Service Manual 92-96 - Lude

I NT RO DUCT ION I
How to Use This Manual This manualis dividedinto 23 sect tion is markedwith a blacktab that linsup with its co.responding thumb indextab on this paqeand the back cover. you can auicklv tind the tirst pageof each sectionwithout lookingthrougha full table of contents.The symbolsprintedat the top cornerof each page can also be used as a quick reference system. Each section includes: 1. A table of contents,or an explodedview index showing: a Partsdisassemblv sequence. a Bolt torquesand thread sizes. a Pagereterences descriptions text. to in 2. Disassembly/assembly procedures and tools. 3. Inspection. 4. Testing/troubleshooting. 5. Repair. 6. Adjustments.
G e n e ra l n fo
Specifications
Maintenance Engine
Cooling
f,|tr
t ll=
It
SpecialInformation
tnai""tes a strong possibility ot sevoro prsonal injury @@ or losa of lite it instluctions ar not tollowed. CAUTION: Indicates a possibility of poBonal iniury ol oquipmont damage if instructions aro not tollowed. NOTE: Gives helpful information. CAUTfON: Detaifoddescriptionsol st ndard wo*shop procedures, satety p nciplesand servicopalationsaro not includod.pleasonot6 that this manualcontainswamings and cautionsagainstsoms spocitic srvice methods which could cause PERSONAL lNJURy, d8mag6 a vahicl or mako it unsafe. Pleaaaundratandthat thos6 warnings cannot cover all concivableways in which sorvice, whethgr 01 not recommended by HONDA might b6 dono, or of tho possible hazardous consequences of evely conceivablo way, no. could HONDA invostigateallsuch ways. Anyono using sorvics proceduros 01toofs. whether or not rocommendedby HONDA,must satjslyhimsel, thoroughly that ngithor pr3onal aatety nor vohicl s8fety will be jsopardized. All informationcontainedin this manualis basedon the latest Droduct info.mationavailable the time of printing.We reservethe right at to makechanges any time without notice.No part of this publicaat tion may be reproduced, storedin retrievalsystem.or transmitted, in any form by any means,electronic.mechanical, photocopying, recording, otherwise,without the prior written permission the or oJ publisher. This includestext, figures and tables.
ri!
Fueland Emissions ZZ *Transaxle
*Steering
If." r
* Brakes (lncludin
* Bo d y * H e a te ra n d Ai r C o n d i ti o n i n
First Edition9/92 1516 pages HONDA MOTORCO..LTD. All Rights Reserved Seruic Publication Offics Specilications apply to U.S.A. and Canada
L'___
As soctions with * includ6 SRS comDononrs. spcial piocautions aro roquirad whoit so.vicing.
* Electrical (lncluding
GeneralInformation
Chassis PaintCodes................. and 1-2 ldentification Number Locations ....... 1-4 Warning/Caution Labels.................. 1-s Lift and SupportPoints Lift ........... . . . . . . . . . . . . .1 .-.9 . F l o oJ a c k r . . . . . . . . . . . . . .1 - . 0 ..1 Safety tands S . . . . . . . . . . . .- 1 1 1 Towing .......1-12 ServicePrecautions
Handlingof SpecialNuts
and Bolts
1-13
'!. 7t
Chassisand Paint Codes

U.S. Model
EngineNumber
JHMBA814'PCOOOOol
F22A1-9200001
Engine Type MultiF22A1; 2.2 / SOHC Sequential port Fuel-injectedengine H22A1t 2-2, DOHCVTEC Sequential engane Multiport Fuel-iniected MultiH23A1t 2.3, DOHC Sequential port Ful-injectedengine EmiesionGroup lOO: Califolniawith H22A1 engine 130: 49ST with H22A1 engine with H23A1 engine 2OO:California 23O: 49ST with H23A1 engine 920: Calilorniawith F22A1 engine 923: 49ST with F22A1 engine Serial Numbel
Type of Vehicle C J H M : H O N D AM O T O R O . , L T D . Car HONDA, Passenger BA8: Prelude2.2 / BBl : Prelude2.2 t VfEC BB2: Prelude2.3 / Body and TransmissionTYPe Manual 1: 2-door s-sDeed 2t 2-doot 4-speedAutomatic Vehicle Grade 4: PreludeS Si 5: Prelude 6: PreludeSi 4WS Si 7: Prelude VTEC Chock Digit Model Yoat '1993 P:,
M2F41000001
M2F4: Manualwith H22A1 engine M2L5: Manualwith F22Al engine M2S4: Manual with H23A1 engine M2F4: l OOOOO1 Exceot M2F4: 20OOOO1
Vehicle ldentificationNumbel and FederalMotor Vehicle Safety Standard Certification'
Paint Code
COLOR B-64P
Fresco Blue Pearl Brittany Blue Metallic GranadaBlsck Peatl SeablingSilver Metallic Frost White Mirano Red
ir
i[ i
ii
CanadaModel
Vehicle ldentificationNumber
JHMBA814* C800001 P
J H M : H O N D AM O T O RC O . . L T D . HONDA, Passenger Ca. BA8: Prelude2.2 / B B 1 :P r e l u d2 . 2 . l E C e BB2: Ptelude 2.3 I Body and T.ansmission Type 1: 2-door s-sDeed Manual 2', 2-doot 4-speedAutomatic
Vehicle Glade 4: Prelude
F22A1: 2.2 / SOHC Sequential Multi port Fuef injected engine H22A'l:2.2 / DOHC VTEC Seouential Multiport Fuel-injected engine H23A1: 2.3 / DOHC Sequential Multipon Fuel-injected engine F22A1 engine; 928OOO1 H22A1 engine: l TOOOO lH23A1 engine: 27OOOO1
5: Prelude SR 6: Prelude 4WS SR 7: PreludeSR-V Check Digit Model Y6at P: 1993 C: SaitamaFactoryin Japan
M2F41000001
M2F4: Manual with H22A1 engine M2L5: Manualwith F22Al engine M2S4: Manual with H23A 1 engine
M2F4: l OOOOO l ExceptM2F4: 2OOOO01
Vehicle ldentificationNumbe] and CanadianMotor Vohicle Safety Standard Certification.
Paint Code
COLOR 8,64P
F esco Blue Pearl Brittany Blue Met8llic Granada Black Pearl SeablingSilverMetallic Frost White Mirano Red
1-3
NumberLocations ldentification
Vehicle ldentif ication Number
V.hicl ldontitication Numbo.
TransmissionNumber (Automaticl
t
'l i,
,l
Tiansmission Number lManual)
Warning/Caution LabelLocations
A: CABLE REELCAUTION A CAUTION: ISRSI BEFORE INSTA-I.IING CABLE REEL: . CENTERTHE FRONTWHEELS. . ALIGN THE MARKS. . READ SERVICEMANUAL. B: CABL REELCAUTION B
D: DRIVER MODULE WARI{|]{G A WARI{ING THEAIRBAG I'{FLATOR EXPLOSIVE IS AND,IF ACCIDEN. TALLYDEPLOYED, CAt{ SERIOUSLY HURTOF KILLYOU. . DOI{OI USEELECTRICAL TESTEOUIPMENT PNOBOR II{G DEVICES.THEY CAN CAUSE ACCIDENTAL DEPTOYI'EI{T. . NO SERVICEABLE PARTSINSIDE,DO OT DISAS. SEMBLE. . PLACE AIRBAG UPf,IGHT WHEI{BEMOVED. a Fou.ow sERvtcE MAI{UAL |]{STRUCT|O]{S CAREFULLY.
E: I FLATOR WARNING TAG A WARNING ACCIDENIAL AIRBAG DEPLOYMEI{I CA]T SERIOUSLY HURTOR KILLYOU. II{STALLTHE REDSERVICE CONNECIOB WHENTHE INFLATORHARITESS DISCONNECTED. IS F: STEERING WHEEL t{OllCE NOTICE IMPROPER STEERING VYHEEL REMOVAL OR II{STALLATION CAN DAMAGE SRS COMPOT{EI{TS. FOLLOWSERVICEMA UA! INSTRUCTION CAREFULLY.
cAUTtOt{:
NO SERVICEABLE PARTSINSIDE;DO NOT DISASSEMBLE OR TAMPER. C: DRIVERMODULE DANGER A DANGER EXPLOSIVE/FLAMMABLE CONTACTWITH ACID, WATEROR HEAVYMETALSSUCH AS COPPER. LEAD OR MEFCURYMAY PRODUCE HARMFUL AND IRRITATING GASES OR EXPLOSIVE COMPOUNDS.STORAGE TEMPERATURES MUST I{OT EXCEED 2OO"F{1OOOCI. FORPROPER HANDLII{G,STORAGE AND DISPOSALPROCEDURES REFERTO SERVICEMANUAL, SRS SUPPI.EMENT. POTSON COI{TAINSPOISONOUS SODIUMAZIDEAND POTASSIUM NITRATE, FIRSTAIO IF CONTENTS ARESWALLOWED. II{DUCEVOMITING.FOR EYE CONTACT, FLUSH EYES WITH WATER FOR 15 MINUTES.IF GASES (FROMACID OR WATER CONTACT) ABE INHALED, SEEI( FRESHAIR. IN EVERY CASE, GET PROMPTMEDICAL ATTENTION. KEEPOUT OF REACHOF CHILDREN.
(cont'd)
1-5
LabelLocations Warning/Caution
(cont'dl
'E: Inflatorwarning tag (Reterto page l-5).
G: SRSWARNING{ENGINE HOOOI SUPPLEMENTAL RESTRAIIIIT SYSTEM ISRS) THIS VEHICLE IS EOUIPPED WITH DRIVERAND FRONT SEAT PASSENGEB AIRBAGSAND FRONTSEAT BELTTEN. SIONERSYSTEMS. ALL SRS ELECTRICAL WIRING AND CONNECTORS ARE COLOREO YELLOW. TAMPERING WITH, DISCONNECTING USINGELECTRIOR CAL TEST EOUIPMENT ON THE SRS WIRING CAN MAKE THE SYSTEMINOPERATIVE CAUSEACCIDENTALFIROR ING OF THE INFLATOR. A WARNING THE AIRBAG INFLATORIS EXPLOSIVE AND. IF ACCIDE . TALLY OEPLOYED. CAN SERIOUSLY HURTYOU. FOLLOW SERVICEMANUAL INSTRUCTIONS CAREFULLY. H: STEERING COLUMNCAUTION
K: DRIVER INFORMATION ISUNVISOB)
ALWAY WEARYOURSEATBELT
AIRBAG AS A CAR IS EOUIPPED WITH A DRIVER SUPPLEMENTAL RESTRAINTSYSTEM {SRSI. . IT IS OESIGNED SUPPLEMENT TO THE SEAT BELT. . BEFORE ORIVING READLABELINSIDE THEGLOVEBOX. 'K: DRIVER INFORMATION
ALWAY WEARYOURSEATBELT
CAR IS EOUIPPEO WITH A DBIVERAIRBAG AND A FRONT AIRBAGAS A SUPPIEMENSEAT PASSENGER TAL RESTRAINTSYSTEM ISRS). . IT IS DESIGNED TO SUPPLEMENT THE SEAT BELT. . BEFORE DRIVING REAOLABELINSIDE THEGLOVEBOX. L: GLOVEBOX INFORMATION DRIVER'SAIREAG INFORMATION . SUPPLEMENTAL RESTRAINT SYSTEMISRSICAN PROVIDE AOOITIONALPROTECTION FORTHE DRIVERIN A FRONTAL COLLISION. FUNCTIONAL A DESCRIPTION OF THE SRS IS IN YOUR OWNER'S MANUAL. . THE SYSTEMMUST BEINSPECTED TEN YEARSAFTER DATE OF MANUFACTURE, NOTEDON THE CERTIFIAS CATION PLATE. . ANY REPAIR, INSPECTION NEARBY OR ACCESSORY II{. STALLATIONSHOULD8E DONE BY AN AUTHORIzED HONDA DEALER. . IF YOUR SRS INDICATOR: . LIGHTSWHILE DRIVINGOR FLASHES; . FAILSTO LIGHTOR STAYS ON AFTERTHE IGNITION IS FIRSTTURNEDON: SEE YOUR AUTHORIZEDHONDA DEALER. 'L: GLOVEBOX INFORMATION DRIVER'S AND FRONTSEAT PASSENGER'S AIRBAG INFORMATION . SUPPLEMENTAL RESTRAINT SYSTEM{SRSICAN PRO. VIDEADDITIONALPROTECTION FORTHE DN|VER AND FRONTSEAT PASSENGER A FRONTALCOLLISION. IN A FUNCTIONAL DESCRIPTION THE SRS IS IN YOUR OF OWNER'S MANUAI.. . THE SYSTEMMUST BE INSPECTEO TENYEARSAFTER DATE OF MANUFACTURE, NOTEDON THE CERTIFIAS CATION PLATE. . ANY REPAIR, INSPECTION NEARBYACCESSORY OR INSTALLATIONSHOULD BE DONE BY AN AUTHORIZEO HONDA DEALER. . IF YOURSRS INDICATOR: . LIGHTS WHII-E DRIVINGOR FLASHES; . FAII.STO LIGHTOR STAYS ON AFTERTHE IGNITION rs FrRsTTUBNEDON; I . SEEYOUR AUTHORIZED HONDA OEALER. M: SRS UNIT CAUTION CAUTIONi . NO SERVICEABLE PARTS INSIOE. . DO NOT OISASSEMELE TAMPER. OR . DO NOT DROP. . STORE A CLEAN,DRY AREA, IN
CAUTION ISRS To AvotD DAMAGIIGrHE sRs CABLE REE|-. oB wHtcH COULDMAKETHESYSTEM INOPERATIVE, REMOVE THE STEERING WHEELBFORE REMOVING THE STEERING SHAFTCONNECTOR BOLT.
l: FRONTSEAT PASSENGER AIRBAGMODULEDANGER A DANGER EXPLOSIVE/FLAMMABLE CONTACTWITH ACID, WATEROR HEAVY METALSSUCH AS COPPER, LEAD OR MERCURYMAY PRODUCE HARM. FUL AND IRRITATING GASES OR EXPLOSIVE COMPOUNDS.STORAGE TEMPERATURES MUST NOT EXCEED (lOOOC} 2OOOF FORPROPEB HANDLING, STORAGE ANO DISPOSAL PROCEDURES REFERTO SERVICEMANUAL, SRS SUPPLEMEI\'T. POISON CONTAINSPOISONOUS SOOIUMAZIDEAND POTASSIUM NITRATE. FIRSTAID IF CONTENTS ARESWALLOWED, INOUCE VOMITING.FOR EYE CONTACT, FLUSH EYES WITH WATER FOR T5 MINUTES. GASESIFROMACID OR WATERCONTACTI IF ABE INHALED, SEEK FRESHAIR. IN EVERY CASE, GET PROMPTMEDICAL ATTENTION. KEEPOUT OF REACHOF CHILDREI\'. A WARNING THE AIRBAG INFLATORIS EXPLOSIVE AND, IF ACCIDEN. TALLY DEPLOYED, CAN SEBIOUSLY HURT OR KILL YOU. . DO NOT USEELECTRICAL TESTOUIPMENT PROBOR ING DEVICES. THEY CAN CAUSE ACCIDENTAL DEPLOYMENT. . NO SERVICEABLEPARTS INSIDE. DO NOT DISASSEMBLE. . PLACEAIRBAG UPRIGHTWHEN BEMOVED. . FOLLOW SERVICEMANUAI- INSTRUCTIONS CAREFULLY.
*This versionof the label is used on cars with lront passenger airbag.
(cont'd)
1-7
LabelLocations Warning/Caution
AIR CLEAI{ERELEMEI{T, OIL FILTEB,RECOMMENDATIOI{ ENGINEOll- and SPARK PLUG
;DZ"N
tl i-l atl
t:
RAOIATORCAP CAUTION
I
.
\..
1-8
Lift and Support Points

wnen heavy real components such as suspension, fuel tank. spare tile and trunk lid are to be removed, @Q plac additional weight in tha trunk betole hoisting. When substantial weight is removed trom the lear of th6 cal, the center of gravity may change and can causs the car to tip forward on tho hoist. NOTE: Sinceeach tire/wheelassemblyweighs approximately lbs { 14 kg), placingthe front wheels in the trunk can 30 assist with weight dist.ibution. 1. Placethe lift blocks as shown. 2. 3. Raisethe hoist a few inches (centimeters) and .ock the car to be sure it is firmly supponed. Raisethe hoist to tull height and inspect lift points for solid support.
DH
REARSUPPORT POINT
(cont'd)
1-9
Lift and SuPPortPoints

Floor Jack
Set the parkingbrakeand blockthe wheelsthat are not being lifted. When liJtingthe rear of the car, put the gearshift in lever in reverse{Automatictransmission @ position). Raisethe ca. high enoughto insertthe safety stands' Adjust and placethe satety standsas shown on page level,then low1-1 1 so the car will be approximately car onto them. er the
@ o Always uso salty stands when wolking on or

undor any vehiclo that is supponed only by a jack. a Nver attmpt to use a bumpel iack for lifting ol supporting tho cat.
BEAM CENTER
Centerthe iacking bracket in the middle of the jack lilt Platform.
PLATFORM
Centerthejacking bracketin the middle

ol the iack lift Platform
LIFT PLATFORM
1-10
Safety Stands
DH
FRONTSUPPORTPOINT SAFEW STANDS REARSUPPORTPOINT
1-11
j
Towing
towing ll the car needsto be towed. call a proJessional service.Nevertow the car behindanothercar with just a roDeor chain. lt is verY dangerous Emelgency Towing There are three popularmethodsof towing a car: loadsthe car on the Equipment- The operator Flat-bed This is the best way of transponingthe back ol a truck. car. Wheel Litt Equipmont - The tow truck uses two plvoring arms that go underthe tires {tront or rear)and lifts them otf the ground. The other two wheels remainon the ground. Sling-type Equipmont - The two truck uses metal cables with hooks on the ends. These hooks go around and the cableslift that Dartsof the trame or suspension and end of the car oft the ground.The car's suspension if damaged this methodof towing body can be seriously is attempted. by lf the car cannotbe transported flst-bed,it shouldbe towed with the front wheels off the ground. lf due to damage,the car must be towed with the front wheels on the ground, do the following: 5-spe6d Manual Tlansmission the Parkingbrake. a Release to a Shift the transmission Neutral. Tlansmission Automatic a Release the Parkingbrake. a Start the engine. a Shift to @ position,then @ position. a Turn off the engine. will damagethe lmpropertowing preparation NOTICE: procedure exactly.It you Followthe above transmission. or shift the transmission start the engine(autocannot your car must be transponedon a matic transmission), flat-bed.
TtEDOWIIHOOKS
HOOK TOWING
.-) t:
a lt is best to tow the car no farther than 50 miles (8okm),and keepthe speedbelow 35 mph (55 km/hl' will Tryingto lift or tow the car by the bumpers NOTICE: to are The bumpers not designed damage. serious cause suooortthe car's weight.
f 'l
\.
1-1 2
Service Precautions
Handlingof SpecialNuts and Bolts
Becausethe tront sub frame sectionson this car a.e constructed with aluminum alloys. use only the special "Dacro" type nuts and bolts recommended Honda. by NOTE: a Dacro finish can be identitiedby gray plating. a Some Dacro tinish bolts have a green coating on the th.ead sectionof the bolt for easielapplication. This type ot bolt is calleda "Torqu6r" bolt, a Use of other types ot nuts and bolts may cause electrolvsis and corrosion,which in turn could caus the bolt to loosen.
l.
When replacing nuts and bolts, use only the same type. Tighten the nuts and bolts with I torqua wrench to providedin this manual. ths specifications
J.
Clean all thread ridges with a non wire type bristle brush. Foroignmatter in the threads may cause the bolt to loosen.
4 . Sctions on this car requiringthe use of Dacro nuts

bv and bolts will be indicated a l* I in this manual.
Gray
Grcon coating on tha thraad! of ao|lro bolta.
Gray plsting: "Dacro" type Gray plating + Greencoating on the threads: "Torquer" type
1-13
Specifications
Standards Service and Limits ...........3-2 Design Specifications ...................... 5 3-1 BodySpecifications ....... 3-18
Standardsand Service Limits

CytinderHead/ValveTrain {F22A1 engine} Section 6 I
Compression
TTaEASuREMENT
25O rpm and wide open throttle Nominal Minimum
sraruolnotruewt
1781 1.250 112.5, 9 5 0 { 9 . 5 ,1 3 5 ) 200 12.0.2al
umtr senvtce
psi) kPa{ks/cm2,
Cylindrhead Camshaft
r49l'm!Il9!919!
Warpage Hoight End play oil Camshalt-to-holder clearance Total runout Cam lobe height Valve clearance Valve stem O.D. Stem-to-guide clearance
IN EX
IN
EX
IN
EX
IN
Valve seat
width Stem installed height
EX IN EX
IN
EX
lN
Valve spring
Freelength
EX
Valve guide
t.D. height Installed
IN EX IN EX
Bocksr arm
Arm-to-shaft clearance
IN EX
0.o5 (0.002) (3 99.95-100.05 .935-3.939) o.5 {0.02) 5 o.05-o.1 (0.002-0.006) (o.oo20-o.oo35) 0.15 (0.006) 0.o50-0.089 o.06 (0.002) max. 0.03 {0.0o1) ( 38.526 1.5168) 3a.77a11.52671 (0.o09-0.o1 1) o.23-0.28 ( 3 0 . 2 7 - 0 . 3 00 . 0 1 ' 0 . 0 1 ) ooss I oet ro.: 1 5 . 4 8 5 - 5 . 4 9 5 . 25 9 - 0 . 26 3 ) 10 1 5.4201o.21341 (0.2146-0.21 50) 5.450-5.460 0.08(o.oo3) {o.0008-o.oo20) 0.o20-0.045 o.1 (0.oo5) 2 ) 0.055,0.o80 {0.0022-o.oo3'l 2.0 {0.08) ( 0 . 0 4 9 - 0 . 0) 1 6 1.25-1.55 2.0 10.08) ) 1 . 2 5 - 1 . 5( O . 0 4 9 - 0 . 0 6 1 5 48.965 1.92781 79) t 15 48.245-48.7 (1.8994-1.91 ( ( 5 5 0 . 3 1 - 5 0 . 7 8 51 . 9 8 0 9 - 1 , 9 9 9 4 ) 5 1 . 0 3 5 2 . 0 0 9 2 1 5 4 . 8 11 2 . 1 5 8 ) 54.82(2.r 58) 2 5 6 . 2 6{ 2 . 2 1 5 ) 56.2A12.21612 5 . 5 3( 0 . 2 1 8 ) 1 7 5,5.53010.217-0.217 | 5.51 5 . 5 3{ 0 . 2 1 8 1 1 5-5.5301o.211-O.21771 5.51 (O.91 5-0.954) 23.75-24.25 2) 15.05-'5.55 {O.593-0.61 1 7-o.050 o.o1 l0.oo07'o.oo20) 0.08 (0.003)
(0.ooo7-o.0021 ) 8-0.054 o.o1
o.08 {o.oo3)
''l: CHUO HATSUJOmanulactured valve sprrng. '2: NIHONHATSUJOmanulactllred valve spring
Cylinder Head/ValveTrain (H23A1 enginel - Section 6

MEASUREMENT
Compression 250 rpm and wide open throttle kPa lkg/cm2, psi) Nominal Minimum Maximumvaiation
Unit of tength:mm (in)
srAr{DARD tt{Ewl
1,250 112.5, 1181 9 5 0 { 9 , 5 ,1 3 5 } 200 12.o,2al
( 1 1 3 1 . 9 5 - 1 3 2 . 0 55 . 1 9 5 , 5 . 9 9 )
stnvtce urirr
Cylinderhead Camshatt
Warpage Heighr End play Camshaft-to-holder clearance oil Total runout Cam lobe height Valve clearance Valve stem O.D. Stem to-guide clearance
0.o5{0.oo2)
IN
EX
IN EX IN EX IN EX IN EX IN EX lN EX
IN
Valve seat
Widrh Stem anstalled height
I .l
0.05 0.15 (0.oo2-o.006) o.5 {0.02} *1 (o.0020-o.oo35) o.050-0.089 o . 1 5{ 0 . 0 0 6 ) . 1 0. 100,o. 39 (o.0039-0.0055)*2 0.20 (o.oo8)*, 1 0 . O 3( 0 . O 0 1 1a x . m 0.06 (0.oo2l 33.661 1.3252} { 3 3. 72 5 t 1. 3 2 7 ) 8 o.07-0.1 (0.003-0.004) 1 o . 15 - 0 . 1 9 0 . o o 6 . 0 0 7 ) 0 t -0.2594) (O.2591 6.580-6.590 6 . 5 5( O . 2 5 8 ) (O.2579-0.2583) 6.550-6.560 6.32 t0.257l -0.002) (o.oo1 o.o2-o.05 0.08 {o.oo3) (o.oo2-0.o031 0.o5-o.08 0 . 1 1( O . O O 4 ) 6 1 . 2 5 - 1 . 5 ( 0 . 0 4 9 - 0 . 0) 1 5 2.0 (o.081 (0 1 . 2 5 - ' 1 . 5 5 . 0 4 9 , O . 0)6 1 2.0 (0.081 3 9 . 3 6 5 - 3 9 . 8 3'5 . 5 4 9 8 - 1 . 5 6 8 3 )4 0 . 0 8 5{ 1 . 5 7 8 1 ) t 1 1 3 9 .19 5 , 3 9 . 6 3 ( 1 . 5 4 3-1 . 5 6 0 4 t 3 9 . 8 8 5 1 . 5 7 0 3 ) 5 {
4 7 . 1 41 1 . 8 5 6 1 47.r4 (1.856)
Valvo spring Valve guide
Freelength
t.D.
Installed height
EX
IN
EX
' 1: ExhaustNo. 5 journal. '2: ExceptexhaustNo. 5 journal.
(O.260-0.261 6.61-6.63 I ( 6 6 . 6 1 , 6 . 6 30 . 2 6 0 - 0 . 2) 1 13.25-1 5 1O.522-0.541 3.7 | 0 1 13 . 75 - 1 . 2 5( O . 5 4-1 . 5 6 ) 4
6.70 to.264l 6.70 {0.264)
{cont'd)
3-3

