. Remove the rear seat cushion (see section 20).

LOW FUEL INDICATOR LlGHT

4. Add less than 8.5 e (2.2 U.S. Gal. 1.8 Imp. Gal) of fuel,and turn the ignition switch ON (II). The low fuel indicator light should come on within five minutes.

Indicator Light Testing

1. Check the No. 25 CLOCK METER (7.5 A) fuse in theunder-dash fuse/relay box, and the gauge relaybefore testing.

2. Park the vehicle on level ground.

'MlWIlbN Do not smoke while working on thefuel system. Keep open flame away from the workarea. Drain fuel only into an approved container.

3. Drain the fuel into an approved container. Theninstall the drain boit with a new washer.

Low Fuel Indicator System

If the readings are beyond the range, replace the fuelgauge sending unit.

Float Position E 1/2 F

Resistancem) 105 - 108 29.5 - 35.5 3.5 - 5

10. Measure the resistance between the No. 1 and No. 2terminais at E (EMPTY), 1/2 (HALF FULL) and F(FULL) by moving the float.

To ST. SWITCH 2 ~ , 1

1 :~I.1 1

To ECM/PCM (A161 1 __ LO __ ~_J_ 4 To FUEL PUMP

3. Attach the battery positive terminal to the No. 5 terminai and the battery negative terminal to the No. 3terminal of the PGM-FI main relay. Then check thatthere is continuity between the No. 7 terminal andNo. 6 terminal of the PGM-FI main relay.• If there is continuity, go on to step 4.• If there is no continuity, replace the PGM-FI main

relay and retest.4. Attach the battery positive terminal to the No. 6 ter

minai and the battery negative terminal to the No. 1terminal of the PGM-H main relay. Then check thatthere is continuity between the No. 5 terminal andNo. 4 terminal of the PGM-FI main relay.• If there is continuity, the PGM-FImain relay is OK.

If the fuel pump still does not work, go to HarnessTesting on the next page.

• If there is no continuity, replace the PGM-FI mainrelay and retest.

To GROUND 3 ~-+--~V\A""~ 6 To ECM/PCM

(All, A241

To IGN. 1

1. Remove the PGM-FI main relay.2. Attach the battery positive terminal to the No. 2 ter

minai and the battery negative terminal to the No. 1terminal of the PGM-FI main relay. Then check forcontinuity between the No. 5 terminal and No. 4 terminai of the PGM-FI main relay.• If there is continuity, go on to step 3.• If there is no continuity, replace the PGM-FI main

relay and retest. No. 2No. 1

NOTE:• If the engine starts and continues to run, the PGM-FI

main relay is OK.• Use the terminal numbers below;

ignore the terminal numbers molded into the relay.

Relay Testing

11-118

FUEL PUMP

PGM-FIMAIN RELAY

DescriptionThe PGM-FI main relay actually contains two individualrelays. This relay is located at the right side of the cowl.One relay is energized whenever the ignition is on whichsupplies the battery voltage to the ECM/PCM, power tothe fuel inje ctors, and power for the second relay. Thesecond relay is energized for two seconds when the ignition is switched ON (II), and when the engine is running,to supply power to the fuel pump.

PGM-FI Main Relay

Fuel Supply System

11-119

(cont'dl


PGM-FI MAIN RELAV 7P CONNECTOR (C443)

(Ta page 11-120)

- Engine will not start.- Inspection of PGM-FI main

relav and relav harness.

1

Check for an open in the wire(GND line):1. Turn the ignition switch OFF.2. Disconnect the PGM-FI main

relay 7P connector.3. Check for conti nuit y between

the PGM·FI main relay 7P con-nectar terminal No. 3 and bodyground.

1NO Repair open in the wire betweenIs there continuitv?

the PGM-FI main relav and G101.

J YES

Check for an open or short in thewire (BAT line):Measure voltage between thePGM-FI main relay 7P connectorterminal No. 7 and body ground.

1

- Repair open or short in thewire between the PGM-FImain

NO relav and the FI E/M (15 A)Is there battery voltage? fuse.

1 YES- Replace the FI E/M (15 A) fuse

in the under-hood fuse/relavbox.

Check for an open or short in thewire (lG1 line):1. Turn the ignition switch ON (II).2. Measure the voltage between

the PGM-FI main relay 7P con-nector terminal No. 5 and bodyground.

1


NO relav and the No. 13 FUElIs there battery voltage? PUMP SRSUNIT (15A) fuse.

1 YES- Replace the No. 13 FUEL

PUMP SRS UNIT (15 A) fuse inthe under-dash fuse/relav box.

Check for an open or short in thewire (STS line):1. Turn the ignition switch ta the

START (III) position.NOTE:• MIT: Clutch pedal must bedepressed .

• AIT: Transmission in I]J orœJ position.

2. Measure the voltage betweenthe PGM-FI main relay 7Pconnector terminal No. 2 andbody ground.

1

Troubleshooting

IGP2IYEL/BlKI


FLR(GRN/YEL) ECM/PCM CONNECTOR A (32PI

FLR(GRN/YEL)

PGM-FI MAIN RELAY 7P CONNECTOR (C443)

11-120

1


NO relay and the No. 31 STARTERIs there battery voltage? SIGNAL (7.5A) fuse.

- Replace the No. 31 STARTERYES SIGNAL (7.5 A) fuse in the

under-dash fuse/relav box.

Check for an open in the wire(FLR line):1. Turn the ignition switch OFF.2. Disconnect the ECM/PCM con-

nector A (32P).3. Check for continuity between

the PGM-FI main relay 7P con-nector terminal No. 1 and ECMIPCM connector terminal A16.

Repair open in the wire betweenNOIs there continuity? the ECM/PCM (A 16) and the

PGM-FI main relay.YES

Check for an open in the wires(lGP1, IGP2 lines):1. Reconnect the ECM/PCM con-

nector A (32P).2. Reconnect the PGM-FI main

relay connector.3. Turn the ignition switch ON (11).4. Measure voltage between

ECM/PCM connector terminaisA 11 and A 10. and betweenA24 and A10.

- Repair open in the wire bet-NO ween the ECM/PCM (A11, A24)Is there battery voltage? and the PGM-FImain relay.

YES- Replace the PGM-FImain relay.

Check for an open in the ECM/PCM:1. Turn the ignition switch OFF.2. Measure voltage between

ECM/PCM connector terminaisA'6 and A 10 when the ignitionswitch is first turned ON (II) fortwo seconds.

Substitute a known-good ECM/NO PCM and recheck. If prescribedIs there '.0 V or less? voltage is now available, replace

YESthe original ECM/PCM.

Check the PGM-FI main relay(see page 11-118).

(From page 1'-119)

PGM-FI Main Relay (cont'd)

Fuel Supply System

11-121

DRAIN BOLT49 N·m (5.0 kgf·m, 36 Ibf.ftl

Replace.FUEL HOSEJOINT PROTECTOR

BASE GASKETReplace.

BASE GASKETReplace.

A-

.

~ ~EVAPTWOWAYVALVECOVER

1. Relieve the fuel pressure (see page 11-110).2. Remove the seat cushion (see section 20).3. Remove the access panel from the floor.4. Disconnect the 2P (C568) and 3P (C569) connectors.5. Disconnect the hose and quick-connect fittings (see pages 11-106, 107).6. Jack up the vehicle, and support it with jackstands.7. Remove the EVAP two way valve cover and the fuel hose joint protector.8. Remove the drain boit, and drain the fuel into an approved container.9. Disconnect the hoses (see page 11-106).

CAUTION:• When disconnecting the hoses, slide back the clamps, then twist hoses as you pull, to avoid damaging them.• Clean the flared joint of high pressure hoses thoroughly before reconnecting them.

10. Place a jack, or other support, under the tank.11. Remove the strap nuts, and let the straps fall free.12. Remove the fuel tank.

NOTE: The tank may stick on the undercoat applied to its mou nt. To remove, carefully pry it off the mount.13. Install the drain boit with a new washer, then coat the drain boit with Noxrust 1248, Allow the Noxrust dry for 20 min

utes.14. Install the remaining parts in the reverse order of removal.

'%If.i;WW; Do not smoke while working on fuel system. Keep open flame away from your work area.

Replacement

Fuel Tank

11-122

AIT:

ENGINECOOLANT

,/1.._-1VARIOUS\~ SENSORS

1 LOlKI! BLU--~

_ORN~ECMI~ PCM

1

BLKI,..---- BLU

'1 B~K-è-

INTAKEMANIFOLD

\

VELl AI From PGM·FI,--------_._---- BLK --------- ......MAIN RELAV

MIT:

The system supplies air for ail engine needs. It consists of the intake air pipe, Air Cleaner (ACL), intake air duct, ThrottleBody (TB), Idle Air Control (lAC) Valve and intake manifold. A resonator in the intake air pipe provides additional silencingas air is drawn into the system.

System Description

Intake Air System

11-123

9.8N·m(1.0 kgf·m,7.2Ibf.ft)

BRACKET

no clearance.

2. Start the engine. Hold the engine at 3,000 rpm withno load (Arr in lliJ or œJ position, Mrr in neutral) untilthe radiator fan comes on, then let it idle.

3. Hold the cable sheath, removing ail slack from thecable.

4. Set the locknut on the cable bracket. Adjust theadjusting nut so that its free play is a mm.

5. Remove the cable sheath from the throttle bracket,reset the adjusting nut and tighten the Jocknut.

ADJUSTING NUT

!

INNER CABLE1

THROTTlE lINK

lOCKNUTCABLEBRAKET

1. Open the throttle valve fully, then install the throttlecable in the throttle linkage, and install the cablehousing in the cable bracket.

Installation

4. If deflection is not within specs, loosen the locknut,turn the adjusting nut until the deflection is as specified, then retighten the locknut.

5. With the cable properly adjusted, check the throttlevalve to be sure it opens fully when vou push theaccelerator pedal to the floor. Also check the throttle valve to be sure it returns to the id le positionwhenever vou release the accelerator pedal.

ADJUSTINGNUT

DEFlECTION10 -12 mm(0.39 - 0.47 in)

1. Start the engine. Hold the engine at 3,000 rpm withno load (AIT in lliJ or œJ position, Mrr in neutral) untilthe radiator fan comes on, then let it idle.

2. Check that the throttle cable operates smoothly withno binding or sticking. Repair as necessary.

3. Check cable free play at the throttle linkage. Cabledeflection should be 10- 12 mm (0.39 - 0.47 in.).

CABLEBRACKET

Inspectionl Adjustment

Throttle Cable

ACL ELEMENTNormal conditions:Replace air cleaner element every30,000 miles (48,000 km) or 24months whichever cames first.ACLHOUSING

COVER

NOTE: Do not clean the ACL element by blowing it withcompressed air.

Air Cleaner (ACL)

Replace the throttle body if there is excessive play in thethrottle valve shaft or if the shaft is binding or sticking.

THROTTLE STOP SCREW(Do not adjust.l

no clearance.

If there are any abnormalities, check for:• Excessive wear or play in the throttle valve shaft.• Sticky or binding throttle lever at the fully closed

position.• Clear.ance between throttle stop screw and throt

tle lever at the fully closed position.

1. Check that the throttle cable operates smoothlywithout binding or sticking.

Inspection

11-124

IOLE AOJUSTINGSCREW

DescriptionThe throttle body is a single-barrel side-draft type. Thelower portion of the throttle valve is heated by enginecoolant from the cylinder head. The idle adjusting screwwhich regulates the bypass air is located on the top ofthe throttle body.

Throttle Body

Intake Air System

11-125

O-RING

.. .

/ IOLE AOJUSTING1. SCREW

~ /' CAP»->

TP SENSOR

O-RINGReplace.

O-RINGReplace.

MAP SENSO~ e "-48Troubleshootmg, pag

21 N'm{ti.21 kgf·m. 1.5 lbf-ft) ~

Disassembly

CAUTION: d' ust the throttle stop serew. ble (see page 11-1231.• Do not a J d' st the throttle caAfter reassembly, a JU ble• . ot remova .• The TP sensor IS n

THROTTLECABLE

GASKETReplace.

22N·m(2.2 kgf.m,~16Ibf·ft) ~

Removal

TWC

FlASHLlGHT

InspectionIf excessive exhaust system back-pressure is suspected,remove the TWC from the car and using a flashlight,make a visual check for plugging, melting or cracking ofthe catalyst. Replace the TWC if any of the visible area isdamaged or plugged.

THREE WAVCATALVSTS

FRONTOF~VEHICLE

HOUSING

DescriptionThe Three Way Catalytic Converter (TWC) is used toconvert hydrocarbons (HC), carbon monoxide (CO), andoxides of nitrogen (NOx) in the exhaust gas to carbondioxide (C02), dinitrogen (N2)and water vapor.

Three Way Catalytic Converter(TWC)

11-126

CO meter should indicate 0.1% maximum.

NOTE: Pull the parking brake lever up. Start theengine, th en check that the headlights are off.

5. Check idle CO with the headlights, heater blower,rear window defogger, cooling fan, and air conditioner off.

4. Warm up and calibrate the CO meter according to themeter manufacturer's instructions.

3. Check and, if necessary, adjust the idle speed (seepage 11-103).


1. Start the engine. Hold the engine at 3,000 rprn withno load (NT in [ffi or ŒJ position, MfT in neutral) untilthe radiator fan comes on, then let it idle.

'8',II.WiihN Do not smoke during this procedure. Keepany open tlame away trom your work area.

Inspection

Tailpipe Emission

The emission control system includes a Three Way CataIytic Converter (TWC), Positive Crankcase Ventilation (PCV)system and Evaporative Emission (EVAP)Control system.

System Description

Emission Control System

11-127

1

Intermittent failure, system is OKat this time.

NO j

1

Check the TWC (see page 11-127).If necessary, replace the TWC.

1 YES

Is DTC P0420 indicated?

1


dure.2. Start the engine. Hold the

engine at 3,000 rpm with noload (Arr in lliJ or [f] position,Mrr in neutral) until the radiator fan cornes on.


4. Test-drive 40 - 55 mph (64 -88 km/hl for approx. two minutes. Then decelerate for atleast 3 seconds with the throttle completely closed. Thenreduce the vehicle speed ta35 mph (56 km/hl, and try tahold i t until the readinesscode cames on.

l- The Milhas been reported on.

OTCP0420 is stored.


Possible Cause• TWC Deterioration• Exhaust system leakage

P0137, P0138: Secondary H02S (Sensor 2)P0141: Secondary H02S (Sensor 2) Heater

NOTE: If some of the OTCs listed below are stored at the same time as OTC P0420, troubleshoot those OTCs first, thentroubleshoot OTC P0420.

DescriptionThis system evaluates the catalyst's capacity by means of the H02S (Primary and Secondary) output during stable drivingconditions. If deterioration has been detected during two consecutive driving cycles, the MIL comes on and OTC P0420 willbe stored.

1 P0420 1 The scan tool indicates Diagnostic Trouble Code (OTC) P0420: Catalyst system efficiency below threshold.

If there is no clicking sound, check the PCV valvegrommet for cracks and damage. If the grommet isOK, replace the PCV valve and recheck.

PCV VALVE

BREATHERHOSE

1. Check the PCV hoses and connections for leaks andclogging.

2. At idle, make sure there is a clicking sound trom thePCV valve when the hose between PCV valve andintake manifold in lightly pinched with your fingersor pliers.

Inspection

11-128

INTAKEMANIFOLD

BREATHERHOSE

The Positive Crankcase Ventilation (PCV) system isdesigned to prevent blow-by gas from escaping to theatmosphere. The PCV valve contains a spring-Ioadedplunger. When the engine starts, the plunger in the PCVvalve is lifted in proportion to intake manifold vacuumand the blow-by gas is drawn directly into the intakemanifold.

Description

Positive Crankcase Ventilation (PCV) System


11-129

(cont'd)

BLK_L

'-- __ RED/__ ----<YEL

FUELFILLCAP

---------------------_-_-_-_-_-_-_-_-_-FUELTANK

FUELTANKEVAPVALVE

VARIOUSSENSORS

ECMIPCM

EVAPCONTROLCANISTER

EVAPPURGE

EVAP CONTROLTWOWAY /SOLENOIDVALVE VALVE From

~ No. 15F=i ==at!l r-----BLK/YEL----___,~. ALTERNATOR

il A)~=======#H1it' ~:'5S!,NSOR

C. Fuel Tank Vapor Control SystemWhen tuel vapor pressure in the fuel tank is higher than the set value of the EVAP two way valve, the valve opens andregulates the flow of fuel vapor to the EVAP control canister.

ENGINE COOLANT TEMPERATURE ABOVE 154°F (6aOC)

EVAP PURGE CONTROL SOLENOID VALVE DUTY CONTROLLED AFTER STARTING ENGINE

B. Vapor Purge Control SystemEVAP control canister purging is accomplished by drawing fresh air through the EVAP control canister and into a porton the throttle body. The purging vacuum is controlled by the EVAP purge controi solenoid valve.

A. Evaporative Emission (EVAP)Control CanisterAn EVAP control canister is used for the temporary storage of fuel vapor until the fuel vapor can be purged trom theEVAP control canister into the engine and burned.

The evaporative emission controls are designed to minimize the amount of fuel vapor escaping to the atmosphere. Thesystem consists of the following components:

Description

Evaporative Emission (EVAP) Controls


~

~/VEL)

cr

EVAP PURGE CONTROLSOLENOID VALVE 2PCONNECTOR (C135)

11-130

(Ta page 11-131)

- The MIL has been reported on.- OTC P0441 is stored,

1

Problem verification:1, Start the engine. Hold the

engine al 3,000 rpm with noload (NT in [ffi or œ:J position,MfT in neutral) until the radia-tor fan cames on.

2. Do the ECM/PCM Reset Proce-dure.

3. Connect the SCS service con-nectar.

4. Test-drive under following con-ditions on the road.- Without any electrical load- AfT in [[hi or ~ position

(Mrr in 3rd-5th gear)- Engine speed between

1,200- 2,400 rpm- Decelerate fram 50 mph (80

km/hl ta 15mph (24 krn/h)

1Intermittent failure, system is OK

NO at this time. Check for poor con-Is DTC P0441 indicated? nections or loose wires at C135

1 YES(EVAP purge control solenoidvalve) and ECM/PCM.

Check for an open in the wire (tGlline):1. Turn the ignition switch OFF.2. Disconnect the EVAP purge

control solenoid valve 2P con-nectar.

3. Turn the ignition switch ON (II).4. Measure voltage between body

ground and the EVAP purgecontrol solenoid valve 2P con-nectar terminal No. 1.

l Repair open in the wires betweenNO the EVAP purge control solenoidIs there battery voltage?

valve and the No. 15 ALTERNA-

I YESTOR SP SENSOR (7.5 A) fuse.


Possible Cause• EVAP Purge Control Solenoid Valve• EVAP Purge Control Solenoid Valve Circuit• EVAP Control Canister• Vacuum Unes• ECM/PCM

DescriptionBy monitoring the purge line vacuum with the MAP sensor, the ECM/PCM can detect insufficient EVAP control systempurge flow.

1 P 1The scan tool indicates Diagnostic Trouble Code (DTC) P0441: Evaporative Emission (EVAP) control system

· 0441., ft" fimsu icrent purge ow.

Evaporative Emission (EVAP) Controls (cont'd)


11-131

(cont'd)

® PCS (RED/VEl)

+

Repair open in the wires betweenthe EVAP purge control solenoidvalve and ECM/PCM IA151.

NO

Is there conti nuit y?YES

Check for a short in the wire IPCSline):1. Turn the ignition switch OFF.2. Oisconnect the ECM/PCM con

nectar A (32P).3. Oisconnect the EVAP purge

control solenoid valve 2P connectar.

4. Check for conti nuit y betweenbodv ground and ECM/PCMconnector terminal A 15.

NO

Wire side of female terminaisJUMPERWIRE

ECM/PCM CONNECTOR D 132PIPG11BlKIr---------------------------~

Repair or replace vacuum lines asnecessary.

Repair short in the wires betweenthe EVAP purge control solenoidvalve and ECM/PCM (A151.

Replace the EVAP purge controlsolenoid valve.

YES


Check for an open or short in thewire IPCS linel:Measure voltage between ECM/PCM connector terminal A 15 andbody ground.

NO

(Ta page 11-132)

YES

Are the vacuum lines OK?

Check the vacuum lines:Check the vacuum lines of EVAPsystem for misrouting, leakage,breakage and clogging.

YES

Ooes the solenoid valve clickwhen the jumper is connected?

Check the EVAP purge controlsolenoid valve:1. Reconnect the EVAP purge

control solenoid valve 2P connectar.

2. Connect ECM/PCM connectorterminais A 15 and A10 with ajumper wire.

(From page 11-130)


WIRE

13

PG1 (BLK)--------------------------------~

ECM/PCM CONNECTOR 0 (J2P)

EVAP CONTROLCANISTER

VACUUMPUMP/GAUGE,o -JO in.Hg

.• A97JX - 041 -~XXXXX

11-132

1

Check the EVAP purge controlsolenoid valve:1. Oisconnect the vacuum hase

trom the EVAP control canister.2. Connect the vacuum pump to

the hose and apply vacuum.

r1

NO Replace the EVAP purge controlOoes it hold vacuum?1

solenoid valve.

YES

Check the EVAP control canister:1. Aeconnect the vacuum hose to

the EVAP control canister.2. Connect the vacuum/pressure r 1 i

gauge to the purge air hase. 1123. Connect ECM/PCM connector

terminais A15 and Al0 with ajumper wire.

4. Start the engine. JUMPER5. Check the vacuum.

Does vacuum appear on the NO 1 Replace the EVAP control canis- lgauge? l ter.

YES

1

Check the EVAP two way valve

1(see page 11-133)

NO~

Does the EVAP two way valve1work properly? Replace the EVAP two way valve.

YES

Substitute a known-good ECM/PCM and recheck. If symptom/indication goes away, replace theoriginal ECM/PCM.

(From page 11-131)

Evaporative Emission (EVAP) Controls (cont' d)


11-133

5. Slowly pressurize the vapor line while watching thegauge. The pressure should stabilize at 1.3 - 4.7 kPa(0 - 35 mmHg, 0.4 - 1.4 in.Hg) .• If the pressure momentarily stabilizes (valve

opens) at 1.3 - 4.7 kPa (10 - 35 mmHg, 0.4 - 1.4in. Hg), the valve is OK.

• If the pressure stabilizes below 1.3 kPa (10 mmHg,0.4 in.Hg) or above 4.7 kPa (35 mmHg, 1.4 in.Hg),install a new valve and retest.

4. Move the vacuum pump hose from the vacuum fitting to the pressure fitting, and move the vacuumgauge hose from the vacuum side to the pressureside as shown. ~_~~

3. Apply vacuum slowly and continuously whilewatching the gauge. The vacuum should stabilizemomentarily at 0.7 - 2.0 kPa (5 - 15 mmHg, 0.2 - 0.6in.Hg).If the vacuum stabilizes (valve opens) below0.7 kPa (5 mmHg, 0.2 in.Hg) or above 2.0 kPa(15 mmHg, 0.6 in.Hg), install a new valve and retest.

VACUUM/PRESSURE GAUGE.0-4in.Hg07JAZ - 0010008T-FITIING

VACUUMPUMP/GAUGE.0- 30 in.HgA973X - 041- XXXXX

~ T-FITTING

2. Remove the vapor line from the EVAP two wayvalve on the fuel tank, and connect it to a T-fittingfrom a vacuum gauge and a vacuum pump asshown.

1. Remove the fuel fill cap.

Evaporative Emission (EVAP) Two Way Valve Testing

Clutch 12-1Manual Transmission 13-1Automatic Transmission 14-1Differentiai 15-1Driveshafts 16-1

Transaxle

Special Toois 12-2lIIustrated Index 12-3Clutch PedalAdjustment 12-4

Clutch Master CylinderRemoval/lnstallation 12-5

Slave CylinderRemovai/lnstailation 12-6

Pressure PlateRemovai/lnspection 12-7

Clutch DiscRemoval/lnspection 12-8

FlywheelInspection 12-9Replacement 12-9

Clutch Disc, Pressure PlateInstallation 12-10

Release BearingRemovai/lnspection 12-11Installation 12-12

Clutch

®®

@

Ref. No. Tooi Number Description Oty Page Reference

CD 07JAF - PM7011A Cluteh Alignment Dise 12-7CID 07JAF - PM7012A Cluteh Alignment Shaft 12-7,8, 10, 11<ID 07LAB - PV00100 or Ring Gear Holder 12-7,9,10,11

07924 - PD20003@ 07746 - 0010100 Attaehment, 32 x 35 mm 12-10® 07749 - 0010000 Driver 12-10® 07936 - 3710100 Handle 12-7,8, 10, 11

12-2

1

Special Toois

12-3

·CLUTCH UNE15 N·m (1.5 kgf·m. 11 Ibf.ft)

\ ~8 x 1.25 mm22 N·m (2.2 kgf·m. 16 Ibf·ft)

• SLAVE CYLINDERRemoval/lnstallation, page 12·6

Removai/lnspection. page 12-7Installation. page 12-10

RELEASEBEARINGRemoval/lnspection. page 12·11Installation. page 12-12

·CLUTCH MASTER CYLINDERRemoval/lnstallation. page 12-5

• CLUTCH UNE19 N·m (1.9 kgf·m.14Ibf·h)

• CLUTCH UNE15 N·m (1.5 kgf·m.11 Ibf.ft)

~o -RESERVOIR TANK

~6 x 1.0 mm

7.2Ibf·ft}

·RESERVOIRHOSE

See section 13

NOTE:• Whenever the transmission is removed, clean and grease the release bearing sliding surface.• If the parts marked with an asterisk (*) are removed, the clutch hydraulic system must be bled (see page 12-6).• Inspect the hoses for damage, leaks, interference, and twisting.

IIlustrated Index

12-4

@ (STRQKEat PEDAL): 130-140 mm (5.12 - 5.51 in)@ (TOTAL CLUTCHPEDALFREEPLAY): 12 - 21 mm (0.47 - 0.83 in) include the pedal play 1 -10 mm (0.04 - 0.39 in)© (CLUTCHPEDALHEIGHT): 165 mm (6.50 in) to the floor@ (CLUTCHPEDALDISENGAGEMENT HEIGHT): 83 mm (3.27 in) minimum to the floor

LOCKNUTA9.8 Nom(1.0 kgf·m. 7.2 Ibf·ft)

CLUTCHSWITCH(or ADJUSTINGBOL1)

4-CLUTCH INTERLOCKSWITCH

11. Tighten locknut B.

10. Thread in the clutch interlock switch an additional3/4 to 1 full turn.

9. Release the clutch pedal 15 - 20 mm (0.59 - 0.79 in)from the fully depressed position and hold it there.Adjust the position of the clutch interlock switch sothat the engine will start with the clutch pedal inthis position.

8. Measure the clearance between the floor board andclutch pedal with the clutch pedal fully depressed.

7. Loosen locknut B or the clutch interlock switch.

6. Tighten locknut A.

5. Turn the clutch switch (or adjusting boit) in an additional 3/4 to 1 full turn .

LOCKNUTC18 Nom(1.8 kqf-m, 13 Ibf.ft)

4. Thread in the clutch switch (or adjusting boit) untilit contacts the clutch pedal, ASSISTSPRING-~

3. Tighten locknut C.

2. Loosen locknut C, and turn the push rod in or out toget the specified stroke (@) and height (@) at theclutch pedal,

1. Loosen locknut A, and back off the clutch switch (oradjusting boit) until it no longer touches the clutchpedal.

CAUTION: If there is no clearance between themaster cylinder piston and push rod, the releasebearing is held against the diaphragm spring,which can result in clutch slippage or other clutchproblems.

NOTE:• To check the clutch interlock switch and clutch

switch, see section 23.• The clutch is self-adjusting to compensate for wear.

Adjustment

Clutch Pedal

12-5

NOTE: Bleed the clutch hydraulic system (see page12-6).

5. Install the clutch master cylinder in the reverseorder of removal.

/CLUTCH MASTER CYLINDER

4. Remove the clutch master cylinder.

~DAl PIN

Ir..~/ IP/~ 08798-90021

NUTS8 x 1.25 mm13 N·m (1.3 kgf·m. 9.4 IbHt)

3. Pry out the cotter pin, and pull the pedal pin out ofthe yoke. Remove the nuts.

CLUTCHMASTERCYLINDER

2. Disconnect the clutch line and reservoir hose fromthe clutch master cylinder.

1. The brake fluid can be removed from the clutchmaster cylinder reservoir with a syringe.

CAUTION:• Do not spill brake fluid on the vehicle; it may damage

the paint; if brake fluid does contact the paint, washit off immediately with water.

• Plug the end of the clutch line and reservoir hosewith a shop towel to prevent brake fluid from coming out.

Removai/lnstailation

Clutch Master Cylinder

4. Bleed the clutch hydraulic system.• Attach a hose to the bleeder screw, and suspend

the hose in a container of brake fluid.• Make sure there is an adequate supply of fluid at

the clutch master cylinder, then slowly pump theclutch pedal until no more bubbles appear at thebleeder hose.

• Refill the clutch master cylinder with fluid whendone.

• Always use Genuine Honda DOT 3 Brake Fluid.Using a non-Honda brake fluid can cause corrosion and decrease the life of the system.

• Confirm clutch operation, and check for leakingfluid.

-;:::::::::===: .c::::::=! GRf.'!L~.:(Brake AssemblyLube)

NOTE: Make sure the boot is installed on the slavecylinder. CLUTCH UNE

15 N'm (1.5 kgf·m. 111bHt)

3. Install the slave cylinder in the reverse order ofremoval.

12-6

2. Remove the slave cylinder from the clutch housing.

CLUTCHUNE

-~: Super High Temp Urea Grease (PIN 08798-9002).

~: Brake Assembly Lube or equivalent rubbergrease.

1. Disconnect the clutch line from the slave cylinder.



• Plug the end of the clutch line with a shop towel toprevent brake fluid from coming out.


Slave Cylinder

12-7

If the warpage exceeds the service limit, replace thepressure plate.

PRESSURE PLA TE

STRAIGHT EDGE

Standard (New): 0.03 mm (0.001 in) max.Service Limit: 0.15 mm (0.006 in)

NOTE: Measure across the pressure plate at threepoints.

6. Inspect for warpage using a straight edge and feelergauge.

5. Inspect the pressure plate surface for wear, cracks,and burning.

4. To prevent warping, unscrew the pressure platemounting bolts in a crisscross pattern in severalsteps, then remove the pressure plate.

RING GEAR HOLDER

1 ADJUSTER NUT

( ADJUSTER BOLT

PRESSURE PLATE

\

tRING GEAR HOLDER07LAB- PVOO100or07924-PD20003

ENGINEBLaCK

3. Install the special tools.

CLUTCH ALlGNMENT DISC07JAF-PM7011ACLUTCH AUGNMENT SHAFT07JAF-PM7012AHAN OLE07936-3710100

If the height exceeds the service limit, replace thepressure plate.

Standard (New): 0.6 mm (0.02 in) max.Service Limit: 1.0mm (0.04 in)

2. Check the diaphragm spring fingers for height usingthe special tools and a feeler gauge.

1. Inspect the fingers of the diaphragm spring for wearat the release bearing contact area.

Removai/lnspection

Pressure Plate

If the depth is less than the service limit, replace theclutch dise.

lINING SURFACE

CLUTCH DISC

Rivet Depht:Standard (New): 1.3 - 1.9 mm (0.05 - 0.07 in) min.Service Limit: 0.2 mm (0.01 in)

4. Measure the depth from the lining surface to therivets, on both sides.

12-8

If the thickness is less than the service limit, replacethe clutch disco

CLUTCH DISC

Clutch Disc Thickness:Standard (New): 8.5 - 9.1 mm (0.33 - 0.36 in)Service Limit: 5.5 mm (0.22 in)

3. Measure the c1utchdise thickness.

2. Inspect lining of the clutch dise for signs of slippingor oil. If it is burned black or oil soaked, replace it.

HANOlE07936-3710100

t. Remove the clutch disc and special tools.

Removai/lnspection

Cluteh Dise

12-9

(cont'd)

3. Remove the bail bearing from the flywheel.

2. Remove the flywheE'1mounting bolts in a crisscrosspattern in several steps as shawn, and remove theflywheel.

RING GEAR HOLOER07LAB- PVOO100or07924-PD20003

1. Install the special tool.

BALL BEARING

FLYWHEEL

4. Turn the inner race of the bail bearing with your finger. The bail bearing should turn smoothly and quietly. Check that the bail bearing outer race tits tightlyin the flywheel. If the inner race does not turnsmoothly, quietly, or tit tight in the flywheel, replacethe bail bearing.

If the runout exceeds the service limit, replace theflywheel.

FLYWHEEL

Service Limit:

NOTE: The runout can be measured with engineinstalled.

3. Measure the flywheel runout using a dial indicatorthrough at least two full turns. Push against the flywheel each time you turn it ta take up the crankshaft thrust washer clearance.

2. Inspect the clutch disc mating surface on the flywheel for wear, cracks, and burning.

1. Inspect the ring gear teeth for wear and damage.

ReplacementInspection

Flywheel

ClUTCH ALlGNMENT SHAFT07JAF- PM7012AHANDlE07936-3710100

RING GEARHOlDER07lAB-PV00100or07924- PD20003

PRESSUREPLATE

3. Install the pressure plate.

2. Install the clutch dise using the special tools.

CLUTCH ALlGNMENT SHAFT07JAF-PM7012A

(PIN 08798- 9002)RINGGEARHOLDER07lAB - PVOO100or07924- PD20003

HANDlE07936-3710100

1. Install the special toot.

12-10

RING GEAR HOLDER07lAB-PV00100or07924- PD20003

MOUNTING BOLTS118 Nom (12.0 kgfom.87 Ibfoftl

6. Install the special tool, then torque the flywheelmounting bolts in a crisscross pattern in several stepsas shown.

5. Align the hole in the flywheel with the crankshaftdowel pin and install the flywheel. Install the mounting bolts finger-tight.

BAll BEARING --

ATTACHMENT.32 x 35 mm07746-0010100

4. Drive the new bail bearing into the flywheel usingthe special tools as shown.

InstallationReplacement (cont'd)

Clutch Dise,Pressure PlateFlywheel

12-11

4. If there is excessive play, replace the release bearing with a new one.

CAUTION: The release bearing is packed withgrease. Do not wash it in solve nt.

3. Check the release bearing for play by spinning it byhand.

RELEASEFORK

RELEASEBEARING

2. Remove the release fork from the c1utch housing bysqueezing the release fork set spring with pliers.Remove the release bearing.

1. Remove the release fork boot from the c1utchhousing.

Remove/lnspection

RINGGEARHOLDER CLUTCHALlGNMENTSHAH07LAB-PV00100 07JAF-PM7012Aor HANDLE07924-PD20003 07936-3710100

1

@ MOUNTINGBOLTS8 x 1.25 mm25 N-m (2.6 kgf-m. 19 IbHtl

CD

4. Torque the mounting bolts in a crisscross pattern asshown. Tighten them in several steps to preventwarping the diaphragm spring.

Release Bearing

4. Install the release fork boot; make sure the boot sealsaround the release fork and clutch housing.

3. Move the release fork right and left to make sure thatit fits properly against the release bearing, and thatthe release bearing slides smoothly.

12-12

2. Align the detent of the release fork with the releasefork boit, then press the release fork over the releasefork boit sequarely.

- -$jiiffi(PIN 08798-9002)0.3-0.9 g (0.01-0.03 oz)

(PIN 08798-9002)..-

RElEASE FORK BOLT12 x 1.25 mm29 Nom(3.0 kqf-rn, 22 IbHt)

1. With the release fork slid between the release bearing pawls, install the release bearing on the mainshaft while inserting the release fork through thehole in the clutch housing.

NOTE: Use only Super High Temp Urea Grease (PIN08798 - 9002).

Installation

Release Bearing

Shift Fork AssemblyIndex 13-25Clearance Inspection 13-26MBS Shift Piece Inspection 13-27

Synchro Sleeve, Synchro HubInspection/Installation 13-27

Synchro Ring, GearInspection 13-28

Shift RodRemoval 13-29

DifferentiaiIndex 13-30Backlash Inspection 13-30Bearing Replacement 13-31Final Driven Gear Replacement 13-31Thrust Shim Adjustment 13-32

Clutch Housing BearingReplacement 13-34

Mainshaft Thrust ShimAdjustment 13-36

TransmissionReassembly 13-39

Oil SealsReplacement 13-43

Gearshift MechanismOverhaul 13-44

Special Toois 13-2Maintenance

Transmission Oil 13-3Back-up Light Switch

Replacement 13-3Troubleshooting 13-4Transmission Assembly

Removal 13-5Installation 13-8

lIIustrated Index 13-10Transmission Housing

Removal 13-12Reverse Shift Holder

Clearance Inspection 13-13Reverse Idler Gear

Removal 13-14Mainshaft, Countershaft, Shift Fork

Disassembly 13-14Mainshaft Assembly

Index 13-15Clearance Inspection 13-16Disassembly 13-17Inspection 13-18Reassembly 13-19

Countershaft AssemblyIndex 13-20Clearance Inspection 13-21Disassembly 13-22Inspection 13-23Reassembly 13-23

Manual Transmission

13-2

@ ®

9 Q~) ~

CD

@ @

® Œ

81

Ref. No. Tooi Number Description Oty Page Reference

CD 07GAJ - PG20110 Mainshaft Holder 13-38CID 07GAJ - PG20120 Cailar 13-37@ 07GAJ - PG20130 Mainshaft Base 13-37*@ 07736 - A01000A Adjustable Bearing Puller, 25 - 40 mm 13-34,35® 07746 - 0010300 Attachment, 42 x 47 mm 13-34,35® 07746 - 0010400 Attachment, 52 x 55 mm 13-34,35(J) 07746 - 0030100 Driver, 40 mm 1.0. 13-19,24

31,32@ 07746 - 0030300 Attachment, 30 mm 1.0. 13-19,24® 07746 - 0030400 Attachment, 35 mm 1.0. 13-19,24@) 07749 - 0010000 Driver 13-34, 35, 43(fi) 07JAD - PH80101 Driver Attachment 13-43@ 07JAD - PH80200 Pilot, 26 x 30 mm 13-43@ 07947 - 6110501 ar Seal Driver Attachment 13-43

07947 - 6110500

* Must be used with commercially-available 3/8"-16 Siide Hammer.

Special T0015

13-3

3. Install the new washer and back-up light switch.

4. Connect the back-up light switch connector.

2. Remove the back-up light switch.

1. Disconnect the connector, then remove the back-uplight switch connector from the connector clamp.

NOTE: To test the back-up light switch, see section 23.

Replacement

DRAIN PlUG39 N'm (4.0 kqf-rn. 29 Ibf·ft)

OIL FILlER PlUG44 Nom (4.5 kqf-rn. 33 IbHt)

WASHER, -:

Replace. ~~'~. ~. :-/>. /.. ..... 0. ..J WASHER,.~\, ,'~ Replace.

',. CJ(~ . ~, q- <, (?~

'9 / J-;:_' 0~/ ,~-.-. /'-, .:_~- ", - /~ r-r::

Always use Genuine Honda Manual TransmissionFluid (MTF). Using motor oil can cause stiffer shifting because it dose not contain the proper additives.

Oil Capacity1.8 f (1.9 US qt, 1.61mp qtl at oil change1.9 f (2.0 US qt, 1.7 Imp qt) at overhaul

5. Reinstall the oil filler plug with a new washer.

NOTE: The drain plug washer should be replaced atevery oil change.

4. Reinstall the drain plug with a new washer, andrefill the transmission with the recommended oil tothe proper levaI.

3. If the transmission oil is dirty, remove the drainplug and drain the oil.

2. The oil level must be up to the filler hole. If it isbelow the hole, add oil untiJ it runs out, then reinstail the oil filler plug with a new washer.

Proper Level

Oll FlllER PlUG44 Nom (4.5 kqf-rn. 33 IbHt)

1. Remove the oil filler plug, then check the level andcondition of the oil.

NOTE: Check the transmission oil with the engine OFFand the vehicle on level ground.

Transmission Oil

Back-up Light SwitchMaintenance

13-4

Replace the reverse shift holder.

YES

NO l,

i Replace the MBS shift piece.L- ~Is it 6.8 mm (0.27 in) or more?

Measure the MSS shift piece pin(see page 13-27).

YES

Replace the 5th shift fork or 5thsynchro sleeve.

Is the clearance 1.0mm (0.04in) or less?

Measure the clearance between5th shift fork and 5th synchrosleeve (see page 13-26).

NO

Replace the 5th synchro hub andsleeve as a set.

Is the gear nose present whenshifting into 5th gear?

Test-drive the vehicle.

Gear noise is present when shifting into reverse after the engineis started.

NOTE: This system is not a fully-synchronized gear noise reduction system.Therefore, vou may hear gear noise whenCD Vou shift into reverse with the vehicle not yet completely stopped.@ Vou shift quickly into reverse du ring fast idling.

Whenever the clutch pedal is depressed to shift into reverse, the mainshaft continues to rotate because of its inertia.The resulting speed difference between mainshaft and reverse idler gear produces gear noise.The reverse gear noise reduction system employs a cam plate which was added to the reverse shift holder. When shiftinginto reverse, the 5th/reverse shift piece, connected to the shift lever, rotates the cam plate. This cause the 5th synchro setto stop the rotating mainshaft. As there is no speed difference between mainshaft and reverse idler gear, there will be lessgear noise.

Reverse Gear Noise Reduction System

Troubleshooting

13-5

(cont'd)

8. Drain transmission oil (see page 13-3).

SLAVECYLINDER

CAUTION:• Do not operate the clutch pedal once the slave

cylinder has been removed.• Take care not to bend the clutch line.

7. Remove the clutch line bracket, clutch line clamp,and slave cylinder.

VSSCONNECTOR

6. Disconnectthe vehicle speed sensor (VSS)connector.

5. Remove the wire harness clamps.

8 x 1.25mm9 N'm (0.9 kgf·m, 7 Ibf.ft)

TRANSMISSIONGROUNDWIRE

BACK-UP lIGHTSWITCH CONNECTOR

6x1.0 mm9.8 N'm (1.0 kgf'm, 7.2 Ibf·ft)

4. Disconnect the starter motor cables, transmissionground wire and back-up light switch connector.

3. Remove the intake air duct and air cleaner housingassembly (see section 5).

2. Disconnect the negative Hcable first, then the positive (+) cable from the battery.

1. Make sure you have the anti-theft code for theradio, then write down the frequencies for theradio's preset buttons.

CAUTION: Use fender covers to avoid damagingpainted surfaces.

'Mhi@n;• Make sure jacks and safety stands are placed properly,

and hoist brackets are attached to correct position onthe engine.

• Apply parking brake and block rear wheels so thevehicle will not roll off stands and fall on vou whileworking under it.

Removal

Transmission Assembly

8 x 1.25 mm24 Nom (2.4 kgfom.171bHti

8)( 1.25 mm24 Nom (2.4 kgtom17 IbHt)

12. Remove the engine stiffeners and clutch cover.

J EXTENSION ROD

"'____PIN PUNCH, 8.0 mm(Commerciallyavailable)

SHIFT ROO

11. Remove the shift rod and extension rod.

13-6

Replace.10 x 1.25mm54 N·m (5.5 kgf·m. 40 IbHt)

Replace.8 x 1.25 mm22 Nom (2.2 kqf-rn.161bHt)

10. Remove exhaust pipe A.

wr AF.LOCKING NUl12x1.25mm ~ ~:~:.ce49 - 59 N·m (5.0- 6.0 kgf·m. 12 x 1.25mm36 - 43 IbHt) COnER PIN 64 N·m 16.5kgf·m, 47 IbHt)

Replace.

SET RINGReplace.

NOTE: Coat ail the precision finished surfaces withclean engine oil or grease. Tie plastic bags over thedriveshaft ends.

9. Remove the driveshafts (see section 16).

Removal (cont'd)


13-7

(cont'd)

TRANSMISSIONMOUNT BRACKET

TRANSMISSIONMOUNT

17. Remove the transmission mount bracket andmount.

16. Place a jack under the transmission.

SPECIAL BOLTSReplace.12 x 1.25 mm64 N·m (6.5 kgf·m,47 IbUt)

15. Remove the right front mount/bracket.

\SPlASH SHIElD

14. Remove the splash shield.

CHAIN HOIST

13. Install the bolts in the cylinder head and attach achain hoist to the bolts, then lift the engine slightlyto unload the engine and transmission mounts.

(PIN 08798- 900210.3-0.9 9(0.01-0.03 oz)

RElEASEFORK

RELEASE FORK BOLT12xl.25mm29 N'm (3.0 kgf·m.221bf.ftl


Install the transmission assembly in the reverse order ofremoval.• Before installing, check that the two dowel pins are

installed in the clutch housing.• Apply grease to the parts as shown, then install the

release fork and release bearing.

13-8

CAUTION: Take care not to bend the clutch line,

20. Pull the transmission away trom the engine until itc1earsthe mainshaft, then lower it on the transmission jack.

REARMOUNTBRACKET

~, "~~. ~:U:;-,.~. ,,-.......:::\"'0 fÇ§

/~ \ //0~ WASHER

SPECIAL BOLTReplace.14 x 1.5 mm84 N-m(8.5 kgf-m. 61 Ibf.ftl

SPECIAL BOLTSReplace.14x1.5mm84 N'm(8.5 kgf·m,61Ibf.ft)12x1.25mm

64 Nom(6.5 kgf·m. 47 Ibf.ftl

19. Remove the rear mount bracket bolts and transmission mounting bolts.

TRANSMISSIONMOUNTING BOLTS12 x 1.25 mm64 Nom(6.5 kgfom.47 Ibfoftl

STARTERMOUNTINGBOLT10 x 1.25 mm44 Nom(4.5 kqf-rn,33 Ibfoft)

18. Remove the three upper transmission mountingbolts and the lower starter mounting boit.

InstallationRemoval (cont'd)


13-9

• Installing the starter cable, make sure that the crimpedside of the ring terminal is facing out (see section 4'.

• Refill the transmission with the recommended ail(see page 13-3).

• Connect th positive (+) cable first, then the negative(-) cable ta the battery.

• Check the clutch operation.• Shift the transmission and check for smooth operation.• Check the front wheel alignment (see section 18'.• Enter the anti-theft code for the radio, then enter the

custorner's radio station presets.

FRONT

• Turn the breather cap sa that the "F" mark points atthe front of the vehide as shawn.

8 x 1.25 mm22 Nom(2.2 kqf-rn,16lbfoft)

-~(PIN08798-9002'

CLUTCHPIPE

1

6 x 1.0 mm9.8 Nom(1.0 kgfom.7.2lbfoft'

CLUTCHL1NEBRACKET


• Apply grease ta the slave cylinder push rad.

• Turn the boat sa the hale is facing down.• Make sure the boat is installed on the shift rad.

CLIPDOWN

Replace.

8 x 1.25 mm22 N-m (2.2 kgf-m. 16 Ibf-ft,

VOl

SHIFT ROD

@ 12 x 1.25 mm74 Nom(7.5 kgfom.541bfoft'

• Check that the bushings are not twisted or offset.• lnstall the clip as shawn.

@12x1.25mm64N·m(6.5kgf·m,47Ibf·ft)

CD 12x 1.25mm64N·m(6.5kgf'm,471bf·ft,

• Torque the mounting boit and nuts in the sequenceshawn.

.....t--------'@

le/@~,

-~@

~--@

13-10

NOTE:• This transmission uses no gaskets between the major housings; use liquid gasket (PIN 08718 - 0001 or 08718 - 0003)

(see page 13-41).• Always clean the magnet @ whenever the transmission housing is disassembled.• Inspect a" the bearings for wear and operation.

Refer to the drawing below for the transmission disassembly/reassembly.Clean ail parts thoroughly in solvent and dry with compressed air.

-"1 Lubricate ail the parts with oil before reassembly.

IIlustrated Index

13-11

@) 80 mm THRUST SHIMSelection. page 13-33

@ DIFFERENTIAL ASSEMBL ySee page 13-30

@ 14 x 25 x 17.5 mm OIL SEALReplace.

@ 35 x 56 x 8 mm OIL SEALReplace.

@ SHIFTROD@ BOOT® OIL GUIDE PLATE@ 30 x 55 x 21 mm

NEEDLE BEARING@ COUNTERSHAFT@ 36 x 41 x 25.5 mm

NEEDLE BEARINGCheck for wear andoperation.

@ 1STGEAR~ FRICTION DAMPER@ SYNCHRO RING@ SYNCHRO SPRING@ 1ST/2ND SYNCHRO HUB~ REVERSE GEAR@ SYNCHRO SPRING@ SYNCHRO RING@ FRICTION DAMPER@ SPACERtij) 39 x 44 x 27 mm

NEEOLE BEARING~ 2NDGEAR® 3RDGEAR@ 4THGEAR® 5THGEAR@ NEEDLE BEARING@ BALL BEARING® SPRING WASHER® LOCKNUT Replace.

108 .. 0 .. 108 N'm

(11.0 .. 0 .. 11.0 kgf.m,)79.6 .. 0 .. 79.6 IbHt

® 5TH/REVERSE SHIFT FORK® 52 mm SNAP RING® 70 mm THRUST SHIM

Selection. page 13-36~ OIL GUIDE PLATE@ WASHER Replace.@ BACK-UP LlGHT SWITCH

25 N'm (2.5 kgf·m, 18Ibf.ft)@ SETSCREW

22 N'm (2.2 kgf'm, 16 lbHt)@ WASHER Replace.@ SPRING L. 31.6 mm (1.24 in)@ STEEL BALL (5/16 in)@ BACK-UP LlGHT .

SWITCH HARNESS BRACKET@ TRANSMISSION HANGER@ 32 mm SEALING BOLT

25 N'm (2.5 kgf'm, 18Ibf.ft)@ OILSEAL

Replace.@) OIL DRAIN PLUG

39 N'm (4.0 kgf'm, 29 Ihf·ft)® WASHER Replace.@ OIL FILLER PLUG

44 N'm (4.5 kgf'm, 33 Ibf·ft)@ WASHER Replace.@ TRANSMISSION HOUSING® RELEASE PIPE BRACKET@ OIL GUrrER PLATE® REVERSE LOCKCAM@ REVERSE SELECT SPRING

L. 63.4 mm (2.496 in)@ REVERSE SELECT RETAlNER®> SHIFT ARM C® SHIFT ARM B@ INTERLOCKr@ COLLAR~ SHIFTARM A<@ SPRING WASHER(@) MAGNETl@ SET BALL SPRING BOLT

22 N'm (2.2 kgf'm, 16Ibf·ft)~ 14 x 20 mm DOWEL PIN

CD BALL BEARING® 5TH SYNCHRO HUB® 5TH SYNCHRO SLEEVE@ SYNCHRO SPRING<ID SYNCHRO RING® 5THGEAR® 32 x 37 x 23.5 mm

NEEDLE BEARING® SPACER COLLAR® 34 x 39 x 23 mm

NEEDLE BEARING@ 4THGEAR@ SYNCHRO RING@ SYNCHRO SPRING@ 3RD/4TH SVNCHRO SLEEVE@ 3RD/4TH SVNCHRO HUB@ 3RDGEAR@ 34 x 39 x 27.5 mm

NEEDLE BEARING@ MAINSHAFT@ WASHER@ SPRING WASHER~ BALL BEARING

Check for wear andoperation.

® 26 x 42 x 7 mm OIL SEALReplace.

@ 28 mm PLUG BOLT54 N'm (5.5 kgf'm, 40 Ibf.ft)

@ 1ST/2ND SELECT SPRINGL. 36.26 mm (1.428 in)

@ SHIFT ARM SHAFT@ CLUTCH HOUSING® INTERLOCK GUIDE BOLT

39 N'm (4.0 kgf'm, 29 Ibf.ft)® REVERSE SHIFT HOLDER® REVERSE IDLER GEAR® REVERSE IDLER GEAR SHAFT®l 5 x 22 mm SPRING PIN

Replace.® 3RD/4TH SHIFT PIE CE@ 5TH/REVERSE SHIFT PIECE@ MBS SHIFT PIECE@ 1ST/2ND SHIFT FORK® 3RD/4TH SHIFT FORK

A - 15 Nrn (1.5 kgf·m, 11 IbHt)8 - 27 Nrn (2.8 kgf·m, 20 lbf-ft)C - 31 N'm (3.2 kgf·m, 23 IbHt)

Torque Value

TRANSMISSION HOUSING

OIL GUTTERPLATEOIL GUIDE PLATE

Remove the thrust shim, oil guide plate, and oil gutter plate from the tramsmission housing.

8.

7. Separate the transmission housing from the clutchhousing, and wipe it c1eanof the sealant.

6. Expand the snap ring on the countershaft bail bearing, and remove it from the groove using a pair ofsnap ring pliers.

SNAP RING

32 mm SEALING BOLT

5. Remove the 32 mm sealing boit.

4. Loosen the transmission housing attaching bolts ina crisscross pattern in several steps, then removethem.

13-12

~AO) 1 CC]~V \ 1

f!I~ ~. ~ 1l~STEel BALLSWASHER~ \ D. 5/16 in

Replace. Â SPRING

~ l. 31.6 mm (1.24 in)

SETTINGSCREW

3. Remove the setting screws, washers, springs, andsteel balls.

2. Remove transmission hanger.

~r\

WASHERReplace.

BACK-UP UGHT SWITCH

TRANSMISSIONHANGER

1. Remove the back-up light switch.

NOTE: Place the clutch housing on two pieces of woodthick enough to keep the mainshaft trom hitting theworkbench.

Removal

Transmission Housing

13-13

• If the width is not within the standard, replacethe reverse shift holder with a new one.

• If the width is within the standard, replace thereverse idler gear with a new one.

1REVERSE SHIFT HOLDER

REVERSE SHIFT FORK

Standard: 12.7 - 13.0mm (0.500- 0.512 in)

4. If the clearance is more than the service limit, measure the width of the reverse shift fork.

REVERSE SHIFT FORK

Service Limit: 1.8mm (0.07 in)0.5 -1.1 mm (0.02- 0.04 in)Standard:

3. Measure the clearance between the reverse id1ergear and the reverse shift fork.

• If the widths of the grooves are not within thestandard, replace the reverse shift holder with anewone.

• If the width of the grooves are within the standard, replace the 5th/reverse shift piece with anewone.

,REVERSE SHIFT HOlDER

Standard: 7.05 -7.25 mm (0.278- 0.285 in)

2. If the clearances are more than the service limit,measure the widths of the groove in the reverseshift fork.

Service Limit: 0.5 mm (0.02 in)0.05 - 0.35 mm (0.002- 0.014 in)Standard:

1. Measure the clearance between the reverse shiftfork and 5th/reverse shift piece pin.


Reverse Shift Holder

Tape the mainshaftsplines.

MAINSHAFT andCOUNTERSHAFTASSEMBLIES

NOTE: Before removing the mainshaft and countershaft assemblies, tape the mainshaft splines to protect the seal.

3. Remove the mainshaft and countershaft assemblieswith the shift fork from the clutch housing.

fINTERLOCKGUIDE BOLT

2. Remove the shift arm B attaching boit.

1. Remove the interlock guide boit from under theclutch housing.

13-14

0'

REVERSE IDLER~GEAR

REVERSEIDlERGEAR SHAH

•

2. Remove the reverse idler gear shaft and reverseidler gear.

1. Remove the reverse shift holder.

DisassemblyRemoval

Mainshaft, Countershaft,Shift ForkReverse Idler Gear

13-15

4TH GEARInspection, page 13-16

e, ,-_ .... ", ...._.-SYNCHRO RINGInspection, page 13-28

Inspection, page 13-18

Check for wearand operation.

Inspection, page 13-' 7

32 le 37 x 23.5 mmNEEDLEBEARINGCheck for wear andoperation.SPACERCOllAR

/ Inspection, page 13-1634 le 39 x 23 mmNEEDLEBEARINGCheck for wearand operation.

CHAMFER

Inspection, page 13-28

5TH SYNCHROSLEEVEInspection, page 13-27

3RD/4THSYNCHRO HUB

3RD/4TH SYNCHRO SLEEVE

--:lI! Prior to reassembling, clean ail the parts in solvent, dry them, and apply lubricant to any contact surfaces ..IlThe 3rd/4th and 5th synchro hubs, however, should be installed with a press before lubricating them.

NOTE: The 3rd/4th and 5th synchro hubs are installed with a press.

Index

Mainshaft Assembly

• If the thickness of 4th gear is less than the servicetimit. replace 4th gear with a new one.

• If the thickness of 4th gear is within the servicelimit, replace the 3rd/4th synchro hub with a newone.

30.12 - 30.17 mm(1.186-1.188 in)

Service limit: 30.05 mm (1.183 in)4TH GEAR

./'

Standard:

If distance @ is less than the service limit, replacethe spacer collar with a new one.If distance @ is within the service limit, measurethe thickness of 4th gear.

5.

SPACERCOLLAR

4TH GEARSIDE..--

-1 .J

4--

Standard: 22.82 - 22.86 mm(0.898- 0.900 in)

Service limit: 22.81 mm (0.898 in)

4. If the clearance is more than the service Iimit, measure distance @ on the spacer collar.

Service Limit:0.31 mm (0.012 in)

.J0.06 - 0.19 mm (0.002- 0.007 in)Standard:

3. Measure the clearance between 4th gear and thespacer collar.

13-16

• If the thickness of 3rd gear is less than the service limit, replace 3rd gear with a new one.

• If the thickness of 3rd gear is within the servicelimit, replace the 3rd/4th synchro hub with a newone.

30.22 - 30.27mm(1.190-1.192 in)


Standard:

If the clearance is more than the service limit, measure the thickness of 3rd gear.

2.

Service Limit:0.33 mm (0.013 in)0.06 - 0.21 mm (0.002- 0.008 in)Standard:

1. Measure the clearance between 2nd and 3rd gears.

NOTE: If replacement is required, always replace thesynchro sleeve and hub as a set.


Mainshaft Assembly

13-17

(cont'd)

ATTACHMENT

PRESS----t~

2. Support 4th gear on steel blocks, and press themainshaft out of the 5th'synchro hub as shown.

CAUTION: Remove the synchro hubs using a pressand steel blocks as shown. Use of a jaw-type pullercan cause damage to the gear teeth.

BAllBEARING

1. Remove the bail bearing using a bearing puller asshown.

Disassembly

• If the thickness of 5th gear is less than the service limit, replace 5th gear with a new one.

• If the thickness of 5th gear is within the servicelimit, replace the 5th synchro hub with a newone.

5TH GEAR

Standard: 28.42 - 28.47 mm(1.119-1.121 in)

Service limit: 28.35 mm (1.116 in)

8. If distance ® is less than the service limit, replacethe spacer collar with a new one.If distance ® is within the service limit, measurethickness of 5th gear.

5TH GEAR__,.SIDE

SPACERCOlLARf4--

1 J

23.53 - 23.56 mm(0.926 - 0.928 in)


Standard:

7. If the clearance is more than the service limit, measure distance ® on the spacer collar.

4TH GEAR

Standard: 0.06 - 0.19 mm (0.002 - 0.007 in)Service Limit: 0.31 mm (0.012 in)•

6. Measure the clearance between the spacer collarand 5th gear.

If the runout is more than the service limit, replacethe mainshaft with a new one.

Rotate two completerevolutions.

NOTE: Support the mainshaft at both ends asshown.

Service limit: 0.05 mm (0.002 in)0.02 mm (0.001 in) max.Standard:

2. Inspeet for runout.

If any part of the mainshaft is less than the servicetirnit, replace it with a new one.

Check oil passagesfor clogging.

and damage.

Standard: A: 21.987 - 22.000mm(0.8656 - 0.8661 in)

B: 26.980 - 26.993 mm(1.0622 -1.0627 in)

C: 33.984 - 34.000mm(1.3380 -1.3386 in)

0: 25.977 - 25.990mm(1.0227 - 1.0232 in)

Service limit: A:21.930 mm (0.8634 in)B:26.930 mm (1.0602 in)C: 33.930 mm (1.3358 in)0: 25.920 mm (1.0205 in)

1. Inspect the gear surface and bearing surface forwear and damage, then measure the mainshaft atpoints A, 8, C, and D.

13-18

3. Support the 3rd gear on steel blocks, and press themainshaft out of the 3rd/4th synchro hub as shown.

InspectionDisassembly (cont' d)

Mainshaft Assembly

13-19

NOTE: Install the bail bearing with the tapered endfacing down.

4. Install the bail bearing using the special tools and apress as shown.

ATTACHMENT.30 mm 1.0.07746-0030300

DRIVER.40 mm 1.0.07146-0030100

3. Install the 5th synchro hub using the special toolsand a press as shown,

NOTE: After installing, check the operation of the3rd/4th synchro hub set.

2. Install the 3rd/4th synchro sleeve by aligning thestops of the 3rd/4th synchro sleeve and hub.

ATTACHMENT.35 mm 1.0.07746-0030400

DRIVER.40 mm 1.007746-0030100

1. Support 2nd gear on steel blocks, then install the3rd/4th synchro hub using the special tools and apress as shown.

NOTE: Refer to page 13-15for reassembly sequence.

CAUTION: When installing the 3rd/4th and 5th synchrohubs, support the shaft on steel blocks, and install thesynchro hubs using a press.

Reassembly

13-20

._ 1ST12NOSYNCHROHUB

REVERSEGEARInspection, page 13-27

SYNCHRO SPRINGCheck for wear and operation.<,

COUNTERSHAFTInspection, page 13-23

SYNCHRO RINGInspection. page 13-28

1ST GEAR/,nspection. page 13-21. 28

SYNCHRO RING

SYNCHRO SPRING

SPRINGWASHERBAll BEARINGCheck. for wear andoperation.

~"fJJIl~~NEEDlE BEARINGck for wearoperation.

5TH GEAR

4TH GEAR

3RD GEAR2ND GEARInspection, page 13-21, 2839 x 44 x 27 mm

/"'" NEEDlE BEARINGCheck for wear andoperation.SPACERCOllARInspection. page 13-21

FRICTION DAMPER

lOCKNUT Replace.108-0- 108 Nom

(11.0-0- 11.0 kgfoml79.6-0-79.6Ibfoft

., Prior to reassembling, clean ail the parts in solvent, dry them and apply lubricant to any contact surfaces. The 3rd,4th, and 5th gears, however, should be installed with a press before lubricating them.

NOTE: The 3rd, 4th, and 5th gears are installed with a press .

Index

Countershaft Assembly

13-21

• If the thickness of 2nd gear is less than the servicelimit, replace 2nd gear with a new one.

• If the thickness of 2nd gear is within the servicelimit, replace the 1stJ2ndsynchro hub with a newone.

31.92 - 31.97 mm(1.257 - 1.259 in)


Standard:

5. If the thickness is less than the service limit, replacethe spacer cailar with a new one.If the thickness is within the service limit, measurethe thickness of 2nd gear

32.03 - 32.06 mm(1.261-1.262 in)


Standard:

4. If the clearance is more than the service limit, measure the thickness of the spacer cailar.

Standard: 0.04 - 0.12 mm (0.002 - 0.005 in)Service Limit: 0.24 mm (0.009 in)

3. Measure the clearance between 2nd and 3rd gears.

• If the thickness of 1st gear is less than the servicelimit, replace 1st gear with a new one.

• If the thickness of 1st gear is within the servicelimit, replace the 1stJ2ndsynchro hub with a newone.

Standard: 30.41 - 30.44 mm(1.197-1.198 in)


2. If the clearance is more than the service limit, measure the thickness of 1st gear.

Service limit: 0.22 mm (0.009 in)0.03 - 0.10 mm (0.001- 0.004 in)Standard:

1. Measure the clearance between the countershaftand 1st gear.

NOTE: If replacement is required, always replace thesynchro sleeve and hub as a set.


5. Support 1st gear on steel blocks, and press thecountershaft out of 3rd gear as shown.

4. Support 4th gear on steel blocks, and press thecountershaft out of 5th and 4th gears as shown.

13-22

BEARING PULLER

3. Remove the bearings using a bearing putier asshown.

2. Raise the locknut tab from the groove of the countershaft, th en remove the locknut and the springwasher.

WOOD BLaCKS

BENCHVISE

CHIS El

AB

\=- ~~~~~eUT

1. Securely clamp the countershaft assembly in abench vise with wood blocks.

CAUTION: Remove the gears using a press and steelblocks as shown. Use of a jaw-type puller can damagethe gear teeth.

Disassembly


13-23

(cont'd)3. Install the parts on the countershaft.

~ REVERSE GEAR

NOTE: Check that the fingers of the friction damperare securely set in the grooves of the 1st/2nd synchro hub.

2. Assemble the parts below as shown.

.._.__ COUNTERSHAFT

L Install the needle bearing on the countershaft.

~4--- 36 x 41 x 25.5 mm., NEEOLE BEARING

NOTE: Refer to page 13-20 for reassembly sequence.

CAUTION:• Press the 3rd, 4th, and 5th gears on the countershaft

without lubrication.• When installing the 3rd, 4th, and 5th gears, support

the shaft on steel blocks and install the gears using apress.

If the runout is more than the service limit, replacethe countershaft with a new one.

Rotate two completerevolutions.

Service Limit: 0.05 mm (0.002 in)0.02 mm (0.001 in) max.Standard:

2. Inspect for runout.

If any part of the countershaft is less than the service limit, replace it with a new one.

A

Standard: A: 30.000 - 30.015 mm(1.1811-1.1817 in)

B: 35.984 - 36.000 mm(1.4167 -1.4173 in)

C: 24.980 - 24.993 mm(0.9835 - 0.9840 in)

Service Limit: A: 29.950 mm (1.1791 in)B: 35.930 mm (1.4146 in)C: 24.930 mm (0.9815 in)

Inspect the gear surfaces and bearing surfaces forwear and damage, then measure the countershaftat points A, B, and C.

1.

ReassemblyInspection

9. Install the spring washer, tighten the locknut, thenstake the locknut tab into groove.

WOOD BLaCKS

LOCKNUT108 - 0 - 108 N'm(11.0 - 0 -11.0 kgf·m, 79.6 - 0 - 79.6Ibf·ft)

8. Securely clamp the countershaft assembly in abench vise with wood blocks.

ATTACHMENT,30 mm 1.0.07746-0030300

BEARING

DRIVER.40 mm 1.0.07746-0030100

CAUTION: Install the bearings with a maximumpressure of 7.8 kN (800 kgf, 5,786Ibf).

7. Install the bearings using the special tools and apress as shown.

13-24

5TH GEAR

ATTACHMENT.30 mm 1.0.07746 - 0030300

6. Install 5th gear using the special tools and a pressas shown.

DRIVER,40 mm 1.0. PRESS07746-0030100----....

DRIVER.40 mm 1.007746-0030100

ATTACHMENT.35 mm 1.0. ---t~~~,._4TH GEAR07746-0030400

5. Install 4th gear using the special tools and a pressas shown.

GEAR

DRIVER.40 mm 1.0.07746-0030100

ATTACHMENT.35 mm 1.0. ---""';1--107746-0030400

4. Support the countershaft on a steel block as shownand install 3rd gear using the special tools and apress as shown.

Reassembly (cont'd)


13-25

5 x 22 mmSPRING PINReplace.

3RD/4THSHIFT PIECE

o

1ST /2ND SHIFT FORK

o

PIN PUNCH. 5.0 mm(Cornrnerciallvavailable)

5 x 22 mmSPRING PINReplace.

MSS SHIFTPIECE

5TH/REVERSESHIFT FORK

, Prior to reassembling, clean ail the parts in salvent, dry them, and apply lubricant ta any contact parts.

Index

Shift Fork Assembly

• If the groove of the shift piece or shift fork is notwithin the standard, replace the shift piece orshift fork with a new one.

• If the groove of the shift piece or shift fork iswithin the standard, replace the shift arm B witha new one.

SHIFT PIECE

Standard: 13.2 - 13.4 mm (0.520- 0.528 in)

4. If the clearance is more than the service limit, measure the groove of the shift piece or shift fork.

SHIFT ARM B


3. Measure the clearance between the shift piece orshift fork and the shift arm B.

13-26

• If the thickness of the shift fork fingers is not within the standard, replace the shift fork with a newone.

• If the thickness of the shift fork fingers is withinthe standard, replace the synchro sleeve with anewone.

Standard:3rd/4th: 7.4 -7.6 mm 10.291- 0.299 in)1st/2nd, 5th: 6.2 - 6.4 mm (0.244- 0.252 in)

2. If the clearance is more than the service limit, measure the thickness of the shift fork fingers.

SHIFT FORK


1. Measure the clearance between each shift fork andits matching synchro sleeve.

NOTE: The synchro sleeve and the synchro hub shouldbe replaced as a set.


Shift Fork Assembly

13-27

SVNCHROSLEEVE

CAUTION: Do not install the synchro sleeve withits longer teeth in the 5ynchro hub 510tsbecause itwill damage the spring ring.SVNCHRO LONGER TEETHHUa

3. When assembling the synchro sleeve and synchrohub, be sure to match the three sets of longer teeth(120 degrees apart) on the synchro sleeve with thethree sets of deeper grooves in the synchro hub.

SVNCHROSlEEVE

NOTE: If replacement is required, always replacethe synchro sleeve and synchro hub as a set.

2. Install each synchro hub in its mating synchrosleeve, and check for freedom of movement.

If the width of the MSS shift piece is less than the service limit, replace the MSS shift piece.

1. Inspect gear teeth on ail synchro hubs and synchrosleeves for rounded off corners, which indicate

Standard: 6.9 -7.1 mm (0.272- 0.280 in) wear.Service Limit: 6.8 mm (0.268 in)

1. Measure the width of the MSS shift piece.

Inspection/InstallationMBS Shift Piece Inspection

Synchro Sleeve,Synchro Hub

SYNCHRO RING

SYNCHRO RING

SYNCHRO SPRING~

B

13-28

If the clearance is less than the service limit, replacethe synchro ring and synchro cone.

Synchro Ring-to-Gear ClearanceStandard: 0.73 -1.18 mm (0.029- 0.046 in)Service limit: 0.4 mm (0.02 in)

NOTE: Hold the synchro ring against the gear evenlywhile measuring the clearance.

Measure the clearance between the synchro ringand gear ail the way around.

2. Coat the cone surface of the gear with oil, and placethe synchro ring on the matching gear. Rotate thesynchro ring, making sure that it does not slip.

F: Inspect the teeth on ail gears for uneven wear,scoring, galling, and cracks.

E: Inspect the cone surface for wear and roughness.

GOOD WORN0: Inspect the gear hub thrust surface for wear.

GOOD WORNC: Inspect the synchro sleeve teeth and matching

teeth on the gear for wear (rounded off).

00

00

B: Inspect the synchro sleeve teeth and matchingteeth on the synchro ring for wear (rounded off).

A: Inspect the inside of the synchro ring for wear.

1. Inspect the synchro ring and gear.

Inspection

Synchro Ring, Gear

13-29

Oll SEAl .Replace. /

SHIFTROO ~

BOOT

DIFFERENTlAl ASSEMBl y

. 10. Remove the magnet.