MEASUREMENT Compression 250 rpm and wide open throttle kPa (kg/cm2,psi)
)n 6 CylinderHead/ValveTrain (H22A1 engine) Sectit

tNEwl STANDARD
1 , 3 0 O( 1 3 . 0 ,1 8 5 ) 950 {9.5, 135) 200 (2.o, 28)
sERvlcELlMlr
Nominal Minimum Maximum varlatron
Cvlinderhead Camshaft
Warpage Heisht End play oil Camshalt-to_holder clearance Total runout lN Cam lobe height EX
o.o5{0.002}
0.5(0.02) 5 o.o5-o.1{O.OO2-0.006} (o.o020-o.oo35) o . 1 5 ( 0 . 0 0 6 ) o.050-0.o89 1 { 141.95 42.05 5.589-5.593)
Valve clearance Valve stem O.D. clearance Stem-to-guide Valve seat
Primary Mid Secondary PrimarY Mid Secondary lN EX lN EX lN EX IN EX IN EX
widrh height Steminstalled
m 0 . 0 3( O . 0 0|1 a x 34.04' 1 {1.3402) ( 36.856 1.4510) 34.971 r.3768} { 33.745 1.3285) { ( 36.323 1.43001 ( 34.683 1.3655) 9 0.15-O.1 (0.006-0.oo7) o.17 0.21 (O.OO7-O.OO8| 59) 56'0.21 1O.2' l 5.475-5.485 (0.21 59) 56-0.21 5.475-5.485 (0.001 0-0.oo22) o.025-0.055 ) {0.0020-0.0031 o.o5o-0.080 ( 0 . 0 4 9 - 0 . 0) 1 6 1.25-1.55 1 . 2 5 - 1 . 5( 0 . 0 4 9 - 0 . 0)6 1 5 (1.4750-' |.4935) 37.465-37.935 8 5 3 7 .16 5 - 3 7 . 6 3 ( 1 . 4 6 3 2 - 1 . 47 )1
' 4 5 . 1 6( 1 . 7 7 8 ) r 4 5 . 7 6 ( 1 . 8 0 2 )' 2 4 1 . 7 8 { 1 . 6 4 5 ') 1 .6441 '2 41 .75 11 ( 1 . 8 3 9 )- r 46.72 '2 46.74 11.8401 3 9 . 3 2 ( 1 . 5 4 8 )* r '2 39.28 (1.546) 69-0.217 7 | 5.51o-5.530 1O.21 ( 8 7 5.535-5.5550.21 9'0.21 7) 3 12 . 5 5 - 1 . O 5 ( O . 4 9 4 - 0 . 5 1 4 1 4) 12.55-13.O5 (O.494-0.51
0.06 {o.oo2)
5.445{0.2144) 0.08 (0.003) 0.11 (0.oo4)
i.oou to.z'tool
2.0 10.079) 2.0 t0.079) ( 38.185 1.5033) 3 7 . 8 8 51 . 4 9 1 5 } {
Valve spring
Freelength
lN
Outer lnner
EX
Outer tnner
Valve guide
t.D. height Installed
IN EX
IN
EX
IN EX
5 . 5 5( 0 . 2 1 9 ) 5.60 {O.220) 1 3 . 3 0{ O . 5 2 4 } 1 3 . 3 0( 0 . 5 2 4 )
Rockerarm
Arm-to-shaft clearance
(O.OO1 0'0.0020) 0.025-0.052 (O.001 0.oo20) 0 o.025-o.052
0.o8(o.003) o.08i0.oo3)
, 2 | NIHONHATSUJOmanufactured valve spring'
valve spr'ng' CHUOHATSUJOmanufactured
ii
ii
3-4
_]]
EngineBlock
Cylinder block
Section
MEASUREMENT STANDARD{NEW} I
Unit of length:mm linl SERVICE LIMIT
-']
Warpageof deck surtace Bore diameterF22A1 engine H23Al, H22A1engines Bore taper Reboring limit F22A1 engine H23A1, H22A1 engines Skirt O.D.*1 F22At engine No Letter (A) Letter B H2341, H22A1 enginesNo Letter {A} Letter B Cfoarancein cylinder F22A1 engine H 2 3 4 ' 1 , 2 2 A 1e n g i n e s H Groovewidth F22A1 engine Top {for ring} Second oil H 2 3 A 1 ,H 2 2 At e n g i n e s T o p Second oil Ring-to-groove clearance Top Second Ring end gap F22Al engine Top Second oil H 2 3 A 1 ,H 2 2 A 1 e n g i n e s T o p Second oil
Piston
Pistonring
0.07 10.003) max. 0 . 1 01 0 . 0 0 4 1 ( 85.01 85.020 3.3468,3.3472) 0 8 5 . 0 71 3 . 3 4 9 ) (3 85.000,85.010.3465 .3468) 3 87.O'f 0-87.020 4256-3.4260) \3. 87.O7t3.4281 87.OOO 87.01013.4252 3.42561 0.o5 (0.002) 0 . 5 0( 0 . 0 2 0 ) 0 . 2 51 0 . 0 1 0 ) ( 8 4 . 9 8 0 - 8 4 . 9 93 . 3 4 5 7 - 3 . 3 4 6 1 8 4 . 9 7 0 3 . 3 4 5 3 ) {0 ) 8 4 . 9 7 0 4 . 9 8 0 3 . 3 4 5 3 . 3 4 5 7 ) 84.960(3.3449) 8 3 { 86.990-87.003 424A-3.42531 87.980(3.4638) 13. 86.980-86.993 42491 87.97013.4634) 13.4244-3. (0.ooo8,0.001 0.020-0.o40 6) 0 . 0 5{ 0 . 0 0 2 ) (0.0003-0.001 o.007-0.030 2) o . 0 4{ o . 0 0 2 ) 1.220-1. 230 {O.0480 0.0484) 1 . 2 5( 0 . 0 4 9 ) 1.220-1. {O.0480,0.0484) 230 1 . 2 5( 0 . 0 4 9 ) (O.1 2.405-2.420 104-0.1 101 1 2 . 8 5( 0 . 1 2 ) 1 '1.2301.245{0.0484-0.0490t 1 . 2 6 5{ 0 . 0 4 9 8 ) 1.2301.245t0.0484-O.0490) 1 . 2 6 5{ 0 . 0 4 9 8 ) (0. 2.405-2.820 1104-0. 110) 1 2 . 8 5t O . 1 1 2 l (o.001 0.035-0.060 4-0.0024) 0 . 1 3( 0 . o o 5 ) 0.030-0.055 2-o.oo22l to.oo1 0 . 1 3( 0 . 0 0 5 ) (0.008-0.01 0.20-o.35 4) 0.60 {0.024) 0.40-o.ss(0.o1 6-0.022) 0,70 {0.028) (0.0080.028) 0.20-0.70 o . 8 0( 0 . 0 3 1 ) o . 2 5 - 0 . 3{ 0 . 0 1 - o . 0 1 4 ) 5 0 o.60 (0.024) (o.0240.o30) 0.60,0.75 0 . 9 0( 0 . 0 3 5 ) *2 0.20-o.50 {0.008-0.o20) 0.60 10.024) *3 (0.oo8-0.0281 0.20-0.70 0 , 8 0( o . 0 3 1 )
Piston Pin
o.D.
Pin-to-pistonclearance F22A1 engine H23Al, H22A1 engines Pin-to-rodinterlerence Small end bore diameter Largeend bore diameter Nominal nd play installed crankshaft on Srhallend bore-tolargeend bore parallelism Main journaldiameter No. 1 and 2 journals No. 3 journal No. 4 journal No. 5 journal Rod journaldiameter Taper Out-of-round End play Total runoul Main bearing-to-journal clearance oil No.1and2 journals _ No. 3 journal No. 4 iournal No. 5 journal Rod bearing-to-journal clearance oil F22A1 engine H 2 3 A 1 ,H 2 2 A t e n g i n e s
Connecting rod
Crankshaft
( 2 1 . 9 6 8 - 2 1 . 9 8 10 . 8 6 4 9 - O . 8 6 5 4 ) 5 1 . 0{ 2 . O 1 ) o. 15-0.30 (0.006-0.01 2) 0 0 . 1 2 ( 0 . O 0 5 ) / 1 0m a x . ( 4 9 . 9 7 6 - 5 0 . 0 0 01 . 9 6 7 6 - 1 . 9 6 8 5 ) 4 9 . 9 7 24 9 . 9 9 6 ( 1 . 9 6 7 4 , 1 . 9 6 8 3 1 ( 4 9 . 9 8 4 - 5 0 . 0 0 81 . 9 6 7 9 - 1 . 9 6 8 8 ) 4 9 . 9 8 8 - 5 0 . 02 ( 1 . 9 6 8 0 - 1 . 9 6 9 0 ) 1 4 7 . 9 7 6 4 9 . 0 0 0 { 1 . 8 8 8 81 . 8 8 9 8 ) 0.005 (0.0002) max. 0.OO5(O.0002)max. o.10,o.35 (0.oo4,0.01 4l O.03 {0.OOl max. )
(0.8659-0.866 21.994-22.OOO 1) o.o1 2-0.o24 {o.0005-o.ooo9} 0.01 2-0.026 to.0005-0.0o10) (o.ooo5-o.001 0.o1 3-o.o32 3l
0 . 4 0( o . o 1 6 ) 0 . 15 ( 0 . o o 6 y 1 0 0
0.006 (0.0002) 0.006 {0.0002) 0 . 4 5{ O . 0 1 8 ) o.04 {o.002) 0.050 (0.0020) 0.055 (0.0022) 0.050 {0.0020) 0 . 0 4 0{ o . 0 0 1 6 ) 0.055 (0.oo22) 0.060 (0.o024t
Eearings
-0.045(o.0008 0.021 0.001 8) (0.0o10-0.001 0.025-0.049 9) 0.013-0.037(0.ooo5-o.001 5) (0.0004,0.001 0.009-0.033 3) -0.049{o.0008-0.oo20) 0.021 'l (o.001 -0.oo22) 0.027-0.055
'1: Measured 2l.O mm (O.83inl on F22A1 at engineand 15.0 mm (0.59 in) on H23A1. H22A1 enginesborh from bottom o{ skirt. '2: TEIKOKU PISTON pisronring. RINGmanufactured '3: RIKENmanufactured piston ring.
3-5

Engine Block - Section 7 (cont'd)
MEASUREMENT
Balancershatl Journaldiameter No. 1 iournal(lront) No. 1 journal(rear) No. 2 journals No. 3 iournals Front Rear
STANOARD INEW}
LIMIT SERVICE
Journaltaper End play
shalt Balancer beanng
Total runout Oil clearance No. 1 journallrear) No. 1 (front)and No 3iournal No. 2 iournals No. 1 journal(frontl LO. No. 1 journal{rear) No.2,ournals No. 3 iournals
(1.6820'1.68241 4 2 . 7 ' l{ 1 , 6 8 9 } 22-42.734 42.7 {O.8243-0.8248) 20.92 Q.A24l 20.938-20.950 -1.52461 3 8 . 7 0( 1 . 5 2 4 ) 24 3A.712-3A.7 11.5241 22-34.7 (1.3670-1.3675) 3 4 . 7 1{ 1 . 3 6 7 ) 34 34.7 0.005 (0.0002) 0. 10,0.35(O.OO4-0.O14) 1 o.06-0. 8 to.002-0.o07) o.os ro.oot t 0 . 0 2( o . o o 1 ) o.09{o.oo4) o.050-0.075 to.oo20-0.0030) 0 . 1 2( O . 0 0 5 ) 18 0.066-0.1 (0.0026-0.0046) 0 . 1 3{ 0 . 0 0 5 ) i o.o76-0 2a {o.oo30-0.0050) 42.AOO-42.820 {1.6850-1.6958) 4 2 . 8 3( 1 . 6 8 6 ) 2 1 . 0 0 0 -1 . 0 1 { 0 . 8 2 6 8 - 0 . 8 2 7 3 ) 21.O2@.A2Al 2 3 ( 6-1.52431 3 8 . S 3 1 . 5 2 9 ) 11.527 38.800-38.820 ( (1.3701-1.3709) 3 4 . 8 3 1 . 3 7 1 ) 34.8OO-34.82O
EngineLubrication- Section 8
MEASUREMENT
Engineoil Capacity (US qt, Imp qt) t F22A1 engine H23A1 engine H22A 1 engine Oil p'rmp ? Displacement IUS qt, lmp qtl/min @rpm lnner-toouter rotor radialclearance Pump body-toouter rotor radialclearance axialclearance Pump body-to-rotor 176oF (80oC) Pressure settingat oil termperature at idle kPa (kg/cm2,psi) at 3,0OOrpm
(IIEW} STAI{DARD
SERVICE LIMIT
4.9 {5.2, 4.3} for engineoverhaul lilte. 3.8 14.0,3.3) for oil change,including 5.4 (5,7, 4.81 for engineovrhaul lilter 4.0 (4.2, 3.5) lor oil change,including 5.9 (6.2, 5.2) for engineoverhaul filter 4.A $i, 4.21 tor oil chnge,including 73.5 177.7,64.7) @6,000
-o.006) 1 o.02-0. 6 10.001 9 0.10,0.1 (0.004-0.007) -0.003) (o.oo1 o.02-0.07

70 {0.7, 1O}min. 350 (3.5, 50) min.
o.20 (0.008) 0.21 (O.OO8) 0 . 1 2( 0 . 0 0 5 )
valve Flelief
Cooling - Section
Radiator
o
MEASUREMENT (NEW} STAI{OARD
M/T: 7.1 (7.5, 6.2) for overhaul 3.5 (3.7, 3.1) for coolantchange .4, AlTt 7.O 17 6.2) tor ovorhaul 3.4 (3.6, 3.0) for coolantchange MlTt 7.4 17.9,6.5) for overhaul 3.8 (4.0, 3.3) for coolantchange .7 All: 7.3 17 , 6.4) lor overhaul 3.7 (3.9, 3.3) lor coolantchange M/T: 7.8 (8.2, 6.9) Ior overhaul 4.2 14.4,3.7) for coolantchange F22A1 engine
Enginecoolantcapacity engine, including heater,cooling line and reservoir { (US qr, lmp qt)
H23A1 engine
H22A1 engine
I! Ir I i
,l
't I
i;
Badiatorcap Thermostat
ReservoircapacitY kPa {kg/cm2,Psi) Openingpressure Start to open F u l l yo p e n Valve lifi at Iully open Displacement f {US qt. lmp qt)hin @rpm oF {oc) 'F {oC)
, o . 6 ( o . 6o . 5 )
, 9 5 - 1 2 5( 0 . 9 5 - 1 . 2 51 3 . 5 ' 1 7 . 8 ) 169-177 {76-80) 194 (90) 8 . O 1 O . 3 1m i n . )
Waler pump
Radialorfan
F22A1 engine H23Al engine H22A1 engine F 2 2 A 1 ,H 2 3 A 1 e n g i n e s E C Ts w i t c h" O N " H22A I engine temperature ECT switch "OFF" tempetatureoF (oC)
1 6 5 ( 1 7 4 ,1 4 5 )@ 6 , 0 0 0 1 s 9 1 1 6 8 1 4 0 )@ 6 , 0 0 0 , 1 6 3 ( 1 7 2 ,1 4 3 )@ 6 , 0 0 0 194,205(90,96) 198-208(92-98) "ON" temperature 4'13 {l-7} tfom actual Subtruct
Fuel and Emission- Section 1 1

MEASUREMENT
Fuel pump Pressureregulator Displacement {US oz, lmp oz} in 10 seconds cc Pressure with regulator vacuumhose dtsconnected k P a{ k g / c m 2p s i } F 2 2 A 1 ,H 2 3 A 1 e n g i n e s , H22A1 engine Capacity{ {US gal, lmp gal) Fast idle rpm ldle speedrpm ldle CO % with headlightand cooling fan ott 205 (6.93, 7 .221 tnin.
Unil ol lengthi mm (in STANDARD(NEW)
Fuel tank Engine
255-305(2.55,3.05, 36-43) 230-280{2.3-2.8. 33-40) 60 (15.9, 3.2) 1 1,400 700 150 (M/T:neurral) 7OO150 {A/T:E o. E position)
0.1 max.
Clutch
Clutch pedal
Section 1 2
MEASUREMENT Pedal height Stroke Pedalplay Disengagement height Clutch surlacerunout Rivet head depth Surface runout Thickness Pressureplate warpage ro ttoor to floor
Flywheel Clutch disc
-]']
Clutch cover
STANDARD INEWI 2 0 8( 8 . 1 1 ) 5 1 3 5 - 1 4(5 . 3 1 - 5 . 7 1 ) ( 1 . 0 - 7 . 00 . O 4 - O . 2 8 ) 9 4 { 3 . 7 0m i n . ) 0.05 {O.002} max. 'l.3 (0.O51) min. O.8(0.03)max. ( 8 . 4 - 9 . 1O . 3 3 1 - 0 . 3 s 8 ) 0 . 0 3( O . 0 0 1 1 a x . m
SERVICE LIMIT
o.15 (0.006) o . 2(0.008) 1 . O(0.04) 6 . O (0.2361 o . 1 5( 0 . 0 6 )
Manual Transmission
Transmissionoil Mainshaft
Section 1 3
MEASUREMENT STANDARo {NEw}
1 . 9 1 2 . O 1 . 7 1 f o ro i l c h a n g e , 2.O 12.1, 1.Al tor overhaul
sERvIcELIMIT
Capacity (uS qt, lmp qt) t End play Diameter ot ball bearing contact area Diameter third gear contact ara of Diameter ol ball bearing contact area Runout LD. End play Thickness
Mainshatt3rd and fourth gears
3rd gear M2L5, M2S4 M2F4 4th gear M2L5, M2S4 M2F4
Mainshaltsth gear
t.D. Endplay Thickness

End play Oiameter needlebearingcontact area of Diameter ball bearingand needlebearing of conlact area Diameter low gear contact area ot Runout
Adjustwith a shim. 27.94 11.1001 3 7 . 9 3( 1 . 4 9 3 ) 2 7 . 9 4( 1 . 1 0 0 ) 0.o5 (0.0021 1. 4 3 . O O 9 - 4 3 . 0(2 5 6 9 3 3 , 1 . 6 9 3 9 ) 4 3 . 0 8 0 1 . 6 9 6 1 ) { 0.06,0.21(0.0024,O.0083) o . 3 0( 0 . o 1 2 ) 3 2 . 4 2 - 3 4 7 t l . 2 7 -1 . 2 7 l 2. 6 8 3 2 . 3( 1 . 2 7 2 1 34.92-34.97 5-1.3771 11.37 3 4 . 81 1 . 3 7 0 1 1 3 0 . 9 2 - 3 0 . 91 1 . 2 1-7 . 2 1 9 1 7 3 0 . 8( 1 . 2 1 3 ) 31.42-31.47 11.237-1.2391 3 1 . 3{ 1 . 2 3 2 ) 4 3 . 0 0 9 3 . 0 2 5 1 . 6 9 3 3 -. 6 9 3 9 } 4 3 . 0 8 0( 1 . 6 9 6 1 ) 4 1 { (o.0024,0.oo83) 0.06-0.21 0 . 3 0{ 0 . 0 1 2 } 1 1 3 0 . 9 2 - 3 0 . 91 1 . 2 1-7 . 2 9 l 7 3 0 . 8( 1 . 2 1 3 )
0.05,0.40 (0.0019-0.0157) 1 3 8 . O O O - 3 8 . 5 { 1 . 4 9 6 '-1 . 4 9 6 7 ) O1 (O.9837-0.9845) 24.947-25.OOO 39. 984-40.OOO 42-1.574al 11.57 O.02 {O.0OO8) max. 4 6 . 0 0 9 - 4 6 . 0 2 51 . 8 1 4 - 1 . 8 1 0 } 1 { 2 0.04,0.10 (o.002 0.oo4)
0. 10-0.16 {0.0039-0.0063) 2 7 . 9 7 7 2 7 . 9 9 0( 1 .1 0 15 1 .10 2 0 ) 3 7 . 9 8 4 - 3 8 . O O1 1 . 4 9 5 41 . 4 9 6 1 O ) (1 2 7 . 9 8 7 2 8 . O O O .10 18 - 1 .1 0 2 4 ) 0.02 (0.0008) max.
Countershaft
o . 5 0{ o . 0 2 )
3 7 . 9 5( 1 . 4 9 4 )
_]]]
24.94lO.982l 3 9 . 9 3{ 1 . 5 7 2 } o.05 (o.oo2)

46.08 (1.8't4) Adiust with a washer. 47.08 ('t.854) Adjust with a collar. 2 8 . 8( 1 . 1 3 )
Countershalt lsl gear Countershatt 2nd gea(
t.D. Endplay LD. Endplay Thickness
4 7. O O 9 - 4O 2 5 1 . 8 5 0 7 . 8 5 1 4 ) .7 ( 1 o.04-0. {0.002-o.004) 10 t 2 8 . 9 22 a . 9 7( 1 . '3 9 , 1 . 1 4 1 )
(cont'd)
3-7

Manual Transmission- Section 13 (cont d l
MEASUREMENT Spacercollar lCountershaft 2nd gear) Spacecollar (Mainshaft 4th and 5th gear) idlergear Reverse Syncro ring Dual cone nng sYncnro STANOARD INEW) I SERVICELIMIT
LD. o.D.
Length LD.
B -Jo a-
o.D.
Length
la
LD. gearshalt clearance reverse Gear-lo

(ringpushedagainst gear clearance Ring-to gearl (ringpushedagainstgear) Clearance Outer synchroring to_gear Innersynchroring-togear Outersynchroring-tosynchrocone M215, M2S4 Fingerthickness M2F4 Forkto syncrosleeveclearance
ri'w, srouvc w,uu, Pawl groove width A Fork'to reverse idle gear clearance I
3 6 . 5 0( 1 . 4 3 7 1 36.48-36.49 {1.4362-1.4366) 1 ( 4 1 . 9 8 9 - 4 2 . O { 1 . 6 5 3-1 . 6 5 3 5 ) 4 1 . 9 4 1 . 6 5 2 ) 00 (1. 4 . 2 9 . O 2 - 2 9 . O 4 1 2 5 - 11 4 3 3 ) -29.09(' |.144-1.45) 1 29.O7 3 1 . 0 0 2 - 3 1 . 2 1 1 . 2 2 0 5 - 1 . 2 2 0 9 ) 3 1 . 0 6( 1. 2 2 3 ) 0( ) 3 7 . 9 8 9 - 3 8 . O ( 1O 9 5 6 - 1 . 4 9 6 1 3 7 . 9 4( 1 . 4 9 4 ) O .4 56.45,56.55 12.222-2.2261 (1.0248-1.0268) 26-03-26.08 (0.7880-0.7891 20.09(o.7909| l 20.o1 6-20.O43 0.160 to.ooo6l 4-0.00331 0.036-0.084 {o.oo1 o.85-1.10 (0.034-0.043) (0.037-0.066) 0.95-1.68 (0.02-0.04) o.5-1.O (0.02-O.041 o.5-1.O 6.2,6.41O.244-0.2521 ( 7.4,7.6O.291-0.299) 4-0.026) o.35-0.65 t0.01 1 3 . 0 - 1 3 .( 0 . 5 1 - 0 . 5 2 ) 3 ( 0.5-1.10.02-0.431 a-O.25541 7.O5-7.2510.27 .301 .7 .29-O 7.4-7 tO o.o5-0.35 10.002-o.o14) 0.4,o.8{o.02-0.03) 6.000 {O.6289-0.6299) 15.973-1 o.005,0.059 to.ooo2-o.oo23) 2) 12.9-1 (0.508-0.51 3.O 0.2-o.5to.ol -o.02l
1-0.3' I 5) 7.9,8.O (O.31 o.o5 0.25 10.002-o.o10) 15 . 4 1 -15 . 6 8 ( 0 . 6 0 7 - 0 . 6 1 7 ) 3-0.0040) 0.032-o.102 (0.OO1 15.941-15.968 {0.6276-0.62871 1 0.027-0.139 (O.001 -O.OO55)
0 . 4 0{ o . o 1 6 l 0.6 (0.024) o . 3( 0 . o 1 1 0 . 3( 0 . 0 1 )
1 . O( 0 . 0 3 9 )
Shift fork
Reverseshitt fork
1 . 8( 0 . 0 7 ) o.5 to.02l 1 . 0{ o . 0 4 )
Groove width Fork-to-tifth/ reverseshift shalt clearance Shift arm B
atA atB atA atB
LD. clearance Shift arm-to-shaft Shift tork diameterat contact area lork t Shift-arm-ro-shaft shaf clearance Pin sizeof contact area Selectleverto-shitt peice clearance Shaft outer diameler Shift arm cover clearance
Selectlever
o.5 (0.o20)
Shift arm lever lntedock
o.D.
housingclearance Tlansmission Eorediameter Shitt arm lever clearance
6.O510.630'0.632) 16.00-1 3-o.oo43) 1 0.032-0.09 (0.001
{r
Automatic Transmission- Section 14

MEASUREMENT
Transmission tluid Capacityf (US qt, lmp qt) STANDARD {NEWI 6.0 (6.3, 5.3) Ior overhaul 2 A 1 2 . 5 ,2 . 1 1 t o rl l u i d c h a n g e
Unit of length mm (in) SERVICELIMIT
Hydraulic Line Dressure 2.OO0rom at pressure inEorEpositron (F22A1 engine) kPa lkg/cm2, psr,
8 0 0 t 8 . 0 ,1 1 4 1 throftleIully-closed I 8 5 0 ( 8 . 5 ,1 2 1 ) lhrottle morethan3/16 open

530 (5.3, 75) throttle fully,closed 850 (8.5.'121) throttle more than 3/16 open
7 3 O1 1 . 5 1 O 7 l , throttle morethan3/16 open

480 (4.8, 68) throttte lully-closed
4th clutch oressure 2.000 rom at in @ position
750 17.5,1071 throttle morethan3/16 open

450 (4.5, 64) throttle fully-closed 750 (7.5,107) throttle more than 3/16 open
3rd and 2nd clutch pressure 2,000 rpm at posrtion in E
5 0 0{ 5 . 0 , 7 1 ) throttleIullv-closed 8 5 0 ( 8 . 5 ,1 2 1 ) throttlo morethan3/16 open
2nd clutch pressure 2,OOO at rpm in Lzl position 1st and 1st-holdclutch pressure at 2.000 rpm in LLI position Throttle B pressure Hydraulic pressure (H23A1 engine) kPa {kg/cm2, pst, Throttle fully closed Throttle fully open Line pressure 2.000 rom at in E or E]position
( 8 0 0 - 8 5 0 8 . 0 - 8 . 5 .1 4 - 1 2 1 1 1 800-850{8.0-8.5, 14-121} 1
7 5 0 1 7 . 51 O 7 l , 750 17.5,1071
7 5 0 1 7 . 5 ,1 0 7 )
0 (0.o) 8 0 0 - 8 5t0 . 0 - 8 . 51 4 - 1 2 1 1 1. 8
8 5 0 ( 8 . 5 ,1 2 1 ) thro le tully-closed 900 (9.o, 129) throttlemorethan 3/16 open 5 3 0( 5 . 3 , 7 5 ) throttle fully-closed 900 (9.o, 128) throttle morethan3/16 open
8O0(8.0. t 14l throttlemorothan 3/16 open

48O (4.8, 68) throtte tully-closed 800 (8.0,114) throttle more than 3/16 open 450 {4.5, 64) rhrottle fully-closed
4rd clutch pressureat 2.OOOrDm in @ positron
3rd and 2nd clutch pressure 2,0OOrpm at position in E
5 O O( 5 . 0 . 7 1 ) throtlle tullv-closed
900 (9.o, 128) throttle morethan3/16 open

2nll_glutch pressrue at 2,OOOrpm in L2l position 1st and 1st-holddutch pressure at 2,000 rpm in Lll posirion Throttle I pressure Throttle fully closed Throtttefully open Stalf speed rpm F22A1 engine {Checkwith car on level ground) H23A1 engine 8 5 0 , 9 0 0 1 8 . 5 - 9 . O .2 1 - 1 8 ) 1 2
8 0 0 { 8 . 0 ,1 1 4 } throttle morethan3/16 open

800 {8.0,114} 800 {8.0,114)
850-900{8.5-9.0, 21-128) 1
o (o,o)
850-900(8.5-9.0, 21-128) 1 2,350-2,650 2,600-2,900
8 0 0 ( 8 . 0 .1 1 4 )
{cont'd)
3-9

Automatic TransmissionClutch
Section 14 (cont'd)
(I{EW) STANDARD -0.039} 0.80-1.00 {0.031 0.65-0.85 {0.026'0.033} 0.4-o.6{o.016-0.024) 33.511.32) 1.88-2.00 lO.O74-O.079) (O.077-O.O81 ) 1.95-2.O5 2.55-2.65(O.089-0.093) (0.077-0.081 | 1.95-2.O5 (O.089-0.0931 2.25-2.35 -O.083) 10 2.05-2. (O.081 2.15-2.20(O.085-0.O87) (0.089-0.091) 2.25-2.30 (0.093-0.094) 2.35-2.40 50 2.45-2. t0.096-0.O98) (O. 2.55-2.60 100-0.102) 106) 2.65-2.70 {0.104-0. 2 . 7 5 - 2 . 8 1 0 . 1 0 8 -11 0 1 0 o. (O. 1 2.85-2.90 112-O.14) (1.0630-1. 1638) 27.OOO-27.O21 4221 3 11.1 29.OOO-29.O1 417-1.1 0.03-0.05 {o.oo1-0.oo2l 041 o.21 0-0.265l0.OO83-0.01 0.070-0.125 {0.OO28-O.00491 84.5525) 14.01 F14.034(0.551 3.990 (0.55040.55081 13.980,1 (o.232-0.236) 5.90,6.00 \ t LIMIT SERVICE
MEASUREMENT Clutch initialclearance lst-hold 1st, 2nd 3rd' 4th Clutchreturnspringfree length 1sr, 2nd, 3rd' 4th Clutch disc thickness Clutch plate thickness 1st, 1st'hold 2nd, F22A1 engine H234 1 engine 3rd,4th Mark l Clutch end plate thickness Mark 2 Mark 3 Mark 4 Mark 5 Mark 6 Mark 7 Mark 8 Mark I Stator shah needlebearingcontact l.D Torque converter side Oil pump side Oil pump gear side clearance Drive clearance Oil pump gear-to-body Diven Oil pump drivengear I.D. Oil pump shatt O.D. Reverseshitt lork finger thickness Parkingbrakeratchet Pawl Parkingbrakegear Throttle cam stopper height Shitt fork shaft bore l.D. Shift lork shatt valve bore l.DSealingring contact LD. Sealingring contact l.D. Sealingring contact l.D. Diameter ot needle bearing contact area On mainshaft of stator shaft On mainshaftot 3rd gear collar gear On mainshalt oI 4th'tst collar gear collar of On countershatt On countershaft of 4th gear of On countershaft Parkinggear of On countershaft reversegeat shaft ot 1st gear On secondary On secondary shaft ol 2nd gear On reverseidler gear shaft lnsidediameter Mainshaft3rd gear Mainshaft4th gear Counte.shaftlst gear Countershaft 4th gear reversegear Countershaft idler gear Countershaft shatt lst gear Secondary shaft 2nd gear Secondary idlergear shaft holder Reverse
g s1. tr.zat
Untilgroovesworn out. Discolorataon

Discoloration Discoloration
t V
t I
I
Discoloration wear ol damage
Valve body
0.07to.oo3) ie", o, d"."ge

wear or damag
Shilting device, parking brake and throttle control system Seryo body Regulatorvalve body Accumulator DOOy Stator shalt Transmission
5 . 4 0( O . 2 1 3 1 Wearor otherdfect
17.O-17.1 {O.669-0,673) 6l 2-O.551 4.010(0.551 r 4.00G1 t 37.OOO-37.039 {1.4567-1.4582) 3 7 . 0 4 5 1 . 4 5 8 5 ) (1.3780-1.3789) 3 5 . 0 5( 1 . 3 7 9 9 ) 35.OOO-35.025

3 32.OOG32.O1 {1.2598-1.2604)
( 32.050 1.26181 ( 29.050 1.14371
-1 29.0OG29.013.1417 .14221 l'l
Wear or damage 22.9A4-23.@O (0.9049-O:90551 04-1.8110) 45.984-46.000(1.81 11.2592'1.2598) 31.984-32.OOO (1.6135-1.6142) 40.984-41.OOO .2595) 31.975'31.991 (' |.2589-1 42-1.57 4a'l 39.984-40.000 11.57 (' 73) 35.979-36.OOO1.4165'1.41 3 1 . 9 7 5 - 3 1 . 9 9( 1 . 2 5 8 9 - 1 . 2 5 9 5 ) 1 1 3 ' t . 9 7 5 - 3 1 . 9 9(1 . 2 5 8 9 - 1 . 2 5 9 5 ) 2) 4.000 {0.5508-0.551 13.990-1 2"2.O4aOl 9 52.OOO-52.O1 12.O47 (1.4963-1.4969) 38.OOs-38.021 1.851 0) 6 {1.850447.OOO-47.O1 6 38.000-38.O1 (1.4961-1.4967) 6 (1.6535-1.6542) 42.OOO-42.O1 6 48.000-48.01 {1.8898'1.8904) 6 37.00G37.01 (1.4567'' 1.4573) 6 37.000,37.o1 {1.4567'1.4573} 5676-0.5683) 14.41 6-1.434 (O.
i :
ii
f 'ji
:t
It
I
Wear or damage
Automati c Transmission- Section 14

MEASUREMENT
Transmission {cont'd) Mainshaft3rd gear collarlengrh Mainshaft4th gear collarlength Countershatt gear collar length 1st Thrust washerthickness Countershaft gear 1st Countershaft idler gear parkinggear length Countershalt Secondary shaft 1st gear distancecollar length Secondary shaft 2nd gear thrust washer thickness Secondary shaft 2nd gear splinewasher thickness STANDARD {NEWI
Unlt ot lngthi mm (in) SERI /ICE LIMIT Wear or damage wear or damage Wear or damage Weor or damage Wear or damage Wear or damage Wear or damage Wear or damage
1 9 . 5 01 9 . 5 ( 0 . 7 6 8 - 0 . 7 7 0 ) - s 4 7 . 5 0 - 4.7 5 l t . 8 1 0 - 1 . 8 7 2 ) 5 1 2 7 . 5 0 - 2 7 . 5(5 . 0 8 3 - 1 . 0 8 5 ) 1 . 4 5 - 1 . 5( 0 . 0 5 7 , O . 0 5 9 ) 0 (0.1 3.45-3.55 36-0. 140) (0.98544.9861 25.030-25.048 l 4.95-5.00 195-0. 97) 1 {O. 4.35-4.45 tO.t 7 13-O. 7 521 1
4.O2-4.05(O.1 58-0.159) 4.07-4.'t0 (0.160-0.161 ) 4 . 12 - 4 . 1 ( 0 . 1 6 2 - 0 . 1 6 3 ) 5 4. 17-4.20 (0.164-0.165) 4.22-4.25 tO.1 66-0.167) 4.27,4.30 {O. 68-0.169) 1 4.32-4.35 lO.17 0-O.1 1| 7 4.37 -4.40 lO.1 2-O. 73l 7 1 4.42-4.45 tO.1 4-O.1 5l 7 7
MEASUREMEI{T
Spring Regultor valvespringA F22A1 engine H23A1engine Regulator valve springB Stator reaction spring Torqueconve er check valve spring Reliofvalve spring Coolerreliefvalve spring 2nd orificecontrol valve spring Oriticecontrol valve spring Servo control valve spring 4th exhaust valve spring Throttlevalve B adjusting sprang Throttlevalve B spring 1-2 shilt valve spring 2-3l3-4 shift valve spring 1st-holdaccumulator spring lst accumulator spring 4th accumulator spring 2nd accumulator spring 3rd accumulator spring Lock-up shitt valve spring Lock-uptirningvalve spring CPC valve spring Modulatorvalve spring Lock-up control valve spring 3rd kick-downvalve spring 3-2 kick down valve spring
STANDARDINEWI
Wir6 Dia.
o.D.
Frco Longth
No, ot Collr
to.5
1 . 8( O . 0 7 1 ) 1 . 8( 0 . 0 7 1 ) '1.8 0.071) ( 4.5 lO.177l 1. 1 ( O . 0 4 3 ) 1 . 0{ 0 . 0 3 9 ) 1 . 1( 0 . 0 4 3 ) 0.6 10.o24) 0.8(0.031) 1 . 0( 0 . 0 3 9 ) 0.9 (0.035) o.8 (0.o31) 1 . 4( 0 . 0 5 5 ) 1 . 41 0 . 0 5 5 1 1 . 4( O . O 5 5 ) 1 . 0( 0 . 0 3 9 ) o.9 (0.035) 4.0(0.157) 1 . 81 0 . 0 7 1 ) 2 . 9{ 0 . 1 1 4 t 3.3{0.130) 2.6t0.102) 0.910.035) 0.8{0.031) 'l.4 {o.055) 1 . 4( 0 . 0 s 5 ) 0.7 (0.028) 1. 1 ( 0 . 0 4 3 ) 1 . 2t O . O 4 1 l
1 4 . 7( 0 . 5 7 9 ) 86.5 (3.406) 14.1 lO.579l 88.6 (3.488) 9.6(0.378t 44.Ot1.732t 3 5 . 4( 1 . 3 9 4 ) 3 0 . 3t 1 . 1 9 3 1 1 8 . 4 ( 0 . 3 3I 3 6 . 4( 1 . 4 3 3 ) 8.4(0.331) 3 9 . 1( 1 . 5 3 9 1 8.4 t0.331) 4 6 . 8( 1 . 8 4 3 ) 6.6 (O.2601 58.3 (2.295) 6.6 (O.2601 52.5 t2.O61l 8.1{0.319) 52.6 (2.O711 7.1(0.280' 6 0 . 8( 2 . 3 9 4 1 6.2 lo.244l s 0 . 0{ 1 . 1 8 1 } 8.5lO.335l 4 1 . 5{ 1 . 6 3 4 ) 8.5{0.335t 4 1 . 5{ 1 . 6 3 4 ) 8 . 5 ( O . 3 3 5 ) 4 1 . 6( 1 . 6 3 8 1 8.6 tO.339) 4 1 . 3{ 1. 6 2 6 ) 7 . 6t O . 2 9 9 t 57.Ot2.2441 2 5 . 0( 0 . 9 8 4 ) 64.7 12,547) 1 6 . 3( 0 . 6 4 2 t 11 5 . 4( 4 . 5 4 3 ) 22.0 {0.866) 9 0 . 1( 3 . 5 4 7 ) 22.0 (0.866) 8 4 . 9( 3 . 3 4 3 ) 1 7 . 5( 0 . 6 8 9 ) 1 0 4 . 5 4 . 1 1 4 ) 1 7.6 tO.229l 73.7 t2.9021 6.6 {0.260} 5 1 . 11 2 . 0 1 2 ) 9.4{0.370) 3 3 . 0( 1 . 2 9 9 ) ( 9.4 (0.370) 33.O 1.2991 6.6 (0.260) 3 8 . 01 1 . 4 9 6 ) 7 . 6 1 0 . 2 9 9 ) 4 8 . 3( 1 . 9 0 2 ) 7 . 1{ 0 . 2 8 0 ) 4 6 . 9( ' t . 8 4 6 )
1.92 12.0 15.1 1 7. O 15.8 33.0 22.4 28.9 8.0 10.5 11.2 12.4 16.9 7.3 18.6 10.9 11 . 1 18.0 14.7 10.5 10.5 14.1
3-11

Differential (Manualtransmission)
MEASUREMENT
Final driven geal Dillerontial carriet Backlash Pinionshaft contact area l.D. Carrier-to-pinionclearance Driveshatt contact aroa LD. Carrisr-to-driveshaftclearance
Section 1 5
STANDARD INEW} I SERVICELIMIT
Right Left
Dillerential
Backlash t.D. gearto-pinion Pinion shaftclaarance

StartingTorqueN.m {kg-cm,lb-in)
Taperroller preload bearing
1 0.085-o.42 {O.OO33-0.0056) '1 8.000,1 8 {0.7087-0.7094} 8.01 9l 0.013-0.047(0.0005-o.oo1 28.005-28.025 1. {' 1026-1.10331 (0.001 0-o.oo26l 0.025-o.066 0.o55-0.091 {o.oo22-o.oo36l 5 o.05-0.'t to.o02-0.0061 ' l 3) 18.042-18.066 tO.7103-0.71 (0.oo22-o.0037) 0.055-o.095 1.4-2.6( 4-26, 12-231
o.20(o.o08l 0.10{o.oo4t 0 . 1 2t o . o o s t 5 0.1 (0.006I

AdjLrstwith a shim o.15 {0.006) Adjust with a shim
Differential (Automatic tlansmission)

MEASUREMENT Finaldrivngar Dlflerential carnef Escklash Pinionshaft contact area l.D. Caftier-to-pinionclearance Driveshaft contact area l.D. CarrieFto-driveahaftclearanace
Section 1 5
(NEW} STANDARO
SERVICELIMIT
I
F
1 o.o85-o.42 {O.0033-0.0056) 18.000-1 8 t0.7087-0.7094) 8.01 9} 0 . 1 0( 0 . 0 0 4 ) o.o17-o.o47 {0.0007-0.oo1 1 2 8 . 0 O 5 - 2 8 . 0{2 5 0 2 6 - 1 . 1 0 3 3 ) 1. o . 1 2( 0 . 0 0 5 ) 0-o.oo26) 0.025-0.066 to.oo1
0.20(o.oo8)
Differcntial
Taperroller bearim preload
Backlash LO. Pinion gear-to-pinionshaft clearance New bearing Starting Torque Reused bearing N.m lkg.cm, lb-inl
1 0.05,0.5 (o.oo2-o.oo6t (O.7103-0.71 13) 18.042,18.066 (o.oo23-o.oo37) 0.059-o.o95

2.A-4.O QA-40, 24-3sl 2.5-3.7 t25-37 22-321 ,
Adjust with a shim o.12 (O.OO5) Adjust with I thim
Ste6ring
Stsring whsel
Section1 7
MEASUREMEl{T
Play at steering wheel circumterence Starting load at stoering wheel circumlronce N {kg, lbsl Engine running When the hydraulic system to the power steerang soeed sensor is cut ofl Angle ot rack-guide-screwloosengd trom locked position Pump pressure with valve closed (oil temp./spoed: 1O5"F {4OoCl min./idle. Do not run for more than 5 sconds}. kPa {kg/cm2, psi} Recommenddfluid Fluid capacity System Reservoir , (US qt. lmp qt) 'lOON (1o kg, 22 lbs) betweenpulleys Deflection with
STAI{DARD INEW}
o-10(o-o.4) 30 {3.O, 6.61 50 (5.0,11.Ol
Gearbox
Pump
Power steering lluid Power stgring belt'
(70-80, 995-1, 38t 1 7.O00-8,OOO fluid-V Hondapowersteoring 1 . 7 { 1 . 8 0 ,1 . 5 0 1 0.5 {o.53,0.441
!i
li
i
!
with used belt 13.5-16.5 10.53-0.65) with new belt 9.5-11,5 {0.37-0.451 350-5OO{35-50. 77-1101with used bslt Belt tension N (kg, lbsl (7O-9O,154-198) with new blt 7OO-9OO Mgasured with belt tension gauge * When using a nsw belt, adjust deflection or tension to new values. Run the engine for 5 minutes then turn it off. Readiust deflsction or tension to used belt values.
Suspension Section18
MEASUREMEIIT
Wheel argnment {2WS) Front Rear Caster Front Total toe Front Rear Front whel turning angle Inward wheel Outward wheel Carhber Front Bear Caster Front Total toe Front Rear Whgel turning angl Inward whoel Front Rear Outward wheel Front Rear Rim runout {Aluminumwhel} Axial Radial Rim runout (Steel wheell Axial Radial End play Front Camber
Unit of lengthmm {in
(NEWI STANDARO
-o" 45' 1 ' to 20 40' !10 0 r 2.0 (o !0.081 rN 2.0 ! 2.0 t0.08 10.08) 360 20' 12. 290 40'
SERVICELIMIT
o" oo' r 10
alrgnment {4WS}
o" oo' i 10 -oo 45, 1300 2040'!1. o t 2.o(0 10.08) t N 2 . Ol 2 . O ( 0 . 0 8t O . O 8 l 3 6 02 0 ' ! 2 " 6 . O O '! 1 " 29" 20' 6" 20' o-0.7 10-0.03) o-o.7 (0-0.03) o-1.0 (o-0.041 0-1.0 (o-0.041
2.OtO.08l 1 . 5( 0 . 0 6 ) 2.0 (o.08) r.5 to.o6)
Wheel bearinq
Rear
(o.oo2) 0-0.05 (0.oo2l o-0.05
Brakes
Parking brake lever F""r braL pedal M*t"|. "y["d* Oisc brake
Section
MEASUREMENT Playin strokeat 2OON (20 kg, 44lbsl levrforce Pedal height (with floor mat removod)
(NEWI STANDARD
To be locked when pulled 6-10 notches 1 6 5 { 6 . 5 }m i n . 1 8 6 { 7 . 3 )m i n . 1-5(1/16-13/64)
SEFVICELIMIT
Free play Piston'to-pushrod clearance Cars without ABS Cars with ABS Disc thickness Front Rear Disc.unout Front Rear Disc parsllslism Front ano rear Pad thickness ftont H22A1, H23A1 engine H22A 1 engine Rear
M/T Atf
o-o.4(o-0.02) 0 - 0 . 2o , o . 0 1 ) t
23.O(0.09) 1 0 . 0( 0 . 3 9 ) ( 21.O 0.83) 8.0(0.31t 0,10 {o.004) o.10 (o.oo4) 0.015 (0.ooo6t 1 . 6( 0 . 0 6 ) 1 . 6( 0 . 0 6 ) 1 . 6( 0 . 0 6 )
t r.u to.ogt
1 1 . O{ 0 . 4 3 ) 9.0 {o.35)
3-13

Air Conditioning
Section 22
MEASUREMENT
Air conditioning Lubricant capacity cc (ll oz) system Condenser Evaporator Line or hose Rservoir
STANDARD {NEW) 10(1/3) 30(1) 10 {r/3) 10(1/3) ( 1 3 0 - 1 5 04 1 / 3 - 5 ) 3.05-3.35 (0.014-0.026) 0.35-0.65 with usedbelt 10.0-12.0 {0.39-0.471 4.5-7.0{0.18-O.28} with new blt
Compressor
Comprgasor belt'
Lubricant capacity cc {tl oz} Et Fieldcoil resistance 68oF {2OoC)0 plate clearance Pulley-to-pressure Dollectionwith lOO N (10 kg, 22 lbs) between pulleys
450-600 (45-60, 99-132) with used bslt Belt tsnsion N (kg. lbs) 950'1.150 (95'115, 209-254) with new bslt Masured with belt tension gauge . Wh* u"ing I new belt, adjust dellection or tension to now values. Run tho engine lor 5 minutes thsn turn it o{f REdiustdflgction or tension to used belt values
Electlical - Section 23
MEASUREMENT
lgnitioncoil Rated voltage V Primarywinding resistanc8t 68 oF (2OoC)o Scoodarvwinding resistanceat 68 oF (20ocl kO
STAI{DARD INEW) 12 0.6-0.8