9. Remove the reverse lock cam.

8. Remove the shift rod, then remove the shift arm A.

7. Remove the shift arm A attaching boit, the set bailspring boit, set spring, and steel bail.

6. Remove shift arms C and B, and the interlock, thenremove the reverse select spring and retainer.

~~~ SHIFT ARM SHAFT

\

1ST/2ND SELECT SPRINGl. 36.26 mm (1.428 in)

28 mm PLUG BOLT

SHIFT ARM C

5. Remove the steel bail, spring, and collar.

NOTE: Be careful not to lose the steel bail.

4. Remove the shift arm shaft.

3. Remove the shift arm C attaching boit.

2. Remove the 28 mm plug boit and 1st/2nd selectspring.

1. Remove the differential assembly.

NOTE: The steel balls are ail of the same size (5/16 in).

Removal

Shift Rad

3. If the backlash is not within the standard, replacethe differential carrier.

Standard (New): 0.05 - 0.15 mm (0.002 - 0.006 in)

2. Measure backlash of bath pinion gears.

13-30

10 x 1.0 mm101N'm (10.3 kgf·m. 74.5 Ibfoft)Left-hand threads

BAll BEA RINGCheck for wear and damage.

Check for wear and damage.

DIAlTHRUST SHIM INDICATOR

1. Place differential assembly on V-blacks, and installbath driveshafts.

Backlash InspectionIndex

Differentiai

13-31

2. Install the final driven gear by tightening the boltsin a crisscross pattern in several steps.

OIFFERENTIAlCARRIER

10x 1.0 mm BOlT101 N-m (10.3 kgf-m. 74.5 IbHt)Left-hand threads.

FINAL ORIVEN GEARChamfer on inside diameter of

NOTE: The final driven gear bolts have left-handthreads.

1. Remove the bolts in a crisscross pattern in severalsteps, then remove the final driven gear from thedifferential carrier.

BAll BEARING

DRIVER. 40 mm 1.0.)7746-0030100

NOTE: Drive the bearings squarely until they bottom against the carrier.

2. Install new bail bearings using the special tool asshown.

1. Remove the bail bearings using a bearing puller asshown.

NOTE: Check bearings for wear and rough rotation. Ifthe bearings are OK, removal is not necessary.

Final Driven Gear ReplacementBearing Replacement

6. Measure clearance between thrust shim and bearing outer race in transmission housing.

5. Use the special tool to bottom the differential assernbly in the clutch housing.

8 x 1.25 mm27 N'm (2.8 kgf·m, 20 Ibf.ft)

4. Tighten the transmission housing attaching borts(see page 13-42).

NOTE: Do not apply liquid gasket to the mating surface of the clutch housing.

3. Install the transmission housinq (see page 13-41).

13-32

TRANSMISSIONHOUSING

NOTE: Install the same size thrust shim that wasremoved.

2. Install the thrust shim.

CLUTCHHOUSING

DRIVER. 40 mm 1.0.07746-0030100

1. Install the differential assembly, making sure it bottoms in the clutch housing, using the special tool asshown.

Thrust Shim Adjustment

Differentiai

13-33

10. Remove the bolts and transmission housing. Applyliquid gasket to the surface of the transmissionhousing and reassemble.

9. Replace the thrust shim selected in step 7, th enrecheck the clearance.

8. Remove the bolts and transmission housing.

Part Number Thickness

41441 - PL3 - BOO 1.0 mm (0.0394 in)

41442 - PL3 - BOO 1.1 mm (0.0433 in)

41443 - PL3 - BOO 1.2 mm (0.0472 in)

41444 - PL3 - BOO 1.3 mm (0.0512 in)

41445 - PL3 - BOO 1.4 mm (0.0551 in)

41446 - PL3 - BOO 1.5 mm (0.0591 in)

41447 - PL3 - BOO 1.6 mm (0.0630 in)

41448 - PL3 - BOO 1.7 mm (0.0669 in)

41449 - PL3 - BOO 1.8 mm (0.0709 in)

41450 - PL3 - BOO 1.05 mm (0.0413 in)

41451 - PL3 - BOO 1.15 mm (0.0453 in)

41452 - PL3 - BOO 1.25 mm (0.0492 in)

41453 - PL3 - 800 1.35 mm (0.0532 in)

41454 - PL3 - BOO 1.45 mm (0.0571 in)

41455 - PL3 - BOO 1.55 mm (0.0610 in)

41456 - PL3 - BOO 1.65 mm (0.0650 in)

41457 - PL3 - BOO 1.75 mm (0.0689 in)

80 mm THRUST SHIM:

Standard: 0 - 0.10 mm (0 - 0.004 in)

NOTE: If the clearance measured in step 6 is withinthe standard, go to step 10.

7. If the clearance is more than the standard, select anew thrust shim from the following table.

\i4--- BALL BEARINGShieldedside down.

CLUTCHHOUSING

ATTACHMENT, 52 x 55 mm DRIVER07746-0010400 07749-0010000

/

4. Drive the bail bearing into the clutch housing usingthe special tools as shown.

DRIVER07749-0010000

/ATTACHMENT. 42 x 47 mm07746-0010300

ClUTCH \HOUSING<,

3. Drive the new oil seal into the clutch housing usingthe special tools asn shown.

13-34

OIL SEALReplace.

CLUTCHHOUSING

2. Remove the oil seal from the clutch housing.

ADJUST ABLE BEARINGPUllER, 25 - 40 mm07736-A01000A

3/8' -16 SLiDE HAMMER(Commercially availablel

1. Remove the bail bearing using the special tool asshown.

Mainshaft

Replacement

Clutch Housing Bearing

13-35

NEEDlE BEARING

OIL GUIDE PLATE

CLUTCHHOUSING

DRIVER07749-0010000

NEEDLEBEARING

ATTACHMENT. 52 x 55 mm07746-0010400

OIL GUIDE PLATE

2. Install the oil guide plate, th en drive the needlebearing into the clutch housing using the specialtools as shown.

AOJUSTABLE BEARINGPULLER.25-40 mm07736-A01000A

3/8" -16 SUOE HAMMER

1. Remove the needle bearing using the special tool asshown, then remove the oil guide plate.

Countershaft

subtract the spring washer height (O.95mm) = therequired thrust shim (1.14 mm)

Example of calculation:Distance @ (2.00 mm) + Distance© (O.09mm):::2.09 mm

(Basic Formula)(B) + (C) - 0.95 = shirn thickness

NOTE: Use only one thrust shim.

5. Select the proper shim on the basis of the followingcalculations:

INNER RACE OF BALL BEARING

END OF CLUTCH HQUSING

~ __ l-----'-r-L_

NOTE:• Use a straight edge and depth gauge.• Measure at three locations and average the

readings.

4. Measure the distance © between the surfaces ofthe clutch housing and bearing inner race.

13-36

NOTE:• Use a straight edge and vernier caliper.• Measure at th ree locations and average the

readings.

3. Measure the distance @ between the end of thetransmission housing and thrust washer.

BALL BEARING

THRUST WASHER

THRUST SHI~ {~~

OIL GUIDE 0c)j /PLATE ~ V___

o ZJ (TRANSMISSION / ~ \HOUSING - //\)

2. Install the 3rd/4th synchro hub, spacer collar, 5thsynchro hub, bail bearing, and thrust washer on themainshaft. Install the assembly in the transmissionhousing.

1. Remove the thrust shim and oil guide plate fromthe transmission housing.

Adjustment

Mainshaft Thrust Shim

13-37

(cont'd)

07GAJ-PG20120

a. Siide the mainshaft base and the collar over themainshaft.

CAUTION: Measurement should be made at roomtemperature.

12. Check the thrust clearance in the manner describedbelow.

11. Tap the mainshaft with a plastic hammer.

8x1.25mm27 N'm (2.8 kgf·m, 20 Ibf.ft)

NOTE: It is not necessary to use sealing agentbetween the housings.

10. Tighten the clutch and transmission housings withseveral 8 mm bolts.

9. Place the transmission housing over the mainshaftand cnte the clutch housing.

8. lnstall the mainshaft in the clutch housing.

.....--- MAINSHAFT

.-- SPRINGWASHER

«@)))

7. lnstall the thrust washer and spring washer in themainshaft.

6. Install the oil guide plate and selected thrust shim inthe transmission housing.NOTE:• Clean the thrust washer, spring washer and

thrust shim thoroughly before installation .• Install the thrust washer, spring washer and

thrust shim properly. r.~~THRUSTSH1M---TC. •• .; ~

Oll GUIDE-TW '~ r --TPLA TE \ T;'/j ~.•

TRANSMISSION ~ ':;J-.-~~ ...y...( . (HOUSING " ~-:-' \

Part Number ThicknessA 23931 - PL3 - BOO 0.60 mm (0.0236 in)

B 23932 - PL3 - BOO 0.63 mm (0.0284 in)

C 23933 - PL3 - BOO 0.66 mm (0.0260 in)

D 23934 - PL3 - BOO 0.69 mm (0.0272 in)

E 23935 - PL3 ..,.BOO 0.72 mm (0.0283 in)F 23936 - PL3 - BOO 0.75 mm (0.0295 in)

G 23937 - PL3 - BOO 0.78 mm (0.0307 in)H 23938 - PL3 - BOO 0.81 mm (0.0319 in)1 23939 - PL3 - BOO 0.84 mm (0.0331 in)

J 23940 - PL3 - BOO 0.87 mm (0.0343 in)1( 23941 - PL3 - BOO 0.90 mm tO.0354in)L 23942 - PL3 - BOO 0.93 mm (0.0366 in)M 23943 - PL3 - BOO 0.96 mm (0.0378 in)N 23944 - PL3 - BOO 0.99 mm (0.0390 in)

0 23945 - PLl - BOO 1.02mm (0.0402 in)P 23946 - PL3 - BOO 1.05mm (0.0413 in)Q 23947 - PLl - BOO 1.08mm (0.0425 in)

R 23948 - PL3 - BOO 1.11 mm (0.0437 in)S 23949 - PL3 - BOO 1.14mm (0.0449 in)

T 23950 - PL3 - BOO 1.17 mm (0.0461 in)

U 23951 - PL3 - BOO 1.20 mm <0.0472in)V 23952 - PL3 - BOO 1.23mm <0.0484in)W 23953 - PL3 - BOO 1.26mm (0.0496 in)X 23954 - PL3 - BOO 1.29 mm (0.0508 in)y 23955 - PLl - BOO 1.32mm (0.0520 in)

Z 23956 - PL3 - BOO 1.35mm (0.0531 in)AA 23957 - PL3 - BOO 1.38mm (0.0543 in)AB 23958 - PL3 - BOO 1.41mm (0.0555 in)AC 23959 - PL3 - BOO 1.44mm (0.0567 in)AD 23960 - PL3 - BOO 1.47mm (0.0579 in)AE 23961 - PL3 - BOO 1.50mm (0.0591 in)AF 23962 - PL3 - BOO 1.53mm (0.0602 in)AG 23963 - PL3 - BOO 1.56mm (0.0614 in)AH 23964 - PL3 - BOO 1.59mm (0.0626 in)AI 23965 - PL3 - BOO 1.62mm (0.0638 in)AJ 23966 - PL3 - BOO 1.65mm (0.0650 in)AI( 23967 - PL3 - BOO 1.68mm (0.0661 in)AL 23968 - PL3 - BOO 1.71mm (0.0673 in)AM 23969 - PL3 - BOO 1.74mm (0.0685 in)AN 23970 - PL3 - BOO 1.77mm (0.0697 in)AO 23971 - PL3 - BOO 1.80mm (00709 in)

70 mm THRUST SHIM:

Standard: 0.11 - 0.18 mm (0.004 - 0.007 in)

g. If the reading is within the standard, the clearance iscorrect.If the reading is not within the standard, recheck theshim thickness.

CAUTION: Turning the mainshaft holder boIt morethan 60 degrees after the needle of the dial gaugestops moving may damage the transmission.

f. Turn the mainshaft holder boit clockwise; stopturning when the dial gauge has reached its maximum movement. The reading on the dial gauge isthe amount of mainshaft end play.

MAINSHAFT HOLOER07GAJ-PG20110

e. Zero a dial gauge on the end of the mainshaft.

13-38

d. Thread the mainshaft holder boit in until it just contacts the wide surface of the mainshaft base.

c. Seat the mainshaft fully by tapping on the end with aplastic hammer.

HEXBOLTSr"!"""---=-....:l.

MAINSHAFT HOLOERBOLT

NOTE:• Back-out the mainshaft holder boIt and loosen the

two hex bolts.• Fit the holder over the mainshaft so its lip is

toward the transmission.• Align the mainshaft holder's lip around the groove

at the inside of the mainshaft splines, then tightenthe hex bolts.

b. Attach the mainshaft holder to the mainshaft asfollows:

Adjustment (cont'd)

Mainshaft Thrust Shim

13-39

(cont'd)

SHIFTROD

Replace.SHIFTARM SHAFT

SPRINGL. 21.4 mm(0.843 in)

SHIFTARM A---------..:JL

6 x 1.0 mmSHIFTARM C 15 N·m (1.5 kgf·m. 11 Ibf·ft)

*A: 8 x 1.0 mm31 N'm (3.2kgf'm,23 Ibf.ft)

10. Install the differential assembly.

9. Install the reverse select retainer and reverse selectspring cnte shift arm shaft.

8. Install shift arm C in shift arm A, then insert the shiftarm shaft.

7. Install the collar, spring, and steel bail into the case.Compress the bail and insert the shift arm shaft.

6. Insert shift arm shaft in the clutch housing.

5. Install shift arm B in the interlock, then set it on theclutch housing.

4. Install the steel bail, spring, and set bail spring boit.

3. Install the spring washer and shift arm A attachingboit.

2. Set shift arm A on the clutch housing, then installthe shift rod.

1. Install the magnet and reverse lock cam.

NOTE: The steel balls are ail of the same size (5/16 in).

Reassembly

Transmission

6 x '.0 mm15 N·m ('.5 kgf·m.11 IbHt)

REVERSESHIFTHOlDER

16. Install the reverse shift holder.

REVERSEIDLERGEAR

REVERSEIDLERGEAR SHAH

15. Install the reverse idler gear and reverse idler gearshaft.

13-40

NOrE: Apply liquid gasket (PIN 08718 - 0001 or08718 - 0003) to the threads of the 28 mm plug boItand interlock guide boit.

14. Install the 1st/2nd select spring, 28 mm plug boit.and interlock guide boIt.

&\INTERLOCKGUIDE BOLT39 N·m (4.0 kgf·m. 29 Ibf.ft)

28 mm PlUG BOLT54 N·m (5.5 kgf·m.40Ibf·ft)

13. Install the spring washer and shift arm 8 attachingboit.

NOTE: Align the finger of the interlock with thegroove in the shift fork shaft.

12. Install the mainshaft, countershaft, and shift forkassemblies.

MAINSHAFTICOUNTERSHAFTSHIFT FORKASSEMBLIES

, t. Position the 36 mm spring washer and washer ontothe mainshaft bearing.

Reassembly (cont'd)

Transmission

13-41

(cont'd)

NOTE: Apply liquid gasket (PIN 08718 - 0001 or08718 - 0003) to the threads.

22. Install the 32 mm sealing boit.

4.6-8.3 mm10.18-0.33 in)

SNAPRING

32 mm SEAlING BOLT25 N'm (2.5 kgf·m. 18 Ibf.ft)

NOTE: Check that the snap ring is securely seatedin the groove of the countershaft bearing.

21. Lower the transmission housing with the snap ringpliers, and set the snap ring into the groove of thecountershaft bearing.

20. Install the dowel pins and the transmission housing.

: liquid gasket

NOTE:• Use liquid gasket (PIN 08718 - 0001 or 08718 -

0003).• Remove the dirty oil from the sealing surface.• If 20 minutes have passed after applyhing liquid

gasket, reapply it and assemble the housings.• Allow it to cure at least 20 minutes after assem

bly before filling the transmission with oil,

19. Apply liquid gasket to the surface of the transmission housing mating with the clutch housing asshown.

18. Install the oil guide plate and thrust shim on thetransmission housing.

TRANSMISSIONHOUSING

OILGUTTERPLATE

17. Install the oil gutter plate.

BACK-UP LlGHT SWITCH25 N·m (2.5 kgf·m. 18 Ibfoftl

8 x , .25 mm27 N·m (2.8 kgf·m. 20 IbHt)

25. Install the back-up light switch and transmissionhanger.

13-42

24. Install the steel balls, springs, and set screws.

o e

BACK-UP LlGHT SWITCHHARNESS STAY

8 x 1.25 mmTorque: 27 N·m (2.8 kgf·m, 20 Ibf.ft)

23. Tighten the transmission housing attaching bolts inthe numbered sequence in several steps shownbelow.

Reassembly (cont'd)

Transmission

13-43

PILOT.26 x 30 mm07JAD-PH80200

DRIVERATTACHMENT07JAD-PH80101

DRIVER07749-0010000

"

2. Install the oil seal into the clutch housing using thespecial tools as shown.

aiL SEALReplace.

1. Remove the oil seal from the clutch housing.

Clutch Housing:

~ PILOT.26 x 30 mm07JAD - PH80200

\

~1

SEALDRIVERATTACHMENT07947-6110501 or07947 -6110500

/

DRIVER07749-0010000 1

<,

2. lnstall the oil seal into the transmission housingusing the special tools as shown.

1. Remove the oil seal from the transmission housing.

Transmission Housing:

Replacement

Oil Seals

13-44

\HOLESPRINGPIN

Replace.

Replace.6 x '.0 mm9.8 Nom (1.0 kqf-rn. 7.2 Ibf.ft)

SElF·lOCKING NUT

SHIFT LEVERBAll HOlDER

SPRINGPIN~Replace. ~

SHIFT ROD

1

END BUSHING

EXTENSIONBOlT

J

8)( 1.25 mm22 Nom (2.2 kgfom. 16 Ibfoft)

NOTE:• Inspect rubber parts for wear and damage when disassembling; replace any worn or damaged parts.• Install the clip as shown.• Turn the boot so the hole is facing down as shown.• Make sure the boot is installed on the shift rod.

Overhaul

Gearshift Mechanism

Valve BodyRepair 14-117

ValveAssembly 14-118

ATF PumpInspection 14-119

Main Valve BodyDisassembly Ilnspection/Reassembly 14-120

Secondary Valve BodyDisassembly Ilnspection/Reassembly 14-122

Regulator Valve BodyDisassembly Ilnspection/Reassembly 14-123

Servo BodyDisassembly Ilnspection/Reassembly 14-124

Lock-up Valve BodyDisassembly Ilnspection/Reassembly 14-125

MainshaftDisassembly/lnspection Reassembly 14-126Inspection 14-127

Sealing RingsReplacement 14-128

CountershaftDisassembly Ilnspection/Reassembly 14-129Disassembly IReassembly 14-130Inspection 14-131

One-way ClutchDisassembly Ilnspection/Reassembly 14-133

ClutchlIIustrated Index 14-134Disassembly 14-136Reassembly 14-138

DifferentiailIIustrated Index 14-142Backlash Inspection 14-143Bearing Replacement 14-143Differentiai Carrier Replacement 14-144Oil Seal Removal 14-145Oil Seallnstallation/Side Clearance 14-145

Torque Converter Housing BearingsMainshaft Bearing/Oii Seal Replacement 14-148Countershaft Bearing Replacement 14-149

Transmission Housing BearingsMainshaft/Countershaft Bearings

Replacement 14-150Reverse Idler Gear

Installation 14-151Parking Brake Stop

Inspection lAd just ment 14-151Transmission

Reassembly 14-152Torque Converter/Drive Plate 14-159Transmission

Installation 14-160Cooler Flushing 14-164

Shift CableRemovai/lnstallation 14-166Adjustment 14-167

Shift Lever 14-168Shift Indicator Panel

Adjustment 14-169ATF Cooler Hoses

Connection : 14-169

Special Toois 14-2Description 14-3

Power Flow 14-6Electronic Control System 14-13Hydraulic Control 14-18Hydraulic Flow 14-23Lock-up System 14-32

Electrical SystemComponent Locations 14-39PCM Circuit Diagram

(AIT Control System) 14-40PCM Terminal Voltage/Measuring Conditions

AIT Control System 14-42Troubleshooting Procedures 14-44Symptom-to-Component Chart

Electrical System 14-48Electrical Troubleshooting

Troubleshooting Flowcharts 14-50Lock-up Control Solenoid Valve A/B Assembly

Test ~ 14-77Replacement 14-77

Shift Control Solenoid Valve A/B AssemblyTest 14-78Replacement 14-78

Linear Solenoid AssemblyTest 14-79Replacement ~ 14-80

Mainshaft/Countershaft Speed SensorsReplacement 14-80

AIT Gear Position SwitchTest 14-81Replacement 14-82Adjustment 14-82

AIT Gear Position IndicatorInput Test 14-83

Interlock SystemInterlock Control Unit Input Test 14-84Key Interlock Solenoid Test 14-86Shift Lock Solenoid Test 14-86Shift Lock Solenoid Replacement 14-87Parking Pin Switch Test 14-87

Hydraulic SystemSymptom-to-Component Chart

Hydraulic System 14-88Road Test 14-92Stail Speed

Test 14-94Fluid Level

Checking/Changing 14-95Pressure Testing 14-96TransmissionTransmission

Removal 14-100lIIustrated Index

Transmission/Right Side Cover 14-104Transmission Housing 14-106Torque Converter Housing/Valve Body 14-108

Right Side CoverRemoval 14-110

Transmission HousingRemoval 14-112

Torque Converter Housing/Valve BodyRemoval 14-114

Valve CapsDescription 14-116

Automatic Transmission

@@@ @

[J

®

®(ID

Q

14-2

@

®

~m1hjj)i1i

* 07HAE - PL50101 may be used to substitute one of these tools.** Must be used with commercially-available 3/8" - 16 slide hammer.

1

Oty Page Reference

14-111, 15614-136,13914-113

1 14-1471 14-1472 14-136, 1394 14-964 14-961 14-452 14-46,92

14-9614-9614-148, 149

14-148, 149, 15014-148,15014-131, 143, 14~ 14614-147,148,149,15014-147

Ref. No. Tooi Number Description

CD 07GAB - PF50101 Mainshaft HolderCID 07GAE - PG40200 or Clutch Spring Compressor Boit Assembly<ID 07HAC - PK4010A Housing Puller@ 07JAO - PH80101 Driver Attachment<ID 07JAO - PH80200 Pilot, 26 x 30 mm*® 07LAE - PX40100 Clutch Spring Compressor Attachment(j) 07MAJ - PY4011A Aff Pressure Hose, 2210 mm® 07MAJ - PY40120 Aff Pressure Hose Adapter® 07PAZ - 0010100 SCS Service Connector@ 07SAZ - 001000A Backprobe Set@ 07406 - 0020400 Aff Oil Pressure Gauge Set w!Panel@ 07406 - 0070300 Aff Low Pressure Gauge w!Panel

**@ 07736 - A01000B or Adjustable Bearing Puller, 25 - 40 mm07736 - A01000A

@ 07746 - 0010500 Attachment, 62 x 68 mm@ 07746 - 0010600 Attachment, 72 x 75 mm@ 07746 - 0030100 Driver 40 mm 1.0.@ 07749 - 0010000 Driver@ 07947 - 611501 Driver Attachment, 68 mm

Special T0015

14-3

(cont'd)

Lock-up Mechanismln _[)~position, in 3rd and 4th, and in ~ position in 3rd, pressurized fluid is drained from the back of the torque converterthrough a fluid passage, causing the lock-up piston to be held against the torque converter cover. As this takes place, themainshaft rota tes at the same speed as the engine crankshaft. Together with hydraulic control, the PCM optimizes the timing of the lock-up mechanism. The lock-up valves control the range of lock-up according to lock-up control solenoid valvesA and B, and linear solenoid. When lock-up control solenoid valves A and B activate, the modulator pressure changes. Thelock-up control solenoid valves A and B and the linear solenoid are controlled by the PCM.

Shift Control MechanismInput from various sensors located throughout the vehicle determines which shift control solenoid valve the PCM will activate. Activating a shift control solenoid valve changes modulator pressure, causing a shift valve to move. This pressurizesa line to one of the clutches, engaging that clutch and its corresponding gear. The shift control solenoid valves A and B arecontrolled by the PCM.

The main valve body contains the manual valve, the 1-2 shift valve, the 2nd orifice control valve, the CPB (Clutch PressureBack-up) valve, the modulator valve, the servo control valve, the relief valve, and ATF pump gears. The secondary valvebody contains the 2-3 shift valve, the 3-4 shift valve, the 3-4 orifice control valve, the 4th exhaust valve and the CPC(ClutchPressure Control) valve. The regulator valve body contains the pressure regulator valve, the torque converter check valve,the cooler relief valve, and the lock-up control valve. The servo body contains the servo valve which is integrated with thereverse shift fork shaft, and the accumulators. The lock-up valve body contains the lock-up shift valve and the lock-up timing valve. The linear solenoid and the shift control solenoid valve NB are bolted on the outside of the transmission housing, and the lock-up control solenoid valve NB is bolted on the outside of the torque converter housing. Fluid from regulator passes through the manual valve to the various control valves. The clutches receive fluid from their respective feedpipes or internaI hydraulic circuit.

Hydraulic ControlThe valve bodies include the main valve body, the secondary valve body, the regulator valve body, the servo body and thelock-up valve body through the respective separator plates. They are bolted on the torque converter housing.

Electronic ControlThe electronic control system consists of the Powertrain Control Module (PCM), sensors, a linear solenoid and foursolenoid valves. Shifting and Iock-up are electronically controlled for comfortable driving under ail conditions. The PCM islocated below the dashboard, under the front lower panel on the passenger's side.

The transmission has two parallel shafts: the mainshaft and the countershaft. The mainshaft is in line with the enginecrankshaft. The mainshaft includes the tst, 2nd and 4th clutches, gears for 2nd, 4th, reverse and lst (3rd gear is integralwith the mainshaft, white the reverse gear is integral with the 4th gear). The countershaft includes the 3rd clutch, andgears for 3rd, 2nd, 4th, reverse, lst and parking. The gears on the mainshaft are in constant mesh with those on the countershaft. When certain combinations of gears in transmission are engaged by clutches, power is transmitted from themainshaft to the countershaft to provide œ, ro;1, 04, and [B] positions.

Torque Converter, Gears and ClutchesThe torque converter consists of a pump, turbine and stator, assembled in a single unit. They are connected to the enginecrankshaft so they turn together as a unit as the engine turns. Around the outside of the torque converter is a ring gearwhich meshes with the starter pin ion when the engine is being started. The entire torque converter assembly serves as aflywheel while transrnittinq power to the transmission mainshaft.

The automatic transmission is a combination of a 3-element torque converter and a dual-shaft electronically controlledautomatic transmission which provides 4 speeds forward and 1 reverse.

Description

14-4

4th ClutchThe 4th clutch engages/disengages 4th gear, as weil as reverse gear, and is located at the middle of the mainshaft. The 4thc1utch is joined back-to-back to the 2nd clutch. The 4th c1utch is supplied hydraulic pressure by its ATF feed pipe within thernainshaft.

3rd ClutchThe 3rd clutch engages/disengages 3rd gear, and is located at the end of the countershaft. The 3rd clutch is suppliedhydraulic pressure by its ATF feed pipe within the countershaft.

2nd ClutchThe 2nd c1utch engages/disengages 2nd gear, and is located at the middle of the mainshaft. The 2nd clutch is joined backto-back to the 4th clutch. The 2nd clutch is supplied hydraulic pressure through the mainshaft by a circuit connected to theinternai hydraulic circuit.

1st ClutchThe 1st clutch engages/disengages 1st gear, and is located at the end of the mainshaft, just behind the right side cover.The 1st clutch is supplied hydraulic pressure by its ATF feed pipe within the mainshaft.

ClutchesThe four-speed automatic transmission uses hydraulically-actuated clutches to engage or disengage the transmission gears.When hydraulic pressure is introduced into the clutch drum, the clutch piston moves. This presses the friction dises andsteel plates together, locking them so they don't slip. Power is then transmitted through the engaged clutch pack to itshub-mounted gear. Likewise, when the hydraulic pressure is bled from the clutch pack, the piston releases the friction disesand the steel plates, and they are free to slide past each other. This allows the gear to spin independently on its shaft,transmitting no power.

Automatic Transaxle (AIT) Gear Position IndicatorThe AIT gear position indicator in the instrument panel shows which gear has been selected without having to look downat the console.

Starting is possible only in ŒJ and [[1positions through the use of a si ide-type, neutral-safety switch.

Use for engine braking or better traction starting off on loose or slippery surfaces; stays in 2nd1 gear, does not shift up and down.

Use for rapid acceleration at highway speeds and general driving; up-hill and down-hill driving; startsoff in 1st. shifts automatically to 2nd, then 3rd, depending on vehicle speed and throttle position.Downshifts through 2nd to 1st on deceleration to stop. The lock-up mechanism comes into operationin 3rd gear.

General driving; starts off in 1st, shifts automatically to 2nd, 3rd, then 4th, depending on vehiclespeed and throttle position. Downshift through 3rd, 2nd and 1st on deceleration to stop. The lock-upmechanism comes into operation in ~ position in 3rd and 4th gear.

Ali c1utches released.

Reverse; reverse selector engaged with countershaft reverse gear and 4th clutch locked.

Front wheels locked; parking brake pawl engaged with parking gear on countershaft. Ali clutchesreleased.

Description

œ SECOND

Position

ŒJ PARK

[ID REVERSE

[R] NEUTRAL

:p.' DRIVE(1st through 4th)

1

1-

DRIVE03(1st through 3rd)

Gear SelectionThe shift lever has six positions: ŒJ PARK, (B] REVERSE,[R] NEUTRAL, [Q;] 1st through 4th gear ranges, [Qi] 1st through 3rdgear ranges, œ 2nd gear.

(cont'd)

Description

14-5

OVER-RIDINGlOCKING SPEED CONDITION

lOCKING CONDITIONSPRAG

OUTSIDE OF ONE-WAYCLUTCH

1The sprags engage/disengage outside

~~~ and inside of theone-way clutch.

INSIDE OF ONE-WAYCLUTCHSplined with countershaft

PARKING GEAR

ONE-WAY CLUTCH

COUNTERSHAFT

lSTClUTCH

4TH ClUTCH2NDClUTCH

However, the one-way clutch disengages when the 2nd, 3rd, or 4th clutches/gears are applied in the ~, [Q!] or 00 position.This is because theincreased rotational speed of the gears on the countershaft overrides the locking "speed range" of theone-way clutch. Thereafter, the one-way clutch free-wheels with the 1st clutch still engaged.

One-way ClutchThe one-way clutch is positioned between the countershaft 1st gear and the parking gear, with the parking gear splined to thecountershaft. The 1st gear provides the outer race surface, and the parking gear provides the inner race surface. The oneway clutch locks up when power is transmitted from the mainshaft 1st gear to the countershaft 1st gear. The 1st clutchand gears remain engaged in the 1st, 2nd, 3rd, and 4th gear ranges in the ~, [Qi] or 00 position.

14-6

0: Operates, x: Doesn't operate.*1: Although the 1st clutch engages, driving power is not transmitted as the one-way clutch slips.*2: The one-way clutch engages when accelerating, and slips when decelerating.

~

TORQUE lSTGEAR 2ND GEAR 3RD GEAR 4TH REVERSE PARKINGlST 2ND 3RDCONVERTER CLUTCH CLUTCH CLUTCH GEAR CLUTCH GEAR GEAR0

œ 0 x x x x x x 0[ft] 0 x x x x 0 0 x

[ID 0 x x x x x x x

lST 0 0*2 x X X X X x

2ND 0 0*' 0 x x x x x[Q;]

3RD 0 0*' 0x x x x x

4TH 0 0*' x x 0 0 x x

lST 0 0*2 x X X X X X

Q3 2ND 0 0*' 0 x x x x. x

3RD 0 0*' x 0 x x x x

[ID 0 i 0*' 0 x x x x x

Power Flow

Description

14-7

(cont'd)

FINAL DRIVEN GEAR

SERVOVALVE

E-WAY CLUTCH

MAINSHAFT

TORQUECONVERTER

[f] PositionHydraulic pressure is not applied to the clutches. Power is not transmitted to the countershaft.The countershaft is locked by the parking pawl interlocking the parking gear.

[ffi PositionHydraulic pressure is not applied to the clutches. Power is not transmitted to the countershaft.

14-8

FINAL DRIVEN GEAR

ONE-WAY CLUTCH

COUNTERSHAFT

MAINSHAFT 1ST GEAR

3. Power is transmitted to the final drive gear, which drives the final driven gear.

2. Power is transmitted to the countershaft 1st gear, which drives the countershaft via the one-way clutch.

1. Hydraulic pressure is applied to the 1st cJutch, which rotates together with the mainshaft, causing the mainshaft 1stgear to rotate.

ln [Q;] or [Q!] position, the optimum gear is automatically selected from 1st, 2nd, 3rd and 4th gears, according to conditionssuch as the balance between throttle opening (engine load) and vehicJe speed.

1st Gear ([Q;] or ~ position)

Power Flow (cont'd)

Description

14-9

(cont'd)FINAL DRIVEN GEAR

l~----COUNTERSHAFT

NOTE: Hydraulic pressure is also applied to the 1st clutch, but since the rotation speed of the 2nd gear exceeds thatof 1st gear, power from 1st gear is cut off at the one-way clutch.

3. Power is transmitted to the final drive gear, which drives the-final driven gear.

2. Power transrnitted to the mainshaft 2nd gear is conveyed via the countershaft 2nd gear, which drives the countershaft.

1. Hydraulic pressure is applied to the 2nd clutch on the mainshaft, and power is transmitted via the 2nd clutch to themainshaft 2nd gear.

œ Position is provided to drive only 2nd gear.

2nd Gear (~, [Qi] or œ position)

14-10

FINAL DRIVEN GEAR

COUNTERSHAFT

FINAL DRIVEGEAR

TORQUECONVERTER

NOTE: Hvdraulic pressure is also applied to the 1st clutch, but since the rotation speed of 3rd gear exceeds that of 1stgear, power from 1st gear is eut off at the one-way clutch.


1. Hydraulic pressure is applied to the 3rd clutch. Power from the mainshaft 3rd gear is transmitted to the countershaft3rd gear.

3rd Gear (~ or [Qi] position)

Power Flow (cont'd)

Description

14-11

(cont'd)

FINAL DRIVEN GEAR

COUNTERSHAFT

fiNAL DRIVEGEAR

TORQUECONVERTER

NOTE: Hydraulic pressure is also applied to the 1st clutch, but since the rotation speed of 4th gear exceeds that of 1stgear, power from 1st gear is eut off at the one-way clutch.


2. Power is transmitted to the countershaft 4th gear, which drives the countershaft.

1. Hydraulic pressure is applied to the 4th clutch, which rotates together with the mainshaft, causing the mainshaft 4thgear to rotate.

4th Gear ([Q;] position)

14-12

SERVO VALVE

- COUNTERSHAFTREVERSE GEAR

REVERSEIOlER~GEAR

TORQUE CONVERTER


3. The rotation direction of the countershaft reverse gear is changed via the reverse id1ergear.

2. Hydraulic pressure is also applied to the 4th clutch. Power is transmitted trom the mainshaft reverse gear via thereverse idler gear to the countershaft reverse gear.

1. Hydraulic pressure is switched by the manual valve to the servo valve, which moves the reverse shift fork to thereverse position. The reverse shift fork engages with the reverse selector, reverse selector hub, and the countershaftreverse gear.

[ID Position

Power Flow (cont'd)

Description

14-13

(cont'd)

Throttle Position Sensor Vehicle Speed SensorSignal Signal

PGM-FIControl System

Engine Coolant Temperature Service Check ConnectorSensor Signal

-----------AIT Control System

-...._ INTERLOCK - P Shift Control

CONTROL UNIT Solenoid Valve A

R '\ Shift Control,./ Shift ControlSolenoid Valve B

N

0.. Linear Solenoid

03r--- Lock-up Control Lock-up Control

2Solenoid Valve A

- -Lock-up ControlSolenoid Valve B

.---- ~ Indicator Light Mainshaft Speed SensorSignal

y Self-Oiagnosis Signal Self-Oiagnosis Countershaft SpeedFunction Sensor Signal

PCM

The electronic control system consists of a Powertrain Control Module (PCM), sensors, a linear solenoid and four solenoidvalves. Shifting and lock-up are electronically controlled for comfortable driving under ail conditions. The PCM is locatedbelow the dashboard, under the front lower panel on the passenger's side.

Electronic Control System

14-14

lock-up Conditionslock-up Control Lock-up Control Linear SolenoidSolenoid Valve A Solenoid Valve B Pressure

Lock-up OFF OFF OFF High

Lock-up, Half ONDuty operation

LowOFF - ON

Lock-up, Full ON ON High

Lock-up ON DutY operationLowduring deceleration OFF - ON

lock-up ControlFrom sensor input signais, the PCM determines whether to turn the lock-up ON or OFF, and activates lock-up controlsolenoid valve A and/or B accordingly. The combination ot driving signais to lock-up control solenoid valves A and Bandthe linear solenoid pressure is shown in the table below.

*See page 14-30 for reverse inhibitor control description.

Position GearShift Control Solenoid Shift Control Solenoid

Valve A Valve B

tst OFF ON

[Q;],[QiJ 2nd ON ON

3rd ON OFF

~ 4th OFF OFF

œ 2nd ON ON

(ID* Reverse ON OFF

Shift ControlThe PCM instantaneously determines which gear should be selected by various signais sent trom sensors, and actuatesthe shift control solenoid valves A and B to control shifting. Also, a Grade Logic Control System has been adopted to control shifting in [Q;J position while the vehicle is ascending or descending a slope, or reducing speed.

Electronic Control System (cont'd)

Description

14-15

(cont'd)

-H Vehicle Speed t-Sensor

r-- r- Judgement of Controlling Area

H Throttle Position r- Driving Resistance.. r-

I-.. SensorT 1e.g

:s H ~Calculation

Detection ofCalculationc Ba rometric standard0

U Pressure Sensor of actual acceleration of decelera-0 acceleration tionc (in Memory):!Q HEngine Coolant Coolant Temperature t- 1 1

Temperature Sensor Calculation of gradient

r ,L-H AIT Gear Position ~ Position

~1 T

Switch Selection of Shifting Mode,1

• Ascending mode(Fuzzy ~ogicl • Normal• Graduai Ascending mode mode• Steep Ascending mode o De-

• Descending mode celerationo Graduai Descending mode mode• Steep Descending mode

TT

Automatic .. Speeds

PCMSIGNALS DETECTEDSENSORS

How it works:The PCM compares actual driving conditions with driving conditions memorized in the PCM, based on the input trom thevehicle speed sensor, the throttle position sensor, the barometoric pressure sensor, the engine coolant temperature sensor,the brake switch signal, and the shift lever position signal. The PCM is then able to control shifting while the vehicle isascending or descendinq a slope, or reducing speed.

Grade Logic Control System

14-16

When the vehicle goes around a corner, and needs to first decelerate and then accelerate, the PCM sets the data for decelerationcontrol to reduce the number of times the transmission shifts. When the vehicle is decelerating trom speeds above 26 mph(41 krn/h), the PCMshifts the transmission from 4th to 2nd earlier than normal to cope with upcoming acceleration.

Deceleration Control

Vehicle speed62mph(100 km/hl

Vehicle speed62mph(100 km/hl

O~------~----------~---- __

STEEP DESCENDING

__/MODE

CIc'ë41Q.o 50QI

"Eo.è1-

."1 STEEP ASCENDfNG

~TROLAREA

!~3RD/4TH SHfFTfNGi CHARACTERfSTICS1 CONTROL AREA

o '--------L-7 j

GRADUAl ASCENDfNGCONTROL AREA

..GRADUAL DESCENDfNGMODE

\%

100

2ND/3RD SHIFTINGCHARACTERfSTfCSCONTROL AREA

\50

QCr:elQ.oel

-=ooC....

%100

DESCENDING MODEASCENDING MODE

When the PCM determines that the vehicle is going down a hill in [Q;] position, the shift-up speed from 3rd to 4th gearwhen the throttle is closed becomes faster than the set speed for fiat road driving to widen the 3rd gear driving area.This, in combination with engine braking trom the deceleration lock-up, achieves smooth driving when the vehicle isdescending. There are two descending modes with different downshift (4 - 3) schedules according to the magnitude of agradient stored in the PCM. When the vehicle is in 4th gear, and vou are decelerating on a graduai hill, or when vou areapplying the brakes on a steep hill, the transmission will downshift to 3rd gear. When vou accelerate, the transmission willthen return to 4th gear.

Descending Control

NOTE:• The PCM memory contains shift schedules between 2nd and 3rd gears, and between 3rd and 4th gears that enable the

PCM's fuzzy logic to automatically select the most suitable gear according to the magnitude of a gradient.• Fuzzy logic is a form of artificial intelligence that lets computers respond to changing conditions much like a human

mind would.

When the PCM determines that the vehicle is climbing a hill in [Q;J position, the system extends the engagement area of2nd gear and 3rd gear to prevent the transmission from frequently shifting between 2nd and 3rd gears, and between 3rdand 4th gears, so the vehicle can run smooth and have more power when needed. There are two ascending modes withdifferent 3rd gear driving areas according to the magnitude of a gradient stored in the PCM.

Ascending Control

Electronic Control System (cont' d)

Description

14-17

o 116PIConnecterC (31Pl ConoectorB 12SPIConnecterA 132PIConnectar

SHIFTCONTROLSOLENOIDVALVE B

SHIFTCONTROLSOLENOIDVALVE A

SH B Bll

LOCK- UPCONTROLSOLENOIOVALVE B

SHA0-8_3 •

AlITOMATICTRANSAXLECONTROLSYSTEM

LCB B4

LOCK- UPCONTROLSOLENOIOVALVE A

PCMTerminal Locations

O.

N

Arr GEARPOSITIONSWITCH

Arr GEARPOSITIONINOICATOR

BRAKESWITCH

PGl

PG2

IGPI

IGP2CIO vau010 VCC201011 TPS

SG2

02 PGM-FIECT CONTROL

SYSTEM

C7 ses

CIB VSS

LS+B2

LlNEARSOLENOIO

LS- BI

NM BIS

NMSG B14

NCNCSG

BIllATPR

B25 ATPPNB24 ATPO. B13B8 O.INO

ATPOJB17

ATP2

INTERLOCKCONTROLUNIT

lCA B5

PCM

111111111

?1

?111

91111111

91111

?

IGNITIONSWITCHST

Circuit Diagram and Terminal Locations

14-18

ATF PUMP GEARS

\LOCK-UP CONTROLSOLENOID VALVE AIBASSEMBlY

MAIN VALVE BODY

SECONDARY VALVEBODY

LOCK-UP VALVEBODY

SERVOBODY

lINEAR SOLENOIO

SHIFT CONTROLSOLENOID VALVE AIBASSEMBlY

The hydraulic control system is controlled by the ATF pump, valves, accumulators, and electronically controlled solenoids.The ATF pump is driven by splines on the end of the torque converter which is attached to the engine. Fluid from the ATFpump flows through the regulator valve to maintain specified pressure through the main valve bodv to the manual valve,directing pressure to each clutch. The valve body includes the main valve body, the regulator valve body, the lock-upvalve body, the secondary valve body, the servo body, the linear solenoid, the shift control solenoid valve NB assembly,and the lock-up control solenoid valve NB assembly. The shift control solenoid valve NB assembly and the linearsolenoid are bolted to the outside of the transmission housing. The lock-up control solenoid valve NB assembly is boltedto the outside of the torque converter housing.

Hydraulic Control

Description

14-19

(cont'd)

SECONDARY VAl VEBODY3-4 ORIFICE CONTROL

VALVE

4TH EXHAUST VALVE

CPC VALVE

2-3 SHIFT VALVE3-4 SHIFT VALVE

The secondary valve body is located on the main valve body. The secondary valve body houses the 2-3 shift valve, the 3-4shift valve, the 3-4 orifice control valve, the 4th exhaust valve and epe valve.

Secondary Valve Body

SERVO CONTROLVALVE

MAIN VALVEBODY

MANUAl VALVE

1-2 SHIFT VALVE

2ND ORIFICE CONTROLVALVE

The main valve body houses the manual valve, the 1-2 shift valve, the 2nd orifice control valve, the ePB valve, the modulator valve, the servo control valve, and the relief valve. The primary functions of the main valve body are to switch fluidpressure on and off and to control the hydraulic pressure 90in9 to the hydraulic control system.

Main Valve Body

14-20

lOCK-UP VALVEBODY

lOCK-UP SHIFTVALVE

Lock-up Valve BodyThe lock-up valve body with the lock-up shift valve and the lock-up timing valve is located on the regulator valve body.

lOCK-UP CONTROLVALVE

Regulator Valve BodyThe regulator valve body is located on the main valve body. The regulator valve body consists of the regulator valve, thetorque converter check valve, the cooler relief valve, and the lock-up control valve.

Hydraulic Control (cont'd)

Description

14-21

(cont'd)STATOR SHAFT ARM

STATOR SHAFTSTATOR

REGUlATOR SPRING CAP

REGULATOR VALVE~Z~0=~:2,:'>~~)

-,~,fj>/ ' -,-~((~J.: :;~

:.-..~

Increases in hydraulic pressure according to torque are performed by the regulator valve using stator torque reaction. Thestator shaft is splined with the stator in the torque converter, and its arm end contacts the regulator spring cap. When thevehicle is accelerating or c1imbing (Torque Converter Range), the stator torque reaction acts on the stator shaft, and thestator arm pushes the regulator spring cap in the direction of the arrow in proportion to the reaction. The stator reactionspring compresses, and the regulator valve moves to increase the line pressure which is regulated by the regulator valve.The line pressure reaches its maximum when the stator torque reaction reaches its maximum.

Stator Reaction Hydraulic Pressure Control

From ATF PUMP

STATOR SHAFT ARM

VALVEORIFICE

To TORQUE CONVERTER lubrication

ENGINE NOT RUNNING ENGINE RUNNING

NOTE: When used, "left" or "right" indicates direction on the illustration below.

The regulator valve maintains a constant hydraulic pressure from the ATF pump to the hydraulic control system, whilealso furnishing fluid to the lubricating system and torque converter. The fluid from the ATF pump flows through Band B'.The regulator valve has a valve orifice. The fluid entering from B flows through the orifice to the A cavity. This pressure ofthe A cavity pushes the regulator valve to the right side, and this movement of the regulator valve uncovers the fluid portto the torque converter and the relief valve. The fluid flows out to the torque converter, and the relief valve and regulatorvalve moves to the left side. According to the level of the hydraulic pressure through B, the position of the regulator valvechanges and the amount of the fluid from B' through D and C also changes. This operation is continued, maintaining theline pressure.

Regulator Valve

14-22

SERVO VAL VE/SHIFTFORK SHAFT

1ST ACCUMUlATOR

SERVO BODV

2ND ACCUMULA TOR

The servo body is located on the secondary valve body. The servo body contains the servo valve which is integrated withthe reverse shift fork shaft, and the accumulators.

Servo Body

Hydraulic Control (cont'd)

Description

14-23

(cont'd)

NO. DESCRIPTION OF PRESSURE NO. DESCRIPTION OF PRESSURE NO. DESCRIPTION OF PRESSURE

MODULATE1 UNE 6B (SHIFT CONTROL SOLENOID 41 4TH CLUTCH

VALVE B)

MODULATE1' UNE 6C (LOCK-UP CONTROL 56 UNEAR SOLENOID

SOLENOID VALVE A)

MODULATE1" UNE 60 (LOCK-UP CONTROL 90 TORQUE CONVERTER

SOLENOID VALVE B)

MODULATE2 UNE 60' (LOCK-UP CONTROL 91 TORQUE CONVERTER

SOLENOID VALVE B)

3 UNE 7 UNE 92 TORQUE CONVERTER

3' UNE 8 UNE/CPC 93 ATFCOOLER

3" UNE 9 UNE 94 TORQUE CONVERTER

4 UNE 10 1ST CLUTCH 95 LUBRICATION

4' UNE 20 2ND CLUTCH 96 TORQUE CONVERTER

4" UNE 20A 2ND ACCUMULATOR 97 TORQUE CONVERTER

5 CPC 25 UNE 99 SUCTION

6 MODULATE 30 3RD CLUTCH X DRAIN

MODULATE6A (SHIFT CONTROL SOLENOID 40 4TH CLUTCH

VALVE Al 1

• 1-2 Shift Valve ::=32-3 Shift Valve ----+--- Clutch Pressure3-4 Shift Valve

• Modulator Valve ---- Modulator Pressure ---r--- Shift Control Solenoid ValvesL_ Lock-up Control Solenoid ValvesL_ Linear Solenoid

• Manual Valve ----- Ta select Line Pressure --- Clutch Pressure

Distribution of Hydraulic Pressure• Regulator Valve ~ Torque Converter Pressure

Lubrication PressureTa regulate Line Pressure

General Chart of Hydraulic PressureATF Pump---Regulator Valve 1Line Pressure -cModulator Pressure --- Linear Solenoid

Clutch Pressure

Torque Converter PressureLubrication Pressure

Hydraulic Flow

14-24

!f'- ~l <s>

r - _ -.'" ..~fc.. ... ';'·: :. ""IIII"'·Jlr;::;;::::::::JI.~ii=lF=(,-1 1 ({jùJ

l!::====U=::::::::::l=-=1 ,"...,.:::{~:1=4~===~ ...._·u-~I---_rr======:dJLOC. vP " ....IN(..VAlY{

I~.l

'~Ou( ç()t~\ f R'!f '"CHECK. v,,~.(

m{• • ;tif

LOC'" vPS~IT ,:'_,:• fil

IJ'H

NOTE: When used, "Ieft" or "right" indicates direction on the hydraulic circuit.

As the engine turns, the ATF pump also starts to operate. Automatic transmission fluid (ATF) is drawn from (99) and discharged into (1). Then, ATF tlowing trom the ATF pump becomes line pressure (1). The line pressure (1) is regulated bythe regulator valve. The torque converter inlet pressure (92) enters (94) of the torque converter through the lock-up shiftvalve and discharges into (90). The torque converter check valve prevents the torque converter pressure trom rising.Under this condition, hydraulic pressure is not applied to the clutches.

lliJ Position

Hydraulic Flow (cont' d)

Description

14-25

(cont'd)

~('JO'I •• I.I' ... t -±-.,. ~

r. ,.,.". ~. ~ ~L'~ ~ ~.

• T

, .. .t1-, ,~,;, •• .\l \ E

IUL. -r- -

p~ +- - - - -lIl ..

• • .. JI..-'r-'l!:======::!J

~....... ,. 1"

u

JL 1" •

...::::::?t=l~=====:dJl!:==~l===:::;'1 r;:::======.i

A((,';."IQR. .4",".t •

ffil·


The line pressure (1) flows to the manual valve and the modulator valve. The line pressure (1) changes to line pressure (4)and (25) at the manual valve, and changes to modulator pressure at the modulator valve. But the modulator pressure (6)does not flow to each shift valve because shift control soleno id valves A and 8 are turned ON by the PCM. The line pressure (4) passes through the CPB valve and the CPC valve, and changes to line pressure (5), then flows to the 1-2 shiftvalve. The line pressure (5) from the 1-2 shift valve changes to 2nd clutch pressure (20) at the 2-3 shift valve. The 2ndclutch pressure (20) is applied to the 2nd clutch, and the 2nd clutch is engaged. The line pressure (4) passes through the 1-2 shift valve and the orifice, and changes to 1st clutch pressure. The 1st clutch pressure (10) also flows to the 1st clutch.However, no power is transmitted because of the one-way clutch.

œ Position

14-26

=

~-I~ ln • - , , ., Il.. -u-

............... ~)r"'--.., OJV u

~ANUll.l ",-Al v{

T

1U.. -r

1_ 'OAOVE CO-MAIEO~ CHfCk VALVE

I~ A(llfFVAlV(

I!:::=:!!::::===;;:-~~II ,""EE~roi


The flow of fluid through the torque converter circuit is same as in [ID position. The line pressure flows to the manualvalve and the modulator valve. The line pressure changes to modulator pressure (6) at the modulator valve and toline pressure (4) at the manual valve. The modulator pressure (6) flows to the left end of the 1-2 shift valve and the 3-4shift valve because shift control solenoid valve A is turned OFF and B is turned ON by the PCM. The 1-2 shift valve ismoved to the right side. The line pressure (4) changes to 1st c1utch pressure (10) at the 1-2 shift valve and the orifice.The 1st clutch pressure (10) is applied to the 1st clutch and the 1st accumulator; consquently, the vehicle will move asthe engine power is transmitted.

1. 1st Gear

[Q;] or [Qi] Position


Description

14-27

(cont'd)

, , .. J~ I·JlII'·.\... 1'" _--

'" A(LI(~ .':'_.f~ TERSHA":!ill, ,',

~..l?=

l oc. vP 'I~I"-'G If·''''AlV't

~i[.'III·....

Il

~0= 1 -- --- _- -AfG,_, • ..:.'OQ• A~ • E . 1".. i- r- -

'OAOuE (~vtAr("CHIC_.."AlVE

..

NOTE: When used, "Ieft" or "riqht" indicates direction on the hydraulic circuit .

The hydraulic pressure also flows to the 1st clutch. However, no power is transmitted because of the one-way clutch.

Fluid flows by way of:- Une Pressure (4) - CPBValve - Une Pressure (5) - 1-2 Shift Valve - Une Pressure (5) - 2-3 Shift Valve- 2nd Clutch Pressure (20) - 2nd Clutch

As the speed of the vehicle reaches the prescribed value, shift control solenoid valve A is turned ON by means of thePCM. The modulator pressure (6A) in the left end of the 1-2 shift valve is released by turning shift control solenoidvalve A ON. The 1-2 shift valve is moved to the left side and uncovers the port to allow line pressure (5) to the 2-3shift valve. The line pressure (5) changes to 2nd clutch pressure (20) at the 2-3 shift valve. The 2nd clutch pressure(20) is applied to the 2nd clutch, and the 2nd clutch is engaged.

2. 2nd Gear

14-28

~~ ±::- - - - -1.. 1 ..

lOCI(·UP TIMINGVALVE

rll: ..

SM'" 'VALVE

oh

.. ,..._-11,- '" II~

lOCI. uPCO""::2SOl(~tD v .A..dlPf

JI 1=

JIL - ,.


The hydraulic pressure also flows to the 1st clutch, However, no power is transmitted because of the one-way clutchas in 2nd gear.

Fluid flows by way of:_ Line pressure (4) - CPB Valve - Une Pressure (5) - 1-2 Shift Valve - Une Pressure (5) - 2-3 Shift Valve- Une Pressure (5) - 3-4 Shift Valve - 3rd Clutch Pressure (30) - 3rd Clutch

As the speed of the vehlcle reaches the prescribed value, shift control solenoid valve B is turned OFF by means of thePCM. Shift control solenoid valve A remains ON. The modulator pressure (6) flows to the right end of the 1-2 shiftvalve and the left end of the 2-3 shift valve. The 2-3 shift valve is moved to the right side by modulator pressure (68).The 2-3 shift valve covers the port to stop line pressure (5) to the 2nd clutch and uncovers to the 3-4 shift valve as the2-3 shift valve is moved to the right side. The line pressure (5) becomes 3rd clutch pressure (30) at the 3-4 shift valve.The 3rd clutch pressure (30) is applied to the 3rd clutch, and the 3rd clutch is engaged.

3. 3rd Gear


Description

14-29

(cont'd)

l "IUIDIDIDI

.,,~~:I=lI=====::!.1lb:::===lI==H:::o::: •

lOCIl uP TIMING

~.


The hydraulic pressure also flows to the 1st clutch. However, no power is transmitted because of the one-way clutchas in 2nd and 3rd gear.

Fluid flows by way of:- Line pressure (4) - CP8 Valve - Line Pressure (5) - 1-2 Shift Valve - Line Pressure (5) - 2-3 Shift Valve- Line Pressure (5) - 3-4 Shift Valve - 4th Clutch Pressure (41) - Manual Valve - 4th Clutch Pressure (40)- 4th Clutch

As the speed of the vehicle reaches the prescribed value, shift control solenoid valve A is turned OFF by means of thePCM. Shift control solenoid valve 8 remains OFF. The modulator pressure (6) flows to the left end of the 1-2 shiftvalve and the left end of the 3-4 shift valve. The modulator pressure (6A) in the left end of the 1-2 shift valve equalsthe modulator pressure (68) in the right end of the 1-2 shift valve, the 1-2 shift valve remains at left side by the tension of the valve spring.The 3-4 shift valve is moved to the right side by modulator pressure (6A). The 3-4 shift valve covers the port to the 3rdclutch and uncovers the port to the 4th clutch as this valve is moved to the right side. The 4th clutch pressure (41)from the 3-4 shift valve becomes 4th clutch pressure (40) at the manual valve. The 4th clutch pressure (40) is appliedto the 4th clutch, and the 4th clutch is engaged.

4. 4th Gear ([Q;] Position)

1l""f AR SOl ENOIDMOOvlAT~ vALVE

14-30

11

Il .. .--'Il (S)~

_.-- -

.

PiEC,_,_.:..'0A.:.": .~ <, .'.

'OAOUI' COIWfATfACHEC- VAlY{

NOTE:When used, "Ieft" or "riçht" indicatesdirection on the hydraulic circuit.

Whenthe [8J position is selectedwhile the vehicle is moving forward at speedsover 6 mph (10km/h),the PCMoutputs the1stspeedsignal to shift control solenoidvalvesA andB;shift control solenoid valve A is turned OFF,shift control solenoidvalve 8 is turned ON. The 1-2shift valve is moved to the right side and covers the port to stop line pressure(3') to theservo valve. The line pressure(3') is not applied to the servo valve, and the 4th clutch pressure(40) is not applied to the4th clutch, as a result, power is not transmitted to the reversedirection.

Reverse Inhibitor Control

The flow of fluid through the torque convertercircuit is the sameas in (ffi position. The line pressure(1)changesto linepressure(3) and flows to the 1-2shift valve. The line pressure (3) changesto line pressure (3') at the 1-2shift valve andflows to the servo valve. The servo valve is moved to the right side (Reverserange position) and uncovers the port toallow line pressure(3") to the manualvalve.The line pressure(3') from the 1-2shift valve flows through the servovalve tothe manualvalve and changesto 4th clutch pressure(40).The 4th c1utchpressure(40) is applied to the 4th clutch, and the4th clutch is engaged.

[ID Position


Description

14-31

--~+-'-- -~

•

.MAINS ....AÇ,.

TOROuECQNv(Af(RCHECk VALVE

l')r ACCUMUlATOA


The flow of fluid through the torque converter circuit is the same as in ŒJ position. The line pressure (1) changes to linepressure (3) and flows to the 1-2 shift valve. The line pressure (3) changes to line pressure (3') at the 1-2 shift valve andflows to the servo valve. The servo valve is moved to the right side (Reverse range position) and uncovers the port toallow line pressure (3") to the manual valve as in [ID position. The fine pressure (3") from the servo valve is intercepted bythe manual valve. However, hydraulic pressure is not supplied to the cfutches, and the power is not transmitted.

ŒJ Position

MAINSHAFT

.............:-:-:.:«« ...;.-,",;.... .;

INLET

+

To ATFcoole,

TORQUE CONVERTER

COVER ~ •..•u,.~ ... ~"

TURBINE

14-32

Engine~

Drive plate~

Torque converter cover~

Pump~

Turbine~

Mainshaft

2. Operation (clutch off)With the lock-up clutch off, the fluid flows in the reverse of "clutch on." As a result, the lock-up piston moves away fromthe converter coyer, and the torque converter lock-up is released.

1 Powerflow

MAINSHAFT

OUTLET

1

T0 ATF coole'

TORQUE CONVERTERCOVER

TURBINE

DAMPER SPRING

Engine~

Drive plate~

Torque converter coyer~

Lock-up piston~

Damper spring~

Turbine~

Mainshaft

The power flows by way of:

1. Operation (clutch on)With the lock-up clutch on, the fluid in the chamber between the torque converter coyer and the lock-up piston is drainedoff, and the converter fluid exerts pressure through the piston against the torque converter coyer. As a result, the converter turbine is locked to the converter coyer. The effect is to bypass the converter, thereby placing the vehicle in direct drive.

1 Power flow 1

Lock-up Clutch

Lock-up System

Description

14-33

(cont'd)

COOLER RELIEF VALVE

4- MODULATOR PRESSURE

TORQUE CONVERTERCHECKVALVE

LOCK-UP CONTROLr;===~I===IF==SOLENOID VALVE

Lock-up Control Linearlock-up Solenoid Valve Solenoid

Conditions PressureA B

Lock-up OFF OFF OFF High

Lock-up, Half ONDuty operation

LowOFF - ON

Lock-up, Full ON ON High

Lock-up Duty operationduring ON

OFF - ONLow

deceleration

lock-up Conditions/lock-up Control Solenoid ValveslLinear Solenoid Pressure

The lock-up system controls the range of lock-up according to lock-up control solenoid valves A and B, and thelinear solenoid. When lock-up control solenoid valves Aand B activate, modulator pressure changes. Lock-upcontrol solenoid valves A and B and the linear solenoidare mounted on the outside of the torque converterhousing, and are controlled by the PCM.

TORQUE CONVERTER

ln [Q;] position, in 3rd and 4th, and [Qi] position in 3rd,pressurized fluid is drained from the back of the torqueconverter through a fluid passage, causing the lock-uppiston to be held against the torque converter cover. Asthis takes place, the mainshaft rotates at the same speedas the engine crankshaft. Together with the hydrauliccontrol, the PCM optimized the timing of the lock-upsystem. Under certain conditions, the lock-up clutch isapplied during deceleration, in 3rd and 4th gear.

14-34

ATF PUMP

COOLER RELIEF VALVE

fl3

l!==:::.-MODUlATOR PRESSURE110

TORQUE CONVERT~CHECK VALVE

LOCK-UP CONTROLI>====~~=~F= SOLENOID VALVE

~~==~~~~~. A B

LOCK-UP CONTROLVALVE

NOTE: When used, "left" or "right" indicates directionon the hydraulic circuit.

TORQUE CONVERTER

The pressurized fluid regulated by the modulator workson both ends of the lock-up shift valve. Under this condition, the pressures working on both ends of the lock-upshift valve are equal, the lock-up shift valve is moved tothe right side by the tension of the valve spring alone.The fluid from the ATF pump will flow through the leftside of the lock-up clutch to the torque converter; that is,the lock-up clutch is in OFFcondition.

• Lock-up Control Solenoid Valve A: OFF• Lock-up Control Solenoid Valve B: OFF• linear Solenoid Pressure: High

No Lock-up

Lock-up System (cont'd)

Description

14-35

(cont'd)ATF PUMP

COOLER RELIEF VALVE

SIIl

.- MODULATOR PRESSURE

90

NOTE: When used, "Ieft" or "right" indicates directionon the hydraulic circuit.

TORQUE CONVERT~CHECK VALVE

LOCK·UP CONTROLrt===~==U== SOLENOID VALVE

r~~"~I~~~~ A B

TORQUE CONVERTER

The PCM switches the solenoid valve A on to release themodulator pressure in the left cavity of the lock-up shiftvalve. The modulator pressure in the right cavity of thelock-up shift valve overcomes the spring force; thus the.lock-up shift valve is moved to the left side.The line pressure is then separated into the two passages to the torque converter:

Torque Converter Inner Pressure: enters into rightside to engage lock-up clutchTorque Converter Back Pressure: enters into left sideto disengage Iock-up clutch

The back pressure (F2) is regulated by the lock-up control valve, whereas the position of the lock-up timingvalve is determined by the linear solenoid pressure andtension of the valve spring. Also the position of the lockup control valve is determined by the back pressure ofthe lock-up control valve, torque converter pressure regulated by the torque converter check valve, and modulator pressure determined by the lock-up control solenoidvalve B. The PCM switches the loçk-up control solenoidvalve B on and off rapidly (dutY operation) under certainconditions to regulate the back pressure (F2) ta lock thetorque converter properly.

LOCK·UP CONTROLVALVE

• Linear Solenoid Pressure: Law

• Lock-up Control Solenoid Valve A: ON• Lock-up Control Solenoid Valve B: Duty Operation

OFF - ON

Hait Lock-up

14-36

ATF PUMP

COOlER RELIEF VALVE

5693

95

80

TOROUE CONVERT:AlCHECK VALVE

1:!==-4- MODULA TOR PRESSURE

le

NOTE: When used, "Ieft" or "riqht" indicates directionon the hydraulic circuit.

lOCK-UP CONTROLrr:===:fF:::=~IF== SOLENOID VALVE

A .....I:-:zrz.#--azzr:IiI A B

TOROUE CONVERTER

When the vehicle speed further increases, the linearsole no id pressure is increased to high, in accordancewith the linear solenoid controlled by the PCM.The lock-up timing valve overcomes the spring forceand moves to the left side. Also, this valve closes thefluid port leading to the left side of the lock-up controlvalve.Under this condition, the modulator pressure in the leftside of the lock-up control valve had already beenreleased by the lock-up control solenoid valve B; thelock-up control valve is moved to the left side. As thistakes place, the torque converter back pressure isreleased fully, causing the lock-up clutch to be engagedfully.

lOCK·UP CONTROLVALVE

• Lock-up Control Solenoid Valve A: ON• Lock-up Control Solenoid Valve 8: ON• Linear Solenoid Pressure: High

Full lock-up

Lock-up System (cont'd)

Description

14-37

ATF PUMP

COOLER RELIEF VALVE

56

t====~- MODULATOR PRESSURE95

TOROUE CONVERT~CHECK VALVE

LOCK·UP CONTROLr.;===*==~F=SOLENOID VALVE1Ii4_"'~""'IZIIIIIII'I_' A B

NOTE: When used, "left" or "right" indicates directionon the hydraulic circuit.

TORQUE CONVERTER

The PCM switches solenoid valve 8 on and off rapidlyunder certain conditions. The slight lock-up and haitlock-up regions are maintained so as to lock the torqueconverter properly.

• Linear Solenoid Pressure: Low

• Lock-up Control Solenoid Valve A: ON• Lock-up Control Solenoid Valve 8: Duty Operation

OFF'" ON

Deceleration Lock-up

14-38

14-39

COUNTERSHAFTSPEED SENSOR

SHIFT LOCKSOLENOID

AUTOMATIC TRANSAXLE (AIT)GEAR POSITION SWITCH

KEY INTERLOCKSOLENOID

Component Locations

TERLOCKNTROL UNITTROL

A R- R- STIN OUT

GRN/WHT

WHT/GRN

14-40ArT GEAR POSITION SWITCH

2P

G401G402

BlK

l

BLU

WHT

YEl

J l,~T, ,YEL GRN BLU

LT GRN~ GRN/BlK

J,1"""",--r--'

GRN/BlK

B17UNDER-DASHFUSE/RELAy BOXNo.25 (7.5A)? GAUGE ASSEMBl V

YEl

ATP 2

POWERTRAIN CONTROL MODULE (PCM)

Gl01

No.47 (7.5A)

DASHLAY BOX.5A)CK-UPHTS

rI'> STARTER1 V _ CUT RElAY

QGR~HT T G~ T GRJsLU T P~ TGRJsLKT ~ G401

GRN/RED GRN/ORN GRN/YEL· YEL BLK/RED G402

l BlK/BlU -<8 ~~1

I-WHT ~ CRUISECONUNIT

1- RED ~ UNDER-FUSE/RENO.19 (7

LBlK/BlU

PNK ~ BA1 LlG1-GRN

YEL

1- BLUGRN/BLK

BLU/BLK

,,1B

12 13 14 7 6 5 9 3 4 11

BATTERYUNDER-HOOD FUSE/RELAY BOX

PCM Circuit Diagram (AIT Control System)

14-41

Gl01

BRN/BLK

l

o 116Pl ConnectOfC t31PIConneclOfA ,32PI Connector

SERVICECHECKCONNECTOR

BRN/BLK BRN/8LK

THROTILEPOSITIONSENSOR

G401,....,.. ....

BLK

1

~~

REDIBlK rYELIBLU GRN/BLK

LOCK - UP CONTROLSOLENOID VALVEASSEMBLY

MAINSHAFTSPEEDSENSOR SHIFT CONTROL

SOLENOID VALVEASSEMBLY

PCM Terminal Locations

B ,25PI ConnectOf

RED

COUNTERSHAFT LlNEAR SOLENOIDSPEEDSENSOR

BLU/YEL GRN/WHT YEL GRN/BLK BRN

HH+BLU/YEL GRN/WHT YEL GRN/BLK BRN

VEHICLESPEEDSENSOR

~ r REDIWHTBLU,wHT

WHTGRNBLU

AIT GEARPOSITIONSWITCHP POSITION

ENGINECOOLANTTEMPERATURESENSOR

6 4

BLK/BLU BLK

~

ATP P GND

TWHT/RED

PARKINGPINSWITCH

WHT/RED

8281822823814

WHTRED

815

LS+LS-NCNMSG

POWERTRAIN CONTROL MODULE (PCMI

NM

G401G402

NCSG

8LK

~HIFTLOCKlSOLENOID

YEL

WHT/BLK

YEUBLK

tYEUBLK

2

2 3 8 7

61WHT/BLU YEL

KEY KEYINTERLOCK INTERLOCKSWITCH SOLENOID

51WHT/YEL

71WHT/GRN

WHT/BLU

1)WHT

1

INTERLOCK CONTROL UNIT

KEY LOCK SHIFT LOCKACC PUSH SIN SOLENOID IG1 SOLENOID P PIN SW SLU

14-42

Terminal Number Signal Description Measuring Conditions/Terminal Voltage

81 LS- Linear solenoid power supply Ignition switch ON (II): Pulsing signalnegative electrode

82 LS+ Linear solenoid power supply Ignition switch ON (II): Pulsing signalpositive electrode

83 SHA Shift control solenoid valve A ln 2nd gear and 3rd gear in [Qi], ~ position,control and in œ position: 8attery voltage

ln 1st gear and 4th gear in [Qi], [0-; position: 0 V

84 LC8 Lock-up control solenoid valve 8 With half lock-up, full lock-up, and duringcontrol deceleration: Pulsing 0 V and battery voltage

With no lock-up: 0 V

85 LCA Lock-up control solenoid valve A When lock-up is ON: 8attery voltagecontrol With no lock-up: 0 V

86 to 87 - Not used

88 ATPD3 Aff gear position switch [Qi] posi- ln ~()3; position: 0 Vtion signal input ln other than D~ position: Battery voltage

89 to 810 - Not used

PCM CONNECTOR B (25P)


A1 to A8 - see section 11 -

Ag LG1 Ground

A10 PG1 Ground

Al1 IGP1 Power suppl y system With ignition switch ON (II): 8attery voltageWith ignition switch OFF: 0 V

A12 to A21 - see section 11 -

A22 LG2 Ground

A23 PG2 Ground

A24 IGP2 Power supply system With ignition switch ON (II): Battery voltageWith ignition switch OFF: 0 V

A25 to A32 - see section 11-

PCM CONNECTOR A (32P)

o 116Pl ConnectorC 131Pl ConnectorB 125Pl ConnectorA 132Pl Connector

PCM Terminal Locations

The PCM terminal voltage and measuring conditions are shown for the connector terminais related to the AIT control system. The other PCM terminal voltage and measuring conditions are described in section 11.

AIT Control System

PCM Terminal Voltage/Measuring Conditions

14-43


01 to 04 - see section 11 -

05 STOP SW 8rake switch signal input With ignition switch ON (II) and brake pedaldepressed: 8attery voltageWith ignition switch ON (II) and brake pedalreleased: 0 V

06 to 016 - see section 11 -

PCM CONNECTOR0 (16P)


Cl to C6 - see section 11 -

C7 SCS Service check signal With ignition switch ON (II) and service checkcorinector open: 5 VWith ignition switch ON (II) and service checkconnector connected with special tool: 0 V

C8 to C9 - see section 11 -

Cl0 V8U 8ack-up power system Always battery voltage

Cll to C31 - see section 11 -

PCM CONNECTORC (31P)


811 SH8 Shift control solenoid valve 8 ln lst gear and 2nd gear in [Qi], ~ position,control and in œ position: 8attery voltage

ln 3rd gear in [Qi), ~ position and 4th gear in~ position: 0 V

812 SLU Interlock control When ignition switch is ON (II), brake pedaldepressed and accelerator pedal released: 0 V

813 041NO 04 Indicator light control When ignition switch is first turned ON (II):8attery voltage for two secondsln ~ position: 8attery voltage

814 NMSG Mainshaft speed sensor ground Always:OV

815 NM Mainshaft speed sensor signal Oepending on engine speed: Pulsing signalinput When engine is stopped: 0 V

816 ATPR AIT gear position switch ŒJ ln [ID position: 0 Vposition signal input ln other than ŒJ position: 8attery voltage

817 ATP 2 AIT gear position switch œ posi- ln [i] position: 0 Vtion signal input ln other than œ position: 8attery voltage

818 to 821 - Not used

822 NCSG Countershaft speed sensor ground Always: 0 V

823 NC Countershaft speed sensor signal Oepending on vehicle speed: Pulsing signalinput When vehicle is stopped: 0 V

824 ATP04 AIT gear position switch ID posi- ln ~ position: 0 Vtion signal input ln other than [Q!] position: 5 V

825 ATP PN AIT gear position switch œ and ln œJ and lB] positions: 0 VlB] position signais input ln other than œ and [ffi positions: 8attery voltage

PCM CONNECTORB (25P) (cont'd)

DATA LlNK CONNECTOR (16P)

üC)

14-44

OSD Il SCAN TOOL orHONDA PGM TESTER

NOTE: See the oao Il Scan Tooi or Honda PGM Tester user's manual for specifie instruction.

When the [Q;I indicator light has been reported on, connect the oao Il Scan Tooi conforming to SAE J1978 or Honda PGMTester to the OLC (16P). Turn the ignition switch on (11), and observe the OTC on the screen of the oao Il Scan Tooi orHonda PGM Tester. After determining the OTC, refer to the electrical system Symptom-to-Component Chart on pages 14-48and 14-49.

When the PCM senses an abnormality in the input or output systems, the ~ indicator light in the gauge assembly willblink. When the 16P Data Link Connector (OLC) (located under the dash on the driver's side) is connected to the oao IlScan Tooi or Honda PGM Tester as shown, the scan tool or tester will indicate the Diagnostic Trouble Code (OTC)whenthe ignition switch is turned ON(II).

Checking the Diagnostic Trouble Code (OTC)with an oao Il Scan tool or Honda PGM Tester


14-45

(cont'd)

See OTC 15

See OTC 2

OFF

Short blinks (five times)

1" '11------------......Long blink

OFF

Short blink (once)

OFF~~·------------------------------~n~---------------------------SeeOTC1

Codes 1 through 9 are indicated by individual short blinks. Codes 10 and above are indicated by a series of long and shortblinks. One long blink equals 10 short blinks. Add the long and short blinks together to determine the code. After determining the code, refer to the electrical system Symptom-to Component Chart on pages 14-48 and 14-49.


GAUGE ASSEMBLY

When the [Q;] indicator light has been reported on, connect the Service Check Connector (2P) with the special tool.Then turn on (II) the ignition switch and observe the [Q;] indicator light.

When the PCM senses an abnormality in the input or output systems, the [Q;] indicator light in the gauge assembly will blink.When the Service Check Connector (located under the dash on the passenger side) is connected with the special tool asshown, the [Q;] indicator Iight will blink the Diagnostic Trouble Code (DTC) when the ignition switch is turned on (II).

Checking the Diagnostic Trouble Code (DTC)with the Service Check Connector and Special Tooi

14-46

DIGITAL MUl TIMETER(Commerciallv available)

,..----------KS - AHM - 32 - 003or equivalent

STACKING PATCHCORD

BACKPROBE ADAPTER

BACKPROBE SET07SAZ - 001000A(two requiredl

Connect the backprobe adapters to the stacking patch cords, and connect the cords to a multimeter. Using the wireinsulation as a guide for the contoured tip of the backprobe adapter, gently slide the tip into the connector from thewire side until it comes in contact with the terminal end of the wire.

How to Use the Backprobe Set

3. Inspect the circuit on the PCM according to the troubleshooting flowchart with the special tools and a digital multimeter as shown.

KICK PANEL

2. Remove the PCM, and turn the PCM over.

1. Remove the kick panel on the passenger's side (see section 20).

(cont'd)


14-47

4. Turn the ignition switch ON (II), and set the radio presets and dock setting.

3. Oisconnect the oao Il Scan Tooi or Honda PGM Tester from the Data Link Connector (16P), or remove the special toolfrom the Service Check Connector (2P).

2. Reset the PCM.


NOTE: This procedure must be done after any troubleshooting.

• Final Procedure

NOTE:• Oisconnecting the BACK UP fuse also cancels the radio preset stations and clock setting. Make note of the radio

presets before removing the fuse so vou can reset them .• The PCM memory cannot be cleared by using the OBO Il Scan Tooi or Honda PGM Tester; be sure to remove the

BACK UP fuse to reset the PCM.

2. Remove the BACK UP fuse (7.5 A) from the under-hood fuse/relay box for 10 seconds to reset the PCM.

1. Turn the ignition switch off.

• PCM Reset Procedure

14-48

(DTC)*: The DTC in parentheses is the code the W indicator light blinks when the service check connector is connectedwith the special tool (SCS service connector).