S6e Sgction 23 1 . 0 - 1 . 1{ 0 . 3 9 - 0 . 4 3 )
Spark Plug lgnitiontiming Alternator belt'
Type Gap
At idling BTOC (10 kg, 22 lbs) with 1OON Defloction between pulleys Belt tension N (kg, lbsl Mgasured with belt tnsion gauge o
STDC 1 5 ol 2 o { R e d ) 10.5-1 2.5 (0.42-0.51 with used belt ) with new blt 8.O-10.0 {0.32-O.4Ol 3OO-45O{30-45, 66-99} with usod belt 550-750 {55-75, 121-165) with new belt SERVICE LIMIT STANDARD {NEW) 80/90 2 . 7- 3 . 1 t r.e to.sot 1 4 . 2 - 1 4 .{ 0 . 5 6 - 0 . 5 7 } 4 1 . 5t 0 . 0 6 ) 1 0 . 5( O . 4 1 ) 300-360t10.6-12.7) magnt Permanent Spargearreduction, 5 0.1 t0.oo6) 0.4-0.5(0.016-0.o20) o.o5(0.oo2) o-0.02{o-0.ooo8) 2 7 . 5( 1 . 0 8 3 ) 2 8 . 0 - 2 8 .( 1 . 1 0 2 , 1 . 1 0 6 ) 1 (0.62-O.64t 10.0(0.39) 15.8-16.2 1 6 . 0 , 1 8 .( 1 . 6 0 - 1 . 8 0 , 0 3.53-3.93) magnet Permanent Spargearreduction, 0 . 1 5( 0 . 0 0 6 ) 0.4-0.5(o.0'16-0.o20l 0.o5 t0.o02) o-o.02{o-o.ooo8) 2 7 . 5{ 1 . 0 8 3 ) 2 8 . 0 - 2 8 .( 1 . 1 0 2 - 1 . 1 0 6 ) 1 ( 10.0 (0.39) 15 . 8 - 1 6 . 20 . 6 2 - 0 . 6 4 ) 1 6 . 0 - 1 8 .( 1 . 6 0 - 1 . 8 0 , O 3.53-3.93)
MEASUREMENT
Output 13.5 V at hot A Alternator (NIPPONDENSOCoil rsistance (rotor) O SIip ring O.D. Erush lngth g {oz) Brush spring tnsion Tvpo motor Starter (MITSUBA Mica depth Commutator runout 1.4 kW) CommutatorO,O. Brush length N (kg, lbsl Brush spring t6naion (new) Starter motor (MITSUBA 1.6 kW) Tvpe Mic8 depth Commutator runout CommutatorO.D. Brush length Brushspringtensionlnw)
ii
:1 !I
I
il
N lkg, lbs)
* When usanga new belt, adjust detlection or tonsion to new valuos. Run the engine lor 5 minutes then turn it ofl. Redjust detloction or tension to used bolt and values.
Design Specifications
Overall Length Ov.all Width OverallHeight Wheelbase Track F/R GroundClearance 4,440mm 1 , 7 6 5m m 1 , 2 9 0m m I I | 1 7 4 . 8j n 69.5 in 5 O . 8i n 6 0 . 0 / 5 9 . 6j n 5.7 in
2 . 5 5 0m m
1,525/1,515 m m 145 mm
I
i |
t O O . qn i
Type
F22A1 engine H23A1 engine H224l engine
l
l
TRANSMISSION
Cylinder A.rangement Bore and F22A1 engine Stroke H23A1 engine H22A 1 enigne OisplacementF22A1 engine H23A1 ngine H22A'l engine Compression F22A1 engine Ratio H23A1 engine H22At engine Valve Train F22A1 engine H2341 engine H22A'l engine Lubrication System Ful Required F22A1 engine H23A1, H22A1 engines Makes/Type Normal Output NominalVoltage Hour Rating Direction Rotation of
Water-cooled, 4,srroke SOHC gasoline engjne Water-cooled, 4-stroke DOHC gasoline engine Water-cooled, 4-stroke DOHC VTECgasolineengine Inline4-cyljnder, transverse 8 5 . 0 x 9 5 . Om m 3 . 3 5x 3 . 7 4 i n 8 7 . 0 x 9 5 . Om m 3 . 4 2x 3 . 7 4 i n 8 7 . Ox 9 0 . 7 m m 3.43 x 3 57 in 2 , 15 6 c m 3 ( c c ) 132cu-in 2,259 cm3 {cc) 138 cu-in 2,157cm3 (cc) 132 cu-in 8.8 : 1 9.8:1 1 0 . 0: 1 Belt driven,SOHC4-vatveper cytinder Belt driven.DOHC4-valveper cytinder Belt drive,DOHC4,valveper cylinderVTEC Forcedand wet sump, trochoidpump gradegasolinewith 86 pump UNLEADED OctaneNumberor higher PremiumUNLEADED gradogasoline with 91 Pump OctaneNumberor MITSUBA/Spur gear reduction, permanent magnet 1.4 kW, 1.6 kW 12V 30 seconds Counterclockwise viewedfrom gearend as
3 . 7k s
8 . 2l b s
MIT M/T
Singleplatesdry, diaphragm spring Torque converter 203 cm2 31 | Synchronized s-speed forward, 1 reverse Electronically controlled -speed automatic, 1 reverse Direct 1 : 1
GearRatio
lsr 2nd 3rd 4th 5th Reverse
4.062
4.266
4.266
(cont'd)
3-15
Design Specifications
(cont'd)
ITEM
TRANSMISSION {conl'dl Automatic GearRatio Engine tYPe lst 2nd 3rd 4th 5rh Reverse Gear tYPe Gear ratio METRIC F2241 ENGLISTI H23A1
NOTES
2.705 1.442 1.028 o.701 2.O47
2.705 1.057 0.750 2.O47
Final Rsduction AIR CONDITIONING
Cooling Capacity Conditions: compressor Speed Outsid Air Temparature Outeide Air HumidilY CondnserAir TemPerature CondenserAir VelocitY Blower Capacity Typg/Mkes Compressor No. oI cylinder CaPacitY Max. Spsd Lubric8nt CaPacitY Condenser Evaporator Elower TyPe Type Type Motor Input Speod Control Max. CaPacity Type Power ConsumPtion Type Ouantity
Singlhelicalgear 4.428 4.285 | '14,682BTU/h 3,7O0Kcauh
1 , 8 0 ( rpm 50 %
81 0F
95.F 35 0C 8.2ltlsec 2.5 mlsec 16,247 ctt-ftlh 460 m3/h ScrooltyP/SANDEN
5.23 cu-in/rev 85.7 cc/rev | 10,000 rpm 4 1/3 tl oz 130 cc I lin Corrugatod type
Corrugated lin type Sirocco lan 220 Wl12 V 4-spsod 16.247 cu-ft/h 460 m3/h I Air-mix type Dry, single plat, poly-V'belt drive 42 W max.l12 V F-l34a
sP-10
Temp. Control Comp, Clutch Rotrigerant STEERNG SYSTEM
osO-8os
t8.a-9.ao oz
Type Ovorgll Rtio Turns, Lock-to-Lock Steedng Whosl Di6. Type. Front Type, Rsar Shock Absorber, Front and Rar
SUSPENSION
Power as8isted, rack and Pinion 2 W S : 1 5 . 8 6 , 4 W S :1 5 . 1 2wS: 2.91, 4WSt 2'77 15.0 in 380 mm I wishbone, lndependent double coil spring with stabilizer lndeDendentdouble wishbone, coil spring with stabilizer Tolescopic, hydraulic nitrogen gas-filled
l. ,i
t,
Camber Caster
Front Rear Front Rear
Omm
In 2.O mm
oin
BRAKESYSTEM
Type, Front
llear
Pad and LiningSurfaceArea: Front Rear ParkingErakeKind and Type Size '1:S ELECTRICAL Battery Starter Allernator FusesIn UndeFdash Fuse/Relay Box In UndeFhood Fuse/Flelay Box
In 0.08 in I Power-assistedselt,adjusting ventilated disc Power-assistodselt-adjustingsotid disc 58.Ocm2 2 x 8.99sq-inx2 I 27.Ocmzx2 4.19sq-inx | 2 Mechanical actuating, rear two whsel brakes
185/70 14 87 H .1 R 205/55 1587 V *2 R f125l7o O l5 {Spare tirel *r T135/80D 15 {Spare rire)*2 12 V-55AH/5HR 12V-1.4 W,12V-.t.6 W k k 1 2 V - 9 0A , '10 , 15 80 A 7 . 5A . A A, 20A, 30 A 7 . 5A , 1 0 A , 1 5 A , 2 0 A , 4 0 A , 50 A. 60 A, 100 A 1 2 V - 6 5W 1 2 V - 5 5W 1 2 V - 3 2C P 1 2V _ 5 W 1 2 V - 4 5C P 12 V-43t3CP 12 V -21 CP 1 2 V - 3C P '12v-3 cP 1 2 V - 3 2W 1 2 V - 8W 1 2V , 8W 1 2 V - 3 . 4W 12V W ' l 2 v - 1 . 1 2 W-,3 . 0 , 1 . 4W 1 . 4W , 3 . 0 W , 3 . 2 W 12V-1.4 W 1 2 V - 1 . 4W , 1 . 1 2W , 0 . 8 4W , L E O 12V-1.4 W
FrontTurn SignalLights Front ParkingLights RearTurn SignalLights Brake/Taillights High Mount BrakeLight Side Marker Lights Front Rear Back{p Lights LicensePlateLights InteriorLights Trunk Lights GaugeLights IndicatorLighrs WarningLights lllumination and Pilot Lights
3-17
Body Specifications
Unit: mm (in)
lr ;i
Maintenance
Lubrication Points Maintenance Schedule .......... 4-z ... 4-4
{l I
Points Lubrication
Indexand variouswolk proreferto the lllustrated to points and types of lubricants be applied, For detailsof lubrication cedures(suchasAssemb|y/Reassemb|Y,RepIacement,overhau|,Insta||ation,etc.)containedineachsection.
"Energy Conserving II" API ServiceGrade:Use SG gradeoil. F22A1, H23A1 engine:5 W-30 preferred. H22A1 engine:1O W-30 Preferred. SAE Viscosity:See chart below. Transmission Manual API ServiceGrade:SF or SG SAE viscosity: 10W-30or1OW-40 HondaPremiumFormulaAulomaticTransmission II DEXRON@ Automatic Fluidor an equivalent fluid transmission Brakefluid DOT3 or DOT4 Brakfluid DOT3 or DOT4 greaseP/N 08733 - BOTOt Steering Shift lever pivots (Manualtransmission) fork {Manualtransmission) Release Steeringboots Steeringball joints Selectlever (Automatictransmission) Pedallinkage shaft lntermediate Brakemaster cylinderPushrod Trunk hingesand latch Door hingesupper/lowerand latches Door openingdetents Fuelfill lid Enginehood hingesand enginehood latch Clutch mastercYlinder Pushrod Throttle cable end Caliper Pistonseal. Dust seal, Caliperpin, Piston and selectcable ends Shift Hondapower steeringfluid-V oil Comoressor SPlO P/N 38899-P13-OO3
Automatic
I
!
to Selectthe oil for your car according this chart: H23A1ongine F22A1,
Amblent Temoeraturo
'l
for An oil with a viscosityoJ 5 W-30 is preferred improtectionin the provedtuel economyand year-round car. You may use a 1O W-30 oil il the climatein range snown your area is limitedto the temperature on the chart.
An oil with a viscosityof 1O W-30 is preferred protecfor improved{uel economYand year-round in the car. You may use a 5 W-30 oil if the tion climatein your area is within the temperature range shown on the chart
4-2
4-3
Schedule Maintenance
3.e e9
dcicicidd L l l
E.9
.g
z 6
P E
B E
[
'=u
o o'-
+r+rE
1!
; ; " 1x zz
Oo
o . 9
3 * E '
6:-:---
stststdstst 6
.l c? ': ': ': ''l 6 l l l i
o ;
== *2 22-?= ];;.
gci ai.+
t : - E ;
.!:
a a96
q 6
F-..j.". B ' is.sd e c . r c .;Y = s

.eE
; p P.9
t_c
i ; 9 t i ;!.
= c ; 6
d P ; 4 P 1i : it b 9: , .
N N A : ;
q t P . :E i; E -o ::r^H
BETH-I
E,i!,iE,i=i ; d
e u2 Jz;oE z z
o >
i i3FF
E 1 e : - -
3-E<3S
ie'Nll
'
l. 'i
ll
; g
E
.::
< 9 a 9 Q ! c 6
;
'd
6 5 9 o b 6
= : i 6
6 3 z .E -x
-:r
;:3
^ F
b i
I:-;-;-;E;-;i ; E 3 3 3 eF 3 ; 3 ; !r'.on.goo
-: aj + { 6 ci ai ;
S:|t)6o:nF (J:('l'!r<ooo
, 9.oi o. )rdc99 o ; : , ; 6 , o
!E! E iE! ; !J: E E : !
E< F:
6 E
9 + a E
9 o
-Ee 95
H5**-*-E:*i
-o
*iS . , ii k
's 5 tB
6 . > q 3 5
: -5 d E i S ee P P
; P :
i - ' . s i.i 6 F , b
6P ; * g t
aisiis! a E
-g
E I
':
l
i
4-5
Schedule(cont'd) Maintenance
P P " ; E * 6 - b g 6 : ( l .
> . o ; 6
t (,) 3
o E
<
s * E E
2
:R E Ee6- ts EE! E l3! s

\ i o E
t ;
E e i EE : EE :
E 9 E
- g ' 6 C
i i o 6 6 i c'6
o
F li
!;,i.8 !
'E ;-E 5 o :
BE
8ri n;; ;3 5
5 . e3
; i ;
ai
<
r;E;i i
o a
tEii:5
z
oo E
EE::i;EF
;
L 6
-;;;Eg;E
9i:!;srs
;oEdds-:s t t t I ; ,
E E R#;:T
i$:EsiEi .i;"qHE!.i
P
.9
li
;;igxB:E
a
E
ir
l
i
E E 9
9 . .4 8
ri
.
b
c
c
;
b t
i
!
>
s : 6 E !E- !; E E ; = t
E ,e!EE tE '9!cc E ! * E E r I
! I .9
cii Fi:!i;
ri 3E8 <,iddci,ii,!
4-6
Engine
Constructionand Function . . . . . . . . . .5 - 1 lH22Al engine) E n g i n e e m o v a l / l n s t a l l a t i.o . . . . . . . . . . . .5 - 1 7 R .n . C y l i n d eH e a d / V a l vT r a i n . . . . . . . . . . . . . . . . . - 1 r e 6 E n g i n B f o c k. . . . . . . . e .........7-1 Engine ubrication L . . . . . . . . .8 - 1 IntakeManifold/Exhaust System ........ 9-1 Cooling . . . . . .1 0 - 1
Construction Function and lH22A1 enginel

Outline Description ................5-2 VTEC Outline .... 5-4 Mechanism ................5-6 Control System ........... 5-7 Gylinder Head Outline .... 5-9 Camshafts . . . . . . . . . . . . . .5.-.1 0 . Valves Valve and Springs............... 5-11 BeltTensioner Outfine ....5-12 A u t o - T e n s i o n . . r . . . . . . . . . . . . . . . . . . .5.-1.3 . .e. . . . C y l i n d e r B l o c.k . . . . . . . ......5-14 . OilFlow ......5-15
Outline
Description
.6 2,157 cm31131 cu in) lt is water cooledand ThenewH22A1 engineis an in-line4-cylinderDoHc designdisplacing fuel and usesa to chamber.lt is specified use premiumunleaded with a centerplug type pent-rootcombustion equipped Valve calledHondaVariable a pGM-Fl(Sequential system.This engineincorporates mechanism Multipon FuelIniection) (VTEC)System. Control Timing and Valve Lift Electronic The simultaneously. enginealsoinThis ststem allowsthe timing and litt oJthe intakeand exhaustvalvesto be changed intake manitoldsystem that variesthe volumeof the intakechamber. cludesa electronically-controlled
I
il
L.
5-2
nd
ll!i)r
Specificstions Water cooled4-stroke,In-line4-cylindergasoline engine 2 , 1 5 7 c m 3( 1 3 1 . 6 c u - i n ) 8 7 . Ox 9 0 . 7 m m t 3 . 4 3 x 3 . 5 7 i n l 1O.O:1 Dual over-head camshaft,VTEC Sequential Multipon Fuel Injection{SFl)
Type Oisplacement
tn-
Eore x Stroke Compression Ratio Cam, Valve Mechanism

Valve Train
FuelSupply System
Main Features: a The cylinderhead ls made of aluminumalloy,a centerplug type, pentroof-shaped combustionchamberis used, and the 4-valvesystem uses 2 intakevalves and 2 exhaustvalves, The camshaftsand the valvetrain are drivenwith the timing belt. andthe two balancer shaftsare drivenby the timing balancerbelt. Belt tension is automatically adjusted. a The cylinderblock is made of aluminumalloy using fiber reinforced metal (FRM)sleves. a The crankshaftis made by torging,the mainshsftis suppo.tedat tive points and has eight balancerweights. a The balancershafts employ a gear-typereve,semechanism reducesecondary to enginevibration. a The intake manifoldis made ot aluminumalloy, and the heat riseris usedfor hatingthe airlfuelmixture. a The exhaustmanifoldis made of stainlesssteel. a The electronicfuel injectionsystem is of a sequentialmaltiport fuel injectiontype and injects fuel into all four cylinders, the throttle body is of a one-barrel side-drafitype. a The ignitionsystem is a fully-transistorized, contactless type. The spark advanceis electronic. a The air cleaneris equippedwith a resonator. a The radiatoris of a corrugated type. and th coolingtan is elctrically powered.
5-3
VTEC
Outline
T h e e n g i n e i s e q u i p p e d w i t h m u | t . p | e c a m I o b e s p e r c y | i n d e r , p r o v i d i n g o n e v a | v e t i m i n g a n d v a | v e I i is p r o ' i | e a t I o w s p e and f t selecied electronically' speed.switch-overfrom one profileto the other is controlled and a differentproiileat hagh by monitoringcurrent enginespeed and load.
lr
il
r'l
CAMSHAFT CAM LOBESFOR LOW RPM CAM LOBESFOR HIGH RPM PRIMARYBOCKERARM ARM MID ROCKER SECONDARYROCKERARM HYDRAULICPISTON(A} HYORAULICPISTOI{ {AI PISTON STOPPER LOST MOTION ASSEMBLY EXHAUST VALVE INTAKE VALVE
5-4
rd
!d
In gnoral,it would be idealif the high rpm performance a racingengineand the low rpm pertormance a standard of ot passenger enginecould be combinedin a singleengine.This would resultin a maximumperformanc car enginewith a wid6 power band. Two of the major differences betweenracingenginesand standardenginesare the timing ot the intake/6xhaust valvesand the degreeof valve lift. Racingengines hsve longerintake/exhaust timing and a highervalvelift than standardengines,The Honda VariableValve Timing and Valve Lift Electronic ControlSystemtakes this into account, Whn valve actuationis set for low rpm timing and lift, low rpm torque is betterthan in a standard engine.Whon valve actuationis then switchedlor high rpm timing and lift, output improves the levelgiven by a racingengine.Until to now. tew variable valvetiming systemshave beencommercialized, thosethat have,only the time that both vatves8re In open (intake/exhaust overlap)could be changed.Honda'ssystem is the first in the world in which both the valvetiming and the degreeof valve litt can be changedas needed,makingit the most advancedvalve train mechanism available.
RacingEngine
VTEC Engine
StandardEngine
Valve Timing (exhsust/intake) Valve Lift
Erh.u.t
lntrk
Erhrurt
lntlk
Exhlult
Intrko
Max. Power Low rpm Torque ldling stability 'TDC = Top Dead Center *BDC = Bottom Dead Center O = Ootimum Characteristic The engineis equippedwith two valve timing and valve lift settingswhich changeaccording drivingconditions. to
RPM switch ovgr pornt
5-5
VTEC
Mechanism
At Low rpm: Asshown,theprimaryandsecondaryrockelarmsalenotconnectedtothemidrockerarmbutaledrivenseparSte|yby cam|obesAandBatdifferenttimrngandIift.A|thoughthemidrockera.misfo||owingthecentercam|obewiththe|ostvalvesin the low rpm range' motion assembly,it has no effect on the openingand closingof the At Low rpm:
FOR CAM PROFILES LOW RPM
CAMSHAFT
*A and B cam lobes ddve the rocker arma sepsrot6lY RETURNSPftNG
HYDRAULIC (AI PISTON

HYDRAULIC PISTONIBI
PISTON STOPPER PRIMARY ARM ROCKER MID ARM ROCKER SECONDARY ARM ROCKEB
At High rpm: Whendrivingathighrpm,plstonlA)movesinthedirectionshownbYthearrowinthefigureba|ow.Asaresu|t,th primary.secondary,andmidrockerarmsareIinkedby2hydrau|icpistons(|ikeaskewerlandthe3rockerarmsmoveas and closingthe valvesat the valvetiming a singleunit. In this state. a the rockerarmsare drivenby cam lobec, opening and valve lift set fot high operation. At High Dm: FOR CAM PNOFILE HIGHRPII
l,
il
+ ;
STOPPR PISTON
HYDRAULIC PISTON (AI HYDNAULIC PISTON(B)
*The rockr arms ere linked via the hydraulic Piston. Cam lobe C drives the rocker arms.
5-6
ControlSystem
The controlsystemfor this mechanism, shown below, constantlymonitorsthe changes enginestatussuch as load, as in rpm and vehiclespeed.this intormationis transmittedto the EngineControlModule {ECM). Valv Timing ChEngeConditions Englne Speed: 4,9OO nm or higher Vohicle Spood: 19 mph (3O km/hl 01 tastel Engino Coolant Temperature: lrtooF {6OoC) or higher
ControlSystem
VTEC PRESSURE SWITCH
VTECSOLENOID VALVE
F.oft
OILPUMP +
Et{Gtt{E CONTROL MODULE {ECM)
5-7
ControlSystem(cont'd)
I
Lost Motlon Machanbm at low spsds' At low spoeds' th lost motion The mid rockr arm is always driven by the high-spesd cam lobe' even mechanismkeepsthemidrockerarmincontactwiththehigh.speedcam|obe'Athighsp6ds,the|ostmotion mechanismscts as part of the valve spring load'
CAM PfiOFILE SPRII{G A SPRIIIG
RETAINEN
GUIDEHOLDER
ASSEMELY LOSTMOTION
Hydraulic Prg$ure Contlol Machanism pressuteswitch VTEC solenoidvalve/VTEC to the oil passaga the rocketarm at low speed' to in The VTECsolenoid,ralve, response a signalfrom the ECM,closes pistons in the rocker arms so the a.ms ope]8t6 indopendent|y.At high sp66d, tho This cuts oiI pressureto the hydrau|ic EcMopsnstheVTEcso|enoidva|ve.Theincreasedoi|pressurecausesthehydrau|icpistonsto|ockthep'imary,sgcon dary, and mid tocker arms together. TheVTECpressureswitchsgrvesasasensortodetermineiftheswitch-overhastakenp|aceinlsponsetothEcM signsl.
I' s
t l: .
5-8
CylinderHead
Outline
The one-piece cylinderhead is made of aluminumalloy to reducethe weight while increasing efficiency The combustion chamberis a compactpent roof shape,centerplugtype. The cylinder headusesa DOHC4-valvesystem with 2 intakevalvesand 2 exhaustvalvesarranged cross flow. Combustion stabledue to the optimization the for is of ignitiontiming, compression ratio and valve timing.
EXHAUST CAMSHAFT
INTAKE CAMSXAFT
EXHAUST ROCKER ARM II{TAKE ROCKER ARM EXHAUST PORT
INTAKE PORT
INTAKEVALVE EXHAUST VALVE
5-9
GylinderHead
Camshafts
T h e c a m s h a f t i s a c a s t p i e c e . B y i m p r o v i n g d i m e n s i o n a | a c c u r a c y , i t b e c a m e p o s s i b | e t o a c h i e v e mforc- u m s p a c g inim with on five bearing iournals tween cams,thus a owing a more compactcylinderhead.Eachcamshaftis supported I intakecyctesrequire totaloJ 24 cam on ed lubrication. the left end of eachcamshaftis a drivenpulley.The exhaustand lobesto oDenand closethe valves
EXHAUST
A: PRIMARY B: MID C: SECONOARY
CAMSHAFTJOURNALS
II{TAKE
CAMSHAFTJOURNALS
valve timing Low-speed
High-speod valve timing <F i Intok6 valva opon : Exhau3t vslvg opon -
INTAKEA
INTAKE B
B XHAUST
INTAKE C
TDC: Top dead center BDC: Bottomdead center
Valves and Valve Springs

t,c lm
The valves are openedand closedby rocke. arms driven by the camshatt. Light weight and large diametervalves made ot a high strength metal with small diameterstems are used. The air resistance decreased the slenderstems and the intakeefticiencyis inc.eased inlet ports that match with laroe is by by diametervalves, Valve specitications U n i t :m m ( i n ) VALVE ITEM
INTAKE
3 5 . O( 1 . 3 8 )
EXHAUST
HEAD DIAMETER STEMDIAMETER

OVERALL LENGTH VALVE LIFT
3 0 . o{ 1 . 1 8 )
5.5 lO.22l
5.5 tO.22l r 0 6 . 7 5( 4 . 2 0 3 )
Secondary: 8.O (O.31 ) Mid: 11 . 5 ( O . 4 5 ) * Primary: 6.5 (O.26)
' 1 0 6 . 9(5 . 2 r 4 1)
( S e c o n d a r y : 7 . 5O . 3 O ) Mid: 1 O . 5( O . 4 1 1 * P r i m a r y : 6 . O{ 0 . 2 4 ) * Indicates high-speed valves
Fr
|
oVERALL LENGTH
,/|l
ffir
HEAD DIAMETER
The valve spring wire uses a moditiedcross-section valve lift in a limitedsoace. to
EGG SHAPE
LEMON SHAPE
5-11
Belt Tensioner
Outline
ThetensionersforthebaIancersha'tdrivebe|tandthetimingbe|tarearrangedinpara||e|onasing|eaxisforamolecom This tensionerallows easv belt maintenance' pact configuration,
TIMING BELT
WATER PUMP PULLEY
SPRINGfol TENSIOI{ER BELT TIMING BALAIIICER
AUTO.
for TIMING BELT
MAINTENANCEBOLT
TIMI G AELT AOJUSTER
BALANCERBELT TENSIONER
5-12
- Auto-tensioner
The auto-tensioner usesa torsionspringto regulate timing belt tension.The maincomponents the torsionsp.ing, the are . malescrew and a temalerod. The assembly filledwith oil and sealed. is The springturnsthe malescrew. which pushes lhe lemalerod out againstthe belt. The designis such that the rod cannot be pushedback into the housingby belt tens'on. To pull the female rod back into the assembly. the male screw must be turned with a screwdriver.
SCREW IMALEI
Machanbm: 8lt Ro6ctlon Fo.ce
o The malescrew is rotated by the

lorsron spflng.
ri The lemale rod is

pushedout as lhe rod rotates,
O The rod stops when the force oI the torsion spring and the timing belt equalize.
5-13
CylinderBlock
are madeoJ FRM,a composite The cylinderblock is a closeddeck designmadeof aluminumalloy . The cylindersleeves shaftsand the deep aluminatiber and carboniiber. The boresin the cylinderblockfor the balancer materialof aluminum, skirt designimprovethe rigidityof the block.
Cylinder spocitications Bore x Stroke Bore Pitch Block Height Skirt Depth Displacement 8 7 . Ox 9 0 . 7 m m ( 3 . 4 3 x 3 . 5 7 i n ) 9 4 . Om m ( 3 . 7 Oi n ) 2 1 9 . 5 2( 8 . 6 4 3i n ) 5 0 . Om m ( 1. 9 7 i n ) 2 . 1 5 7 c m 3( 1 3 1. 6 c u - i n )
7.0 mm {0.28 inl
-.-----\L----J-JJ \7-J\^/\-
O O O
Q O
,.\
/zr
.\
iEff
BALA'{CERSI{AFT BORES
Oil Flow
Lubrication the c.ankshattand connectingrod bearings done by oil pumpedthroughthe main bearing of is caps ano Inro passages the crankshalt.The pistonsand cylinderwalls are lubricated oil spray nozzlesmountedon the cvlinder in by block.
INTAKECAMSHAFT
OIL CONTROL ORIFICE VTEC SOLENOID VALVE CAMSHAFT HOLDER PIPEOIL
swtTcH
VTEC PRESSUBE
IHAUST CAMSHAFT .XXJRI{AL
ENGINE OIL COOLER
ENGINEOIL FILTER FRONTBALANCER
ENGINECOOI"ANT
ENGINEOIL PRESSURE SWITCH
OIL JET NOZZLE
REAR BALANCER
(cont'd)
5-15
Oil Flow
(cont'd)
oi|pumpedtothecy|inderheadservestwopurposes;to|ub'icatethecomponentsandtooperatetheVTEC.oi|is pumpedintothecamshaftho|dertoIub'icatethejourna|s,anditsprayslfomorificesintheho|derto|ubricatetherocker valve.At high RPM.this valveopensand oil is pumpedat high to arms and valves.oil is alsosupplied the VTECsolenoid through the rockerarm shatts to operatethe VTEC' Dressure
r
)
VTEC SOLEIIOIDVALVE
OIL CONTROL ORIFICE ENGINEOIL FILTER ENGINEOIL COOLER OIL JET NOZZLE
EngineRemoval/lnstallation
EngineRemoval/lnstallation @ frla-i6iwe
iacks and saletY stands 8re placod ploperly and hoist brackots are attachod to the corr'ct positions on th 6ngin6. a Mako suls tho car will not roll ofl stands 6nd lall whlle you are working undal it. CAUTION: a Use tendl covers to svoid damaging paintd surtacas. a Unspocified itoma alo common a Unplug th wiring connoctolE carstullY while holding the connoctor portion to avoid damago. a Mark all wiring and hosas to avoid miaconnection. Also. bo 3u1that thoy do not contact othar witing ol hosos or into.lernco with othar parts. cirNOTE: The radiomay hsve a codedthett protection cuit. Be sureto get the customer'scode numbrbelore - Disconnecting the battery. - Romoving the No. 43 (10 A) Juse(ln the under-hood tuse/relavboxl. - Removing the radio. Atter service,reconnectpower to the radio and turn at on. "CODE" is displayed. enter the When the word customer's5-digit code to restoreradio operation. 1. Securethe hood as far open as possible. terminaltirst, then the 2. Disconnect batterynegative the positivetetminal. HOUSI'{G AIRCLEA'{EF 3. Removethe radiatorcap use care vuhonremoving tho radiator !@ cap lo avoid scalding by hot coolant ol atoam. 4. Raisethe hoist to full height. Remove the Jront wheels and the engine splssh shield. 1O. Removethe pulsed secondaryair iniectionIPAIR) vacuum tank and bracket. PAIR TANK VACUUM 5. Loosenthe drain plug on the radaator. the drain oil/lluid. Reinstall 6. Drainthe transmission plug using a new washer. the 7 . Orainthe engineoil. Reinstall drainplug usinga new wasnef. CAUTION: Do not ovsrtighlan tho dlain plug' 8. Lower the hoist. the air cleanerhousingand intakeair duct' 9. Remove
6 x 1.O ]||m 10 .m {1.0 ks-m, 8 lb-ftl
6x1.Omm lO N.m 11.0kg-m,
I rb-trl
6 x 1 . Om m '10t{.m (1.O kg-m,
a tb-ft|
BRACKET
6 x 1.0 mm 1O N.ln (1.0 kg-m, 7 lb-ftl
I
Front
5-18
11. Remove the battery, battery base, battery cable and starter cable. MANUAL TRANSMISSION tM/TI: 8 r 1,25rnm 22 tt.m 12.2kg-m, 16 tb-ft)
CAUTION: a Bfore disconnocting any fu6l line, r6livs the tuel prssur os dosc.ibod above. a Place I shop towol ovel the tultilter to prevent prossulizod tuol trom sprsying ovor tho ongine. 13. Removethe fuel feed hose from the fuel rail.
WASHER
STARTER CABLE AUTOMATIC TRANSMISSION {A/r}: NOTE: When installingthe starter cable clamp. make sure the tab is in the hole in the bracket,
14. Removethe injectorresistorconnectoron th8 left side of enginecompartment.

6x1.0mm 10 N.m {1.0 kg-m, INJECTOR RESISTOR
INJECTOR
0 r 1.0 rnm 1 0 N . m( 1 . 0k g - m , 7 tb-ftl
1 2 . Relievefuel pressureby slowly looseningthe service bolt on the fuel rail aboutone turn (seesection 11 ) . Do not smoke while working on tul @ systom. Keop opsn tlame or spark away ttom work alaa. Drain tuol only into an apptoved containet.
(cont'd)
5-19
(cont'd)
the the 15. Remove throttlecableby loosening locknut' end out of the throttle linkage' then slip the cable NOTE; a Take care not to bend the cablewhen removlng it. Always replaceany kinked cable with a new one. a Adiust the throttle cable when installing(see s e c t i o n1 1 ) . emis18. Removethe brakeboostervacuum hoss and vacuum tubes from the intake sion control manilold. CONTROL IEVAPI EMISSION EVAPORATIVE
BOOSTER BRAKE HOSE VACUUM
I
NUT ADJUSYING
1 9 .Disconnect the connector and vacuum tube' thn

remove th cruise control actuatol.
Ir
to.
Removethe engine wire harnessconnectors.rerminal snd clamps on the right side of engine compartment. Bemove the power cable from the under-hood tuse/relaybox. CABLE POWER UNDER.HOOD
CRUISECO'{TROL ACTUATOR
8r1.Omm 10 .m (1.o kg-m, 7 tb-frl
t l
Il'
20. Remove the engine g.ound cable from the body side. 21. Removethe power steering (p/Sl pump belt and pump. a Do not disconnectthe p/S hoses.
8 x 1.25 rhm 22 .m (2.2 kg-m.
23. Loosenthe alternatormounting bolt, nut and adjusting nut, then removethe alternatorbelt,
MOUNTING EOLT
t8
LOCKI{UT
PI,MPBELT
ALTERNATOR AELT
P/S PUMP
r 1 . 2 5m m 22 N.m {2.2 kg-m, 16 tb-frl 24. Loosen the mounting bolt, then remove the A/C compressof. Disconnect the connector. a Do not disconnectthe A/C noses.
22. Rsmove the air conditioning{A/C} condenserlan shroud. then install a protector Dlate on the radiator.
6x1.Omm 10 N.m (1.0 kg-m, 7 tb-ft}
8 x '1.25mm 22 N.m 12.2 kl-m. 16 rb-ft} . Do not remove tho bohs
(conr'd)
5-21
(cont'd)
the upperand lower radiatorhosesandthe 25, Remove heaterhoses. 27. Removethe shift cable and selectcable (M/T)' NOTE: a Take care not to bend the cablewhen removing it. Always replaceany kinkedcablewith a new one. a Adjust the shiJtcable and seleci cable when installing(seesection 13). I x 1 . 2 5m m
WASHER
BRACKET
i
\ COTTER Roplace. STEEL WASHER 26. Remove the transmissionground cable and the automatic transmissionfluid (ATF) cooler hoses (A/T).
WASHER SELECT CAELE
PI.ASTIC WASHCR
Removeth clutch slave cylinder and the pipe/hose assembly(M/T). NOTE: a Do not ooerate the clutch pedal once the slave cvlinderhas been lemoved. a Take care not to bend the PiPe.
ASSEMBLY
SLAVECYLINDEB
t
I
8 r 1.25mm 22 N.m 12.2 kg-m, 16 rb-frl
5-22
29, Removethe clutch damperassembly. NOTE: Take care not to bend the pipe.
tng
31. Raisethe hoist to ful hoight. 32. Removethe exhaust pipe A and bracket. GASKET
CLUTCH DAMPER
rin-
SEI.F-LOCKIIIG NUT 18 N.m {1.8 ks-m, t3 tb-ft} Replace.
@'
tHER
nc
IER
8 r 1 . 2 5m m 22 N.m 12.2kg-m, t6 tb_ftl
55 N.tn (5.5 kg-h, 40 b-trl Replace.
I{UT
EXHAUST PIPEA
30. Remove the vehicle speed sensor {VSS)/power steeringlPlS) speedsensorassembly. NOTE: Do not disconnectthe noses.
18 N.m (1.8 kg-m, ilave
33. Removethe A/T shift cable (A/T). NOTE: a Take ca.e not to bend the cable when removing it. Always rplaceany kinkedcable with a new one. a Adiust the shift cable when installing (see section 14).
ISLY
P/S
6 x 1 . Om m 10 N.m (1.0 kg-m, 7 lb-ft) tg N.m (1.8 kg-m, 13 tb-ftl
(cont'dl
5-23
(cont'd)
34. Bemove the damper fork. BOLT SELF-LOCKING 10 r 1.25 mm /+4 N.m (4.4 kg-m, 32 lb-frl
36. Removethe driveshafts.
I
I
t
I
|l
DRIVESHAFT 1 2 x 1 . 2 5m m 65 N'm 185 kg-m,47 lb-ftI RePlace. lower arm balljointwith the 35. Disconnect suspension the special tool. Refer to section 18 tor the procedure.
37. Swing the driveshaftunder the fender. NOTE: surfaceswith clean a Coat all precision-finished engineoil or grease' a Tie plastic bags over the driveshaJtends'
PLASTICBAG
CASTLENUT 14 x 2,O mm 50-60 N.m
fl
36-43 tb-ft)
38. Lower the hoist. 39. Attach the chain hoist to the engine.
5-25
lcont'd)
40. Removethe rear mount bracket 42. Removethe lelt side enginemount.
BEAR STIFFENER
4 3 . Remove the transmrsslon

41. Removethe front mount bracket. bracket.
and mount
l
i' 5-26
44. Raisethe chain hoist to removeall slack from the chain. free of vacuum 45. Checkthat the engineis completely hoses, fuet and coolant hoses, and elect.ical wiring. 150 mm {6 46, Slowly raisethe engineapproximately an). Check once again that all hoses and wires have trom the engane. been disconnected the engineallthe way and removeit Jromthe 47. Raise car.
48. Installth8 enginein the reverseordr of removal. NOTE: After the engineis in place: a Torque the engine mounting bolts in the squence shown below. CAUTION: Fallurto tlghton the bolts In the p?opor aoquencccln cauae orcegtivo noiar and vlbrstion. and rcduce bushing litc; check thst thc bushing! aro not twirtrd or offsot.
a Check that the spring clip on the end ot each driveshaftclicks in to olace. CAUTION: lnstall now spring cllps
TRAIISMISSIOT{ MOUI{T
Eleed air from the cooling system at the bleed bolt with the heatervalve open. a Adjust the throttle cable tension. a Checkthe clutch pedalfree play {M/T). a Check thst the transmissionshifts into gear smoothly. l 2 x 1 . 2 6m m 1 0 r 1 . 2 5m m REARMOUITIT @ es .m le.s tg-m, 1s b-ft} @2r 'm t2.1 47 b-trl 1 0 r 1 , 2 5m m Rplace. .m {3.9 kg-m.28lb-ft} 39
10 r 1.25mm @ 39 .ln t3.9 ks-m.
O Tightsnsnugonty. 1 2 r 1 . 2 5m m @ 65 t{.h {6.5 kg-h, 47 b-trl
12 x 1.25mrn O 55 .m 15.5ks-m, 40 tb-trl ReDlace.
12 x 1.25mm @ 65 .ln (6.5 kg-m, 47 tb".ft) RgDlac6.
FROI{T MOUI{T SIDEE'{GI E IIOUNT the 12| 7.29

@ 55 .m (5.5lg-ln, 40
tum 'acal
r {6
6Ve @ Tighton snug onty. l O x 1 . 2 5m m NOTE: . Torque th mounting bolts/nuts in the numbgred squenceas shown (O-@). . After road t6sting, loosen and rtighten the thre bolts on the front r'lount brackoi.
the
@ 39 N.m (3.9 kg-m,28 tb.ft}
1 2 r 1 . 2 5m m O 65 t{.m lO.5 kg-m,47 tb-ftl (cont'dl
@ Tighten
only.
5-27
(cont'd)
a Adiust the tensionof the following drive belts: Alternatorbelt (section23). Power steeringpump belt (section17). belt {section22). compressor Air conditioner a Clean battery posts and cable tetminals with then apply greaseto preassemble, sandpaper, vent corrosron. Mount and BracketBolts/NutsTorque Value Specifications:
TRANSMISSIONMOUNT MOUNT 1 2 r 1 . 2 5m m 95 N'm {9.5 kg-m, 69 lb-ftl
a InsDectfor fuel leakage. After connectingall tuel line parts. turn on the ignition switch (do not operate the starterl so that the fuel pump operatesfor approximately two seconds and the fuel line is pressurized. Repeatthis operationtwo or three times, then check for fuel leakageat any point in the Juel line.
REABMOUNT
TRANSMISSION MOUNT '10 r '1.25mm BRACKET 39 N.m (3.9 kg-m, 10 r 1.25mm 39 N.m 13.9kg-m, 28 lb-tt)
2a tb-ft|
(Standardfor some tvpos) SIDE ENGINE MOUNTING BRACKET
'10x 1.25mrr 48 N.m (4.8 kg-m. 35 tb-ft|
I x 1.25mm 22 N.m 12.2 kg-m, 16 lb-ftl H23A'1.H22Al ngine: Et{GINEMOUNT BRACKETA lO x 1.25mm 45 N.m {4.5 kg-m, 33 lb-tr) 12 x 1.25mm 95 N.m (9.5 kg-rn,69 lb-ftl MOUNT FRONT
!r
8 x 1 . 2 5m m 22 N.n 12.2ks-m, 16 rb-ft|

lO x '1.25mm 48 N.m (4.8 kg-m, 35 lb-ft)
5-28
AdditionalTorqueValue Specifications;
P/S BRACKET {F22A1 onginol
TRANSMISSIONMOUNT BOLTS 65 N.m 16.5kg-m,47 lb-ftl
8 x 1,25mm 22 N.m 12,2 kg-m, 16 tb-ftt
.ft) INTAKE MANIFOLO x 1.25mm 50 N.m {5.O kg-m, 36 rb-ftt
8 x 1.25mm N.m {2.2 kg-m, 16lb-ftt EXHAUST MANIFOI.D BRACKET
10 x 1.25mm 50 N.m {5.O kg-m, 36 lb-frl
P/SBRACKET (H23A1, H22Al ongino)
tg-m,
10 r 1.25mm 45 N.m {4.5 kg-m, 33 lb-ftl
I for es)
1 0 x 1 . 2 5m m kg-m,36 lb-trl 50 .m {5.O
10 x 1.25mm 50 N.m (5.O kg-m, 36 lb-ftl Apply liquidgasket to the bok threads,
ALTERNATORBRACKET
10 x '1.25 m m 50 N.m {5.O kg-m, 36 lb-ftl
A/C BRACKET
5-29
Cylinder Head/ValveTrain
F22A-1 engine H 2 3 A 1e n g i n e H22Al engine ............... 6-1 . . . . . . . . . . . .6.- 3 7 . .............. 6-71
CylinderHeadA/alve Train lF22A1 enginel

Speciaf Tools .........6-2 Valve Seats l l l u s t r a t oId d e x . . . . . . . . . . . . . . . . . . . . . . .6.-.3 n . . Reconditioning .... 6-17 Valve Seals Valve Guides (Gylinder head Replacement V a l v e o v e m e n.t. . . . . . . . . . . . . . . . . .6 - . . 8 M ..1 removalnot rquiredl ............. 6-5 Replacement .......6-19 CylinderHead Reaming .............6-20 Removal . . . . . . . . . . . .6 - 7 . Camshaft/Rocker Arms and Warpage ............6-18 CamshaftSeals/Pulley Installation .........6-23 fnstalfation .........6-22 Camshaft Pulley Timing Belt and Timing Balancer Belt Removal .............6-12 lllustrated Indox ........................ 6-25 Rocker Arm Assembly Replacemont .......6-29 Removal . . . . . . . . . . . . . 6 - 1 2 Timing Belt Rocker Arms lnspection ..........6-26 Overhaul . . . . . . . . . . .6 - 1 3 . Tension Adjustment ................... 6-26 Clearance ...........6-15 Positioning CrankshaftBefore lnstalling Timing Belt .............. Camshaft 6-28 Belt Inspection . . . . . . . . . . 6 - 1 4 Timing Balancer fnspection ..........6-27 Valves, Valve Springs and Valve Seals Valve Clearance Removal . . . . . . . . . . . .6 - 1 6 . Adjustment .........6-34 Valve Spring and Valve S6al Installation Sequence .............. 6-21 Valve Installation ....................... 1 6-2
SpecialTools
Ref. No. I
Tool [tlumber or 07HAH-PJ701OA OTHAH_PJ701OB OA PTOOl OTNAF_ OTNAF_PTOO20A OA OTNAG-PTOOl o7742-OO10100

Valve Guide Reamer,5.5 mm CUP Installer lnstaller Shalt Seal Guide Valve Guide Drivr, 5.5 mm
o o
6-20 6-22 6-22 6-22 6 - 1 9 ,2 0
@ @ @
I
e:Gt'r----------E
fllustratedIndex
CAUTION: a To avoid damaging the cyllnder head. wsit until th6 engine coolant tompe.aturo drops bolow loooF {38ocl bforo romoving it. a In handling a metal gaskot. tak6 caro not to fold it or damago the contacl surtaco ot tho gasket. NOTE: a Use new O-ringsand gasketswhen reassembling, a Cleanthe oil control orifice before installino. CAP NUT 6 r 1.0 rrn 10 N.m11.O kg-m.7lb-ftI
?
HEADCOVER CYLII{OER RUBEER SEALS Rplaco whon dEmagd or dteriorstd.
Put longer bolt
T
8 x 1 . 2 5m m la N.m11.8kg-m,13lb-ftl
CYUITDER HEADBOLT 1 2 r 1 . 2 5m m 1OO ,m (lO.Okg{n, 72 lb-ft} page6-23 Tightening. Apply sngineoil to the thrgadg.
CYLII{DER HEAD
DOWEL PI'{ otl coilTRol oRtFtcE

Clean. O.RING Roplace. CYLINDER HEADGASKET GASKETI {METAL Rolacg. 8 r 1.25mrn 22 t{,m (2.2 kg-m, 16 lb-ftl TIMING BELT
Rsplacement,page 6-29 Inspoction/Adjustmont, page 6-26
./--'77'---)
---
AD.'UST|IG ruT 10 r 1.25mm 45 [.m 14.5 kg-m, 33 lb-ft, Loos6n, but do not r6movg.
(cont'd)
6-3
lllustratedIndex
(cont'd)
nl to dry cleanall the partsin solvent, them.nd applylubricant any contsctparts' ,rto, to teassembling,
6 x 1 . Om m 12 N'm tl.2 ks-m, 9 lb-ft)
@
I
e
I
r 1.25mm 22 trl,m (2.2 kg-h, 16 lb-ft)
VALVE ADJUSTING SCREW 7 r 0.75 mm 20 .m (2.0 kg-m, 14 lb-ft, Apply oil. Adjustment, psge 6-34
ROCKEBARM ASSEMBLY Ovorhsul,pag 6-13 lnspoction, page 6-1 5
oo*:..rn-y'
SEAL lnstdflation, page 6-22 Rplace.
PULLEY CAMSHAFT page6-12 Romovsl, pago6-22 Installation,
CAMSHAFT
8 x 1.25 mm
38 .m (3.8 kg-m.27 lb-ft)
VALVE KEEPERS-*_-_-\ ---ro --_ spRtl{GRETATNER
i vALvE spntitc
-'^"'-"-'-"-' -------Ib
vALvE ExHAUsr
vALvEsEAL ExHAUsr
p8gs6-5 8nd 16 Replacment, Reptace.
;ili' spRrNG...-_____la
q
rgli Fz-->.I @
--"i
w
VALVEIGEPERS RETAII{ER ITTAIG VALVE SPfiI C
II{TAKE VALVE SEAL RDlace.
I ExHAUsr
e-une .V valvE
SEAT VALVESPRING II{TAKEVALVE GUIDE EACr COVER

CYLINDERHEAD
6 x 1.Orm 12 N.mll.2 kg-m,9 lb-ftl INTAKEV

B6movsl,pao 6-16 Installation, page 6-21
6-4
Valve Seals
(Gylinder Replacement head removalnot requiredl
NOTE: Cylinder head removal is not required in this orocedure. Ths procdur6shown below applies when using the incar valve spring compressor. (Snapon YA8845 with YA8845-2 A 7/8' attachmentl Intake V!lv. Soals: 6. Slgct the 7/8 in diameter long compressor attachmnt 8nd fasten the gttachment to th6 No. 5 hole of th levor arm with the speed pin supplid. Insrt an air adaptor into the spa.k plug hole. Pump air into the cylinder to ke6p the valve closod whils comprssing springs and rsmoving th valv ke6o6rs.
6.
@E
Alway woar approv.d oyc prot.ctron
whon uslng th6 in-cel valvo spring compt!3!or. 1. Turn the crankshaftso that th6 No. I 8nd the No. 4 pistons are at top desd center (TDC). 2. Removeth cvlinder head cover and the rocker arm assembly. NOTE; a Rsfr to p8ge 6-12 for rocker arm assembly removal. I When removing or installing the rocker arm 8ssambly, do not r6mov6th camshaft holdorbolts, Th6 bolts will keepthe holders,sprirs and rocksl arms on th shaft, 3. 4. Remove the fuel injectors and the wire hsrnss. Using the 8 mm bolts supplied with the tool, mount the two uprightsto the cylinderh6adatthe end camshaft holders. Th uprights tit ov8r the camshatt as shown, Insertthe cross shaft through th6 top hola of th two uprights.
Position the levr arm und6r ths cross shaft so the lover is porpondiculsrto th shaft and the compres8or sttachm6nt rests on top of the rgtsinsr tor the spring being compressd.Us th tront position slot on ths lvsr as shown. NOTE: RJt shop towek over the oil passages preto vent th6 valvo kepB from falling into the cylindsr h6ad.
OII. PA&gAGES
5.
trl
(cont'd)
6-5
Valve Seals
(cont'dl not headremoval required) Replacement lGylinder

'15. Using a downwatd motion on the levsr arm, compress the valve spring and remove the keepersfrom the valve stem. Slowly release paessuleon the sprlng. 16. Removethe valve seals(page6-16). 17. Installthe valv seals lpage 6-21). 8nd th koop.sin 18. Installthe springs,the rtainers rgvorso ordr of romovSl, 19. Repeatsteps 6 to 18 on the other cylinde,s.
9. Using a downward motion on the lve, arm, comfrom pressthe valvespringand removethe keepers valve stem. Slowly release pressureon the the sprlng. t 1 O . R e m o v e h e v a l v es e a l s( p a g e6 - 1 6 ) . 1 1 . Installthe valve seals (page6-21). 12. Installthe springs,the retainers and the keepersin reverseorder of removal. ExhaustValv6 Seals: attachshortcompressor 13. Selectthe 7/8 in. diameter ment and lasten the attachmentto the No. 4 hole of the lever arm with the speedpin supplied. 14. Positionthe lever arm under the cross shaft so the to leveris perpendicular the shaft and the compressor attachment rests on top of the retainerfor the spring Use the front position slot on the being compressed. lever as shown. to NOTE: Put shop towels over the oil passages prevent the valve keepersfrom falling into the cylinder head.
6-6
CylinderHead
Removal
Engineremovalis not requiredtor this procedure. 1 . Disconnect the negativeterminalfrom the battery.
2 . Drain engine the coolant{seesection101.

o Make sur6 iacks and sefsty stands are placed propsdy and hoist bfackets are sttachod to co.roct @shions on tho ongin, o Maks sure the car will not roll off stfltds and tall whilo you are working under it. CAUTION: a Us tndr covors to avoid damaging paintod surtacas. a Unspecifiad hms arc common. o Unplug tho wiring connec{ors carefully whil holding ths connoctor Fprtion to avok ddylago. . Mark a[ wMng and hosos to avokt miEconnection.Abo, bo su.o that they do not contact oth6. widng or hosos ol innerto?e with othq parts. o To avoid damaging th cylinder hoad. wah untilthe sngine coolant temp.aturs drop6 blow 100oF (38oC) botor loosoning tho ltaining boh. o Inspect th timing beh bofore removing the cylnder hoad. . Tum the crankshaft pulley so that tho No. 1 dston is at top doad center {pag6-281. a Maks all emission hoss betore disconnocting thm. NOTE; The radio may have a coded theft protectioncircuit. Be sure to get the customer'scode numberbefore Disconnecting battery. the - Removing the No.43 (1OA)tuse (ln the under-hood fuse/relavboxl. Removing the radio. After service,reconnectpower to the radioand turn it on. Whenthe word "CODE" is displayed. enterthe customer's s-digit code to restoreradioope.ation. 4. . Removethe radiatorcap to speeddraining
5.
Relieve the fuel pressure. @ Do not snoke whlc wo*rng on ftrc sydem, krop oFn ffrnc or spark away trom wor* s!. Drdn ft|ol ody into an approvrd contrlnor. SERVICE EOLT 12 N.m {1.2 kg-m,9 tb-ft}
SHOP TOWEI-
FUEL RAIL
Rmovethevacuumtube,breatherhoseand intskeair duct. Removethewater bypasshosefrom the cylinderhead Removethe fuel feed hose and evaDorative emission (EVAP) controlcanisterhosefrom the intakemaniJold.
(cont'dl
6-7
Head Cylinder
(cont'd) Removal
7. Remove the brakeboostervacuum hose and vacuum hosemount (A/T only)fromthe intakemanitold. 10. Removalthe ignitioncoil. * 8x 1.25mm 22 N.m(2.2kg-m,16lb-ftl
8 . Removethe luel return hose and cruisecontrol vacuum hose.
CRUISE
Removethe spark plug caps and the distributor, 9. Removethe throttle cableand the throttle control ca bl; (A/T only) from the throttle body. NOTE: o Take care not to bend the cablewhen removingit. Always replaceany kinkedcable with a new one. a Adjust the throttle cable when installing(seesection 1 I ).
1 2 . Remove connectorand the te.minalfrom the alterthe

nator, then removethe enginewire harnesstrom the cylinderhead cover.
1 3 .Removethe followingenginewire harnessconnectors

and clamps f.om the cylinder head and the intake manitold: a Fourtuel injectorconnectors o Intakeair temDerature {lAT) sensorconnector o ldle air control (lAC) valve connector . Throttle position (TP)sensorconnector o Exhaustgas recirculation(EGR)valve lift sensor connector . Groundcableterminals . Enginecoolant temperature(ECT)switch B connecror o Heatedoxygen sensor (HO25)connector a ECTsensorconnector o ECTgaugesendingunit connector . lgnition coil conneclor . CKP/TDC/CYP sensorconnector . Vehiclespeedsensor(VSS)connector a ECTswitch A connector
BOLT r!: CORROSION RESISTANT
6r10mm k 1 2 N . m( 1 . 2 g - mI, l b - f t l
THROTTLECONTROL CABLE (A/T onlyl
14. Removethe upper and lower radiatorhosesand heater noses.
18. Disconnect connector the andvacuumtube,then remove the cruisecontrol actuator