Diagnostic~ Indicator Refer toTrouble Code Symptom Possible Cause

(DTC)* light Page

• Lock-up clutch does not engage. • Disconnected lock-up control solenoid

P1753• Lock-up cfutch does not disen- valve connector

(1) Blinks gage. • Short or open in lock-up control 14-50• Unstable id le speed. solenoid valve A wire

• Faulty lock-up control solenoid valve A

• Lock-up clutch does not engage. • Disconnected lock-up control solenoid

P1758valve connector

(2) 81inks • Short or open in lock-up control 14-52solenoid valve 8 wire

• Faulty lock-up control solenoid valve 8

P1705 • Fails to shift other than 2nd - 4th • Short in Aff gear position switch wire

(5) 81inks gears. • Faulty Aff gear position switch 14-54• Lock-up clutch does not engage.

• Fails to shift other than 2nd - 4th • Disconnected Aff gear position switch

P1706 gears. connector

(6) OFF • Lock-up clutch does not engage. • Open in Aff gear position switch wire i 14-56• Lock-up clutch engages and dis- • Faulty Aff gear position switch

1engages alternately .

• Fails to shift (between 1st - 4th • Disconnected shift control solenoid

P0753gear only). valve connector

(7) 81inks • Short or open in shift control solenoid 14-58valve A wire

• Faulty shift control solenoid valve A

• Fails to shift (between 3rd - 4th • Disconnected shift control solenoid

P0758 gear only). valve connector

(8) 81inks • Short or open in shift control solenoid 14-60valve 8 wire

• Faulty shift control solenoid valve B

• Lock-up clutch does not engage. • Disconnected countershaft speed sen-

P0720 sor connector

(9) 81inks • Short or open in countershaft speed

1

14-62sensor wire

• Faulty countershaft speed sensor

Electrical System

Symptom-to-Component Chart

14-49

NOTE:• If a customer describes the symptom for code P1706 (6), it will be necessary to recreate the symptom by test-driving,

then recheck the DTC.• The [Q;] indicator light and the Malfunction Indicator Lamp (MIL) may come on simultaneously. Check the PGM-FI sys

tem according to the DTC, then reset the memory by removing the BACK UP (RADIO) fuse in the under-hood fuse/relaybox for more than 10 seconds. Drive the vehicle for several minutes at a speed over 30 mph (50 km/hl, then recheck theDTC.

• Disconnecting the BACK UP (RADIO) fuse also cancels the radio anti-theft code, preset stations and the dock setting.Get the customer's code number, and make note of the radio presets before removing the fuse 50 vou can reset them.

Symptom Inspection1

Ref. page

~ indicator light does not come on for two seconds after ignition is

1

14-70first turned on (II).

~ indicator light is on constantly (not blinking) whenever the ignition

1

14-72is on (II).

Shift lever cannot be moved trom (f] position with the brake pedal .Check interlock system-Shift 1

i 14-73depressed. lock system iIgnition key cannot be moved from ACC (1) position to LOCK (0) posi- Check interlock system-Key

i 14-75tion while pushing the ignition key with the shift lever is in (f] position. interlock system1

If the self-diagnostic ~ indicator light does not blink, perform an inspection according to the table below.

NOTE: When the 080 Il Scan Tooi or Honda PGM Tester indicate the DTC(s) for the automatic transmission control system, the scan tool or tester also indicates code P0700 simultaneously. Code P0700 means detection of some automatictransmission problem on the PGM FI control system.

(DTC)*: The DTC in parentheses is the code the ~ indicator light blinks when the service check connector is connectedwith the special tool (SCS service connecter).

Diagnostic~ Indicator Refer toTrouble Code Symptom Possible Cause

(DTC)* Light Page

• Transmission jerks hard when • Disconnected mainshaft speed sensor

P0715shifting. connector

(15) OFF • Short or open in mainshaft speed sen- 14-63sor wire

• Faulty mainshaft speed sensor

P1768 • Transmission jerks hard when • Disconnected linear solenoid connector

(16) 8links shifting. • Short or open in linear solenoid wire 14-65• Lock-up clutch does not engage. • Faulty linear solenoid

• Lock-up clutch does not engage. • Faulty lock-up control systemP0740 OFF • Lock-up clutch does not disen- 14-66(40) gage.

• Unstable idle speed.

P0730OFF • Fails to shift (between 1st - 3rd or • Faulty shift control system

14-68(41) 3rd - 4th gears only).

P0700 • Any automatic transmission problem-- To eliminate DTCP0700,troubleshoot the other automatic transmission prob- --(none)

lem(s) according to the DTC(s)indicated.

Check for loose PCM connectors.If necessary, substitute a knowngood solenoid valve assemblv orPCM and recheck.

YES

Repair short to power in the wirebetween the 85 terminal and thelock-up control solenoid valve A.

YES


LG1 (BRN/BLK)A (32P)

PCM CONNECTORS

• Oisconnected lock-up controlsolenoid valve connector

• Short or open in lock-up controlsolenoid valve A wire

• Faulty lock-up control solenoidvalve A

Possible Cause

14-50

Ta page 14-51

NO

Is the resistance 14 - 25m

Measure Lock-up Control Solenoid Valve A Resistance:1. Turn the ignition switch OFF.2. Measure the resistance

between the 85 and A9 or A22terminais.

NO

Is there voltage?

Check for a Short to Power:1. Turn the ignition switch OFF.2. Disconnect the A (32P) and 8

(25P) connectors trom thePCM.

3. Turn the ignition switch ON (11).4. Measure the voltage between

the 85 and A9 or A22 terrninais.

• 080 Il Scan T001 indicates CodeP1753.

• Self-diagnosis [Q;J indicatorlight blinks once.

Troubleshooting Flowchart - Lock-up Control Solenoid Valve A

Electrical Troubleshooting

14-51

Check for open in the wirebetween the 85 terminal and thelock-up control solenoid valve A.


LOCK-UP CONTROLSOLENOID CONNECTOR

Repair short to ground in the wirebetween the 85 terminal and thelock-up control solenoid valve A.


PCM CONNECTORS

YES

YES

Replace the lock-up control solenoid valve assembly.

NO

Is the resistance 14 - 25m

Measure Lock-up Control Solenoid Valve A Resistance at theSolenoid Connector:Measure the resistance betweenthe No. 2 terminal of the lock-upcontrol solenoid connector andbody ground.

NO


Check Lock-up Control SolenoidValve A for a Short Circuit:1. Disconnect the 2P connector

from the lock-up control solenoid valve assembly.

2. Check for continuity betweenthe 85 and A9 or A22 terminais.

From page 14-50

Check for loose PCMconnectors.If necessary, substitute a knowngood solenoid valve assembly orPCMand recheck.

YES


L

lGA (32PI

Repair short to power in the wirebetween the B4 terminal and thelock-up control solenoid valve B.

!YES J

PCMCONNECTORS

• Oisconnected lock-up controlsolenoid valve connector

• Short or open in lock-up controlsolenoid valve Bwire

• Faufty lock-up control solenoidvalve B

Possible Cause

14-52

To page 14-53

NO

Is the resistance 14 - 25 n?

Measure lock-up Control Solenoid Valve BResistance:1. Turn the ignition switch OFF.2. Measure the resistance

between the 84 and A9 orA22 terminais.

NO

Is there voltage?

~-------------~-----------------


(25P) connectors from thepeM.

3. Turn the ignition switch ON (II).4. Measure the voltage between

the 84 and A9 or A22 terminais.

• OBOIlScan Tool indicates CodeP1758.

• Self-diagnosis ~ indicator lightblinks twice.

Troubleshooting Flowchart - Lock-up Control Solenoid Valve B


14-53




1

Check Lock-up Control Solenoid LValve B for a Short Circuit: A (32PI1. Disconnect the 2P connector r,} J 4

from the lock-up control sole- Ill" '4 11noid valve assembly.2. Check for continuity between lL~

the 84 and A9 or A22 termi- Lnais.

YES Repair short to ground in the wire15 there conti nuit y? between the B4 terminal and the

lock-up control solenoid valve B.NO

Measure Lock-up Control Sole-noid Valve B Resistance at theSolenoid Connector:Measure the resistance betweenthe No. 1 terminal of the lock-upcontrol solenoid connector andbodv ground.

YES Check for open in the wire15 the resistance 14 - 25 m between the 84 terminal and the

lock-up control solenoid valve B.NO

Replace the lock-up control 501e-noid valve assembly.

PCM CONNECTORSFrom page 14-52

14-54T0 page 14-55


ATPR(WHT)

PCM CONNECTORS

• OBO Il Scan Tooi indicates Code Possible CauseP1705. • Short in AIT gear position switch

• SeH-di.gnosis [Q;J indicator light wireblinks five times. • Faulty AIT gear position switch

NOTE: Code P1705 (5) is caused whenthe PCM receives two gear position

Observe the AIT Gear Position inputs at the same time.Indicator:t. Turn the ignition switch ON (11).2. Observe the AIT gear position

indicator, and shift to eachposition.

Do any indicators stay on NO The system is OK at this time.when the shift lever is not in Check the wire harness for dam-those positions? age.

YES

1

Oisconnect the AIT gear position

1switch connector.

Do ail gear position indica- YES Replace the AIT gear position

1tors go out? switch.

NO

Reconnect the AIT gear position

1

A(3

switch connector. l, 12 J

l!1_n 14

t_Me.sure ATP RVoltage:,. Shift to ail positions other than

ŒJ.2. Measure the voltage between

the 816 and A9 or A22 termi-nais.

Check for short in the wirebetween the B16 terminal and the

NO AIT gear position switch or AITIs there battery voltage? gear position indicator. H wire is

OK, check for loose PCM connec-YES tors. If necessary, substitute a

known-good PCM and recheck.

Measure ATP PN Voltage:1. Shift to ail positions other than l' 12 3

[ffi or [f). !;1n u2. Measure the voltage between ~the 825 and A9 or A22 termi-

nais.Check for short in the wirebetween the B25 terminal and theAIT gear position indicator, orshort in the Œl or (ffi position wire

NO between the AIT gear positionIs there battery voltage7indicator and the AIT gear posi-

YES tion switch. If wires are OK, checkfor loose PCM connectors. If nec-essary, substitute a known-goodPCMand recheck.

L

Troubleshooting Flowchart - AIT Gear Position Switch (Short)


14-55


From page 14-54

1

A (32P11 1 Z ,

Measure ATP 04 Voltage: VI l' 1.

1. Shift to ail positions other than ~[Q;].

2. Measure the voltage betweenthe B24 and A9 or A22 termi-nais.


NO AIT gear position switch. H wireIs there approx. 5 V? is OK, check for loose PCM con-

YESnectors. If necessary, substitute aknown-good PCM and recheck.

Measure ATP 03 Voltage: A (321. Shift to ail positions other than

~. 11 1 Z ,

2. Measure the voltage between VI" 1.the B8 and A9 or A22 termi- Lnais.





Measure ATP2 Voltage:1. Shift to ail positions other thanœ. 11 1 Z ,2. Measure the voltage between VI" 1.the B17 and A9 or A22 termi- Llnais.

Check for short in the wire .between the B17 terminal and the




Check for loose PCM connectors.If necessary, substitute a known-good PCM and recheck.

PCM CONNECTORS


PCM CONNECTORS

14-56

T0 page 14-57

• OBO Il Scan T001 indicates Code Possible CauseP1706. • Oisconnected AIT gear position

• Self-diagnosis [Qi) indicator light switch connectorblinks six times. • Open in AIT gear position switch

wire• Faulty AIT gear position switch

Test the AIT gear position switch(see page 14·81).

NO Replace the AIT gear positionIs the switch OK? switch.

YES

Measure ATP R Voltage: L1. Turn the ignition switch ON (11). A 132P)

2. Shift to [ID position. l'Il , .3. Measure the voltage between Vi" ,. '1

the 816 and A9 or A22 termi- ~/nais.L

YES Repair open in the wire betweenIs there voltage? the 816 terminal and the AIT gear

position switch.NO

L

Measure ATP PN Voltage: l, 12 , .1. Shift to [El or [f] position. Vl" ,. ,.2. Measure the voltage between YIthe 825 and A9 or A22 terrni-

nais. L

Repair open in the wire betweenthe 825 terminal and the AIT gear

YES position indicator or repair openIs there voltage? in the ŒJ or [El position wire

between the AIT gear positionNO switch and the AIT gear position

indicator.

L

Measure ATP 04 Voltage:1. Shift to 1);1 position. : , /2 J •

2. Measure the voltage between VI" ,. "the 824 and A9 or A22 terrni- i!_nais.

L

1Repair open in the wire betweenYES

15 there voltage?

1

the B24 terminal and the AIT gear

1 NO

position switch.

Troubleshooting Flowchart - AIT Gear Position Switch (Open)


14-57

Repair open in the wire betweenthe 817 terminal and the AITgear position switch.

ATP2 (8LU)

Repair open in the wire betweenthe 88 terminal and the AIT gearposition switch.


PCM CONNECTORS

YES

YES

Check for loose PCM connectors.If necessary, substitute a knowngood PCM and recheck.

NO

Is there voltage?

Measure ATP2 Voltage:1. Shift to œ position.2. Measure the voltage between


NO

Is there voltage?

Measure ATP 03 Voltage:1. Shift to [Qi] position.2. Measure the voltage between


From page 14-56

Check for loose PCM connectors.If necessary. substitute a knowngood solenoid valve assembly orPCM and recheck.

YES

Repair short to power in the wirebetween the B3 terminal and theshift control solenoid valve A.

YES


PCM CONNECTORS

• Disconnected shift control solenoidvalve connector

• Short or open in shift control solenoid valve A wire

• Faufty shift control solenoid valve A

Possible Cause

14-58

T0 page 14-59

NO

Is the resistance 14 - 25 m

Measure Shift Control SolenoidValve A Resistance:1. Turn the ignition switch OFF.2. Measure the resistance

between the 83 and A9 or A22terminais.

NO

Is there voltage?

Check for a Short to Power:1. Turn the ignition switch OFF.2. Disconnect the A (32P) and B

(25P) connectors trom thePCM.


the 83 and A9 or A2.2terminais.

• OBO Il Scan T001 indicates CodeP0753.

• Self-diagnosis IQ!] indicator lightblinks seven times.

Troubleshooting Flowchart - Shift Control Solenoid Valve A


14-59

Terminal side of male terminaIs

SHIFT CONTROL SOLENOIDCONNECTOR


1L

Check Shift Control SolenoidA (32PIValve A for a Short Circuit:

1. Disconnect the 2P connector l' 12J ,

from the shift control solenoid 1/111 " 1S

valve assembly.~~2. Check for continuity between

the 83 and AS or A22 terminais. L

YES Repair short to ground in the wireIs there continuity? between the 83 terminal and the

sh~ control solenoid valve A.NO

Measure Shift Control SolenoidValve A Resistance at the SolenoidConnector:Measure the resistance betweenthe No. 1 terminal of the shift con-trol solenoid connector and bodyground.

YES Check for open in the wireIs the resistance 14 - 25 n? between the 83 terminal and the

shift control solenoid valve A.NO

Replace the shift control solenoidvalve assembly.

PCM CONNECTORSFrom page 14-58

Check for loose PCM connectors.If necessary, substitute a knowngood solenoid valve assembly orPCM and recheck.

YES

Repair short to power in the wirebetween the B11 terminal andthe shift control solenoid valve B.

YES


A (32P

SH B (GRN/WHT)

PCM CONNECTORS

• Oisconnected shift control solenoidvalve connector

• Short or open in shift control solenoid valve B wire

• Faulty shift control solenoid valve B

Possible Cause

14-60

To page 14-61

NO

Is the resistance 14 - 25 O?

Measure Shift Control SolenoidValve B Resistance:1. Turn the ignition switch OFF.2. Measure the resistance

between the 811 and A9 orA22 terminais.

NO

Is there voltage?


(25P) connectors trom the peM.3. Turn the ignition switch ON (II).4. Measure the voltage between

the B11 and A9 or A22 terminais.

• OBO Il Scan Tooi indicates CodeP0758.

• Self-diagnosis ~ indicator lightblinks eight times.

Troubleshooting Flowchart - Shift Control Solenoid Valve B


14-61

Check for open in the wirebetween the B11 terminal and theshift control solenoid valve B.



Repair short ta ground in the wirebetween the B11 terminal and theshift control solenoid valve B.


PCM CONNECTORS

YES

YES

Replace the shift control solenoidvalve assembly.

NO

Is the resistance 14 - 25 O?

Measure Shift Control SolenoidValve B Resistance at the Solenoid Connector:Measure the resistance betweenthe No. 2 terminal of the shift control solenoid connector and bodyground.

NO


Check Shift Control SolenoidValve B for a Short Circuit:1. Disconnect the 2P connector

from the shift control solenoidvalve assembly.

2. Check for continuity betweenthe B11 and A9 or A22 terminais.

From page 14-60


PCM CONNECTOR 8 (25P)


COUNTERSHAFT SPEED SENSORCONNECTOR

14-62

• 080 Il Scan Tooi indicates Code Possible CauseP0720. • Loose or faulty connection between

• Self·diagnosis ~ indicator light the PCM and vehicle harnessblinks nine times. • Oisconnected countershaft speed

1

sensor connector• Short or open in countershaft speedsensorwire

Check the countershaft speed sen- • Faulty countershaft speed sensorsor installation.

1NOIs the countershaft speed sensor

1installed properly? Reinstall and recheck.

1 VES

Measure Countershaft Speed Sen-sor Resistance at the Sensor Con-nector:1. Disconnect the 2P connector

trom the countershaft speedsensor connector.

2. Measure the resistance of thecountershaft speed sensor:.

1NO Replace the countershaft speedIs the resistance 400 - 600 m

sensor.

1 VES

Check Countershaft Speed Sensorfor a Short Circuit:1. Disconnect the 8 (25P) con-

nector trom the PCM.2. Check for continuity between

the body ground and the 823terminal and 822 terminalindividually.

1 Repair short in the wires betweenYESIs there continuity? the 823 and 822 terminais and

1 NO

the countershaft speed sensor.

Measure Countershaft Speed Sen-sor Resistance:1. Connect the countershaft

speed sensor connector.2. Measure the resistance

between the 823 and 822 ter-minais.

l Repair loose terminal or open inNO the wires between the 823 andIs the resistance 400 - 600 m

822 terminais and the counter-

1 VESshaft speed sensor.


Troubleshooting Flowchart - Countershaft Speed Sensor


14-63

(cont'd)




MAINSHAFT SPEEOSENSOR CONNECTOR

NOTE: Code P0715(15) on the PCMdoesn't always mean there's an electricalproblem in the mainshaft or countershaftspeed sensor circuit; code P0715(15) mayalso indicate a mechanical problem in thetransmission.

T0 page 14-64

• 080 Il Scan Tooi indicates Code Possible CauseP0715. • Oisconnected mainshaft speed sen-

• Self-diagnosis ~ indicator light sor connectorindicates Code 15. • Short or open in mainshaft speed

sensorwire• Faulty mainshaft speed sensor

Check the mainshaft and counter-shaft speed sensor installation.

Are the mainshaft and countershaft NOspeed sensor installed properly? Reinstall and recheck.

YES

Measure Mainshaft Speed SensorResistance at the Sensor Con-nector:1. Disconnect the 2P connector

from the mainshaft speed sen-sor connector.

2. Measure the resistance of themainshaft speed sensor.

NO Replace the mainshaft speed sen-Is the resistance 400 - 600 n?sor.

YES

Check Mainshaft Speed Sensorfor a Short Circuit:1. Disconnect the 8 (25P) connec-

tor from the PCM.2. Check for continuity between

body ground and 815 terminaland the 814 terminal individu-ally.

YES Repair short in the wires betweenIs there continuity? the 815 and 814 terminais and

the mainshaft speed sensor.NO

Troubleshooting Flowchart - Mainshaft Speed Sensor

MAINSHAFT SPEEDSENSORCONNECTOR



14-64

Measure Mainshaft Speed SensorResistance:1. Connect the mainshaft speed

sensor 2P connector.2. Measure the resistance

between the 815 and 814 ter-minais.

Run the Electrical TroubleshootingYES Flowchart for code P0720(9).

Is the resistance 400 - 600 {l? Check for loose PCM connectors.If necessary. substitute a known-

NO good PCM and recheck.

Check NM Wire Continuity:1. Disconnect the 2P connector

from the mainshaft speed sen-sor connector.

2. Check for continuity betweenthe 815 terminal and the No. 2terminal of the mainshaftspeed sensor connector.

NO Repair open in the wire betweenIs there continuity? the 815 terminal and the main-

shaft speed sensor.YES

Check NMSG Wire Continuitv:Check for conti nuit y between the814 terminal and the No. 1 termi-nai of the mainshaft speed sensorconnector.

Repair open in the wire betweenNOIs there continuity? the 814 terminal and the main-

shaft speed sensor.YES

Check for loose PCM connectors.If necessary. substitute a known-good PCM and recheck.

From page 14-63

Troubleshooting Flowchart - Mainshaft Speed Sensor (cont'd)


14-65


lS - (WHT) lS + (RED)



LlNEAR SOlENOID CONNECTOR

• OBD Il Scan Tooi indicates Code Possible CauseP1768. • Disconnected linear solenoid con-

• Self-diagnosis ~ indicator light nectorindicates Code 16. • Short or open in linear solenoid

wire• Faulty linear solenoid

Measure Linear Solenoid Resist-ance at the Solenoid Connector:1. Disconnect the 2P connector

from the linear solenoid con-nector.

2. Measure the resistance of thelinear solenoid.

NO Replace the linear solenoid assem-Is the resistance 4.0 - 9.0 mbly.

YES

Check Linear Solenoid for a ShortCircuit:1. Disconnect the 8 (25P) connec-


the body ground and the 81terminal and 82 terminal indi-vidually.

YES Repair short in the wires betweenIs there conti nuit y? the B1 and B2 terminais and the

linear solenoid.NO

Measure Linear Solenoid Resist-ance:1. Connect the linear solenoid

connector.2. Measure the resistance

between the 81 and 82 termi-nais.

NO Repair loose terminal or open inIs the resistance 4.0 - 9.0 m the wires between the 81 and 82

terminais and the linear solenoid.YES


Troubleshooting Flowchart - Linear Solenoid

14-66

To page 14-67

eshooting until the causes of any

• OBO Il Scan T001 indicates Code Possible CauseP0740. Faulty Loek-up control system

• Self-diagnosis ~ indicator lightindicates Code 40.

1

Check for Another Code:Check whether the OBO Il scantool or the ~ indicator lightindicates another code.

1

Does the OBO Il scan tool or YESPerform the Troubleshooting

the ~ indicator light indicate Flowchart for the indicatedCode(s). Recheck for code P0740another code? (40) after troubleshooting.

1 NO NOTE: 00 not continue with this troublother OTCs have been corrected.

Test Line Pressure:Measure the line pressure (seepage 14-96 and 14-97).

1

Is the line pressure within the NO Repair the hydraulic system asservice limit? necessary (see page 14-97'.

J YES

Test 1st, 2nd, 3rd and 4th ClutchPressure:Measure the 1st, 2nd, 3rd and 4thclutch pressure (see page '4·96thru 14-98).

1

Is each clutch pressure within NO Repair the hydraulic system as

the service limit? necessary (see page 14-96 th ru14-98).

1 YES

Replace the Lock-up ControlSolenoid Valve Assembly andRecheck:1. Replace the lock-up control

solenoid valve A/B assembly(see page 14-77).

2. Turn the ignition switch OFFand reset the PCM by rernov-ing the BACK UP (7.5 A) fusein the under-hood fuse/relaybox for more than 10 seconds.

3. Drive the vehicle at 50 mph(80 km/hl constantly for morethan one minute.

4. Recheck for code P0740 (40).

1

Does the OBO Il scan tool or NO

1 1the lQ~. indicator light indi- The system is OK at this time.cate code P0740 (40)?

1 YES

Troubleshooting Flowchart - Lock-up Control System


14-67

1

Replace the Linear SolenoidAssembly and Recheck:1. Replace the linear solenoid

assembly (see page 14-80).2. Turn the ignition switch OFF

and reset the PCM memory byremoving the BACK UP (7.5 A)fuse in the under-hood fuselrelay box for more than 10seconds.

3. Drive the vehicle at 50 mph (80km/h) constantly for more thanone minute.


Ooes the OBO Il scan tool or NO1

1the ~ indicator light indi-

1The system is OK at this time.

cate code P0740 (40)7

YES

Replace the Torque Converter andRecheck:1. Replace the torque converter.2. Turn the ignition switch OFF

and reset the PCM memory byremoving the BACK UP (7.5 A)fuse in the under-hood fuselrelay box for more than 10 sec-onds.

3. Drive the vehicle at 50 mph (80km/h) constantly for more thanone minute.


Ooes the OBO Il scan tool or NO1

1the ~ indicator light indi-


cate code P0740 (40)7

YES

Replace the transmission.1

From page 14-66

Repair the hydraulic system asnecessary (see page 14-96 thru14-98).

NO

Perform the TroubleshootingFlowchart for the indicatedCode(s). Recheck for code P0730(41)after troubleshooting.

YES

NOTE: Do not continue with this troubleshooting until the causes of anyother OTCshave been corrected.

Perform the TroubleshootingFlowchart for the indicatedCode(s). Recheck for code P0730(41) after troubleshooting.

YES

1Faulty shift control system

Possible Cause

14-68

T0 page 14-69

1 YES

Is each clutch pressure withinthe service limit?

Test 1st, 2nd, 3rd and 4th ClutchPressure:Measure the 1st. 2nd, 3rd and 4thclutch pressure (see page 14-96thru 14-98).

NO

Ooes the 080 Il scan tool orthe ~ indicator light indicate another code?

Test-drive and Recheck for 1

Another Code: 1

1. Drive the vehicle at a speed ,over 12 mph (20 km/hl in 2nd,3rd and 4th gear for morethan 30 seconds.

2. Check whether the 080 Il scantool or the Jj~ indicator lightindicates another code.

NO

Ooes the 080 Il scan tool orthe ~b4_ indicator light indicate another code?

Check for Another Code:Check whether the 080 Il scantool or the ~ indicator lightindicates another code.

• OBO Il Scan Tooi indicates CodeP0730.

• Self-diagnosis ~D.; indicatorlight indicates Code 41.

Troubleshooting Flowchart - Shift Control System


14-69

1

Replace Shift Control SolenoidValve Assembly and Recheck:1. Replace the shift control

solenoid valve NB assembly(see page 14-78).

2. Turn the ignition switch OFFand reset the PCM memory byremoving the BACK UP (7.5 A)fuse in the under-hood fuselrelay box for more than 10seconds.

3. Drive the vehicle at over 12mph (20 km!h) in 2nd, 3rd and4th gear for more than 30 sec-onds.


Does the OBD Il scan tool or NO1

1the ;Q! indicator light indi-


cate code P0730 (41)?

YES

Replace Unear Solenoid Assemblyand Recheck:1. Replace the linear solenoid

assembly (see page 14-80).2. Turn the ignition switch OFF

and reset the PCM memory byremoving the BACK UP (7.5 A)fuse in the under-hood fuselrelay box for more than 10 sec-onds.

3. Drive the vehicle at over 12mph (20 km/h) in 2nd, 3rd and4th gear for more than 30 sec-onds.


Does the OBD Il scan tool or NO1

1the cD~_ indicator light indi-


cale code P0730 (41)?

YES

Replace the transmission.

From page 14-68

14-70

Ta page 14-71


PCM CONNECTOR A (32P)

The ~ indicator Iight does notcome on when the ignition switchis first turned ON (11). (lt shouldcome on for about two seconds.'

Check the Service Check Connec-tor:Make sure the special tool (SeSService Connector) is not connect-ed ta the service check connector.

1

Is the special tool (SCS Service YES1 Disconnect the special tool trom!Connector) connected ta the ser- !. the service check connector and

vice check connector? recheck.

NO

Check the [Q;J indicator Light:Shift to ~ position.

Ooes the [Q;] indicator light come YES Check for loose PCM connectors.

on? If necessary, substitute a known-good PCM and recheck.

NO

Check the Ground Circuit:1. Turn the ignition switch OFF.2. Disconnect the A (32P) connec-


the A9 terminal and bodyground and the A22 terminaland body ground.

J . Repair open in the wires betweenNOIs there continuity? • the A9 or A22 terminais and G101.

1 • Repair poor ground (G101).YES

Troubleshooting Flowchart - ~ Indicator Light Does Not Come On


14-71


GAUGE ASSEMBLY 14PCONNECTOR

PCM CONNECTOR B (25P)


IGP2 (YEL/BLK)

IGP1 (YEL/BLKI

PCM CONNECTORA (32Pl

1

Measure Power Supply CircuitVoltage:1. Turn the ignition switch ON (II).2. Measure the voltage between

the A11 and A9 terminais andbetween the A22 and A24 ter-minais.

1NO

Repair open or short in the wirebetween the A11 and/or A24 ter-Is there banery voltage? minais and the PGM-FI main

1 YESrelay, and the fuse box.

Measure 04 INo Voltage:LG11. Turn the ignition switch OFF.

2. Connect the A (32PI connec- A (32P)torto the PCM. 1 'L z 1 •

3. Connect a digital multimeter 1/1" 1. 111to the 813 and Ag or A22 ter- ~~~minais.

4. Turn the ignition switch ON (II) LG2and make sure that the volt-age is available for two sec-onds.

J Check for open in the wirebetween the B13 terminal and

YES the gauge assembly. If wire isIs there voltage?OK, check for a faulty [Q;] indica-

1 NOtor light bulb or a faulty gaugeassembly printed circuit board.

Check 04 INo for a Open Circuit:1. Turn the ignition switch OFF.2. Disconnect the 8 (25P)connec-

tor trom the PCM.3. Check for continuity between

the 813 terminal and the No. 904terminal of the gauge assembly

14Pconnector.

l Repair open in the wire betweenNOIs there continuity? the B13 terminal and the gauge

1 YESassemblv.

Check 04 INo for a Short Circuit:Check for conti nuit y between the813 terminal and body ground.

1 Repair short in the wire betweenYESIs there continuity? the B13 terminal and the gauge

1 NO

assembly.

Check for 1005ePCM connectors.Check the AIT gear positionswitch. If necessary. substitute aknown-good PCM and recheck.

From page 14-70


PCM CONNECTOR 8 125P)

14-72

The ~ indicator light is on con-stantly (not blinking) wheneverthe ignition switch is ON (II).

Measure 04 INO Voltage:1. Turn the ignition switch OFF.2. Disconnect the B (25P) con-

nector trom the PCM.3. Turn the ignition switch ON (II).4. Measure the voltage between

the B13 terminal and bodyground.

YES Repair short to power in the wireIs there voltage? between the 813 terminal and

the gauge assembly.NO

Measure ATP 04 Voltage:1. Turn the ignition switch OFF.2. Connect the B (25P)connector

to the PCM.3. Turn the ignition switch ON (11).4. Shift to any position other

than ~.5. Measure the voltage between

the B24 terminal and bodyground.

YES

1 1Is there approx. 5 V? Replace the PCM.

NO

Test the AIT gear position switch(see page' 4-81).

l1

NO Replace the AIT gear positionIs the switch OK?1

switch.

YES

Check for a short to ground inthe wire between the 824 termi-nai and the AIT gear positionswitch. If the wire is OK, substi-tute a known-good PCM andrecheck.

Troubleshooting Flowchart -I041lndicator Light On Constantly


14-73

(cont'd)

Check open in the wire betweenthe No. 7 tenninal of the interlockcontrol unit and the 812 terminalof the PCM. If wire is OK. check forloose PCM connectors. If necessary, substitute a known-goodPCM and recheck.

NO


fR ~ZffiJ8SLU (WHT/REO) ~

INTERLOCK CONmOL UNIT (SPI CONNECTOR

Repair open in the wire betweenthe 05 terminal and the brakeswitch.

NO


PCM CONNECTORS

NO 1 Repair faulty brake switch circuit(see section 231.

Ta page 14-74

YES

Is there 1 V or less?

Measure SLU Voltage:1. Connect the A (32PI and 0

(16PI connectors to the PCM.2. Oisconnect the 8P connector

from the interlock control unit.3. Turn the ignition switch ON (II).4. Measure the voltage between

the No. 7 terminal of the interlock control unit and bodyground with the brake pedaldepressed.

YES


Measure STOP SW Voltage:1. Turn the ignition switch OFF.2. Oisconnect the A (32PI and

o (16PI connectors from thePCM.

3. Measure the voltage betweenthe 05 and A9 or A22 terminais with the brake pedaldepressed.

YES

Are the brake lights ON?

Check Brake Light Operation:Oepress the brake pedal.

Shift lever cannot be moved from[El position with the brake pedaldepressed.

Troubleshooting Flowchart - Interlock System - Shift Lock System


SHIFT LOCK SOLENOIDCONNECTOR(directly on solenoidl


INTERLOCK CONTROL UNITCONNECTOR (BPI


INTERLOCK CONTROL UNIT (BP) CONNECTOR

Replace the shift lock solenoid.NO

NOTE: Do not connect the No. 2 terminal tathe battery positive terminal, or vou willdamage the diode inside the shift Jocksolenoid.

Repair open in the wire betweenthe No. 3 terminal of the interlockcontrol unit and the shift lock solenoid.

NO

Repair open in the wire betweenthe No. 6 terminal of the interlockcontrol unit and the Arr gear position switch.

NO

NOTE: Shift Jever must be in [fJ.

14-74

Check for a loose interlock control unit connector. If necessary,substitute a known-good interloék control unit and recheck.

YES

Does the shift lock solenoidoperate properly?

Check Shift Lock Solenoid Operation:1. Connect the No. 1 terminal of

the shift lock solenoid connector ta the battery positive terminaI, and connect the No. 2terminal ta the battery negative terminal.

2. Check that the shift lock soleno id operates.

YES


Check Shift Lock Solenoid for aOpen Circuit:1. Turn the ignition switch OFF.2. Disconnect the shift lock sole

noid connector.3. Check for continuity between

the No. 3 terminal of the interlock control unit and the No. 2terminal of the shift lock solenoid connector.

YES

Is there 1 V or less?

Measure ATPP Voltage:Measure the voltage between theNo. 6 terminal of the interlock control unit and body ground.

1

From page 14-73

Troubleshooting Flowchart -Interlock System - Shift Lock System (cont'd)


14-75

(cont'd)

+STOPSW (WHT/GRN)


IGINITION SWITCH CONNECTOR(7P)

Ta page 14-76

Ignition key cannot be movedfrom ACC (1) position to lOCK (0)position while pushing the igni-tion key with the shift lever in [f]position.

Check Key Interlock SolenoidOperation:1. Disconnect the ignition switch

connector (7P).2. Connect the No. 5 terminal of

the ignition switch connector tothe battery positive terminal,and connect the No. 6 termi-nai to the battery neqative ter-minaI.

3. Check the key interlock sole-noid operation. A clickingsound should be heard.

Ooes the key interlock NO Faulty key interlock solenoid.

solenoid operate properly7 Replace the ignition key cylinderlsteering lock 8ssembly.

YES

Check Key Interlock Switch Oper-ation:1. Connect the No. 7 terminal of

the ignition switch connectorto the battery positive termi-nai, and connect the No. 6 ter-minai to the battery negativeterminal.

2. Turn the ignition switch toACC (1), then push it.

3. Check the key interlock sole-noid operation. A clickingsound should be heard whilepushing the ignition key, andno sound should be heardwhen releasing the ignitionkey.

Ooes the key interlock NO Faulty key interlock switch.

solenoid operate properly? Replace the ignition key cylinder 1steering lock assembly.

YES

Troubleshooting Flowchart - Interlock System - Key Interlock System


OCK SOL (WHT/BLUI

INTERLOCK CONTROL UNIT (SPI CONNECTOR

14-76

1 KEY L

Check Key Interlock Solenoid fora Short Circuit:,. Disconnect the 8P connector

from the interlock control unit.2. Check for conti nuit y between

the No. 1 terminal and bodyground and between the No. 5terminal and body ground indi-vidually.

YESRepair short in the wire betweenthe No. 1 or No. 5 terminal of theIs there continuity?interlock control unit and the igni-

NO tion switch connector.

Check Parking Pin Switch Oper-ation:Check for continuity between theNo. 8 terminal and body ground.

Check for short in the wireYES between the No. S terminal of

Is there continuity? the interlock control unit and theparking pin switch. If wire is OK.

NO check the parking pin switch.

Measure ATP P Voltage: NOTE: Shift lever must be in ŒJ.1. Turn the ignition switch ON (11).2. Measure the voltage between

the No. 6 terminal and bodyground.

Repair open in the wire betweenYES the No. 6 terminal of the interlockIs there voltage?

control unit and the AIT gear

NO position switch.

Check for 100se interlock controlunit connectors. If necessary. sub-stitute a known-good interlockcontrol unit and recheck.

From page 14-75

Troubleshooting Flowchart - Interlock System - Key Interlock System (cont' d)


14-77

3. Check the connector for rust, dirt or oil, and reconnect it securely.

2. Clean the mounting surface and fluid passages ofthe lock-up control solenoid valve A/B assembly,and install a new lock-up control solenoid valve A/Bwith a new filter/gasket.

FILTER/GASKETReplace.

Clean the mounting surfaceand fluid passages.

6x1.0mm12 N'm (1.2 kgf·m, 8.71bHtl

1. Remove the mounting bolts and lock-up controlsolenoid valve A/B assembly.

NOTE: lock-up control solenoid valves A and'B must beremoved/replaced as an assembly.

4. If the resistance is within the standard, connect theNo. 1 terminal of the lock-up control solenoid valveconnector to the battery positive terminal. A c1ickingsound should be heard. Connect the No. 2 terminal tothe battery positive terminal. A clicking sound shouldbe heard. Replace the lock-up control solenoid valveassembly if no clicking sound is heard.

3. Replace the lock-up control solenoid valve A/Bassembly if the resistance is out of specification.

STANDARD: 14 - 25 n

2. Measure the resistance between the No. 2 terminal(solenoid valve A) of the lock-up control solenoidvalve connector and body ground, and between theNo. 1 terminal (solenoid valve B) and body ground.

~/~

..."----""-,--,,,Lte/~

/LOCK-UP CONTROLSOLENOID VALVE A/BASSEMBLY

LOCK-UP CONTROLSOLENOID CONNECTOR(2P)

1. Disconnect the 2P connector from the lock-up control solenoid valve A/B assembly.

ReplacementTest

Lock-up Control Solenoid Valve A/B Assembly

3. Checkthe, connector for rust, dirt or oil, and reconnect it securely.

2. Clean the mounting surface and fluid passages ofthe shift control solenoid valve assembly, andinstall a new shift control solenoid valve A/B assemI:>lywith a new filter/gasket and the clamp.


SHIFT CONTROLSOLENOIO VALVE A/BASSEMBlY

CLAMP6xl.0mm12N·m(1.2 kgf'm, 8.7 Ibf.ftl

\0'C',/,fT'>.. 'fMIY

1. Remove the mounting bolts, the clamp and the shiftcontrol solenoid valve A/B assembly. Then, disconnect the connector.

NOTE: Shift control solenoid valves A and B must beremoved/replaced as an assembly.

14-78

4. If the resistance is within the standard, connect theNo. 1 terminal of the shift control solenoid valveconnector to the battery positive terminal. A clickingsound should be heard. Connect the No. 2 terminalto the battery positive terminal. A clicking soundshould be heard. Replace the shift control solenoidvalve assembly if no clicking sound is heard.

3. Replace the shift control solenoid valve A/B assembly if the resistance is out of specification.

STANDARD: 14 - 25 0

2. Measure the resistance between the No. 1 terminal(solenoid valve A) of the shift control solenoid valveconnector and body ground, and between the No. 2terminal (solenoid valve B) and body ground.

SHIFT CONTROLSOLENOIO VALVE AlBASSEMBLY

male terminais

1. Disconnect the 2P connector from the shift controlsolenoid valve A/B assembly.

ReplacementTest

Shift Control Solenoid Valve A/8 Assembly

14-79

9. If the valve binds, or moves sluggishly, or if the linearsolenoid does not operate, replace the linear solenoidassembly.

lINEAR SOLENOID

8. Disconnect the negative battery terminal, and makesure the valve releases.

7. Connect the No. 2 terminal of the linear solenoidconnector to the battery positive terminal and connect the No. 1 terminal to the battery negative terminaI. Make sure the valve moves.

6. Check the linear solenoid fluid passage for dust ordirt.

5. If a clicking sound is not heard, remove the linearsolenoid assembly.

4. Connect the No. 2 terminal of the linear solenoid connector to the battery positive terminal and connectthe No. 1 terminal to the battery negative terminal. Aclicking sound should be heard.

3. If the resistance is out of specification, replace thelinear solenoid assembly.

STANDARD: 4.0 - 9.0 n

2. Measure the resistance between the No. 1 and theNo. 2 terminais of the linear solenoid connector.

1. Disconnect the linear solenoid connector.

NOTE: You can see the valve movement throughthe fluid passage in the mounting surface of the lin-

maleterminais ear solenoid assembly.

Test

Linear Solenoid Assembly

3. Replace the O-ring with a new one before installingthe countershaft speed sensor or the mainshaft speedsensor.

2. Remove the 6 mm boit and the mainshaft speedsensor from the transmission housing.

MAINSHAFTSPEEDSENSOR

O-RING


6 x 1.0 mm12N·m (1.2 kgf·m.8.7 IbHt)

\<:>:

~

1<0

/'0....

s;'~O-RING C »<>»:Replace. , ./ .>. /! ./' .

(_ ',7' /7\ '- / ~/..._ / .L_ -: .: //2//

6 x 1.0mm12N'm ('.2 kgf·m.8.7 IbHt)

1. Remove the 6 mm boit and the countershaft speedsensor from the right side cover.

14-80

4. Check the linear solenoid connector for rust, dirt oroil, and connect it securely.

NOTE: Do not pinch the gasket when installing thelinear solenoid; make sure that the gasket is installedproperly in the mounting groove of the linear solenoid.

3. Install a new linear solenoid assembly with a newgasket.

2. Clean the mounting surface and fluid passage of thelinear solenoid assembly and transmission housing.

LlNEARSOLENOIDASSEMBLY

GASKET


1. Remove the mounting bolts and the linear solenoidassembly.

ReplacementReplacement

Mainshaft/CountershaftSpeed SensorsLinear Solenoid Assembly

14-81

*1:With cruise control system

r-, Terminal-. 1 5 6 7 9·' 12 13 14 3 4 10 11Position

Il] 0---0

[Qi]

~ 0- -()

[ID 0- -()

ŒJ 0- f---o[f] 0- -0

Neutra 1Position Switch

Back-upLight SwitchAIT Gear Position Switch

Terminar side of male terminais

12 13 14

5 6 7

~

~14PCONNECTOR

If there is no continuity within the range of free play, adjust the position of the switch as described on the next page.

4. Move the shift lever back and forth without pushing the push button at each switch position, and check for continuitywithin the range of free play.

3. Check for continuity between the terminais in each switch position according to the table below.

2. Disconnect the AIT gear position switch connector (14P).

1. Remove the front console (see section 20).

Test

AIT Gear Position Switch

NOTE: If adjustment is not possible, check for damage to the shift lever detent and/or the shift levermounting bracket.

3. Check for continuity between each of the terminais.

2. Move the AIT gear position switch to the rear sideup to 2.0 mm (0.079 in). There should be conti nuitybetween the No. 1 and No. 12 terminais of the AITgear position switch connector, in the range of thefree play of the shift lever.

lOCK PIN

~1

1

Free playMOUNTING NUTS

Adjust rearwardwithin 2.0 mm (0.079 in).

~ position

1. Shift to the œJ position, and loosen the AIT gearposition switch mounting nuts.

14-82

7. Connect the 14Pconnector.

6. Test the AIT gear position switch.

5. Move the shift lever to 00 position, then install theAIT gear position switch while aligning the switchslider with the switch slider guide pin.

4. Position the switch slider of the new AIT gear position switch to [BJ position.

3. Remove the AIT gear position switch from the shiftlever mounting bracket.

MOUNTING NUTS6x1.0 mm9.8 N'm (1.0 kgf·m, 7 Ibf·ftl

SWITCH SUDERGUIDE PIN

2. Disconnect the AIT gear position switch connector(14P).


AdjustmentReplacement

AIT Gear Position Switch

14-83

Terminal Wire Test Condition Test: Oesired ResultPossible Cause

Number Color (Hresult is not obtained)

1 YEL Ignition switch ON (II) Check for voltage to ground: • Blown No. 25 (7.5 A) fuse in theThere should be battery voltage. under-dash fuse/relay box


2 RED/BLK Combination light switch Check for voltage between No. 2 • Blown No. 25 (7.5 A) fuse in theON and dash lights and No. 3 terminaIs: under-dash fuse/relay boxbrightness control dial on There should be battery voltage. • Faulty combination light switch

3 RED full bright • Faulty dash light brightnesscontroller


4 BLU Shift lever in m Check for continuity to ground: • Faulty AIT gear position switchThere should be continuity. • An open in the wireNOTE: There should be no conti-nuit y in any other shift leverposition.

8 BLK Under ail conditions Check for continuity to ground: • Poor ground (G401, G402)There should be continuitv, • An open in the wire

9 GRN/BLK Ignition switch ON (II) Check for voltage to ground: • Faulty PCMand shift lever in any There should be battery voltage • An open in the wireposition except ::p~ for two seconds after the ignition

switch is turned ON (II), and lessthan 1V two seconds later.

10 GRN Shift lever in Q3_ Check for continuity to ground: • Faulty AIT gear position switch

11 RED Shift lever in ffi) There should be continuity. • An open in the wire

Shift lever in ŒJ NOTE: There should be no conti-12 WHT nuity in any other shift lever13 BLK/BLU Shift lever in [f] position.

NOTE: Do not push thebrake pedal.

14 LTGRN Ignition switch ON (II) 1 Check for voltage to ground: • Faulty PCM1 There should be about 5 V. • An open in the wiref


GAUGE ASSEMBLV 14P CONNECTOR

2. Inspect the connector and socket terminais to be sure they are ail making good contact.• If the terminais are bent, loose or corroded, repair them as necessary, and recheck the system .• If the terminaIs look OK, make the following input tests at the 14Pconnector.

-If a test indicates a problem, find and correct the cause, then recheck the system.-If ail the input tests prove OK, but the indicator is faulty, replace the printed circuit board.

1. Remove the gauge assembly from the dashboard (see section 20), and disconnect the 14P connector from the gaugeassembly (see section 23).

Input Test

AIT Gear Position Indicator

14-84

INTERLOCK CONTROLUNIT

8P CONNECTOR

/,/

NOTE: If the shift lock solenoid clicks when the ignition switch is turned ON (II) and brake pedal is depressed with theshift lever in [f] position, the shift lock system is electronically normal; if the shift lever cannot be shifted from [f] position, test the AIT gear position switch.

2. Inspect the connector and connector terminais to be sure they are ail making good contact.• If the terminaIs are bent, loose, or corroded, repair them as necessary, and recheck the system.• If the terminais look OK, make the following input test at the connector.

- If a test indicates a problem, find and correct the cause, then recheck the system.- If ail the input tests prove OK, substitute a known-good control unit, and recheck the system. If the check is OK,

the control unit must be faulty; replace it.

1. Disconnect the 8P connector from the interlock control unit.

Interlock Control Unit Input Test

Interlock System

14-85

Terminal Wire Test Condition Test: Oesired Result Possible CauseNumber Color (If result is not obtained)

1 WHT/BLU Ignition switch turned to Check for voltage to ground: • Blown No. 48 (30A) fuse in theACC (1), ignition key There should be battery voltage. under-hood fuse/relay boxpushed ail the way in • Blown No. 33 (7.5 A) fuse in the

under-dash fuse/relay box• Faulty steering lock assembly(key interlock solenoid)


2 YEL Ignition switch turned ON Check for voltage to ground: • Blown No. 19 (7.5 A) fuse in the(II) There should be battery voltage. under-dash fuse/relay box

• Faulty steering lock assembly(key interlock solenoid)


3 YEL/BLK Ignition switch turned ON Check for voltage to ground: • Blown No. 19 (7.5 A) fuse in the(II) There should be battery voltage. under-dash fuse/relay box

• Faulty shift lock solenoid• An open in the wire

4 BLK Under ail conditions Check for conti nuit y to ground: • Poor ground (G401, G402)There should be continuity. • An open in the wire

5 WHT Ignition switch turned to Check for voltage to ground: • Blown No. 48 (30 A) fuse in theACC (1), ignition key There should be battery voltage. under-hood fuse/relay boxpushed ail the way in • Blown No. 33 (7.5 A) fuse in the

under-dash fuse/relay box• Faulty steering lock assembly(key interlock solenoid)


6 BLK/BLU Shift lever in :fJ Check for continuity to ground: • Faulty AIT gear position switchThere should be continuity. • Poor ground (G401, G402)


8 WHT/BLK Shift lever in ~ and push Check for continuity to ground: • Faulty parking pin switchbutton pressed There should be continuity. • Short to ground

Shift lever in [f] and push Check for continuity to ground:button released There should be no continuity.

Reconnect the interlock control unit 8P connector.

7 WHT/RED Ignition switch ON (II) Check for voltage to ground: • Faulty brake switchand brake pedal pushed There should be 1 V or less. • Faulty throttle position (TP)

Ignition switch ON (II), Check for voltage to ground: sensor

brake pedal and accelera- There should be battery voltage. • Faulty PCM

tor pedal depressed at • An open in the wire

the same time


INTERLOCK CONTROL UNIT CONNECTOR (8P)

5. If the solenoid does not work, replace it.

4. Check that the shift lock releases when the releaselever is pushed, and check that it locks when therelease lever is released.

NOTE:• Do not connect power to the No. 2 (-) terminal

(reverse pola rity), or vou will damage the diodeinside the solenoid.

• Make sure there is clearance between the stoppin and the base bracket when the solenoidswitches ON and OFF.

3. Connect battery power to the No. 1 terminal, and tothe No. 2 terminal of the solenoid, momentarily.


2. Disconnect the shift lock solenoid 2P connector.


14-86

• If the key cannot be removed, the key interlocksolenoid is OK.

• If the key can be removed, replace the steeringlock assembly (the interlock solenoid is not avaitable separately).

4. Check that the key cannot be removed with powerand ground connected to the No. 7 and No. 5 terminais.

\ Terminal

\ 5 6 7Position

Ignition Key pushed inswitchACC (1) Key released

3. Check for continuity between the terminais in eachkey position according to the table.

female terminais~

~

2. Disconnect the 7P connector from the main wireharness.

1. Remove the driver's dashboard lower cover andknee bolster (see section 20).

Shift Lock Solenoid TestKey Interlock Solenoid Test

Interlock System

14-87

NOTE: The parking pin switch is assembled withthe position plate. If parking pin switch replacementis required, refer to page 14-168.

If necessary,replacethe parking pin switch.5.

Terminal side ofmale terminaIs

PARKING PIN SWITCH4P CONNECTOR

There should be continuity while pushing the pushbutton.There should be no continuity when the push button is released.

4. Checkfor continuity between the No. 3 and No. 4terminais.

3. Disconnectthe parking pin switch 4Pconnector.

2. Shift toœ position.

1. Removethe front console (seesection20).

10. Checkthe shift lock solenoid operation.

9. Connectthe 2Pconnector to the shift lock solenoid.

8. Installthe Aff gear position switch.

7. Besure to install the projectedtips of the shift locksolenoidin the holesof the positionplate,thentightenthescrews.

SHIFT LOCKSOLENOID

SHIFT LOCKSTOP

SCREWS3 N·m (0.3 kgf·m,2lbf.ftJ

6. Install the shift lock solenoid and connect the shiftlocksolenoid plunger to the shift lockstop.

5. Apply silicone grease to the shift lock solenoidplungermating surfaceswith the shift lockstop.

4. Remove the two screws securing the shift locksolenoid,then remove the shift locksolenoid.

3. RemovetheAff gear position switch.

2. Shift toœ position, then disconnectthe 2Pconnector from the shift lock solenoid.

1. Removethe front console (seesection20).

Parking Pin Switch TestShift Lock Solenoid Replacement

14-88

SYMPTOM Check these items on the Check these items onPROBABLECAUSE List the NOTESList

Engine runs, but vehicle does not move in any gear. 1,2,3,5,6,7,36,38 K, L, R,S

Vehicle moves in @J, [BJ, but not in [Q!], [Q;J, position. 6,8,9,10,30,54 C,M,O

Vehicle moves in ~, ~, [BJ, but not in œ position. 6, 1l, 12,24 C,L

Vehicle moves in [Q!], [Q;], @J, but not in [BJ position. 4,6, 14, 15,31 C, c.oVehicle moves in lliJ position. 10,12,13,14,16,29,33,34,35 C,D

Excessive id le vibration 1,2,19,32,36,45,47,48,52 B,K,L

Poor acceleration; tiares on starting off in [Q;], ro; positionStail rpm high in fD.l, [Q!], @J position 1,2,3,6,38,41 K,L,R

Stail rpm high in fD.\ ~ position 6,8,10 C,D

Stail rpm high in œ position 6, 12 C,D

Stail rpm is in specification 14 N

Stail rpm low 17,18,32,45,47,48,52 R

No shift 19,20,40,48,49,52 G, L

Fails to shift in [Q!], [Q;] position; from 1st to 3rd gear 22,49,52

Fails to shift in [Qil, ~ position; from 1st to 4th gear 22,23,48,52

Erratic upshifting

1-2 upshift, 2-3 upshift, 3-4 upshift 18,52,59

1-2 upshift 21,48,52

2-3 upshift 22,49,52

3-4 upshift 23,48,52

Harsh upshift (1-2) 12,19,20,29,50,51,52,58,59 C,D,E

Harsh upshift (2-3) 13,19,20,24,27,29,50,51,52,58,59 C,D,E,H,L

Harsh upshift (3-4) 14,19,20,25,28,29,50,51,52,58,59 C, D, E,', LHarsh downshift (2-1) 19,20,24,43,52,55,58,59 0Harsh downshift (3-2) 12,19,20,25,43,52,56,58,59 C,D,E,H

Harsh downshift (4-3) 13,19,20,26,43,52,57,58,59 C, D, E, 1Flares on 2-3 upshift 13,19,20,24,27,51,52 E, L

Flares on 3-4 upshift 14,19,20,25,28,51,52 E,L,N

Excessive shock on 2-3 upshift 13,19,20,24,27,43,50,51,52,58,59 E,L,N

Excessive shock on 3-4 upshift 14,19,20,25,28,43,50,51,52,58,59 E, L,N

Late shift from lliJ position to ~ or ~ position 10,30 M

Late shift from [ffi position to Œl position 4,14,21,53 aNoise trom transmission in ail shift lever positions 2,37 K, L, aVehicle does not accelerate more than 31 mph (50 km/h). 17

Shift lever does not operate smoothly. 6,39 P

Fails to shift; stuck in 4th gear 48,49,52

Transmission will not shift into parking gear in ŒJ position. 6,39 P

Stail rpm high; ail clutch pressures are in specification. 41 D,K,O

Lock-up clutch does not disengage. 19,44,45,46,47,50,51,52,59 E,L

Lock-up clutch does not operate smoothly. 19,41,44,45,46,47,50,51,52,59 L

Lock-up clutch does not engage. 19,41,44,45,46,47,50,51,52,59 E, L

Vibration in ail positions 36

Hydraulic System


14-89

(cont'd)

PROBABLE CAUSE

1 LowATF 41 Torque converter check valve stuck2 ATF pump worn or binding 42 Foreign material in separator plate3 Regulator valve stuck 43 CPB valve stuck4 Servo valve stuck 44 Lock-up timing valve stuck5 Mainshaft worn/damaged 45 Lock-up shift valve stuck6 Shift cable broken/out of adjustment 46 Lock-up control valve stuck7 Final gears worn/damaged 47 Lock-up piston defective8 One-way (sprag) clutch worn/damaged 48 Shift control solenoid valve A defective9 1st gears worn/damaged (2 gears) 49 Shift control solenoid valve B defective10 1st c1utch defective 50 Lock-up control solenoid valve A defective11 2nd gears worn/damaged (2 gears) 51 Lock-up control solenoid valve B defective12 2nd clutch defective 52 PCM defective13 3rd clutch defective 53 Servo control valve stuck14 4th clutch defective 54 . 1st accumulator defective15 Reverse gears worn/damaged (3 gears) 55 Foreign material in 2nd exhaust orifice16 Excessive ATF 56 Foreign material in 3rd exhaust orifice17 Torque converter one-way clutch defective 57 Foreign material in 4th exhaust orifice18 Engine throttle cable out of adjustment 58 Mainshaft speed sensor defective19 Linear solenoid assembly defective 59 Countershaft speed sensor defective20 CPCvalve stuck21 1-2shift valve stuck22 2-3 shift valve stuck23 3-4 shift valve stuck24 2nd accumulator defective25 3rd accumulator defective26 4th accumulator defective27 2nd orifice control valve stuck28 3-4orifice control valve stuck29 Foreign material in main orifice30 Foreign material in 1st orifice31 Foreign material in reverse orifice32 Engine output low33 Needle bearing worn/damaged34 Thrust washer worn/damaged35 Clutch clearance incorrect

36 Drive plate defective or transmission misas-sembly

37 Torque converter housing or transmissionhousing bearing worn/damaged

38 ATFstrainer clogged

39 Joint in shift cable and transmission or bodyworn

40 Modulator valve stuck

14-90

PROBABLE CAUSE DUE TO IMPROPER REPAIR

Rl Improper clutch clearance

R2 Improper gear clearance

R3 Parking brake lever installed upside down.

R4 One-way (sprag) clutch installed upside down.

R5 Reverse selector hub installed upside down.

R6 ATF pump binding

R7 Torque converter not fully seated in ATF pump.

R8 Main seal improperly installed.

R9 Springs improperly installed.

Rl0 Valves improperly installed.

Rl1 Shift fork boit not installed.

The following symptoms can be caused Check these items on the Items on thePROBABLE CAUSE DUE TOby improper repair or assembly IMPROPER REPAIR List NOTES List

Vehicle creeps in [ffi position. R1, R2

Vehicle do es not move in [Q;J or ~ position. R4

Transmission locks up in Œl position. R3, Rl1

Excessive drag in transmission R6 K,R

Excessive vibration, rpm related R7

Noise with wheels moving only R5

Main seal pops out. R8 S

Various shifting problems R9,R10

Hydraulic System (cont'd)


14-91

NOTES

A See flushing procedure, page 14-164 and 165.

B Set id le rpm in gear to specified idle speed. If still no good, adjust the motor mounts as outlined in theengine section of this manual.

C If the large c1utch piston O-ring is broken, inspect the piston groove for rough machining.

D If the clutch pack is seized or is excessively worn, inspect the other clutches for wear, and check the orificecontrol valves, CPC valve, and linear solenoid for free movement.

E If the linear solenoid is stuck, inspect the clutches for wear.

G Ifthe 1-2 shift valve is stuck c1osed, the transmission will not upshift. If stuck open, the transmission hasno 1st gear.

H If the 2nd orifice control valve is stuck, inspect the 2nd and 3rd clutch packs for wear.

1 If the 3-4 orifice control valve is stuck, inspect the 3rd and 4th clutch packs for wear.

J If the c1utch pressure control valve is stuck c1osed, the transmission will not shift out of 1st gear.

K Improper alignment of main valve body and torque converter housing may cause ATF pump seizure. Thesymptoms are mostly an rpm-related ticking noise or a high-pitched squeak.

L If the ATF strainer is clogged with particles of steel or aluminum, inspect the ATF pump and differentialpinion shaft. If both are OK and no cause for the contamination is found, replace the torque converter.

M If the 1st c1utch feed pipe guide in the right side cover is scored by the mainshaft, inspect the bail bearingfor excessive movement in the transmission housing. If OK, replace the right side cover as it is dented. TheO-ring under the guide is probably worn.

N • Replace the mainshaft if the bushing for the 4th feed pipe is loose or damaged. If the 4th feed pipe is dam-aged or out of round, replace the right side cover.

• Replace the mainshaft if the bushing for the 1st feed pipe is loose or damaged. If the 1st feed pipe is dam-aged or out of round, replace it.

0 A worn or damaged sprag c1utch is mostly a result of shifting the transmission in [Q,J or ~ position whilethe wheels rota te in reverse, such as rocking the vehicle in snow.

P Inspect the frame for collision damage.Q Inspect for damage and wear:

1. Reverse selector gear teeth chamfers.2. Engagement teeth chamfers of countershaft 4th and reverse gear.3. Shift fork for scuff marks in center.4. Differentiai pinion shaft for wear under pinion gears.5. Bottom of 3rd c1utch for swirl marks.Replace items 1, 2, 3 and 4 if worn or damaged. If the transmission makes a c1icking, grinding, or whirringnoise, also replace mainshaft 4th gear, reverse idler gear, and countershaft 4th gear.If the differential pin ion shaft is worn, overhaul the differential assembly, replace ATF strainer, thoroughlyclean the transmission and flush the torque converter, cooler, and lines.If bottom of 3rd clutch is swirled and transmission makes gear noise, replace the countershaft and final drivengear.

R Be very careful not to damage the torque converter housing when replacing the main bail bearing. Youmay also damage the ATF pump when Vou torque down the main valve body. This will result in ATF pumpseizure if not detected. Use the proper tools.

S Install the main seal flush with the torque converter housing. If vou push it into the torque converterhousing until it bottoms out, it will block the fluid return passage and result in damage.

14-92


TPS (RED/BlKI

PCM CONNECTORS

.... -------- DIGITAL MUlTIMETERICommercially availablelKS - AHM - 32 - 003.or equivalent

STACKING PATCH ~CORD

BACKPROBE ADAPTER

BACKPROBESET~------~07SAZ - 001000AItwo requiredl

a. Unbolt the PCM for road testing; refer to page 14-46.b. Set the digital multimeter to check voltage between 01 (+) terminal and A9 (-) or A22 (-) terminal of the PCM for

the throttle position sensor.

NOTE: Throttle position sensor voltage represents the throttle opening.

3. Test-drive the vehicle on a fiat road in the [Q;: position. Check that the shift points occur at the approximate speeds(shown on the next page) on a fiat road. Also check for abnormal noise and clutch slippage.

2. Repeat same test in [Qi position.

1. Apply the parking brake and block the wheels. Start the engine, then shift to [Q;] position while depressing the brakepedal. Oepress the accelerator pedal and release it suddenly. The engine should not stail.

NOTE: Warm up the engine to normal operating temperature (the radiator fan cornes on).

Road Test

14-93

6. Test in ŒJ (Parking) PositionPark the vehicle on slope (approx. 16°), apply the parking brake, and shift into ŒJ position. Release the brake; the vehicie should not move.

[ft] (Reverse) PositionAccelerate from a stop at full throttle, and check for abnormal noise and clutch slippage.

œ (2nd Gear) Positiona. Accelerate from a stop at full throttle. Check that there is no abnormal noise or clutch slippage.b. Upshifts and downshifts should not occur with the selector in this position.

5. Check for abnormal noise and clutch slippage in the following positions.

CAUTION: Do not shift from 04 or ~ position to œ position at speeds over 63 mph (100 km/h); vou may damagethe transmission.

4. Accelerate to about 35 mph (57 km/hl so the transmission is in 4th, then shift from ~ position to œ position. Thevehicle should immediately begin slowing down from engine braking.

NOTE:• Lock-up ON: The lock-up control solenoid valve A turns ON.• Lock-up OFF:The lock-up control solenoid valve A turns OFF.

Throttle Opening Unit of speed Lock-up OFF 4th - 3rd 3rd - 2nd 2nd - 1st

Fully-closed throttle mph 19- 22 17 -20 7 - 10 (3rd - lst)Throttle position sensorvoltage: 0.5 V km/h 30-35 27 -32 10 - 15 (3rd - 1st)

Fully-opened throttle mph 92 - 103 86-97 54- 61 25 - 31Throttle position sensorvoltage: 4.5 V km/h 147 - 163 137 - 153 87 -98 40- 48

• Downshift

Throttle Opening Unit of speed 1st - 2nd 2nd - 3rd 3rd - 4th Lock-up ON

Throttle position sensor mph 9-12 20-23 28-33 22 -25voltage: 0.75 V km/h 15 -19 32-37 45- 52 34- 39

Throttle position sensor mph 22 - 26 41- 47 59-65 61- 67voltage: 2.25 V km/h 34-40 65-73 95 -104 99 - 108

Fully-opened throttle mph 32-38 62 -71 97 - 108 96 -107Throttle position sensorvoltage: 4.5 V km/h 51-59 99 - 112 155 - 172 153-170

• Upshift

14-94

TROUBLE PROBABLECAUSE

Stail rpm high in ~, II]and Œl positions • Low fluid level or ATF pump output• Clogged ATF strainer• Pressure regulator valve stuck closed• Slipping clutch

Stail rpm high in Œl position Slippage of 4th clutch

Stail rpm high inœ position Slippage of 2nd clutch

Stail rpm high in [Q';J position Slippage of 1st clutch or 1st gear one-way clutch

Stail rpm low in [Q;J, œ and ŒJ positions • Engine output low• Torque converter one-way clutch slipping

Stail Speed RPM:Specification: 2,700 rpmService Limit:2,550 - 2,850 rpm2

NOTE:• Stail speed tests should be used for diagnostic purposes only.• Stail speed should be the same in ~, œ and Œl positions.

6. Allow two minutes for cooling, then repeat the test in [Q';J and Œl positions.

5. Fully depress the brake pedal and accelerator for 6 to 8 seconds, and note engine speed.

4. After the engine has warmed up to normal operating temperature (the radiator fan comes on), shift into œ position.

3. Make sure the AlC switch is OFF.

2. Connect a tachometer to the engine, and start the engine.

1. Engage the parking brake, and block the front wheels.

CAUTION:• To prevent transmission damage, do not test stail speed for more than 10 seconds at a time.• Do not shift the lever while raising the engine speed.• Be sure to remove the pressure gauge before testing stail speed.

Test

Stail Speed

14-95

* Always use Genuine Honda Premium FormulaAutomatic Transmission Fluid (ATF). Using a nonHonda ATF can affect shift quality.

DRAIN PLUG18x1.5mm49 N'm (5.0 kgf·m, 36 Ibf.ft)

Recommended Automatic Transmission Fluid:Genuine Honda Premium Formula AutomaticTransmission Fluid (ATF)*

Automatic Transmission Fluid Capacity:2.7 f (2.9 US qt, 2.4 Imp qt) at change5.9 f (6.2 US qt, 5.2 Imp qt) at overhaul

2. Reinstall the drain plug with a new sealing washer,then refill the transmission with the recommendedfluid* to the upper mark on the dipstick.

NOTE: If a cooler flusher is to be used, see page 14-164 and 165.

1. Bring the transmission up to operating temperatureby driving the vehicle. Park the vehicle on levelground, turn the engine off, then remove the drainplug.

Changing

Install the dipstick in the extentof the direction shown.

6. Reinstall the dipstick in the direction shown.

FRONT

5. If the level is below the lower mark, pour the recommended fluid* into the filler hole to bring it to theupper mark.

4. Remove the dipstick and check the fluid level. Itshould be between the upper and lower marks.

3. Insert the dipstick into the transmission.

__ UPPER MARK-- LOWER MARKDIPSTICK (YELLOW LOOP)

2. Remove the dipstick (yellow loop) from the transmission, and wipe it with a clean cloth.

1. Park the vehicle on level ground. Turn off theengine.

NOTE: Check the fluid level with the engine at normaloperating temperature (the radiator fan comes on).

Checking

CAUTION: While checking or changing fluid, be surenot to allow dust and other foreign particles to enterinto the transmission.

Checking/Changing

Fluid level

14-96

NOTE: Do not reuse old sealing washers.

TORQUE: 18 N·m (1.8 kgf·m, 13 Ibf.ft)

6. Install a new washer and the sealing boit in the inspection hole, and tighten to the specified torque.

5. Measure the following pressure:• Line Pressure: page 14-97• 1st Clutch Pressure: page 14-97• 2nd, 3rd and 4th Clutch Pressure: page 14-98

NOTE: the Aff Oil Pressure Gauge Set (07406 - 0020003) or Aff Low Pressure Gauge (07406 - 0070000) may also beused.

AIT PRESSURE HOSEADAPTER07MAJ - PY40120(4 Requiredl

AIT LOW PRESSUREGAUGE W/PANEl07406 - 0070300

@J~

AIT PRESSURE HOSE,2210 mm07MAJ - PY4011A(4 RequiredlQAIT Oll PRESSURE GAUGE

SET W/PANEl074('5 - 0020400

CAUTION: Connect the oil pressure gauges securely; be sure not to allow dust or other foreign particles to enter theinspection holes.

TORQUE: 18 N·m (1.8 kgf·m, 13Ibf.ft)

4. Connect the oil pressure gauges to each inspection hole.

3. Warm up the engine, then stop the engine and connect a tachometer.

2. Raise the front of the vehicle, and support it with safety stands (see section 1).

1. Set the parking brake, and block both rear wheels securely.

CAUTION:• Before testing, be sure the transmission fluid is filled to the proper level.• Warm up the engine before testing.

'%#i@dN• While testing, be careful of the rotating front wheels.• Make sure lifts, jacks, and safety stands are placed properly (see section 1).

Pressure Testing

14-97

(cont'd)

SHIFTLEVER FLUID PRESSUREPRESSURE SYMPTOM PROBABLE CAUSE

POSITION Standard Service Limit

Line [ill or œ No (or low) Torque converter, 830 - 880 kPa 780 kPaline pressure ATF pump, pres- (8.5 - 9.0 kgf/cm2, (8.0 kgf/cm2, 110 psi)

sure regulator, 120 - 130 psi)torque convertercheck valve

1st Clutch [Q;J No or low lst lst Clutchpressure

SHIFT CONTROL SOLENOIDVALVE AIS ASSEMSL y

1ST CLUTCH PRESSUREINSPECTION HOLE(Marked with "L'"

LOCK-UP CONTROLSOLENOID VALVE AISASSEMSLY

UNE PRESSUREINSPECTION HOLE

3. Shift to [Q;] position, then measure 1st clutch pressure.

NOTE: Higher pressure may be indicated if measurements are made in shift lever positions other than [ill or œ position.

2. Shift to [ID or [f] position, then measure line pressure.

1. Start the engine, and run it at 2,000 rpm.

Line Pressure/1st Clutch Pressure Measurement

14-98

SHIFT LEVER FLUID PRESSUREPRESSURE POSITION

SYMPTOM PROBABLE CAUSEStandard Service Limit

2rd Clutch ~ No or low 2nd 2nd Clutch 800 - 850 kPa 760 kPapressure (8.2 - 8.7 kgf/cm2, (7.7 kgf/cm2, 110 psi)

120 - 120 psi) with linear solenoidwith linear solenoid disconnecteddisconnected

0- 150 kPa 150 kPa( 0 - 1.5 kgf/cm2, (1.5 kgf/cm2, 21 psi)0- 21 psi) with linear solenoidwith linear solenoid connected to batteryconnected to battery voltagevoltage

3rd Clutch No or low 3rd 3rd Clutch 810 - 860 kPa 760 kPapressure (8.3 - 8.8 kgf/cm2, (7.8 kgf/cm2, 110 psi)

120 - 130 psi) with linear solenoid

4th Clutch No or low 4th 4th Clutch 1 with linear solenoid disconnected

pressure disconnected

0- 150 kPa 150 kPa( 0 - 1.5 kgf/cm2, (1.5 kqf/crn", 21 psi)0- 21 psi) with linear solenoid

ŒJ

1

Servo Valve or 4th with linear solenoid connected to batteryClutch connected to battery voltage

voltage

3RD CLUTCH PRESSUREINSPECTION HOLE(Marked with "3")

2ND CLUTCH PRESSUREINSPECTION HOLE

4. Connect battery voltage and ground to the linearsolenoid connecter terminais, then measure eachclutch pressure.

3. Shift to [Q;j position, and measure each clutch pressure.

2. Start the engine, and run it at 2,000 rpm.

2nd, 3rd and 4th Clutch Pressure MeasurementlINEAR SOLENOIDCONNECTOR1. Disconnect the linear solenoid connector.

(cont'd)

Pressure Testing

14-99


COUNTERSHAFTSPEED SENSORCONNECTOR

6. Disconnect the vehicle speed sensor (VSS) connector and the countershaft speed sensor connector.


5. Remove the transmission ground cable, and disconnect the lock-up control solenoid connector.

14-100

STARTER CABLE

STARTER CABLE

4. Remove the starter cables and cable holder fromthe starter motor.

3. Remove the intake air duct and the air cleaner housing assembly.

2. Disconnect the battery negative (-) terminal fromthe battery, then remove the positive (r) terminal.

1. Before disconnecting power, make sure you havethe anti-theft code for the radio, then write downthe frequencies for the radio's preset buttons.

CAUTION: Use fender covers to avoid damaging painted surfaces.

'MhUMiN• Make sure lifts, jacks and safety stands are placed

properly, and hoist bracket are attached to the correct position on the engine (see section 1).

• Apply parking brake and block rear wheels so vehiclewill not roll off stands and fall on Vou while workingunder it.

Removal

Transmission

14-101

(cont'd)

~ \SPlASH SHIElO

10. Remove the splash shield.

ORAIN PLUG18xl.5mm49 N·m (5.0 kgf·m, 36 Ib"'t)

9. Remove the drain plug, and drain the automatictransmission fluid (ATF). Reinstall the drain plugwith a new sealing washer.

MAINSHAFTSPEEO SENSORCONNECTORCONNECTOR

BRACKET

lINEAR SOLENOIOCONNECTOR

SHIFT CONTROLSOLENOIO CONNECTOR

8. Disconnect the shift control solenoid, the linear solenoid, and the mainshaft speed sensor connectors.

TRANSMISSION HOUSINGMOUNTING BOlTS

REARENGINEMOUNTING BOlT

7. Remove the transmission housing mounting boltsand the rear engine mounting boit.

ATF COOLERHOSE

RIGHTFRONTMOUNT IBRACKET

ATFCOOLERLlNE

NOTE: Check for any sign of leakage at the hosejoints.