CNUISE CONTROL ACTUATOR
UPPER RADIATOR HOSE
6 x '1.0rnm 10 N.m {'1.0kg-h, 7 tb-trl
VACUUMTUBE
HEATER OUTLET HOSE HEATER INLET HOSE
cor{r{EcToR
15. Remove the emission vacuum hoses and water bypasshosesfrom the intake manifoldassemblv. '16. Removethe water bvoass hose from thermostat housing.
,4
,//
./ 1 9 .Removethe enginegroundcablefrom the bodyside. 20. Removethe power steeringlP/S)pumpbelt and pump.
NOTE: a Do not disconnect the P/S hoses. . After installingsdiust the tension of the P/S pump belt (seesection 17).
erne
17. Remove the thermostat assemblv from intake manifold.
ke
P/S PUMP
THERMOSTATASSEMALY
LOCKNUT 1 5 N . m l t . 5 k g - m ,1 1 l b - f t ) P/S PUMPBELT
I x 1.25mm 22 N-lm 12.2 kg-m, 16 tb-ftt
(cont'd)
6-9
Head Cylinder
Removal {cont'd)
21. Remove the intake manitold bracket and intake mani{old. with air conthe 24. Remove heat insulator(carsequipped onlY). ditioning 25. Removethe self]ocking nuts and disconnectthe exhaust manifoldand exhaustPiPeA. 26. Bemove the exhaust manifold bracket and exhaust manifold.
MANtFoLo TNTAKE
GASKET
BRACKET
22. Lift the tront of the car up andplaceit on safetystands' PIPA EXHAUST
Mako sure lifts, iacks and safaty stands aro dacsd propsdy. and hoist brackts are attachd to the corrct position on the ongin (seo page 1-10 rhlu 1-121. Apply pa*ing b.ake and block rear wheeb, so car will not roll oft slands and lsll on you wh e workng und91il. the 23. Remove front wheelsand the enginesplashshield (page5-18).
HEAT INSULATOR (Carsoquippedwith air conditioningl
2 7 . Remove the positive crankcase ventilation (PCV)

hose, then removethe cylinderhead cover.
24. Removethe upPercover. 29. Loosanthe adjuatingnut 27O - 3600. 30. Pushthe tensionerto releasetensionfrom the timing
blt, then retightenthe adiustingnut.
6-10
31 . Removethe timing belt from the camshaft pulley.
NOTE: Separate the cylinderhead from ihe block with a llat bladescrewdriveras shown.
ex
CAUTION: Do not crimp or bend tho timing balt mor than 90o or less than 25 mm (1 inl in diameter.
GA
No Good
32. Removethe cylinderhead bolts. then removethe cylinderhead. CAUTION: To prevont warpag. unscrow tho bolts in soquonc 1/3 turn at a timo; ropat untllall bohs ars loosonad. CYLIT{OER HEAOSOLTLOOSENING SEOUENCE
ning)
>cv)
mrng
6-11
CamshaftPulleY
Removal
1. turn the camshaftpulleyuntilthe To easereassembly, "UP" mark faces up, and the front timing mark is alignedwith the cylinderhead upper surface.
RockerArm AssemblY
Removal
1. Loosenthe sdjustingscrews, then remove the bolts and the rockerarm assembly. NOTE: . Unscrsw the camshaft holderbolts two tums at a time, in a crisscrosspsnern to pre\nt damaging the valvesor rocker arm assmbly. . When removingthe rocker arm assembly.do not remove the camshaft holder bohs. The bolts will keep the camshaft holders, the springs and the rockerarms on the shafts.
,.UP"MARK
b%
TDCGROOVES Alignfronttimingmarkon with the cylinder Pulley surfac, headupper Removethe timing belt.
J.
Removethe retaining bolt, the special washer, the camshaft pulley and the key, then removethe back cover.
6 mm BOLTS
CAMSHAFT PULLEY
BACK COVER
6-12
Rocker Arms
r Overhaul
NOTE: a ldentify partsastheyareremoved ensure to reinstallation original in locations.
a Inspectrockershafts and rockerarms (page6-15). . Rockerarms must be installedin the same positionif reused. a When removingor installingrockerarm assembly, not removethe camshaftholderbolts. The bolts will keepthe do holders, springsand rockerarms on the shaft. o when reassembling, the projectionof the intakerocker shaft to the notch in the camshaftholder. fit ' ! Priorto reassembling. clean all the part in solvent, dry them and apply lubricantto any contact parts.
Letter "9" is stamped on tocker atm.
Lefter "A" is stampod on tocker arm.
IITITAKE BOCKER
sHAFr @
INTAKE ROCKER
lshon, 2 placesl
sxmr @ (long,
INTAKE ROCKER
3 places)
ARM s
(4 plsces)
lh,,tr"o., liif.ro" I HoLDER HoLDER

I
I
I
ti;or"or, HoLDER
ll"t "o' HoLDER
ll
|
l l
#,dffifu,Lffi,#u/=m LpC .ffig*ffir |flry 16tr

* " r * l
| t . l^ l , l ^
s ' g U f " #[ U t
/
| .,nou.,,,or".^ |
l'u"'TI ' "
' o
or.,t o
(short, 2 palces)
"*,n('
(long, 3 places)
rc
EXIIAUST ROCTER SHAFT
ROCKER ARM (8 places)
6-13
Camshaft
Inspection
Note: . Do not rotate the camshaftduringinspection. a Removethe rockerarms and rockershafts. 1. Rrt the camshaft and the camshaft holders on the cylinder head, then tighten the bolts to the specilied torque. Specified tolque: 8 mm bohs: 22 N m (2.2 kg-m, 16 lb-ft) 6 mm bohs: 12 N'm (1.2 kg-m,9 lbjt)
6 mm BOLTS
Removethe bolts, then removethe camshaftholders lrom the cylinderhead. - Lift camshaftout ot cylidnerhead,wipe clean,then camshaftif lobesarep'tinspectlift ramps.Replace worn. scored,or excessively ted, - Cleanthe camshaftbearingsurfscesin the cylinder head,then set camshaft back in place' - Insertplastigage strip acrosseach iournal' lnstall the camshaft holders,the tighten the bohs to the specijiedtorque as shown in the left column on this page.
o.
on Measurewidest portionof plastigage eachjournal' Camshatt-tolloldcr Oil Clearance: standard (Newl: 0 050-0.O89 mm (o.0020-o.0O35 in) O.15 mm {0.000 in) Servbe Limh:
8 mm BOLTS
PTASTIGAGE STNIP
Seatthe camshaftby pushingittoward distributorend of cylinderhead. Zerothe dial indicatoragainstend ol distributordrive. then push the camshaft back and forth and read the end play. Camshaft End Play: Standard lNow): 0.o5-o.1 5 mm (O.0O2-O.0O6 in) in) mm {O.O2 O.5 SrviceUmh:
CAMSHAFT
6-14
RockerArms
Clearance
efs
7.
lf camshaft-to-holder clearance out ot tolerance: oil is - And the camshaft has alreadybeen replaced,you must replacethe cylinderhead. - lt camshafthasnot beenreplaced, tirst checktotal runout with the camshaft supportedon V-blocks. Canshaft Total Runout: Standard(Nw): O.O3mm (0.0O1in) max. Srvice Limit: 0.06 mm (0.002 in)
Measureboth the intake rockershafts and exhaustrocker shaft. Measure diameter ot the shaft at the tirst rocker location.
!n
pit-
der
tto on
nal.
Surfaceshouldbe smooth.
Zero the gaugeto the shaft diameter.
- lf the total runout of the camshaft is within tolerance, replacethe cylinderhead. - lf the total runout is out of tolerance,reDlace the camshaftand recheck,lfthe oilclearance stillout is ol tolerance,replacethe cylinderhead. Measurecam lobe height. Cam Lob Height: lntakeStanda.d: 38.526 mm (1.5168in) Erhaust Standard: 38.778 mm { 1.5267 in) Measure the insidediameter the.ocker arm and of check tor out-of-roundcondition. Rockr Am-to-Shaft Cloarance: Standdd(Nw) lmak6: O.O17-O.O5O mm (0.OOO7-O.OO2O in) Exhaust: O.O18-O.054mm {O.OOO7-O.0O21 in) Ssrvico Linit: 0.O8 mm (O.0O3in)
Inspectrocker arm laca tor wear, Inspectthis areator wear.
Repeatfor all rockers.lf over limit, replacethe rocker shaft and all over-tolerance rockerarms.
6-15
Valves, Valve Springsand Valve Seals

Removal
NOTE: ldentify valvesand valve springsas they are rein moved so that each item can be reinstalled its original Dosition. 1. Tap each valve stem with a plastic mallet to loosen the valvekeepersbeforeinstalling springcompressor' Install the spring compressor.Compressthe spring and removethe valve keepers. 4. Removethe valve seal.
2.
AVAILABLE COMMRCIALLY
3.
as specialtool shown. Installthe
SEALREMOVER VALVEGUIDE LISLE 57900or KD3350 P/N AVAILABLE COMMERCIALLY
lntako Valvo txrronsions A Standtd(tlowl: 33.90-34.1O mm (1.335- 1.343 in) B Standtdocw): 1 1O.88-l 1 1.18 mm (4.365-4.377 in) C Strdard{ ow}: 5.485- 5.495 mm n { O . 2 1 5 9 - O . 2 1 6 i3 ) 5.455 mm (0.2148 in) C SorviceLinit: 0.85-1.1 5 mm D Standard(t{ow}: (0.033-O.045 in) 0.65 mm (0.026 inl Linit: D Srvbr Exha.|3t Valvo Dlmonsions A Sta.!dsd(t{ow): 28.90-29.10 mm i t 1 . 1 3 8 - 1 . 1 4 6n ) 8 Stard1*d(ltswl: 122 15 -122.45 mm (4.809-4.821 in) C Siandsdl ewl: 5.450- 5.460 mm ( 0 . 2 1 4 6 - O . 2 1 5 0n l i 34 5.420 mm (O.21 in) C SorvicoUmh: D Standard(Now): I .O5- 1.35 mm -O.O53 in) (O.O41 0.95 mm {0.037 in) D SrvicoLimit:
6-16
Valve Seats
Reconditioning
Renew the valve seats in the cylinder head using a valve seat cutter. NOTE: lf guidesare worn (page6-18),replace them (page6-191beforecutting the valve sears. 5. After resurfacing sat, inspectforeven valveseatthe ing; Apply Prussian Bluecompoundto the valve face, and insertvalvein originallocationin the head,then lift it and snap it closedagsinstthe seat severaltimes.
PRUSSIAI{
6.
2.
Carefully cut a 45o seat, removing only enough materialto ensurea smooth and concentricseat. Bvelthe upper edge ot the seat with the 3Oo cutter and the lower edge of the seat with the 600 cutter. Check width of seat and adjust accordingty. Make one more very light passwith the 45o cutter to removeany possibleburrscausedbv the other cutter. Valve Sat Width: Stsdard (Nowl: 1.25-1.55 mm (O.049-O.061in) ServiceLimit: 2.OOmm (0.079 in)
3.
The actualvslveseatingsurface,as shown bythe blue compound,should be centeredon the seat. . lf it is too high {closrto the valvestem), you must make a secondcut with the 600 cutter to move it doun,then one mor cut with the 45o cutter to restore sest width. a lf it is too low (closerto the vslve edge),you must make a secondcut with the 3Oo cutter to move it up, then one more cut whh the 45o cutter to re_ store seat width. NOTE:The final cut should alwavs be made with the 45o cutter. Insertintakeandexhaustvalvesin the headand measure vatve stem installedheight. Intako Valv6 Stam lnstalsd Hight: Standnd (New): 48.245-48.]15 mm (1.8994- 1.9179 inl Ssrvice Limh: 48.965 mm (1.9278in) Exhaust Valve Stem I]rrtaH Hotght: Standrd (t{ow}: 50.315-8O.785 mm Sorvice Linh:
7.
4.
1 1 . 9 8 0 91 . 9 9 9 4n l i 51.O35 (2.OO92 mm in)
SEAI WIDTH
8.
lf valve stem installedheight is over the servicelimit, replacethe valve and recheck.li still over the service limit, replacethe cylindef head; the valve seat in the head is too deep.
6-17
Head Cylinder
Warpage
oil NOTE: lf camshaft-to-holder clesrance{page6-14) are not within specitication, the cylinder head cannot be resurfaced. are oil lf camshaft-to-holder clearances within speciticacheck the cvlinderheadfor warpage. tions. in)cylinderhead . lf warpageis lessthan O.05 mm {0.OO2 resurfacingis not .equired. in) . lf warpageis betweenO.O5mm (O.0O2 and 0.2 mm (0.008 in), resurtacecrinder head. a Maximumresurfacelimit is 0.2 mm {0.008 in) basedon a heightof 10Omm {3.94 in). EDGE STRAIGHT PRECISION
ValveGuides
Valve Movement
clearancewith a dial indicator Measurethe guide-to-stem while rocking the stem in the direclion ol normal thrust (wobble methodl. lntako Valve Stem-to4ulde Clearanca: Standrd {New}: 0.04-O.O9 mm (O.OO2-0.OO4 inl 0 16 mm (0.006 in) ServiceLimh: Exhaust Valve Stom'to4uite Clea.ance: (New): 0.1 1 -0.16 mm Standard {0.0O4-0.0O6in) O.24 mm (0.OO9in) SorvicoLimit:
Valve extended 1Omm out from seat
o --\-_z
\ ' =
a lf measurement excedsthe servicelimit, recheck using a new valve. a l{ measurementis now within service limit, reassmbleusing a new valve, limit, recheckusingala lf measurement exceeds still below. then replace valve and ternate method guide, it necessary. NOTE: An ahemate method oJ checking guide to stem clearanceis to subtract the O.D. ol the valve stem, measuredwith a micrometer,from the l.D. of the valve guide, measuredwith an insidemicrometer or ball gauge. inthree placesalongthe valve Takethe measurements stem and three placesinsidethe valve guide. The difference between the largest gulde measureshouldnot ment and the smalleststem measurement exceedthe servicelimit. Measurealong edges,and 3 ways acrosscenter. Cyfndr Hoad Hoight: Strdard lNew): 99.95- 1o0.O5mm (3.935- 3.939 in) lntako Valvo Stom-toukle Clearance: Standqd (Newl: 0.020-0.045 mm SrvicoLimit; in) O.Ogmm (O.OO3
(0.ooo8-o.oo18 in)
Exhaust Valvo Stm-to-Guide Clearancr: Standcd (Newl: o.055-o.08o mm (O.OO22-O'OO31 in) in} 0.1 2 mm {O.OO5 SorvicaLimh:
6-18
- Replacement
1. As illustratedin the removalst6ps of this procedure, use a commercially-available air-impact ddver attachment modified to fit tho diameter of the valve guides. ln most cases, tho same procedurecan be done usingthe ValveGuideOriverand a convntional nammer. 4. Workingtrom the camshaftside.Usethe driverand an air hammer to drive the guide about 2 mm {0.1 in) towards the combustionchamber.This will knock off some of the carbon and make removaleasier.
VALVE GUIDE ORIVER COMMERCIALIY AVAILABLE
GAUTION: o AlwEys woar satsty goggles or a face shiold when uCng tha air hamnr6r. . Hold th6 ak hdnmcf dkecdy in lina wlth iha valv guue to prevni darnaglng th driv$. 5. Turn the headover and drive the guideout toward the camshaftside of head.
RcmovC.nd lrddlrtlon VALVE GUIDE DR|VER. mm 8.5 07742-0Or0100
Selectthe properreplacement guidossnd chillthem in the treezersectionot a refrigerator about an hour. Jor Usea hot plsteor ovento evenlyheattha cylinderhead to 3OOoF(150oC). Monitor the temperaturewith a cookingthermometer. eck )asJ aland
,to alve r. ol eler alve iurenor
c)o
CAUTION: . Oo mt uso a tordr; h may wrp thc hoad. . Do not glt dro he.d hotter rhan 3{X)oF fi5oocl: oxccsslvc hoat may looaan tl|c vdw rcat3. a To avoid brrB. uco heavy gbves whon hsnding tho hoad cyrer h.ad. 6.
lf a valveguidestillwon't move, drillit out with a I mm (5/16 inch)bh, then try again. CAUTION: Ddd gridos only in xtrm6 casas; you couH damago tho cytndcr hoad if ths guilo breaks. Remove new guide(s) the from the refrigerator, one at 8 time, as you needthem. (cont'dl
6-19
Valve Guides
(cont'dl Replacement
7. Slipa 6 mm (0.2 in)steelwashet andthe correctdriver attachmert ovr the end of the driver(Thewasherwill absorbsome ot the impact and xtend the life of the driver).
Reaming
NOTE: For new valve guidesonly. 1. 2. Coat both reamerand valve guide with cutting oil Rotatethe reamerclockwisethe full lengthol the valvs guide bore. Continueto rotatethe reamerclockwisewhile removing it from the bore. Thoroughlywash the guide in detergentand water to removeany cutting residue. Check clesrancewith a valve {page6-181. - Verify that the valve slides in the intake and exhaust vslve guideswithout exertingpressure.
F:-p-qo t t
DROER
3.
6 mm (0.2In) WASHER
ATTACHMENT 5.
4.
Instsllthe new guide(s)trom the camshaftside of the head;drive each one in until the attachmentbottoms on the head.lf you have all sixteenguidesto do, you mav have to reheatthe headone or two more times.
REAMER, VALVEGUIDE
5.5 mft
HANDLE REAMER
OTHAH-PJ7OlOA ot
oTHAH-PJ70l08
Turn teamgrin clockwise diroctiononlY.
VALVEGUIDEDRIVER, 07742-OOlO100
Valve Gulde Insta{od H.iglrt: 5-O.947 inl fntak: 23.75-24.25 mm (O.91 Exhaust: 15.o5- 15.55 mm (0'593-0.61 2 in)
6-20
Valves,ValveSprings and VatveSeals

ValveSpringand ValveSealInstallation Sequence
NOTE: Exhsustand intakevalve salsare NOT intsrchangeable.
@A=----UO|-UEKEEPERS
NOTE: Pl6cs the snd ot valve spring wilh closly wound coitg towa.d tllo cvlinds. he6d.
INTA(EVALVE SEAL (WHTTE SPRINGI Replace.
VALVERETAIT{ER
ALVESPRII{G
VALVEGUIDE SEAII STALTIR KD-2899 COUMERCIAI,I.Y AVAILABT"E t{OlE: Usgsrnall endof tool. lO
EXHAUST VALVESEAL IBLACTSPRIITGI Replace.
I{OTE: Installlhe vatve springcests bofore installinothe vstvg seals.
ValveInstallation
When installingvalves in cylinderhead, coat valve stems with oil before insertinginto vslve guides,and make sure valvesmove up and down smoothlv, Whenvalvesand springsare in place,lightlytap the end of eachvalvestem two or th.ee times with a plasticmalletto ensureproperseatingof valve and valve keepers. NOTE: Tapthe valvestem only alongits axisso you do not bend the stem.
6-21
Seals/Pulley Arms and Camshaft Camshaft/Rocker

lnstallation
CAUTION: . Mako suro that alltoc*rs aro in algffnnt vvith valvas whn to(qukrg rockr assambly bohs' . Vshrs tocknds shodd bo bosonad and 8di$t Ecrows backed ofi beloro in3tal8don' . To Fovont rocker arm as!6mbly trom coming apart' leavo baring crp holding bohs h tho hobs' 1. After wiping down the camshaft and journals in cylinder heod. lubricate both sur(aces and install camshaft. OIL SEAL
SEAL GUTOE o7t{AG - PT0010A o.
CUP INSTALLEF OTNAF_PIOOlOA
afterreassembly. ""m tobes aubrt""a"

Turn the camshaftuntil its keywsy is facing up. (No.1cylinder TDC). Apply liquidgasketto the headmating surfacesof the No. 1 and No. 6 camshaftholders' - Apply liquidgasketto the shadedareas.
No.1
Tiohteneach bolt two turns at a time in the sequence belowto ensurethatthe rockersdo not bind on sh-own the valves. Spcdffod torcuo: 8 mm bolts: 22 N'm (2'2 kg-m, 16 lb-ft) 6 mm bohs: 12 N'm ( l .2 kg-m, 9 lb-ft) 6 mm BOLTS
-B
\J-
lt
v
in Setthe rockerarm assembly place8nd looselyinstall the bolts. - Make sure that the rockerarms are propeflyposltioned on the valve stems. lnstallthe camshaftoil s8al using the speci8ltools as shown.
CAMSHAFT SEAL GUIDE
8 mm BOLTS 7. 8. lnstallthe back cover. Installths key and the camshaftpulleyonto the camshaft, then tighten the retaining bolt to the torque shown. BACKCOVER
CAMSI{AFT PULLEY
o7l{ac-PTOOl0A Applyoil.
Sssl housing sudace should b dry. CAMSHAFT OIL SEAL Apply a light coar oI oil to camshaft and inner lip of seal.
w M
I
INSTALLER SHAFT OTNAF_PTOO2OA
BOLT RETAINING 8 x 1.25 mm 1 2 N m ( ' 1 . 2 k g - m38 N.rn{3.8 kg-m, . 27 tb-ft) I lb-ftl
6-22
Cylinder Head
Installation
Installthe cylinderhead in the reverseorder of removal: FT ,A NOTE: a Always use a new headgasket. . Cylinderheadand engineblock surfacemust be clean. a "UP" mark on camshaftpulleyshouldbe at the too. . Tum the crankshaftso the No. 1 cylinderis at TDC (psge Installthe bolts that securethe intake manifoldto its bracketbut do not tighten them yet,
J.
Positionthe camshaftcorrectly (page6-29).
4. Tighten the cylinder head bolts sequentiallyin three

steps. 1rt stop to.que: 40 N.m (4.0 kg-m, 29 lb-ft) 2nd stop torque: 70 N.m (7.0 kg-m, 51 tb-ft) 3.d ctep to?quo: 10O N.m (10.Okg-m. 72 tb-ft) NOTE: a W recommendusinga beam-type torque wrench. When using a preset-type torque wrench, be sure to tighten slowly and not to overtighten. a lf a boh makesany noisewhile you are torquingit, loosenthe boh and retightenit from the I st steo.
6-28t.
o Cleanthe oil contrclorifice before installino. \ nce ,on 1. Cylinderhead dowel pins and oil control orifice must be aligned.
DOWEL PIN CYLINDER HEAD GASKET Replace.
ooml P {
a/
OILCONTROL ORIFICE Clean.
O-RING Replace.
CYLI'{DER HEADBOLTS TOROUE SEOUENCE
CYTJI{DER 12 r 1.25mm
lOO N.m ('lO.Okg-m, 72 tb-ftt Apply clsan engineoil to bolt threads and under bott heads,
(cont'd)
6-23
Cylinder Head
(cont'd) lnstallation
the 7 . lnstall the exhaust mdtifold and tighten "ri"""roo innel nut' a Always use 8 now exhaust manifoldgasket' nuts n a putt"a in 2 or 3 steps' beginning with the
the nuts In-a and " 5. Installthe intakemanifold tighten with the in 2 ot 3 steps' beginning "t't"""too p.orn innernuts. o Alwavsusea newintakemanifddgasket'
GASXET Replace.
thn instsll the 8 . lnstall th exhaust manifold bracket'
pip",q and the bracket, and then install the i"h"tt covf.
GASKET Replace.
8x l'25mm 32Nm13.2kg-m. 23 lb-ft) Replace.
MANIFOLD
8 x 1 . 2 5m m 22 N.m {2.2 kg-m' 16 rb-ftl
I x 1.25mm 22 N.m(2 2 kg-m'

16 tb-ft)
1Ox 1.25mm 45 N.m(4.5kg-m, 33 tb-ft) and the lnstallthe heat insulatorto the cylinderhead block.
GASKET Rplaco. 6r1.Omm 1ON.m(1.0kg-m, 7 tb-ft)
10 x 1.25 mm 55 N.m {5.5 kg-m. 40 lb-ft) Replace,
A PIPE EXHAUST
6-24
TimingBelt and TimingBalancer Belt

lllustrated Index
NOTE:
o Referto page 6-28 tor positioningcrankshaftand pulley beforeinstallingtiming belt. o Beforeremoving,mark directionof rotation.
ADJUSTING NUT POWER STEERING BELT 45 N.m(4.5kg-m, Adjustment, section 17 33 rb-ft) 6x l.Omm 12Nm(1.2kg-m, I tb-ft) \ \
UPPER COVER RUBBER SEALS Replace whendamaged or detsrioratod.