19. Remove the ATF cooler hoses at the ATF coolerlines. Turn the ends ot the ATF cooler hoses up toprevent ATF trom tlowing out, then plug the ATFcooler hoses and lines.

18. Remove the right front mount/bracket.

CONTROL lEVERReplace.

CONTROLSHAFT

CAUTION: Take care not to bend the shift cable.

17. Remove the shift cable cover, then remove the shiftcable by removing the control lever.

14-102

ReplaceEXHAUST PIPE A

Replace.

_.~

-- "'{/J}. :~~~- /~:_ J,. GASKET.>: .~.Replace

\SElF-lOCKINGNUT

16. Remove the exhaust pipe A.

NOTE: Coat ail precision finished surfaces with cleanengine oil,

15. Tie plastic bags over the driveshaft ends.

14. Pull on the inboard joint and the right and left driveshafts (see section 16).

13. Pry the right and left driveshafts out of the differential.

12. Rernove the right darnper fork boit, then separatethe right damper fork and darnper.

DAMPER FORKBOlT

DAMPER FORK

~r , COTTER PIN\ Replace.

CASTlE NUT

SElF-lOCKINGNUTReplace.

DAMPER PINCH BOLT

11. Remove the cotter pins and castle nuts, then separatethe right and left bail joints trom the lower arms (seesection 18).

Removal (cont'd)

Transmission

14-103

TRANSMISSIONJACK

REAR ENGINEMOUNTING BOLTSReplace.

TRANSMISSION HOUSINGMOUNTING BOLTS

26. Pull the transmission away from the engine until itclears the 14 mm dowel pins, then lower it on thetransmission jack.

25. Remove the transmission housing mounting boltsand the rear engine mounting bolts.

TRANSMISSION MOUNT

TRANSMISSIONMOUNT BRACKET

24. Place a jack under the transmission, and raise thetransmission just enough to take weight off of themounts, then remove the transmission mount.

HOISTBRACKET

23. Attach a hoisting bracket to the engine, then lift theengine slightly.

22. Remove the distributor.

21. Remove the eight drive plate bolts one at a timewhile rotating the crankshaft pulley.

20. Remove the engine stiffener and the torque converter cover.

8Fr:(Sl)12A

14-104

Transmission/Right Si de Cover

IIlustrated Index

14-105

Bolt/Nut No. Torque Value Size Remarks

6A 12 N'm (1.2 kgf·m, 8.7 Ibf.ft) 6x 1.0 mm6B 14 Nrn (1.4 kgf·m, 10 IbHt) 6x1.0mm8F 22 N'm (2.2 kgf·m, 16 IbHt) 8 x 1.25 mm12A 28 Nrn (2.9 kgf·m, 21 IbHt) 12 x 1.25 mm Joint boit180 49 N'm (5.0 kgf·m, 36 IbHt) 18xl.5mm Drain plug21M 78 Nrn (8.0 kgf·m, 58 IbHt) 21 x 1.25 mm Mainshaft locknut: left-hand threads23C 103 Nrn (10.5 kgf-m, 75.9Ibf·ft) - 0- 23 x 1.25 mm Countershaft locknut:

103 Nrn (10.5 kgf·m, 75.9 Ibf·ft) left-hand threads

TORQUE SPECIFICATIONS

@ RIGHT SIDE COVER® 1ST CLUTCH FEED PIPE® O-RINGS Replace.® FEED PIPE FLANGE@SNAPRING® MAINSHAFT LOCKNUT (FLANGE NUT) 21 x 1.25 mm

Replace.@ CONICAL SPRING WASHER Replace.@ 1ST CLUTCH ASSEMBLY@ O-RINGS Replace.@ THRUST WASHER@ THRUST NEEDLE BEARING@ NEEDLE BEARING@ MAINSHAFT 1ST GEAR@ MAINSHAFT 1ST GEAR COLLAR@ ATF COOLER UNE@ SEAUNG WASHERS Replace.@JOINTBOLT@> ATF DIPSTICK@ ATF COOLER UNE® JOINT BOLT@ SEAUNG WASHERS Replace.@ VEHICLE SPEED SENSOR@ O-RING Replace.

CD ROLLER@COLLARCID O-RING Replace.@ FEED PIPE FLANGECID O-RING Replace.® SNAPRING(J) 3RD CLUTCH FEED PIPE® COUNTERSHAFT LOCKNUT (FLANGE NUT)

23 x 1.25 mm Replace.® CONICAL SPRING WASHER Replace.@ PARKING GEAR® ONE-WAY CLUTCH@ COUNTERSHAFT 1ST GEAR@ NEEDLE BEARING@ COUNTERSHAFT 1ST GEAR COLLAR@ O-RINGS Replace.@ RIGHT SIDE COVER GASKET Replace.@DOWELPINS@ PARKING BRAKE PAWL STOP@ LOCK WASHER Replace.® PARKING BRAKE STOP Selective part@ PARKING BRAKE LEVER@ PARKING BRAKE LEVER SPRING@DRAINPLUG@ SEAUNG WASHER Replace.® O-RING Replace.® COUNTERSHAFT SPEED SENSOR® PARKING BRAKE PAWL@ PARKING BRAKE PAWL SPRING® PARKING BRAKE PAWL SHAFT@ UNEAR SOLENOID ASSEMBL y® UNEAR SOLENOID GASKET Replace.

\@

14-106

@ 6A


IIlustrated Index .

14-107


6A 12 N·m (1.2 kgf·m, 8.7 IbHt) 6 x 1.0 mm6B 14 Nrn (1.4 kgf·m, 10 lbf-ft) 6 x 1.0 mm10A 44 N·m (4.5 kgf·m, 33 lbf-ft) 10 x 1.25 mm


@ THRUST NEEDLE BEARING® MAINSHAFT@ SEAUNG RINGS, 35 mm@ SEAUNG RING, 29 mm@ NEEDLE BEARING@SETRING@ SHIFT CONTROL SOLENOID VALVE A/B ASSEMBL y@ HARNESS CLAMP BRACKET@ SHIFT CONTROL SOLENOID FILTER/GASKET Replace.@ CONNECTOR BRACKET@ TRANSMISSION HANGER@ BREATHER CAP@ MAINSHAFT SPEED SENSOR@ O-RING Replace.@SNAPRING@ TRANSMISSION HOUSING MAINSHAFT BEARING®> TRANSMISSION HOUSING COUNTERSHAFT BEARING® REVERSE IDLER GEAR SHAFT HOLDER ASSEMBL y@ NEEDLE BEARING@ OIL SEAL Replace.@ SET RING, 80 mm Selective part® TRANSMISSION HOUSING@ REVERSE IDLER GEAR® DOWEL PINS .@ TRANSMISSION HOUSING GASKET Replace.®l DIFFERENTIAL ASSEMBL y@l OIL SEAL Replace.@) TORQUE CONVERTER HOUSING

CD LOCK WASHER Replace.<ID REVERSE SHIFT FORK@ COUNTERSHAFT REVERSE GEAR COLLAR@ COUNTERSHAFT REVERSE GEARCID NEEDLE BEARING® REVERSE SELECTOR(j) REVERSE SELECTOR HUB@ COUNTERSHAFT 4TH GEAR® NEEDLE BEARING@ DISTANCE COLLAR, 28 mm Selective part<fi) COUNTERSHAFT 2ND GEAR@ THRUST NEEDLE BEARING@ COUNTERSHAFT 3RD GEAR@ NEEDLE BEARING@ COUNTERSHAFT 3RD GEAR COLLAR@ THRUST NEEDLE BEARING@ SPLINED WASHER@ 3RD CLUTCH ASSEMBLY@ O-RINGS Replace.®) COUNTERSHAFT® SNAPRING@ THRUST WASHER@ THRUST NEEDLE BEARING® MAINSHAFT 4TH GEAR/REVERSE GEAR@ NEEDLE BEARINGS® THRUST NEEDLE BEARING@ MAINSHAFT 4TH GEAR COLLAR@ 2ND/4TH CLUTCH ASSEMBLY® O-RINGS Replace.®> THRUST WASHER, 36.5 x 55 mm Selective part® THRUST NEEDLE BEARING® MAINSHAFT 2ND GEAR@ NEEDLE BEARING

14-108

6A

Illustrated 1 dn ex

Torque Convert er Housing/Valve Body

14-109


6A 12 N·m (1.2 kgf·m, 8.7 IbHt) 6 x 1.0 mm


@ATFMAGNET® TORQUE CONVERTER HOUSING COUNTERSHAFT

BEARING@ ATF GUIDE PLATE@ TORQUE CONVERTER HOUSING@ OIL SEAL Replace.@ TORQUE CONVERTER HOUSING MAINS HAFT

BEARING@ OIL SEAL Replace.@ LOCK-UP CONTROL SOLENOID FILTER/GASKET

Replace.@ LOCK-UP CONTROL SOLENOID VALVE A/B ASSEMBL Y@ CONNECTOR BRACKET

CD ATF FEED PIPECID ATF STRAINER®SERVOBODY@ SERVO SEPARATOR PLATE® SECONDARY VALVE BODY@DOWELPINS(j) SECONDARY SEPARATOR PLATE® SERVO DETENT BASE® ATF FEED PIPES@ ATF FEED PIPES(fi) SHAFTSTOP@ CONTROL SHAFT@ DETENT ARM SPRING@DETENTARM@ DETENT ARM SHAFT@ FILTER Replace.@ CHECK BALLS@ TORQUE CONVERTER CHECK VALVE@ TORQUE CONVERTER CHECK VALVE SPRING® DOWELPINS® LOCK-UP VALVE BODY@ LOCK-UP SEPARATOR PLATE@ REGULATOR VALVE BODY® DOWELPINS@ COOLER REUEF VALVE SPRING® COOLER REUEF VALVE@ O-RING Replace.@ STATOR SHAFT@STOPSHAFTQg) ATF FEED PIPE@ MAIN VALVE BODY@ ATF PUMP DRIVEN GEAR SHAFT@ ATF PUMP DRIVEN GEAR@DOWELPINS@ ATF PUMP DRIVE GEAR@ MAIN SEPARATOR PLATE® sucnon PIPE COLLAR

14-110

SEALING WASHERS

COUNTERSHAFTJOINTBOLT

CONTROL SHAFT

NEEOLE BEARING

COUNTERSHAFT1ST GEAR COLLAR

MAINSHAFT~1ST GEAR

MAINSHAFT1ST GEAR COlLAR

ONE-WAY ClUTCH

PARKING GEAR

LOCKNUT

CONICAlSPRINGWASHER

PARKING BRAKE LEVER

~~~TRSIOE~

RIGHT SIDE . 1COVER GASKET

ATFCOOLERUNES

NOTE:• Clean ail parts thoroughly in solvent or carburetor cleaner, and dry with compressed air.• Blow out ail passages.• When removing the right side cover, replace the following:

- O-rings- Mainshaft and countershaft locknuts- Conical spring washers- Right side cover gasket- Lockwasher- Sealing washers

Removal

Right Side Cover

14-111

11. Remove the ATF cooler lines and ATF dipstick .

10. Remove the needle bearing and the countershaft1st gear collar trom the countershaft.

PARKING GEAR

PULLER(Commercially availablel

9. Using a universal two-jaw puller, remove the parkinggear, one-way clutch and countershaft 1st gearassembly.

8. Remove the parking brake lever trom the controlshaft.

7. Remove the parking brake pawl, spring and shaft.

6. Remove the 1st clutch and mainshaft 1st gear assernbly and mainshaft 1st gear collar from the mainshaft.

5. Remove the special tool trom the mainshaft afterremoving the locknuts.

lOCK TAB

lOCKNUT

CHISEl

NOTE:• Mainshaft and countershaft locknuts have left

hand threads.• Always wear satety glasses.

CAUTION: Keep ail of the chiseled particles out ofthe transmission.

4. Cut the lock tabs ot the mainshaft and countershaftlocknuts using a chisel as shown, then remove thelocknuts and conical spring washers.

3. Engage the parking brake pawl with the parkinggear.

MAINS HAFT HOLDER07GAB - PF50101

2. Slip the special tool onto the mainshaft as shown.

1. Remove the 13 bolts securing the right side coyer,then remove the right side coyer.

14-112

~ TORQUE CONVERTERHOUSING

OIFFERENTIALASSEMBLY

COUNTERSHAFTSUB·ASSEMBL y

MAINSHAFTSPEED SENSOR

REVERSE SELECTOR

NEEDLE BEARING

REVERSE GEARCOlLAR

TRANSMISSION HOUSING

TRANSMISSIONHANGER

MAINSHAFTSUB·ASSEMBL y

\

Removal


14-113

8. Remove the differential assembly from the torqueconverter housing.

MAINSHAFTSUB-ASSEMBL y

7. Remove the countershaft sub-assembly and themainshaft sub-assembly together.

6. Remove the lock boit securing the shift fork, thenremove the fork with the reverse selector from thecountershaft.

5. Remove the countershaft reverse gear with the collar and needle bearing.

CAUTION: Make sure the mainshaft speed sensorhas been removed trom the transmission housingbetore removing the transmission housing trom thetorque converter housing.

4. Install the special tool on the transmission housing,then remove the housing as shown.

HOUSING PULLER07HAC - PK4010A

SPRING PIN

3. Align the spring pin on the control shaft with thetransmission housing groove by turning the controlshaft.

2. Remove the transmission housing mounting boltsand hanger.

1. Remove the mainshaft speed sensor from the transmission housing.

NOTE:• Clean all parts thoroughly in solvent or carburetor

cleaner, and dry with compressed air.• Blow out ail passages.• When removing the transmission housing, replace

the following:- O-ring- Transmission housing gasket- Lock washer

SECONDARYSEPARATOR PLATE

SERVOBODY

6" 100mm7 Bolts

ATF STRAINER

6" 100mm2 Bolts

TORQUE CONVERTERHOUSING

14-114

DOWElPIN

6" 100mm __ ---it'~~5 Bolts

MAIN VALVEBODY

ATF PUMP DRIVENGEARSHAFT

ATFPUMPDRIVENGEAR

MAIN SEPARATORPLATE

ATF FEED PIPE

TORQUE CONVERTERCHECK VALVE

SERVO DETENTBASE

ATF FEEDPIPES

ATF FEED PIPE

6 x 100mm

7BO~

REGULATORVALVE BODY

LOCK-UP SEPARATORPLATE

LOCK-UP VALVEBODY

Removal

Torque Converter Housing/Valve Body

14-115

NOTE: The ATF strainer can be reused if it is notclogged.

14. Test the filter by pouring clean ATF fluid throughthe inlet opening. Replace the ATF strainer if it isclogged or damaged.

INLET OPENING

ATF STRAINER

13. Clean the inlet opening of the ATF strainer thoroughly with compressed air, then check that it is ingood condition, and the inlet opening is not clogged.

12. Remove the main separator plate and two dowelpins.

11. Remove the ATF pump driven gear shaft, then removethe ATF pump gears.

NOTE: Do not let the eight check balls fall out of themain valve body when removing the main valvebody.

10. Remove the main valve body (five bolts).

9. Remove the detent arm and detent arm shaft fromthe main valve body.

8. Remove the detent spring from the detent arm, thenremove the control shaft from the torque converterhousing.

7. Remove the stator shaft and stop shaft.

6. Remove the regulator valve body (one boit).

5. Remove the lock-up valve body and separator plate(seven bolts).

4. Remove the secondary valve body, shaft stop andsecondary separator plate (three bolts).

3. Remove the servo body and servo separator plate(seven bolts).

2. Remove the ATF strainer and serve detent base(two bolts).

1. Remove the ATF feed pipes from the servo body,secondary valve body and main valve body.

NOTE:• Clean ail parts thoroughly in solvent or carburetor

cleaner, and dry with compressed air.• Blow out ail passages.• When removing the valve body, replace the O-ring.

Toward inside of valve bedv.

Sectional view.

Toward outside of valve body.

• Caps with fiat ends and a groove around the cap areinstalled with the grooved side toward the outsideof the valve body.

Toward inside of valve body.


• Caps with hollow ends are installed with the hollowend away from the inside of the valve body.

• Caps with notched ends are installed with the notchtoward the inside of the valve body.

• Caps with fiat ends and a hole through the centerare installed with the smaller hole toward the insideof the valve body.

14-116



• Caps with one projected tip and hollow end areinstalled with the tip toward the inside of the valvebody. The tip is a spring guide.



• Caps with one projected tip and one fiat end areinstalled with the fiat end toward the inside of thevalve body.

• Caps with a projected tip on each end are installedwith the smaller tip toward the inside of the valvebody. The small tip is a spring guide.

Description

Valve Caps

14-117

7. Remove the valve, then thoroughly dean it and thevalve body with solvent. Dry ail parts with compressed air, then reassemble using ATF as a lubricanto

6. Coat the valve with ATF, then drop it into its bore.It should drop to the bottom of the bore under itsown weight. If not, repeat step 4, then retest. If thevalve still sticks, replace the valve body.

5. Remove the #600 paper and thoroughly wash theentire valve body in solvent, then dry it with compressed air.

CAUTION: The valve body is aluminum and doesn'trequire much polishing to remove any burrs.

4. Roll up half a sheet of ATF-soaked paper, and insertit in the valve bore of the sticking valve.Twist the paper slightly, so that it unrolls and fits thebore tightly, then polish the bore by twisting thepaper as vou push it in and out.

3. Inspect the valve for any scuff marks. Use the ATFsoaked #600 paper to polish off any burrs that areon the valve, then wash the valve in solvent and dryit with compressed air.

CAUTION: It may be necessary to use a smallscrewdriver to pry the valve free. Be careful not toscratch the bore with the screwdriver.

2. Carefully tap the valve body so the sticking valvedrops out of its bore.

1. Soak a sheet of #600 abrasive paper in ATF forabout 30 minutes.

NOTE: This repair is only necessary if one or more ofthe valves in a valve body do not siide smoothly in theirbores. You may use this procedure to free the valves inthe valve bodies.

Repair

Valve Body

CAP

CLIP

• Install the valve, spring and cap in the valve body.Push the cap, then install the clip.

VALVE BODY

SPAIHG

• Set the spring in the valve and install it in the valvebody. Push the spring in with a screwdriver, theninstall the spring seat.

14-118

ROLLER

• Install the valve, valve spring and cap in the valvebody and secure with the roller.

NOTE:Coat ail parts with ATF before assembly.

Assembly

Valve

14-119

ATFPUMPDRIVEN GEAR

ATF Pump Drive/Driven Gear Thrust (Axial) Clearance:MAIN VALVE BODY Standard (New): 0.03 - 0.05 mm (0.001 - 0.002 in)


3. Remove the ATF pump driven gear shaft. Measurethe thrust clearance of the ATF pump driven gearto-valve body.

ATFPUMPDRIVE GEARInspeet teeth for wear and damage.

ATFPUMPDRIVENGEARInspeet teeth for wear and damage.

MAIN VALVE BODY

ATF Pump Gears Side (Radial) Clearance:Standard (New):ATF Pump Drive Gear0.105 - 0.1325 mm (0.004 - 0.005 in)ATF Pump Driven Gear0.035 - 0.0625 mm (0.0014 - 0.0025 in)

2. Measure the side clearance of the ATF pump driveand driven gears.

ATF PUMP DRIVEN GEARGrooved and ehamfered sidefaeing up.

ATF PUMP DRIVEGEAR

NOTE:• Lubricate ail parts with ATF during inspection.• Install the ATF pump driven gear with its grooved

and chamfered side facing up as shown.

1. Install the ATF pump gears and ATF pump drivengear shaft in the main valve body.

Inspection

ATF Pump

14-120

SERVOCONTROLVALVE

Inspect for wear, scratchesand scoring.

/MANUAL VALVEREUEFVALVE

1STACCUMULATORCHOKE

1-2SHIFTVALVE4

CPBVALVE VALVECAPCUP

~/..~

CAUTION: Do not use a magnet to remove the check balls; it may magnetize the baUs.

NOTE:• Clean ail parts thoroughly in solvent or carburetor cleaner, and dry with compressed air. Blow out ail passages.• Replace the valve body as an assembly if any parts are worn or damaged.• Check ail valves for free movement. If any fail to si ide freely, see Valve Body Repair on page 14-117.• Coat ail parts with ATF during assembly.

Disassembly Ilnspection IReassembly

Main Valve Body

14-121

Standard (New)No. Springs

WireOia. 0.0. Free Length No. of Coils

CD Relief valve spring 1.1 (0.043) 8.6 (0.342) 37.1 (1.461) 13.4CID Modulator valve spring 1.4 (0.055) 9.4 (0.374) 35.0 (1.378) 10.9@ CPB valve spring 0.9 (0.035) 8.1 (0.322) 47.2 (1.858) 18.3@) 1-2 shift valve spring 0.9 (0.035) 7.6 (0.302) 41.3 (1.626) 16.3CID 2nd orifice control valve spring 0.7 (0.028) 6.6 (0.262) 34.8 (1.370) 22.0® Servo control valve spring 1.0 (0.039) 8.1 (0.322) 52.1 (2.051) 20.8

Unit: mm (in)SPRINGSPECIFICATIONS

MAIN VALVE BODY(Sectional viewl

Replace.

CHECK BALlS

CHECK BALlS

CHECKBALl

14-122


Wire Dia. 0.0. Free length No. of Coils

CD 3-4 shift valve spring 0.9 (0.035) 7.6 (0.302) 57.0 (2.244) 26.8CID 2-3 shift valve spring 0.9 (0.035) 7.6 (0.302) 57.0 (2.244) 26.8CID 4th exhaust valve spring 0.9 (0.035) 6.1 (0.242) 36.4 (1.433) 19.5@ 3-4 orifice control valve spring 0.7 (0.028) 6.6 (0.262) 37.5 (1.476) 24.6

Unit: mm (in)SPRING SPECIFICATIONS

3-4 ORIFICE CONTROL VALVE

SECONDARY VALVE BODYInspect for wear, scratches andscoring.

VALVE CAP~~~//22-3 SHIFT VALVE

(((rr" '-i~

~~~VECAP~

3-4 SHI~ VALVE

NOTE:• Clean ail parts thoroughly in solvent or carburetor cleaner, and dry with compressed air. Blow out ail passages.• Replace the secondary valve body kit, PIN 27700 - P4R - 305 (The secondary valve body kit includes the linear solenoid

assembly) if any parts are worn or damaged.• Check ail valves for free movement. If any fail to slide freely, see Valve Body Repair on page 14-117.• Coat ail parts with ATF during assembly.• The CPC valve is installed in the secondary valve body, held in place by the lock boit.

Disassembly Ilnspection/Reassembly

Secondary Valve Body

14-123


Wire Dia. 0.0. Free length No. of Coïls

CD Regulator valve spring A 1.8 (0.071) 14.7 (0.584) 87.8 (3.457) 16.5CID Regulator valve spring B 1.8 (0.071) 9.6 (0.381) 44.0 (1.732) 11.0@ Stator reaction spring 4.5 (0.177) 35.4 (1.407) 30.3 (1.193) 1.9@ Cooler relief valve spring 1.0 (0.039) 8.4 (0.334) 33.8 (1.331) 8.2® Torque converter check valve spring 1.0 (0.039) 8.4 (0.334) 33.8 (1.331) 8.2® Lock-up control valve spring 0.7 (0.028) 6.6 (0.262) 38.0 (1.496) 14.1


LOCK-UP CONTROL VALVE~

~~ ,~

COOLERREUEFVALV:~ .ATORQUE CONVERTER CHECK VALVE / /~

VALVESLEEVE J "<.VALVE CAP

ROLLER

REGULA TOR VALVE

~REGULATOR SPRING CAP

STOP BOLT6x 1.0 mm12 N'm (1.2 kgf'm, 8.7 Ibf.ft)

REGULATOR VALVE BODY

NOTE:• Coat ail parts with ATF during assembly.• Align the hole in the regulator spring cap with the hole in the valve body, then press the spring cap into the valve

body, and tighten the stop boit.

2. Reassembly is the reverse order of the disassembly procedure.

1. Hold the regulator spring cap in place while removing the stop boit. The regulator spring cap is spring loaded. Oncethe stop boit is removed, release the spring cap slowly so it does not pop out.

NOTE:• Clean ail parts thoroughly in solvent or carburetor cleaner, and dry with compressed air. Blow out ail passages.• Replace the valve body as an assembly if any parts are worn or damaged.• Check ail valves for free movement. If any fail to slide freely, see Valve Body Repair on page 14-117.

o isassem bly Il nspection/Reassem bly

Regulator Valve Body

14-124


Wire Dia. 0.0. Free Length No. of Coils

CD 1st accumulator spring 2.1 (0.083) 16.0 (0.636) 89.1 (3.508) 16.2CID 4th accumulator spring A 2.6 (0.102) 17.0 (0.676) 87.0 (3.425) 14.2CID 4th accumulator spring B 2.3 (0.091) 10.2 (0.402) 51.6 (2.031) 13.8@ 3rd accumulator spring A 2.8 (0.110) 17.5 (0.695) 89.3 (3.516) 15.6® 3rd accumulator spring B 2.2 (0.087) 31.0 (1.220) 35.1 (1.382) 2.4® 2nd accumulator spring C 2.2 (0.087) 14.5 (0.576) 68.0 (2.677) 13.9(j) 2nd accumulator spring A 2.4 (0.094) 29.0 (1.152) 39.0 (1.535) 2.9® 2nd accumulator spring B 1.6 (0.063) 9.0 (0.358) 20.7 (0.815) 6.1


~ SERVO VAlVE/SHIFTFORKSHAFT

1ST ACCUMULATOR PISTON

SERVO BODYInspect for wear, scratches and scoring.

~,

®~ <,

~ r~7

®~~: 1

~ ~2ND ACCUMULATOR~,~ iVPISTON -.8 Ci; ~ ~ Al

SNAPRING Q

4TH ACCUMULATOR PISTON

SNAPRING~

O-RINGReplace,

NOTE:• Clean ail parts thoroughly in solvent or carburetor cleaner, and dry with compressed air. Blow out ail passages.• Replace the valve body as an assembly if any parts are worn or damaged.• Coat ail parts with ATF du ring assembly.• Replace the O-rings.


Servo Body

14-125


Wire Dia. 0.0. Free Length No. of Coils

CD Lock-up shift valve spring 0.9 (0.035) 7.6 (0.302) 73.7 (2.902) 32.0CID Lock-up timing valve spring 0.9 (0.035) 8.1 (0.319) 80.7 (3.177) 45.8


VALVE CAP~-,

.:2 ~VALVECAPCLlP

LOCK-UP TtMING VALVE

LOCK-UP SHIFT VALVE

LOCK-UP VALVE BODYInspect for wear, scratchesand scoring.

NOTE:• Clean ail parts thoroughly in solvent or carburetor cleaner, and dry with compressed air. Blow out ail passages.• Replace the valve body as an assembly if any parts are worn or damaged.• Check ail valves for free movement. If any fail to slide freely, see Valve Body Repair on page 14-117.• Coat ail parts with ATF during assembly.


Lock-up Valve Body

14-126

THRUST NEEOLEBEARING

NEEOLEBEARING

2NO GEAR

THRUST WASHER. 36.5 x 55 mmSelective part

O-RINGSReplace.

2NO/4TH CLUTCHASSEMBLY

TRANSMISSIONHOUSING BEARING4TH GEAR COLLAR


NEEOLEBEARINGS

THRUST WASHER


NEEOLEBEARING


THRUST WASHER

MAINSHAFTCheck splines for excessivewear and damage.Check bearing surface for scorinç,scratches. and excessive wear.

\

1ST CLUTCHASSEMBLY

LOCKNUT (FLANGENUT)21 x 1.25 mm78 Nom (8.0 kgfom. 58 Ibfoft)Replace.Left-hand threads

\CONICAL SPRINGWASHERReplace.

SNAP RING

NOTE:• Lubricate ail parts with ATF during reassembly.• Inspect the thrust needle bearings and the needle bearings for galling and rough movement.• Before installing the a-rings, wrap the shaft splines with tape to prevent damaging the a-rings.• Locknut has left-hand threads.• Inspect the condition of the sealing rings. If the sealing rings are worn, distorted, or damaged, replace them (see page

14-128).

Disassembly Il nspectio n1Reassembly

Mainshaft

14-127

(cont'd)

THRUST WASHER.36.5 x 55 mm

L Gn=u

2ND CLUTCH

STANDARD: 0.05 - 0.13 mm (0.002 - 0.005 in)

NOTE: Takemeasurementsin at least three places,and usethe averageas the actualclearance.

4. Hold 2nd gear against the 2nd clutch, then measurethe clearancebetween2ndgear and 3rd gearwith afeeler gauge.

LOCKNUT29 N-m '3.0 kgf-m. 22 Ibf-ft'

NOTE: Mainshaft locknut has left-handthreads.

3. Torque the mainshaft locknut ta 29 N·m (3.0 kgf·m,22 Ibf·ft).

MAINSHAFT

THRUST NEEDLEBEARING

THRUST WASHER36.5 x 55 mmSelective part

THRUST NEEDlEBEARING

~C::;o,Y...rll~--2ND GEAR

NEEDlE BEARING

2ND/4TH CLUTCHASSEMBLY

4TH GEARCOLLAR

TRANSMISSIONHOUSING BEARING

THRUST WASHER

1ST GEARCOLLAR

THRUST WASHER

1ST CLUTCH ASSEMBLy

SNAP RING

LOCKNUT

NOTE:Do not assemblethe O-rings during inspection.

2. Assemblethe parts below on the mainshaft.

1. Removethe mainshaft bearing from the transmission housing(seepage14-150).

NOTE: lubricate ail partswith ATFduring assembly.

ClearanceMeasurement

Inspection

MAINSHAFT

Install the sealing ringmating faces as shown.

• The sealing rings are fully seated in the groove.• The sealing rings are not twisted.• The chamfered ends of the sealing ring are prop

erly joined.

3. After installing the sealing rings, verify the following:

2. Install new sealing rings on the mainshaft.

1. Squeeze the sealing ring together slightly beforeinstalling, for better fit.

NOTE: Lubricate ail parts with ATF during assembly.

The sealing rings (35 mm and 29 mm) are synthetic resinwith chamfered ends. Check the condition of the sealingrings and replace them only if they are worn, distortedor damaged.

14-128

7. After replacing the thrust washer, make sure theclearance is within tolerance.

No. Part Number Thickness

1 90441 - P4P- 010 4.00 mm (0.157 in)

2 90442 - P4P- 010 4.05 mm (0.159 in)

3 90443 - P4P- 010 4.10 mm (0.161 in)

4 90444 - P4P- 010 4.15 mm (0.163 in)

5 90445 - P4P- 010 4.20 mm (0.165 in)

6 90446 - P4P- 010 4.25 mm (0.167 in)

7 90447 - P4P- 010 4.30 mm (0.169 in)

8 90448 - P4P- 010 4.35 mm (0.171 in)

9 90449 - P4P- 010 4.40 mm (0.173 in)

10 90450 - P4P- 000 4.45 mm (0.175 in)

THRUSTWASHER36.5 x 55 mm

6. Select and install a new washer, then recheck.

5. If the clearance is out of tolerance, remove thethrust washer and measure the thickness.

ReplacementInspection (cont' d)

Sealing RingsMainshaft

14-129

3RD CLUTCH ASSEMBLy


SPLINEDWASHER

TRANSMISSIONHOUSING BEARING

NEEDLEBEARING

lST GEAR

ONE-WAYCLUTCH

PARKINGGEAR

Replace.

LOCKNUT(FLANGENUT)23 x 1.25mm103N'm(10.5kgf·m, 75.9Ibf.ft) - 0-103N'm(10.5kgf·m, 75.9 Ibf·ft)Replace.Left-hand threads

CONICAL SPRINGWASHER

3RD GEAR COLLAR

NEEDLEBEARING

3RD GEAR

THRUST NEEDLEBEARINGCOUNTERSHAFT

Check splines for excessivewear and damage.Check bearing surface for scoring,scratches and excessive wear.

\

2ND GEAR

NEEDLEBEARING

DISTANCE COLLAR,28 mmSelective part

REVERSESELECTORHUB4TH GEAR

NEEDLEBEARING~

~

REVERSEGEAR

REVERSEGEAR COLLAR

• Install the conical spring washer, the one-way clutch, the reverse selector, and the reverse selector hub in the directionshown.

NOTE:• Lubricate ail parts with ATF before reassembly.• Inspect the thrust needle bearings and the needle bearings for galling and rough movement.• Before installing the O-rings, wrap the shaft splines with tape to prevent damaging the O-rings.• Locknut has left-hand threads.


Countershaft

COUNTERSHAFT

O-RINGSReplace.

3RD CLUTCH ASSEMBL y

TH RUST NEEDLE BEARING

3RD GEAR COLLAR

NEEDLE BEARING

3RD GEAR

THRUST NEEDlE SEARING

2ND GEAR

DIST ANCE COlLAR. 28 mmSelective part

NEEDLE BEARING

NOTE:• Lubricate ail parts with ATF during assembly.• Before installing the O-rings, wrap the shaft splines

with tape to prevent damaging the O-rings.

2. Assemble the parts on the countershaft as shownbelow.

14-130

4TH GEAR

REVERSESELECTOR HUS

SHAFT PROTECTOR(Commerciallyavailable)

t. Remove the reverse selector hub and the 4th gearusing a universal two-jaw (or three-jaw) puller asshown.


Countershaft

14-131

(cont'd)

COUNTERSHAFT

3RD ClUTCH ASSEMBLy

SPLINEDWASHER

3RD GEAR COllAR


NEEDlE BEARING

3RD GEAR

THRUST NEEDlE BEARING

2ND GEAR

NEEDLEBEARING

DISTANCE COLLAR. 28 mmSelective part

NOTE: Do not assemble the O-rings during inspection.

2. Install the parts below on the countershaft using thespecial tool and a press as described on this page.

1. Remove the countershaft bearing from the transmission housing (see page 14-150).

NOTE: Lubricate ail parts with ATF during assembly.

Clearance Measurement

Inspection

~ COUNTERSHAFTSUB-ASSEMBLy

3. Install the reverse selector hub on the countershaftsub-assembly, and then press the reverse selectorhub using the special tool and a press as shown.

7. Recheck the distance collar clearance to make sureit is within tolerance.

No. Part Number Width

1 90503 - PC9 - 000 39.00 mm (1.535 in)

2 90504 - PC9 - 000 39.10 mm (1.539 in)

3 90505 - PC9 - 000 39.20 mm (1.543 in)

4 90507 - PC9 - 000 39.30 mm (1.547 in)

5 90508 - PC9 - 000 39.05 mm (1.537 in)

6 90509 - PC9 - 000 39.15 mm (1.541 in)

7 90510 - PC9 - 000 39.25 mm (1.545 in)

8 90511 - PC9 - 000 38.90 mm (1.531 in)

9 90512 - PC9 - 000 38.95 mm (1.533 in)

DISTANCE COLLAR, 28 mm

6. Select and install a new distance collar, thenrecheck.

5. If the clearance is out of tolerance, remove the 28mm distance collar and measure the width.

FEELER GAUGE1

2ND GEAR

DISTANCE COLLAR, 28 mm

STANDARD: 0.10 - 0.18 mm (0.004 - 0.007 in)

NOTE: Take measurements in at least three places,and use the average as the actual clearance.

4. Measure the clearance between the 2nd gear andthe 28 mm distance collar with a feeler gauge.

COUNTERSHAFTSUB-ASSEMBL y

14-132

~ TRANSMISSION HOUSING~ BEARING

r=: REVERSE GEAR~ COLLAR

1ST GEAR COLLAR

NEEDLE BEARING

PARKING GEAR/ONE-WAYCLUTCH/1 ST GEARASSEMBLY -

LOCKNUTLeft-hand threadsCONICAL SPRINGWASHER

NOTE: Countershaft locknut has left-hand threads.

3. Install the parts below on the countershaft subassembly, then torque the locknut to 29 N'm (3.0kgf·m, 22 Ibf·ft).

Inspection (cont' d)

Countershaft

14-133

COUNTERSHAFT 1ST GEAR

PARKING GEAR

4. After the parts are assembled, hold countershaft 1stgear and turn the parking gear in the directionshown to be sure it turns freely. Also make sure theparking gear does not turn in the opposite direction.

1ST GEARInspect countershaft 1st gearfor wear and scoring.

ONE-WAY CLUTCHInspect the one-wayclutch for damageandfaulty movement.

PARKING GEARInspect the parking gearfor wear and scoring.

3. Inspect the parts as follows:

ONE-WAY CLUTCHCOUNTERSHAFT1STGEAR

2. Remove the one-way clutch by prying it up with theend of a screwdriver.

COUNTERSHAFT 1ST GEAR

PARKINGGEAR

1. Separate countershaft 1st gear from the parkinggear by turning the parking gear in the directionshown.


One-way Clutch

14-134

CHECK VALVE

Standard thickness:1.6 mm (0.063 in)

Standard thickness:1.94 mm (0.076 in)

SNAP RING

1STCLUTCHSNAPRING

Standard thickness:, .94 mm (0.076 in)

CLUTCH PISTONOISCSPRING

RETURN SPRINGSPRING RETAINER

SNAP RING

CLUTCH PLATES

",."" .."',-

O-RINGS

3RO CLUTCH

lIIustrated Index

Clutch

14-135

Replace.

CLUTCH DISCSStandard thickness:1.94 mm (0.076 in)

SNAPRIN!/

SPRING RETAINER

RETURN SPRING

2ND/4TH ClUTCH

CLUTCH SPRINGCOMPRESSORATTACHMENT07LAE - PX40100 or07HAE - PL50101

CLUTCH SPRINGCOMPRESSORATTACHMENT07LAE - PX40100

CLUTCH SPRINGCOMPRESSORATTACHMENT07LAE - PX40100 or07HAE - Pl50101

ClUTCH SPRINGCOMPRESSORATTACHMENT07LAE - PX40100

CLUTCH SPRINGCOMPRESSORBOLT ASSEMBl y07GAE - PG40200 or07GAE - PG4020A

CLUTCH SPRINGCOMPRESSORBOlT ASSEMBLY07GAE - PG40200 or07GAE - PG4020A

3. Install the special tools as shown.

14-136

Dise SPRING

NOTE: Except 2nd clutch.

2. Remove the dise spring.

·SCREWoRIVER

1. Remove the snap ring, then remove the clutch endplate, clutch discs and plates.

Disassembly

Clutch

14-137

OSHA-APPROVED30 psi NOZZLE

6. Wrap a shop rag around the clutch drum, and applyair pressure to the ATF passage to remove the piston.Place a finger tip on the other end while applyingair pressure.

SPRING RETAINER

5. Remove the snap ring. Then remove the special tools,spring retainer and return spring.

SPECIAL TOOL

4. Compress the return spring.

SPRING RETAINER

Do not set here.

CAUTION: If either end of the special tool is set over anarea of the spring retainer which is unsupported by thereturn spring, the retainer may be damaged. Be sure thespecial tool is adjusted to have full contact with thespring retainer.

RETURN SPRING

SPRING RETAINER

SNAP RING

4. Install the return spring and spring retainer, andposition the snap ring on the retainer.

CAUTION: Do not pinch the O-ring by installing thepiston with too much force.

NOTE: Lubricate the piston O-ring with ATF beforeinstalling.

3. Install the piston in the clutch drum. Apply pressureand rotate ta ensure proper seating.

14-138

PISTONO-RING

O-RING

iO-RINGS

2. Install new O-rings on the clutch piston.

PISTON

CHECK VALVE

1. Inspect the check valve; if it's loose, replace the piston.

NOTE:• Clean ail parts thoroughly in solvent or carburetor

cleaner, and dry them with compressed air.• Blow out ail passages.• Lubricate ail parts with ATF before reassembly.

Reassembly

Clutch

14-139

(cont'd)

SPECIAL TOOL

6. Compress the return spring.SPRING RETAINER

Do not set here.

CAUTION: If either end of the special tool is setover an area of the spring retainer which is unsupported by the return spring, the retainer may bedamaged. Be sure the special tool is adjusted tohave full contact with the spring retainer.





CLUTCH SPRINGCOMPRESSORBOLT ASSEMBL y07GAE - PG40200 or07GAE - PG4020A

CLUTCH SPRINGCOMPRESSORBOLT ASSEMBL y07GAE - PG40200 or07GAE - PG4020A

5. Install the special tools as shown.

SCREWDRIVER

12. Install the snap ring.

CLUTCH END PLATECLUTCH DISC

CLUTCH END PLATE

NOTE: Before installing the plates and discs, makesure the inside of the clutch drum is free of dirt orother foreign matter.

11. Starting with a clutch plate, alternately install thec1utch plates and discs. Install the c1utch end platewith fiat side toward the disco

10. Soak the c1utch dises thoroughly in ATF for a minimum of 30 minutes.

14-140

NOTE: Install the disc spring in the directionshown, except 2nd clutch.

9. Install the disc spring.

8. Remove the special tools.

SNAP RING

7. Install the snap ring.

Reassembly (cont'd)

Clutch

14-141

Plate No. Part Number Thickness

1 22551 - P4R - 003 2.1 mm (0.083 in)2 22552 - P4R - 003 2.2 mm (0.087 in)3 22553 - P4R - 003 2.3 mm (0.091 in)4 22554 - P4R - 003 2.4 mm (0.094 in)5 22555 - P4R - 003 2.5 mm (0.098 in)6 22556 - P4R - 003 2.6 mm (0.102 in)7 22557 - P4R - 003 2.7 mm (0.106 in)8 22558 - P4R - 003 2.8 mm (0.110 in)9 22559 - P4R - 003 2.9 mm (0.114 in)

CLUTCH END PLATE

CLUTCH END PLATE

ThicknessPLATE NUMBER

NOTE: If the thickest clutch end plate is installed,but the clearance is still over the standard, replacethe clutch discs and clutch plates.

14. If the clearance is not within the service limits,select a new clutch end plate from the followingtable.

CLUTCH DISC

CLUTCH ENDPlATE

Clutch Service Limit

1st 0.65 - 0.85 mm (0.026 - 0.033 in)2nd 0.65 - 0.85 mm (0.026 - 0.033 in)3rd 0.40 - 0.60 mm (0.016 - 0.024 in)4th 0.40 - 0.60 mm (0.016 - 0.024 in)

Clutch End Plate-to-Top Dise Clearance:

NOTE: Take measurements in at least three places,and use the average as the actual clearance.

13. Measure the clearance between the clutch end plateand top disc with a dial indicator. Zero the dial indicator with the clutch end plate lowered and lift it upto the snap ring. The distance that the clutch endplate moves is the clearance between the clutch endplate and top disco

14-142

BAlL BEARINGInspect for faulty movement.

SNAP RING

DIFFERENT'AL CARRIER/lnspeCI forcracks.

BALL BEARINGInspect for faulty movement.

FINAL DRIVEN GEAR_/ Inspect for excessive wear.

~ Install in this direction.

/SET RING. 80 mm/' Selective pan

SPEEDOMETER DRIVEGEAR

lIIustrated Index

Differentiai

14-143

2. Install new bearings using the special tool as shown.

BEARING

BEARING PULLER(Commercially available)

1. Remove bearings using a bearing puller.

NOTE: Check bearings for wear and rough rotation. Ifbearings are OK, removal is not necessary.

3. If backlash is out of tolerance, replace the differential carrier (see page 14-144).

Standard (New): 0.05 - 0.15 mm (0.002 - 0.006 in)

• 2. Check backlash of both pinion gears.

SIDE GEAR

1. Place differential assembly on V-blocks and installboth axles.

Bearing Replacement8acklash Inspection

7. Install the bail bearings (see page 14-143).

- "DIFFERENTIALCARRIER

FINAL DRIVENGEARInstall in thisdirection.

BOLTS10 x 1.0 mm101 N·m (10.3 kgf·m.74.5 Ibf·ft)Left-handthreads


TORQUE:101N'm (10.3kgf'm, 74.5Ibf.ft)

6. Install the final driven gear, then tighten the bolts tothe specified torque.

GROOVESPRING PIN

SNAP RINGInstall in this direction.Hookedend

5. Align the hooked end of the snap ring with the pinion shaft as shown, then install the snap ring in thedifferential carrier groove.

14-144

4. Install the speedometer drive gear with its chamfered side facing the carrier. Align the cutout on thebore of the speedometer drive gear with the 5 x 10mm roller.

ROLLER.5 x 10 mm

Cutout

3. Install the 5 x 10 mm roller in the differential carrier.

SPEEDOMETERDRIVE GEAR

/DIFFERENTIALCARRIER

SNAP RING

2. Pry the snap ring off differential carrier, then removethe speedometer drive gear and 5 x 10mm roller.


1. Remove the final driven gear from the differentialcarrier.

,.. ~')

Differentiai Carrier Replacement

Differentiai

14-145

(cont'd)

3. Install the transmission housing and tighten thebolts (see page 14-154 and 14-155).

i~

/

~~TORQUEL_r-J' "CONVERTERHOUSING

2. Install the differential assembly into the torque converter housing using the special tool as shown.

TRANSMISSIONHOUSING

NOTE: Do not install the oil seal veto

1. Install a 2.50 mm (0.098 in) set ring, 80 mm in transmission housing.

TORQUECONVERTERHOUSING

Oll SEAlReplace.

3. Remove the oil seal from the torque converterhousing.

OIL SEALReplace.

2. Remove the oil seal from the transmission housing.

1. Remove the differential assembly.

Oll Seal Installation/Side ClearanceOil Seal Removal

8. Replace the 2.50 mm (0.098 in) 80 mm set ring withthe one of the correct thickness selected in step 6.

7. Remove the transmission housing.

NOTE: If the 80 mm set ring-to-ball bearing outerrace clearance measured in step 5 is less than thespecification, it is not necessary to perform steps 7and 8.

Part Number Thickness

90414 - 689 - 000 2.50 mm (0.098 in)90415 - 689 - 000 2.60 mm (0.102 in)90416 - 689 - 000 2.70 mm (0.106 in)90417 - 689 - 000 2.80 mm (0.110 in)90418 - 689 - 000 2.90 mm (0.114 in)90419 - PH8 - 000 3.00 mm (0.118 in)

SET RING, 80 mm

6. If the clearance is more than the standard, select anew 80 mm set ring trom the following table andinstall:

FEElER GAUGE

SETRING.80 mm

STANDARD: 0 - 0.15 mm (0 - 0.006 in)

5. Measure the clearance between the 80 mm set ringand outer race of the bail bearing in the transmission housing.

14-146

DRIVER40 mm 1.0.07746-0030100

4. Tap on the transmission housing side of the differential assembly with the special tool to seat the differential assembly in the torque converter housing.

Oil Seal Installation/Side Clearance (cont' d)

Differentiai

14-147

26 x 30 mm07JAD - PH80200

DRIVERATTACHMENT07JAD - PH80101

DRIVER07149 - 0010000

10. Install the oil seal in the torque converter housingusing the special tools as shown.

DRIVER ATTACHMENT, 68 mm07947 - 6110501

PILOT,26x30mm07JAD - PH80200

DRIVER07749 - 0010000

9. Install the oil seal in the transmission housing usingthe special tools as shown.

ATTACHMENT,72 x75 mm07746- 0010600

DRIVER01749- 0010000

3. Install the new oil seal flush with the housing usingthe special tools as shown.

AITACHMENT,62x68mm07746- 0010500

DRIVER07749- 0010000

2. Drive in the new mainshaft bearing until it bottomsin the housing using the special tools as shown.

14-148

ADJUSTABLEBEARINGPULLER,25 - 40 mm07736- A01000Bor07736- A01000A

1. Remove the mainshaft bearing and oil seal usingthe special tools as shown.

Mainshaft Bearing/Oil Seal Replacement

Torque Converter Housing Bearings

14-149

0-0.03 mm(0 - 0.001 in)

DRIVER07749 - 0010000

3. Drive the new bearing into the housing using thespecial tools as shown.

2. Install the ATF guide plate.

ADJUSTABLEBEARINGPULLER,25-40 mm07736 - A01000B or07736 - A01000A

1. Remove the countershaft bearing using the specialtools as shown.

Countershaft Bearing Replacement

SNAPRING

END GAP: 0 -7 mm(0-0.28 in)

• The snap ring is seated in the bearing and housing grooves.

• The snap ring operates properly.• The ring end gap is correct.

4. After installing the bearing verity the following:

3. Release the pliers, then push the bearing down intothe housing until the ring snaps in place around it.

NOTE: Coat ail parts with ATF.

2. Expand each snap ring with snap ring pliers, theninsert the new bearing part-wav into the housingusing the special tools and a press as shown. Installthe bearing with the groove tacing outside thehousing.

14-150

ATTACHMENT• Mainshaft Bearing Installation use:

ATTACHMENT, 72 x 75 mm07746 - 0010600

• Countershaft Bearing Installation use:ATTACHMENT, 62 x 68 mm07746 - 0010500

TRANSMISSIONHOUSING

ATTACHMENT

COUNTERSHAFTBEARING

DRIVER07149 - 0010000

AnACHME~ ! e:?62x68mm NT. ~07146 - 0010500 -

PRESS -.NOTE: Do not remove the snap rings unless ifsnecessary to clean the grooves in the housing.

1. To remove the mainshaft and countershaft bearingsfrom the transmission housing, expand each snapring with snap ring pliers, then push the bearing outusing the special tools and a press as shown.

ATTACHMENT• Mainshaft Bearing Removal use:

ATTACHMENT, 72 x 75 mm07746 - 0010600

MAINSHAFT BEARING • Countershaft Bearing Removal use:ATTACHMENT, 62 x 68 mm

DRIVER 07746 - 001050007749 - 0010000

Mainshaft/Countershaft Bearings Replacement

Transmission Housing Bearings

14-151

4. After replacing the parking brake stop, make surethe distance is within tolerance.

Mark Part Number L1 U

1 24537 - PA9 - 003 11.00mm 11.00mm(0.433 in) (0.433 in)

2 24538 - PA9 - 003 10.80mm 10.65 mm(0.425 in) (0.419 in)

3 24539 - PA9 - 003 10.60mm 10.30mm(0.417 in) (0.406 in)

PARKING BRAKESTOP

L1Lz

PARKING BRAKESTOP

3. If the measurement is out of tolerance, select andinstall the appropriate parking brake stop from thetable below.

PARKING BRAKEPAWL SHAFT

PARKINGBRAKELEVER

STANDARD: 72.9 - 73.9 mm (2.87 - 2.91 in)

2. Measure the distance between the parking brakepawl shaft and the parking brake lever roller pin asshown.

1. Set the parking brake lever in the Œl position.

REVERSEIOLERGEAR SHAFTASSEMBLY

6 x 1.0 mm12 N-m (1.2 kgf-m.8.71bfoft)

2. Install the reverse idler gear shaft holder and needlebearing into the transmission housing, then tightenthe bolts.

1. Install the reverse idler gear.

Inspectionl AdjustmentInstallation

Parking 8rake StopReverse Idler Gear

14-152

TORQUE CONVERTERHOUSING

DOWELPINS.2

SECONDARYSEPARATOR PLATE

ATF PUMP DRIVEN

GEARSHAFT ~ATF PUMP DRIVENGEAR \

MAIN SEPARATORPLATE

MAIN VALVE BODY

DOWEL PINS. 2

SECONDARY VALVEBODY

O-RINGSTOP SHAFT

ATF FEED PIPE: H

6x 1.0mm5 Bolts

SERVO SEPARATORPLATE

TORQUE CONVERTERCHECK VALVE

STATOR SHAFT

SERVOBODY

6x 1.0mm7 Bolts

DOWEL PINS. 2

SERVO DETENTBASE

REGULATORVALVEBODY

ATF FEEDPIPES:

ATF STRAINER

LOCK-UP VALVEBODY

6 x 1.0mm2 Bolts

ATF FEED PIPE: A6x 1.0mm7 Bolts

TORQUE: 12 N'm (1.2 kgf'm, 8.7Ibf.ft)

NOTE:• Coat ail parts with ATF.• Replace the following parts:

- O-rings- Lock washers- Gaskets- Mainshaft and countershaft locknuts and conical spring washers- Sealing washers

Reassembly

Transmission

14-153

(cont'd)

16. Install the ATF feed pipe in the main valve body, thethree ATF feed pipes in the secondary valve and thefour ATF feed pipes in the servo body.

15. Install the lock-up valve body on the regulator valvebody (seven bolts).

14. Install the torque converter check valve, cooler reliefvalve and valve springs in the regulator valve body,then install the regulator valve body on the mainvalve body (one boit).

13. Install the bolts and the shaft stop on the secondaryvalve body, then tighten the bolts (three bolts).

12. Install the stator shaft and stop shaft.

,-~......._._-

""1 J

<; -~-

ATFPUMPDRIVEGEAR

CAUTION: Failure ta align the ATF pump drivengear shaft correctly will result in a seized ATF pumpdrive gear or ATF pump driven gear shaft.

11. If the ATF pump drive gear and ATF pump drivengear shaft do not move freely, loosen the five boltson the main valve body, and disassemble the valvebodies.Realign the ATF pump driven gear shaft and reassemble the valve bodies, then retighten the bolts to thespecified torque.

10. Tighten the five bolts on the main valve body to 12N'm (1.2 kgf·m, 8.7 Ibf·ft).Make sure the ATF pump drive gear and ATF pumpdriven gear shaft move smoothly.

9. Install the servo detent base and the ATF strainer(two bolts).

8. Install the servo body and separator plate on thesecondary valve body (seven bolts).

DETENT ARM SPRING

CONTROLSHAFT

SERVO SEPARATOR PLATE

6. Install the control shaft in the housing with the control shaft and manual valve together.

7. Install the detent arm and arm shaft in the mainvalve body, then hook the detent arm spring to thedetent arm.

NOTE: Do not install the bolts.

4. loosely install the main valve body with five bolts.Make sure the ATF pump drive gear rotates smoothlyin the normal operating direction and the ATF pumpdriven gear shaft moves smoothly in the axial andnormal operating directions.

5. Install the secondary valve body, separator plateand two dowel pins on the main valve body.

Groovedand chamferedsidtt faces separatorplate.

NOTE: Install the ATF pump driven gear with itsgrooved and chamfered side faeing down.

ATFPUMPDRIVEGEAR

1. Install the ATF magnet and suction pipe collar in thetorque converter housing, if necessary.

2. Install the main separator plate and the two dowelpins on the torque converter housing.

3. Install the ATF pump drive gear, ATF pump drivengear and ATF pump driven gear shaft on the torqueconverter housing.

14-154

TOROUE CONVERTER-tOUSING

TRANSMISSIONHOUSING GASKET

MAINSHAFTSPEED SENSOR

TRANSMISSIONHANGER

Reassembly (cont'd)

Transmission

14-155

26. Install the mainshaft speed sensor on the transmis-sion housing. (cont'd)

TRANSMISSIONHANGER

TORQUE:44 N'm (4.5 kgf·m, 33 Ibf.ft)

25. Install the transmission housing mounting boltsalong with the transmission hanger, then tightenthe bolts in two or more steps in the sequence asshown.

CAUTION: Make sure that the mainshaft speedsensor is not installed on the transmission housingbefore installing the transmission housing on thetorque converter housing.

24. Place the transmission housing on the torque converter housing.

23. Install the two dowel pins and a new gasket on thetorque converter housing.

SPRING PIN

22. Align the spring pin on the control shaft with thetransmission housing groove by turning the controlshaft.

21. Install the needle bearing, countershaft reverse gearand reverse gear collar on the countershaft.

large chamfered halefaces this way.

6 x 1.0 mm14N-m(1.4 kgf-m. 10 Ibf·ftl

20. Turn the shift fork 50 the large chamfered hole isfacing the fork boit hole, then install the shift forkwith the reverse selector, and torque the lock boit.Bend the lock tab against the boit head.

MAINSHAFTSUB-ASSEMBLy

19. Assemble the mainshaft and the countershaft subassembly, then install them together in the torqueconverter housing.

18. Install the differential assembly in the torque converter housing.

17. Install the reverse idler gear and the gear shaftholder (see page 14-151).

MAINSHAFTHOLDER07GAB- Pf50101

33. Slip the specialtool onto the mainshaftasshown.

PARKING GEAR

CONICAL SPRINGWASHERUseold one.

lOCKNUTUse old one.

TORQUE: 103 N·m (10.5 kgf·m.75.9Ibf.ft)

NOTE:• The locknuthasleft-handthreads.• Do not use an impact wrench, always use a

torquewrenchto tighten the locknut.

32. Install the old locknut and conical spring washeronthe countershaft.Tighten the old locknut to seattheparking gear to the specified torque, then removethem.

14-156

COUNTERSHAFTMAINSHAFT

THRUSTWASHER

PAWlPARKINGGEAR

1STCLUTCHASSEMBlY

31. Install the parking brake pawl shaft, pawl spring,pawl, and pawl stop on the transmission housing,then engagethe parking brakepaw! with the parking gear.

30. Install the countershaft 1stgear collar, needlebearing, and the countershaft 1st gear/parking gearassemblyon the countershaft.

29. lubricate the following partswith ATF:• Countershaftthreads• Old locknutthreadsand fiat end• Oldconicalspringwasher• Parking gear contact area with conical spring

washer

28. Assemblethe one-wayclutch and the parking gearwith the countershaft1stgear(seepage14-133).

27. Install the parkingbrakeleveron the control shaft.

Reassembly (cont'd)

Transmission

14-157

(cont'd)

PARKING BRAKE PAWL

6 x 1.0 mm14 N·m (1.4 kgf·m. 10 Ibf·ft'

o

43. Tighten the lockboit andbendthe lock tab.

42. If the pawl doesnot engagefully, checkthe distancebetweenthe parkingbrakepawl shaft and the parking brakelever roller pin (seepage14-151).

41. Set the parking brake lever in the œJ position, thenverity that the parkingbrakepawl engagesthe parking gear.

0.7-1.2 mm(0.03 - 0.05 in)

Point to bestaked.

COUNTERSHAFTLOCKNUT

40. Stakeeachlocknutusinga3.5mm punchasshown.

CONICAL SPRING WASHERSInstall in this direction.

MAINSHAFTLOCKNUTLeft-hand threads

/

NOTE:• The locknuts have left-hand threads.• Do not use an impact wrench, always use a

torque wrench to tighten the locknuts.

TORQUE:MAINSHAFT: 78 N'm (8.0 kgf·m, 58 IbHt)COUNTERSHAFT: 103 N'm (10.5 kgf·m, 75.9IbHt)

39. Lubricate the fiat side of the new locknuts with ATF,then install and tighten the locknuts to the specifiedtorque.

38. Install the new conical spring washer with the "U"facing the locknut side on the mainshaft in the direction shown.

37. Install the new conical spring washer with the tIC"facing the locknut side on the countershaft in thedirection as shown.

36. Install the 1st clutch assembly on the mainshaft.

35. Wrap the shaft splines with tape to prevent O-ringdamage, then install new O-rings on the mainshaft.

34. Install the mainshaft 1st gear collar, mainshaft 1stgear, needle bearing, thrust needle bearing, and thethrust washer on the mainshaft.

14-158

46. Install the ATF dipstick.

TORQUE: 28 N'm (2.9 kgf·m, 21Ibf.tt)

45. Install the ATF cooler lines with new sealing washers.

RIGHT SIOE COVER

TORQUE: 12 N'm (1.2 kgf·m, 8.7Ibf.ft)

44. Install the right side cover with two dowel pins anda new gasket (thirteen bolts).

Reassembly (cont'd)

Transmission

14-159

RING GEARITORQUE CONVERTERASSEMBLY

Replace.

WASHER

6x1.0mm12 N·m 11.2 k9f.~f.h)

~-

Torque Converter IDrive Plate

8. Remove the transmission jack.

TRANSMISSION HOUSINGMOUNTING SOlTS12 x 1.25mm64 N·m (6.5kgf·m. 47 Ibf·ft)

REAR ENGINEMOUNTING SOlT14x1.5mm83 N'm (8.5kgf·m,611bf.ft)

7. Install the remaining transmission housing mounting bolts and remaining rear engine mounting boit.

TRANSMISSION MOUNT12 x 1.25mm74N·m (7.5kgf·m.54Ibf·ft)

12x 1.25mm64 N'm (6.5kgf·m, 47 Ibf.ft)

6. Install the transmission mount bracket.

"l

14-160

REARENGINEMOUNTING SOlTS14x 1.5mm83N'm (8.5kgf·m, 61 IbHt)Replace.

TRANSMISSION HOUSINGMOUNTING SOlTS12x 1.25mm64 N·m (6.5kgf~m,47 IbHtl

5. Attach the transmission to the engine, then installtwo transmission housing mounting bolts and tworear engine mounting bolts.

4. Place the transmission on a jack, and raise it to theengine assembly level.

3. Install the starter motor on the torque converterhousing, then install the two 14 mm dowel pins inthe torque converter housing.

Replace.14mm DOWEl PINTORQUE

CONVERTER

2. Install the torque converter assembly securely witha new O-ring on the mainshaft.

1. Flush the ATF cooler as described on page 14-164and 14-165.

Installation

Transmission

14-161

(cont'd)

SELF·LOCKING NUTReplace.8 x 1.25mm22N'm (2.2kgf·m, 16Ibf.tt)

Replace.10x 1.25mm54N·m(5.5kgf·m,40 Ibf.ft)

SELF·LOCKING NUTReplace.8x 1.25mm16N·m(1.6kgf·m,121bf.ttl

Replace.

EXHAUST PIPE A

15. Install the exhaust pipe A.

SHIFT CABLE COVER 6 x 1.0mm14N'm (1.4kgf·m,101bHt)

SHIFTCABLE

CAUTION: Take care not to bend the shift cable.

14. lnstall the control lever with a new lock washer tothe control shaft, then install the shift cable cover.

13. Install the right front mount/bracket.

12x 1.25mm64N'm (6.5kgf·m,47Ibf.ft)

10x 1.25mm«N'm (4.5kgf·m,33Ibf.tt)

RIGHTFRONTMOUNT IBRACKET

12. Connect the ATF cooler hoses to the ATF cooler lines(seepage 14-169).

11. Tighten the crankshaft pulley boit, if necessary (seesection 6).

10. Install the torque converter cover and the enginestiffener.

TORQUE CONVERTERCOVER

8x1.25mm24N'm (2.4kgf'm,17Ibf.ft)

/~---_/'"'- 6 x 1.0mm12N'm (1.2kgf·m,8.7Ibf.ft)

DRIVEPLATE

10x 1.25mm44N·m(4.5kgf·m,33 Ibf.ft)

TORQUE: 12 N'm (1.2 kgf·m, 8.7 Ibf.ft)

9. Attach the torque converter to the drive plate witheight drive plate bolts and torque as follows:Rotate the crankshaft pulley as necessary to tightenthe bolts to 1/2 of the specified torque, then to thefinal torque, in a crisscross pattern.After tightening the last boit, check that the crankshaft rotates freely.

VEHICLE SPEEOSENSOR CONNECTOR

21. Connect the countershaft speed sensor and the vehicie speed sensor (VSS) connectors.

CONNECTOR BRACKET

6x1.0mm12N'm (1.2 kgf·m,a.7 Ibf.ft)


20. Connect the mainshaft speed sensor, the linear solenoid and the shift control solenoid connectors.

14-162

SPLASH SHIELO, '" ®/ 6xl.0mm

CLIP 12 N'm (1.2 kgf·m, a.7 Ibf.ftl

19. Install the splash shield.

CASTLE NUT12 x 1.25 mm49-59 N'm(5.0- 6.0 kgf-m. 36 - 43 Ibf.ft)

\_~,corrsa PINReplace.

SElF·lOCKING NUT12 x 1.25mm64 N'm (6.5 kgf·m, 47 Ibf.ft)Replace.

DAMPER PINCH BOLT10 x 1.25mm43 N'm (4.4 kgf·m.32Ibf.ft)

16. Install a new set ring on the end of each driveshaft.17. Install the right and left driveshafts (see section 16).

CAUTION: While installing the driveshafts in thedifferential, be sure not to allow dust and other foreign particles to enter into the transmission.NOTE:• Clean the areas where the driveshafts contact the

transmission (differential) thoroughly with solvent or carburetor cleaner, and dry with cornpressed air.

• Turn the right and left steering knuckle fully outward, and slide each driveshaft into the differential until you feel its set ring clip engage the sidegear.

18. Install the damper Iork, then install the right and leftbail joints to the each lower arm with the castle nutsand new cotter pins.


Transmission

14-163

32. Enterthe anti-theft code for the radio, then enterthecustomer's radio station presets.

31. Roadtest asdescribedon pages14-92and 14-93.

30. Let the engine reach operating temperature (thecooling fan cornes on) with the transmission in [ffior œ position, then turn it off and check the fluidlevel.

29. Checkthe front wheel alignment (seesection18).

28. Start the engine.Set the parkingbrake,andshift thetransmission through ail gears, three times. Checkthe shift cableadjustment (seepage14-167).

27. Checkthe ignition timing (seesection23).

26. Connectthe positive (+) cable first, then the negativeH cableto the battery.

25. Refill the transmissionwith ATF(seepage14-95).

24. Install the intake air duct and the air cleaner housing assembly.

STARTER CABLE


NOTE:When installing the starter cable terminal,makesurethat the crimped sideof the ring terminalis facing out.

23. Connectthe starter cableson the startermotor, andinstall the cableholder.



6 x 1.0 mm12 N·m (1.2 kgf·m, 8.7 Ibf.ft)

22. Connect the lock-up control solenoid connector, andinstall the transmission ground cable.

16. Install the transmission, and leave the drain hoseattached to the cooler line.

15. Remove the flusher from the cooler line. Attach thedrain hose to a container.

CAUTION: Residual moisture in the cooler or pipescan damage the transmlsslon.

14. Turn the air valve on to dry the system out with airfor two full minutes or until no moisture is visibleleaving the drain hose.

13. Turn the water valve off, and turn off the water supply.

12. Release the trigger, and rinse the cooler with wateronly for one minute.

11. Turn the water valve off. Release the trigger, thenreverse the hoses to the cooler so you can flush inthe opposite direction. Repeat steps 8 through 10.

10. While flushing with the water and flushing fluid fortwo minutes, turn the air valve on for five secondsevery 15 - 20 seconds to create a surging action.AIR PRESSURE:MAX 845 kpa (8.45 kgf/cm', 120 psi)

9. Oepress the trigger to mix the flushing fluid into thewater flow. Use the wire clip to hold the trigger down.

NOTE: If water does not flow through the cooler, itis completely plugged, cannot be flushed, and mustbe replaced.

8. Turn on the flusher water valve so water will flowthrough the cooler for 10 seconds.

OFF

7. With the water and air valves off, attach the water andair supplies to the flusher. (Hot water if available.)

14-164

or equivalent

(CommerciallyavailablelKent-Moore J38405-A

TRANSMISSION COOLERFLUSHER

DISCHARGEHOSE

/';/~

\~

/BUCKET

IMPORTANT:Securely clamp the opposite end of the drain hose to abucket or floor drain.

6. Connect the drain hose to the inlet line on the transmission cooler using a clamp.

5. Attach the tank's discharge hose to the return lineof the transmission cooler using a clamp.

4. Hang the tool under the vehicle.

NOTE: The air line should be equipped with a watertrap to ensure a dry air system.

3. Secure the flusher filler cap, .and pressurize the tankwith compressed air to between 550 - 829 kpa (5.6 -8.45 kgf/cm2, 80 - 120psi).

2. Using the measuring cup, fil! the tank with 21 ounces(approximately 2/3 full) of biodegradable flushingfluid (J35944 - 20). Do not substitute with any otherfluid. Follow the handl.ing procedure on the fluidcontainer.

1. Check tool and hoses for wear and cracks beforeusing. If wear or cracks are found, replace the hosesbefore using.

NOTE: This procedure should be performed before reinstalling the transmission.

'''',.,MlldN T0 prevent injury to face and eyes, alwayswear safety glasses or a face shield wh en using thetransmission flusher.

Cooler Flushing

Transmission

14-165

5. The fluid orifice is located behind the filter.Clean it with the pick stored in the bottom of thetank handle, or blow it clean with air. Securelyreassemble ail parts.

4. Remove the in-line filter from the discharge side andclean if necessary.

O-RING

FILTER COUPLINGNUT

FILLERCAP

3. To clean, disconnect the plumbing from the tank atthe large coupling nut.

2. If discharge liquid does not foam, the orifice may beblocked.

1. Empty and rinse after each use. Fill the can with waterand pressurize the canoFlush the discharge line toensure that the unit is clean.

TOOL MAINTENANCE

19. Refill the transmission with ATF to the proper level(see page 14-95).

18. Remove the drain hose, and reconnect the coolerreturn hose to the transmission (see page 14-169).

17. Make sure the transmission is in the Œ1 position.Fill the transmission with ATF, and run the enginefor 30 seconds or until approximately 0.95 t (1.0 USqt., 0.8 Imp qt.) is discharged.

8. Check the cable adjustment on reassembly.

7. Install the shift cable in the reverse order of removal.

6xl.0mm14N'm(1.4 kgf·m, 10 Ibf·tt)

CONTROL LEVER

Replace.

SHIFT CABLE HOlDER8 x 1.25mm22N·m(2.2 kgf·m.161bf·ttl

6. Remove the control lever trom the control shaft,then remove the shift cable. Take care not to bendthe cable when removing/installing it.

5. Remove the shift cable cover.

4. Remove the shift cable holder.

14-166

6xl.0mm9.8N·m(1.0 kgf·m. 7.2 Ibf·ttl

SHIFT CABLEBRACKET

3. Remove the shift cable bracket.

lOCKNUT7N·m(0.7 kgf·m, 5 IbHt)

ADJUSTER

2. Shift to [ffi position, then remove the lock pin fromthe adjuster.


'%hMMN Make sure lifts are placed properly (seesection 1).


Shift Cable

14-167

10. Insert the ignition key into the key cylinder on theAIT gear position indicator panel, and verity that theshift lock lever is released.

9. Start the engine, and check the shift lever in ailgears. If any gear does not work properly, refer totroubleshooting (see page 14-92 and 14-93).

8. Move the shift lever to each gear, and verity that theshift position indicator follows the automatic transaxle gear position switch.

7. Make sure the lock pin is seated in the adjustersecurely.

6. Install the lock pin on the adjuster. If vou feel thelock pin binding as vou reinstall it, the cable is stillout of adjustment and must be readjusted.

5. Tighten the locknut to 7 N·m (0.7 kgf·m, 51bf·ft)_

4. If the hole is not perfectly aligned, loosen the locknut on the adjuster and adjust as required.

ExactAlignment

CableToo Long

CableToo Short

O'_

SHIFTCABLE

ADJUSTER

3. Check that the hole in the adjuster is perfectlyaligned with the hole in the shift cable. There aretwo holes in the adjuster. They are positioned 90°apart to allow cable adjustment in 1/4 turn increments.

LOCKNUT7 N'm (0.7 kgf·m,S Ibf.ft)

ADJUSTER

2. Shift to [ill position, then remove the lock pin fromthe adjuster.


*;\I,f.Wih1!; Make sure lifts are placed properly (seesection 1).

Adjustment

14-168

6x1.0mm9.8 N'm (1.0 kgf·m. 7.2Ibf·ft)

SHIFT LEVER BRACKETBASE COLLAR

SHIFT LEVER BRACKET BASE

SCREW3 N'm (0.3 kgf·m.21 Ibf·ft)

AIT GEAR POSITION SWITCH

....umtt / LOCKPIN

~@~------ADJUSTER

SHIFT LEVER ASSEMBLY

SHIFT LOCKSOLENOID

LEVER COVER

PUSH KNOB~ / PUSH KNOB SPRING

/

~~ /SHIFTLEVER KNOB

/ SCREW

_--fiiÏéSILICONE GREASE

6x 1.0mm9.8 N'm (1.0 kgf·m.7.2Ibf.ft)

Shift Lever

14-169

TRANSMISSION CLIP

1. Connect the ATF cooler hoses to the ATF cooler linesand ATF cooler, and secure them with the clips asshown.

NOTE: Whenever the shift indicator panel is removed,reinstall the panel as described above.

3. Remove the shift indicator panel mounting screwsand adjust by moving the panel.

2. If not aligned, remove the front console (see section20).

SHIFT INDICATORPANEL

MOUNTING SCREW3 N'm (0.3 kgf'm, 2 Ibf-ft]

INDEX MARK

1. Check that the index mark on the shift lever alignswith the 00 mark on the shift indicator panel whenthe transmission is in NEUTRAL.

ConnectionAdjustment

ATF Cooler HosesShift Indicator Panel

Manual Transmission section 13Automatic Transmission section 14

Differentiai

Special Toois 16-2DriveshaftsInspection 16-3Removal 16-3Disassembly 16-5Reassembly 16-7Installation 16-10

Driveshafts

16-2

Ref. No. Tooi Number Description Oty PageReference

<D 07MAC - SLOO200 Bali Joint Remover, 28 mm 1 16-4

~

CD

Special Toois

1

16-3

(cont'd)

7. Remove the damper fork.

SELF-LOCKING NUT12x 1.25mmReplace.

DAMPERFORKCheckfor damage.

FLANGE BOLT10 x 1.25mm

6. Remove the self-Iocking nut and flange bolts.

5. Raise the locking tab on the spindle nut, thenremove the nut.

22x 1.5mmReplace.

4. Drain the transmission fluid (seesection 13 or 14).

FRONTWHEEL

3. Remove the wheel nuts and front wheels.WHEELNUT12x 1.5mm

2. Raise the front of the vehicle, and support it withsafety stands in the proper locations (seesection 1).

1. Loosen the wheel nuts slightly.

BOOTBANDS

OUTBOARD BOOTINBOARD BOOT

DRIVESHAFT

Twisted or CrackedMake sure the driveshaft is not twisted or cracked.Replaceit if necessary.

LooseSplinesTurn the driveshaft by hand and make sure the splinesand joint are not excessively loose. If any damage isfound, replace the inboard joint.

Driveshaft BootCheck the boots on the driveshaft for cracks, damage,leaking grease and loose boot bands. If any damage isfound, replace the boot and boot bands.

RemovalInspection

Driveshafts

DRIVESHAFT

KNUCKLE

13. Pull the knuckleoutward, and removethe driveshaftoutboard joint from the front wheel hub using aplastic hammer.

SCREWDRIVER

INBOARDJOINT

CAUTION:• Do not pull on the driveshaft; the inboard joint

may come apart .• Use care when prying out the assembly, and pull

it straight to avoid damaging the differential oilseal.

12. Pull the inboard joint, and remove the driveshaftfrom the differential caseasanassembly.

16-4

3.5mm (0.14in)

SCREWDRIVER

11. Pry the driveshaft assemblywith a screwdriver, asshown, to force the set ring at the driveshaft endpastthe groove.

NOTE: If necessary,apply penetrating type lubricant to foosenthe bail joint.

CAUTION: Be careful not to damage the bail jointboot.

10. Usethe specialtool as shown in section 18,to separatethe bail joint and lower arm.

9. Install a 12 mm hex nut on the bail joint. Be surethat the hex nut is flush with the bail joint pin end,or the threadedsectionof the bail joint pin might bedamagedby the specialtoof.

LOWERARMHEXNUT ~

CASTLENU~~

12X1.25mm/ .COTTERPIN BALLJOINTREMOVER,28mmReplace. 07MAC- SL00200

8. Removethe cotter pin from the lower arm bail jointcastlenut, and removethe nut.

Removal (cont'd)

Driveshafts

16-5

(cont'd)

Marks

INBOARD JOINTCheck splines for wear or damage.Check inside bore for wear.Inspact for cracks.

NOTE: Be careful not to drop the rollers when separating them from the inboard joint.

3. Mark each roller and inboard joint to identify thelocations of rollers and grooves in the inboard joint.Then remove the inboard joint on the shop towel.

- If the boot band is the crimping type, pry up theend of the band with a screwdriver.

\

BOOTBANDReplace.

/

BOOTBAND

- If the boot band is the welded type, cut it off asshown.

SET RINGReplace.

NOTE: Carefully clamp the driveshaft in a vise withsoft jaws.

CAUTION: Take care not to damage the boot.

2. To remove the boot band, pry up the locking tabswith a screwdriver and raise the end of the band.

1. Remove the set ring from the inboard joint.

Disassembly

OUTBOARDJOINT

13. Inspect the outboard joint for faulty movement andwear. If any roughness or excess play is felt, replacethe outboard joint.

12. Remove the boot bands and outboard boot, thenremove the vinyl tape.

CAUTION: Take care not to damage the dynamicdamper.

11. Remove the dynamic damper band and dynamicdamper, if equipped.

CAUTION: Take care nat ta damage the boat.

10. Remove the boot band and inboard boot.

DYNAMICDAMPERBAND

Inspect for cracking, BOOTBANDsplitting and wear. Replace.

Checkfor damage.INBOARDBOOT

9. Wrap the splines on the driveshaft with vinyl tape toprevent damage to the boots and dynamic damper.

DYNAMICDAMPER

16-6

8. Remove the stop ring.

7. Remove the spider using a bearing remover.

6. Mark the spider and driveshaft to identify the position of the spider on the shaft.

5. Remove the circlip.

STOPRING

BEARINGREMOVER(Commerciallyavailable)

4. Mark the rollers and spider to identify the locationsof rollers on the spider, then remove the rollers.

Disassembly (cont' d)

Driveshafts

16-7

(cont'd)

OUTBOARDJOINT

Packcavity with grease.

DYNAMICDAMPERBANDReplace.

BOOTBANDSReplace.

DYNAMICDAMPER

SETRINGReplace. INBOARDJOINT

~~

115 - 135 9 (4.0 - 4.8 oz)Outboard Joint120 - 130 9 (4.2 - 4.6 oz)Inboard Joint

Greasequantity:

NOTE: Clean the disassembled parts with solvent, and dry them throughly with compressed air. Do not wash the rubberparts with solvent.

-~ : Thoroughly packthe inboard joint and both joint boots with the joint grease included in the new driveshaft set.

Reassembly

NOTE:• Reinstall the rollers in their original positions on

the spider by aligning the marks.• Hold the driveshaft pointed up to prevent the

rollers from falling Off.~ .. ~

SPIDERROUERHigh shoulder facestoward outside

7. Fit the rollers to the spider with their high shouldersfacing outward.

NOTE: AIways rotate the circlip in its groove to besure it is fully seated.

Fit the circlip into the driveshaft groove.6.

Install the spider on the driveshaft by aligning themarks on the spider and end of the driveshaft.

5.

Mark

NOTE: Always rotate the stop ring in its groove tobe sure it is fully seated. 0.---CIRCUP

Mark~ ti.ZD SPIDER

~STOP RING

Install the stop ring into the driveshaft groove.4.

16-8

Grease quantity:115-135 g (4.0- 4.8 oz)

3. Packthe outboard joint with the joint grease includedin the new driveshaft set.

CAUTION: Take care not to damage the boots anddynamic damper.

INBOARD BOOT2. Install the outboard boot, dynamic damper and

inboard boot to the driveshaft, then remove thevinyl tape.

1. Wrap the splines with vinyl tape to prevent damageto the boots and dynamic damper.

~TAPE OUTBOARD BOOT

Reassembly (cont'd)

Driveshafts

16-9

(cont'd)

12. Lightly tap on the doubled-over portions to reducetheir height.

BOOTBAND

11. Install new boot bandson the boots, and bend bothsetsof lockingtabs.

1 1· 1

~~

Left driveshaft: 773.1 - 778.1 mm (30.44 - 30.63 in)Right driveshaft: 500.6 - 505.6 mm (19.70 -19.91 in)

NOTE:The ends of boots seat in the groove of thedriveshaft and joint.

10. Adjust the length of the driveshafts to the figurebelow, then adjust the boots to halfway betweenfull compressionand full extension.

INBOARDJOINT

NOTE:• Reinstallthe inboard joint onto the driveshaft by

aligning the marks on the inboard joint with themarkson the rollers.

• Hold the driveshaft so the inboardjoint points upto prevent it from falling off.

9. Fit the inboard joint onto the driveshaft.

Grease quantity:120 -130 9 (4.2 - 4.6 oz)

8. Pack the inboard joint with the joint grease includedin the new driveshaft set.

SET RINGReplace.

16-10

Right:55± 2mm (2.2± 0.1in) CAUTION:Always use a new set ring wheneverthe driveshaft is being installed.

2. Install the newset ring onto the driveshaftgroove.

OUTBOARD JOINT

KNUCKLE

1. Install the outboardjoint into the knuckle.

DYNAMIC DAMPERBAND

... ; .'...:~:~.//,~~

INBOARDBOOTDYNAMIC DAMPER

Left:75± 2mm (2.9± 0.1in)

13. Positionthe dynamicdamperasshownbelow.• Install a new dynamic damper band, and bend

down both setsof lockingtabs.• Lightly tap on the doubled-over portion of the

bandto reduceits height.

InstallationReassembly (cont'd)

Driveshafts

16-11

8. Installthe front wheelwith thewheel nuts.NOTE:Beforeinstallingthewheel,clean the matingsurfacesof the brakediseandthewheel.

9. Tighten the flange bolts and the new self-Iockingnutwith the vehicle'sweight on the damper.

10. Retill the transmissionwith recommendedtluid (seesection13or 14).

11. Checkthe front wheel alignment and adjust if necessary(seesection18).

SPINDLE NUT 22 x 1.5 mm181 N'm (18.5 kgf·m, 134 IbHtl

FRONTWHEEL

6. Loosely install the flange bolts and the new selflockingnut.NOTE:The bolts and nut should be tightened withthe vehicle'sweight on the damper.

7. Installa newspindlenut, then tighten the nut.

SELF-LOCKING NUT12x 1.25 mm64 N·m (6.5 kgf·m. 47 IbHt)Replace.

FLANGEBOLT10 x 1.25 mm43 N·m (4.4 kgf·m. 32 IbHt)

DAMPERFORKAUGNINGTAB

5. Install the damperfork over the driveshàftand ontothe lower arm. Install the damper in the damperfork 50 the aligning tab is aligned with the slot inthe damperfork.

COTTER PINReplace.On reassernblv,bend the catter pinas shawn.

CASTLE NUT12 x 1.25 mm49 - 59 N·m (5.0 - 6.0 kgf·m.36 - 43 IbHt)

CAUTION:• Becarefulnot to damagethe bail joint boot.• Torquethe castle nut to the lower torque speci

fication, then tighten it only far enoughto atignthe slot with the pin hole. 00 not atign the nutby loosenlnq,

NOTE:Wipe off the grease before tightening thenut at the bail joint.

4. Install the knuckleon the lower arm, then tightenthe castlenut and install a newcotterpin.

NOTE:Cleanthe areaswhere the driveshaftcontactthe transmission(differential)thoroughlywith solventor carburetorcleaner,anddrywith compressedair.INBOARD JOINT

3. Insert the inboard end of the driveshaft into the differential until the set ring locksin the groove.

*Steering ColumnRemovai/lnstailation 17-19Inspection 17-20Steering Lock Replacement 17-21

Power Steering Hoses, Unesfluid Leakage Inspection 17-22Replacement 17-22

Power Steering PumpReplacement 17-23Disassembly 17-24Inspection 17-25Reassembly 17-27

Power Steering GearboxRemoval 17-30Disassembly 17-32Reassembly 17-38Installation 17-48Bali Joint Boot Replacement 17-50

Special Toois 17-2Component Locations

Index 17-3Troubleshooting

General Troubleshooting 17-4Noise and Vibration 17-8fluid Leaks 17-10

Inspection and AdjustmentSteering Operation .....•.................... 17-12Power Assist Check

With vehicle Parked 17-12Steering Linkage and Gearbox 17-13Pump Belt 17-14Rack Guide Adjustment 17-15fluid Replacement 17-15Pump Pressure Check 17-16

*Steering WheelRemoval 17-17Installation 17-17Disassembly IReassembly 17-18

Steering

NOTE: The original radio has a coded theft protection circuit. Be sure to get the customer's code number before- disconnecting the battery.- removing the No. 47 (7.5 A) fuse trom the under-hood fuse/relay box.- removing the radio.After service, reconnect power to the radio and turn it on. When the word "CODE" is displayed, enter the customer's5-digit code to restore radio operation.

i!SWWMiN• To avoid rendering the SRS inoperative, which couJd Jead to personal injury or death in the event of severe

frontal collision, ail SRS service work must be performed by an authorized Acura dealer.• Improper service procedures, including incorrect removal and installation of the SRS, could lead to personal

injury caused by unintentionaJ activation of the airbags.• Do not bump the SRS unit. Otherwise, the system may fai! in case of a collision, or the airbags may deploy

when the ignition switch is ON (11).• Ali SRS electrical wiring harnesses are covered with yellow insulation. Related components are Jocated in the

steering column, front consolé, dashboard, dashboard lower panel, and in the dashboard above the glove box.Do not use electrical test equipment on these circuits.

The Acura 1.6EL SRS includes a driver's airbag located in the steering wheel hub, and a passenger's airbag locatedin the dashboard above the glove box. Information necessary to safely service the SRS is included in this ServiceManual. Items marked with an asterisk (*) on the contents page include, or are located near, SRS components.Servicing, disassembling or replacing these items will require special precautions and tools, and should therefore bedone by an authorized Acura dealer.

SUPPLEMENT AL RESTRAINT SYSTEM (SRS)(If the steering wheel and steering column maintenance are required)

,.,. ........

§ 0» U ~b;d)q• ~3 14 (IJ. (j6 :17

~ E1~~

Ci (9) @ @ @

(6)®

Ref. No Tooi Number Description Oty Page Reference

CD 07GAF - PH70100 Pilot Cailar 17-37® 07GAG - S040100 or Piston Seal Ring Guide 17-42

07GAG - S04010A@ 07GAG - S040200 or Piston Seal Ring Sizing Tooi 17-42

07GAG - S04020A@ *07JGG - 001010A Belt Tension Gauge 17-14CID 07MAC - SL00200 Bali Joint Remover, 28 mm 17-30® 07NAO - SR3020A Cylinder End Seal Remover Attachment 17-34(J) 07NAG - SR30900 or Piston Seal Ring Sjzjng Tooi 17-39

07NAG - SR3090A® 07RAK - S040110 PIS Joint Adaptor (Purnp) 17-16® 07RAK - S040120 PIS Joint Adaptor (Hase) 17-16@ 07406 - 0010001 PIS Pressure Gauge 17-16® 07725 - 0030000 Universal Holder 17-25,29@ 07746 - 0010100 Attachment, 32 x 35 mm 17-40,41@ 07746 - 0030300 Attachment, 30 mm 1.0. 11-27@ 07749 - 0010000 Driver 17-40@ 07916 - SA50001 Locknut Wrench, 40 mm 17-15@ 07974 - SA50200 or Sleeve Seal Ring Sizing Tool 17-40

07974 - SA5020A@ 07974 - SA50800 Bail Joint Boat Clip Guide 17-50, 40

* Included in the Belt Tension Gauge, 07TGG - 001000A.

17-2

1

Special Tools

17-3

TIE-RODEND BALL JOINT8all Joint 800t Replacement, page 17-50

POWERSTEERINGPUMPPump 8elt Inspection, page 17-14Pump Belt Adjustment. page 17-14Pump Pressure Check, page 17-16Replacement, page 17-23Disassembly/Reassembly, page 17-24

STEERINGCOlUMNRemoval/lnsta"ation, page 17-19Inspection, page 17-20CABLE REELRemoval/lnstallation, see section 24IGNITION SWITCHSee section 23

POWERSTEERINGGEARBOXRack Guide Adjustment, page 17-15Removal, page 17-30Disassembly, page 17-32Reassembly, page 17-38Installation, page 17-48VALVE BODY UNITOverhaul, page 17-35

STEERINGWHEELRemovai/lnstailation, page 17-17Disassembly/Reassembly, page 17-18DRIVER'S AIRBAG ASSEMBLyRemoval/lnstallation, see section 24

SRScomponents are located in this area. Review the SRScomponent locations, precautions, and procedures in the SRSsection (24) before performing repairs or service.

NOTE:• If an intact airbag assembly has been removed from a scrapped vehicle or has been found defective or damaged dur

ing transit, storage or service, it should be deployed (seesection 24).• Before removing the gearbox, remove the driver's airbag assembly and steering wheel.• After installing the gearbox, checkthe wheel alignment and adjust if necessary.

Index

Component Locations

17-4

Faulty flow control valve(Replace the pump as anassembly)

Faulty pump assembly

jjAbnormalNormalNormal relief pressure

jGo to page 17-5

Check the flow control valve (see page 17-25).• Check the valve for smooth movement in the housing.

• Check the relief valve for leaks.

Relief pressuretoolow --~

Check the pump fluid pressure(see page 17-16).Measure pump relief pressurewhile idling with the pressure control valve fully closed.It should be 6,400 -7,400 kPa (65-75 kgf/cm2, 920 - 1,070 psi)

Faulty valve body unit

Normal lNormalline and hose

Check the feed and return circuit lines and hose betweenthe gearbox and pump for clogging and deformation.

Abnormal fluidpressure(fluid pressureis too high)

Hard Steering: Check the power assist (see page 17-12).1 If the force is over 29N (3.0 kgf, 6.6 Ibf), procede with this troubleshooting.

Check the pump fluid pressure(see page 17-16).Measure steady-state fluid pressure while idling with the bothvalves fully open.It should be 1,500 kPa (15 kgf/cm2,

213 psi) or less.

Checkthe following before vou begin:• Has the suspension been modified in a way that would affect steering?• Are tire sizes, tire variety and air pressure correct?• Is the steering wheel original equipment or equivalent?• Is the power steering pump belt properly adjusted?• Is steering fluid reservoir filled to proper level?• Is the engine idle speed correct and steady?

General Troubleshooting

Troubleshooting

17-5

(cont'd)

Improperly adjustedrackguide

Checkthe parts other than the gearbox-relatedparts forproper rotation.• Improper rotation of the steeringcolumn-relatedpartes)• Faultysteeringjoint• Faulty rackend/tie-rodend bail joints• Interferencein the steeringsystem

Faultyvalvebody unit

AdjustmentOK

Not bent ---~

Faultycylinder lines

Deformed

l

Faultygearbox

Checkrackguide adjustment (taotight).

Checkfor bent rackshaft.

..--------- Not deformed

Checkcylinder lines A and 8 fordeformation.

Normal

Normal

Abnormall

Faultygearboxl

Abnormal

Adjust the rack guide (see page17-15), and recheck the piniontorque.

1Abnormal

~

Checkthe gearbox.Remove the gearbox and measurethe pinion torque.Thetorque should be;• 0.7- 1.2N·m(7 - 12kgf·cm,6-10 Ibf·in)with the steering rackin the straight driving position.

• 1.3 N·m (13 kgf·cm, 11.3 lbf-in)with the steering rack in anyother position.

1Normal

~

Checkpump fluid pressure (seepage17-16).Turnthe steeringwheelfully to theright and left while idling with thepressurecontrol valve fully open,andmeasurethefluid pressure.It shouldbe6,400- 7,400kPa(65-75kgf/cm2,920- 1,070psi).

1Normal

!

Check the force required ta turnthe wheel (see page 17-12).Start the engine and measure theforce required ta turn the wheelta the right and left. Difference of f---- Abnormalthe force required to turn thewheel to the right and to the leftshould be 2.9 N (0.3 kgf, 0.7 Ibnor less.

If the problem is not corrected byadjusting the rack guide, replacethe gearbox.

l

If the measurements are out ofspecifications, adjust the rackguide.

• It should be 0.7 - 1.2 N'm (7 -12 kgf-cm, 6 - 10 Ibf.in) or lesswith the steering rack in thestraight ahead driving position.

• 1.3 N-m (13 kgf·cm. 11.3 Ibf·in)with the steering rack in anyother position.

Wheel alignment is normal.Remove the gearbox from theframe and measure the pin iontorque on the gearbox.

l

A and B cylinder lines are normal, check wheel alignment (seesection 18). H Wheel alignment is abnormaJ,

adjust as needed.L...--- __

~-------~-------~

A or B cylinder line is deformed;replace it.

Check cylinder lines A and B fordeformation.

17-6

Steering wheel will not returnsmoothly. -------,

J Check the rack guide for proper Rack guide was backed off exces-

1adjustment (see page 17·15). sively.

J1

Adjust the rack guide.

lRack guide is adjusted properly.

l If the problem is not corrected byadjusting the rack guide, replace

Check the belt for slippage and the gearbox.

adjust as necessary (see page17-14).

J Check the rack guide for proper 1-----11 adjustment (see page 17·15).

If the problem is not corrected byadjusting the rack guide, adjustthe front wheel alignment (seesection 18).

Shock or vibration when wheel isturned to full lock.

Assist (excessively light steering) athigh speed.

General Troubleshooting (cont'd)

Troubleshooting

17-7

Pump belt slipping on pulley Adjust the belt tension (see page(pump stops momentarily). 17-14)or replacebelt.

Checkif pump pressure is normaland the gauge needle travel is

Install the power steering pressure 500kPa(5 kgf/cmZ, 71 psi) or less.

- gauge. Close the pressure control - Check the flow control valve ifvalve fully and measure the pump the needle travel exceeds500kPapressure(seepage 17-16). (5 kgf/cm2, 71 psi). If the flow

control valv.e is normal, replacethe pump as an assembly.

Steering wheel kicks backduring wide turns.

J Improperly adjusted rack guide. Adjusttherack guide(seepage17-15).1

1

If the problem is not corrected byadjusting the rack guide, replacethe gearbox.

~ Belt slipping on pulley. Adjust the belt tension.Replacethebelt. if necessary(seepage17-14).

If the engine stalls when the

H 1 wheel is turned while the vehicleIdle speed low or erratic.

1is stopped or moving at lowspeed, adjust the idJespeed (seesection 11).

Checkpower steering fluid Jevel.If

~Air in reservoir, or check power

~the level is excessively low, check

steering fluid level. for leaks in the system. Add f1uidto the specitiedlevel.

1If fluid level is OK, check O-ringsand seals on both ends of thepump inlet hose, and the PISpump housing mating surfacesand the pump shaft oil seal forsuction leaks. Replace parts asnecessary.

Uneven or rough steering.

CAUTION: When inspecting, do not hold the steering wheel ail the way tothe right or the left.

Pump noise, though not loud, from the valve body unit can be heard when turning the steering wheel right or left. This is normal.

Rattling sound and feeling when turning the steering wheel right and left with theengine OFF is the sound when the valve body unit contacts the stop. This is normal.

Adjust, if necessary.Check the rack guide for properadjustment (see page 17-15).

Replacethe column assembly.Column shaft wobbling.

Check and tighten, or replaceparts as necessary.

Loose steering shaft connector,tie-rod, or bail joint.

1Reposition the line.

High-pressure line touching theframe.

.._____--,

1

If equipped with automatic transmission, the hum could be thetorque converter or pump noise .

Confirm by temporarily removing 1the pump belt.

J

Humming due to pulsation of fluid is normal, particularly when the wheel is 1turned with the vehicle stopped.

17-8

Hissing ---------------i

Rattle or chattering -------.,.-----1

1---

Humming ------------r---i

NOTE: Pump noise in first 2 - 3 minutes after starting in cold weather is normal.

Noise and Vibration

Troubleshooting

17-17

6. Check the horn and cruise control switches forproper operations.

5. Install the driver's airbag assembly, and confirmproper systemoperation (seesection24).

4. Connectthe horn connector.

3. Attach the cruise control switches connectorto thesteeringwheel clip.

STEERING WHEEl

NOTE: Be sure the steering wheel shaft engagesthe cable reel and cancelingsleeve.

2. Install the steering wheel with the steering wheelnut.

ARROWMARK

1. Before installing the steering wheel, center thecable reel. Do this by first rotating the cable reelclockwise until it stops. Then rotate it counterclockwise approximately two turns. The arrow mark onthe cable reellabel should point straight up.

NOTE: Before installing the steering wheel, align thefront wheels straight ahead.

CAUTION:Do not tap on the steeringwheel or steeringcolumn shaft when installing the steeringwheel.

4. Removethe steeringwheel by rockingit slightly fromside-to-sideasyou pull steadilywith both hands.

STEERING WHEEl NUTReplace.49 N·m (5.0kgf·m, 36 Ibf.ft)

3. Removethe steeringwheel nut.

2. Disconnectthe horn connector and cruise controlswitchesconnector.

1. Remove the driver's airbag assembly from thesteeringwheel (seesection24).

NOTE: Before removing the steering wheel, align thefront wheelsstraight ahead.

SRScomponents are located in this area. Review theSRScomponent locations, precautions,and proceduresin the SRSsection(24)before performing repairsor service.

InstallationRemoval

Steering Wheel

17-10

J Leaking from cylinder line A or B Tighten the connector. It it's still

connections (at flare nut). leaking, replace the line, cylinderor valve housing.

~Leaking caused by a damaged Replace cylinder line A or B.

1cylinder line A or B.

Leaking trom feed line and return Tighten the connector. If it's still- line joint fitting on the valve bodv leaking, replace the line, joint fit-

unit (at flare nut). ting or valve housing.

Lines

Replace the valve bodv unit.Leaking from the shaft upper endsection or pin engagement section of the pinion shaft.

Replace the cylinder end seal onthe cylinder end side.

Leaking trom cylinder end intoright tie-rod boot.

Replace the cylinder end seal onthe gear housing side.

Replace the valve oil seal tromthe pinion shaft.

leaking trom cylinder end intoleft tie-rod boot.

Replace the valve oil seal fromthe valve housing.

Leaking from the oil seal on thetop of the valve housing.

Steering Gearbox --------..----1

Check the gearbox assembly for oil leaks carefully. Oil can leak out of various points, depending on location of the faultyoil seals/seal rings. Check the following before removing the gearbox from the frame.

Fluid leaks

Troubleshooting

17-11

Replaceor repair as necessary.leaking becauseof damage, deterioration, or improper assembly.Pump inlet line ------------1

(low-pressure)

Replacethe pump outlet hose.J1~ Leaking at the swagged joint.

Tighten the fitting. If it's stillleaking, replace the O-ring or pumpoutlet hose.

Pump outlet hose --------..,.----il Leaking at the threaded fitting. }--(high-pressure) L- --'

Reservoir is overfilled.1 11 Leaking from around cap. J Pull off the hose and drain the

reservoir to the proper level.

Air leak in suction side of the sys-L..- tem (reservoir, inlet hose, front

pump sea!).

Reservoir

Pump 1 Front sealleaking. 1 Replacefront seal.1 1

~Pump housing leaks at either l Replacethe housing O-rings.

end. J If the housing still leaks, replacethe pump.

4. The scale should read no more than 29 N (3.0 kgf,6.6 Ibf). If it reads more, check the gearbox andpump.

(Commerciallyavailable)

3. Attach a spring scale to the steering wheel. With theengine idling and the vehicle on a dean, dry floor,pull the scale as shown and read it as soon as thetires begin to turn.

2. Start the engine, allow it to idle, and turn the steering wheel from lock-to-lock several times to warmup the fluid.

1. Check the power steering f1uid level (see page 17-15) and pump belt tension (see page 17-14).

Power Assist Check withVehicle Parked

17-12

ROTATIONAL PLAY

If the play exceeds the service limit, perform rack guideadjustment (see page 17-15).If the play is still excessive after rack guide adjustment,inspect the steering linkage and gearbox as describedon the next page.

ROTATIONALPLAY:0 -10 mm (0 - 0.39 in)

Place the front wheels in the straight ahead position,and measure the distance the steering wheel can beturned without moving the front wheels.

Steering Operation

Inspection and Adjustment

17-13

BALL JOINT BOOTInspect for damage and deterioration.Seepage 17-50for replacement.

Inspect for loose mounting bolts.GEARBOX MOUNTING CUSHIONSInspect for deterioration.

PINION SHAFT GROMMETInspect for damage and deterioration.

TtE-ROD END BALL JOINT

STEERING COLUMN

Steering Linkage and Gearbox

3. 5tart the engine and turn the steering wheel fromlock-to-lockseveraltimes, then stop the engineandrecheckthe deflectionof the belt.

2. Adjust the belt tension by moving the power steering pumpwith a 1/2" drive breakerbar to obtain theproper belt tension, then retighten the mountingbolts.

PUMP MOUNTING BOLT24 N'm (2.4 kgf-m, 17 Ibf.ftl

PUMP MOUNTING BOLT24 N·m (2.4 kgf'm, 17Ibf.ft)BREAKER BAR

1. Loosenthe powersteeringpumpmounting bolts.

Adjustment

17-14

Measure here.

Detlection:UsedBelt:10.5-14.0 mm (0.41- 0.55 in)New Belt: 7.5 - 10.0mm (0.30- 0.39 in)

~_- POWER STEERING PULLEY

Measurementwithout BeltTensionGauge:Applya force of 98 N (10 kgf, 22 Ibf) and measurethedeflection between the power steering pump and thecrankshaftpulleys.

Inspectthe pump belt for cracksor any damage.Replacethe belt with a newone if necessary.

Tension:UsedBelt:340 - 490N (35- 50 kgf, 77 -110 Ibf)New Belt: 640 -780 N (65- 80 kgf, 143-176Ibf)NOTE:• If there arecracksor any damageevidenton the belt,

replaceit with a newone.• Followthe manufacturer'sinstructionsfor the tension

gauge.

Attach the special tool to the belt and measurethe tension of the belt.

Inspection

NOTE:When usinga newbelt, first adjust the deflectionor tension to the values for the new belt, then readjustthe deflection or tension to the values for the used beltafter running enginefor five minutes.

Pump Belt


17-15

3. Start the engine, let it run at idle, and turn the steering wheel from lock-to-Iock several times. Whenfluid stops running out of the hose, shut off theengine.Discardthe fluid.

4. Refit the return hoseon the reservoir.5. Fill the reservoir to the upper level line.6. Start the engine and run it at fast idle, then turn the

steering from lock-to-lockseveral times ta bleed airtram the system.

7. Recheckthe fluid levelandadd some if necessary.CAUTION: Do not fill the reservoir beyond theupper levelline.

1. Raisethe reservoir,then disconnectthe return hose.2. Connect a hose of suitable diameter to the discon

nected return hose,and put the hose end in a suitable container.CAUTION: Take care not to spill the fluid on thebody and parts. Wipeoff anyspilled fluid at once.

Checkthe reservoir at regular intervals,and add fluid asnecessary.CAUTION:Always useGenuineHONDAPowerSteeringFluid-V or S. Using any other type of power steeringfluid or automatic transmissionfluid cancauseincreasedwear andpoor steering in coldweather.SYSTEMCAPACITY:

0.85liter (0.90US.qt, 0.75Imp.qt)at disassembly

RESERVOIRCAPACITY:0.4 liter (0.42US.qt, 0.35Imp.qt)

~ -.~\~,.~ .':;he:~\ //.'-~

<S '.\ /~ _J__ UPP~R LEVEL UNE

.~,.....-----..."......-~~~~ .. ~-: .: -x.' ,""~

p---. -. LOWER LEVEL UNE~.

• Steeringoperation (seepage17-12).• Powerassistwith vehicle parked.

6. Performfollowing inspections:

5. Checkfor tight or loose steering through the completeturning travel.

4. Tighten the locknut while holding the rack guidescrew.

SpecifiedReturnAngle: 20°max.

3. Retightenthe rackguide screwto 3.9N·m(0.4 kgf·m,2.9 Ibf.ft), then backit off to specifiedangle.

2. Tighten the rack guide screw to 25 N·m (2.5kgf·m,18 Ibf.ft), then loosen it.

1. Loosenthe rack guide screw locknut with the special tool, then loosen the rackguide screw.

NOTE: Perform the rack guide adjustment with thewheels in the straight aheadposition.

Fluid ReplacementRack Guide Adjustment

SHUT-OFF VALVE

If the pump is in good condition, the gauge shouldread at least 6,400 - 7,400 kPa (65 - 75 kgf/cm2, 920 -, ,070 psi). A low reading means pump output is toolow for full assist. Repair or replace the pump.

PIS PRESSURE GAUGE07406 - 0010001

CAUTION: Do not keep the pressure control valveclosed more then 5 seconds or the pump could bedamaged by over-heating.

10. Immediately open the pressure control valve fully.

9. Close the pressure control valve, then close theshut-off valve gradually until the pressure gaugeneedle is stable. Read the pressure.

8. Measure steady-state fluid pressure while idling. Ifthe pump is in good condition, the gauge shouldread less than 1500 kPa (15 kgf/cm2, 213 psi).If it reads high, check the outlet hose or valve bodyunit (see General Troubleshooting 17-4).

7. Turn the steering wheel from lock-to-lock severaltimes to warm the fluid to operating temperature.

6. Start the engine and let it idle.

17-16

5. Open the pressure control valve fully.

4. Open the shut-off valve fully.

PIS JOINT ADAPTOR (PUMP)07RAK - S040110

6mmNUT(Part of tooll11 N'm(1.1 kgf·m, 8Ibf.ft)

s x 1.0 mm BOLT(Part of tool)

OUTLET HOSE FITTING

3. Install the power steering pressure gauge to the PISjoint adaptor (pump) as shown.

2. Connect the PIS joint adaptor (hase) to the powersteering pressure gauge, then conrrect the outlethose ta the adaptor.

1. Disconnect the pump outlet from the pump outletfitting, then install the PIS joint adaptor (pump) onthe pump out let.

CAUTION: Disconnect the high pressure hose with careso as not to spill the power steering fluid on the frameand other parts.

NOTE: First check the power steering fluid level andpump belt tension.

Check the fluid pressure as follows to determinewhether the trouble is in the pump or gearbox.

Pump Pressure Check


17-17

6. Check the horn and cruise control switches forproper operations.

5. Install the driver's airbag assembly, and confirmproper systemoperation (seesection24).

4. Connectthe horn connector.

3. Attach the cruise control switches connectorto thesteeringwheel clip.

STEERING WHEEl

NOTE: Be sure the steering wheel shaft engagesthe cable reel and cancelingsleeve.

2. Install the steering wheel with the steering wheelnut.

ARROWMARK

1. Before installing the steering wheel, center thecable reel. Do this by first rotating the cable reelclockwise until it stops. Then rotate it counterclockwise approximately two turns. The arrow mark onthe cable reellabel should point straight up.

NOTE: Before installing the steering wheel, align thefront wheels straight ahead.

CAUTION:Do not tap on the steeringwheel or steeringcolumn shaft when installing the steeringwheel.

4. Removethe steeringwheel by rockingit slightly fromside-to-sideasyou pull steadilywith both hands.

STEERING WHEEl NUTReplace.49 N·m (5.0kgf·m, 36 Ibf.ft)

3. Removethe steeringwheel nut.

2. Disconnectthe horn connector and cruise controlswitchesconnector.

1. Remove the driver's airbag assembly from thesteeringwheel (seesection24).

NOTE: Before removing the steering wheel, align thefront wheelsstraight ahead.

SRScomponents are located in this area. Review theSRScomponent locations, precautions,and proceduresin the SRSsection(24)before performing repairsor service.