CAP NUT
LOWER COVER 6 x l . O m m Remove five 1 0 N . m ( 1 . 0k g - m , the 7 tb-ft) bolts.
CYLINDER HEAD COVER
::aNm(22.0ks-m, :3 bft) \:ot engineoil to the :crr threads,but not u '- surfacethat r.--ts the washet. .uGAELT .lo.ction, page 6-26 Sustmnt, Page6-26 :,.dacement, pago 6-29
ltrcnNartia
l-
Adjustment, section 23
CRAr{KSHAFT .^ UAMSHAFT WIIIV PYLEY aelr i"-*" "n" oir.
6r l.Omm 12 N.m {1.2 kg-m,_,glb-tr) ,.'
SEALS Replace when damaged or dgtrioroled.
BELT TE SIOITERS
Remove any oil. SPRING
6r 1.Omm r 2 N . m( 1 . 2 s - m . k I rb,ft)
SPRII{G Installwith concave surfacefacing in. Femove any oil.
AELT ADJUSTING BOLT 68 N.m(6.8ks-m, 49lb-ft)
8 x 1.25 mm 38 N.m (3.8 kg-m,27 tb-ft)
TIMII{G AALA CEREELT Inspection,page 6-27
6-25
TimingBelt
Inspection
the Disconnect altelnatorterminaland the connector. from the cylinder then removethe enginewire harness head cover. head cover' Removethe cYlinder Removethe upper cover. 4. Inspect the timing belt for cracks and oil or coolant soaking. NOTE: . Replace belt if oil or coolant soaked. the a Removeany oil or solventthat gets on the belt'
TensionAdiustment
CAUTION: AhtvavsadFst timing boh tensbn with th6 ongin6 cold. NOTE: to o The tensioneris springloaded applypropertens'onto the belt sutomaticsllYafter making the lollowing adjustment. a Always rotate the crankshaftcounterclockwisewhen viewed lrom the pulleyside. Rotatingit clockwisemay result in improperadlustmentof the belt tension the belt beforeadiusting belt . Inspectthe timing balancer tension. . Do not loosenthe adjustingnut morethan one full turn' 1. terminaland the connector' the Disconnect alternator flom the cylinder then removetheenginewire harness headcover. Removethe cylinderheadcover'
a 4.
Inspectthis arealor wear.
Set the No. 1 piston at TDC (page6-28). Loosenthe adiustingnut 2/3-1 turn, then tighten it'
NUT ADJUSTING 33lb-ft) 45 N.m(4.5kg-m,
Rotate the crankshaft counterclockwise3-teeth on nutto the the camshaftpulley.then reloosen adiusting createtensionon the timing belt.
5,
to the After inspecting,retorque crankshaftpulleybolt N.m (22.Oks-m, 159 lb-ftl' 220
6.
Tightenthe adjustingnut. After sdiusting,retorquethe crankshaftpulleybolt to 22ON.m (22.0 ks-m, 159 lb-ft).
TimingBalancer Belt
Inspection
1. Disconnect altematorterminaland the connector, the then removethe enginewire harnesstromthe cylinder headcover. Removethe cylinderheadcover Removethe uppercover. Removethe crankshaftpulley. Removethe lower cover, Installthe crankshaftpulley. Inspectthe timing balancerbelt for c.acks and oil or coolantsoaking. NOTE: o Replace belt if oil or coolant soaked. the a Removeany oil or solventthat gets on the belt. Inspect area wear. this tor
2. 3. 4. 5, 6. 7.
pulley Botate andrnspect belt. After inspecting,retorque crankshaftpulleybolt to the 22O N'm (22.Oks-m, 159 tb-ftl. NOTE: Refer to page 6-32 tor timing batancerbelt tension adjustment.
6-27
Timing Belt
TimingBelt BeforeInstalling Crankshaft Positioning
NOTE: . Installthe timing belt with the No. 1 piston at TDC. . After installingretorquethe crankshaftpulley bolt to 220 N.m (22.0 kg-m, 159 lb-ft).
CAMSHAFTTDC POSITION:
TDC POSITIO]T: CRANKSHAFT MANUAL TRANSMISSION: FLYWHEEL HOLE INSPECTIOI{
,,UP"MARK
AUTOMANC TRANSMISSION:
DRIVEPTATE
INSPECNO HOLE
TOC MARK (WHITEI
POINTERS
ot{ BLocK
NOTE: When turning the crankshaft with a socket wrench, installthe crankshaftpulleyand rhe pulleybolt'
6-28
TimingBeltand TimingBalancer Belt

. Replacement
CAUTION: Inspoct tho walor pump whon radachg th6 timing blt (Pag610-12) NOTE: Turn the crankshaftso that the No. 1 piston is at TDC (page6-28). I . Removethe splashshield. 3. Removethe mounting bolts, nuts and P/S pump belt from the power steering(P/S)pump. NOTE: a Do not disconnectthe PiS pipe and hose. . After installing,adiustthe tensionof the P/Spump belt {seesection171. POWEB STEERING PUMP MOUNTING BO(TS LOCKNUT 1 5N . m{ 1 . 5 g - m , k 11 tb-ft)
8x1.25mm SPLASH SHIELD
22 N.m 12.2kg-m, 1E rb-ftl
P/SPUMP AELT
.,
Disconnectthe connector. then remove the cruise control actuator. NOTE: a Do not disconnectthe control cable. a Takecarenot to bendthe cablewhen removingthe actuator.Always replace kinkedcablewith a new a one.
4 . Disconnect alternator the terminaland the connector, then removetheenginewire harness from the cvlinder head cover. Loosenthe alternatormountingbolt/nut and adjusting bolt, then rernovethe altematorbelt. NOTE: After installing, adjustthe tensionof the alternator bett lsee section 231.
MOUNTIM! EOLT 1 Ox 1 . 2 5m m 45Nm{4.5kg-m, 33 tb-fr)
CRUISE ACTUATOR
6x1.Omm 10 t{.m {1.0 kg-m, 7 tb-ttl
ALTENNATOR AELT
MOUI{TINGNUT 8 x 1.25 mm 22 N.m (2.2 kg-m, 16lFft) (cont'd)
6-29
Belt TimingBeltand TimingBalancer

(cont'd) Replacement
Removethe cylinderheadcover. for Remove sideenginemount bracketB {standard the some typesl. Removeth uppercover. Removethe side enginemount. I 1. Removethe pulleybolt and the crankshaftpulley Remove the two rearboltsfrom the centerbeamto allow to the engineto drop down and give clearance remove the lower cover. 12. Removethe rubbsr seal aound the adiustingnut. Do not loosn the adiusting nut. 13. Removethe lower cover'
'10.Removethe dipstick and the pipe.
6 r 'l,Omm 12 N m ('t.2 kg-m, 12 r, 1,25''un 9 rb-ft) 55 N.m (5.5kgfl, 40 lb-ft|
DIPSTICK/PIPE
HEAD CYUNDER COVER
e
e
RUBEER SEALS
l2 x 1,25 mm 65 N.m (6.5 kg-m, SIDE 47 tb-ft) MOUNT Rplacewhn damagdor deterioratsd.
UPPR COVER
6xl.Omft 1 2 N . m ( 1 . 2k g - m , I rb-ft)
RUBBER SEALS when Replace damagedor deterior6ted.
SEAL RUEBER
whsn damaged Replace or detorioratod. AOJUSTINGNUT 1 0 x 1 . 2 5m m 45 N.m (4.5 kg-m, 33 lb-ft)
PULTfYEOLT 14 x 1.25mm
220 N.m 122.0ksn, 159 lb-ftl 6xt.Omm Apply 6n9ineoil to th boli ihraads, n LLEY 12 N m (1.2kg-m, but not to the sudace that Removs oil. I lb-ft) any contads the washer.
TIMING BALAITCEFBELT Inspection,Page6-27
6-30
e-
'1 4. Lockthe timing belt adjusterarm in placeby installing one of the 6 x 1.0 mm lower cover mounting bolts, 15. Loosenthe timing belt adjusringnut. push on the pu! ley to removetension trom the timing balancerbelt, then tighten the adjustingnut. 16. Removethe timing balancerbelt. NOTE: It you are removingonly the timing balancer belt, goto step 22. lf you areremovingboth belts,con, tinue with this procedure.
17. Loosen 6 x 1.0 mm lock bolt andthe adjustingnut. the Pushon the timing belt adjusterpulleyto removetension from the belt, then tighten the adiustingnut. 18. Removethe timing belt. 19, Installthe timing belt in the reverseorderof removal. Adjust the valve clesrances(page6-34) - Betoreinstalling riming blt, the crankshaftand the camshaft pulleysas shown on page 6-28. 2O. Perform the timing belt tension adjustment lpage 6-26). 21 . Tightenthe 6 x 1.0 mm bolr to tockthe timing belt adJusterarm'
)o
TIMINGBELT ADJUSTER ARM
aDJUsnNGNUT 45 N.m14.5 kg-m, 33lb-tt)
DRIVE PULLEY
(cont'd)
6-31
Timing Belt and Timing BalancerBelt

Replacement(cont'dl
22. Make surethe crankshaftis positionedwith the No 1 piston at TDC. after pulleywith 23. Alignthe grooveon the front balancer the pointeron the oil pump housingas shown, 24. Align the rear balancershaft pulleyby using 6 x 1OO mm bolt or equivalentas an alignmenttool. Scribea line 74 mm (2.9 in) from the end ol the bolt. holeto the scribed Inserttheboh intothe maintenance line. 27. Turn the crankshaft pullev about one turn counterclockwise,then tighten the adjustingnuit to the speci{ied torque. NOTE: Both belt adiusters are spring-loaded to properly tensionthe behs.Do not spply any extm pressure to the pulleysor tensionerswhile performingthe adiustment,
SHAFT REARBALANCER
25. Loosenthe adjusting nut and verity that the timing

balancerbelt adjustermovesfreely. Installthe timing balancerbelt. Removethe 6 x 1OO mm bolt from the rear balancershaft.
74 mm 12.9in) 6 x 10O mm BOLT
MAII{TENANCE HOLE WASHER Replace. 12 mm SEAU G BOLT 30 N.m(3.0 kq-tn,22 lb-ftl the NOTE:Tighten boltafter installingthe belt. AI'JUSTII{GNUT BOLT 6 x 100 1'|m
Align the groove of the front driven pulley with the pointer on the oil pump housing.
BELT TIMINGBALA'TCER DRIVEPULLEY Set the crankshaftat TDC.
6-32
24. Removethe 6 x 1.Omm bolt from the timing belt adJusterarm.
32. Installthe upper cover. 33. Installthe crankshaftpulley.
29. Removethe crankshaftpultey. 30. Installthe lower cover. 3 1 .Installa rubberseal aroundthe adjustingnut. Do not
loosenthe nut. Specifiodtorqus: 220 N.m {22.Okg-m. 159 tb-ft}
34. Coat the threads and seatingtace oJ the putley bolt

with engine oil. Install and tighten to the specified rorque.
UPPER COVER
6r1.0mm 12 N.m(1.2kg-m, lb-ftl I
ADJUSTING I{UT 10x1.25r n

45 N.m (4.5 kg-m, 33 rb-ft)
SEAL
Replgcswhon damsged or dsterioratsd.
PULLEY BOLT 1 4x 1 . 2 5 m m
22O N.m {22.0 kg-m, 159 lb-ft) Apply engine oilto the bolt threads. 6x1.0mm 12 N.m {1.2 kg-m,9 lb'ft}
6-33
Valve Clearance
Adiustment
NOTE: . Valvesshouldbe adjustedcold when the cylinderhead is temoerature lessthan loOoF {38oC). . After adiusting,retorquethe crankshaftpulley bolt to 22ON.m (22.0 kg-m, 159 lb-ft). 1. headcover. the Remove cvlinder INTAKE Adjust valves on No. 1 cylinder.
in} mm Intake:0.26 {o.o1o 1333fll13.ffi!lll in) o.30 {0.o12 13.33ffi13ffi9ili Exhaut: mm

Loosenlocknut and turn adjustmentscrew untilJeeler gaugeslidesbackandforth with slightamountofdrag.
N o . 4 N o . 3 N o , 2 N o .1
N o . 4 N o . 3 N o . 2 N o .1
EXHAUST
LOCKlrlUTTxO.T5mm 14lb-ft) 20 N.m(2.0kg-m, oil. Applyengine GAUGE FEELER
2.
"UP" mark on the camshaft Set No. 1 piston at TDC. pulleyshouldbe at top, and TDC grooveson the camshaft pulleyshould alignwith cylindrhad surface.
5.
adagain.Repeat Tightenlocknut8nd checkclearance justment if necessary.
Numbor1 riston at TDC:
@-
\
) l-24
Ut\-/
6-34
6.
(Camshaft Rotatecrankshaft180o counterclockwise pulley turns 9Oo). The "UP" mark should be at exhaust side, Adjust valveson No. 3 cylinder.
8.
Rotatecrankshat180o counterclockwise bring to No. 2 pistonto TDC. The "UP" mark shoutdbe at intske side. Adjust valves on No. 2 cylinder.
Number 3 Piston at TDC:
Number 2 Pbton at TDC:
,,UP" MARK
7,
Rotatecrankshaft180o counterclockwise bring to No.4 piston to TDC. Both TDC g.ooves are once again visible.Adjust valves on No. 4 cylinder.
Numbor 4 Piston at TDC:
6-35
CylinderHead/Valve Train
(H23A1engane)
Special Tools .........6-38 lllustratod lndex ........................... 6-39 Valve Seals Replacement (Cylinder head removalnot requiredl .............6-41 Cylinder Head Romoval ............. 6-43 Warpage ............6-52 Installation .........6-56 Camshaft Pulleys Removal .............6-48 Camshafts lnspection ..........6-48 Valves, Valve Springs and Valve Seala Removal ............. 6-50 Valve Spring and Valve Seal Installation Sequence .............. 6-55 Valv Installation ....................... 6-55 Valve Seats Recondltioning ..... 6-51
Valve Guldes ValveMovement ....................... 6-52 Replacernent .......6-53 Reaming ............. 6-54 RockerArms/Camehafte and Camrhaft Soals/Pulleys lnstallation .........6-57 Tlmlng Belt and Timing Balancer Belt lllustratod Index ........................ 6-59 Replacement .......6-63 Timing Belt Inspoctlon ..........6-60 Tension Adjustment ................... 6-60 Positionlng CrankshaftBefore Installing Tlming Belt .............. 6-62 Timing Balancer Beh Inspoction ..........6-61 Valve Clearance Adjustment .........6-68
SpecialTools
Ret.l{o.
Too\ l{urnbor 07GAD-PH70100 o7757-PJ1010A 07942-6570100 or O7984-657O1OC 07984-657010D
O6r,cdgl0tr\ Valve Guide Sal lnstall6] Valve Spring Compressor Attachment Valve Guide Driver,6.6 mm Valve Guide Reamer,6.6 mm
qq
1 I 1 1
Prq. Rd.r.nca 6-55 6-50 6-53,54 6-54
@ @ @
t
o
--fl'------------
6-38
lllustratedIndex
CAUTION: To avoid darnaglngtho cylinder head, wait until tho engino coolant tomporature drop6 blow 100oF (38ocl betoro romoving it. NOTE: Use new O-ringsand gasketswhen reassembling. 6 r 1 0m m 10 N'm {1.0 kg-m,7 lb-ftl
6 r 1 . 0m m 10 N..n l1.O kg-m.7 lb-ft}
WASHER
RUBBEB SEAIS
Replace wlrsn or doterioratd.
8 x 1.25mrn 22 .m (2.2 lg-m, lE lb-ttl 6rlOmm 12 N.m (1.2 kg-m,9 lb-ttl
DOWEL PIII
8 x 1 . 2 5m m 18N.ft11.a
13 lb-frl
ui ffiHnfl ,&V, W#
L!, e
I fr n-'-'' flE uflE
6x10mm lO N.m (1.2 kg-m,7 lb-ft}
/tt{TAKE CAMSHAFT HOLDER
8-
iih qub
o
|l{TAKE CAMSHAFT roction,pag66-48 SEALS psge 6-57 Instsllation, Roplacs.

CAMSHAFT PULLEYS Removal, pag6 6-48 Installation, page 6-57
HEX
DISTRIBUTOR EXHAUST CAMSHAFT

ROCKERARM ADJUSTING SCREW Adjustment, page 6-68 LOCKT{UT 27 N.n 12.7 kg-m, 20 lb-ft)
8 x 1.25mm 38 N.m (3.4 ks-m. 27 lb-ftl tor ntanual p.r-lllgnriant ot caftah6tt
{cont'd)
6-39
lllustratedIndex
(cont'd)
CAUTION: In handllng a motal gasket. tako car6 not to lold it or damage tho contact surtaco of tho gsskt. NOTE: Cleanthe oil control orifice beJoreinstalling.
'11
clean all the pans in solvent, dry them and apply lubricantto any contact parts, Priorto reassembling,
INTAKE VALVE GUIDE Inspction, page 6-52 Replacement,page 6-53 pag 6-54 Rsaming,
VALVE
SPRINGRET
HEADBOLT 12 x 1.26 mrn lOO N.m (10.0 ks-m, 72 lb-ft) Apply cleanongine to oil threadsand underthg bolt heads.
EXHAUSTVALVE EXHAUSTVALVESEAL Rsplaca. SEAT VALVESPRING VALVE EXHAUST
nfl
VALVEKEEPERS RETAINER SPEING A(E VAIV SPNI G I]{TAXEVALVE SEAL

Replacamnt, psgs 6-41 and 50
ALVESPRI G SEAT EIID PIVOT EOLTS 64 N'm 16.4kg-m,46 lb-ftl

CYLINDERHEAD Rmoval. page 6-43 Reconditioningvalve seat, pago 6-51 Warpage, page 6-52 Installation, pag 6-56 CYLINDERHEAD GASKET IMETAL GASKET} Roplace. OOWEL PIN OIL CONTROL ORIFICE Clean. O-RING Feplace.
BACK COVER MOUNT ENGII{E B BRACKET 1 0 r 1 . 2 5m m
45 N.m (4.5 kg-m,
33 rb-ft) 8 x 1 . 2 5m m 22 N.m {2.2 kg-m, 16 lb-ftl INTAKEVALVE Replacemont,

Dimonsions, pag 6-50 Reconditioningvslve sat, pag 6-5'l Adiustment. paga 6-68 TIMING BELT Inspection/Adiristment,page R6placoment.page 6-63
ADJUSTIT{G 10 x '1.25mm 45 N.m (4.5 kg-m,
33 tb-ft) Loosen, do not remove. but
6-40
Valve Seals
Replacement head removalnot requiredl {Cylinder
NOTE: Cylinder head removal is not required in this procdure. Usethe procedure shown below applies when usingthe in-car valve spring compressor(Snap-on YA8845). Alway waar approved oye protcction l@ when using tho in-car valvo spring compas{rr. 1. Turn the crankshaftso that the No. 1 and the No. 4 Distonsare at TDC. 2. 3. Removethe cvlinderhead cover. Loosen and remove timing belt from the camshaft pulleys. Remove the distributor. Removethe camshsft holder bolts, then removethe camshaft holders, the camshafts, and the rocker arms. Usingthe 6 mm boltssupplied with the tool, mount the two uprights to the cylinder as shown. Insert the cross shaft through the bottom holes ol the two uprights. Intako Valva Sorb: 8. Selectthe 1-1l18 in. diameter longcompressor attachment and fasten the attachment to the hole of the lever arm with the speed pin supplied.
9 . Insert an air sdaptor into the spark plug hole. Pump

air into the cylinder to keep the valve closed while compressing springs and removing the valve keeoers.
1 0 . Positionthe lever arm under the cross shalt so the

lever is perpendicular the shaft and the compresto sor attachment rests on top of the retainer for the spring boing comp.essed, Use the tront position slot on the lever as shown. NOTE: Put shop towels over the oil passagesto prevent ths valve keepers from lalling into the cvlinderhead.
4. 5.
OIL PASSAGES
OIL PASSAGES
(cont'd)
6-41
Valve Seals
1 1.
(cont'dl (Cylinder head removalnot required) Replacement

Usinga downward motion on the leverarm, compressthe valve spling and removethe keepersfiom ths valve stem. Slowly releasepressureon the spnng. Repeatstep 1 1 for the other intakevalve in that cvlinder. Removethe valve seals (page 6-50). Replace the valve seals (page6-55). Installthe springs,the retainers8nd the keepers in reverse order of removal.
1 8 . Using a downward motion on the lever arm, compressthe valve spring and removethe keepersfrom the valve stem. Slowly release pressurs on the spflng.
12.
1 9 . Repeatstep 18 tor the othor exhaust valve in that

cylinder.
13. 14. 15.
20. Removethe valve sals (page 6-50). 2 1 . Replacethe valve ssals (page 6-55). 2 2 . Install the springs, the retainers and the keepers
in reverse order of removal.
Exhaust Valvo Soals: 16. Slectthe 7/8 in. diametercompressorattachmnt 8nd tasten the attachment to the No. 5 hole of the lever arm with the speed pin. 17. Positionthe lever arm under the cross shaft so it is perpendiculsrto the shaft and the compressor attachment rests on top of the retainer for the spring being comprcssed. Use the front position slot on the lever as shown. to NOTE: Put shop towels over the oil passages prevent the valve keepers from Jalling into the cvlinderhead.
23. Repat stps 8 to 22 for the other cylinders.
ll
6-42
Cylinder Head
Removal
Enginer8movalis not requiredJor this procedure.
l.
Disconnect the negative terminal trom the battery.
2 . Drainthe enginecoolant (seesection 1O).

a Mako sure iscks and safoty stands ars placad propedy and hoist bfacksG era attachod to corract positions on ths oingino. a Mako suro tho car will not roll oft stands and fall while you ar6 working undr it. CAUTION: a Uso fendor covors to avoid damaging paintod surtaces. a Unspocifiod items ara common. a Unplug tlF widng connectoB caroft.fy while hol+ ing th6 connocto? ponion to avoid damags, a Ma.k 8t wHng and hoss3 to rvdd rrisconncctlon. Also, bo sur6 that thsy do not contact othor wiring oi hosos o. intorfats with other parts. a To avoid damaging the cylindar herd, w8it untll tho engine coolant tmporaturo &opr bclow 100oF (38ocl befoio loosanlng the rotllnlng bohs. NOTE: a Inspect the timing belt befo.e removing the cvlinder head. a Turn the crankshaftpulleyso that tho No. 1 piston is at top dead csnter (page 6-62). a Mark 8ll emission hoses belore disconnecting them. a The radio may have a coded theft protection circuit. Be sure to get the customer's code number before. - Disconnecting the battery. - Removing the No. 43 (lOAl fuse. (ln the under-hood fuse/relav boxl - Removingthe radio. After service. reconnect Dowe. to th radio and turn it on. Whenthe word "COOE" is displayed, enter the customer's 5-digit code to restore radio ooeration. a Removethe radiatorcap to speed draining.
3 . Relieve fuel pressure, the

Do not smoko whilo workino on fuel @ aystem, koop open flamo or spark arlay from work area, Draln fuol only into an approved containar. 4.
E
Removethe intske air duct. Removethe fuel teed hose and evaporativeemission (EVAP) control canister hose from the intake manifold.
6.
Removethe throttle control cabletrom the throttle body (A/T onlyl. NOTE: a Take care not to bendthe cable when removing it. Always replaceany kinkedcablewith a new one. a Adiust the throttle cable when installing(seesect i o n 11 1 .
6 x l.O mm 12 .ft 11.2kg-m, 9lb-ftl THROTTLECAALE
THROTTLECONTROL CABLE LOCKNUT
(cont'd)
6-43
Head Cylinder
(cont'd) Removal
7. the Remove tuel feed hose,the tuel returnhoseand the brake boostervacuum hose. FUELFEEDHOSE 9. Rmoveth engine ground cable Jtom th cylinder head cover.
10, Disconnect the alternator terminal and connector, then remove the engine wire harness from tho cvlindsr head cover. WIRE EI{GINE HARNESS
WASHER Replace.
6r
8 t{.m (0.8 kg-m, 6 lb-ftl
6x l.Orr|m 10 'm (1.0 kg-m,7 lb-ftl
the lP/S)pump belt and 11. Removo powsr steering pump. the a Do not disconnect P/S hosos.
the lollowingenginewire hsrnessconnecRemove tors and clamps ftom the cylindr head and the intake manifold: o a a a a a a o a a a a a a a a a Four fuel injectorconnectors (lAT) sensorconnector lntake air temDerature ldle air control (lACl valve connector Throttle position (TP) sensor connector Exhaust g8s recirculstion (EGR)valve lift sensor connecror Groundcableterminals (ECT)switch B concoolanttemperature Engine necror Heatedoxygen sensor (HO2S)connectot ECT sensor connector ECT gauge sendingunit connector lgnition control module llCMl connector sensorconnector CKP/ToC/CYP VehiclesDeedsensor (VSS)connector lgnition coil connector Intake air bypass solenoid valve connsctor ECT switch A connector Knock sensorconnector 8 x 1.25mm 22 .|n (2.2 kg-m, 16 tb-ft1
15 N.m ll.5 *g-m, I I lb-ftl
6-44
12. Removethe ignitioncoil.
16. Remove the intake manifold bracket and intake manitold.
IGNITION COIL
*8 x 1.25lnm *6x LOmm 22 N.m 12.2 ke-m, CO ECTOR 12 rr| {1.2 kgn, 16 tb-trl 9 tb-ft1 13. Remove the emission vacuum hoses and water bypass hoses from the intake manifold asemblv. 14. Removethe radiatorupper hose and heater hose from the cvlinderhead. 1 5. Removethe water bypass hose and the thermostst housing. 17. Removethe selt-lockingnuts and disconnectthe ex_ haust manitold8nd exhaustpipe A. 18. Removethe heat insulator(carsequippedwith A/Cl, exhaustmanifoldbracketand exhau$ manifold.
6 x 1.0mm 12 tt.m 11.2 kg_m,9 tb-ft| *: CORNOSION RESISTANTBOLT EXHAUST PIPEA
HEAT INSULATOR {carsoquippedwith A/C) (cont'd)
6-45
CylinderHead
Removal {cont'd)
1 9 . Remove the PCV hose, then remove the cylinder head cover. 24. Remove the camshatt Pullsys. NOTE: To set the camshafts at TDC for No. 1 alignthe holesin the camshaftswith thg cylinder, holesin the No. 1 camshaftholdersand insert 5.O mm oin punches.
20. Removethe middlecover. 2 1 . Loosenthe adjustingnut 180".