InstallationRemoval

Steering Wheel

17-18

WHEEL LOWER COVER

~~~tc,0-~}

œ~

STEERING WHEEL


Steering Wheel

17-19

COMBINATIONSWITCHASSEMBLY

9. Installation is the reverse of the removal procedure.NOTE:• Make sure the steering joint is connected as follows:

a. Insert the upper end of the steering joint onto thesteering shaft (line up the boit hole with the fiat onthe shaft), and loosely install the upper joint boIt.

b. Slip the lower end of the steering joint onto thepinion shaft (line up the boit hole with the groovearound the shaft), and loosely install the lowerjoint boit.Be sure that the lower joint boit is securely in thegroove in the pinion shaft.

c. Pull on the steering joint to make sure that thesteering joint is fully seated. Then tighten the jointbolts.

• Be sure the wires are not caught or pinched by anyparts when installing the column.

• Make sure the wire harness is routed and fastenedproperly.

• Make sure the connectors are properly connected.

Boft must fine up withgroove around on shaft.

P'NIONSHAFT

~CLAMPS

CLIP

STEERINGJOINT BOLTS22 N'm (2.2 kgf·m, 161bHt)

STEERINGJOINT

RETAININGCOLLARNOTE: Takecare not to let theretaining collar fall out ofposition during installation.

SRS components are located in this area. Review theSRS component locations, precautions, and proceduresin the SRSsection (24) before performing repairs or service.NOTE: Before removing the steering column for SRS,remove the driver's airbag assembly and cable reel (seesection 24).1. Remove the steering wheel (seepage 17-17).2. Remove the driver's dashboard lower coyer and

driver's knee bolster (seesection 20).3. Remove the combination switch assembly from the

steering column shaft by disconnecting the connectors.

4. Disconnect the ignition switch connectors.5. Remove the steering joint coyer.6. Remove the steering joint bolts.7. Disconnect the steering joint by moving the joint

toward the column, and remove it from the columnshaft.

8. Remove the steering column by removing theattaching nuts and boit.


Steering Column

6 mm lOCK BOLT9.8 N·m (1.0 kgf-m, 7 IbHt)

... 11..-10 mm (0.4 in)

ruT LOCKBOLTTighten the lock boit withthe tilt lever raised.

SPRINGSCALE(Commerciallyavailable)

17-20

CAUTION: Be careful not to loosen the tilt leverwhen installing the stop or tightening the 6 mmlock boit.

a. Loosen the tilt lever, and set the steering columnin the neutral position.

b. Remove the 6 mm lock boit and remove the stop.c. Adjust the preload by turning the tilt lock boit left

or right.d. Pull up the tilt lever to the uppermost position,

and install the stop. Check the preload again. Ifthe measurement is still out of specification,repeat the above procedures "a" through "c" toadjust.

2. If the measurement is out of the specification,adjust the preload using the following procedures.

Preload: 70 - 90 N (7 - 9 kgf, 15 - 20 Ibn

1. Move the tilt lever trom the loose position to the lockposition 3 to 5 times; then measure the tilt leverpreload 10 mm (0.4 in) trom the end of the tilt lever.

SLiDINGCAPSUlE---..I.~ •This part is attachedto the column bracketwith the plastic injections.

See section 23.

• Check the steering column bail bearing and the steering joint bearings for play and proper movement. Ifthere is noise or if there is excessive play, replace thesteering column as an assembly.

• Check the retaining collar for damage. It it is damaged, replace the steering column as an assembly.

• Check the -absorbing plates, absorbing plate guidesand sliding capsules for distortion or breakage. ABSORBINGPLATESReplace them as an assembly if they are distorted orbroken.

Inspection

Steering Column

17-21

1WIST-OFF PORTION

SHEAR BOlT

7. Tighten the shear bolts until the hex heads twist off.

6. Insert the ignition key, and check for proper operation of the steering wheel lock and that the ignitionkey turns freely.

5. Loosely tighten the new shear bolts.

4. Install the switch body without the key inserted.

3. Remove the shear bolts from the switch body.

CAUTION: Do not damage the switch body wh enremoving the shear bolts.

2. Center punch each of the two shear bolts, and drilltheir heads off with a 5 mm (3/16 in) drill bit.

1. Remove the steering column (see page 17-19).

Steering Lock Replacement

2.5-5.5 mm(0.01 - 0.22 in)

HOSECLAMP:• Positionthe hoseclampsat the points indicatedby (b)

in the drawing above.• Siide the haseover the line until it contactsthe stop.

CAUTION:Check ail clamps for deterioration or detormation; replace with the clamps new ones if necessary.

GEARBOX and VALVE BODY UNITCheck for leaks at the mating surfaceand flare nut connections.

VALVE BODY UNIT-to-CYUNDER UNES17 N-m (1.7 kgf-m, 121bf.ftl

VALVE BODY UNIT-to-PUMP OUTlET HOSERETURNUNESPump outlet hose: 14 x 1.5 mm flare nut37 N'm (3.8 kgf·m, 27 IbHt)Retum Une Joint: 16 x 1.5 mm flare nut26 N'm 12.7kgf·m, 20 Ibf.ft)

17-22

2.0-4.0 mm(0.08- 0.16 inl

2.5-5.5 mm(0.01 - 0.22 inl

ADJUSTABLE HOSE CLAMP:• Position the adjustable hose clamps at the points

indicated by (a) in the drawing above.• Siide the hoseover the line until it contactsthe stop.

NOTE:• Connecteachhoseto the correspondingline securely

until it contacts the stop on the line. Install the clampor adjustableclampat the specifieddistancefrom thehoseend as shown.

• Add the recommended power steering fluid to thespecified level on the reservoirand checkfor leaks.

Replacement

PUMP INLET HOSE(Low-pressure)

Check for leaks at the pumpseal, jnlet and outlet fjttings.

PUMP OUTLET HOSEIHigh-pressure)llN·mlU kgf·m, 8 Ibf.ft)

BOOT

CYUNDER HOUSING-to-CYUNDER UNES28 N'm (2.7 kgf·m, 20 Ibf·ft)

HOSES and UNES• Inspecthasesfor damage,leaks,interferenceand twisting.• Inspect fluid lines for damage,rusting and leakage.• Inspect for leaksat haseand line joints and connections.

POWER STEERING PRESSURE SWITCH12 N'm Il.2 kgf'm, 9lbHt)

Fluid Leakage Inspection

Power Steering Hoses, Lines

17-23

9. Fill the reservoir to the upper level line (see page17-15).

PULLEY

8. Adjust the pump belt (seepage17-14).

POWER STEERtNG PUMP BElT

CAUTION:• Make sure that the power steering belt is prop

erly positioned on the pulleys.• Do not get power steering fluid or greaseon the

power steering belt or pulley faces.Cleanoff anyfluid or greasebefore installation.

7. Install the pump belt.

6. Loosely install the pump in the pump bracketwithmounting bolts.

5. Connectthe inlet hose and the outlet hose, Tightenthe pump fittings securely.

4. Wrap the opening of the pump with a pieceof tapeto preventforeign material from entering the pump.

NOTE: Do not turn the steering wheel with thepump removed.

3. Removethe pump mounting bolts, then remove thepump.

NOTE:Takecare not to spill the tluid on the bodyor parts.Wipeoff any spilled fluid at once.

2. Coverthe Ale compressorwith severalshop towelsto protect it from spilied power steering fluid.Disconnectthe inlet hose and the outlet hose tromthe pump, and plug them.

1

"'~ .i11

/PUMP/ tNLET

/ HOSE/////

PUMP MOUNTlNG BOlT24 N·m (2.4kgf·m, 17Ibf·ft)

11N·m (1.1kgf·m,8tbf.ft)

PUMP OUTLET HOSE

1. Removethe belt by loosening the pump mountingbolts.

NOTE:Before disconnectingthe hoses from the pump,placea suitablecontainerunder the vehicle.

Replacement

Power Steering Pump

17-24

PUlLEY NUl64 N-m (6.5kgf-m,47 1bf.ft 1

PUllEY

FLANGEBOlTS11N'm (1.1kgf-m, ~._8lbf.ftl

PUMP SEAlReplace.

51 x 2.4 mm O-RINGReplace.

·PUMP HOUSING

·PUMPROlOR

PUMP COVERSEAL

·PUMPCOVER

FLANGEBOlTS20 N·m '2.0 kgf·m.141bHtl

NOTE:• Clean the disassembled parts with a solvent, and dry them with compressed air. Do not dip the rubber parts in a sol-

vent.• Always replace the O-rings and rubber sealswith new ones before assembly.• Apply recommended power steering fluid to the parts indicated in the assembly procedures.• Do not allow dust, dirt, or other foreign materials to enter the power steering system.• Replacethe pump as an assembly if the parts indicated with asterisk (*) are worn or damaged.

CAUTION: The power steering components are made of aluminum. Avoid damaging the components during assembly.

Disassembly

Power Steering Pump

17-25

(cont'd)

HaSEFLOW CONTROL VALVE

4. Attacha hoseto the endof the valveasshown.

If OK,go on step 4; if not, replacethe pump as anassembly. The flow control valve is not availableseparately.

3. Slip the valve back in the pump, and check that itmovesin andout smoothly.

2. Inspectthe boreof the flow control valvefor scratchesor wear.

Checkfordamage to edges.

FLOWCONTROL VALVE

1. Checkthe flow control valve for wear, burrs, andother damage to the edges of the grooves in thevalve.

FlowControlValve:

Inspection

10. Removethe pump sealspacerandpump seal.

9. Remove the circlip, then remove the pump driveshaft by tapping the shaft endwith the plastic hammer.

8. Removethe snap ring, then remove the sub-valvefrom the pumphousing.

7. Removethe outer side plate,pump cam ring, pumprotor, pumpvanes,sideplateandO-rings.

6. Removethe pumpcoverandpumpcoverseal.

5. Removethe inlet joint andO-ring.

4. Removethe O-ring,flow control valveand spring.

3. Loosenthe flow control valvecapwith a hexwrenchand remove it.

UNIVERSAl HOLDER07725 - 0030000

CAUTION: Be careful not to damage the pumphousing with the jaws of the vise and extension bar.

2. Hold the steering pump in a vise with soft jaws,hold the pulley with the special tool, and removethe pulley nut and pulley.

1. Drain the fluid from the pump.

NOTE: Support the inner racewith the tool securely.

Press

'nstall

Press

Removal

Replace the bail bearing using a press as shown.2.

BAlL BEARING

1. Inspect the bail bearing by rotating the outer raceslowly. If any play or roughness is felt, replace thebail bearing .

Bali Bearing:

17-26

NOTE: If necessary, relief pressure is adjusted atthe fàctory by adding shims under the check bailseat. If you found shims in your valve. be sure youreinstall as many as you took out.

8. Clean ail the parts in solvent, dry them off, thenreassemble and retest the valve. If the flow controlvalve tests OK, reinstall it in the pump. If the flowcontrol valve still leaks air, replace the pump as anassembly. The flow control valve is not availableseparately.

FLOW CONTROL VALVEClamp this end ina open end wrench.

RELIEF VALVESPRING

IRE~UEF CHECK BA~~IMISI

If used.

~~

SEAT9N·m10.9 kgf·m. 6.5 Ibf.ft)

RELIEF VALVE

7. Unscrew the seat in the top end of the valve, andremove any shims, the relief check bail, relief valveand relief valve spring.

6. Hold the bottom end of the valve with a open endwrench.

...-- POWER STEERINGFLUID or SOLVENT

.- AIR PRESSURE.

5. Submerge the valve in a container of power steering fluid or solvent, and blow in the hose. If air bubbles leak through the valve at less than 98 kPa(1.0 kgf/cm2, 14.2 psi), repair it as follows.

Inspection (cont'd)

Power Steering Pump

17-27

(cont'd)

ROllERS

PUMP CAM RING

7. Set the pump cam ring over the two rollers with the,,0 "mark on the cam ring upward.

COVER BUSHING ii

5 mm ROLLER

4.5 mm ROLLER

ilPUMP caVER SEAL

ROLLER SET HOLES

6. Install the outer side plate over the two rollers.

5. Coat the pump coyer seal and the coyer bushingwith the power steering fluid, then install the pumpcoyer seal into the groove in the pump coyer.

~PUMPSEAL~ Replace.

PUMP SEAL SPACER

c8(

4. Install the 40 mm circlip with its radiused side fac-ing out. 40 mmCIRCLIP

ATTACHMENT, 30 mm 1.0. ~07746 - 0030300 ~ 6)

PUMP DRIVE SHAFT

3. Position the pump drive shaft in the pump housing,then drive it in using a special tool as shown.

NOTE: Insert the pump seal with its grooved sidefacing in.

2. Install the new pump seal in the pump housing byhand, then install the pump seal spacer.

SNAP RING

1. Align the pin of the sub-valve with the oil passagein pump housing, and push down the sub-valve.Install the snap ring properly.

OILPASSAGEAlign the pin ofsub-valve withthe oil passage.

Reassembly

17. Install the flow control valvecapon the pumphous-ing, and tighten it. ;;;

FLOW CONTROL VALVE !!!I

SPRING il~ 15.2.2.4 mm O·RING

d~FLOW CONTROLVALVE CAP49 N'm (5.0 kgf·m.36lbf.ftl

16. Coat the O-ring with power steering fluid, andinstall it on the flow control valvecap.

15. Install the flow control valve and spring on thepump housing.

14. Coat the flow control valve with power steeringfluid.

13. Install the pump cover assemblyin the pump housing.

12. Coatthe O-ringwith power steeringfluid, and position it into the pump housing.

17-28

ROllERS

/13 x 1.9 mmO-RING/ r- Replace.

Grooves.

11. Install the sideplateon the cam ring by aligning theroller set holesin the side platewith the rollers.

10. Coat the O-ring with power steering fluid, andinstall it into the groovesin the side plate.

VANE

PUMPROTOR

NOTE:Besurethat the round endsof the vanesarein contactwith the sliding surfaceof the cam ring.

9. Setthe 10vanesin the groovesin the rotor.

8. Installthe pump rotor to the pump cover.

Reassembly (cont'd)

Power Steering Pump

17-29

22. Checkthat the pump turns smoothly by turning thepulley by hand.

PULlEYNUT64 N'm (6.5 kgf'm,47Ibf·ft)

UNIVERSAL HOLDER07725 - 0030000

21. Holdthe pulleywith the specialtool, and tighten thepulley nut.

CAUTION:Becarefulnot to damagethe pumphousingwith the jaws of the vise.

20. Install the pulley as shown below, then looselyinstall the pulley nut. Hold the steering pump in avisewith soft jaws.

15.2 x 2.4 mm O-RINGReplace.

ilFLANGE BOLTS11 N'm (1.1 kgf·m.8Ibf·ft)

19. Install the inlet joint on the pump housing.

18. Coat the O-ring with power steering fluid, andinstall it into the grooves in the inlet joint.

12. Disconnectthe shift linkage(seesection13or section14).

11. Removeexhaust pipe A (seesection9).

10. Removethe left tie-rod end,then slidethe rackail theway to the right.

CAUTION:Avoid damaging the bail joint boot.

9. Separatethe tie-rod bail joint and knuckleusing thespecialtool.

NOTE: Removethe bail joint using the specialtool,Reter to section 18 for how to use the bail jointremover.

8. Install the 10mm hex nut on the bail joint.Besure that the 10mm hex nut is flush with the bailjoint pin end, or the threaded section of the bailjoint pin might be damagedby the specialtool.

BAll JOINT REMOVER,28 mm07MAC - Sl00200

COTTERPINReplace.

TIE-RODEND

7. Remove the cotter pin trom the castle nut andremovethe nut.

17-30

STEERING JOINT~lOWER BOlT

6. Remove the steering joint lower boit, and disconnect the steering joint by moving the joint towardthe column.

CLIP

5. Removethe steeringjoint coyer.

4. Removethe driver's airbag assembly,and steeringwheel (seepage17-17).

3. Removethe front wheels.

2. Raisethe front of vehicle, and support it on safetystandsin the proper locations(seesection1).

1. Drain the power steering fluid asdescribedon page17-15.

NOTE: Using solvent and a brush,wash any oil and dirtoff the valve body unit its lines, and the end if the gearbox. Blow dry with compressedair.

Removal

Power Steering Gearbox

17-31

STEERINGGEARBOX

CAUTION: Be careful not to bend or damage thepump outlet hose and cylinder lines wh en removingthe gearbox.

19. Move the steering gearbox to right 50 the left rackend clears the rear beam, then tilt the left side downto remove it trom the vehicle.

18. Pull the steering gearbox ail the way down to clearthe pinion shaft trom the bulkhead, then remove thepin ion shaft grommet.

17. Remove the mounting brackets.

~'__-GEARBOX MOUNTING BOLTS

NOTE: Sorne stiffener plate attaching bolts are alsoused as gearbox mounting bolts. The gearbox willtilt to side when these bolts are removed.

16. Remove the stiffener plate.

NOTE: Do not loosen the cylinder line A and Bbetween the valve body unit and cylinder.

CAUTION: After disconnecting the hose and line,plug or seal the hose and line with a piece of tapeor equivalent to prevent toreign materials tromentering the valve body unit.

15. Loosen the 16 mm tiare nut and remove the returnhose joint trom the valve body unit.

PUMPOUTlET HOSE

14. Loosen the adjustable hose clamp and disconnectthe return hose.

ADJUSTABLEHOSECLAMP

13. Loosen the 14 mm flare nut and disconnect thepump outlet hose.

RACK GUIDE

7. Remove the spring and the rack guide trom thegearboxhousing.

6. Loosen the locknut, then remove the rack guidescrewandO-ring.

STEERING RACK END

CAUTION:Be careful not to damagethe rack surfacewith the wrench.

5. Hold the steering rackwith a wrench, and unscrewthe rackendwith anotherwrench.

17-32

TIE-ROD CLIP

4. Removethe boot bands and tie-rod clips. Pull thebootsaway trom the endsof the gearbox.

3. Removeair tube andclips.

2. Removethe tie-rod endand locknut.

1. Removethe steeringgearbox(seepage17-30).

NOTE:• Batorayou disassemblethe gearbox,wash it off with

solventanda brush.• Donot dip sealsandO-ringsin solvent.

5teering RackDisassembly

Disassembly


17-33

(cont'd)13. Loosenand removethe cylinder end.

C-CLAMP:STEERING GEARBOX (Commercially available)

12. Hold the steering gearbox using a C-clamp asshown.

STAKED POINT

~h: 2.5 -3.0 mm 10.10-0.12 inl

t

CAUTION:• Do not allow metal shavings to enter the cylin

der.• After removing the cylinder end, remove any

burrs at the staked point.

11. Drill a 3 mm (0.12in) diameter hole approximately2.5 - 3.0 mm (0.10- 0.12 in) in depth in the stakedpoint on the cylinder.

FlANGEBOlTVALVE BODY UNIT

10. Removethe two tlange bolts, then removethe valvebody unit trom the gearbox housing. (Seepage 17-35 tor valvebody unit disassembly.)

9. Drain the tluid trom the cylinder tittings by slowlymoving the steeringrackbackandtorth.

CYUNDER UNE ACYUNDER UNE B

8. Remove cylinder lines A and B trom the gearbox.

CYLINDER END SEALREMOVER ATTACHMENT07NAD - SR3020A

CYUNDER END SEALReplace.

BACKUPRINGReplace.

24 "LONG 3/S" DRIVE EXTENSION:(CommerciaUvavailablel

Press

.a.

21.

Insert a 24" long, 3/8" drive extension and the special tool into the cylinder trom the gearbox side.NOTE: Make sure that the special tool is securelypositioned on the backup ring edges.CAUTION: Be careful not damage to inner surfaceof the cylinder with the special tool.Set the gearbox housing in a press, then press outthe cylinder end seal and backup ring from thegearbox housing.CAUTION:• Keep the tool straight to avoid damaging the cylin

der wall. Check the tool angle, and correct it if necessary, wh en removing the cylinder end seal.

• Use a press to remove the cylinder end seal. Donot try to remove the seal by striking the tool, ftwill break the backup ring, and the cylinder endseal will remain in the gearbox housing.

20.STEERING RACK

CYUNDER END SEAlReplace.

18. Remove the 12 mm boit and nut trom the steeringrack.

19. Remove the cylinder end seal from the steeringrack.

GEARBOX HOUSING

17-34

CAUTION:• Be caretul not damage to inner surface of the

cylinder with the flange boit.• Do not place your fingers under the steering rack.

NOTE: Hold the steering rack to keep it from fallingwhen pressed clear.

17. Set the gearbox in a press so the gearbox housingpoints upward, then press the cylinder end seal andsteering rack out of the gearbox housing.

BEARING SEPARA TOR0-41/2":(CommerciaUy availablel

12 x 175mmFLANGEBOlT

16. Install the bearing separator on the gearbox housingas shown.

15. Install the tlange boit into the end ot the steeringrack until it bottoms in the hole, then back thetlange boit out 1/4 turn. Hold the tlange boit, andtighten the tlange nut against the rack by hand.

12 mm FlANGE NUTVINYl TAPE

NOTE: Wrap the tlange portion of the boit withvinyl tape to protect the cylinder.

14. Assemble a 12 x 1.25 mm tlange nut cnte a 12 x 175mm grade 10 tlange boit as shown.

Disassembly (cont'd)


17-35

(cont'd)

NOTE:• There may be the sliding marks from the seal

ring on the wall of the valve housing. Replacethe valve housingonly if thewall is stepped.

• When the valve housing is replaced,install newshim(s)on the bearingsurfaceof the housing toadjust the thickness.

Check the inside of valve housingwhether the wall is stepped.

25. Checkthe innerwall of the valve housingwhere theseal ring siideswith your finger. If there is a step inthe wall, the valve housing is worn. Replace thevalvehousing.

Vinyl tape

PINION SHAFT

24. Separatethe valve housing from the pinion shaft/valveusinga press.

23. Beforeremovingthe valvehousing,apply vinyl tapeto splinesof the pinion shaft.

ValveBodyUnit Disassembly

Replace.

O-RING -----4~........Replace.

CAUTION: Be careful not to damage the inside ofseal ring groove and piston edges when removingthe seal ring.

22. Carefully pry the piston seal ring and O-ring off thepiston rack.

Replace.

Cutting slot position.

CAUTION: Be careful not to damage the edges ofthe pinion shaft groove and outer surface whenremoving the valve seal ring and O-ring.

29. Using a cutter or an equivalent tool, cut the valveseal ring and O-ring at the groove the pinion shaft.Remove the valve seal ring and 0-rin9.

SLEEVE SEAL RINGSReplace.

SLEEVE

CAUTION: Be careful not to damage the edges ofthe sleeve grooves and outer surface when removing the seal rings.

28. Using a cutter or an equivalent tool, cut and removethe four seal rings from the sleeve.

17-36

27. Remove the circlip and pin ion shaft sleeve trom thepinion shaft.

SLEEVE

SLEEVE SEAL RINGS

NOTE: The pinion shaft and sleeve are a precisionmatched set. If either the pinion shaft or sleevemust be replaced, replace both parts as a set.

26. Check for wear, burrs and other damage to theedges of the grooves in the sleeve.

Disassembly (cont'd)


17-37

PILOT COlLAR07GAF - PH70100

31. Press the valve oil seal and roller bearing out of thevalve housing using a hydraulic press and specialtool shown below.

VALVE ail SEAlReplace.

BACKUP RING

BALL BEARING

NOTE:• Inspect the bail bearing by rotating the outer race

slowly. If there is any excessive play, replace thepinion shaft and sleeve as an assembly.

• The pinion shaft and sleeve are a precise fit; donot intermix old and new pinion shafts andsleeves.

30. Remove the valve oil seal and backup ring from thepinion shaft.

17-38

STEERING RACK

CYLINDER END69 N'm (7.0 kgf·m. 511bf·ftl

Replace.PISTON SEAl RING

SPl~:~KNUTRACK GUIDE SCREW Q·RING

Replace.

Replace.

~-----PINION SHAFT

CYlINDER END SEAlReplace.

O·RING

VAlVEOllSEAl-----~. ~BACKUPRINGReplace. ~

®• VALVE SEAl RING~RePI.ce.

O·RINGReplace.

CYllNDER END SEAlReplace.

FLARE NUTS ~ ROlLER17 N·m (1.7 kgf·m, 12 Ibf·ftl ~ BEARING

VALVE SEAl RING ~~)7Replace. / ~ 1---J~ . CIRCLIP

SlEEVESEAlRINGS~ . ~/ Replace.Replace. .~

FLANGE BOLTS20 N'm (2.0 kgf·m, 14 Ibf·ftl

NOTE:• Clean the disassembled parts with a solvent, and dry them with compressed air. Do not dip the rubber parts in a sol-

vent.• Always replace the O-rings and rubber seals with new ones before assembly.• Apply the recommended power steering fluid to the parts indicated in the assembly procedures.• Do not allow dust, dirt, or other foreign materials to enter the power steering system.• Use the appropriate special tools where necessary.

Reassembly


17-39

(cont'd)

12. Turn the special tool over, and set the smaller diameter end of the special tool over the valve seal ring.Move the special tool up and down several times tomake the valve seal ring fit snugly in the pinionshaft.

Make the valve seal ringfit snugly in the pinionshaft using the other end(smaller diameter end) ofthe special tool.

Use the larger diameterend of the specialtool first ta makethe valve seal ringfit in the pinionshaft.

11. Remove thé special tool.

,(

,

10. Move the special tool up and down several times tomake the valve seal ring fit in the pinion shaft.

PISTONSEALRINGSIZINGTOOl07NAG- SRlO9OO

or07NAG- SRlO9OA

9. Apply power steering fluid to the inside of the special tool. Set the larger diameter end of the specialtool over the valve seal ring.

8. Apply power steering fluid to the surface of thevalve seal ring that was installed on the pinionshaft.

7. Remove the vinyJ tape from the pin ion shaft.

VALVE SEAl RINGReplace.Do not over-expand.

6. Fit the new O-ring in the groove of the pinion shaft.Then slide the new valve seal ring over the shaftand the groove in on the pin ion shaft.

O-RINGReplace.Do not twist.

Apply vinyl tape to the splines and stepped portionof the shaft, and coat the surface of the vinyl tapewith the power steering fluid.

5.

CAUTION: Install the valve oll seal with its groovedside faeing opposite the bearing.

4. Siide the valve oil seal over the pinion shaft, beingcareful not to damage the sealing tip.

3. Coat the inside surface of the new valve oil sealwith power steering fluid.

2. Install the backup ring with its tapered side asshown above.

Sealing lip

liBACKUPRING

VALVEOll SEAlReplace.

Make sure the spring isseated in the ail seal.

;;;; Vinyl tape!!!! (Stepped portion)

1. Apply vinyl tape to the stepped portion of the pinion shaft, and coat the surface of the vinyl tape withthe power steering fluid.

Valve Body Unit Reassembly

Replace.Make sure thespring is in theoil seal.

ATTACHMENT,32 x 35 mm07746 - 0010100Press

CAUTION: Install the valveoil sealwith its groovedside faeingthe tool.

19. Apply power steeringfluid to the seal ring lip of thevalve oil seal,then install the seal in the valve housing using a hydraulic press and special tools asshown.

NOTE:• Be careful net to damage the valve seal ring

when insertingthe sleeve.• Install the circlipwith its radiusedsidetoward the

sleeve.

18. Apply power steeringfluid to the surfaceof the pinion shaft.Assemblethe sleeveover the pinion shaftby aligning the locating pin on the inside of thesleevewith the cutout in the shaft. Then install thenew circlip securelyin the pinion shaftgroove.

17-40

NOTE:Besurethat the sealringsare not turned up.

SLEEVE SEAL RINGSIZINGTOOL07974 - SA50200 or07974 - SA5020A

17. Move the sleeve each direction several times tomakethe seal rings snugly fit in the sleeve.

16. Insertthe sleeveinto the specialtool slowly.

15. Apply power steering fluid te the seal rings on thesleeve, and to the entire inside surface of the special tool.

SlEEVE SEAl RINGReplace.

SLEEVE

BAlL JOINT BOOT CLIP GUIDE07974 - SA50800

NOTE: After installation, compress the seaJringswith your fingers temporarily.

14. Align the specialtool with eachgroove in the sleeve,andslidea sleevesealring into eachgroove.

NOTE:• Do not over-expandthe sealring. Install the resin

seal rings with care so as not to damage them.After installation, be sure to contract the sealrings using the specialtool (sizingtooü,

• There are two types of sleeve seal rings: blackand brown. Do not mix the different types ofsleeveseal rings asthey are not compatible.

13. Apply power steering fluid to the surfaceof the special tool. Set the new seal ringsover the specialtoolfrom the smalter diameter end of the tool, andexpand the seal rings. Do two rings at a time fromeachendof the sleeve.

Reassembly (cont'd)


17-41

(cont'd)

Press

NOTE: Check that the pin ion shaft/sleeve turnssmoothly by turning the pinion shaft.

24. Press the pin ion shaft/sleeve using a hydraulicpressasshown.

23. Removethe vinyl tapefrom the pinion shaft.

CAUTION: Becareful not to damagethe valve sealrin9s.

22. Insertthe pinion shaft into the valvehousing.

SLEEVE SEAL RINGS .:!E---~!!!Replace.Be sure that theseal rings are notturned up, theninstall.

VALVE HOUSING

VALVE OIL SEAL

21. Apply vinyl tape to the pinion shaft, then coat thevinyl tapewith powersteeringfluid.

liSealing lip face.

ROUER BEARINGLetter stamped faceupward.

DRIVER07749-0010000

NOTE: Place the roller bearing on the valve housing with the stamped letter facing up towards thevalve side.

20. Press the new bearing into the valve housing usinga hydraulic press and special tool as shown.

34. Remove the vinyl tape from the steering rack.NOTE: Remove any residue of tape adhesive.

Make sure thespring is in the cylinderend seal.

CYUNDER END SEALReplace.

33. Install the cylinder end seal onto the steering rackwith its grooved side toward the piston.CAUTION: When installing the cylinder end seal,be careful not damage the sealing lip face of theseal with the edges or teeth of the steering rack.

32. Coat the inside surface of the new cylinder end sealwith power steering fluid.

VINYL TAPE

31. Wrap vinyl tape around the rack teeth and rack endedges, then coat the surface of the tape with thepower steering fluid.NOTE: Make sure that the vinyl tape is wrappedcarefully so that there is no stepped portion.

17-42

PISTON SEAL RINGSIZING TOOL07GAG - S040200 or07GAG - S04020A

PISTON SEAL RINGReplace.

li

30. Move the special tool back and forth several times tomake the piston seal ring fits snugly in the piston.

29. Carefully slide the tool onto the rack and over thepiston seal ring.

28. Coat the piston seal ring and the inside of the special tool with power steering fluid.

Replace.

Replace.

PISTON SEAL RINGGUIDE07GAG - SD40100 or07GAG - SD4010A

PISTON

27. Pull the O-ring off into the piston groove, then pullthe piston seal ring off into the piston groove on topof the O-ring.

NOTE:• Do not over expand the resin seal rings. Install

the resin seal rings with care so as not to damage them. After installation, be sure to contractthe seal ring using the special tool (sizing tool).

• Replace the piston's O-ring and seal ring as a set.

26. Position the new O-ring and new piston seal ring onthe special tool, then slide them down toward thebig end of the tool.

25. Coat the piston seal ring guide with power steeringfluid, then slide it onto the rack, big end first.

Steering Rack Reassembly

Reassembly (cont'd)


17-43

(cant'd)

VINVl TAPE

NOTE: Make sure that the vinyl tape is wrappedcarefully so that there is na stepped portion.

40. Wrap vinyl tape around the rack end edges, andcoat the surface of the tape with the power steeringfluid.

39. Remove the flange boit, and center the steeringrack.

CYLINOER END SEAlReplace.

12 x 175 mm FLANGE BOlT(PIN 90177 - SlO - 000)

Press

JJ

CAUTION:Do not push on the boit with excessiveforce as it may damagethe cylinder end seal.

38. Install the cylinder end seal into the bottom of thecylinder by pressing on the boit with a press asshawn.

37. Install the tlange boit into the end of the steeringrack until it bottoms in the hale, then back thetlange boit out 1/4 turn. Hold the tlange boit andtighten the tlange nut against the rack by hand.

STEERING RACK

GEARBOX HOUSING

CAUTION: Be careful not to damage to inner surfaceof the cylinder with the rackedges.

36. Grease the steering rack teeth, then insert the steering rack into the gearbox housing.

CVlINDER END SEAl

BACKUP RING

35. Install the new backup ring on the steering rack,then place the cylinder end seal ta piston.

CAUTION: The four 32 mm shims do not havethickness identification marks. Measure the thickness of each shim using a micrometer, and markthe shim for identification.

Shim selection:a. Set the four 32 mm shims on the bearingsurfaceof

the gearbox housing. Total thickness of the fourshims should equal no more than 0.70mm.Shim set: four 32 mm shims (Thickness:0.10mm,0.15mm, 0.20mm, 0.25mm r.espectively)

NOTE: Only reinstall the original 32 mm shim(s)when the steering gearbox is reassembledwithoutreplacingthe pinion shaft, valve housing,andgearbox housingwith new ones.If the pin ion shaft, valve housing, and gearboxhousing are replaced,select the new shim(s)as follows.

49. Selectthe 32mm shim(s).

Be careful not to damagethe bushing when insertingthe cylinder end.

CYLINDER END69 N'm 17.0 kgf·m. 51 Ibf.ft)

NOTE: Stake the cylinder in the position oppositefrom where the stake was removed during disassembly.

48. After tightening the cylinder end, stakethe point ofthe cylinder housing shown below.

47. Removethe C-c1ampfrom the steeringgearbox.

46. Coat the inside surface of the cylinder end withpower steering fJuid,then install the cylinderendbyscrewing it into the cylinder.

17-44

WOODENBLOCKS

STEERING GEARBOX

C-CLAMP:ICommercially available)

45. Holdthe steeringgearboxusingaC-clampasshown.

NOTE:Removeany residueof tape adhesive.

44. Removethe vinyl tapefrom the steeringrack.

CYLINDER ENDSEAL

Grooved side.

position.

CYLINDER END SEALReplace.Make sure the springis in the cylinder end seal.

CAUTION: When installing the cylinder end seal,be careful not damage the sealing face of the sealwith the threads and burrs at the staked position ofthe cylinder.

43. Pushin the cylinderendsealwith your finger.

42. Install the cylinder end seal onto the steering rackwith its groovedsidetoward the piston.

41. Coatthe inside surfaceof the newcylinder end sealwith power steering fluid.

Reassembly (cont'd)


17-45

(cont'd)

54. Tighten the flange bolts ta the specified torque.

NOTE: Note the valve body' unit installation position (direction of line connection).

53. Install the valve body unit on the gearbox housingby engaging the gears.

52. Apply grease ta the needle bearing in the gearboxhousing.

51. Coat the" new O-ring with grease. and carefully fit iton the valve housing.

NEEOLE BEARING_--..

50. Set the selected 32 mm shims on the bearing surface of the gearbox housing.

FLANGE BOlT20 N·m (2.0 kgf·m, 14 Ibf.ft)

If the required shim thickness is 0.10 mm or less, noshims are necessary.

The selected shims should be 0.25 mm (0.010 in) and0.15 mm (0.006 in) in thickness.

Example:Measurement is 0.28 mm (0.011 in):0.70 - 0.28 = 0.42 mm (0.028 - 0.Q11 = 0.017 in)

NOTE: Select the shims sa that the total thicknessis close ta, but less than, the required thickness.

d. Determine the required thickness of the 32 mmshims by subtracting the clearance obtained in thestep HC" from the total thickness of the four shims.(Total thickness of the 4 shims) - (Clearance) =Required thickness of the shims

NOTE: Measure the clearance at the point midwaybetween the two mounting bolts.

c. Measure the clearance between the gearbox andvalve body unit using a feeler gauge as shawn.

b. Install the valve body unit on the gearbox, andtighten the flange bolts ta the specified torque.

VALVE BODY UNIT FLANGE BOLT20 N·m (2.0 kgf·m. 141bHt)

WOODEN BLOCK

to prevent puncturingof metal washer.

63. After tightening the rack ends, stake the four sections of lockwasherwith a drift andamallet.• Placethe wood blackon the presstable, then set

the lock washer section of the rack end on thewood blacksecurely.

• Besure the tool is aligned with the fIat sectionsof the steering rackendbeforepressing.

• Stake the lock washer in the center of the fiatsectionof the steering rackend.

ROLL PIN DRIFT:(Commerciallyavailable)Snap-On No. PPR8 or equivalent.

CAUTION: Be careful not to damage the rack surface with the wrench.

62. Hold the steering rack with a wrench, and tightenthe rackends.

61. Screweachrackends into the rack.

STEERING RACK END54 N'm (5.5 kgf'm, 40 Ibf.ft)

60. Install the new lockwasher in the groove in thesteeringrack.

17-46

RACK GUIDESCREW

LOCKNUT

~

O-RINGReplace.

NOTE: After adjusting, check that the rack movessmoothly by sliding the rackright and left.

RACK GUIDE

SPRING

59. Adjust the rackguide screw(seepage17-15).

58. Install the spring, rackguide screw and locknut onthe gearboxhousing.

57. Apply a thin coat of greaseto the new O-ring, andinstall it on the rackguidescrew.

56. Grease the sliding surface of the rack guide, andinstall it onto the gearboxhousing.

11N'm (1.7kgf'm, 121bHt)

NOTE:• Clean the joints of the cylinder lines A and B

thoroughly. The joints must be free of foreignmaterial.

• Install the cylinder lines A and B by tighting theflare nuts by hand first, then tighten the flarenuts ta the specifiedtorque.

55. Install the cylinder linesA andB.

Reassembly (cont'd)


17-47

(cont'd)

70. Siide the rack right and left to be certain that theboots are not deformed or twisted.

69. lightly tap on the doubled-over portions to reducetheir height.

Replace.

LOCKING TABS

CAUTION: Stake the band locking tabs firmly.

68. Install new boot bands on the boot, and bend bothsets of locking tabs.

BOOT AIR HOSE FITTING

AIR HOSEFIITING

RIGHTBOOT(Viewed from theright side)

LEFTBOOT(Viewed from theleft side)

67. Adjust the air hose fitting position of the boots byturning it as shown below.

~~ SILICONE GREASE

~TIE-ROD CLIP

BOOT

RACK END

NOTE: Install the boots with the rack in the straightahead position (right and left tie-rods are equal inlength).

66. Install the boots in the rack end with the tie-rodclips.

65. Apply a light coat of silicone grease to the bootgrooves on the rack ends.

~SIUCONE GREASE

64. Apply grease to the circumference of the rack endhousing.

NOTE: Install the bracketwith the arrow pointingtoward the front.

4. Install the mounting bracket over the mountingcushion, then install two gearbox mounting bolts.

<.»

NOTE: Align the notch in the pinion shaft grommetwith the tab on the valve housing.

3. Install the pinion shaft grommet, then insert the pinion shaft up through the bulkhead.

2. Install the mounting cushion on the steering gearbox.

1. Before installing the gearbox, slide the rack ail theway to right.

CAUTION: Be careful not to bend or damage the pumpoutfet hose and cylinder lines wh en installing the gearbox.

Installation

17-48

CLIP

CYLINDER UNE A

72. Install the clips on the cylinder lines, then clamp theair tube with the clips.

71. Connect the air tube between the right and leftboot.

r:(

Reassembly (cont'd)


17-49

(cont'd)

11. Center the cable reel by tirst rotating it clockwiseuntil it stops. Then rotate it counterclockwise(approximately two turns) until the arrow mark onthe label points straight up. Reinstall the steeringwheel (see page 17-17).

STEERINGJOINTlOWER BOlT22 N·m (2.2 kgf·m, 161bHtl

STEERINGJOINT

NOTE:• Connect the steering shaft and pinion with the

cable reel and steering rack centered.• Be sure that the lower steering joint boit is securely

in the groove in the steering gearbox pinion.• If the steering wheel and rack are not centered,

reposition the serrations at lower end of thesteering joint.

10. Slip the lower end of the steering joint ante the pinion shaft (line up the boit hole with the groovearound the shaft), and tighten the lower boit.

9. Center the steering rack within its stroke.

NOTE: Make sure that there is no interferencebetween the tluid lines, the rear beam or any otherparts.

8. Connect the pump outlet hose and tighten the 14mm flare nut.

7. Connect the return hose securely, and tighten theadjustable hose clamp trom the engine compartment.

PUMPOUTLETHOSE

6. Install the return hose joint by tightening the 16 mmflare nut.

ADJUSTABlE HOSECLAMP

snFFENERPLATEATTACHINGBOLTS38N'm (3.9kgf'm, 28 Ib"'t)

t:7..----GEARBOX MOUNTINGBOLTS43 N'm (4.4kgf·m. 32 IbHt)

NOTE: Install the bolts loosely first, then tightenthem securely.

CAUTION: Be sure the air tube is not caught orpinched by stiffener plate.

5. Install the stiffener plate with the two gearboxmounting bolts and stiffener plate attaching bolts.

CAUTION: After installing the boot, check the bailpin tapered section for grease contamination andwipe it if necessary.

5. Adjust the special tool with the adjusting boIt untilthe end of the tool aligns with the groove on theboot. Siide the set ring over the tool and into position.

BOOT

BALl JOINT BOOTCLIP GUIDE07974 - SA50800

ADJUSTING BOLTAdjust the depthby turning the boit.

4. Install the boat in the groove of the boat installationsection securely, then bleed the air from the boat.

-~BOOT INSTALLATIONSECTIONWipe off the grease.

BOOT INSTALLATIONSECTIONWipe off the grease.

BAll PIN TAPE REDSECTIONWipe off the grease.

LlP

CAUTION:• Keep grease off the boot installation section and

the tapered section of the bail pin.• Do not allow dust, dirt, or other foreign materi

ais to enter the boot.

3. Wipe the grease off the sliding surface of the bailpin, then pack the lower area with tresh grease.

2. Pack the interior of the boat and lip with grease.

CAUTION: Do not contaminate the boot installation section with grease.

1. Remove the boat set ring and the boat.

17-50

t~.<::>~-}0 -." 6'~

-:...--,,", - -'_,.,.,..../-

~~ ~-=

'~ '~~--',- /'bI' "-----~ ~ " CASTlE NUT

COTTER PIN ;;==-' 40 - 48 N'mReplace. (4.0 - 4.8 kgf·m.On reassembly, bend 29 - 351bHt)the cotter pin as shown.

14. Install exhaust pipe A (see section 9).15. Connect the shift linkage (see section 13 or section

14).16. Install the front wheels.17. Fill the system with power steering tluid, and bleed

air trom the system (see page 17-15).18. After installation, perform the tollowing checks.

• Start the engine, allow it ta idle, and turn thesteering wheeJ from Jock-ta-JockseveraJtimes tawarm up the tJuid. Check the gearbox for Jeaks(see page 17-22).

• Adjust the front toe (see section 18).• Check the steering wheel spoke angle. Adjust by

turning the right and left tie-rods, if necessary.NOTE:Turn the right and left tie-rods equally.

TlE-ROD END

CAUTION: Torque the castle nut to the lower torquespecification, then tighten ilonly far enough to alignthe slot with the pin hole. Do not aUgn the nut byloosening.

13. Reconnect the tie-rod ends to the steering knuckles,tighten the castle nut to the specified torque, andinstall new cotter pins.NOTE: Betore connecting the tie-rod ends, wipe offany grease contamination trom the bail joint taperedsection and threads.

12. Install the steering joint cover with the clamps and aclip.

Bali Joint Boot ReplacementInstallation (cont' d)


Front DamperRemoval ~ 18-16Disassembly Ilnspection 18-17Reassembly 18-18Installation 18-18

Rear SuspensionSuspension Arms Replacement 18-20Hub Bearing Unit Replacement 18-21Upper Arm Bushing

Replacement 18-22Rear Damper

Removal 18-23Disassembly/lnspection 18-24Reassembly 18-25Installation 18-26


Index 18-3Wheel Alignment

Caster 18-4Camber 18-4Front Toe Inspectionl

Adjustment 18-5Rear Toe Inspectionl

Adjustment 18-5Turning Angle Inspection 18-6

Wheel/Hub InspectionBearing End Play 18-7Wheel Runout 18-7

Front SuspensionSuspension Arms Replacement 18-8Knuckle/Hub Replacement 18-9Lower Bali Joint Replacement 18-15Bali Joint Boot Replacement 18-16

Suspension

-

~

( J-g "- ~.._........ -q 1~\'<'...."J

® @ @ @

@@

.q 1 Ô,.:1. ®

18-2

1

1

Ref.No. Tooi Number Description Qty PageReference

CD 07GAF- SE00200 Hub Assembly Guide Attachment 1 18-14<ID 07GAF- SE00401 Hub Ois/Assembly Base 1 18-13<ID 07GAG- S040700 Bali Joint Boot Clip Guide 1 18-16@ 07JAF- SH20110 Hub Ois/Assembly Pilot, 38 mm 1 18-13@ 07JAF- SH20120 Hub Ois/Assembly Shaft, 22.4 x 25.4mm 1 18-13@ 07JAF- SH20200 Bali Joint Remover Base 1 18-15(j) 07MAC- SL00200 Bali Joint Remover, 28 mm 1 18-11,12® 07746 - 0010500 Attachment, 62 x 68 mm 1 18-13® 07749- 0010000 Driver 1 18-13@ 07947- 6340201 Driver Attachment 1 18-14@ 07965- 5B00100 Bali Joint Remover/lnstaller 1 18-15@ 07965- SB00200 Bali Joint Installer Base 1 18-15@ 07965- 5090100 Support Base 1 18-14@ 07974- 5A50700 Bali Joint Boot Clip Guide 1 18-15,16

Special Tools

18-3

TRAllING ARMReplacement. page 18-20

COMPENSA TOR ARMReplacement, page 18-20

UPPER ARMReplacement, page 18-20

REAR DAMPER• Removal, page 18-23• Disassembly/lnspection, page 18-24• Reassembly, page 18-25• Installation, page 18-26

ST ABILIZER BARReplacement, page 18-20

LOWERARMReplacement, page 18-20

Rear Suspension:

STABILIZER BARReplacement, page 18-8KNUCKLE/HUB

• Replacement, page 18-9• Wheel Bearing Replacement, page 18-13• Lower Bali Joint Replacement, page 18-15

UPPERARM~ / Replacement,page '8·8

LOWERARMReplacement, page 18-8

FRONT DAMPER• Removal, page 18-16• Disassembly/lnspection, page 18-17• Reassembly, page 18-18• Installation, page 18-18

Front Suspension:

Wheel Alignment, page 18-4

Index

Component Locations

2. If out of specification, check for bent or damagedsuspension components.

Camber angle:Front: 0°00' ± 1°Rear: _1° ± 1°

1. Check the camber angle.

NOTE: Use commercially-available computerized fourwheel alignment equipment ta measure wheel alignment (caster, camber, toe, and turning angle). Followthe equipment manufacturer's instructions.

Inspection

18-4

2. If out of specification, check for bent or damagedsuspension components.

Caster angle: 1°40' ± 1°

1. Check the caster angle.

NOTE: Use commercially-available computerized fourwheel alignment equipment to measure wheel alignment (caster, camber, toe. and turning angle). Followthe equipment manufacturer's instructions.

Inspection

• Check that the suspension is not modified.• Check the tire size and tire pressure.• Check the runout of the wheels and tires.• Check the suspension bail joints. (Hold a wheel with

your hands and move it up and down and right andleft ta check for wobbling.)

NOTE: For proper inspection/adjustment of the wheelalignment check and adjust the following before checking the alignment.

CamberCaster

Wheel Alignment

18-5

Example: After the rear toe inspection, the wheel is 2mm (0.08 in) out of the specification.

- Move the arm so the adjusting boit moves 2 mm(0.08 in) inward from the position recorded before theadjustment.

- The distance the adjusting boit is moved should beequal to the amount out-of-specification.

4. Tighten the adjusting bolts.

ln COMPENSATOR ARM

ADJUSTING BOLT10x 1.25mm64 N'm (6.5kgf·m, 47Ibf.ft)

3. Loosen the adjusting bolts, and slide the compensator arm in or out, as shown, to adjust the toe.

2. Before adjustment, note the locations of adjustingbolts on the right and left compensator arms.

- If no adjustment is required, remove alignmentequipment.

- If adjustment is required, go to step 2.

Rear toe-in: 2::mm (0.08 -.::)

NOTE:• Measure difference in toe measurements with

the wheels pointed straight ahead.• If the parking brake is engaged, vou may get an

incorrect reading.

1. Release parking brake.

NOTE: Use commercially-available computerized fourwheel alignment equipment to measure wheel alignment (caster, camber, toe, and turning angle). Followthe equipment manufacturer's instructions.

NOTE: Reposition the tie-rod boot if it is twisted ordisplaced.

6. After adjusting, tighten the tie-rod locknuts.

5. Turn both tie-rods equally until the toe reading onthe turning radius gauge is correct.

TIE-ROD

TIE-ROD LOCKNUT14x 1.5mm54 N'm (5.5kgf·m, 40 Ibf.ft)

4. Loosen the tie-rod locknuts, and turn both tie-rodsin the same direction until the front wheels are instraight ahead position.

- If no adjustment is required, remove alignmentequipment.

- If adjustment is required, go on to step 4.

Front toe: IN 2 ~ 2 mm (IN 0.08 ~ 0.08 in)

3. Check the toe with the wheels pointed straightahead.

2. Center steering wheel spokes.

1. Check the tire pressure.

NOTE: Use commercially-available computerized fourwheel alignment equipment to measure wheel alignment (caster, camber, toe, and turning angle). Followthe equipment manufacturer's instructions.

Rear Toe Inspectionl AdjustmentFront Toe Inspection lAd just ment

18-6

2. If the turning angle is not within the specifications,check for bent or damaged suspension cornponents.

Turning angle:'nward whee': 35°50'Outward wheel (referenceJ:30°50'

1. Turn the wheel right and left while applying thebrake, and measure the turning angle of bothwheels.

NOTE:Usecommercially-availablecomputerizedfourwheel alignment equipment to measurewheel alignment (caster,camber, toe, and turning angle). Followtheequipmentmanufacturer'sinstructions.

Turning Angle Inspection

Wheel Alignment

18-7

5. If the wheel runout is more than the service limit,replace the wheel.

Front and Rear Wheel Radial Runout:Standard:

Steel Wheel: 0 - 1.0 mm (0 - 0.04 in)Aluminum Wheel: 0 - 0.7 mm (0 - 0.03 in)


Front and Rear Wheel Axial Runout:Standard:

Steel Wheel: 0 - 1.0 mm (0 - 0.04 in)Aluminum Wheel: 0 - 0.7 mm (0 - 0.03 in)


4. Measure the wheel runout by turning the wheel.

3. Attach the dial gauge as shawn.

2. Check for bent or deformed wheels.

1. Raise the vehicle off the ground, and support it withsafety stands in the proper locations (see section 1).

5. If the bearing end play measurement is more thanthe standard, replace the wheel bearing.

Measure end play at center ofthe hub cap.

Rear:

108 N'm(11 kgf·m, 80 IbHt)

1_-/

Front:

Front/Rear:Standard: 0 - 0.05 mm (0 - 0.002 in)

4. Measure the bearing end play by moving the dise inor outward.

3. Attach the dial gauge as shown.

2. Remove the wheels, then reinstall the wheel nuts.

1. Raise the vehicle off the ground, and support it withsafety stands in the proper locations (see section 1).

Wheel RunoutBearing End Play

Wheel/Hub Inspection

18-8

Checkfor deterioration and damage.

Replace.64 N'm (6.5kgf·m, 47 Ibf·ft)DAMPERFORK

RUBBERBUSHING

12x 1.25mmSElF-lOCKING NUl

FlANGE BOlT10x 1.25mm43N·m (4.4kgf·m,32lbf.ftl

~_ SElF-lOCKING NUl 8 x 1.25mm.. =UI1DISllICONE GREASE 22 N'm (2.2 kgf·m. 161bHt)STABILIZERENDRUBBERBUSHINGS Replace.Note the directionof the bushings.

FLANGEBOlTSx 1.25mm22 N'm (2.2kgf·m.161bHt)

0~ SELF-LOCKINGNUl~ 14x1.5mm

Replace.83 N·m (8.5kgf·m. 61 Ibf.ft)

FLANGEBOLT

LOWERARMRUBBERBUSHING

• Checkfor deterioration and damage.• See page '18-16for boot replacement.

STABllIZER BARCheckfor bending and damage.

BALLJOINT BOOTMARK

Checkthe bushing for deterioration and damage.

STABILIZERBARAlign the stabilizer markwith end of stabilizer bushing.

FLANGEBOlTS10x 1.25mm54 N'm (5.5 kgf·m.401bHt)

SELF-lOCKINGNUT10x 1.25mm 29 N'm (3.0 kgf·m. 221bHt)Replace.Hold the bail joint pin using a hex wrench,and t!9hten the seIIOlo\;n9 nut.

NOTE:• Wipe off any dirt, oil from grease on the threads before tightening the fasteners.• The right and left damper forks are not interchangeable. The left damper fork is marked with "AL" while the right

damper fork is marked with "AR".• The right and left upper arms are not interchangeable. The left upper arm is marked with "S01-L" while the right arm

is marked with "SOl-R".• Before tightening the upper and lower mounting nuts on the stabilizer link, adjust the location of the link with the sus

pension under vehicle load.• When installing the radius arm washers, the "FR" mark faces the front of the vehicle.• After installing the suspension arm, check the front wheel alignment, and adjust if necessary (see page 18-4).

CAUTION:• Replace the self-Iocking nuts after removal.• The vehicle should be on the ground before any bolts or nuts connected to rubber mounts or bushings are tightened.

Suspension Arms Replacement

Front Suspension

18-9

(cont'dl

6 mm BRAKE DISC RETAINING SCREW9.8 N'm (1.0 kqf-rn. 7 Ibf.ft)

12 x 1.5 mm108 N·m(11 kgf·m. 80 IbUt)

rust.Replacement. page 18·10Inspection. section 19.

22x 1.5mm181 N'm (18.5 kgf·m. 134 Ibf.ft)Replace.NOTE:• Before installing the spindle nut, applyengine oil to the seating surface of the nut.

• After tightening, use a drift to stake thespindle nut shoulder against the driveshaft.

FRONTHUBCheck for damage andcracks.Replacement.page 18-10BALLJOINTBOOTAI '>.

Check for deterioration COTTER PINand damage. Replace.

CASTLE NUT12 x 1.25 mm49 - 59 N'm (5.0 - 6.0 kgf·m. 36 - 43 Ibf.ft)

SPLASH GUARD

CASTLE NUT10 x 1.25 mm39 - 47 N'm (4.0 - 4.8 kgf·m. 29 - 35 Ibf.ft)

COTTER PIN

CALIPER MOUNTING BOLT

NOTE:• Use only genuine Honda wheel weights for aluminum wheels. Non-genuine wheel weights may corrode and damage

the aluminum wheefs.• On the aluminum wheels. remove the center cap from the inside of the wheef after removing the wheel.• Before installing the brake dise. clean the mating surfaces of the front hub and brake dise.• Before installing the wheel, elean the mating surfaces of the brake dise and wheel.• Wipe off the grease before tightening the nut at the bal! joint.

CAUTION:• Replace the self-Iocking nuts after removal.• The vehicle should be on the ground before any bolts or nuts connected to rubber mounts or bushings are tightened.• Torque the castle nut to the lower torque specification. then tighten it only far enough to align the slot with the pin

hole. Do not align the nut by loosening.

Knuckle/Hub Replacement

III

SENSOR MOUNTINGBOLTS9.8N·m(1.0 kgf·m, 7 Ibf·ft)

WHEEl SENSOR

NOTE: Do not disconnect the wheel sensor connector.

11. Remove the wheel sensor from the knuckle (for vehides with ABS).

10. Check the front hub for damage and cracks.

9. Remove the brake disc from the knuckle.

NOTE: Turn each boit two turns at a time to preventcocking the disc excessively.

8. Screw two 8 x 1.25mm bolts into the dise to push itaway from the hub.

8 x 1.25 mm BOLTS

7. Remove the 6 mm brake dise retaining screws.

18-10

6. Remove the caliper mounting bolts and hang thecaliper assembly to one side.

CAlIPER MOUNTING BOLTS12 x 1.25mm108 N'm (11.0 kgf·m, 80 Ibf.ft)

BRAKE HOSE MOUNTING BOLT8x 1.25 mm22 N'm (2.2 kgf·m, 1Slbf·ftl

CAUTION: To prevent accidentai damage to thecaliper assembly or brake hose, use a short piece ofwire to hang the caliper from the undercarriage.

5. Remove the brake hose mounting bolts.

SPINOLE NUT1S1 N·m (18.5 kgf'm, 134 Ibf·ftlReplace.NOTE: Before installing the spindle nut, applyengine oil to the seating surface of the nut. Aftertightening, use a drift to stake the spindle nutshoulder against the driveshaft.

4. Raise the locking tab on the spindle nut, then removethe nut.

3. Remove the wheel nuts and wheel.WHEELNUT10SN·m(11 kgf·m, SO Ibf·ft)

2. Raise the front of vehicle, and support it with safetystands in the proper locations (see section 1).

1. loosen the wheel nuts slightly.

Knuckle/Hub Replacement (cont'd)

Front Suspension

18-11

(cont'd)

19. Remove the tool, then remove the nut trom the endof the bail joint and pull the bail joint out of thesteering/suspension arme Inspect the bail joint bootand replace it if damaged.

'MlW@; Wear eye protection. The bail jointcan break loose suddenly and scatter dirt or otherdebris in your eyes.

18. With a wrench, tighten the pressure boit until thebail joint shaft pops loose from the steering arme

NOTE: After making the adjustment to the adjusting boit, be sure the head of the adjusting boit is inthis position to the allow the jaw to pivot.

17. Once the special tool is in place, turn the adjustingboit as necessary to make the jaws parallel. Thenhand-tighten the pressure boit, and recheck thejaws to make sure they are still parallel.

CASTlENUT~10)( 1.25mm ~ __ .....

COTTER PIN COTTER-PIN _.1,,-~.:~"'f'~

Replace. Replace.On reassembly,bend the cotter pinas shown.

16. Install the special tool as shown. Insert the jawscarefully, making sure vou do not damage the bailjoint boot. Adjust the jaw spacing by turning thepressure boit.

15. Install a 10 mm hex nut on the bail joint. Be surethat the hex nut is flush with the bail joint pin end toprevent damage to the threaded end of the bailjoint.

PRESSURE BOLT

14. Apply grease to the special tool on the areas shown.This will ease installation of the tool and preventdamage to the pressure boit threads.

13. Remove the cotter pin from the steering arrn andremove the nut.

12. Clean any dirt or grease off the bail joint.

CAUTION: Be careful not to damage the bail joint boot.

NOTE: Use the special tool to separate the bail jointsfrom the suspension or steering arme

KNUCKLECheckfor damage.

26. Pull the knuckle outward and remove the driveshaftoutboard joint trom the knuckle by tapping the driveshaft end with a plastic hammer, then remove theknuckle.

NOTE: If necessary, apply penetrating type lubricant to loosen the bail joint.

25. Use the special tool as shown on page 18-11 to separate the bail joint and knuckle.

24. Install the 12 mm hex nut on the bail joint.Be sure that the hex nut is flush with the bail jointpin end, or the threaded section of the bail joint pinmight be damaged by the bail joint remover.

12mm HEXNUT

BAlLJOrNTREMOVER, 28 mm07MAC - SL00200

CAST LE NUT12 x 1.25mm39-47 N'm14.0- 4.8 kgf·m,29 - 35 Ibf·ft)

COTTER-PiNReplace.On reassembly,bendthe coner pin asshown.

23. Remove the cotter pin from the upper bail joint castle nut, and remove the nut.

18-12

NOTE: If necessary, apply penetrating type lubricant to loosen the bail joint.

22. Use the special tool as shown on page 18-11 to separate the bail joint and lower arm.

21. Install a 12 mm hex nut on the bail joint. Be surethat the hex nut is flush with the bail joint pin end,or the threaded section of the bail joint pin might bedamaged by the bail joint remover.

SALL JOINT REMOVER, 28 mm07MAC - SL00200

CASTLE NUT12x 1.25mm

COrrER PINReplace.

@ ~~~:~:~embIY,bend the cotter pinas shown.

CASTlE NUT12 x 1.25mm49 - 59 N'm (5.0 - 6.0 kgf·m,36 - 43 Ibf.ft)

COTTER-PIN

20. Remove the cotter pin from the lower arm bail jointcastle nut, and remove the nut.


Front Suspension

18-13

(cont'd)

HUB 0151ASSEMBL ySHAFT. 22.4 )( 25.4 mm07JAF - SH20120

BEARINGSEPARATOR0- 41/2 in.(Commercially available)

HUB 0151ASSEMBL yPILOT,l8 mm07JAF - SH20110

Press•30. Press the wheel bearing inner race trom the hub

using the special tools, a bearing separator, and apress as shown.

WHEEL BEARINGReplace.

HUB 0151ASSEMBL y BASE07GAF - SEoo401

ATTACHMENT,

PressDRIVER07149 - 0010000

29. Press the wheel bearing out of the knuckle using thespecial tools and a press as shown.

SPLASH GUAROCheck for bending and damage.

28. Remove the circlip and the splash guard from theknuckle.

!+-_---l':--_HUB OIS/ASSEMBLYSHAFT, 22.4 )( 25.4 mm07JAF - SH20120

CAUTION:• Take eare not to distort the splash guard.•. Hold onto the hub to keep it from falling when

pressed elear.• To prevent damage to the tool, make sure the

threads are fully engaged before pressing.

27. Separate the hub from the knuckle using the specialtools and a hydraulic press.

NOTE: Replace the bearing with a new one after removal.

• Be careful not ta damage the bail joint bootswhen installing the knuckle.

• Torque ail mounting hardware to the specifiedtorque values.

• Torque the castle nuts to the lower torque specifications, then tighten them only far enough taalign the slot with the pin hale. Do not align thecastle nut by loosening.

• Install new cotter pins on the castle nuts aftertorquing.

• Avoid twisting the sensor wires when installingthe whee! sensor.

• Before installing the brake dise, clean the matingsurfaces of the front hub and the inside of thebrake dise.

• Before installing the wheel, clean the mating surface of the brake dise and the inside of the wheel.

• Check the front wheel alignment, and adjust it ifnecessary (see page 18-4).

35. Install the knuckle in the reverse arder of removal,and pay particular attention to the following items:

HUB OISI ASSEMBL VGUIDE AlTACHMENT07GAF - SE00200

CAUTION: Take tare not to distort the splash guard.

34. lnstall the hub on the knuckle using the special toolsshawn and a hydraulic press as shawn.

18-14

SCREWS4.9 N'm (0.5 kgf· m, 4 Ibf.ft)

33. Install the splash guard and tighten the screws.

32. Install the circlip securely in the knuckle groove.

SUPPORT BASE07965 - S090100

DOUBLE LlP SEAL(BLACK COLORI

Press

NOTE: Place the wheel bearing on the knuckle withthe pack sea! (metal color) toward the inside. Becareful not ta damage the sleeve of the pack seal.

31. Press a new wheel bearing into the knuckle usingthe special tools and a press as shawn.

NOTE: Wash the knuckle and hub thoroughly inhigh flash point solvent before reassembly.


Front Suspension

18-15

• Be careful not to damage the bail joint bootswhen installing the knuckle.

• Torque ail mounting hardware to the specifiedtorque values.

• Torque the castle nuts to the lower torque specifications, then tighten them only far enough toalign the slot with the pin hole. Do not align thecastle nut by loosening.

• Install new cotter pins on the-castle nuts aftertorquing.

• Avoid twisting the sensor wires when installingthe wheel sensor.

• Before installing the brake disc, clean the matingsurfaces of the front hub and the inside of thebrake disco

• Before installing the wheel, c1eanthe mating surface of the brake disc and the inside of the wheel.

• Check the front wheel alignment, and adjust it ifnecessary (see page 18-4),

9. Install the knuckle in the reverse order of removal,and pay particular attention to the following items:

ADJUSTING BOLTAdjust the depth byturning the boit.

BALL JOINT BOOT CLIP GUIDE07974- SA50700

8. Install the bail joint boot and set ring using the special tool (see page 18-16).

SALL JOINT HOUSING SURFACE

BALL JOINT INSTALLER BASE07965 - SB00200BALL JOINT REMOVERI

INSTALLER07965 - SB00100

7. Install the special tools over the bail joint as shown,then press the bail joint in.

8ALL JOINT REMOVER BASE07JAF - SH20200

6. Place the bail joint in position by hand.

5. Position the special tools over the bail joint asshown, then set the assembly in a vise. Press thebail joint out of the knuckle.

8ALL JOINT REMOVER/INSTALLER07965 - S8oo1oo

4. Install the special tools on the bail joint and tightenthe castle nut.

3. Check the boot for deterioration and damage,replace if necessary.

2. Remove the boot' by prying the set ring off.

1. Remove the knuckle (see page 18-10).

Lower Bali Joint Replacement

DAMPER

4. Remove the damper by removing the two nuts.

3. Remove the damper fork boit and self-Iocking nutfrom the bottom of the damper fork, then removedamper fork.

Replace.12 x 1.25mmSELF-LOCKING NUT

DAMPERPINCHBOLT10 x 1.25mm

2. Remove the damper pinch boit from the top ofdamper fork.

1. Remove the front wheels (see page 18-10).

18-16

CAUTION: After installing the boot, check the bailpin tapered section for grease contamination andwipe it if necessary.

CIRCLIP

ADJUSTING BOLTAdjust the depthbyturning the boit.

BALLJOINTBOOT CLlP""_______GUIDE ~

UPPER BALLJOINT BOOT:07GAG - SD40700LOWER BALLJOINT BOOT:07974 - SA50700

Lower bail joint: Adjust the special tool with theadjusting boit until the end of the tool aligns withthe groove on the boot. Siide the set ring over thetool and into position.

5. Install the upper and lower bail joint boot set ringsusing the special tools as fo!lows:

4. !nstall the boot in the groove of the boot installationsection securely, then bleed air.

CAUTION:• Keep grease off the boot installation section and

the tapered section of the bail pin.• Do not allow dust, dirt, or other foreign materi

ais to enter the boot.

3. Wipe the grease off the sliding surface of the bailpin and packwith fresh grease.

BOOT INSTALLATION SECTION BOOT INSTALLATION SECTIONWipeoff thegrease. Wipeoff the grease.

BALL PIN TAPERED SECTIONUP

2. Packthe interior of the boot and lip with grease.

CAUTION: Do not contaminate the boot installation section with grease.

1. Remove the set ring and the boot.

RemovalBali Joint Boot Replacement

Front DamperFront Suspension

18-17

DUSTCOVERCheckfor bending and damage.

Checkfor deteriorationDAMPERSPRING and damage.1Checkfor weakened compressionand damage.BUMPSTOPCheckfor weaknessanddamage.

SELF-LOCKINGNUT10x 1.25mm29 N·m (3.0kgf·m,22 Ibf.ft'~Replace.DAMPERMOUNTINGWASHER

DAMPERMOUNTING ----...®RUBBER ~~Checkfor deterioration c:::::::;Jand damage. _____..(JDAMPER MOUNTING COLLAR ~DAMPERMOUNTING ...

BASE DAMPERMOUNTING ~RUBBER

3. Check for smooth operation through a full stroke,both compression and extension.NOTE: The damper should move smoothly. If itdoes not (no compression or no extension), the gasis leaking, and the damper should be replaced.

4. Check for oil leaks, abnormal noises or binding during these tests.

WOODENBLOCK

Inspection1. Reassemble ail parts, except the spring.2. Push on the damper assembly as shown.

2. Release the pressure trom the spring compressor,then disassemble the damper as shown in the nextcolumn.

STRUTSPRINGCOMPRESSOR:(Commerciallyavailable)BRANICKaTIN 7200,TIN MST-SaOA,or equivalent

10mm SELFLOCKINGNUTReplace.

CAUTION: 00 not compress the spring more thannecessary to remove the nut.

Oisassembly1. Compress the damper spring with the spring corn

pressor according to the manufacturer's linstructions, then remove the self-Iocking nut.

Disassembly Ilnspection

FLANGE NUT10 x 1.25 mm49 N'm\0 kgf·m. 36 Ibf.ftl

1. Loosely install the damper on the framè with thealigning tab facing inside, then loosely install thetwo flange nuts.

18-18

SELF-LOCKING NUT10)( 1.25mm29 N'm (3.0 kgf·m, 22 Ibf.ft)Replace.

6. Hold the damper shah and tighten the 10 mm selflocking nut.

5. Install the damper mounting rubber, damper mounting washer and a new 10mm self-Iocking nut.

4. Compress the damper spring.

3. Position the damper mounting base on the damperunit as shown.

SPRING LOWER SEAT

STRUT SPRING COMPRESSOR:(Commerciallv available)BRANICKe TIN 7200,TIN MST -580A, or equivalent

NOTE: Align the bottom of damper spring andspring lower seat as shown.

2. Assemble the damper in reverse order of removalexcept the damper mounting washer and self locking nut.

1. Install the damper unit on a spring compressor.

InstallationReassembly

Front Damper

18-19

10. Install the front wheel.

9. Install the brake hose mounts with the brake hosemounting bolts.

8. Tighten the flange nuts on top of the damper.

7. Tighten the damper fork boit and self-Iocking nut.

6. Tighten the damper pinch boit.

,%i/.i;i.'@; The floor jack must be securely positioned or personal injury may result.

5. Raise the knuckle with a floor jack until the vehiclejust lifts off the safety stand.

4. Loosely install the damper fork boit and a new selflocking nut on the bottom of the damper fork.

3. loosely install the damper pinch boit on the top ofthe damper fork.

SELF·LOCKING NUT12" 1.25 mm64 N·m (6.5 kgf'm, 47 Ibf·ft)Replace.

DAMPERPINCHBOLT10" 1.25mm43 N'm (4.4 kgf·m, 32 IbHt)

DAMPERFORKBOLT

2. Install the damper fork over the driveshaft and ontothe lower arm. Install the front damper in thedamper fork so the aligning tab is aligned with theslot in the damper fork.

18-20

STABILIZERlINK and damage.• Check far bending and damage.• Check the bushing far deteriaratian and damage.

SELF-lOCKINGNUT10x 1.25mm 29 N'm (3.0kgf·m. 22Ibf·ft)Replace.Hold the bail jaint pin using a hex wrench.and tighten the self-Iacking nut.

lOWER ARMBUSHING~SILICONE

_ '. GREASE

12)( 1.25mm64 N'm (6.5kgf'm,47 Ibf.ft)

FlANGE NUT10x 1.25mm29 N'm (3.0kgf·m, 22 Ibf.ftl8efore tightening the flange nut,position the bail joint pinin the middle of its range oftravet, with the suspension under

\

vehicle 100id.lOWERARM

\ \ Check for cracks~ and damage.

""""~,.,'\., ....

COMPENSATORARMINNERBUSHING~;. SILICONE

_-=I!mJDI GREASECheck for deteriorationand damage.

FLANGEBOlT10x 1.25mm54N·m(5.5kgf·m, 40 Ibf.ft)

STABllIZER BARAlign the stabilizer markwith end of stabilizer bushing.

DAMPERMOUNTING BOLT(FLANGEBOLTI10 x 1.25mmS4N·m(5.5 kgf·m, 40 Ibf.ftl

10mm FlANGE BOlT39 N'm (4.0 kgf·m, 29 IbHt)

UPPERARMCheck for bendingand damage.

UPPERARM INNERBUSHINGCheck for deteriorationand damage.

ADJUSTINGBOLT ~. SILICONE 1

(FlANGE BOlT) ~~ GREASE :10x1.25mm "64 N'm (6.5kgf·m, "47Ibf.ft) "

11

~ ",i~ \

\,

10 Je 1.25mmS4N·m(5.5kgf·m, 40 Ibf.ft)--- __ ~g:_ __ '\.~

FlANGE BOlT10x 1.25mm64N'm (6.5kgf·m,47 Ibf.ft)

STABILIZERBUSHINGFlANGE BOlT

• Make sure the toe adjusting bolts on the compensator arm are installed in the same direction.• Nt UP L" or lit UP LH G" or lit UP LK" or lit UP LS" is stamped on the left upper arm and lit UP R" or lit UP RH G" or

Ht UP RK" or Ut UP RS" on the right upper arm.• The right and left compensator arm are symmetrical. Install so the Ut UP" mark stamped side faces forward.• After installing the suspension arm, check the rear wheef alignment, and adjust if necessary (see page 18-4).

8mm BOlTS22 N·m (2.2kgf·m, 16 Ibf.ft)

STABILIZERBAR

NOTE:

CAUTION:• Replace the self-Iocking nuts after removal.• The vehicle should be on the ground before any bolts or nuts connected to rubber mounts or bushings are tightened.

'""UMM; When the suspension arms are to be removed. place additional weight in the trunk before hoisting. Whensubstantial weight is removed from the rear of the vehicle, the center of gravity may change causing the vehicle to tipforward.

Suspension Arms Replacement

Rear Suspension

18-21

(cont'd)

WHEELNUT12 x 1.5 mm108 N'm (11.0 kgf'm, 80 Ibf.ft)

Checkfor wearand damage.

10x 1.25 mm54 N'm (5.5 kgf·m, 40 Ibf.ftl

REARWHEELHUBBEARINGUNITCheckfor crackingand damage.

SPINDLENUT22x 1.5 mm181 N'm (18.5 kgf·m. 134 1bf·ft 1Replace.NOTE: After tightening, use a driftpunch ta lock the spindle nut shoulderinto the spindie.

TRAILINGARMCheckfor crackingand damage.

NOTE:• Use only genuine Honda wheel weights for aluminum wheels. Non-genuine wheel weights may corrode and damage

the aluminum wheels.• On the aluminum wheels, remove the center cap from the inside of the wheel after removing the wheel.• Before installing the brake drum, clean the mating surfaces of the rear hub and the brake drum.• Before installing the wheel, clean the mating surfaces of the brake drum and wheel.

Hub Bearing Unit Replacement

NOTE: Drive in the upper arm bushing and innerbushing until their leading edges are flush with theupper arm.

5. Drive the upper arm bushing into the upper arm.

4. Drive in the upper arm inner bushing with the marksaligned.

BOLTMOUNTINGSURFACE

MARK

3. Mark on the upper arm at two points 50 that theyare in li ne and make a right angle with the arm asshown.

2. Mark a scribe li ne on the upper arm inner bushingso that it is in line with the boit mounting surface.

REARUPPERARM

UPPERARMBUSHINGUPPERARM INNERBUSHING

Remove the upper arm bushing and inner bushingas shown.

1.

Upper Arm Bushing Replacement

18-22

9. Screw two 8 x 1.25 mm bolts into the drum to pushit away from the hub bearing unit.NOTE: Turn each boit two turns at a time to prevent cocking the drum excessively.


4. Pull the parking brake lever up.5. Remove the hub cap.6. Raise the locking tab on the spindle nut, then remove

the nut.7. Release the parking brake lever.a. Remove the brake drum, hub bearing unit and spin-

die washer. '8 x 1.25 mm BOLTS

D ~

HUBCAPReplace.NOTE: Takecare not ta damage the hub bearing uniton disassembly. WHEELNUT

12 x 1.5mm108 N'm (11.0 kgf·m, 80 Ibl·ft)

SPINOLENUT22x 1.5mm181 N'm 118.5 kgf·m, 134Ibl·ft)Replace.NOTE: After tightening, use a drift tastakethe spindle nut shoulder againstthe spindle.

1. loosen the wheel nuts slightly.2. Raise the rear of vehicle, and support it with safety

stands in the proper locations (see section 1).3. Remove the wheel nuts and rear wheel.

Hub Bearing Unit Replacement(cont'd)

Rear Suspension

18-23

DAMPER

6. Lower the rear suspension, and remove the damper.

5. Remove the tlange boit that connects the lower armto the trailing arm.

10 x 1.25mmFlANGE BOlT10 x 1.25mm

4. Remove the tlange boit trom the damper.

FLANGE NUTS10 x 1.25mm

3. Remove the two tlange nuts.

2. Remove the trunk side panel (see section 20).

1. Remove the rear wheels (see page 18-22).

Removal

Rear Damper

4. Check for oil leaks, abnormal noises and binding during these tests.

NOTE: The damper should move smoothly. If itdoes not (no compression or no extension), the gasis leaking, and the damper should be replaced.

3. Check for smooth operation through a full stroke,both compression and extension.

2. Push on the damper as shown.

1. Reassemble ail parts, except the spring.

Inspection

18-24

SlRUl SPRING COMPRESSOR:(Commercially availablelBRANICKe TIN 7200, TIN MST-580A,or equivalent

2. Release the pressure from the spring compressor,then disassemble the damper as shown on page 18-25.

Replace.10 x 1.25 mmSELF-LOCKING NUl

CAUTION: Do not compress the spring more thannecessary to remove the self-Iocking nut.

1. Compress the damper spring with the spring cornpressor according to the manufacturer's instructions, then remove the self-Iocking nut.

Disassembly

Disassembly Ilnspection

Rear Damper

18-25

10 x 1.25 mm29 N·m (3.0 kgf·m, 22 lbf-ft]Replace.

oAMPERMOUNTINGWASHER

SELF-LOCKING NUT

Hold the damper shaft with a hex wrench and tightenthe self-Iocking nut.

6.

5. Install the damper mounting washer, and looselyinstall a new self-Iocking nut.

4. Compress the damper spring with the spring cornpressor.

SPRING LOWER SEAT

STRUT SPRING COMPRESSOR:(Commercially available)BRANICKeT/N 7200, TIN MST-580A,

oAMPER MOUNTINGBASE

Position the damper mounting base on the damperunit as shown.

3.

NOTE: Align the bottom of damper spring andspring lower seat as shown.

Assemble the rear damper in reverse order of disassembly except the damper mounting washer andself-Iocking nut.

2.

NOTE: Follow the manufacturer's instructions.

Install the damper unit on a spring compressor.1.

Reassembly

oUSTCOVER.Check for bendingand damage.

Check for weakness,compression and damage.

SPRING MOUNTINGRUBBERCheck for deteriorationand damage,

OUST COVER PLATE BUMP STOPCheck for weaknessand damage,

e

deteriorationand damage.

Check for

SELF-LOCKING NUT10 x 1.25 mm29 N·m (3.0 kgf·m, 22 IbHt)

Replace. ~

oAMPERMOUNTINGWASHER ~

oAMPER MOUNTING ~@RUBBER ~Check for !deteriorationand damage. ~

oAMPER MOUNTINGCOLLAR

oAMPER ~@MOUNTING BASE ~ ~ ,

oAMPER MOUNTINGRUBBER

18-26

7. Check the rear wheel alignment and adjust if necessary (see page 18-4).

6. Tighten the two tlange nuts on top of the damper tothe specified torque.

5. Tighten the tlange boit.

'MnmbH The tloor jack must be securely positioned or personal injury may result.

4. Raise the rear suspension with a tloor jack until thevehicle just lifts off the satety stand.

FLANGE BOLT10 x 1.25 mm54 N'm (5.5 kgf·m,40Ibf.ft)

FLANGE BOLT

3. loosely install the tlange boit.

_ FLANGE NUTS10 x 1.25 mm49 N'm (5.0 kgf·m, 36 IbHt)Tighten these nuts inStep 7.

2. loosely install the two tlange nuts.

1.

Installation

Rear Damper

Conventional Brakes 19-1Anti-Iock Brake System (ABS) 19-25

Brakes

Rear Drum BrakeIndex/Inspection 19-18Inspection 19-19Brake Shoe Replacement 19-20

Brake Hoses/UnesInspection/T orque Specifications 19-22Hose Replacement 19-23

Parking Brake CableInspection and Replacement 19-24


Index 19-3Inspection and AdjustmentBrake System Rubber Parts

and Brake Booster ~ 19-4Brake Pedal 19-5Parking Brake 19-6Bleeding 19-7Brake System Indicator 19-8

Front Brake PadsInspection and Replacement 19-9

Front Brake DiscDisc Runout Inspection 19-11Disc Thickness and Parallelism

Inspection 19-11Front Brake Caliper

Disassembly 19-12Reassembly 19-13

Master Cylinder/Brake BoosterRemoval/lnstallation 19-15Pushrod Clearance Adjustment 19-16Brake Booster Inspection 19-17

Conventional 8rakes

19-2

19-1607JAG- 5040100 Pushrod Adjustment Gauge

Ref. No. Page ReferenceTooi Number . OtyDescription

Special Toois

1

19-3

FRONT BRAKESFront Brake Pads, page 19-9Front Brake Dise, page 19-11Front Brake Caliper, page 19-12

Adjustment, page 19-6

PARKING BRAKE CABLEInspection and Replacement,page 19-24

REAR DRUM BRAKESInspection, page 19-19Brake Shoe Replacement, page 19-201

MASTER CYUNDER/BRAKE BOOSTERRemovai/lnstailation, page 19-15Pushrod Clearance Adjustment, page 19-16Brake Booster Inspection, page 19-17

BRAKE HOSES/UNESInspectionfTorque specifications, page 19-22Hose Replacement, page 19-23

BRAKE PEDAL

Index

Component Locations

19-4

<ID Wheel Cylinder Piston Cup and Oust CoverCheck brake operation by applying the brakes.Visually check for damage or signs of fluid leakage.If the pedal does not operate properly, the brakesdrag, or there is damage or signs of fluid leakage,inspect the wheel cylinder. If necessary, replace thewheel cylinder as an assembly.

@ Caliper Piston Seal and Piston BootsCheck brake operation by applying the brakes.Visually check for damage or signs of fluid leakage.-If the pedaJ does not operate properly, the brakesdrag, or there is damage or signs of fluid leakage,disassemble and inspect the brake caliper. Replacethe boots and seals with new on es whenever thebrake caliper is disassembled.

© Brake HosesVisually check for damage or signs of fJuid Jeakage.Replace the brake hose with a new one if it is damaged or leaking.

• Check for a difference in brake pedal strokebetween quick and slow brake a-pplications.Replace the master cylinder if there is a difference in pedal stroke.

® Piston Cup and Pressure Cup Inspection• Check brake operation by applying the brakes.

Visually check for damage or signs of fJuid leakage. Replace the master cylinder as an assemblyif the pedal does not work properly or if there isdamage or signs of fluid leakage.

@ Brake BoosterCheck brake operation by applying the brakes.If the brakes do not work properly, check the brakebooster. Replace the brake booster as an assemblyif it does not work properly or if there are signs ofleakage.

Brake System Rubber Parts and Brake Booster


19-5

PEOAl FREE PLAY

CAUTION: If the pedal free play is insufficient, itmay result in brake drag.

2. If the pedal free play is out of specification, adjustthe brake switch.

Free Play: 1 - 5 mm (1/16 - 3/16 in)

Pedal Free Play1. With the engine off, inspect the playon the pedal

pad by pushing the pedal by hand.

5. Check the brake pedal free play as described below.

CAUTION: Make sure that the brake lights go offwh en the pedal is released.

4. Screw in the brake switch until its pluriger is fullydepressed (threaded end touching the pad on thepedal arm). Then back off the switch 1/4 turn tomake 0.3 mm (0.01 in) of clearance between thethreaded end and pad. Tighten the locknut firmly.Connect the brake switch connector.


NOTE: Do not adjust the pedal height with thepushrod depressed.

3. Loosen the pushrod locknut, and screw the pushrodin or out with pliers until the standard pedal heighttrom the tloor is reached. After adjustment, tightenthe locknut tirmly.

Standard Pedal Height (with carpet removed):MIT: 156.5 mm (6.16 in)AIT: 161 mm (6.34 in)

INSULATOR(CUTOUT)

MEASURINGPOINT

BRAKE SWITCHLOCKNUT

2. Turn up the carpet. At the insulator cutout, measurethe pedal height from the right side center of thepedal pad.

PUSHRODLOCKNUT

Pedal Height1. Disconnect the brake switch connector, loosen the

brake switch locknut, and back off the brake switchuntil it is no longer touching the brake pedal.

8rake Pedal

7. Reinstallthe rearconsole.

6. Makesure that the parking brakesare fully appliedwhen the parkingbrakelever is pulledup fully.

5. Releasethe parkingbrakeleverfully, andcheckthatthe rear wheels do not drag when turned. Readjustif necessary.

ADJUSTING NUT

4. Tighten the adjusting nut until the rearwheelsdragslightly when turned.

3. Pull the parkingbrakeleverup onenotch.

2. Removethe rearconsole(seesection20).

19-6

'%,.,MildN Block the front wheels before jackingup the rearof the vehicle.

1. Raise the rear wheels off the ground, and supportthe vehicleon safetystands.

NOTE:After rear brakeshoeservicing, loosen the parking brake adjusting nut, start the engine, and depressthe brake pedal several times to set the self-adjustingbrakebeforeadjustingthe parkingbrake.

Adjustment

2. Adjust the parkingbrakeif the levernotchesare outof specification.

LEVER LOCKED NOTCHES

~

PulJed up with 196 N (20 kgf, 44 Ibf)

PARKING ,BRAKE LEVER<,

lever locked Notches:6 - 9

Inspection1. Pull the parkingbrakeleverwith 196N (20kgf,44 Ibf)

force to fully apply the parking brake.The parkingbrake lever should be locked within the specifiednotches.

Parking 8rake


19-7

BLEEDSCREW7 N'm (0.7 kgf·m. 5 Ibf·h)

BLEEDSCREW9 N'm (0.9 kgf'm, 6.5 Ib"'t)

REAR:

FRONT:

E) Rear leha Front leh

..o Rear Righto Front Right

5. Refill the reservoir of master cylinder to the MAX(upper) levelline.

BLEEDING SEQUENCE:

4. Repeat the procedure for each wheel in the sequenceshown below until air bubbles no longer appear inthe fluid.

3. Loosen the brake bleed screw to allow air to escapetrom the system. Then tighten the bleed screwsecurely.

2. Have someone slowly pump the brake pedal severaltimes, then apply steady pressure.

MASTER CYUNDER

t. Make sure the brake tluid level in the reservoir is atthe MAX (upper) levelline.

NOTE: The reservoir on the master cylinder must be atthe MAX (upper) level mark at the start of bleeding procedure and checked atter bleeding each brake caliper.Add fluid as required.

CAUTION:• Always use Genuine Honda DOT3 8rake Fluid. Using a

non-Honda brake fluid can cause corrosion anddecrease the life of the system.

• Make sure no dirt or other foreign matter is allowedto contaminate the brake fluid.

• Do not spill brake fluid on the vehicle, it may damagethe paint; if brake fluid does contact the paint, washit off immediately with water.

Bleeding

s-,$witch contacts open atproper fluid level.

Switch contacts closedwhen float drops.

RESERVOIR CAP

B

\ Terminal

\ A BPosition

FLOATUP

FLOATDOWN


1. Remove the reservoir cap. Check that the tloatmoves up and down treely; if it doesn't, replace thereservoir cap assembly.

19-8

NOTE: If the parking brake switch is OK, but thebrase system indicator does not function, performthe input test for the daytime running lights controlunit (see section 23).

UP

1\ Terminal\ Positive Terminal Body Ground

Position

BRAKELEVERUP

BRAKELEVERDOWN


1. Remove the rear console, and disconnect the connector trom the switch.

Brake Fluid Level Switch TestParking Brake Switch Test

BRAKEFLUIDLEVELSWITCHON: Law

G~ED

~BU<

j_

8RAKESYSTEMlIGHT

GRNlRED

~

PARKINGBRAKESWITCHON: Pull

IGNITION SWITCH

[email protected]>---YEL -;:::~ __ --,

Brake System Indicator


19-9

(cont'd)

6. If the brake pad thickness is less than service limit,replace the front pads as a set.

NOTE: Measurement does not include pad backingplate thickness.

BACKING pLATE

8rake Pad Thickness:Standard: 9.5 -10.5 mm (0.37 - 0.41 in)Service Limit: 1.6 mm (0.06 in)

5. Using vernier calipers, measure the thickness ofeach brake pad lining.

Check for wear.

Check for wear.

NOTE: When the caliper is equipped with on outerpad shim, replace the shim together with the padsas a set.

4. Remove the pad shim, pad retainers and pads.

NOTE: Check the hoses and pin boots for damageand deterioration.

CALIPER BOLTCALIPER BODY

BRAKE HaSE BRACKET

3. Remove the caliper boit, and pivot the caliper upout of the way.

2. Remove the brake hose bracket from the knuckle.

1. Loosen the front wheel nuts slightly, then raise thevehicle, and support it on safety stands.

'MhhilidN• Never use an air hose or dry brush to clean brake

assemblies.• Use an OSHA approved vacuum cleaner to avoid

breathing brake dust.

Inspection and Replacement

Front 8rake Pads

16. After installation, check for leaks at hose and linejoints or connections, and retighten if necessary.

NOTE: Engagement of the brake may require agreater pedal stroke immediately after the brakepads have been replaced as a set. Several applications of the brake pedal will restore the normalpedal stroke.

15. Depress the brake pedal severa! times to make surethe brakes work, then test-drive.

NOTE: Inspect the brake hose for interference ortwisting.

14. Install the brake hose bracket on the knuckle.

CAUTION: Be careful not damage the pin bootwh en pivoting the ealiper down.

13. Pivot the caliper down into position, then installcaliper boit and tighten it.

CAUPER BOlT34 N'm (3.5kgf·m, 25 Ib"'t)

12. Push in the piston 50 that the caliper will fit over thepads. Make sure that the piston boot is in positionto prevent damaging it when pivoting the caliperdown.

19-10

NOTE: Install the pad with the wear indicator onthe inside.

'%hWM'• Wh en reusing the pads, always reinstall the

brake pads in their original positions to prevent105sof braking effieieney.

• Contaminated brake discs or pads reduee stopping ability. Keep grease off the dises and pads.

11. Install the brake pads and pad shim correctly.

INNER PAO

• Piston end and inner pad contact surface• Pad and caliper bracket contact surface• Outer pad and caliper body contact surface• Outer pad shim and outer pad contact surface• Outer pad shim and caliper body contact surface

NOTE: Use the pad grease included in the pad setor Molykote M77 grease, and apply a thin coat ofgrease evenly to the designated points.

10. Apply grease to the points indicated by the arrowsin the following illustration:

7. Clean the caliper thoroughly; remove any rust, andcheck for grooves and cracks.

8. Check the brake disc for damage and cracks.9. Install the pad retainers.

~l(

/' <,Inspection and Replacement (cont'd)

Front Brake Pads

19-11

NOTE: See section 18 for brake dise replacement.

4. If the dise is beyond the service limit for parallelism,refinish the brake dise with an on-car brake lathe.The Kwik-Lathe produeed by Kwik-Way Manufaeturing Co. and the "Front 8rake Dise Lathe" offeredby Snap-on Tools Co. are approved for this operation.

NOTE: This is the maximum allowable differencebetween the thickness measurements.

Brake Oise Parallelism: 0.015 mm (0.0006 in) max.

NOTE: Replace the brake dise if the smallest measurement is less than the max. refinishing limit.

8rake Oise Thiekness:Standard: 20.9 - 21.8 mm (0.82 - 0.86 in)Max. Refinishing Limit: 19.0 mm (0.75 in)

3. Using a micrometer, measure dise thickness ateight points, approximately 45° apart and 10 mm(0.4 in) in from the outer edge of the dise.

2. Remove the brake pads (see page 19-9).

1. Loosen the front wheel nuts slightly, then raise thevehicle, and support it on safety stands. Removethe front wheels.

Disc Thickness and ParallelismInspection

NOTE: A new dise should be refinished if its runoutis greater than 0.10 mm (0.004 in)

Max. Refinish Limit: 19.0 mm (0.75 in)

5. If the dise is beyond the service limit, refinish thebrake dise with an on-car brake lathe. The KwikLathe produced by Kwik-way manufaeturing Co.and the "Front 8rake Dise Lathe" offered by Snapon Tools Co. are approved for this operation.

WHEEl NUT ANDPLAIN WASHER108 N·m111 kgf'm, 80 IbHt)

Brake OiseRunout:Service Limit: 0.10 mm (0.004 in)

4. Use wheel nuts and suitable plain washers to holdthe dise securely against the hub, then mount a dialindicator as shown, and measure the runout at10 mm (0.4 in) from the outer edge of the dise.

3. Inspeet the dise surface for damage and cracks.Clean the dise thoroughly and remove ail rust.

2. Remove the brake pads (see page 19-9).

1. Loosen the front wheel nuts slightly, then raise thevehiele, and support it on safety stands. Removethe front wheels.

Disc Runout Inspection

Front Brake Dise

Replace.

CALIPER BODVCheck for scoringon cylinder wall.

PISTON SEAlbore.CAUTION: Take care not ta damage the cylinder

6. Remove the boot clip, piston boot and piston sea!.

5. Remove the piston trom the caliper, and check thepiston tor scoring.

'Mhwm;• Do not place your fingers in front of the piston.• Do not use high air pressure; use an OSHA

approved 30 PSI nozzle.

4. If necessary, apply compressed air to the caliperfluid inlet to get the piston out. Place a shop rag orwooden block as shawn to cushion the piston whenit is expelled. Use low pressure air in short spurts.

PIN BOOTSReplace.

CAUPER BRACKETCheck for cracks.

3.

19-12

2. Remove the caliper bolts, then remove the calipertrom the bracket.

Replace.

BANJO BOlT

CAUPER

1. Remove the banjo boit, and disconnect the brakehose from the caliper.



• Ta prevent spills, caver the hose joints with rags orshop towels.

• Clean ail parts in brake fluid and air dry; blow out ailpassages with compressed air.

'Mf.MiId;• Never use an air hase or dry brush ta elean brake

assemblies.• Use an OSHA approved vacuum eleaner ta avoid

breathing brake dust.

Disassembly

Front 8rake Caliper

19-13

(cont'd)

Replace. PISTON BOOTReplace.

_-UÏiDi. BOOTCLIP

PISTON JCAlIPER BODY

PISTON SEAl

.r:BlEED SCREW ~9 N·m (0.9 kgf·m, 6.5 Ibf·ftl

Install inner pad withits wear indicator upward.

;A-=NA~~

CALIPER BOLTS ~PAD RETAINERS34 N'm (3.5 kgf·m, 25 Ibf·ft)

~ ~

OUTER PAO SHIM

Replace.PIN BOOTS CALIPER BRACKET MOUNTING BOLT

/,108 N'm(11.0kgf·m,80Ib"'t)

-~ WCALIPER PIN B~ ""'" 1~ ~._

BRAKE PADS

NOTE:• Coat the piston, piston seal, and caliper bore with c1ean brake fluid.• Replace ail rubber parts with new ones whenever disassembled.

~: Use recommended rubber grease in the caliper seal set.

-~: Use recommended seal grease in the caliper seal set.

CAUTION:• 00 not spill brake fluid on the vehicle; it may damage the paint; if brake fluid does contact the paint, wash it off imme-

diately with water.• Clean ail parts in brake fluid and air dry; blow out ail passages with compressed air.• Before reassembling, check that ail parts are free of dust and other foreign particles.• Replace parts with new ones whenever specified to do so.• Make sure no dirt or other foreign matter is allowed to contaminate the brake fluid.• Always use Genuine Honda DOT 3 Brake Fluid. Using a non-Honda brake fluid can cause corrosion and decrease the

lite of the system.

'MUiJlibN .• Never use an air hose or dry brush to clean brake assemblies.• Use an aSHA approved vacuum cleaner to avoid breathing brake dust.• Contaminated brake dises or pads reduce stopping ability.• When reusing the pads, always reinstall the brake pads in their original positions to prevent loss of braking efficiency.

Reassembly

13. Fill the brake reservoir and bleed the brake system(see page 19-7).

14. Perform the following checks.• Check for leaks at hose and line joints and con

nections, and retighten if necessary.• Checkfor brake hoses for interference and twisting.

SEALING WASHERSBANJO SOlT34 N'm (3.5kgf·m, 25 Ibf.ft)

"

Insert pin A and pin B into the caliper bracket.Install the pin boots into the grooves in the pinsproperly.

9. Install the brake pads in their original positions (seepage 19-'0).

10. Push in the piston so that the caliper will fit over thepads, and install the caliper.

11. Tighten the caliper bolts.12. Connect the brake hose to the caliper with new seal

ing washers, and tighten the banjo boit.

-~PIN BOOTSReplace.

-~CALIPER PIN B

CALIPER BRACKET,-PIN BOOTReplace. ~

CALIPER PIN

5. Apply the recommended seal grease in th~ caliperseal set to the sliding surface' of the pins and theinside of the new pin boots.

6. Install the pin boots into the grooves in the caliperbracket properly.

19-14

/

4. Lubricate the caliper and piston with brake fluid,then install the piston in the cylinder with the dishedend facing in.

Replace...~SiliCONE GREASE

BOOTCLIP PISTON SEAlReplace.

~,r-----..j!~f:----.._::J RUBSER GREASE

CAUTION: Be careful not to damage the calipercylinder wall.

3. Apply the recommended seal grease in the caliperseal set to the sealing lips and inside of a new piston boot, and secure install it in the caliper with thenew boot clip.

2. Coat the new piston seal with the recommendedrubber grease in the caliper seal set, and install theseal in the cylinder groove.

1. Clean the piston and caliper bore with brake fluid,and inspect for wear and damage.

Reassembly (cont'd)

Front Brake Caliper

19-15

15 N'm (1.5 kgf·m.11 Ibf·ttl15 N'm (1.5 kgf·m. 11 Ibf·ttl

(With ABS: Ta modulator unit)

~--------------------~

BRAKE FLUID LEVELSWITCH CONNECTORS

BRAKE BOOSTER(With ABS: 7" + 8- tandem brake booster)

13. Fill the master cylinder reservoir, and bleed thebrake system (see page 19-7).

14. After installation, check the brake pedal height andbrake pedal free play (see page 19-5) and adjust ifnecessary.

NOTE: If replacing the master cylinder or brakebooster, check and adjust the pushrod clearancebefore installing the master cylinder (seepage 19-19).

CAUTION:• When connecting the brake lines, make sure

that there is no interference between the brakelines and other parts.

• Be careful not to bend or damage the brake lineswh en installing the master cylinder.

9. Remove the four booster mounting nuts.10. Pull the brake booster forward until the clevis is

clear of the bulkhead.11. Remove the brake booster from the engine corn

partment.12. Install the brake booster and master cylinder in the

reverse order of rernoval.

~-\To Front Caliper \(Without ABS)

corraa PINReplace.

CAUTION: Do not disconnect the clevis by removing it from the operating rod of the brake booster.If the clevis is loosened, adjust the pushrod lengthbefore installing the brake booster (seepage 19-17).

1. Disconnect the brake fluid level switch connectors.2. Remove the reservoir cap from the master cylinder.3. The brake fluid may be sucked out through the top

of the master cylinder reservoir with a syringe.4. Disconnect the brake lines from the master cylinder.5. Remove the master cylinder mounting nuts and

washers.6. Remove the master cylinder from the brake booster.7. Disconnect the vacuum hose from the brake booster.8. Remove the cotter pin and clevis pin from the clevis.

CAUTION:• Be careful not to bend or damage the brake lines when

removing the master cylinder.• Do not spill brake fluid on the vehicle; it may damage


• To prevent spills, coyer the hose joints with rags orshop towels.

Removal/lnstallation

Master Cylinder/Brake Booster

HOSEConnect a hose ofsuitable diameter.

(Commerciallyavailablel0-101 kPa(0 - 760 mm Hg, 30 in.Hg)

Clearance: 0 - 0.4 mm (0 - 0.02 in)

2. Without disturbing the center shaft's position, installthe special tool upside down on the booster.

3. Install the master cylinder nuts and tighten to thespecified torque.

4. Connect the booster in-line with a vacuum gauge 0 -101 kPa (Q - 760 mmHg, 30 in.Hg) to the booster'sengine vacuum supply, and maintain an enginespeed that will deliver 66 kPa (500 mmHg, 20 in.Hg)vacuum.

5. With a feeler gauge, measure the clearance betweenthe gauge body and the adjusting nut as shown.

AOJUSTINGNUT

PUSHROO AOJUSTMENT GAUGE07JAG- S040100

1. Set the special tool on the master cylinder body; pushin the center shaft until the top of it contacts the endof the secondary piston by turning the adjusting nut.

NOTE:• Master cylinder pushrod-to-piston clearance must be

checked and adjustments made, if necessary, beforeinstalling master cylinder.

• ABS type is shown, conventional brake type is similar.

19-16

MASTER CYLINDERCheck for leaks, rust and damage.

...-Uiim

/RESERVOIR

RODSEALCheck for damageand deterioration.

STRAINER

RESERVOIR CAPCheck for blockageof vent holes.

RESERVOIR SEALCheck for damage anddeterioration.



• Before reassembling, check that ail parts are free ofdust and other foreign particles.

• Do not try to disassemble the master cylinder assembly. Replace the master cylinder assembly with anew part if necessary.

• Make sure no dirt or other foreign matter is allowedto contaminate the brake fluid.

Pushrod ClearanceAdjustmentInspection/Disassembly

Master Cylinder/Brake Booster

19-17

BRAKE BOOSTERVACUUM HOSE

Booster Check Valve Test1. Disconnect the brake booster vacuum hose at the

booster.2. Start the-engine and let it idle. There should be vac

uum. If no vacuum is available, the check valve isnot working properly. Replace the brake boostervacuum hose and check valve, and retest.

leak Test1. Depress the brake pedal with the engine running,

then stop the engine. If the pedal height does notvary while depressed for 30 seconds, the vacuumbooster is OK. If the pedal rises, the booster isfaulty.

2. With the engine stopped, depress the brake pedalseveral times using normal pressure. When thepedal is first depressed, it should be low. On consecutive applications, the pedal height should gradually rise. If the pedal position does not vary, checkthe booster check valve.

Functional Test1. With the engine stopped, depress the brake pedal

several times to deplete the vacuum reservoir, thendepress the pedal hard and hold it for 15 seconds. Ifthe pedal sinks, either the master cylinder isbypassing internally, or the brake system (mastercylinder, lines, modulator, proportioning controlvalve, or caliper) is leaking.

2. Start the engine with the pedal depressed. If thepedal sinks slightly, the vacuum booster is operatingnormally. If the pedal height does not vary, thebooster or check valve is faulty.

3. With the engine running, depress the brake pedallightly. Apply just enough pressure to hold backautomatic transmission creep. If the brake pedalsinks more than 25 mm (1.0 in.) in three minutes;the master cylinder is faulty. A slight change inpedal height when the AlC compressor cycles onand off if normal. (The A/C compressor loadchanges the vacuum available to the booster.)

Brake Booster Inspection

10. Install the master cylinder (see page 19-15),

PUSHRODLOCKNUT15 N·m (1.5 kgf·m, 11 Ibf.ftl

PUSHROOAOJUSTMENT GAUGE07JAG - S0401 009. Adjust the pushrod length as shown if the booster

is removed.

8. Remove the special tool.o - 0.4 mm (0 - 0.02 in)

7. Tighten the star locknut securely.

NOTE:• Adjust the clearance while the specified vacuum

is applied to the booster.• Hold the clevis while adjusting.

6. If clearance is incorrect, loosen the star locknut andturn the adjuster in or out to adjust.

NOTE: If the clearance between the gauge bodyand adjusting nut is 0.4 mm (0.02 in), the pushrodto-piston clearance is 0 mm. However, if the clearance between the gauge body and adjusting nut iso mm, the pushrod-to-piston clearance is 0.4 mm(0.02 in) or more. Therefore it must be adjusted andrechecked.

19-18

BRAKE DRUMInspection. see page 19-19

SELF-ADJUSTERSPRINGCheck for weaknessand damage.

Check for weaknessand damage.

BRAKE SHOEInspection. see page 19-19If brake shoes are to bereused, mark and reassemblein same position.

ADJUSTER Bal TCheck ratchet teethfor wear and damage.

ClEVIS B

PIVOT PIN

i RETAINER SPRINGln stail securely on/,ens;on pin.

UPPER RETURN SPRINGCheck for weaknessand damage.

PARKING BRAKE LEVERMarked left and right.

8ACKING PLATEMarked left and right.

WHEEl CYLINDERIn~pect for leakage.If necessary. replace as an assembly.9 N'm (0.9 kgf·m. 6.5 Ibf.ftl

2. Releasethe parking brake, and remove the rear brake drum.

1. Block the front wheels, loosen the rear wheel nuts slightly, support the rear of vehicle on safety stands, then removethe rear wheels.

'MUMMN• Never use an air hose or dry brush to clean brake assemblies.• Use an OSHAapproved vacuum cleaner to avoid breathing brake dust.• Contaminated brake linings or drums reduce stopping ability.• Block the front wheels before jacking up the rear of the vehicle.

Index/Inspection

Rear Drum Brakes

19-19

8. Check the brake drum for scoring, grooves andcracks.

7. If the inside diameter of the brake drum is morethan service limit, replace the brake drum.

tBRAKE DRUM

Drum Inside Diameter:Standard: 199.9 - 200.0 mm (7.870 -7.874 in)Service Limit: 201.0 mm (7.913 in)

6. Measure the inside diameter of the brake drumusing the inside vernier calipers.

5. Check the bearings in the hub unit for smooth operation. If defective, refer to section 18.

4. If the brake lining thickness is less than servicelimit, replace the brake shoes as a set.

NOTE: Measurement does not incJude brake shoethickness.

LlNINGS

WHEEL CYLINDER

Brake Lining Thickness:Standard: 4.0 mm (0.157 in)Service Limit: 2.0 mm (0.08 in)

3. Measure the brake lining thickness.

2. Check the brake linings for cracking, glazing, wearand contamination.

1. Check the wheel cylinder for leakage.

Inspection

PIVOTPIN~<./ WAVE WASHER

~ (g ..-- U-CLIP~ Replace.

NOTE: Pinch the U-clip securely to prevent the pivotpin from coming out of the brake shoe.

8. Install the parking brake lever and wave washer onthe pivot pin and secure with U-clip.

7. Apply brake cylinder grease (PIN: 08733 - B020E) orequivalent rubber grease to the sliding surface ofthe pivot pin, and insert the pin into the brake shoe.

PARKING BRAKELEVER

PIVOT PIN<6. Remove the wave washer, parking brake lever and

pivot pin from the brake shoe by removing the Uclip.

19-20

SElF-ADJUSTERSPRING

SElF-ADJUSTERLEVER

~\\\\\\\\\,.)

UPPER RETURN SPRINGCheck for weaknessADJUSTER BOLT

Check ratchet teeth forwear and damage.

Remove the upper return spring, self-adjuster leverand self-adjuster spring, and separate the brakeshoes.

5.

Disconnect the parking brake cable from the parkingbrake lever.

4.

3. Remove the brake shoe assembly.

NOTE: Be careful not to damage the dust cover onthe wheel cylinder.

RETAINER SPRINGS

2. Lower the brake shoe assembly, and remove thelower return spring.

TENSION PINS

1. Remove the tension pins by pushing the retainersprings and turning them.

8rake Shoe Disassembly

Rear Drum Brakes

19-21

19. Adjust the parking brake (see page 19-6).

18. Depress the brake pedal several times to set theself-adjusting brake.

17. If the wheel cylinder has been removed, bleed thebrake system (see page 19-7), and check for leaks atbrake line connections, and retighten if necessary.

16. Install the brake drum.

LOWER RETURN SPRING

UPPER RETURN SPRING

15. Install the tension pins and retaining springs.

14. lnstall the lower return spring .

NOTE: Be careful not to damage the wheel cylinderdust covers.

13. Install the clevises and upper return spring notingthe installation direction .

12. Hook the self-adjuster spring to the self-adjusterlever first, then to the brake shoe.

11. Clean the threaded portions of clevises A and B.Coat the threads of the clevises with grease. Toshorten the clevises, turn the adjuster boit.

... Opposite edge of the shoec:') 0 Brake shoe ends

• Apply Molykote 44MA to the brake shoe ends andopposite edges of the shoes as shown.

.. • Siiding surface

• Apply brake cylinder grease (PIN: 08733 - B020E)or equivalent rubber grease to the sliding surfaces as shown.

'MlMilba Contaminated brake linings reducestopping ability. Keep grease or oil off the brake linings. Wipe any excess grease off the parts.

10. Apply grease on each sliding surface.

9. Connect the parking brake cable ta the parkingbrake lever.

19-22

BRAKE HOSE-to-CALIPER(BANJO BOLT)34 N'm (3.5kgf·m, 25 Ibf·ftl

ABS MODUlATOR UNIT

BRAKE UNE-to-BRAKE HOSE15N'm (1.5kgf·m, 11 Ibf·ftl

PROPORTIONING CONTROL VAlVEto-BRAKE UNE15N'm (1.5kgf·m, 111bf·ftl

BRAKE L1NE-to-WHEEl CYLINDER15N'm (1.5kgf·m, 11 Ibf.ft)BLEEDSCREW7 N'm (0.7kgf·m, 5 Ibf.ft)MASTER CVLlNDER-to-BRAKE UNE

15N'm (1.5 kgf·m, 11 Ibf.ft)

BRAKE UNE-to-BRAKE HOSE15N'm (1.5kgf·m, 111bHt)

CAUTION: Replace the brake hose clip whenever the brake hose is serviced.

4. Check the master cylinder and ABS modulator unit for damage and leakage.

3. Check for leaks at hose and line joints and connections, and retighten if necessary.

2. Check the brake lines for damage, rusting and leakage. Also check for bent brake lines.

1. Inspect the brake hoses for damage, deterioration, leaks, interference and twisting.

Inspection/Torque Specifications

Brake Hases/Lines

19-23

10. Perform the tollowing checks.• Check the brake hose and line joint for leaks. and

tighten if necessary.• Check the brake hoses for interference and twist

ing.

9. After installing the brake hose, bleed the brake system (see page 19-7).

8. Connect the brake line to the brake hose.

UPPERBRAKE HOSE BRACKET

BRAKE HOSE

BRAKE HOSE CLIPReplace.

15N'm(1.5 kgf·m. 11Ibf·ft,

7. Install the brake hose on the upper brake hose bracketwith a new brake hose clip.

BANJO BOlT34N·m(3.5 kgf·m. 25 Ibf·ft)

6 mm HOSE BRACKETBOlTS9.8N·m(1.0 kgf·m. 7 Ibf·ft,

6. Install the brake hose bracket and brake hose on theknuckle first, then connect the brake hose to thecaliper with the banjo boit and new sealing washers.

5. Remove the brake hose bracket from the knuckle.

4. Remove the banjo boit, and disconnect the brakehose from the caliper.

6 mm HOSE BRACKETBOlTS

BRAKE HOSE CLIP

3. Remove and discard the brake hose clip from thebrake hose.

FLARENUTWRENCH(Commerciallyavailable)

2. Disconnect the brake hose from the brake line usinga 10mm tiare nut wrench.

t. Replace the brake hose it the hose is twisted, cracked,or if it leaks.

CAUTION:• Before reassembling, check that ail parts are free of

dust and other foreign particles.• Replace parts with new ones whenever specified to

doso.• Do not spill brake fluid on the vehicle; it may damage


Hose Replacement

19-24

12mmOFFSET WRENCH(Cornmercialtv available)

BACKING PLATE

\Remave the parking brake cable tram the backing plateusing a 12 mm affset wrench as shawn.

PARKING BRAKE SWITCH--(Sliding surface)

EQUALIZER

operation.Check for smoothPARKING BRAKE LEVER

PARKING BRAKE CABLE

CAUTION: The parking brake cables must not be bent or distorted. This will lead to stiff operation and premature cablefailure.

Inspection and Replacement

Parking Brake Cable

OTC 11 -18:Wheel Sensor 19-45

OTC 31 - 38:Solenoid 19-47

OTC 51- 53:ABS Pump Motor 19-49

DTC 54:Main Relay 19-52

OTC 61:Ignition Voltage 19-54

OTC 81:Central Processing Unit (CPU) .... 19-55

Modulator UnitRemoval/lnstallation 19-56

ABS Control UnitReplacement 19-57

Pulsers/Wheel SensorsInspection 19-57Wheel Sensor Replacement 19-58

Special Toois 19-26Component Locations 19-27Anti-Iock Brake System (ABS)

Features/Construction 19-28Operation 19-29

Circuit Oiagram 19-32ABS Control Unit Terminal

Arrangement 19-34Troubleshooting Precautions 19-36Diagnostic Trouble Code (OTC)

Diagnostic Trouble Code (OTC)Indication (SCS Mode) 19-38

DTC Erasure (MES Mode) 19-39Troubleshooting Index 19-40

TroubleshootingABS Indicator light Ooes Not

Come On 19-41ABS Indicator light Ooes Not

Go Off (No OTC) 19-43

Anti-Iock Brake System (ABS)

19-26

19-3807PAZ - 0010100 SCS Service Connector

Page ReferenceRef. No. QtyTooi Number Description

Special Toois

1

19-27

MTR CHECK (7.5 Al FUSERA DEF RELAY (7.5 Al FUSE

PUMP MOTOR (40 Al FUSEABS +B (20 Al FUSECLOCK/METER (7.5 Al FUSE

UNDER-HOOD ABS FUSE/RELAV BOXUNDER-DASH FUSE/RELAV BOX

HORN/STOP (15 Al FUSE

GAUGE ASSEMBL VIG1 (40 Al FUSE

BATTERV(80 A) FUSE

UNDER-HOOD FUSE/RELAV BOX

LEFT-FRONT WHEEL SENSOR

RIGHT-FRONT WHEELSENSOR CONNECTOR

SERVICE CHECK CONNECTOR (2P)

Component Locations

19-28

NO: Normally OpenNe: Normally Closed

HELSENSOR

~

IlASTER CYL, M:lER

SUP RATE =.! = VEHICLE SPEED - WHEEl SPEEDC VEHICLE SPEEDSLIP RATE

A:Distance without slipB:Slipped distanceC: Actual distance to stop

cA

RADIALDIRECTIONOF THEROTATIONALDIRECTION

STOP POINTBRAKINGSTARTPOINTTARGET SLIP RATE

Slip RateGrip Force of Tire and Road Surface

COEFFICIENT OFFRICTION

When the brake pedaJ is depressed during driving, the wheeJs can Jock before the vehicle comes to a stop. Jn such a case,the maneuverability of the vehicle is reduced if the front wheels are Jocked, and the stability of the vehicJe is reduced if therear wheels are locked, creating an extremely unstable condition. The ABS precisely controls the slip rate of the wheels toensure the grip force of the tires, and it thereby ensures the maneuverbility and stability of the vehicle.Judging the vehicle speed, the ABS calculates the slip rate of the wheels based on the vehicle speed and the wheel speed,then it controls the brake fluid pressure to attain the target slip rate.

Features/Construction

Anti-Iock 8rake System (ABS)

19-29

(cont'd)

On-board Diagnosis FunctionThe ABS control unit is connected to the data link connector (16P).The ABS system can be diagnosed with the Honda PGM Tester.

The self-diagnosis can be classifield into these four categories.CD: Initial diagnosis@: Except ABS control@: During ABS control@: During warninq

*1: Except CPU failure

MODE ABS INDICATOR LlGHTMAIN SOLENOID

CPU Restart condition DTCRELAY VALVE

SYSTEMON No Drive Ignition 1 OFF- ON (II) Memory

DOWN operation inhibition Operation:" switch

CONTROLON No Drive

Operation Automatic MemoryINHIBITION operation inhibition

Self-diagnosis FunctionThe ABS control unit is equipped with a main CPU and a sub CPU, and the CPUs check each other.The CPUs check the circuit of the system.When the CPUs detect failure, they shift to the "system down mode" or the "control inhibition mode".

Main ControlThe ABS control unit detects the wheel speed based on the wheel sensor signal it received, then it calculates the vehiclespeed based on the detected wheel speed. The control unit detects the vehicle speed during deceleration based on therate of deceleration. .The ABS control unit calculates the slip rate of each wheel, and it transmits the control signal to the modulator unitsolenoid valve wh en the slip rate is high.The pressure reduction control is a three-mode system, that is pressure reduction, pressure retaining and pressure intensifying modes.

ABS Control Unit

Operation

19-30

Pressure intensifying mode: Inlet valve open, outlet valve closed IN: INLETVALVE (NORMALLYOPEN)Master cylinder fluid is pumped out to the caliper. OUT: OUTLET VALVE (NORMALlY CLOSEDl

Pressure retaining mode: Inlet valve closed, outlet valve closedCaliper fluid is retained by the inlet valve and outlet valve.

Pressure reduction mode: Inlet valve closed, outlet valve openCaliper fluid flows through the outlet valve to the reservoir.

Motor operation mode: When starting the pressure reduction mode, the pump motor is ON.When stopping ABS operation, the pump motor is OFF.The reservoir fluid is pumped out by the pump, through the damping chamber, to the mastercylinder.

LFRRLRRF

----------------------,1

11

11

11

11

11_J

MODULATOR UNIT,-----------------1

11

11

11

11

11

L _

MASTER CYlINDERPUMPMOTOR

The ABS modulator consists of the inlet solenoid valve, outlet solenoid valve, reservoir, pump, pump motor and thedamping chamber.The modulator reduces the caliper fluid pressure directly. It is a circulating-type modulator because the brake fluid circulatesthrough the caliper, reservoir and the master cylinder.The hydraulic control has three modes: pressure reduction, pressure retaining and pressure intensifying.The hydraulic circuit is the independent four channel-type, one channel for each wheel.

SOLENOIDVALVE

ABS Modulator

Operation (cont' d)

Anti-Iock Brake System (ABS)

19-31

at LOW SPEED

at HIGH SPEEDWHEEL SENSORGEAR PULSER

o

The wheel sensors are the magnetic contactless type.As the gear pulser teeth rotate past the wheel sensor's magnetic coil, AC current is generated. The AC frequency changesin accordance with the wheel speed. The ABS control unit detects the wheel sensor signal frequency and thereby detectsthe wheel speed.There are four wheel sensors, one for each wheel.The gear pulser has 50 teeth.

Wheel Sensor

When the wheel speed drops sharply below the vehicle speed, the inlet valve closes to retain the caliper fluid pressure.When the wheel speed drops further, the outlet valve opens momentarily to reduce the caliper fluid pressure. The pumpmotor starts at this time.As the wheel speed is restored, the inlet valve opens momentarily to increase the caliper fluid pressure.

PRESSURETIME

WHEEL SPEED

Wheel Speed and Modulator Control

Wire sideof famale terminais

Terminal sideof female terminais

GAUGEASSEMBLy SPCONNECTOR

Il L215JZ1s 1

PUMPMOTOR2P CONNECTOR(0number)

UNOER-DASHFUSEIRELAy BOX,8P CONNECTOR (0number)

MODULATORUNIT 10PCONNECTOR(Onumber)

UNDER-DASHFUSEIRELAy BOX20PCONNECTOR (0number)

LEFT-FRONT SOLENOID

...--+--==t:...~~II---:--<~.:..;;.;;.;.-----::l~----------MODULATOR UNITSCOM

RIGHT·FRONT SOLENOIDMD=t:t=~RED WHT

r----------------------------BLAANHT-------------

19-32

BRAKESWITCHCONNECTOR

UNDER-HOOOABS FUSEIRELAy BOX2P CONNECTOR (0number)

@J

UNDER-HOODABS FUSEIAELAy BOX3PCONNECTOR (0 number)

rrt2t1

WHT

LEFT -AEAR SOlENOID

RED---f\@ÎIN 1 GRNRED~~L

RIGHT·REAR SOLENOID

"'- ::=t:j=:__<J).-------RE::------------PUMPMOTOR

......-----------WHT-----~ l--------REO-@-BLK

_.------4'------------------------------------G~HT------------GIlrqNHT

r---------------------------------------BR~L-----------------------------------------------------------------~~D-------------

GAUGE ASSEMBL y1,:-------.1 5 ~~CATOR 11 LIGHT CIRCUIT

11

1

.B

I---------------------------------------WHT/GRNI---------UNDER·HOOD ABSFUSElRElAY BOX

IGNmoNSWlTCH

U>---<>--WHT-©:-S:_l_-o __ <1"' ~_-='--_

BRAlR�sv.TTCHUNDER·HOOD FUSEIRElAY BOX Close<!:arlke pedll depressed

HORN/STOPC1SAI ~....--<:>-... -Cf\..o---:>-WHT/GRN-U-GRNfNHT-------------------------GRNfNHT·--------:+

BATTERY

Circuit Diagram

19-33

Wire side al lemale terminaisTerminai side 01male terminais

DATA LlNKCONNECTOR (16P)ABS CONTROL UNIT 22P CONNECTOR(0 number)

WHEEL SENSOR2P CONNECTOR

FRONT~~:~REAR

r®


iimABS CONTROL UNIT 26P CONNECTOR(0 number)

---------------------------------------- REDiW~

-----------------------------------------BLU----~

------------------------------------- YHJBLU

WHEEL

FL1 GRNIORN~SENSORLEFT·

FLO - FRONT8R~ ,

FR1

GRtWLX~ _ RIGHT·FRO FRONT

GRN ,--------------------- VEtmLK

------------------~~~--------~-----

+BY' G401-:-G402

OLC W~!RED14 LTBLU~DATALINK .

~ CONNECTOR ('6PI

BLX..A..

ECM 1PCM(SCS) SERVICECHECK

I ~.. N__ ... CTrFPI.L

----------------------GR~~-----------ëj5~---BRAKELlGHT

19-34

Terminal Wire Terminal signVoltage

Description Measurement Conditionsnumber col or (Terminal name)terminais (Ignition Switch ON (11)) Output voltage

PCOM Power source for the solenoid "0 ON OV"(5, GRN/WHT (Primary valve and pump motor. '-GND ON cCI)

CI)

common) 0 OFF AC: 3-6 Vc en'0,SCOM Power source for the solenoid c OFFw

2 SlK/WHT (Secondary valve. 2-GND (ConnecttheSCSserviCe) Approx. 3 Vcommon) connector

3 SlKIBlU IG2 Detecta ignition switch 2 3-GND VS(Ignition 2) signal. (System activa te signal)

4 BlU/YEl RRO Detects right-rear wheel 4-'7 53mVoraboveon(Rear-right 0) sensor signal.

When the wheel is digitaltester(AC

6 GRY RlO Detects left-rear wheel sensor 6-19 turned at 1 turn/second. range)(Referance)fRear-left 0) signal. 150mVp-porabove

FRO Detects right-front wheel onoscilloscope8 GRN (Front-right 0) sensor signal. 8-21 Stops Approx.2.5V

GRN/WHT STOP Detectsbrakeswitchsignal. Srake pedal depressed. VB9 9-GND(Stop) (PreventsunnecessaryABSoperation) Srake pedal released. OV

Detects left-front wheel sensor 53mVoraboveonsignal. When the wheel is digitaltester(AC

10 BRN/WHT FlO 10-23 turned at 1 turn/ range)(Referance)(Front-Ieft 0) second. 150mVp-porabove

onoscilloscopeStops Approx. 2.5 V

Drives left-rear outlet solenoid "0 ON OVRL-OUT '012 YEl valve. 12-GND ON c

(Rear-Ieftoutlet) CI)CI)

0 OFF AC: 3-6 Vc en'0,RR-IN Drives right-rear inlet solenoid c: OFFw

13 RED/VVHT (Rear-right valve. 13-GND (ConnecttheSCSserviCe) Approx. 3 Vinlet) connector

14 ~HT/GRN B1 Power source for the solenoid 14-GND(Batterv 1) valve and pump motor.B2 Power source for the solenoid

VB15 WHT/GRN (Battery 2) valve and pump motor. 15-GND

16 BLK GND2 Ground for the ABS control 16-GND BelowO.3 V(Ground 2) unit.

17 GRN/YEL RR1 Detects right-rear wheel 17-4(Rear-right 1) sensor signal. 53 mV or above

RL1 Detects left-rear wheel sensor on digital tester19 LTBLU (Rear-Ieft 1) signal. 19-6 When the wheel is turned (AC range)

at 1 turn/second. (Referance) 15021 GRN/BLK FR1 Detects right-front wheel 21-8 mVp-p or above

(Front-right 1) sensor signal. on oscilloscope

23 GRN/ORN Fl1 Detects left-front wheel sensor 23-10(Front-Ieft 1) signal. Stops Approx. 2.5 VDrives Jeft-rear inlet solenoid "0 ON OV'0valve. ON c

CI)CI) '0 OFF AC: 3-6 VRL-IN c: en25 RED (Rear-Ieft inlet) 25-GND '0,

OFFc:w (connecttheSCSserviCe) Approx. 3 V

connector

26 8LK GND3 Ground for the ABS control 26-GND 8elow 0.3 V(Ground3) unit.

VS: Sattery VoltageWire side of female terminais

ABS CONTROLUNIT26P CONNECTOR

ABS Control Unit Terminal Arrangement

19-35

Terminal Wire Terminal signVoltage

Description Measurement Conditionsnumber color (Terminal name)tenninals (Ignition Switch ON (11)) Output voltage

Drives right-front inlet "'C ON OVë5solenoid valve. ON c:

CDCP

FR-IN "0 OFF AC: 3-6Vc en1 RED/BLU (Front-right 1-GND riOFFinlet) cw

(ConnecttheSCSservie, Approx. 3 Vconnector

SCS Detects service check signal SCS service connector OV(Diagnostic trouble code connected.

4 BRN (Service check 4-GNDsignal) indication) SCS service connector Approx. 5 Vdisconnected.

WALP Drives ABS indicator light (The Indicator light ON Approx. 2 V7 BLU/RED (Warning indicator light goes off when 7-GNDABS control unit outputs bat-lamp) tery voltage). Indicator light OFF VB

FL-OUT Drives left-front outlet "'C ON OV10 YEL/BLK (Front-Ieft solenoid valve. 10-GND '0ON c:

outlet) CP"0 OFF AC: 3-6VCD en

FL-IN Drives left-front inlet solenoid c11 RED/BLK (Front-Ieftinlet) valve. 11-GND '0

c OFFwFR-OUT Drives right-front outlet (connecttheSCSservie, Approx. 3 V

12 YEL/BLU (Front-right solenoid valve. 12-GND connectoroutlet)DLC Communicates with Honda

14 LT BLU (Data link PGM Tester. 14-GND -- Approx. 5 Vconnector)

MCK Detects pump motor drive Pump ON VB17 BRN/YEL (Motor check) signal. H-GND motor

relay OFF OV

Drives pump motor relay. "'C ON OV'0ON c:

CDCP

PMR "0 OFF AC: 3-6 Vc en19 YEL/RED (Pump motor 19-GND '0OFFrelay) cw

(ConnecttheSCSservic~ Approx. 3 Vconnector

Drives right-rear outlet Pump ON OVsolenoid valve. ON motor

AC: 3':6 VRR-OUT CD relay OFFc21 BLU (Rear-right 21-GND '0,

OFFoutlet) cw(ConnecttheSCSservie, Approx. 3 V

connector .

22 BLK GND2 Ground for the ABS control 22-GND BelowO.3 V(Ground 2) unit.

VS: Sattery VoltageWire side of female terminais

ABS CONTROLUNIT 22PCONNECTOR

19-36

*1: Except CPU failure

MODE ABS INOICATOR LlGHT MAIN SOLENOIOCPU Restart condition OTC

RELAY VALVE

SYSTEMON No Drive Ignition 1 OFF- ON (II) Memory

OOWN operation inhibition Operation*' switch

CONTROLON No Drive Operation Automatic Memory

INHIBITION operation inhibition

Self-diagnosis1. The self-diagnosis can be classifield into these four categories.

• Initial diagnosis: Performed right after the engine starts and until the ABS indicator light goes off.• Except ABS control: Performed when the ABS is not functioning.• Ouring ABS control: Performed when the ABS is functioning.• Ouring warning: Performed when the ABS indicator light is ON.

2. The system performs the following controls when a problem is detected by the self-diagnosis.• ABS indicator light ON• Memory of OTC• Mode change to the "system down mode" or the "control inhibition mode".

Diagnostic Trouble Code (DTC)1. The diagnostic trouble code (OTC) is memorized when a problem is detected and the ABS indicator light does not go

off, or when the ABS indlcator light comes on.The OTC is not memorized when the ABS indicator light comes on unless the CPU is activated.

2. The memory can hold any number of OTCs. However, when the same OTe is detected twice or more, the later one iswritten over the old one.Therefore, when the same problem is detected repeatedly, it is recorded as one OTC.

3. The OTCsare indicated in the order of ascending number, not in the order they occur.4. The OTCsare memorized in the EEPROM (non-volatile memory).

Therefore, the memorized OTCs cannot be canceled by disconnecting the battery. Perform the specified procedures toerase.

ABS Indicator Light1. If the system is OK, the ABS indicator light goes off two seconds after turning the ignition switch ON (II) without start

ing the engine. After starting the engine, the ABS indicator light cornes on again and goes off after two seconds. Thisoccurs because the ABS control unit is activated by the IG2 power source.

2. The ABS indicator light comes on when the ABS control unit detects a problem in the system. However, even thoughthe system is normal, the ABS indicator light can come on, too, under the following conditions. To determine theactual cause of problem, question the customer about the problem, taking the following conditions into consideration.• Signal disturbance• Wheel spin• Only drive wheels rotate• Battery voltage fluctuates

3. When a problem is detected and the ABS indicator light comes on, the indicator light can stay on until the ignitionswitch is turned off, or it can automatically go off, depending on the mode.• Light stays on until the ignition switch is turned off: When the system is in the system down mode.• Light automatically goes off:' When the system is in the control inhibition mode.

(refer to symptom-to-system chart)4. The ABS indicator light stays on when the system is reactivated without erasing the OTC, but it goes off after starting

the vehicle.When the wheel sensor system is faulty and the ABS indicator light comes on, the algorithm of the system automaticallyturns off the ABS indicator light after the wheel speed signal returns to the normal speed. While, when the OTCis erased,the CPU is reset and the ABS indicator light goes off when the system checked out normal by the initial diagnosis.Therefore, test-drive the vehicle after servicing the wheel sensor system, and be sure that the ABS indicator light doesnot come on.

5. When the ABS control unit outputs battery voltage to gauge assembly, the ABS indicator light goes off.

Troubleshooting Precautions

19-37

Connect the PGMTester ta the 16PData Link Connector (DLC).When the System Select menu is displayed, select theABSTest Mode menu and follow the tester's prompts.

ABS Function TestTo simulate ABS operation and activate the solenoid valves and pump, use the Honda PGMTester.

5. The connector illustrations show the female connectors with a single outline and the male connector with a doubleoutline.

4. After troubleshooting, erase the DTCand test-drive the vehicle. Be sure that the ABS indicator light does not come on.

3. When the ABS indicator light does not come on during the test-drive, but the troubleshooting is performed based onthe DTC,check for the loose connectors, poor contact of the terminais, etc, before troubleshooting.

2. Question the customer about the conditions when the problem occurred, and try to reproduce the same conditions fortroubleshooting.Self-diagnosis is made at various times such as the initial diagnosis, except ABS control, during ABS control, duringacceleration, during the specified vehicle speed, etc. Therefore, the symptom cannat be checked unless the checkconditions match with the problem conditions.

Troubleshooting1. The troubleshooting flowcharts procedures assume that the cause of the problem is still present and the ABS indica

tor light is still on. Following the flowchart when the ABS indicator light does not come on can result in incorrectjudgement.

Brake Fluid Replacementl Air Bleeding1. Brakefluid replacement and air bleeding procedures are the same as vehicles without ABS.Toeasebleeding, start with

the front wheels.

2. The ABS control unit checks the pump motor operation during acceleration. You may hear the faint operation soundat this time, but it is normal.

Pump Motor1. The pump motor operates when the ABS is functioning.

2. The ABS control unit operates the solenoid valve when the brake pedal is released after the initial diagnosis. You mayhear the faint solenoid valve operation sound at this time, but it is normal.

Kickback1. The motor operates when the ABS is functioning, and the fluid in the reservoir is forced out ta the master cylinder

causing kickback at the brake pedal.

19-38

• When ignition switch is turned ON (II), the ABS indicator light cornes on to check the bulb. Do not count it as a OTC.• The ABS control unit can memorize any number of DTCs.• The new DTC is not memorized when the ABS control unit has already memorized the same DTC.• If the DTC is not memorized, the ABS indicator light stays ON after it goes off for 3.6 seconds.

Secondcycle

0.4 sec.

3.6 sec.3.6 sec.

OTC: 3 3

ABS INDICATOR LlGHT

*:Bulb check mode

0.3 sec.

First cycle

Ignition SwitchON (II)

3.6sec.2 sec.

OFF ---- --------+------4

ON - - - - -.r----..ABS INDICATOR LlGHT

OTe: 12

SERVICE CHECKCONNECTOR (2PI

The OTC indication stops and the ABS control unit executes the software function if at least one of the following conditions is satisfied.• The car is not stopped.• The ABS control unit receives the normal signal (which is for the ABS control unit) from a Honda PGM Tester.• The SCS service connector is disconnected during this procedure.

Conditions for OTC indication• The car is stopped.• The SCS service connector is connected before the ignition switch is turned ON (II).• The brake pedal is released.• The SCS service connector remains connected during this procedure.

5. Erase the OTC.

4. Turn the ignition switch OFF, and remove the SCS service connector.NOTE: The Malfunction Indicator Lamp (MIL) will stay on after the engine is started if the SCS service connector isconnected.

3. Record the blinking frequency of the ABS indicator light. The blinking frequency indicates the OTC.

2. Turn the ignition switch ON (II).NOTE: Do not depress the brake pedal when turning the ignition switch.

t. Connect the SCS service connector to the service check connector inside the passenger's side kick panel.

NOTE: This operation can also be done with the Honda PGM Tester.

Diagnostic Trouble Code (DTC) Indication (SCS Mode)

Diagnostic Trouble Code (OTC)

19-39

Ignition switchON (II)

AELEASED

DEPRESSED

BRAKE PEDAL

ON

ABS INDICATOR LlG

-+ f+-- - -- .. ....ole .. ... .. ... ..

HT 2 sec. 4 sec. 4 sec. 4 sec. 2 sec.

- 1.. .. ._s

-+ ._within 3 sec~ ...within 3 sec.p 1

...within 3 sec. Q. 3 sec.----- 1 -----

1 1 11 1 11 1 1

. - - - - ---------- 1 _____ J 1 C1

OFF

Q. 3 sec.

The OTC erasure stops and ABS control unit executes the software function if at least one of the following conditions issatisfied.• The car is not stopped.• The SCS service connector is disconnected during this service.• The ABS control unit receives the normal signal (which is for the ABS control unit) from a Honda PGM Tester.• The brake pedal is not operated according to the indicator light indication.'• The DTC erasure is finished.

Conditions for OTC erasure• The car is stopped.• The SCS service connector is connected before the ignition switch is turned ON (11).• The brake pedal is depressed before the ignition switch is turned ON (II).• The SCS service connector remains connected during this procedure.

NOTE: Always maintain these steps. If you disconnect the SCS service connector and/or fail to operate the brake pedalaccording to the indicator light indication, the DTC will not be erased.

8. Confirm the DTC indication, and check that the DTC was erased.

7. After four seconds, the indicator light blinks twice for 0.3 second and the DTC is erased.

6. After the indicator light goes off, release the brake pedal again.

5. After the indicator light comes on, depress the brake pedal again. The indicator light goes off again after four seconds. (the brake pedal is still depressed.)

4. After the indicator Iight goes off, release the brake pedal. The indicator light comes on after four seconds.

3. Turn the ignition switch ON (II) while keeping the brake pedal depressed. The ABS indicator light goes off after twoseconds.

2. Depress the brake pedal.

1. Connect the SCS service connector to the service check connector inside the passenger's side kick panel.

NOTE: This operation can also be done with the Honda PGM Tester.

OTe Erasure (MES Mode)

19-40

*: If OTCs11-18 (wheel sensor codes) were detected the last the vehicle was driven, the ABS indicator light will stay onuntil the ignition switch is turned ON (II), and the control unit confirms that the wheel sensors are OK.

DETECTIONTIMINGa::0 CI)

~ REFER(1) ...... ëi) ~ 0 PROBLEMDTC mc:(X DIAGNOSIS/SYMPTOM c:( .... ct .... O~ TOc:(~~ ..JO

t::0 eJo LOCATIONc:(2~~

22 PAGE~ -0 w~ -a::

Cc:( a::c:(00 ~o E~2- ~o_0 cu

OFF ABS indicator light does not come on when ignition 19-41No switch is turned ON (11).

OTC ABS indicator light does not go off after engine isON started. (No OTC) 19-43

11 FR13 Wheel sensor (open/short to body ground/short to 0 0 0 0

FlON* power) 19-45

15 RR17 Rl12 FR14 Wheel sensor/Pulser (chipped pulser gear/electrical 0 0 0

FlON* noise) 19-45

16 RR18 Rl31 FR-IN

32 FR-OUT

33 Fl-IN34 Solenoid (open/short to body ground/short to 0 0 0

FL-OUTON power/stuck) 19-47

35 RR-IN36 RR-OUT37 RL-IN

38 RL-OUT51 ON Motor lock 0 0 19-49

52 ON Motor stuck OFF 0 0 19-49

53 ON Motor stuck ON 0 19-4954 ON Main relay stuck OFF 0 0 0 19-5261 ON Ignition voltage (Iow voltage/high voltage) 0 0 0 0 19-54

81 ON CPU 0 0 0 0 19-55

NOTE: This operation can also be done with the Honda PGMTester.

Troubleshooting Index

Diagnostic Trouble Code (OTe)

19-41

(cont'd)

~G'(YELI


GAUGEASSEMBLy 5PCONNECTOR

(Topage19-42)

The ABS indicator light does notcome on when ignition switch isturned ON (11).

Checkthe CLOCK/METER(7.5A) NOTE:Ali indicator lights except the charg-

fuse in the under-dashfuse/relay ing system light will not come on when the

box. CLOCK/METER(7.5A) fuse is blown.

NO 1

~Is the fuseOK?1

Replacethe fuseand recheck.

YESNOTE:Reinstallthefuse if it is OK.

Checkfor an open in the IG1eir-cuit:1. Disconnectthe gauge assem-

bly 5Pconnector.2. Turnthe ignitionswitchON(II).3. Measurethe voltage between

the gauge assembly 5P con-nector terminal No. 5 andbody ground.

• Repairopenin the wire betweenthe CLOCK/METER(7.5A) fuse

NO andgaugeassembly.Is there batteryvoltage? • Replace the under-dash fuselYES

1

relay box. (Open circuit insidethe box.

Check the ABS indicator light1bulb in the gaugeassembly.

NO Replacethe ABS indicator lightIs the bulb OK? bulb.YES

Checkfor a short to power in theWALPcircuit:Measurethe voltage betweenthegauge assembly 5P connectorterminal No. 1and body ground.

Repairshort to power in the wireYESIs there batteryvoltage? between the gauge assembly

1 NO

andABScontrol unit.

The ABS indicator light does not come on when ignition switch is turned ON (11).

ABS Indicator Light Does Not Come On

Troubleshooting

Wire side of female terminais=

GAUGE ASSEMBLy 5P CONNECTOR

Replace the ABS ;nd;cator lightdrive circuit in the gauge assembly.

NO

19-42

• Repair open in the wirebetween the gauge assemblyand body ground .

• Repair poor ground (G401,G4021.

YES

Does the ABS indicatorlight come on7

Check the gauge assembly:1. Turn the ignition switch OFF.2. Connect the gauge assembly

5P connector.3. Connect the terminal No. 3 to

body ground with a jumperwire.

4. Turn the ignition switch ON (11).

1

(From page 19-41)

ABS Indicator light Does Not Come On (cont'd)

Troubleshooting

19-43

(cont'd)

Repair open in the wire betweenthe ABS +B (20 A) fuse and ABScontrol unit.

Wire side of female terminaisNO

Bl (WH

Repair open in the wire betweenthe RR OEFRElAY (7.5 A) fuseand ABS control unit. ABS CONTROLUNIT 26P CONNECTOR

NO


Replacethe fuse and recheck.NO

(To page 19-44)

YES


Check for an open in the Bl andB2circuit:Measure the voltage betweenbody ground and terminais No. 14and No. 15 individually.

YES


Check for an open in the IG2 circuit:1. Turn the ignition switch ON (11).2. Measure the voltage between

the ABS control unit 26P connector terminal No. 3 andbody ground.

ABS CONTROLUNIT 26P CONNECTOR

IG2 (BlK/BlU)

NOTE: Reinstall the fuse if it is OK.YES

Is the fuse OK?

1

Check the ABS +B (20 Al fuse inthe under-hood fuse/relaybox.

L------,---___"

YES NOTE: Reinstall the fuse if it is OK.

NOIs the fuse OK? Replacethe fuse and recheck.

Check the RRDEFRELAY(7.5 Alfuse in the under-dash fuse/relaybox.

- Wrth engine running, the ABSindicator light is ON.

- Wrth the ses service connector connected(seepage 19-38),no OTCis indicated.

The ABS indicator light does not go off after the engine is started.

ABS Indicator Light Does Not Go Off (No OTe)


GAUGE ASSEMBl y 5P CONNECTOR

• Repair open in the wire betweenthe ABS control unit and bodyground.

• Repair poor ground (G401,G402).

YES


ABS CONTROL UNIT 26P CONNECTOR

WAlP (BlU/RED)



WAlP (BlU/RED)

Repair open in the wire betweenthe ABS control unit and gaugeassembly.

Check for loose ABS control unitconnectors. If necessary, substitute a known-good ABS controlunit and recheck.

NO


Check for an open in the GND2circuit:t. Connect the ABS control unit

26P connector terminal No. 16to body ground with a jumperwire.

2. Measure the voltage betweenthe ABS control unit 22P connector terminal No. 7 andbody ground.

Repair short to body ground inthe wire between the ABS control unit and gauge assembly.

NO

NO

YES

19-44

Replace the ABS indicator lightdrive circuit in the gauge assembly.

YES


Check for an open in the WAlPcircuit:Measure the voltage between thegauge assembly 5P connectorterminal No. 1 and body ground.

YES


Check the ABS control unit:1. Connect the ABS control unit

22P connector.2. Turn the ignition switch ON (II).3. Measure the voltage between

the ABS control unit 22P connector terminal No. 7 andbodv ground.

NO


Check for a short to body groundin the WALP circuit:1. Turn the ignition switch OFF.2. Disconnect the ABS control

unit 22P and gauge assembly5P connectors.

3. Check for continuity betweenthe ABS control unit 22P connector terminal No. 7 andbody ground.

(From page 19-43)

ABS Indicator Light Does Not Go Off (No OTe) (cont'd)

Troubleshooting

19-45

(conr'd)


FR1 (GRN/BLK)RLl (LT BLU)


RLO(GRY) FRO(GRN)

(Ta page 19-46)

Is there continuity?YES

Check for a short to body groundin the wheel sensor circuit:1. Oisconnect the ABS control

unit 26P connector.2. Check for continuity between

the ABS control unit 26P connectar appropriate wheel sensor (0) circuit terminal andbody ground (see table).

NONOTE:• Normal voltage: Approx. 2 V• 0 V: Replace the ABS control unit.• 4 V or more indicates a short ta power.

• Repair short to body ground inthe (0) or (1) circuit wirebetween the ABS control unitand appropriate wheel sensor.

• Replace the appropriate wheelsensor.

Is there 4 Var more?YES

Repair short to power in the (0)or (1) circuit wire between theABS control unit and appropriatewheel sensor.

NOTE: Judgement value for short ta poweris 4 V.

Check for a short to power in thewheel sensor circuit:1. Reconnect the ABS control unit

26Pconnector.2. Start the engine.3. Measure the voltage between

the ABS control unit 26P connectar appropriate wheel sensor (0) circuit terminal andbody ground (see table).

YES

Is the resistance OK? NO

(Front: 750 - 1050 O/20°C 1 ;---

Rear: 850 - 1150 O/20°C (orum)~

• Repair open in the (0) or (1) circuit wire, or short to the (0) circuit wire in the (1) circuit wirebetween the ABS control unitand appropriate wheel sensor.

• Replace the appropriate wheelsensor.

Check the wheel sensor circuit: OTCAppropriate Terminal

1. Oisconnect the ABS control (O)SIDE (1)SIDE

unit 26P connector. 11.12(Right-front) No. 8: FRO No. 21: FR12. Measure the resistance 13.14(Left-front) No. 10:FLO No. 23:FL1

between the appropriate wheel 15. 16 (Right-rear) No. 4: RRO No..17:RR1sensor (0) and (1) circuit termi-

17. 18(Left-rear) No.6: RLO No. 19:RL1nais (see table).

- With the ignition switch ON(II), the ABS indicator lightdoes not go off.

- After driving, the ABS lndicator light comes on.

- With the SCS service eonneetor connected (see page 19-38),OTCs11 - 18are indicated.

NOTE: The ABS indicator light comes on when only the drive wheels are turning, signal disturbance is detected, etc. Therefore,test-drive the car at a speed of 12 mph (20 krn/h) or more after turning the ignition switch from OFF to ON (11), and if the ABSindicator light does not come on, the system is OK.

OTe 11 - 18: Wheel Sensor

19-46

OTC 11, 13, 15, 17: Replace theABS control unit.OTe 12, 14, 16, 18: The ABS control unit may have detected signaI disturbance.

YES

Is the wheel sensor installedcorrectly?

Reinstall the wheel sensor correctly.

Check the wheel sensor installation.

YES

Is the pulser OK? Replace the driveshaft or hubunit. (Chipped pulser gear.'

Check for chipped pulser gear.

(From page 19-45)

OTe 11 - 18: Wheel Sensor (cont'd)

Troubleshooting

19-47

(cont'd)

FR-IN (RED/BLU)




FR-IN (RED/BLU)


Fl-OUT (YEl/BLK)

Check for loose ABS control unitconnectors. If necessary, substitute a known-good ABS controlunit and recheck.

NO

DTC AppropriateTerminal

31: FR-IN No. 2: SCOM32:FA-OUT NO.2:SCOM33: Fl-IN No. 1:PCOM34: Fl-OUT NO.1:PCOM35:RR-IN No. 1:PCOM36:RR-OUT No. 1:PCOM37:Al-IN No.2:SCOM38: Rl-OUT No. 2: SCOM

YES• Repair short to body ground inthe appropriate solenoid circuitwire between the ABS controlunit and modulator unit .

• Replace the modulator unit.

Repair short to power in theappropriate solenoid circuit wirebetween the ABS control unitand modulator unit.

YES

DTC Appropriate AppropriateConnector Terminal

31: FR-IN 22P No. 132:FR-OUT 22P No. 1233: Fl-IN 22P NO.1134: Fl-OUT 22P No. 1035:RR·IN 26P No. 1336:RR-OUT 22P No. 2137:Al-IN 26P No. 2538: Rl-OUT 26P No. 12

(To page 19-48)

YES


Check the ABS control unit:1. Turn the ignition switch OFF.2. Connect the ABS control unit

22P and 26P connectors.3. Connect the SCS service con

nector.4. Turn the ignition switch ON (II).5. Measure the voltage between

the appropriate ABS controlunit 26P connector COM circuitterminal and body ground (seetable).

NO


Check for a short to body groundin the solenoid circuit:Check for conti nuit y between theappropriate solenoid circuit terrninaI and body ground (see table).

NO


Check for a short to power in thesolenoid circuit:1. Disconnect the ABS control

unit 22P and 26P connectors.2. Start the engine.3. Measure the voltage between

the appropriate ABS controlunit connector solenoid circuitterminal and body ground (seetable).

With the ignition switch ON(II), the ABS indicator lightdoes not go off, or the ABSindicator light comes onwhile ABS is functioning.

- With the ses service connector connected (see page 19-38),DTCs31 - 38 are indicated.

OTe 31 - 38: Solenoid


RL-OUT (YEL)

RR-IN(RED/WHT)




19-48

oTC Appropriate AppropriateConnector Terminal

31: FA-IN 22P No. 132: FA-OUT 22P No. 1233: FL-IN 22P No. 1134: FL-OUT 22P No. 1035: AA-IN 26P No. 13

Check for an open in the solenoid 36: AA-OUT 22P No. 21circuit: 37: AL-IN 26P No. 25Measure the voltage between the 38: AL-OUT 26P No. 12appropriate ABS control unit con-nector solenoid circuit terminaland body ground (see table).

• • Repair open in the appropriateCOM circuit wire between theABS control unit and modulator

NO unit.Is there approx. 3 V? • Repair open in the appropriate

solenoid circuit wire betweenYES the ABS control unit and modu-

lator unit.• Replace the modulator unit.

Check for loose ABS control unitconnectors. If necessary, substi-tute a known-good ABS controlunit and recheck.

(From page 19-47)

OTe 31 - 38: Solenoid (cont'd)

Troubleshooting

19-49

rre page 19-50)


- With the SCS service connec-tor connected (seepage 19-38),OTCs51 - 53 are indicated.

Check the MTR CHECK(7.5A) fusein the under-hood ABS fuse/relaybox.

NOIs the fuse OK? Replace the fuse and recheck.

ABS CONTROL UNIT 22P CONNECTORYES NOTE: Short the PMR terminal to body

,.. ,.. F=I nNOTE: Reinstall ground for a moment, and recheck the fuse. Il [/1/1 4 VI/! 7 VV1lOJll 1the fuse if it is OK. If the fuse is blown, check for a short to body

ground in the MCK circuit. [12 VI14 VVl171/! 19V121 1221-Check the PUMP MOTOR (40 Al

PMR (YEL/REO) JUMPER

fuse in the under-hood ABS fuselWIRE

relay box. -

Wire side of female terminaIsNO

Is the fuse OK? Replace the fuse and recheck.

YES NOTE: Short the PMR terminal to bodvNOTE: Reinstall ground for a moment, and recheck the fuse.

the fuse if it is OK. If the fuse is blown, check for a short to bodyground in the wire between the under-hood

1

ABS fuse/relay box and pump motor.Check the pump motor relay (seesection 23).

NOIs the relay OK? Replace the pump motor relay.

YES

Check the pump motor powersource circuit:Turn the ignition switch ON (11).

YES Check for a short to power in theOoes the pump motor operate? pump motor power source circuit:

Remove the pump motor relay.NO

1YES

Repair short to power in the wirebetween the under-hood ABS

Ooes the pump motor operate? fuse/relay box and ABS pump

1 NOmotor.


(cont'd)

OTe 51 - 53: ABS Pump Motor



Replace the modulator unit.(Faulty pump motor)

terminaismale

Terminalside of

Repair open in the w;re betweenthe under-hood ABS fuse/relaybox and pump motor.

NO

PUMP MOTOR 2P CONNECTOR(m) ~OR.B IWHTI

Terminal side of female terminais

+BTERMINAL

UNDER-HOOD ABSFUSE/RELAy BOX

JUMPERWIRE

Repair short to body ground inthe wire between the underhood ABS fuse/relay box andABS control unit.

Repair open in the wire betweenthe pump motor and body ground,or poor ground (G301).

YES

Ooes the pump motor operate?

Check the pump motor operation:Connect the battery (+) terminal tothe pump motor 2P connector terminai No. 1, and the (-) terminal tathe terminal No. 2 for a moment.

YES


Check for an open in the pumpmotor +B circuit:1. Turn the ignition switch OFF.2. Oisconnect the pump motor

2P connector.3. Turn the ignition switch ON (11).4. Connect the pump motor relay

connector +B and MOTOR terminais with a jumper wire.

- 5. Measure the voltage betweenthe pump motor 2P connectorterminal No. 1 and bodyground.

YES

NO

19-50

(Ta page 19-511

NO


Check for a short to body groundin the PMR circuit:1. Turn the ignition switch OFF.2. Oisconnect the ABS control

unit 22P connector.3. Check for continuity between

terminal No. 19 and bodyground.

YES

Ooes the pump motor operate?

Check the pump motor circuit:1. Remove the pump motor relay.2. Turn the ignition switch ON (11).3. Connect the pump motor relay

connector +B and MOTOR terminais with a jumper wire fora moment.

(From page 19-491

OTe 51 - 53: ABS Pump Motor (cont'd)

Troubleshooting

19-51



1

Check for an open in the PCOMcircuit:1. Turn the ignition switch OFF.2. Reconnect the ABS control

unit 22P connector.3. Connect the SCS service con-

nector.4. Turn the ignition switch ON (11).5. Measure the voltage between

the pump motor relay con-nector PCOM terminal andbodv ground.

NO Repair open in the wire betweenIs there approx. 3 V? the under-hood ABS fuse/relay

box and ABS control unit.YES

Check for an open in the PMR cir-cuit:Measure the voltage between theABS control unit 22P connectorterminal No. 19 and body ground.

NO Repair open in the wire betweenIs there approx. 3 V? the under-hood ABS fuse/relay


Check for an open in the MCKcircuit:1. Turn the ignition switch OFF.2. Disconnect the SCS service

connector.3. Turn the ignition switch ON (11).4. Measure the voltage between

the ABS control unit 22P con-nector terminal No. 11 andbody ground while connect-ing the pump motor relayconnector +B and MOTOR ter-minai with a jumper wire formoment.

NO Repair open in the wire betweenIs there battery voltage? the under-hood ABS fuse/relay



(From page 19-50)

19-52

(Ta page19-53)

SCOM(BLK/WHT)

MIWHTI

Wire sideof femaleterminais=

ABSCONTROLUNIT22PCONNECTOR

Wire side of femaleterminais-=-=

ABSCONTROLUNIT26PCONNECTOR

- With the ignition switch ON(II), the ABS indicator lightdoesnot go off.

- With the ses serviceconnec-tor connected(588page19-38),OTC54 is Indicated.

Checkthe ABS +B (20 A) fuse inthe under-hood ABS fuse/relaybox.

NO1 Replacethe fuse and recheck.Is the fuseOK?1

YESNOTE: Reinstallthe fuse if it is OK.

BlCheckfor an open in the B1, B2 IWHTIcircuit:Measure the voltage betweenbody groundand the ABScontrolunit 26PconnectorterminalNo.14andNo. 15 individually.

NO Repairopen in the wire betweenIsthere batteryvoltage? the ABS control unit and under-

hood ABSfuse/relav box.YES

Checkfor a short to bOdygroundin the PMRcircuit:1. Turn the ignition switchOFF.2. Disconnect the ABS control

unit 22Pconnector.3. Checkfor continuity between

terminal No. 19 and bodyground.

YESRepair short to body ground inthe wire between the under-15 therecontinuity? hood ABS fuse/relav box andABScontrol unit.NO

Checkfor a short to body ground PCOin the PCOM,SCOMcircuit: (GRN1. Removethepumpmotorrelay.2. Disconnect the ABS control

unit 26Pconnector.3. Checlefor continuity between

bodygroundandtheABScon-• Repair short to body ground introl unit 26Pterminais No. 1the PCOMcircuit wire betweenandNo.2 individually.the ABScontrol unit and under-hood ABSfuse/relav box.

YES • Repair short to body ground inIstherecontinuity? the PCOMor SCOMcircuit wireNO between the ABS control unit

andmodulator unit.• Replace the modulator unit.(Short circuit insidethe unit)

OTe 54: Main Relay

Troubleshooting

19-53


ABS CONTROLUNIT 26P CONNECTOR

PCOM(GRN/WHT)

1

Check for a short to power in thePCOM,SCOM circuit:1. Start the engine.2. Measure the voltage between

body ground and ABS control • Repair short to power in theunit 26P connector terminais PCOM circuit wire between theNo. 1 and No. 2 individually. ABS control unit and under-1 hood ABS fuse/relay box.

YES • Repair short to power in theIs there 8 V or more?PCOM or SCOM circuit wire

1 NObetween the ABS control unitand modulator unit.

Turn the ignition switch OFF and • Replace the modulator unit.(Short to power inside the unit)connect the SCS service connec-

tor. Then turn the ignition switch NOTE: 8 V or more indicates a short toON (II) and measure the voltage power.between the PCOM and SCOMterminaIs and body ground. Ifthere is 0 V, replace the ABS con-trol unit.

(From page 19-52)


ABSCONTROLUNIT 26PCONNECTOR

19-54

- With the engine running, theABS indicator light is ON.

- Wlth the ses service connec-tor connected (seepage19-50),OTC61 is indicated.

Problem verification:1. Erasethe OTC.2. Start the engine.

NOOoesthe ABS indicator light 1 lcome on and is OTC61 indicated? 1The system is OK at this time.

YES

Checkthe IG2circuit:Measure the voltage between theABS control unit 26P connectorterminal No. 3 and body ground.

15 there 18V or above?YES 1

Checkthe charging system. l1

NO

If the voltage is 0 V, check for anopen in the IG2circuit.If there is 12 - 17 V, substitute aknown-good ABS control unit andrecheck.

OTe 61: Ignition Voltage

Troubleshooting

19-55


- With the ses service connec-tor connectec:l (see page 19-50),OTe 81 is indicated.

Problem verification:1. Erase the OTC.2. Test-drive the vehicle.

YESOoes the ABS indicator light 11come on and is OTC 81 indicated? 1

Replace the ABS control unit.

NO

The system is OK at this time.

OTC 81: Central Processing Unit (CPU)

19-56

TORX BOLT9.8 N'm 11.0 kgf'm, 7 Ibf·ft)

MODULA TOR UNIT

PUMPMOTOR2P CONNECTOR

Fromright·rearMODULA TOR UNIT

10P CONNECTOR

(

5. Test-drive the vehicle, and check that the ABS indicator light does not come on.

4. Start the engine, and check that the ABS indicator light goe5 off.

3. Bleed the brake system, starting with the front wheels.

2. Connect the modulator unit 10Pand pump motor 2P connectors.

1. Install the modulator unit, then connect the brake lines.

Installation

2. Disconnect the brake lines, then remove the modulator unit.

1. Disconnect the modulator unit 10Pand pump motor 2P connectors.

Removal

NOTE: Tighten the flare nuts to 15 N'm (1.5 kgf'm, 11 lbf-ft).

CAUTION:• Do not spill brake fluid on the vehicle; it may damage the paint; if brake fluid does contact the paint, wash it off imme

diately with water.• Take care not to damage or deform the brake lines during removal and installation.• To prevent the brake fluid trom flowing, plug and coyer the hose ends and joints with a shop towel or equivalent

material.

Removal/lnstallation

Modulator Unit

19-57

Rear

Front

NOTE: If the gap exceeds 1.0 mm (0.04 in), theprobability is a distorted suspension arm whichshould be replaced.

Standard: 0.4 - 1.0 mm (0.02 - 0.04 in)

2. Measure the air gap between the wheel sensor andpulser ail the way around while rotating the pulser.

1. Check the front and rear pulser for chipped or damaged teeth.

CONNECTORS

ABS CONTROL UNIT

4. Install the ABS control unit in the reverse order ofremoval.

3. Remove the ABS control unit.

2. Disconnect the ABS control unit connectors.

1. Remove the right side kick panel.

InspectionReplacement

Pulsers!WheelSensorsABS Control Unit

19-58

WHEEL SENSOR

1. Remove the hub bearing unit (see section 18).2. Remove the four backing plate bolts.3. Pull the backing plate away trom the trailing arm, then remove the wheel sensor. It is not necessary to disconnect the

brake fine.

Rear

Front

NOTE:• Be careful when installing the sensors to avoid twisting the wires .• The torque value of the bolts is at 9.8 N'm (1.0 kgf-m, 7 Ibf·ft).

Wheel Sensor Replacement

Pulsers/Wheel Sensors

NOTE: The original radio has a coded theft protection circuit. Be sure to get the customer's code number before- disconnecting the battery.- removing the No. 47 (7.5 A) fuse from the under-hood fuse/relay box.- removing the radio.After service, reconnect power to the radio and turn it on. When the word "CODE" is displayed, enter the customer's5-digit code to restore radio operation.

','",nw@;• To avoid rendering the SRS inoperative, which could lead to personal injury or death in the event of severe

frontal collision, ail SRS service work must be performed by an authorized Acura dealer.• Improper service procedures, including incorrect removal and installation of the SRS, could lead to personal

injury caused by unintentional activation of the airbags.• Do not bump the SRS unit. Otherwise, the system may fail in case of a collision, or the airbags may deploy

when the ignition switch is ON (II).• Ali SRS electrical wiring harnesses are covered with yellow insulation. Related components are located in the

steering column, front console, dashboard, dashboard lower panel, and in the dashboard above the glove box.Do not use electrical test equipment on these circuits.

The Acura 1.6ELSRS includes a driver's airbag located in the steering wheel hub, and a passenger's airbag locatedin the dashboard above the glove box. Information necessary to safely service the SRS is included in this ServiceManual. Items marked with an asterisk (*) on the contents page include, or are located near, SRS components.Servicing, disassembling or replacing these items will require special precautions and tools, and should therefore bedone by an authorized Acura dealer.

SUPPLEMENTAL RESTRAINT SYSTEM (SRS) (if body maintenance is required)

DoorsFront Door Index 20-2Rear Door Index 20-8

EmblemsInstallation 20-76

ExteriorComponent Location Index 20-58

* Frame Repair Chart 20-78*Interior

Component Location Index 20-38MirrorsIndex 20-17Power Mirror RemovallInstallation 20-18

Mirror Holder RemovallInstallation 20-18

Mirror Coyer Removai/lnstailation 20-19Rearview Mirror Removal/Installation 20-19

MoonroofIndex 20-30

Opener Cable/Opener and LatchlWiper and WasherComponent Location Index 20-69

SeatsComponent Location Index 20-50

Sub-frame 20-77Windshield/Rear WindowIndex 20-20

Body

20-2

~SPEAKER

OOOR POCKET

OOOR

~SPEAKER ~COVER

11--._-- OOOR PANELRemoval/lnstallation,page 20-4

~ DOOR~ PROTECTOR

OOORAdjustment, page20-16

POWER WINOOWSWITCH

PLASTICCOVER

OUTER --tl~

WEATHERSTRIP

INNERWEATHERSTRIP

1

Front Door Index

Doors

20-3

INNERHANDLE

POWER DOORLOCKACTUATOR

LATCHPROTECTOR

INNER HANDLE ROD

OUTER HANDLE . 20-5Removaltlnstallatlon, page

REGULA TOR . ~Hemoval/lnstallation,page 20-6 ~ ~

GLASS RUNCHANNEL

LATCH .Removal/lnstallatlon,20-6

CYUNDERROD

STRIKERAdjustment,page 20-16

LOCKRODPROTECTOR

CENTER LOWERCHANNEL

GLASS .Rernovel/lnstallation,page 20-6Adjustment,page 20-14

Installation is the reverse of the removal procedure.4.

Disconnect thespeaker connector.

OOOR PANEL

1

ij

1

CLIP iREMOVER

--_.Y

[>: Clip locations, 5

1mm(0.04 in)

TRIM PAOREMOVER(Commerciallyavailable)Snap-on#A177A, orequivalent

1 95 mm (3.74 in)

~~

L~r' ,1 145 mm(1.77 in)

12mm(0.47 in)

NOTE: Remove the door panel with as little bendingas possible to avoid creasing or breaking it.

3. Release the clips that ho Id the door panel. Removethe door panel by pulling it upward.

20-4

SPEAKERCOVER

Speaker cover:

POWER WINOOWSWITCH

Ooor grip cover:

~: Screw location, 5

~I

t>: Hook locations

A~ IB~.~IC~ID~~({)2. Remove the door grip cover and speaker cover, then

remove the screws.

1. Remove:• Inner handle (see page 20-3)• Mirror mount cover panel (see page 20-18)

NOTE: Take care not to scratch the door panel and otherparts.

Door Panel Removai/lnstailation

Ooors

20-5

6. Installation is the reverse of the removal procedure.NOTE: Make sure the door locks and opens properly.

BUSHINGReplace.

~

OUTER HAN OLEROD

Pull out the outer handle. Pry the outer handle rodout of its joint using diagonal cutters.NOTE:• To ease reassembly, note distance location @ of

the outer handle rod on the joint before disconnecting it.

• Take care not to bend the outer handle rod.• Use a shop towel to protect the opening in the

door.

5.

CYLINDERPROTECTOR

\

B ...., 1

@= 1

~ 6xl.0mm~ 9.8 N·m (1.0 kgf·m,

7.2Ibf.ft)

Remove the bolts and screw, then remove the cylinder protector, lock cylinder, cylinder switch andouter handle.....: Boit, screw locationsA"", 2

4.

RETAINERCLIP

LOCK CYLINDER

3. Pull out the retainer clip.

LOCKROD

2. Disconnect the connector, and detach the harnessclip from the door.

1. Remove:• Door panel (see page 20-2)• Plastic coyer (see page 20-2)

NOTE: Raise the glass fully.

Outer Handle Removai/lnstailation

REGULATOR

6x 1.0mm9.8 N·m (1.0 kgf·m.7.2IbHt)

...: Boit locations, 2

NOTE: Take care not to drop the glass inside the door.

2. Carefully move the glass until vou can see the bolts,th en remove them. Carefully pull the glass outthrough the window slot.

1. Remove:• Ooor panel (see page 20-4)• Plastic cover (see page 20-2)

Glass and Regulator RemovallInstallation

20-6

NOTE:• Make sure the inner handle rod and connector

are connected properly.• Make sure the door locks and opens properly.

4. Installation is the reverse of the removal procedure.

CENTER LOWERCHANNEL

HARNESS-----~~~~~~rCLIP

LOCK ROD

6x 1.0 mm6 N·m (0.6 kgf·m,4lbHt)

...: Screw locations, 3

NOTE: Take care not to bend any of the rods.

3. Oisconnect the connector, and detach the harnessclip trom the door. Remove the latch through thehole in the door.

2. Remove the boit, then move the center lower channelforward.

1. Remove:• Door panel (see page 20-4)• Plastic cover (see page 20-2)• Outer handle (see page 20-5)

NOTE: Raise the glass fully up.

Latch Removal/lnstallation

Doors

20-7

NOTE: Roll the glass up and down to see if it movesfreely without binding. Also make sure that there isno clearance between the glass and glass run channel when the glass is closed. Adjust the position ofthe glass as necessary (see page 20-14).


POWER WINDOWMOTOR

REGULATOR

4. Grease ail the sliding surfaces of the regulator whereshown.

AHARNESSCLIP--

REGULATOR

6x 1.0mm~ 8 N·m (0.8 kgf·m.~6Ibf.ft'

Loosen.

6x 1.0mm~ 8 N·m (0.8 kgf·m.

6Ibf·ft)

B~.3A~.4

~: Boit locations

3. Disconnect the connector, and detach the harnessclip, then remove the regulator through the hole inthe door.

20-8

DOORGRIPCOYER

DOORGRIP

-DOOR PANELRemoval/lnstallafpage 20-10 Ion,

DOORPROTECTOR

DOORAdjustmentpage 20-16 '

SASHTRIM

OUTERWEATHERSTRIP

Rear Door Index

Doors

20-9

INNERHANDLE

INNERHANDLEROD

POWERDOOR RLOCK ACTUATO

LOCKROD

LATCH .ai/ Installation,Remov

page 20-12

CENTERLOWERCHANNEL

REGULATOR .l/lnstallation.Remova

page 20-12

UTER HAN OLE . e 20-11o I/Installat.on, pagRemova ER WINDOW

POWMOTOR

~REAR CHANNEL ~COLLAR

c;.

~

REAR CHANNEL

GLASSRUNCHANNEL

QUARTER

GLASS . ge 20-12I/Installat.on, paRemova

STRIKERAdjustment,page 20-16

GLASS . age 20-12l/lnstallation. pRemova e20-14Adjustment, pag


DOORPANEL

1

1

1

1

TRIMPAD U'REMOVER

---------

t>: Clip locations. 7

1mmL~ .-, '(0.04 in) T 1 1

45 mm(1.77 in)

TRIM PAOREMOVER(Commerciallyavailable)Snap-on#A177A, orequivalent

1 95 mm (3.74 in)

j__ 112mm ~(0.47;n) .--

NOTE: Remove the door panel with as little bending as possible to avoid creasing or breaking it.

3. Release the clips that hold the door panel. Removethe door panel by pulling it upward.

20-10

DOOR GRIPCOVER

Disconnect theconnector.

CLIP

1>:Hook, clip locationsAI>,9 81>,1 CI>,1

@jS@j....: Screw location, 1

~

2. Remove the door grip cover, then remove the screws.

1. Remove:• Inner handle (see page 20-9)• Regulator handle (see page 20-4)

NOTE: Take care not to scratch the door panel and otherparts.

Ooor Panel Removal/lnstallation

Doors

20-11

NOTE: Make sure the door locks and opens properly.


SHOPTOWEl

OUTERHANDlE

OUTERHANDLEROD

BUSHINGReplace.

~:

NOTE:• To ease reassembly, note location ® of the outer

handle rod on the joint before disconnecting it.• Take care not to bend the outer handle rod.• Use a shop towel to protect the opening in the

door .

4. Pull out the outer handle. Pry the outer handle rodout of its joint using diagonal cutters.

6 x 1.0 mm9.8N·m(1.0 kgf·m, 7.2 Ibf.ft)

....: Boit locations, 2

3. Move the latch down, and remove the bolts .

LJLLATCH

6x 1.0 mm6 N·m (0.6 kgf·m,4Ibf.ft)

....: Screw locations, 3

2. Remove the screws.

1. Remove:• Door panel• Plastic cover (see page 20-8)


Outer Handle Removai/lnstailation

6xl.0mm~ N·m (0.8 kgf·m. 6Ibf·ft)~_jI!l!J))

B,l

A,l

~6)(1.0mm~ 8 N'm (0.8 kgf'm,

6lbf·ftl

C,l

~: Boit, screw locations


3. Carefully lower the glass. Remove the bolts andscrew from the rear channel, th en remove the glasstrom the rear channel.

6 x 1.0 mm9.8 N·m (1.0 kgf·m,7.2Ibf·ftl

~: BoIt locations, 2


2. Carefullv move the glass until vou can see the bolts,then rem ove them.

1. Remove:• Door panel (see page 20-10)• Plastic cover (see page 20-8)

Glass and Regulator RemovallInstallation

20-12

NOTE: Make sure the door locks and opens properlv.

Installation is the reverse of the removal procedure.5.

Remove the latch through the hole in the door.4.

Disconnect theconnector.

6x 1.0mm8 N'm (0.8 kgf·m.6Ibf.ft)

NOTE: Take care not to bend the lock rod and innerhandle rod.

3. Remove the rear channel collar.

LOCKCRANK

~J 1>: Clip location. 1

~

~: Screw location. 1

2. Remove the lock crank and clip.

1. Remove:• Door panel (see page 20-10)• Plastic cover (see page 20-8)• Outer handle (see page 20-11)


Latch Removai/lnstailation

Doors

20-13

NOTE: Roll the glass up and down to see if it movesfreely without binding. Also make sure that there isno clearance between the glass and glass run channel wh en the glass is closed. Adjust the position ofthe glass as necessary (see page 20-14).

REGULATOR8. Installation is the reverse of the removal procedure.

6x 1.0mm7 N·m(O.7kgf·m.S.bf·ftl


NOTE:• If necessary, remove the power window motor

from the regulator.• Before removing the power window motor, scribe

a line across the sector gear and regulator.

SECTOR GEAR REGULATOR

CLIP7. Grease ail the sliding surfaces of the regulator where

shown.

B .....26 x 1.0mm8 N'm (0.8 kgf·m.6.bf·ftlLoosen.

6 x 1.0mm8 N'm 10.8kgf·m.6Ibf·ft)

6. Disconnect the connector, and detach the harnessclip, then remove the regulator through the hole inthe door.

OUTERMOLD'NG

QUARTERGLASS

4. Carefully remove the glass from the window slot.

Front:

~: Front and rearchannel mountingboit locations

g. Push the front or rear channels against theglass while you tighten the mounting bolts.

f. Lower the glass.

e. Loosen the front channel mounting bolts(front door or rear channel mounting boit (reardoor).

REGULATOR

GLASS

Rear:

20-14

REGULATOR

Front:

A"': Glass mounting boitlocations.

B"': Regulator mountingboit locations.

d. Tighten the glass mounting bolts (front door)and regulator mounting bolts.

c. Push the glass rearward (front door glass) orforward (rear door glass).

b. Loosen the glass mounting bolts (front door)and regulator mounting bolts.

a. Raise the glass fully.

2. Adjust the glass.

1. Remove:• Door panel (see page 20-4, 10)• Plastic cover (see page 20-2, 8)

NOTE:• Place the vehicle on a firm, level surface when adjust

ing the glass.• Check the weatherstrips and glass run channel for dam

age or deterioration, and replace them if necessary.

Glass Adjustment

Doors

20-15

7. Reattach the plastic cover, then reinstall the doorpanel (see pages 20-4, 10).

12 mm (0.47 in) 1~r'_'_(,o'~~ 0.5 m C1.6ftl

HOSE ~UHOSE

NOTE:• Adjust the water pressure as shown.• Do not squeeze the tip of the hose.

Spray water over the roof and on the sealing areaas shown.

6. Check for water leaks.

NOTE: Check that the glass contacts the glass runchannel evenly.

5. Check the glass operation.

4. Raise the glass fully and check for gaps.

3. Check that the glass moves smoothly.

Rear:

4. If the door latches properly, loosen the screws, thenremove the shop towel. Tighten the screws andre~~~ .

CAUTION: Do not tap the striker too hard.

3. Wrap the striker with a shop towel, then adjust thestriker by tapping it with a plastic hammer.

2. lightly tighten the screws.

SHOPTOWEL

8x 1.25 mm18 N·m Il.8 kgf·m.13Ibf·ft)

3mm10.1 in)

1.5mm 1.5mm10.059 in) 10.059 in)

STRIKER

1. loosen the screws, then insert a shop towel betweenthe body and striker.

NOTE: The striker nuts are fixed. The striker can beadjusted 1.5 mm (0.059 in) up or down, and 3 mm (0.1 in)in or out.

Make sure the door latches securely without slamming.If it needs adjustment:

20-16

NOTE: Check for water leaks.

If necessarv, . ~adju~t the dO~~f.cushions, ~

SHOPTOWEL

HINGES

8 x 1.25 mm28 N'm 12.9kgf·m, 21 Ibf·ft)Remove the inner tender.loosen the hinge mountingbolts, and move the doorBACKWARD or FORWARD,UP or DOWN as necessaryta equalize the gaps.Lower the glass.

CAUTION: Place a shop towel on the jack to preventdamage to the door when loosening the door and hingemounting bolts for adjustment.DOOR MOUNTING BOLTS8x 1.25 mm28 N'm (2.9 kgf·m. 21Ibf·ft)Loosen the door mounting bolts slightlyto move the door IN or OUT untilifs flush with the body. If necessary,you can install a shim behind onehinge to make the door edgesPARALLEL with the body.

___y-D __OOR HINGE HINGE MOUNTING BOLTS

~\

After installing the door, check for a flush fit with thebody, then check for equal gaps between the front, rear,and bottom door edges and the body. The door andbody edges should also be parallel, Adjust at the hingesas shown.

NOTE: Place the vehicle on a firm, level surface whenadjusting the doors.

NOTE: Hold the outer handle out, and push the dooragainst the body to be sure the striker allows a flush

The door and body edges should be parallel. fit.

Striker AdjustmentPosition Adjustment

Ooors

20-17

REARVIEWMIRRORRemoval/lnstallation, page 20-19

COVER ~----~

STAY BASE

~

RUBBER DAMPER

MIRROR HOlDERRemoval/lnstallationpage 20-18 '

POWER MIRRORRemoval/lnstallationpage 20-18 '

MIRROR COVERRemoval/lnstallationpage 20-19 '

/MIRROR MOUNTCOVER PANEL

Index

Mirrors

NOTE: Apply grease to the locations indicated bythe arrows.


SHOPTOWEL

PIVOT-~MIRRORDEFOGGERTERMINALS

1. Carefully pry out the mirror holder with a fiat tipscrewdriver as shown. Disccnnect the mirror defogger terminais.

CAUTION:• When prying with a fiat tip screwdriver, wrap itwith

a shop towel to prcvent damage.• Wear gloves to remove and install the mirror holder.

20-18

NOTE: Make sure the connector is connected properly.


5xO.8 mm5 N·m (0.5 kgf·m.4lbHt)

• : Nut locations, 3

3. Disconnect the mirror connector. While holding themirror, remove the nuts and remove the mirror .

HOOKS

UPPERHOOK

2. Carefully pry out the mirror mount cover panel byhand.

t. Lower the door glass.

NOTE: Take care not to scratch the mirror, or the door.

Mirror Holder Removal/lnstallationPower Mirror Removai/lnstailation

Mirrors

20-19


REARVIEWM'RROR

SHOPTOWEL

..

COVER

SCREW5xO.8mm4 N·m (0.4 kgf·m,llbf·ft)

3. Remove the screws, then remove the rearview mirror.

CAUTION: When prying with a fiat tip screwdriver,wrap it with a shop towel to prevent damage.

2. Pry the cover off using the end of a fiat tip screwdriver.

t. Remove the rubber damper.

Rearview Mirror Removal/Installation

MIRROR BASE

Ta remave the screws,pull the seal away.

~ICCCCCC((CC(!)

B ....,2

~j....: Screw locationsA .....a

Mirror Coyer Removai/lnstailation

20-20

SPACER.2

~

FASTENER,04(Self-adhesive-type. glass side)

/ FASTENER, 4Qdhes;ve-type, bodyside)

REARWINDOWRemoval. page 20-26Installation. page 20-27

Rear Window:

LOWER RUBBERDAM

MOLDING SIDESEAl.2

FASTENER,2(Self-adhesive-type. glass side)

Windshield:

NOTE: The numbers after the part names show the quantities of the parts used.

Index

Windshield/Rear Window

20-21

6. Carefully remove the windshield.

WINDSHIELD

11111

Fl\\

5. With a helper on the outside, pull the piano wireback and forth in a sawing motion, and carefullv eutthrough the rubber dam and adhesive around theentire windshield.

CAUTION: Hold the piano wire as close to the windshield as possible to prevent damage to the bodyand dashboard.

ADHESIVE

-PIANOWIRE

)PROTECTIVETAPE

PROTECTIVETAPE

PIANOWIRE

4. Apply protective tape along the edge of the dashboard and body as shown. Using an awl, make ahole through the rubber dam and adhesive frominside the vehicle. Push a piece of piano wirethrough the hole, and wrap each end around apiece of wood.

CAUTION: Take care not to bend the headlinerexcessively or you may break it.

3. Pull down the front portion of the headliner (seepage 20-41).

GLASSBRACKET

ADHESIVE

WlNDSHIElD

NOTE: If removing the windshield molding is difficult, eut the molding with a utility knife.

2. Remove off the windshield molding, and removethe glass brackets.

1. To remove the windshield, first remove the:• Rearview mirror (see page 20-19)• Sunvisors and holders (see page 20-41)• Front pillar trim (see page 20-39)• Windshield wiper arms and cowl coyer (see page

20-73)

CAUTION:• Wear gloves to remove and install the windshield.• Use seat covers to avoid damaging any surfaces.

Windshield Removal

13.5 mm(0.53 in)

WINDSHIELD

/UPPERRU88ERDAM

ALlGNMENTMARK

13.5 mm10.53 in)'1 1

FASTENER

13.5~(0.53 in) ALlGNMENT

MARKS

NOTE: Be careful not to touch the windshield whereadhesive will be applied.

t>: Fastener locations, 2

4. Glue the rubber dam and fasteners to the insideface of the windshield as shown.

20-22

WINDSHIELD

CLEANING WIDTH

~

lZ?'lJ1)t

WINDSHIELD

Inside

NOTE:• Clean the shadowed area.• Clean area @ as shown.

CAUTION: Avoid setting the windshield on its edges;small chips may later develop into cracks.

NOTE: Make sure the bonding surface is kept freeof water, oil and grease.

3. If the old windshield is to be reinstalled, use a putt Yknife to scrape off ail traces of old adhesive and therubber dam, then clean the windshield surface withalcohol where new adhesive is to be applied.

NOTE: After cleaning, keep oil, grease and waterfrom getting on the surface.

2. Clean the body bonding surface with a sponge dampened in alcohol.

NOTE:• Do not scrape down to the painted surface of the

body; damaged paint will interfere with properbonding.

• Remove the rubber dams and fasteners from thebody.

• Mask off surrounding surfaces before painting.

1. Using a putt Y knife, scrape the old adhesive smoothto a thickness of about 2 mm (0.08 in) on the bondingsurface around the entire windshield opening f1ange.

Windshield Installation


20-23

9. (cont'd)SCREW

Remove the windshield.

NOTE: Adjust the glass brackets to center the windshield inthe opening, then tighten thescrews.


AUGNMENTMARK

8. Set the windshield on the glass brackets, then center it in the opening. Make alignment marks acrossthe windshield and body with a grease pencil at thefour points shown.

GLASS BRACKETS, 2

e-. Fastener locations, 2

F~

NOTE: The numbers after the part names show thequantities of the parts used.

7. Install the glass brackets and fasteners as shown.

Apply primer (3M N-200, or equivalent) to edgeof the windshield.

50 mm(2 in)

50 mm(2 in)

ALlGNMENT

l 'd ~ARK (White)nSI e

ALlGNMENT~~MARK ...........MOLDING

ADHESIVEWINDSHIELD TAPE


6. Align and glue the mol ding to the edge of the windshield.

MOLDINGSIDE SEAL

~/

1MOLDING

MOLDING-,

MOLDING~SIDESEAL

5. Glue the molding side seal to the windshield molding on each side.

7 mm (0.27 in)

eut nozzle endas shawn.

13. Before filling a cartridge, eut the end of the nozzleas shown.

NOTE:• Clean the plate with a sponge and alcohol before

mixing.• Follow the instructions that come with the adhe

sive.

12. Thoroughly mix the adhesive and hardener togetheron a glass or metal plate with a putt Y knife.

!~

/

16mm(0.63 in)

• : Apply body primer here.16mm(0.63 in)

NOTE:• Do not apply glass primer to the body, and be care

fui not to mix up glass and body primer sponges.• Never touch the primed surfaces with your hands.• Mask off the dashboard before painting the flange.

11. With a sponge, apply a light coat of body primer tothe original adhesive remaining around the windshield opening tlange. Let the. body primer dry forat least 10 minutes.

20-24

/WINDSHIELDMOlDING

Apply glass primer

9.5 mm tlo the molding.

(0.37 in)

Inside

. 1! UPPER1 RUBBER DAM

1

i1

1i1

WINDSHIElD

~ : Applv glass primer here.

NOTE:• Do not apply body primer to the windshield, and

do not get body and glass primer sponges mixedup.

• Never touch the primed surfaces with your hands.If vou do, the adhesive may not bond to the windshield properly, causing a leak after the windshieldis installed.

• Keep water, dust, and abrasive materials awayfrom the primed surface.

10. With a sponge, apply a light coat ot glass primeraround the edge of the windshield as shown, thenlightly wipe it off with gaule or cheesecloth.

Windshield Installation (cont' d)


20-25

NOTE:• Install the rearview mirror rubber damper after

the adhesive has dried thoroughly.• Advise the customer not to do the following things

for two to three days:- Siam the doors with ail the windows rolled up.- Twist the body excessively (such as when

going in and out of driveways at an angle ordriving over rough, uneven roads).

18. Reinstall ail remaining removed parts.

NOTE:• Let the adhesive dry stand for at least four hours

after windshield installation. If the vehicle has tobe ùsed within the first four hours, it must bedriven slowly.

• Keep the windshield dry for the first hour afterinstallation.

• Check that the ends of the side molding are setunder the air scoop.

17. Let the adhesive dry for at least one hour, then spraywater over the windshield and check for leaks. Markthe leaking areas, let the windshield dry, then sealwith sealant.

NOTE: To remove adhesive from a painted surface orthe windshield, wipe with a soft shop towel dampenedwith alcohol.

16. Scrape or wipe the excess adhesive off with a putt Yknife or towel.

ALlGNMENT MARKis dry.NOTE: Do not open or close the doors until adhesive

15. Use suction cups to hold the windshield over theopening, align it with the alignment marks made instep 8, and set it down on the adhesive. Lightlypush on the windshield until its edge is fully seatedon the adhesive ail the way around.

1mm(0.04 in)

WINDSHIELD

LOWERRUBBERDAM

5mm(0.2 in)

WINDSHIELD

WINDSHIELDMOLDING

Make a slightly thickerbead at each corner.

12mm (0.47 in)

~ ADHESIVE

-t---+8 mm (0.31 in)

NOTE: Apply the adhesive within 30 minutes afterapplying the glass primer.

14. Pack adhesive into the cartridge without air pocketsto ensure continuous delivery. Put the cartridge in acaulking gun, and run a bead of adhesive aroundthe edge of the windshield as shown.

6. Carefully remove the rear window.

REARWINDOW

5. With a helper on the outside, pull the piano wireback and forth in a sawing motion, and carefully eutthrough the adhesive around the entire rear window.

CAUTION: Hold the piano wire as close to the rearwindow as possible to prevent damage to the body.

PROTECTIVETAPE

PIANOWIRE

1 ADHESIVE

REARWINDOW

/

4. Apply protective tape along the edge of the body asshown. Using an awl, make a hole through theadhesive from inside the vehicle. Push a piece ofpiano wire through the hole, and wrap each endaround a piece of wood.

20-26

MOLDING

ADHESIVE

REARWINDOW

REARMOLDING

~~GLASS

~

NOTE: If removing the rear molding is difficult, cutthe molding with a utility knife.

3. Remove off the rear molding.

2. Disconnect the rear window defogger connectorsfrom each side and window antenna connector.

,. To remove the rear window, first remove the:• Trunk lid (see body repair manual)• Rear seat cushion (see page 20-55)• Rear seat side bolsters (see page 20-55)• Rear shelf (see page 20-39)• Rear pillar trim (see page 20-39)• Rear roof trim (see page 20-41)

CAUTION:• Wear gloves to rem ove and install the rear window.• Use seat covers to avoid damaging any surfaces.• Do not damage the rear window defogger grid lines,

window antenna grid fines, and terminais.

Rear Window Removal


20-27

(cont'd)

REARWINDOW

C>:Fastener. spacerlocations

AC>. 4 FASTENER

1~~L_Y;ALlGNMENTMARKS

MOLDING

NOTE: Be careful not to touch the rear windowwhere adhesive will be applied.

5. Glue the fasteners and spacers to the inside face ofthe rear window as shown.

ADHESIVE TAPE867 mm (34.1 in)

ALlGNMENT MARK

In~m

GLASS if:2:'J. 10,2in!ADHESIVETAPEThickness:0.16 mm (0.006 in)

REARMOLDING

ALlGNMENT

7~~;;;.:::::.::::.::::..:;;;;..0-", MF--JLASS

REAR~ .s»;....:--:i~~ow MOLDING~.:. JOINT

NOTE: Be careful not to touch the rear windowwhere adhesive will be applied.

4. Apply the double-faced adhesive tape to the edge ofthe rear window, then install the molding aroundthe edge of the rear window as shown.

CLEANING WIDTH

NOTE: Clean the shadowed area.

CAUTION: Avoid setting the rear window on itsedges; small chips may later develop into cracks.

NOTE: Make sure the bonding surface is kept treeof water, oil and grease.

3. If the old rear window is to be reinstalled, use a puttyknife to scrape off ail traces of old adhesive and therubber dam, then clean the rear window surface withalcohol where new adhesive is to be applied.

NOTE: After cleaning, keep oil, grease and watertrom getting on the surface.

2. Clean the body bonding surface with a spongedampened in alcohol.

NOTE:• Do not scrape down to the painted surface of the

body; damaged paint will interfere with properbonding

• Mask off surrounding surfaces before painting.• Remove the fasteners and spacers from the

body.

1. Using a puttY knife, scrape the old adhesive smoothto a thickness of about 2 mm (0.08 in) on the bonding surface around the entire rear window openingflange.

Rear Window Installation

7mm(0.28 in)

~ : Apply body primer here.

NOTE:• Do not apply glass primer to the body, and be care

tul not to mix up glass and body primer sponges.• Never touch the primed surfaces with your hands.

~-----~ASTENER

REARWINDOW

10. With a sponge, apply a light coat of body primer tothe original adhesive remaining around the rearwindow opening tlange. let the body primer dry forat least 10minutes.

MOLDING

GLASS Ali around.

~

!

10 mm (0.39 in)MOLDING

NOTE:• Do not apply body primer to the rear window,

and do not get body and glass primer spongesmixed up.

• Never touch the primed surfaces with your hands.If you do, the adhesive may not bond to the rearwindow properly, causing a leak after the rearwindow is installed.

• Keep water, dust, and abrasive materials awayfrom the primed surface.

~ : Apply glass primer here.

9. With a sponge, apply a light coat of glass primeraround the edge of the rear window as shown, thenlightly wipe it off with gauze or cheesecloth.

20-28

8. Remove the rear window.

AlIGNMENT MARK

NOTE: Be careful not to touch the rear window whereadhesive will be applied.

7. Set the rear window in the window opening, and thencenter it. Make alignment marks across the rear window and body with a grease pencil at the four pointsshown.

FASTENER

~

~FLANGE NOTCH

C>: Fastener locations. "

6. Glue the fasteners to the body as shown.

Rear Window Installation (cont' d)


20-29

• SIam the doors with ail the windows rolled up.• Twist the body excessively (such as when going

in and out of driveways at an angle or drivingover rough, uneven roads).

NOTE: Advise the customer not to do the foltowingthings for two to three days:

17. Reinstall ail remaining removed parts.

NOTE: Let the adhesive stand for at least fourhours after rear window installation. If the vehiclehas to be used within the first four hours, it must bedriven slowly.

16. Let the adhesive dry for at least one hour, thenspray water over the rear window and check forleaks. Mark the leaking areas, let the rear windowdry, then seal with sealant.

NOTE: To remove adhesive from a painted surfaceor the rear window, use a soft shop towel dampened with alcohol.

15. Scrape or wipe the excess adhesive off with a puttYknife or towel.

ALlGNMENTMARK

NOTE: Do not open or close the doors until the adhesive is dry.

14. Use suction cups to hold the rear window over theopening, align it with the alignment marks voumade in step 7, and set it down on the adhesive.Lightly push on the rear window until its edges arefully seated on the adhesive ail the way around.

REARMOLDING

GLASS

~ ,REARMOLDING

Make a slightly thickerbead at each corner.12 mm (0.47 in)

~ ADHESIVE~8 mm (0.31 in)

NOTE: Apply the adhesive within 30 minutes afterapplying the glass primer.

13. Packadhesive into the cartridge without air pocketsto ensure continuous delivery. Put the cartridge in acaulking gun, and run a bead of adhesive aroundthe edge of the rear window as shown.

7 mm (0.27 in)

10mm (0.39 in)

Cut nozzleend as shown.

12. Before filling a cartridge, cut the end of the nozzleas shown.

NOTE:• Clean the plate with a sponge and alcohol before

mixing.• Follow the instructions that came with the adhe

sive.

11. Thoroughly mix the adhesive and hardener togetheron a glass or metal plate with a puttY knife.

20-30

FRONT DRAIN TUBE

REAR DRAINVALVE

REAR DRAINTUBE

TUBE ;fCLIP ~

/~TUBERemovai/lnstailation, page 20-34 I.J CLIP

d~

FRONT DRAINVALVE

Removai/lnstaliation, page 20-35 Removaillnstailation,page 20-34

\~ERCABLE

71MOTORGUIDE RAILRAIL HOLDER A ~

Removai/lnstailation,page 20-32

CABLE ASSEMBL yRemovaillnstallation, page 20-35

SWITCH PLATEAdjustment, page 20-36

MOONROOF GLASSRemovai/lnstallation, page 20-32Height adjustment, page 20-31

1 ..Index

Moonroof

20-31

Forward3. Repeat on opposite side if necessary.

Shim thickness: Front max. 3 mm (0.12 in)Rear max. 2 mm (0.08 in)

2. loosen the nuts, and install the shims between theglass frame and glass bracket as shown.

1. Remove the bracket cover.

NUT6x1.0mm9.8 N·m (1.0 kgf·m.7.2Ibf.ft)

BRACKETCOVER

NUT6 x 1.0 mm9.8 N·m (1.0 kgf·m.7.2Ibf.ft)

GLASSSHIM

GLASSBRACKETSHlM

The roof panel should be even with the glass weatherstrip, to within 1.7 ~tg mm (0.07 :g:8: in) ail the wayaround. If not, open the glass fully, and:

GLASS WEATHERSTRIP1.7 :::: mm

(0.07 =::: in)

Glass Height Adjustment

Symptom Probable Cause

Water leaks 1. Clogged drain tube.2. Gap between glass weatherstrip and roof panel.3. Defective or improperly installed glass weatherstrip.4. Gap between drain seal and roof panel.

Wind noise 1. Excessive clearance between glass weatherstrip and roof panel.

Motor noise 1. loose motor.2. Worn gear or bearing.3. Cable assembly deformed.

Glass does not move, but motor turns 1. Clutch out of adjustment.2. Foreign matter stuck between guide rail and slider.3. Inner cable loose.4. Cable assembly not attached properly.

Glass does not move and motor does not turn 1. Blown fuse.(glass can be moved with moonroof wrench) 2. Faulty switch.

3. Battery run down.4. Defective motor.5. Faulty relay.

Troubleshooting

\\

\

SCREWS

8. Using the moonroof wrench, move the glass bracketto the position where the moonroof normally pivotsdown, and remove the screws.

7. Remove the halder cover, then rem ove the railholder B.

6. Remove the drain channel.

20-32

NOTE: Do not damage the roof panel.

5. Remove the glass by lifting up and pulling forwardas shown.

NUTS6x 1.Omm9.8 N'm (1.0 kgf·m. 7.2Ibf.ft)

GLASS BRACKET

4. Remove the nuts tram bath glass brackets.

Forward

3. Remove both bracket covers.

2. Siide the sunshade ail the way back.

1. Close the glass fully.

Glass, Glass Bracket and Sunshade Removai/lnstaliation

Moonroof

20-33

NOTE: Do not use high-pressure water.


NOTE: Check the glass height (see page 20-31).


SUNSHADE

\

12. Siide the sunshade forward, then remove it.

11. Detach the drain channel rod stop from the cutoutof the guide rail as shown.

10. Remove the drain channel rod slider by moving thecable slider forward using the moonroof wrench.

DRAIN CHANNEL ROD STOPRotate as shown to remove it from the guide rail.

DRAIN CHANNELROD SlIDER

DRAIN CHANNELROD

RAIL HOLDER A

NUT6 x 1.0mm9 N·m (0.9 kgf·m,7Ibf.f'\

9. Remove the rail holder A.

20-34

BOLT6 Je 1.0 mm9.8 N'm (1.0 kgf·m,7.2IbHt)

CEILING lIGHTHARNESS

FRAME

6x1.0mm9.8 N'm (1.0 kgf·m, 7.2 IbHtl

REARHOOK

HOLE(Body side)

NOTE: Remove the front bolts last.

5. The moonroof frame with an assistant holding, remove the frame mounting bolts. Detach the rear hooks by movingthe frame forward, and remove the frame.

4. Disconnect the drain tubes, and detach the ceiling light harness.

3. Remove the moonroof glass (see page 20-32).

2. Disconnect the motor connector and glass position switch connector, then remove the bolts and nuts, and remove themotor.

1. Remove the headliner (see page 20-41).

CAUTION:• Wear gloves to remove and install the frame.• Be careful not to damage the seats, the dashboard or any other interior panels.

Motor, Drain Tube and Frame Removal/lnstallation

Moonroof

20-35

• Install the frame seal securely.• Before installing the motor, make sure both slid

ers are parallel.• Before installing the motor, install the frame and

glass, then check the opening drag (see page 20-37).

NOTE:• Damaged parts should be replaced.• Grease the sliding portion with Super High Temp

Urea Grease, PIN 08798 - 9002.• Fill the groove in each grommet with seaJant.

GROMMET

4. Installation is the reverse of the removaJ procedure.

GROMMET

NUT

NOTE: Take care not to bend the cable tubes andthe guide rails.

3. Remove the nuts, and lift off each guide rail, thenremove the cable assembly with the slidersattached.

2. Remove the motor and glass bracket (seepage 20-32).

1. Remove the frame.

CAUTION: Wear gloves to rem ove and install the guiderails and cable assembly.

Guide Rails and Cable AssemblyRemovai/lnstailation



DRAIN TUBE

Upward

r

NOTE:• Before installing the frame, clear the drain tubes

and drain valves using compressed air.• Check the frame seal.• Clean the surface of the frame.• When installing the frame, first attach the rear

hooks into the body holes.• When connecting the drain tube, slide it over the

frame nozzle at least 10 mm (0.39 in).• Install the tube clip as shown.


REAR DRAINVALVE

FRONT DRAINVALVE

NOTE: Before removing the drain tube, tie a stringto the end of it 50 it can be reinstalled.

6. Pull the drain tubes out the front and rear pillars.

20-36


6. Close the glass fully, and check for water leaks.

While moving the switch plate little by little. secure the switchplate at the position where the switch cam contacts the switchA (a faint click is heard).

INNER CABLE ENDSWITCHCAMSWITCHPLATE

SWITCHPLATE

Check the switch plate contacts thecable bracket.

CABLE BRACKET

NOTE: Check the glass height (see page 20-31).

5. Check the operation of the glass (from tilt-up position to fully closed position, from the fully open position to the fullyclosed position) by operating the moonroof switch.

4. Adjust position of the switch plate (switch cam) as shown.

3. Using an open-end wrench, loosen the switch plate mounting bolts.

NOTE: Check the glass fit to the roof panel.

2. Using the moonroof wrench, close the glass fully.

1. Remove the headliner (see page 20-41).

Switch Plate Adjustment (Fully Closed Position)

Moonroof

20-37

COUNTERCLOCKWISETo decreaseforce.

CLOCKWISETo increaseforce.

MOTOR CLUTCHADJUSTING NUT

LOCKWASHERReplace.

2. If the force in not within specification, install a newlock washer, adjust the tension by turning the motorclutch adjusting nut, and bend the lock washeragainst the motor clutch adjusting nut.

SPRINGSCALE

SHOPTOWEL

Closing Force: 200 - 290 N(20 - 30 kgf, 44 - 66 'bf)

CAUTION: When using a spring scale, protect theleading edge of the glass with a shop towel.

1. After installing ail removed parts, have a helperhold the switch to close the glass while vou measure the force required to stop it. Attach a springscale as shawn. Read the force as saon as the glassstops moving, then immediately release the switchand spring scale.

Closing Force Check(Motor Installed)

SPRINGSCALE

SHOPTOWEL

If load is over 40 N (4 kgf, 9 Ibf), check the side clearanceand glass height (see page 20-31).

CAUTION: When using a spring scale, protect the leading edge of the glass with a shop towel.

Before installing the motor, measure the effort requiredto open the glass using a spring scale as shown.

Opening Drag Check(Motor Removed)

20-38

SIDE TRIM(see page 20-39)

TRUNKTRIMPANEL(see page 20-40)

Removal/lnstallation, page 20-42

(see page 20-40)

Removai/lnstailation, page 20-43

Component Removal/lnstallation,page 20-44Removal, page 20-47SEAT

SIDETRIM

REAR SHELFKICK PANEL(see page 20-39)

REAR ROOF TRfM(see page 20-41)

HEADLINERRemovai/lnstaliation, page 20-41

FRONT PILLARTRIM(see page 20-39)

CENTER PllLARUPPERTRfM(see page 20-39)

CENTER PILLARLOWER TRIM PANel(see page 20-39)

SRS components are located in the parts areas marked with an asterisk (*). Review the SRS component locations, precautions, and procedures in the SRSsection (24) before performing repairs or service.


Interior

20-39

(cont'd)

• If necessary, replace any damaged clips.• Before installing the front seat belt upper anchor

and rear shelf, make sure there are no twists orkinks in the seat belts.

LEFT KICKPANEL

NOTE:

Installation is the reverse of the removal procedure.o

SEAT SIDE TRIMRemove the rear seat cushion and rearseat side bolster (see page 20-55).SIDE TRIM

RIGHTKICKPANEL

C

FRONTSEATBELT UPPERANCHOR(see section 24)

ceNTER PILLARLOWERTRIMPANEL

B

REAR SHELFBCENTER PILLAROUTERTRIM

REAR PILLARTRIM

CENTER PILLAR___ C_L_IP -..J UPPER TRIM

E C>, 2D C>, 2CC>,21B C>, 6C>: Clip locationsAC>,2

NOTE: Take care not to bend or scratch the trim and panels.

CAUTION:• Wear gloves to remove and install the trim and panels .• When prying with a fiat tip screwdriver, wrap it with protective tape to prevent damage.

Interior Trim Removai/lnstailation

20-40

NOTE:• If necessary, replace any damaged clips .• To install the A clips, pull the inner clip up, install

the clip, then push the inner clip until it's flush.

Installation is the reverse of the removal procedure.

SPARE TIREllO

.:~~:Hook locationsA ~_';"1

/",-_" ....""(

)

B

TRUNKTRIMPANEL

}~(!:~ INNER

CLIP

REARTRIMPANELA.

c> : Clip locationsAC>,6NOTE: Do not pushthe inner clip in tao far.

NOTE:• Take care not to bend or scratch the trim and panels.• When removing the trunk side trim or trunk trim panel, fold the seat-back forward.

CAUTION:• Wear gloves to remove and install the trim and panels.• When prying with a fiat tip screwdriver, wrap it with protective tape to prevent damage.

Trunk Trim Removai/lnstailation

Interior

20-41

NOTE:• When inserting the headliner through the open

ing, be careful not to fold or bend it. Also, be carefui not to scratch the body.

• Check that both sides of the headliner aresecurely attached to the trirn.

• When installing the roof trim, install the jointtoward the right side (with moonroof rnodel).


7. Carefully remove the headliner through the passenger's door opening.

6. Lower the headliner .

5. Lower the rear pillar trim on both sides.

ROOFTRIM

JOINT

REARPILLARTRIM

REAR ROOFTRIM

:l:J.J_._.~ ---_=:....../

1>:Clip locationsAI> 7 BI> With moonroof, 1

Without moonroof, 3

4. Remove the rear roof trim and clips, and removethe roof trim and socket plug (moonroof model).

SCREWSACCESSllO

3. Remove the grab handles and coat hanger.

~HOOK

~~.-... HOLOER

2. Remove the sunvisor and holder from each side.

• Front pillar trim (both sides, see page 20-39)• Center pillar lower trim panel (both sides, see page

20-39)• Upper anchor boit from the front seat belt (both

sides, see section 24)• Center pillar outer trim and center pillar upper trim

(both sides, see page 20-39)• Ceiling light (see section 23)• Rearview mirror (see page 20-19)

1. Remove:

NOTE:• Take care not to bend and scratch the headliner.• Be careful not to damage the dashboard and other

interior trim.

CAUTION: When prying with a fiat tip screwdriver,wrap it with protective tape to prevent damage.

Headliner Removai/lnstailation

20-42

CHANGELEVERBOOT

HOOKS

NOTE:• If necessary, replace any damaged clips.• Make sure the wire harnesses are not pinched.

Change lever boot removal (MIT):

CD REAR CONSOLE

® FRONT CONSOLERemove the shift lever knob (MIT).


• : Screw locations t>: Clip locations

~~f:J1d~Disassemble in numbered sequence .

NOTE: Take care not to scratch the front and rear consoles, front seat and related parts.

Consoles and Beverage Holder Removai/lnstailation

Interior


2. Remove the bolts, then remove the knee bolster.

(with moonroofmode!)

MIRROR DEFOGGERSWITCH CONNECTOR

POWER MIRRORSWITCH CONNECTOR

C>: Clip locationsA~iU...: Screw, boit locationsA"',3 8 ....2

®mm6X1.0mm 1

9.8 N'm 11.0kgf.m'j7.21bHtl

1. Remove the screws, and detach the clips. thenrem ove the driver's dashboard lower coyer. Disconectthe power mirror switch and mirror defogger switchconnector. If equipped with and moonroof, disconnectthe connector.

SRS components are located in this area. Review the SRScomponent locations, precautions, and procedures in theSRS section (24) before perlorming repairs or service.

Oriver's dashboard lower coyer and knee bolster,removal:

20-44


INSTRUMENTPANEL

C>: Clip locations. 2

b...: Screw locations. 2

2. Remove the screws, and detach the clips, then carefully remove the instrument panel.

1. Tilt the steering column down.

Instrument panel removal:

NOTE: Take care not to scratch the dashboard and relatedparts.

CAUTION:• When prying with a fiat tip screwdriver, wrap it with

protective tape, and apply protective tape around therelated parts, to prevent damage.

• Were gloves to remove and install the dashboardcomponent parts.

Oashboard Component Removai/lnstailation

Interior

20-45

(cont'd)

CASSETTEPLAYERCONNECTOR

5 xO.8mm9 N·m (0.9 kgf'm,71bHtl

t>: Clip locations, 2

(~ 1


2. Remove the screws. Disconnect the cassette playerconnector trom glove box opening, then rem ovethe cassette player. Disconnect the accessory socketconnector.

1. Remove:• Driver's dashboard lower coyer• Glove box• Beverage holder

Center dashboard lower:

CLIP

SIDE AIR VENT

HOOKS

SIDE DEFOGGER TRIM

Side air vent/Side defogger trim:


,

15xO.8mm .9 N'm (0.9 kgf·m, !71bHtl )_ ..._ ..._-_ .._ ..-


Lower the glove box, and remove the bolts, th enremove the glove box.

Glove box:

20-48

CAUTION: Use protective tape on the bottom of the front pillar trim.

6. Remove the bolts, then lift and remove the dashboard.

AIR MIX CONTROLCABLE

DASHBOARDCI>,6

~10x1.25mm~ 38 N'm (3.9 kgf·m,

281bHt)

6 x 1.0 mm9.8 N'm (1.0 kgf'm,7.2IbHt)

~10x1.25mm~ 38 N'm (3.9 kgf·m,

281bHt)

DRIVER'SDASHBOAROSIDECOVER

C",1.. : Boit, screw locationsA",7

To avoid accidentai deployment and possible injury, always disconnect the front passenger's airbagconnector when the SRSmain harness is disconnected (see section 24).

5. Disconnect the connectors and air mix control cable.

4. Remove:• Driver's dashboard side cover• Passenger's dashboard lower cover• Dashboard center lid

Oashboard Removai/lnstailation (cont' d)

Interior

20-54

SEATFRAME

UPHOLSTERY RING PLiERS(Commercially available)

NOTE:• To prevent wrinkles when installing a seat cush

ion cover, make sure the material is stretchedevenly over the pad before securing the clips.

• Replace the clips with new ones.


Front Seat Cover Replacement(cont'd)

Seats

NOTE:• To prevent wrinkles wh en installing a seat cush

ion coyer, make sure the material is stretchedevenly over the pad before securing the clips andhooks.


4. Installation is the reverse orthe removal procedure.

LEFT SEAT·BACKCOVER

!RIGHT SEAT-BACKCOVER

T "\.. : .- : .~ :

," ..~ " .... ,....'. : '- .~:' .. ..'..

t> : Clip locations-::-:Hook locations

3. Pull back the edge of the seat-back cover ail the wayaround, and release the hooks and clips. Removethe seat-back coyer.

LEFT SEAT-BACKCOVER

~RIGHT SEAT·BACKCOVER

~7 \J \J \J ~Ir" Lifo J~> 0

0 0 i

> 1 k0100 0

> 0 0 ~0 0

0 00 0

;> 0 0 ~0 ..,POL{1 l ~ DJ

t

~7 ~~Ir"

If" 0II(

~ 0II(

1c- 0II(

0

;> 0 ~~~ à~ °~

c- : Clip locations

2. Release the hooks and clips, and loosen the seatback coyer.

1. Remove the seat-back (see page 20-55).

Seat·back cover:

NOTE: Take care not to tear the seams or damage the seatcovers.

CAUTION: Wear gloves to remove and install the seatcovers.

Rear Seat Cover Replacement

20-56

NOTE:• Make sure each lock rod is connected securely.• Make sure each seat-back locks securely and

opens properly.• If necessary, adjust the seat-back latch.


LEFT SEAT·BACK LATCH

RIGHT SEAT·BACK LATCH

AéJ.)

1

lOCKCVUNDER

REARSHELFLOCK CVUNDER

TRIM

,6x 1.0mm9.8 N'm (1.0 kgf·m,7.21bHtl

B~,2~: Boft, screw locationsA~,4

NOTE: Take care not to bend each lock rod.

Remove the lock cylinder trim, then remove the rearshelf (see page 20-39),

Rear Seat-back Latch and LockCylinder Removai/lnstailation

Seats

20-57

SEATFRAME

UPHOLSTERY RING PLIERS

NOTE:• To prevent wrinkles wh en installing a seat cush

ion cover, make sure the material is stretchedevenly over the pad before securing the clips.



SEAT CUSHIONCOVER

t>: Clip locations

3. Pull back the edge of the seat cushion cover ail theway around, and release the clips, then remove theseat cushion coyer.

SEAT CUSHIONCOVER

C>: Clip locations

2. Loosen the seat cushion cover by releasing ail theclips.

1. Remove the seat cushion (see page 20-55).

Seat cushion coyer:

NOTE:• To prevent wrinkles when installing a seat side

bolster cover, make sure the material is stretchedevenly over the pad before securing the clips.

• Replace the released clips with new ones.


SEAT SIDEBOLSTERCOVER

C>: Clip locations

2. Loosen the seat side bolster coyer by releasing ailthe clips, then remove it.

1. Remove the seat side bolster (see page 20-55).

Seat side bolster coyer:

20-60

NOTE:• If necessary, replace any damaged clips.• Make sure the rear bumper engages the side clip on each side securely.


REAR BUMPER

A

ABSORBER

~: Screw. boit locationsjAv B~ ~!~.~2~5~~gf.m{+ons.1. ~ 401bHt)

NOTE:• An assistant is helpful when removing the rear bumper .• Take care not to scratch the rear bumper and body.

CAUTION: Wear gloves to remove and install the rear bumper.

Rear Bumper Removai/lnstailation

Exterior

20-61

( ~---------

HOODLATCH

f

11

11

1-,

11

1

HOODLATCH

HOOD EDGECUSHION

HOOD

\

HOOD EDGECUSHION

NOTE: Move the hood latch right or left until the strikeris centered in the hood latch as shown.

3. Adjust the hood latch to obtain the proper height at the forward edge.

4. After adjustment, tighten each boit securely.

2. Turn the hood edge cushions, as necessary, to make the hood fit flush with the body at front and side edges.

1. Adjust the hood hinges right and left, as weil as fore and aft, by using the elongated holes.

NOTE: Before adjusting the hood, loosen each boit slightly.

Hood Adjustment

sTRfKER

C------6x1.0~m

9.8 N'm (1.0 kgf'm,7.2Ibf·h)

TRUNK uoEOGE eUSHION

sTRIKER

.:TRUNK llOEDGE eus HfON

TRUNK uo

TRUNK uo EOGEeUSHION

20-62

(),.... _ ,1 11 •

TRUNK llOLATCH

/sTRfKER

NOTE: Move the striker right or left until it's centered inthe trunk lid latch as shown.

1

11

NOTE: Take care not 1

to hit the rear window 1

11

11

11

11

6x1.0mm 19.8 N·m (1.0 kgf·m, 7.2 lbf-ft) 1

--------------_j

3. Adjust the fit between the trunk lid and the trunk lid opening by moving the striker.

4. After adjustment, tighten each boit securely.

2. Turn the trunk lid edge cushions, as necessary, to make the trunk lid fit flush with the body at the rear and side edges.

1. Remove the rear shelf (see page 20-39), and adjust the trunk lid hinges right and left, as weil as fore and aft, by usingthe elongated holes.

NOTE: Before adjusting the trunk lid, loosen each boIt slightly.

Trunk Lid Adjustment

Exterior

20-65

(cont'd)

.: Plastic nut location, 1Bt>,2

REAR OOORMOLDING

t>: Clip locationsAt>,11

FRONTSIOEMOlDING

NOTE:• To remove the front side molding, remove the inner fender (see page 20-68).• To rem ove the door molding, remove the door panel (see pages 20-4, 10) and plastic cover.• Take care not to bend the door moldings.• Before reassembling, c1ean the door bonding surface with a sponge dampened in alcohol.• After cleaning, keep oil, grease and water from getting on the surface.• If necessary, replace any damaged clips.

CAUTION: When prying with a fiat tip screwdriver, wrap it with protective tape to prevent damage.

Door and Side Moldings Removai/lnstailation

20-68

REAR AIROUTLET

C>: Clip locationsAC>,4 BC>,4

li_~NOTE:• Take care not to bend the fenderwell trim.• Before installing the fenderwell trim, clean the body

bonding surface with a sponge dampened in alcohol.• After cleaning, keep oil, grease or water from getting on

the surface.• To remove the fuel pipe protector, first remove the rear

wheel (see section 18).• To remove the rear air outlet, tirst rem ove the rear

bumper (see page 20-60).

Fenderwell trim/Fuel pipe protector/Rear air outlet:

C>: Clip locations, 7

....: Screw locations, 4

Inner tender: INNER FENDER

CLIP

NOTE: If necessary, replace any damaged clips.

Inner Fender, Fenderwell Trim, Fuel Pipe Protector and Rear Air OutletRemovai/lnstailation

Exterior

~on~~

~~

ener cable:Trunk 'id/Fue' 'id op the left side of

. parts trom (seethe tollowmg k as necessaryNOTE: Remove Il the carpet bac ,. 1 then puthe vehic e,e 20-43).

pag e 20-551shion (see pag 20-55)

• Rear seat c~e bolster (see page page 20-39)•

Rear seat SI irn panel (see·1 lower tn• Center pli ar ge 20-39)

• Side trim (see pa age 20-39) e 20-40)• Seat side trim (see: spare tire lid (see pag• Rear trir:n pan~~la(~eepage 20-40)• Trunk tnm pa

20-70

1procedure.f the remova. he reverse 0Installation IS t

ble is routed andNOTE: hood opener caMake sure the

• connected proper'~ opens properlv,• Make sure the hoc

Route the openercable through thehole in the body.

HOODRELEASEHANDLE 71)(see page 20-

the clips.NOTE: llp remover to remove ner cables.• Use a c J bend the ope• Take care not to

Hood opener cable: age 20-59) andb mper (see pthe front uNOTE: Remove e 20-68).

. fender (see paginner

d Washerand Latch/Wiper anO ner Cable/Openerpe . n

I/InstallatloC bles RemovaOpener a

20-73

(cont'd)

....: Boit loe.tions, 4

f 6X1.0mm9.8 N·m (1.0 kgf·m,7.2Ib"'t,

WINDSHIELDWIPER LINKAGEASSEMBLY

2. Disconnect the connector, then remove the windshieldwiper linkageassembly.

c>: Clip loc.tions

A, bi:WINDSHIELDWIPERARMS

NUlS

1. Remove the windshield wiper arms, then removethe hood sealandcowl cover.

NOTE:Takecarenot to scratchthe hood and body.

CAUTION:Wear gloves to remove and install the windshieldwiper linkage.

Windshield Wiper Arms and LinkageRemovai/lnstailation

NOTE:• Greasethe trunk lid latch.• Makesurethe trunk lid opensproperty and tocks

securely.• Make sure the connector and cylinder rod are

connectedproperly.

Installationis the reverseof the removal procedure.

TRUNKUDOPENERCABLE

/"

CYLINDERROD


i 6x 1.0mme 9.8N·m(1.0kgf·m,7.2Ibf.ft)

Trunk lid latch:

20-76

1.6EL Emblem

Unit: mm (in)ACURA Emblem

ACURA EMBLEM

Attachment Points (Reference):

NOTE:• Before applying, clean the body surface with a

sponge dampened in alcohol.• After cleaning, keep oil, grease and water from get

ting on the surface.

Apply the emblems where shown.

Installation

Emblems

20-78

011 (0.43) Engine Mount ....1ct(.)

i=wIX:Z~:::i

017 (0.67) Rear Beam Point012 (0.47) Left Side Front Stopper PointPOINTe3

POINT j4

013 (0.51) EngineMount Point

10 x Pl.25

013 (0.51) Engine Mount PointPOINTe2

POINTf

013 (0.51) TransmissionMount PointPOINTel

015 10.59)TransmissionMount Point

POINT d2015 (0.59)TransmissionMount Point

POINT dl

2150184.65)

POINT d3

1900174.8011365153.74)

DETAIL AREA Y

wZ:J_,ct(,Jj:IX:w>

POINT blPOINT a

CENTER_---'=-+--.UNE

Unit: mm (in)0: Inner diameter

Frame Repair Chart

21-2

TEMPERATURE CONTROLLEVER

Replacement, page 21-22Overhaul, page 21-22

Test, page 21-26

1Test, page 21-25

Test, page 21-23Replacement. page 21-23

REARWINDOWDEFOGGER SWITCHSee section 23

AIR MIX CONTROL CABLEAdjustment, page 21-21

Test, page 21-7

RECIRCULATIONCONTROL MOTORTest, page 21-24Replacement, page 21-24BLOWER UNIT

Replacement. page 21-16Overhaul, page 21-17

(BLOWER MOTOR)Test, page 21-8HEATER UNIT

Adjustment, page 21-21

SRScomponents are located in this area. Review the SRS component locations, precautions, and procedures in the SRSsection (24) before performing repairs or service.

IIlustrated Index

21-3

DASHUGHTSBRIGHTNESSCONTROLLER

COMBINATIONlIGHTSWITCH

1WHTIBLU

G401G402

Sl

iSlK

1

REC.REARWINDOWDEFOGGERRELAY

r

G401G402

RECIRCULATIONCONTROLMOTOR 1

~KNELl

• • •GRN

AICTHERMOSTAT~y'BLUIRED GRN/WHT Jm REDIBLK

YEL/WHT GRNIRED YEUBlU YEL BLU/WHT YEURED BLKNEl

1 10 11 4 3 14 15 16 7 12 8 6

1

If- f~ -i,- -

1 DIMMING~1 CIRCUIT

-!-GiD AIC ~ ~ '!!; l~;J~jI ~jI~~ ~~ ,:1 ~~ ~~ ~o ~~." (D'1-

01- ".4Wx21

*~ Of.:- ï *:+* (f:~ 1

-r -r -r -r f~r~CONTROLCIRCUIT 1 \-\- - ~ - - ~ - '- - ~ - -and DEFOGGERTlMER

1CIRCUIT

-!- ~ -:..:-

2 13 HEATERCONTROLPANEL 9 5

._K RED

G401G402

Heater Fan SwotchPosotoon:

BlK

lHEATERFAN 4SWITCH

BLU BLUNEL

BLU/WHT BLUIBlK

BlOWERRESISTOR---

~U/BLK

BLU/WHT

~--------_4~---------------~BLK--~--_O

MODECONTROLMOTOR

BLKNEL

BLK

BLOWERMOTORRELAY

~~~~-O~~-+---WHT/BLU----------------------------~~----------~

r---------~---- ~KNEL -----------------.-------------------tNo.47 (7.5AINo.55 (40AI

IGNITIONSWITCH

BATTERY ~NO.41(SOAI No.42(40AI+}--+---<::r""-..lO-- ....-<T'\...J>-+-- WHT/BLK__'_WHT 2 YEl --+--O""'....D-+-- ... ---------- .....

UNOER- HOOOFUSEIRElAy BOX

Circuit Diagram

21-4

Symptom Remedy

Hot air flow is low. Blower motor runs, but one or more Perform the procedures in the flowchart (see page 21-6).speeds are inoperative.

Blower runs properly. Check for the following:• Clogged heater duct• Clogged heater outlet• Incorrect door position

No hot air flow. Blower motor does not run at ail. Perlorm the procedures in the flowchart (see page 21-8).

Blower motor runs. Check for the following:• Clogged heater duct• Clogged blower outlet• Clogged heater valve• Faulty air mix door• Heater valve cable adjustment (see page 21-21)• Air mix control cable adjustment (see page 21-21)• Faulty cooling system thermostat (see section 10)• Clogged evaporator (with air conditioning)• Frozen evaporator (with air conditioning)

Mode control motor does not run, or one or more modes Perform the procedures in the flowchart (see page 21-11).are inoperative.

Recirculation control door does not change between Perlorm the procedures in the flowchart (see page 21-14).FRESHand RECIRCULATE.

NOTE:• Check the engine coolant level, and allow the engine to warm up before troubleshooting.• Any abnormality must be corrected before continuing the test.• Because of the precise measurements needed, use a multimeter when testing.• Before performing any troubleshooting procedures check:

- Fuses No. 47 (7.5 A), No. 55 (40 A) in the under-hood fuse/relay box, and No. 17 (7.5 A) in the under-dash fuse/reJaybox.

- Grounds No. G401, G402- Cleanliness and tightness of ail connectors

Symptom Chart

Troubleshooting


BlOWER MOTOR2P CONNECTOR

21-8

To page 21-10

Blower motor does not run at ail.

lCheck the No. 55 (40 A) fuse in theunder-hood fuse/relay box, andthe No. 17 (7.5 A) fuse in theunder-dash fuse/relay box.

1NO 1 JAre the fuses OK?

1Replace the fusels), and recheck.

1 YES

Check the blower motor:1. Connect the No. 2 terminal of

the blower motor 2P connec-tor to body ground with ajumper wire.


1YES

Does the blower motor run? To page 21-9

1 NO

Check for an open in the wire:1. Disconnect the jumper wire

and the blower motor 2P con-nector.

2. Measure the voltage betweenthe No. 1 terminal and bodyground.

1YES 1

Is there battery voltage? Replace the blower motor. J1

1 NO

Check the blower motor relay:1. Turn the ignition switch OFF.2. Remove the blower motor

relay from the under-hoodfuse/relay box, and test it (seepage 21-25).

1NO 1 JIs the relay OK?

1Replace the blower motor relay.

1 YES

Blower Motor

Troubleshooting

9

2


®l-

GRN/YEL15 169

2

l/8LU

HEATER CONTROL PANEL 16P CONNECTOR

21-12

To page 21-13

YECheck for a short in the wires: 11. Remove the audio unit (see

section 20), and disconnect the 8heater control panel 16P con-nectar.

2. Check for conti nuit y between nthe No. 3, 7, 14, 15 and 16 ter-minais and body ground indi·vidually.

-c-

YES Repair any short in the wire(s)Is there continuity? between the mode control motor

and the heater control panel.NO

YE

1

8

Check for a short ta power:Check the same wires for voltage. V

-e-

Repair short ta power in the wireYES bétween the mode control motor

Is there any voltage? and the heater control panel.(This short damages the heater

NO control panel.l

From page 21-11

Mode Control Motor (cont'd)

Troubleshooting

21-13

GRN/VEL

Repair any open in the wire(s)between the mode control motorand the heater control panel.

NO


MODE CONTROL MOTOR 7PCONNECTOR

8 9 15 16

2

YEL/BlU



Check for loose wires or poorconnections at the heater controlpanel 16P connector and at themode control motor 10P connector. If the connections are good,replace the heater control panel.

YES


Checkfor an open in the wires:Check for continuity between thefollowing terminais of the modecontrol motor 7P connector andthe heater control panel 16P connectar.7P: 16P:No. 2-No. 3No. 3- No. 14No. 4- No.15No. 5 - No. 16No. 6- No. 7

From page 21-12

III

5. Install in the reverse order of removal. Make surethat there is no air leakage.

6 x 1.0 mm9.8 N·m (1.0 kgf·m.7.2Ibf.ft)

6x 1.0mm9.8 N·m (1.0 kgf·m,7.2Ibf.ftl

Disconnect the connectors from the blower motor,blower resistor and recirculation control motor.Remove the wire harness clip from the recirculationcontrol motor, and release the wire harness from theclamp on the blower unit. Remove the mountingbolts, the mounting nut and the blower unit.

4.

6 x 1.0 mm9.8 N·m (1.0 kgf·m, 7.2Ibf.ftl

6x1.0mm9.8N·m(1.0 kgf·m, 7.2Ibf.ftl

With Air Conditioning3-b. Remove the evaporator (see page 22-27).

21-16

HEATER DUCl

Without Air Conditioning3-a. Remove the wire harness from the heater duct, then

remove the self-tapping screws and the heater duct.

PASSENGER'SDASHBOARDLOWERCOVER

/GLOVE BOX FRAME

KNEEBOLSTER

2. Remove the self-tapping screw and the passenger'sdashboard lower cover. Remove the boit, the nutand the knee bolster, then remove the bolts and theglove box frame.

1. Remove the glove box (see section 20).

Replacement

Blower Unit

21-17

BLOWERMOTORTest, page 21-8

/BLOWERRESISTORTest, page 21-7

RECIRCULA TIONCONTROL MOTOR

NOTE:• The recirculation control motor, the blower resistor and the blower motor can be replaced without removing the blower

unit.• Before reassembly, make sure that the recirculation control door and linkage move smoothly without binding.• After reassembly, make sure the recirculation control motor runs smoothly (see page 21-24).• Make sure that there is no air leakage.

Overhaul

NOTE: When removing the mounting nut, take carenot to damage or bend the fuel lines, the brakelines, etc.

6. Remove the mounting nut from the heater unit.

HEATER HOSE(lNLET SIDE)

HEATER HOSE(OUTlET SIDE)

NOTE: Engine coolant will run out when the hosesare disconnected; drain it into a clean drip pan.

CAUTION: Engine coolant will damage paint.Quickly rinse any spilled engine coolant from paintedsurfaces.

5. Disconnect the heater hoses from the heater unit.

21-18

HEATER VALVE CABLE

CLAMP

4. Open the clamp, then disconnect the heater valvecable from the heater valve arm.

'%#P@§ Do not remove the radiator cap whenthe engine is hot; the engine coolant is under pressure and could severely scald Vou.

3. When the engine is cool, set the temperature control lever to MAX. HOT (open the heater valve), thendrain the engine coolant from the radiator (see section 10).

2. Disconnect the negative cable from the battery.

1. Make sure you have the anti-theft code for theradio, then write down the frequencies for theradio's preset buttons.

SRS components are located in this area. Review theSRS component locations, precautions, and proceduresin the SRS section (24) before performing repairs or service.

Replacement

Heater Unit

21-20

HEATER CORE

/

HEATER CORECOVER

5. Assemble in the reverse order of disassembly.3. Remove the self-tapping screw and the clamp.

2. Pull out the grommet from the heater core pipes.

4. Pull out the heater core from the heater unit.

NOTE: Be careful not to bend the inlet and outletpipes during heater core removal.

1. Remove the self-tapping screws and the heater corecover.

Overhaul

Heater Unit

21-21

7. Hold the heater valve arm in the closed position,and gently pull on the heater cable outer housing totake up any slack, then install the heater valve cablehousing into the cable clamp.

HEATER VALVE ARM

6. Under the hood, move the heater valve arm to thefully closed position, then attach the heater valvecable to the heater valve arm.

5. Hold the air mix control arm against the stop, thensnap the air mix control cable housing into thecable clamp.

4. With the air mix control cable attached ta the airmix control arm, gently pull on the outer cablehousing to fully close the door and to remove anyslack in the cable. Don't pull to hard, or the temperature cotrol lever will move.

3. Set the tempe rature control lever to MAX. COOL.

AIRMIXCONTROLCABLE

CLAMP

2. Under the dash, disconnect the air mix control cablehousing from the cable clamp, and air mix controlcable from the air mix control arm.

1. Under the hood. Open the cable clamp, then disconnect the heater valve cable tram the heater valvearm.

Adjustment

Temperature Control

HEATER FAN SWITCHTest, page 21·25

21-22

5. Install in the reverse order of removal. Make note ofth following items .• Adjust the air mix control cable and the heater

valve cable (see page 21-21).• Enter the anti-theft code for the radio, then enter

the customer's radio station presets.

HEATER CONTROL PANEL

Remove the self-tapping screws and the heater control panel from the center panel.

4.

CENTER PANEL

1. Remove the audio unit (see section 20).NOTE: Make sure vou have the anti-theft code forthe radio, then write down the frequencies for theradio's preset buttons.

2. Disconnect the air mix control cable from the heaterunit (see page 21-21).

3. Remove the center panel together with the heatercontrol panel, then disconnect the connectors.

OverhaulReplacement

Heater Control Panel

21-23

4. Install in the reverse arder of removal. After installation, make sure the mode control motor runssmoothly.

3. Remove the self-tapping screws and the mode control motor.

2. Remove the rad from the arm of the mode controlmotor.

ARM7P CONNECTOR

1. Disconnect the 7P connector tram the mode controlmotor.

4. If the mode control motor does not run in step 3,remove it, then check the mode control linkage anddoors for smooth movement. If they move smoothly,replacethe mode control motor.

NOTE: If the mode control motor does not run whenjumping the first terminal, jump that terminal againafter jumping the other terminais. The mode controlmotor is OK if it runs when jumping the first terminai again.

3. Using a jumper wire, connect the No. 7 terminalindividually ta the No. 2, 3, 4, 5 and 6 terminais inthat arder. Each time the connection is made, themode control motor should run smoothly and stop.

2 3 4 5 6 7

MODE CONTROL MOTOR

CAUTION: Never connect the battery in the opposite direction.

2. Connect battery power ta the No. 1 terminal, andground the No. 7 terminal.

1. Disconnect the 7P connector from the mode controlmotor.

ReplacementTest

IIIMode Control Motor

3. Install in the reverse order of removal. After installation, make sure the recirculation control motor runssmoothly.

2. Remove the self-tapping screws and the recirculation control motor.

RECIRCULA TIONCONTROL MOTOR

4P CONNECTOR

1. Disconnect the 4P connector and the wire l'larnessclip from the recirculation control motor.

21-24

4. If the recirculation control motor does not run in step2, remove it, then check the recirculation control linkage and door for smooth movement. If they movesmoothly, replace the recirculation control motor.

NOTE: Don't cycle the recirculation control motorfor a long time.

3. Disconnect the No. 2 or No. 4 terminais trom ground;the recirculation control motor should stop at FRESHor RECIRCULATE.

RECIRCULATION CONTROL MOTOR

CAUTION: Never connect the battery in the opposite direction.

2. Connect battery power to the No. 1 terminal, andground the No. 2 and No. 4 terminais; the recirculation control motor should run smoothly.

1. Disconnect the 4P connector from the recirculationcontrol motor.

ReplacementTest

Recirculation Control Motor

21-26

~3 7 9 14 15 16

n

Heat

Heat/Def 0-~Def

Vent 0-~Heat/Vent 1

Check for continuity between the terminais according tothe table below.

Test

Mode Control Switch

A/C System ServicePressure Test Chart 22-21Performance Test 22-22Recovery 22-24Evacuation 22-25Charging 22-26leak Test 22-26

EvaporatorReplacement 22-27Overhaul 22-28

CompressorReplacement 22-29lIIustrated Index 22-31Clutch Inspection 22-32Clutch Overhaul 22-33Thermal Protector Replacement 22-35Relief Valve Replacement 22-35

A/C Compressor BeltAdjustment 22-36

CondenserReplacement 22-37

Special Tools 22-2lIIustrated Index 22-3Wiring/Connector locations 22-4Description 22-5Circuit Diagram 22-6Troubleshooting

Symptom Chart 22-7Flowharts

Condenser Fan 22-8Compressor 22-11A/C System 22-15

A/C ThermostatTest 22-18

RelayTest 22-18

A/C Service Tips and Precautions 22-19A/C System Torque Specifications 22-20

Air Conditioning

22-2

* Included in the Belt Tension Gauge Set, 07TGG - 001000A

CD *07JGG - 001010A Belt Tension GaugeCID 07SAZ - 001000A Backprobe Set@ 07947 - 6340300 Driver Attachment@ 07965 - 6920500 Hub Assembly Guide Attachment

1

22-3622-12, 1422-3322-34

OtyTooi Number Page Reference

12

DescriptionRef. No.

Special Tools

22-4

ENGINECOMPARTMENTWIRE HARNESSCOMPRESSOR CLUTCH

CONNECTOR

CONDENSER FANCONNECTOR

A/CPRESSURE SWITCHCONNECTOR

DIODE,CONDENSER FAN RELAY,COMPRESSOR CLUTCH RELAy(Located in the under-hcod fuse/relay box)

Wiring/Connector Locations

22-5

• Do not mix refrigerants CFC-12(R-12)and HFC-134a(R-134a).They are not compatible.• Use only the recommended polyalkyleneglycol (PAG) refrigerant oil (SP-10) designed for the R-134a compressor.

Intermixing the recommended (PAG)refrigerant oil with any other refrigerant oil will result in compressor failure.• Ali AlC system parts (compressor, discharge line, suction line, evaporator, condenser, receiver/dryer, expansion valve,

O-rings for joints) have to be proper for refrigerant R-134a.Do not confuse with R-12parts.• Usea halogen gas leak detector designed for refrigerant R-134a.• R-12and R-134arefrigerant servicing equipment are not interchangeable.Useonly a Recovery/Recycling/ChargingSystem

that is U.L.-listedand is certified to meet the requirements of SAEJ2210to serviceR-134aair conditioning systems.• Always recover the refrigerant R-134awith an approved Recovery/Recycling/ChargingSystem before disconnecting any

AlC fitting.

CONDENSER

This vehicle uses HFC-134a(R-134a)refrigerant which does .not contain chlorofluorocarbons. Pay attention to the following service items:

SUCTIONUNE

uaUID UNE

.__-- ---J EVAPORATOR<r-- ----IIEXPANSION VALVE• ..

More liquidifiedlow-pressure vapor

Less moisturizedlow-pressure vapor

Absorption of heat

COMPRESSOR CONDENSER .~ RECEIVER/DRYER •

Radiation of heatSuction and compression

High-temperature/high-pressure liquid

Traps debris,and removesmoisture

High-temperature/high-pressure liquid

High-temperature/high-pressure gas

The air conditioner system removes heat from the passenger compartment by circulating refrigerant through the systemas shown below.

IIIDescription

22-6

G401G402

Heater Fan SwitchPosition:

• • • •234

GRN

9 13HEATERCONTROLPANEL

2HEATER FAN 4SWITCH

BlK BlK

l lG7S1 G401

G402

.-

YSLYTY ~yBlU BlUIYEl523

2RESISTOR

CONDENSERFAN MOTOR

COMPRESSORClUTCH

BlKIYEl

8

BlU/REDA/CTHERMOSTAT

.....--------+--- BlU/WHT +-...J

3

BlKIYElBlU/WHT RED

~~~SSURESWITCH

2

BlU/RED

BlU/WHTWHT BlK/RED

DIODECl

BlKIYEl~2 4 2 4

~~------- - CONDENSER W-------- COMPRESSORClUTCHFAN RELAY RELAY

1 3 1 3

No.56120A)~

NO.4lI80A) NO.42140A) ~ No.1717.SA)+ l---+---(y-'_.J>-...--<:r'_.J>--f-- WHT/BlK ~WHT ~ YEl -r--v __~BATIERY

IGNITION SWITCHUNDER- HOOD FUSE/RELAy BOX UNDER-DASHFUSE/RELAy BOX

Circuit Diagram

22-7

Svmptom Seepage

Condenser fan does not run at ail. 22-8

Compressor clutch does not engage. 22-11

NC system does not come on (condenser fan and compressor). 22-15

NOTE:• Check the engine coolant level, and allow the engine to warm up before troubleshooting.• Any abnormality must be corrected before continuing the test.• Because of the precise measurements needed, use a multimeter when testing.• Before performing any troubleshooting procedures check:

- Fuse No. 56 (20 A) in the under-hood fuse/relay box and fuse No. 17 (7.5 A) in the under-dash fuse/relay box.- Grounds No. G401, G402, G751- Cleanliness and tightness of ail connectors

Symptom Chart

Troubleshooting

4

JUMPERWIRE

WHT

CONDENSER FAN RELAY 4P SOCKET

To page 22-9

Replace the under-hood fuse/relaybox.

Replace the condenser fan relay.

Replace the fusels), and recheck.

NO

22-8

To page 22-10

YES

Ooes the condenser fan run?

Check the condenser fan:Connect the No. 1 and No. 2 terminais of the condenser fan relay4P socket with a jumper wire.

YES


Check the under-hood fuse/relaybox:Measure the voltage between theNo. 2 terminal of the condenserfan relay 4P socket and bodyground.

YES

Is the relay OK?

Remove the condenser fan relay,and test it (see page 22-18).

YES

Are the fuses OK?

Check the No. 56 (20 A) fuse in theunder-hood fuse/relay box, andthe No. 17 (7.5 A) fuse in theunder-dash fuse/relay box.

Condenser fan does not run at ail.

Condenser Fan

Troubleshooting

~ OABa

8 A

1

NO 11 Replace the diode.

NOTE: Use a multimeter with diode checking capabilities.

22-10

Replace the under-hood fuselrelay box.

YES

Is there current flow in onlyone direction?

Check the diode:1. Disconnect the jumper wire.2. Remove the diode from the

under-hood fuse/relay box.3. Check for current flow in both

directions between the A andB terminais.

lFrom page 22-8

Condenser Fan (cont'd)

Troubleshooting

22-11

(cont'd)

Wire side offernale terminais

COMPRESSOR ClUTCH 1P CONNECTOR

JUMPERWIRE

4

RED

4

COMPRESSOR CLUTCH RELAy 4P SOCKET

Compressor clutch does notengage.

1

Check the No. 56 (20 A) fuse inthe under-hood fuse/rel av box,and the No. 17 (7.5 A) fuse in theunder-dash fuse/relav box.

1NO

Are the fuses OK? Replace the fusels), and recheck.

1 YES

Remove the compressor clutchrelav, and test it (see page 22-18'.

1NO Replace the compressor clutchIs the relav OK?

relay.

1 YES

Check the under-hood fuse/relaybox:Measure the voltage between theNo. 2 terminal of the compressorclutch relav 4P socket and bodvground.

1NO Replace the under-hood fuselIs there battery voltage?

relay box.

1 YES

Check the compressor clutch:Connect the No. 1 and No. 2 termi-nais of the compressor clutch relay4P socket with a jumper wire.

1YES

Ooes the compressor clutch click? To page 22-12

t NO

Check for an open in the wire:1. Oisconnect the jumper wire.2. Oisconnect the compressor

clutch 1P connector.3_ Check for conti nuit y between

the No. 1 terminal of the com-pressor clutch relay 4P socketand the terminal of the com-pressor clutch 1P connector.


Is there continuity? the compressor clutch relay and

J YESthe compressor clutch.

Inspect the compressor clutchclearance, the thermal protector,and the compressor clutch fieldcoil (see page 22-32).

Compressor

III

* How to use the backprobe setsConnect the backprobe adapters to the stacking patch cords. andconnect the cords to a multimeter. Using the wire insulation as aguide for the contoured tip of the backprobe adapter. gently slidethe tip into the connector trom the wire side until it comes in contact with the terminal end of the wire (see section 11).


-=


-=

2

COMPRESSOR CLUTCH RELAy 4P SOCKET

22-12

To page 22-13

1

Check for an open in the wire:1_ Disconnect the jumper wire.2. Turn the ignition switch ON (11).3. Measure the voltage between

the No. 4 terminal of the corn-pressor clutch relay 4P socketand body ground.

NO Replace the under-hood fuselIs there battery voltage? relay box.

YES

Check for an open in the wire:,. Turn the ignition switch OFF,then reinstall the compressorclutch relay.

2. Make sure the AlC and heaterfan switches are OFF.then turnthe ignition switch ON (II).

3. Using a *Backprobe Set (TIN07SAZ - 001000A). measurethe voltage between the No. 17terminal of the ECM/PCM con-nector A (32P) and bodyground with the ECM/PCMcon-nectors connected.

Repair open in the wire betweenNOIs there battery voltage 7 the compressor clutch relay and

the ECM/PCM.YES

From page 22-11

Compressor (cont'd)

Troubleshooting

* How ta use the backprobe setsConnect the backprobe adapters ta the stacking patch cards, andconnect the cards ta a multimeter. Using the wire insulation as aguide for the contoured tip of the backprobe adapter, gently slidethe tip into the connector tram the wire side until it cames in contact with the terminal end of the wire (see section 11).


ECM/PCM CONNECTORC 131P)

Repair open in the wire betweenthe A/C pressure switch and theECM/PCM.

NOr------------------------------

22-14

Check for loose wires or poorconnections at the ECM/PCMconnectors A (32P) and C 131Pl. Ifthe connections are good, substitute a known-good ECM/PCM,and recheck. If the symptomlindication goe5 away, replacethe original ECM/PCM.

YES

Is there less than , volt?

Check for an open in the wire:1. Reconnect the AIC pressure

switch 2P connector.2. Turn the AlC and heater fan

switches ON, then turn theignition switch ON (II).

3. Using a *Backprobe Set (TIN07SAZ - 0010DDA). measurethe voltage between the No. 5terminal of the ECM/PCM connectar C (31P) and bodyground with the ECM/PCMconnectars connected.

1

From page 22-13

Compressor (cont'd)

Troubleshooting


13 14 15 16

4 5 6 7


22-16

To page 22-17

1Check for an open in the wire:Measure the voltage between theNo. 1 terminal of the AlC thermo-stat 3P connector and bodyground.

NO Repair open in the wire betweenIs there battery voltage? the condenser fan relay and the

AIC thermostat.YES

Check the AIC thermostat:1. Turn the ignition switch OFF.2. Reconnect the NC thermostat

3P connector.3. Connect the No. 2 terminal to

ground with a jumper wire.4. Start the engine.

Ooes the condenser fan run NOand does the compressor Replace the AlC thermostat.clutch engage?

YES

Check for an open in the wire:1. Turn the ignition switch OFF,

BLUthen disconnect the jumperwire.

2. Remove the audio unit (seesection 20), and disconnect theheater control panel 16P con-nector.


the No. 1 terminal and bodyground.

Repair open in the wire betweenNOIs there battery voltage? the AlC thermostat and the heater

control panel.YES

From page 22-15

Ale System (cont'd)

Troubleshooting

1~ 2

JZ3 4

42

3

There should be continuity between the No. 1 and No. 2terminais when power and ground are connected to theNo. 3 and No. 4 terminais, and there should be no continuity when power is disconnected.

22-18

12V, 3W -18 W

If the Iight doesn't come on and go off as specified,replace the Ne thermostat.

The light should go off at 36 - 39·F (2 - 4·C) or Jess,andshould come on at 39 - 41·F (4 - S·C)or more.

Dip the NC thermostat into a cup filled with ice water, andcheck the test light.

NOTE: Use a 12V, 3 W - 18W test light.

Connect battery power to the No. 3 terminal, ground theNo. 2 terminal, and connect a test light between the No. 1and No. 3 terminais.

TestTest

RelayAle Thermostat

22-19} 130 ml 141/311-oz, 4.6lmp-ozl

rQI)~~ a} DRAININGrr-SAME LEVEL - r~VOLUME

NEWCOMPRESSOR

REMOVEDCOMPRESSOR

'%If.i;lJiiJ!N Sorne mixtures of air and R-134a have been shown to be combustible at elevated pressures and can resuftin fire or explosion causing in jury or property damage. Never use compressed air to pressure test R-134a service equipment or vehicle air conditioner systems.

Additional health and safety information may be obtained from the refrigerant and lubricant manutacturers.

1. Always disconnect the negative cable from the battery whenever replacing air conditioning parts.2. Keep moisture and dust out of the system. When disconnecting any lines, plug or cap the fittings immediately; don't

remove the caps or plugs until just before Vou reconnect each line.3. Before connecting any hose or line, apply a few drops of refrigerant oil to the O-ring.4. When tightening or loosening a fitting, use a second wrench to support the matching fitting.5. When discharging the system, use a R-134a refrigerant Recovery/Recycling/Charging System; don't release refriger

ant into the atmosphere.6. Add refrigerant oil after replacing the following parts:

NOTE:• To avoid contamination, do not return the oil to the container once dispensed, and never mix it with other retriger

ant oils.• Immediately after using the oil, replace the cap on the container, and seal it to avoid moisture absorption.• Do not spill the refrigerant oil on the vehicle; it may damage the paint; if the refrigerant oil contacts the paint, wash

it off immediately.

Condenser 20 mi (2/3 fl·oz, 0.7Imp·oz'Evaporator 45 mi (1 2/3 fl-oz, 1.6Imp·oz'Line or hose 10 mi (1/3 fl-ez, O.4Imp·oz'Receiver/Dryer 10 mi (1/3 fl-oz, 0.4Imp·oz'Leakage repair 25 mi (5/6 fl-oz, 0.9 lmp-oz!Compressor For compressor replacement, subtract the volume of oil drained from the

removed compressor trom 130 mi (41/3 fI·oz, 4.6Imp·oz), and drain the calculatedvolume of oil trom the new compressor: 130 ml (4 1/3 fI·oz, 4.6 Imp-oz) - Volumeof removed compressor = Volume to drain trom new compressor.NOTE: Even if no oil is drained from the removed compresser, don't drain morethan 50 mi (1 2/3 fl·oz, 1.8Imp·oz) trom the new compressor.

R-134a service equipment or vehicle air conditioner systems should not be pressure tested or leak tested with compressedair.

The air conditioner system uses HFC-134a (R-134a) refrigerant and polyalkyleneglycol (PAG) refrigerant oil*, which are notcompatible with CFC-12 (R-12) refrigerant and minerai oil. Do not use R-12 refrigerant or minerai oil in this system, and donot attempt to use R-12 servicing equipment; damage to the air conditioner system or your servicing equipment will result.* Sanden SP-10:• PIN 38897 - P13 - A01AH: 120 mi (4 ft-oz, 4.2 lrnp-oz)• PIN 38899-P13-A01: 40 mi (11/3fl·oz,1.4Imp·oz)

Use only service equipment that is U.L.-Iisted and is certified to meet the requirements of SAE J2210 to remove R-134afrom the air conditioner system.

CAUTION: Exposure to air conditioner refrigerant and lubricant vapor or mist can irritate eyes, nose and throat. Avoidbreathing the air conditioner refrigerant and lubricant vapor or mist.

If accidentai system discharge occurs, ventilate work area before resuming service.

l1liAle Service Tips and Precautions

22-20

CD Discharge hose to the compressor (6 x 1.0 mm) ...............•.....•...•..............................................9.8 N'm 11.0kgf·m, 7.2Ibf.ft)CID Discharge hose to the condenser (6 x 1.0 mm) ...............................•...........................................9.8 N'm (1.0 kgf·m, 7.2Ibf.ft)® Condenser line to the condenser (6 x 1.0 mm) 9.8 N'm (1.0 kgf·m, 7.2Ibf.ft)@ Condenser line to the receiver/dryer (6 x 1.0 mm) 9.8 N'm (1.0 kgf·m, 7.2Ibf·ft)<ID Receiver line A to the receiver/dryer (6 x 1.0 mm) ..................................................................•..9.8 N'1Tl(1.0 kgf·m, 7.2Ibf·ft)® Receiver line B to the receiver line A 13 N'm (1.3 kgf·m, 9.4Ibf·ft)(j) Receiver line C to the receiver line B ....•....................................................................................... 13 N'm (1.3 kgf·m, 9.4Ibf·ft)® Receiver line C to the evaporator (6 x 1.0 mm) 9.8 N'm (1.0 kgf·m, 7.2Ibf·ft)® Suction line B to the evaporator (6 x 1.0 mm) 9.8 N'm (1.0 kgf·m, 7.2Ibf·ft)@ Suction line A to the suction line B 31 N'm (3.2 kgf·m, 23 Ibf·ft)® Suction hose to the suction line A 31 N'm (3.2 kgf·m, 23 Ibf·ft)@ Suction hose to the compressor (6 x 1.0 mm) 9.8 N·m (1.0 kgf·m, 7.2Ibf·ft)@ Compressor to the compressor bracket (8 x 1.25 mm) 24 N'm (2.4 kgf'm, 17 Ibf·ft)@ Compressor bracket to the cylinder block (10 x 1.25 mm) 44 N'm (4.5 kgf'm, 33Ibf·ft)@ Compressor bracket to the left front mount (12 x 1.25 mm) 59 N'm (6.0 kgf·m, 43lbf·ft)

Ale System Torque Specifications

22-21

Test results Related symptoms Probable cause Remedy

Discharge (high) After stopping compressor, pres- Air in system Recover, evacuate, andpressure abnor- sure drops to about 200 kPa recharge with specified amount.mally high (2.0 kgf/cm2, 28 psi) quickly, and Evacuation: see page 22-25

then falls gradually. Charging: see page 22-26

Reduced or no air flow through • Clogged condenser fins • Cleancondenser • Condenser fan not work- • Check voltage and fan rpm.

ing properly • Check fan direction.

Line to condenser is excessively Restrrcted flow of refriger- Restricted lineshot. ant in system

Discharge pres- High and Jowpressures are bal- • Faulty compressor dis- Replace the compressor.sure abnormally anced soon after stopping compres- charge valvelow sor. Low side is higher than normal. • Faulty compressor seal

Outlet of expansion valve is not • Faulty expansion valve • Replacefrosted, low-pressure gauge indi- • Moisture in system • Recover, evacuate, andcates vacuum.

1recharge with specifiedamount.

Suction (Iow) Expansion valve is not frosted, and • Frozen expansion valve Replace the expansion valve.pressure abnor- low pressure line is not cold. Low- • Faulty expansion valvemally low pressure gauge indicates vacuum.

Discharge temperature is low, and Frozen evaporator Run the fan with compressorthe air flow from vents is restricted. off, then check AlC thermostat.

Expansion valve is frosted. Clogged expansion valve Clean or replace.

Receiver/dryer outlet is cool, and Clogged receiver/dryer Replaceinlet is warm (should be warmduring operation).

Suction pres- Low-pressure hose and check • Expansion valve open too Repair or replace.sure abnormally joint are cooler than the tempera- longhigh ture around evaporator. • Loose expansion capillary

tube

Suction pressure is lowered when Excessive refrigerant in sys- Recover, evacuate, andcondenser is cooled by water. tem recharge with specified amount.

High and low pressure are equal- • Faulty gasket Replace the compressor.ized as soon as the compressor is • Faulty high pressure valvestopped, and both gauges fluctu- • Foreign particle stuck inate while running. high-pressure valve

Suction and dis- Reduced air flow through con- • Clogged condenser fins • Clean condenser.charge pres- denser. • Condenser fan not work- • Check voltage and fan rpm.sures abnormally ing properly • Check fan direction.high

Suction and dis- Low-pressure hose and metal end Clogged or kinked low- Repair or replace.charge pressure areas are cooler than evaporator. pressure hose partsabnormally low Temperature around expansion Clogged high pressure line Repair or replace.

valve is too low compared withthat around receiver/dryer.

Refrigerant leaks Compressor clutch is dirty. Compressor shaft seal leaking Replace the compressor.

Compressor bolt(s) are dirty. Leaking around bolt(s) Tighten bolt(s) or replace com-pressor.

Compressor gasket is wet with oil. Gasket leaking Replace the compressor.

NOTE: Performance Test is on page 22-22.

Pressure Test Chart

l1liAle System Service

LOW-PRESSURES'DE

RecoveryIRecycling/Charging System

22-22

4. After running the air conditioning for 10 minutesunder the above test conditions, read the deliverytemperature from the thermometer in the dash ventand the high and low system pressure from the NCgauges.

3. Test conditions:• Avoid direct sunlight.• Open hood.• Open front doors.• Set the temperature control lever to MAX. COOL,

the mode control switch on VENT and the recirculation control switch on RECIRCULATE.

• Turn the NC switch on, and the heater fan switchon MAX.

• Run the engine at 1,500 rpm.• No driver or passengers in vehicle

2. Insert a thermometer in the center air vent.Determine the relative humidity and air temperature.

1. Connect a R-134a refrigerant Recover/RecyclinglCharging System to the vehicle, as shown, following the equipment manufacturer's instructions.

Additional health and safety information may be obtainedfrom the refrigerant and lubricant manufacturers.

'%iMmn; Some mixtures of air and R-134ahave beenshown to be combustible at elevated pressures and canresult in fire or explosion causing injury or pro pert ydamage. Never use compressed air to pressure test R-134a service equipment or vehicle air conditioner systems.

R-134a service equipment or vehicle air conditioner systems should not be pressure tested or leak tested withcompressed air.

If accidentai system discharge occurs, ventilate workarea before resuming service.

CAUTION: Exposure to air conditioner refrigerant andlubricant vapor or mist can irritate eyes, nose andthroat. Avoid breathing the air conditioner refrigerantand lubricant vapor or mist.

Use only service equipment that is U.L.-listed and is certified to meet the requirements of SAE J2210 to removeHFC-134a(R-134a)from the air conditioner system.

The performance test will help determine if the air conditioner system is operating within specifications.

Performance Test

Ale System Service

22-23

INTAKE TEMPERATURE

95(35)

86(30)

77(25)

104(40)

68(20)

/

/'//

,////

DELIVERVTEMPERATURE

/

INTAKEPRESSURE

30%

800/0

DELIVERVPRESSURE

800/0

./

kPa(kgf/cm2)

[psi)

2900(30)[430]

2500(25)[360]

2000(20)

kPa(280)(kgf/cm2) OF(psi] (OCI

1500 400 86(15) (4) (30)[210] [57]

DELIVERVPRESSURE

980 300 77(10' (3) (251[140] (43]

200 68(2) (20)(28]

100 59(1) (15)

INTAKE (14)PRESSURE

0 50(10)

DELIVERVTEMPERATURE

41(5) Y

5. To complete the charts:• Mark the delivery temperature along the verticalline.• Mark the intake temperature (ambient air temperature) along the bottom line.• Draw a line straight up from the air temperature to the humidity.• Mark a point one line above and one line below the humidity level (10% above and 10% below the humidity level).• From each point, draw a horizontalline across the delivery temperature.• The delivery temperature should fall between the two lines.• Complete the low side pressure test and high side pressure test in the same way.• Any measurements outside the line may indicate the need for further inspection.

III

5. After checking and repairing leaks, the system mustbe evacuated (seeSystem Evacuation on page 22-25).

4. If you find leaks that require the system to be opened(to repair or replace hoses, fittings, etc.), recover thesystem according to the Recovery Procedure on page22-24.

3. Check the system for leaks using a R-134a refrigerant leak detector with an accuracy of 14 9 (0.5 oz)per year or better.

Refrigerant capacity: 650~~9 (22.9~.8oz)

2. Open high-pressure valve to charge the system tothe specified capacity, then close the supply valve,and remove the charging system couplers.

NOTE: Be sure to install the same amount of newrefrigerant oil back into the NC system before charging.

1. Connect a R-134a refrigerant Recovery/Recycling/Charging System to the vehicle, as shown in theprevious column following the equipment manufacturer's instructions.

Additional health and safety information may be obtainedfrom the refrigerant and lubricant manufacturers.

'MhWiHN Sorne mixtures of air and R-134a havebeen shown to be combustible at elevated pressuresand can result in fire or explosion causing injury orproperty damage. Never use compressed air to pressuretest R-134a service equipment or vehicle air conditionersystems.

R-134a service equipment or vehicle air conditioner systems should not be pressure tested or leak tested withcompressed air.

If accidentai system discharge occurs, ventilate workarea before resuming service.

CAUTION: Exposure to air conditioner refrigerant andlubricant vapor or mist can irritate eyes, nose and throat.Avoid breathing the air conditioner refrigerant and lubricant vapor or mist.

Use only service equipment that is U.L.-listed and is certified to meet the requirements of SAE J2210 to removeHFC-134a(R-134a) from the air conditioner system.

22-26-

LOW-PRESSURESIDE

Recovery/Recycling/Charging System

Connect a R-134arefrigerant Recovery/Recycling/ChargingSystem to the vehicle, as shown, following the equipmentmanufacturer's instructions.

CAUTION: Do not overcharge the system; the compressorwill be damaged.

Refrigerant capacity: 650~~9 (22.9~~.8oz)

If accidentai system discharge occurs, ventilate workarea before resuming service. Additional health andsafety information may be obtained from the refrigerantand lubricant manufacturers.

CAUTION: Exposure to air conditioner refrigerant andlubricant vapor or mist can irritate eyes, nose andthroat. Avoid breathing the air conditioner refrigerantand lubricant vapor or mist.

Use only service equipment that is U.L.-listed and is certified to meet the requirements of SAE J2210 to removeHFC-134a(R-134a)from the air conditioner system.

leak TestCharging

Ale System Service

22-27

• If vou're installing a new evaporator, add refrigerant oil (SP-10) (see page 22-19).

• RepJace the O-rings with new ones at each fitting,and applv a thin coat of refrigerant oil beforeinstalling them.NOTE: Be sure to use the right O-rings for HFC-134a (R-134a) to avoid leakage.

• Apply sealant to the grommets.• Make sure that there is no air leakage.• Charge the system (see page 22-26), and test its

performance (see page 22-22).• Enter the anti-theft code for the radio, then enter

the customer's radio station presets.

8. Install in the reverse order of removal. Make note ofthe following items.

6xl.0mm9.8 N·m (1.0 kgf'm, 7.2Ibf.ft)

EVAPORATOR

AIC THERMOSTATCONNECTOR

6xl.0mm9.8N·m

(1.0 lm.7.2 IbHtl

e

7. Disconnect the connector from the NC thermostat,and remove the wire harness from the evaporator.Remove the self-tapping screws, the mounting boitand the mounting nut. Disconnect the drain hose,then remove the evaporator.

PASSENGER'SDASHBOARDLOWERCOVER

6. Remove the selt-tapping screw and the passenger'sdashboard lower coyer. Remove the boit, the nutand the knee bolster, th en remove the bolts and theglove box frame.

RECEIVER UNE

5. Remove the glove box (see section 20).

SUCTION UNE

NOTE: Plug or cap the lines irnrnediatelv after disconnecting them to avoid moisture and dust contamination.

4. Remove the bolts, then disconnect the suction andreceiver lines trom the evaporator.

3. Recover the refrigerant with a Recovery/Recvcling/Charging System (see page 22-24).

2. Remove the battery.

1. Make sure vou have the anti-theft code for theradio, then write down the frequencies for theradio's preset buttons.

Replacement

Evaporator

22-28

TAPES(Replace)Make sure there is no foreign matter stuck betweenthe capillary tube and outlet line.

CAPllLARV TUBE

A/C THERMOSTATTest: page 22-18

6th tin trom inlet side

• Replace the O-rings with new ones at each fitting,and apply a thin coat of refrigerant oil beforeinstalling them.NOTE: Be sure to use the right O-rings for HFC-134a (R-134a)to avoid leakage.

• Install the expansion valve capillary tube withthe capillary tube in contact with the outlet line,and wrap it with tape.

• Reinstall the AlC thermostat sensor to its originallocation.

• Make sure that there is no air leakage.

5. Assemble in the reverse order of disassembly. Makenote of following items.

CLIP

lOWER HOUSING

24 N'm (2.4 kgf·m,17 IbHt)

with compressed air.

EVAPORATOR

NOTE: When loosening the nuts of the expansionvalve, use a second wrench to hold the expansionvalve or the evaporator line. Otherwise, they can bedamaged.

4. If necessary, remove the expansion valve.

3. Carefully separate the housings, then remove theevaporator.

2. Remove the self-tapping screws and clamps fromthe housings.

1. Pull out the AlC thermostat sensor from the evaporator fins.

Overhaul

Evaporator

• If you're installing a new compressor, drain ailthe refrigerant oil from the removed compressor,and measure its volume. Subtract the volume ofdrained oil from 130mf (4 1/3 fi·OZ, 4.6 lrnp-oz):the result is the amount of 0;1 vou should drainfrom the new compressor (through the suctionfitting).

• Replace the O-rings with new ones at each fitting, and apply a thin coat of refrigerant oilbefore installing them.NOTE: Be sure to use the right O-rings for HFC-134a (R-134a)to avoid leakage.

• Use refrigerant oil (SP-10) for R-134aSanden spiral type compressors only.

• To avoid contamination, do not return the oil tothe container once dispensed, and never mix itwith other refrigerant oils.

• Immediately after using the oil, replace the capon the container, and seal it to avoid moistureabsorption.

• Do not spill the refrigerant oil on the vehicle; itmay damage the paint; if the refrigerant oil contacts the paint, wash it off immediately.

• Adjust the AlC compressor belt (see page 22-36)and the power steering pump belt (seesection 17),

• Charge the system (see page 22-26), and test itsperformance (see page 22-22).

• Enter the anti-theft code for the radio, then enterthe customer's radio station presets.

11. Install in the reverse order of remova!. Make note ofthe following items.

22-30

1.0 x 1.25 mm44 N'm (4.5 kgf·m, 33 Ibf.ft)

12)( 1.25 mm59 N·m (6.0 kgf'm,43 Ibf.ft)

• Remove the four mounting bolts and the cornpressor bracket.

NOTE: When tightening the nut to the left frontmount, make sure the washer is set properly onthe left front mount as shown.

• Remove the nut and the washer trom the leftfront mount.

10. If necessary, remove the compressor bracket as follows.

Replacement (cont' d)

Compressor

If resistance is not within specifications, replace thefield coil.

Field Coil Resistance: 3.2 ± 0.15 ohms at 68°F (200e)

• Check resistance of the field coil.

• Release the field coil connector from the holder, thendisconnect it. Check the thermal protector for continuity. If there is no continuity, replace the thermalprotector.

22-32

ROTORPULlEY

ARMATUREPLATE

NOTE: The shims are available in four thicknesses:0.1 mm, 0.2 mm, 0.4 mm and 0.5 mm

Clearance: 0.5 ± 0.15 mm (0.020 ± 0.006 in)

• Measure the clearance between the rotor pulley andthe armature plate ail the way around. If the clearance is not within specified limits, the armature platemust be removed and shims added or removed asrequired, following the procedure on page 22-33.

r J. /'

~:_j\"J/,' 'gA( '-- c,_;, i" .:»:~ j J --:- (::jr,/(--~'

:f

ROTOR/PUlLfV

• Check the rotor pulley bearing play and drag by rotating the rotor pulley by hand. Replace the clutch setwith a new one if it is noisy or has excessive play/drag.

• Check the plated parts of the armature plate for colorchanges, peeling or other damage. If there is damage, replace the clutch set.

Clutch Inspection

Compressor

5. Recheck the tension of the Ale compressor belt.

4. Retighten the center nut of the id1erpulley.

3. Turn the adjusting boit to get proper belt tension.

2. Loosen the center nut of the idler pulley.

~J BELT TENSION GAUGE~ 07JGG - 001010A

NOTE:• FoIJow the manufacturer's instructions for the

belt tension gauge.• If there are cracks or any damage evident on the

belt, replace it with a new one.• "Used belt" means a belt which has been used

for five minutes or more.• "New belt" means a belt which has been used

for less than five minutes.

A/C Compressor BeltUsed Belt: 340 - 490 N (35 - 50 kgf, 77 - 110 IbnNew Belt: 690 - 830 N (70 - 85 kgf, 150 -190 Ibf)

1. Attach the special tool to the Ale compressor belt asshown below, and measure the tension of the belt.

Tension Gauge Method

22-36

5. Recheck the deflection of the Ale compressor belt.

4. Retighten the center nut of the idler pulley.

3. Turn the adjusting boit to get proper belt tension.

2. Loosen the center nut of the idler pulley.

NOTE:• If there are cracks or any damage evident on the

belt, replace it with a new one.• "Used belt" means a belt which has been used

for five minutes or more.• "New belt" means a belt which has been used

for less than five minutes.

A/C Compressor BeltUsed Belt: 7.5 - 9.5 mm (0.30 - 0.37 in)New Belt: 5.0 - 6.5 mm (0.20 - 0.26 in)

1. Apply a force of 98 N (10 kgf, 22 Ibf), and measurethe deflection between the Ale compressor and thecrankshaft pulley.

Deflection Method

Adjustment

A/C Compressor Belt

Documents

97-00 Acura 1.6 EL Repair Manual