Pushthe tensionerto releasetension from the timing belt, then retightenthe adjustingnut.
8 r 1.25mm 38 .m 13.8kg{r, 27 tb-ft) 25. Loosen the rocker arm adiusting screws, then remove the camshaft holders and camshafts. 23, pulleys. Remove timing belttrom the camshaJt the
ADJUSTING SCREWS
CAUTION: Do not crimp or bond tho timing belt more than 90 o ol lsss than 25 mm ( l inl in diametor.
G4z
No Good ADJUSTING SCREWS
6-46
Removethe side engine mount bracket B and back covea.
NOTE: Separate the cvlinderheadfrom the block with a flat tip screwdriveras shown.
ENGII{E MOUI{T SRACKET B
10 r 1.25mm
45 N.m (4,5 kg-m, 33 rb-ft}
BRACKET
8 x 1 . 2 5m m 22 N.m 12.2kg-m, 16 tb-ftl
27. Removethe cylinderhead bolts, then removethe cylinderhead. CAUTION: To prevont vvalpaga,unscrlw tho bohr in sequenc 1/3 turn at a timo; rapaat until all bohr arg loosaned, CYLINOER HEAD BOLT LOOSEI{INGSEOUEI{CE
6-47
Gamshaft Pulleys
Removal
"UP" turn the pulleyuntil the 1. To easereassembly, marks face up, and the front timing marks are aligned with the marks on the Dullevs.
Camshafts
Inspection
NOTE: Do not totate camshaft during inspection' 1. Removethe rocker arms. NOTE: Rockerarms musi be installedin the same oosition if reused.
"UP" m6rks
2.
Put the camshaftsand the camshaftholderson the cylinder head, then tighten the bolts to the specified toroue. Specifled torque: Exc8pt Intake @, @. Exhaust @, @: l0 N'm (1'0 kg'm, 7 lb'ft| Intake @, @. Exhaust @' @: 12 N'm (1.2 kg-m, 9 lb-ft1 TIGHTEI{II{G SEOUECE
Align the marks on the pulleys.
Removethe timing belt, Removethepulleybolts,then removethe camshaft pulleys. NOTE: To set the camshafts at TDC for No. 1 cylinder,alignthe holesin the camshsftswith the holes in the No. 1 camshaftholdersand insert 5 0 mm pin punches.
@ @
t ,
PULLEYBOLTS
6-48
I
?
Seatcamshaftsby pushing them toward distributor end of cylinderhead. Zero dial indicatoragainstend of camshsft, then push camshaft back and forth, and readthe end play. Camshaft End Play: Standard(New): 0.O5-O.15 mm (0.0O2-O.006 in) Sorvice Limit: 0.5 mm {0.02 in}
7.
lf camshaft-to-holder oilclearancsis out oftolerance: a And th6 camshaft has alreadybeen replaced,you must r6placgthe cylinderhead. r lf camshaft has not been replaced,first check total runout with th6 camshaft supported on Vblocks. Crmrheft Total Runout: Standard (Nowl: 0.03 mm (O.0Ol Inl max. Sorvlce Llmh: 0.06 mm (0.002 Inl
4.
Rotate camshaft while msssuring
5.
Removethe camshaft holder bolts from the cylinder head. a LiJt camshaft out of cylinder head, wipe clean, then inpsect lift ramps,/Replac camshaft if lobes are pitted, scored, ot excessively worn, a Clean the camshaft beadng surfaces in the cylinderhead.then set csmshaft back in place. a Insert plastigage strip acrosseach journsl. a Install the camshaJt holders and torque bolts to the valuesand in the sequence shown on page 6-48.
- lf the total runout of the camshsft is within tolerance, replace the cylinder head. - lf the total runout is out ot tolerance, replacethe camshaft and recheck. lf the oil clearanceis still out of tolerance,replacethe cylinderhead. 8. Measurecamshaft lobe height. Intak. Standlrd: 33.661 mm (1.3252 inl Exhlurt Stlnda.d: 33.725 mm (1.3278 Inl
6.
Measure widest portion ot plastigage on each journal. Camshsfi-to-Holdor Oil Cloaiance: Standard(Now): O.O5O-0.089 mm (0.0020-O.OO35 inl SorvicaLimit: O.15 mm (0.0O6inl Exhaust No. 5 Jounal: Standard(Newl: O.lOO-0.139 mm {0.0039-0.OO55 inl Servics Limit: 0.20 mm (O.OOB inl
Inspect this are for wear.
6-49
Valves,Valve Springsand Valve Seals

Removal
NOTE: ldentify valves and valve springs as they are remov6d so that ach item can be reinstalledin its original position. 1. Tap ach valve stem with a plastic mallet to loosen valve keepers before installing the spring comDressor. Compress springand Installthespling compressor. remove valve keeper. 4. Removeth valve se8l.
2.
COMPRESSOR VALVESPFING AVAILABLE COMMERCALLY
VALVESPRING COMPRESSOR ATTACHMENT 07757-PJIOIOA
3.
Installthe sDecial tools as shown, lntake Valvo Dlncndons A Standard (Nowl: 33.90-34.10 mm
VALVE GUIDESEALRETVIOVER LISLE P/N57900 or KD335o AVAILABLE COMMERCIALLY
(1.335- 1.343inl mm B Standard l]{.wl: 102.6O-1O2.8O (4.035-4.047 lnl C Standard {rw}: 6.58O-6.590 mm inl 10.2691-O.2594 Inl 6.55 mm 10.258 C Sorvic. Llmh: D StandErd ( !rv): O . 8 5 -1 . 1 5m m (O.O33-o.o45 Inl inl 0.65 mm (O.O26 D Servic Llmh:
Exhoust Valvo Dlmcnalonr A Standsrd(Newl: 28.9o-29.10 mm
( 1. 1 3 8 - 1 . 1 6 1I n l (3.992-4.oO4inl
m B stand.rd lt{cw}: 1 0 1 . 4 0 -1 O 1 . 7 0 m
C StandErd lt{ewl: 6.550-6.560 mm
Inl 10.2579*O.2583 inl 6.52 mm 10.257 C Servico Lknh: m D Standard (Nrw): 1 . 0 5 - ' 1 . 3 5 m
D Sorvico Lirit:
(O.O41-0.O53 In) inl o.85 rnm (O.O33
6-50
Valve Seats
Reconditioning
Renew the valve seats in the cylinder head using a valve seat cutter. NOTE: lf guidesare worn (page6-52), replacethem (page6-531betorecutting the valve seats. After resurfacing the seat, inspect Jor even valv seating: Apply PrussianBlue compound to the valve face, and insen valv in originallocation in the he8d, then lift it and snapit closedagainstthe seatseveral times. ACTUAL SEAN G SURFACE
VALVE SEAT o
PRUSSIANBLUE COMPOUI{D
K@"8
Carefully cut a 45o se8t. removing only enough materialto ensurea smooth and concentricseat. Bevelthe upper edge of the seat whh the 3Oo cutter and the lowsr edg of the seat with the 600 cutter, Check width of sest and adjustaccordingly. Make one more very ligt|t pass whh tha 45o cutte, to removeany possible burrscaussdby the other cufters. VCv. Sct Wld$ (ht!k lnd.xhaltl: Standlrd: 1.25- 1.55 mm (O.O49-O.061 int Sendcellmh: 2.0O mm (0.079 in)
The actualvslve seatingsudace, as shown by the blue compound,should bo centeredon the seat. a lf it is too high (closer to the valv6 stem), you must make a second cut with the 600 cuttef to move it down, then onB more cut with the 45o cutter to rgstore saat width. a ]f it is too low (closeto th6 valve edge), you must make a second cut with the 30o cutter to move it up, then one more cut with the 45o cutter to restore seat width. NOTE: The tinal cut shoutdalways be made wirh the 45o cutter. Insen intake and exhaust valves in the head and measurovalve stem installedheight. Intake Valve St.m Inliall.d Hright: Standard (l{cwl: 39.365-39.835 mm (1.5498- 1.5683 inl Scrvlce Limlt: 4O.Oa5 (1.5781 tnl Exhau* Valve Stom lnstallcd Hdght: Standard(Now): 39.165-39.635 mm 1 1 . 5 4 1 9 -1 . 5 6 0 4i n l S.rvlce Limit: 39.885 mm ('1.5703inl
) VALVESTEM INSTALLED HEIGHT
8.
It valve stem installedheight is over the servicelimit, replacevalve and recheck.lf still ovef the service limit, replacecylinderhead;the valve seat in the head is too deeo.
6-51
CylinderHead
Warpage
oil NOTE: lf camshaft-to-holder clearances(page 649) are not within specitication,the cylinder head cannot be resurfaced. oil lf camshaft-to-holder clearancesare within specifications, check the cylinderheadlor warpage . lf warpageis lessthan0'05 mm (0.0O2in)cylinderhead resurfacingis not requard . lf wsrpage is btw6n O.05 mm {0.0O2 in) 8nd 0.2 mm (0.008 in), rosurfacecylinderhead. in) . Maximumresurface limit is 0.2 mm (0.OO8 basedon a heightof 132.o mm (5.20 in)
Valve Guides
Valve Movement
clearancewith dial indicstor Measurethe guide-to-stem while rocking the stem in the direction of normsl thrust (wobblemethod). lntsko Vdvo St.m-to{iukla Clearance: Standard(New): 0.04-0' 10 mm {0'002-0.0O4 in) O.16 mm (0.006 in) Sewlca Umh: Exha6t Valve Stom-to4ulde Clearanca: Standrd lNow): O.10-0.16 mm (O'0O4-O.006 in) 0 22 mm (0.OO9in) Limh: Sowic.
1O mm out trom sat.
..
.o
Mssuro along gdggg. and 3 ways across center'
a lf measuremant excedsthe servicelimit, r8check using a new valvs. a lf measurement is now within the servic limit. reassembleusing a ngw valv. a lf measurementstill excaads limit, recheck using alternate mthod blow, then replace vslve snd guide, if necessary, NOTE: An altsrnate mthod of chcking guide to stem clearanceis to subtract the O.D. of ths valve stem, measurgdwith a micrometer. from the l.D. ot the valve guide, measured with an inside micrometer o. ball gauge. Take the measurements in three places along the valve stem and three placesinsidethe valve guide. The difference betwesn the largest guide measureshouldnot ment and the smalleststem measurement exceedthe servicelimit.
Cyllrdor H6ad Hight: Stardard(Nowl: 131.95- 132.05mm 1 5 . 1 9 5 5 . 1 9 9i n l -
Intake Valvo Stom-tecuida Closrsnca: Stardtd lt{rw}: 0.02-0.05 mm -O.OO2 in) (O.OOl O.08 mm (O.0O3in) Servba Limit: Erhaust Valw Stom-to4uidc Cbarancs: Stsrdrd (ltlew): O.05-O.O8 mm (O.OO2-0.OO3 inl in) O.11 mm (O.0O4 ServlccLimit:
6-52
Replacement
1. As illustratedin the removalsteps of this procedure, use a commercially-available air-impact driver attachment moditied to fit the diameter ot the valve guides. In most cases, the same procedurecan be done using Valve Guide Drivers and a conventional hammer. Tool numbers are at the end of this Drocedure. 4. Workingfrom the camshaftside, usethe driverand an air hammer to drive the guide about 2 mm (0.1 in) towards the combustionchamber.This will knock off some oJthe carbonand make removaleasier, CATUION: a Always wear salty goggles 01 a taco shield when using th aL hamm6.. . Hold the ak hammer directly in lin with tho valve $.rido to pr8vont damaging the driver. 5, Turn the headover and drivethe guideout toward the camshaftside of head.
VALVECUIDE DRIVER Y AVAILAELE

6,4 mm {O.25ln}
87 mm +tr+l3.rt:l In) I
57mln
l2-24h,tl
l_l lr_r
1 1 . 3m m O.44In)
Rmoval installation and VALVE GUIDE DRIVER. mm 6.6 07942-6570100 Selectthe properreplacement guidesand chillthem in the freezersectionof a refrigerator about an hour. for Usea hotplate oroven to evenlyheatthecylinderhead to 3OOoF{150oC). Monitor the temperarure\îith a cooking thermometer.
VALVE GUIDE DRIVER COMMEBCIALLY AVAILABLE
lo
-\
R@ig
CAUTION: a Do not uss a lorch; h may wan rh had. . Do not got ths head hotr6r than 3O0oF (1soocl; oxcasaivo hsat may loosen tho valve seats. a To avoid burns. uso hoavy glovas when handling ths heatod cylinde. hoad. 6. lf a valve guide still won't move, drill it out with a I mm (5/16 inch) bit, then try again. CAUTION: Drill guides only in extremo casos; you could damage tho cylinder head it th gukte breaks. Remove new guide(slfrom the refrigerator, the one at a time, as you needthem. {cont'd)
6-53
Valve Guides
Replacement {cont'd}
7. SliDa 6.5 mm (0.26 in) steel washer and the correct driver attachment over the end of the driver (The washerwill absorbsome of the impact and extendthe life of the driver).
Reaming
NOTE: For new valve guidesonly. 1. 2. Coat both reamerand valve guide with cuning oil. clockwisethe fulllengthofthe valve Rotatethe reamer guide bore. Continueto rotatethe teamerclockwisewhile removing it trom the bore. Thoroughlywash the guide in detergentand water to removeany cutting residue. check clearance with a valve (page 6-52) o Verify that the valve slides in the intake and exhaust valv gurUeswithoui exerting pressufe.
T:-r-w
DRIVER hl 6.5 rm 10.26 WAHSER T ATTACHME Insta,,thenew guidels)trom the camshaftside ot the head:drive each one in until the attachmentbottoms on the head.lf you have allsixteen guidesto do, you mav have to rcheat the head one ot two more times DRIVER, VALVEGUIDE 6.6 mm 07942-65701fi,
3.
4.
5.
REAMER HA'{DLE
07984-65701OC ol 07984-657010D
Vdvo Guide InstatredHoight: Standard(Newl: l m a k e : 1 3 . 2 5 - 1 3 . 7 5m m ( O . 5 2 2 - O . 5 4 1n ) i Erhaust: 13.75- 14.25 mm ( O . 5 4 1 - O . 5 6 1n ) i VALVEGUIDE
6-54
Valves,ValveSprings and ValveSeals

ValveSpdngand ValveSealInstallation Sequence
NOTE: Exhaustand intake valve sealsare NOT interchangeable.
@A.--.--.-uo..uEKEEPERS
NOTE: Placethe end ol valve spring with closely wound coils toward the cylinderhead.
IIITAKEVALVESEAL WHITESPRIIIGI Beplace.
VALVERETAINER
VALVESPNNO VALVEGUIDE SEAL IITSTALLER oTGAO-PH701(x)
EXHAUST VALVESEAL (BTACK SPRING} Replac.
SPRING SEAT NOTE:Installthe valve springseats before installinothe valve seals.
ValveInstallation
When installingvalves in cylinderhead. coat valve stems with oil before insening into valve guides,and make sure valvesmove up and down smoothly. When valvesand springsare in place,lightlytap the end of each valvestem two or three times with a plasticmalletto ensureproperseatingof valve and valve keeprs. NOTE; T8p the valvestem only alongits axisso you do not bendthe stem.
6-55
Head Cylinder
lnstallation
Installthe cylinderheadin the reverseorderol removal: NOTE: a Always use a new head gasket a Cylinderhead and engineblock surfacemust be clean a "UP" marks on camshaft pulleysshouldbe at the top. . Turn the crankshaftso the No. 1 piston is at TDC (page 6-62). a Cleanthe oil control orifice beforeinstalling 1. Cylinderhead dowel pins and oil control orifice must be aliqned.
in headboltssequentially three the 2. Tighten cylinder steps. lst stoptorque: 40 N m (4.0 kg-m,29 lb-ft) 2ndsteptorque:70 N'm (7.0kg-m,51 lb-ft) 3rd stoptorquo: 10ON m {10.0kg-m,72 lb-ft) NOTE: wrench' torque a a We recommend using beam-type torquewrench,be sure usinga preset-type When slowlyandnot to overtighten' to tighten it, whileyou aretorquing . It a boltmakes noise any it tromthe Ist step' the loosen bohandretighten SEOUENCE TONOUE HEAD CYLINOER BOLTS
DOWEL
\ \ \
CYLINOER HEADGASKET Replace.
OIL CONTROL ORIFICE Clean. O-RING Replace.
HEADBOLTS CYLII{OER m 1 2x 1 . 2 5 m 72lb-ft) 1OO llO.Okg-m. N.m oil engine bolt Applyclean boltheads threads under and
6-56
RockerArms/Camshafts and Seals/Pulleys

Installation
lnslallthe intakemanifoldand tighten the nuts in a paltern in 2 or 3 steps. beginningwith criss-cross the Inner nuts. GASKET . Mak6 sura drat the keyways on th camdrafts a] fackrg up. (No. 1 r* on TDCI. a Valv locknuts should b loosonedand boforo scrsws backed off botoio installation. a Replacthe rocker arms in thsir origlnal positions, 1. Place rocker the armson the pivotboltsandthe valve srems. Installthe camshaftsand the camshalt sealswith the open side (spring)facing in.
2.
8 r 1.25 m m 22 N.m(2.2kg-m, 16 tb-ft) 22 N.m(2.2kg-m, 16 tb_ft} 4. Install exhaustmanifold the and bracket. Tighten the patternin 2 or 3 steps, beginnuts in a criss-cross ning with the inner nuts. GASKET I x 1.25mm Replace. 32 N.m{3.2kg-m, 23 rb-ft)
ROCKERARM
3.
Apply liquidgasketto the head mating surtacesof the No.1 and No. 6 camshaft holders,then install them, along with No. 2, 3. 4 and 5. NOTE: a "1" or "E' marks are stampedon the camshaft holders. a Do not apply oil to the holdermating surfaceof camshaftseals. a Apply liquid gasketto the shadedareas. a The a.rows marked on the camshaft holders should point toward the timing bett.
1 0 x 1 . 2 5m m 45 N.m (4.5 kg-m, I x 1 . 2 5m m 22 N.m (2.2 kg-m, 16 rb-ft)
33 rb ft) 6 x 1 . 0m m
K g H H F HWi
Ili H
l"'l_m*ll ^/'""1"'"1*" trBfr m ffi n

/No.
No.2
TNTAKE
GASKET Replace.
1 ON . m ( 1 . O g m , k 7 tb-tr) HEAT INSULATOR
1 0 x 1 . 2 5m m 55 N.m 15.5kg,m,40 lb,ft) Replace.
tru
M H
H
6r &{ pI
LOJ
16r M
tl
liT
4.n**" ffi
{cont'd)
6-57
and Seals/Pulleys RockerArms/Camshafts

4. Tightenthe camshaftholderstemporarily' a Make sure that the rocker arms are properlyposltioned on the valve stems'
Torque:Exhaust SDecifi6d 7lb-ft) Exceot (O: 10 N m {1.0kg-m, G), k , 1 2 N . m{ 1 . 2 s - m 9 l b - f t ) @, @i
\
5. Pressin the camshaftsealssecurely.
lnstallthe back cover.
8 . Installkeys into camshaftgrooves.

NOTE: To set the camshaftsat TDC positionfor No' 1 piston, align the holes in the cdnshafts with the holesin llo. 1 camshaftholdersand insert 5'O mm pin punchesin the holes.
Tighteneach bolt in two stepsto ensurethat the rockers do not bind on the valves. Specified Torque: lntake qceq@,O, 1ON.m (1.Okg'm, 7 lb-ft) 12 N.m (1.2 kg-m,I lb-ft)
(9,(r,
INTAKE
I x 1 . 2 5m m
9.
Push camshaft pulleys onto camshafts,then tighten the retainingbolts to the torque specified'
(page6-68). 1 0 . Adjust the valve cle316nes check that the all tubes, hosesand 1 1 .After installation, connectorsare installedcorrectly.
6-58

lllustrated Index
NOTE:
. Referto page 6-62 for posilioningcrankshaftand pulley beJore installingtiming belt. a BeJore removing,mark directiono{ rotationon each belt.
POWER STEERING IP/SI PUMP BELT Adiustment, section17
ALTERNATOR BELT Adjustment, section ADJUSTTNG 23 NUT

45 N.m {4.5 kg-m, 33 rb-ft)
LOWER COVEB COVER Remove tive bolts. the
6x1.0mm
12Nm(1.2kg-m,
RUEBER SEALS ReDlace when damaged deto.iorated. or
CAPt{UT 6 r 1 . 0] n m 'lON.m kg-m, lb-ftl l1.O 7

CYLINDER HEAD 6x1.0mm 1 2 N . m ( 1 . 2k g - m , CRANKSHAFI I lb'ft)
Removg oil. any 14 x 1.25 mm RUEBER SEALS 220 N.m (22.0 kg-m, 159 tb-ft) Roplace when damaged Apply engineoil to th6 bolt or detoriorated. thrcads, but not to the surfacethat contacts the 8 r 1.25 mm washer. 38 N.m(3.8ks-m, 27lb-ft) TEI{SIO'{ER SPAII{G KEYS
PULLEY 8OL
R'LLEY
------+o WASHEB
TE SIOI{ER SPRII{G
BELT tENStOa{ERS
CAMSI{AFT PULLEYS
I(EY TIMING BELT ADJUSTING BOLT 68 N.m(6.8kg-m, 49lb'ft)

Remove any ofl. 6 x 1,0 rhm 12 N.m (1.2 kg-m,I lb-ftl
BELT
Inspection,pag6 6-60 Adjustment,page 6-60 page 6-63 Beplacement,
TIMING BALANCERBELT Inspectjon, page 6-61.
surlacelacing in. Bemoveany oil.
6-59
TimingBelt
Inspection
1. the Disconnect alternatorterminaland the connector, from the cylinder then removetheenginewire harness head cover. Removethe cylinderheadcover. Removethe middlecover. lnspect the timing belt for cracks and oil or coolant soaking. NOTE: a Replace belt if oil or coolant soaked. the . Removeany oil or solvent that gets on the belt.
this Inspect area{or wear.
TensionAdiustment
CAUTION: AtwaF adiust timing boh tension with thew enginecold. NOTE: to o The tensioner springJoaded applypropertensionto is after making the following adthe belt automatically justment. . Alwavs rotate the crankshaft counterclockwise when viewed trom the pulleyside. Rotatingit clockwisemay result in improperadiustmentot the belt tension. the belt beforeadjusting belt . Inspectthe timing balancer tension. a Do not loosenthe adjustingnut morethan one full turn' 1. terminaland the connector, the Disconnect alternator then removetheenginewire harnesstrom the cylinder head cover. Removethe cylinderheadcover. Set the No. 1 piston at TDC (page6-62). Loosenthe adiustingnut 2/3-1 turn, then tighten it'
2. 3. 4.
2. 3. 4.
Rotatepulley ano rnspect belt.
After inspecting, retorque the crank*|aft pulley bolt to 22ON.m (22.Okg-m, 159 lb-ft).
o.
3-teethon the Rotatethe crankshaftcounteclockwise then reloosenthe adjusting nut to camshafqpr.rlley, createtensionon the timing belt. Tightenthe diustingnut. After adiusting,ratorquethe crankshaftpulleybolt to 22O N.m {22.Okg-tn, 159 lb-ft).
6-60
TimingBalancer Belt
Inspection
1, Disconnect alternatorterminaland the connector, the then removethe enginewire harness from the cylinder headcover. Removethe cylinderheadcover. Removethe middlecover. Removethe crankshaftpulley. Removethe lower cover. Installthe crankshaftpulley. Inspect the timing belt for cracks and oil or coolant soaking. NOTE: a Replace belt if oil or coolant soaked. the o Removeany oil or solventthat gets on the belt.
2. 3. 4. 5. 6. 7.
pullgy Rotate andinspect bglt. After inspcting, retorquethecrankshaftpulleybolt to 22O N.m (22.Okg-m, 159 lb-ft). NOTE: Refer to psge 6-66 for timing batancerbelt tensionadiustmnt.
6-61
Timing Belt
TimingBelt. BeforeInstalling Crankshaft Positioning
NOTE: . Installthe timing belt with the No. 1 piston at TDC. . After installing,retorquethe crankshaftpulley bolt to 22ON.m (22.Oks-m, 159 lb-ft). CMN(SHAFTTDCFOSITION: TDC CAMSHAFT FOSITION: ,,UP''MARKS
POINTERS ON BLOCK
TDC MARKS Align the marks on the pullays.
FLYWHEEL
DRIVEPLATE PI Pt CHES,5.0 nm
CAUTIOI{: Romovc thr pln Frnchos attor installlng th. tlming boh.
NOTE: When turning the crankshaft with a socket pulleyand the pully wrench, installthe crankshaJt bolt.
6-62
TimingBeltandTimingBalancer Belt
Replacement
CAUTION: lmpoct tho water pump whon roplacing the timing bh lpags 10-12). NOTE; Turn the crankshaftso that the No. I oiston is at TDC (page6-62). 1. Remove sDlash the shield,
3. Removethe mounting bolts,nutsandpoly-V-blt from (P/Sl pump. the powersteering NOTE: . Oonot disconnect P/SpiDe hose. the and . Afterinstalling, adiust tension the P/Spump the ot
belt (seesection 171. LOCKI{UT ' 1 5 . m( 1 . 5 g - m , N k 11 tb-ft)
P/S PUMP
SPLASH SrmU) Disconnectthe connector, then remove the cruise control actuator. NOTE: a Do not disconnectthe control cabte. . Takecarenot to bendthe cablewhen removingthe actuator.Always replace kinkedcablewith a new a one. CNU|sE CONTROL ACTUATOR 6r1.0mm 1oNm(1.okg-m, 7 tb-ft) 4.
BOLTS/T{UTS 8 r 1.25rfn 22 N.m 12.2 kg-m, 16 rb-ftt Disconnect alternatorterminaland the connector, the then removethe enginewire hamessfrom the cylinder headcover. Loosen the altemator mounting bolt, nd rnd the adiusting boh, then removethe ahernatorbeh. NOTE: After installing,adiustthe tensionof the alternator beh {seesection 23). J:aLIERNlton ool{]{ECTOR MOUI{TIXG BOLT tO x 1.25mrn 45 N.m(4.5kg{, 33 lb-ft)
ADJUSTING BOLT
MOUNTI{G NUT 8xt.25mm 22 N.m {2.2 kg-m, 16lb_ft}
ALTERI{ATOR BELT (cont'd)
6-63
Belt TimingBeltandTimingBalancer
6. Removethe cylinderheadcover. 7. Removethe middlecover. 8. Removethe side enginemount. 9. Removethe dipstick and the pipe. 1 1 .Removeth rubberseal aroundthe adiustingnut. Do not loosnthe adjustingnut. 12. Removethe lower cover. 6x1.0mm k 9 1 2 N . m( 1 . 2 g ' m , rb-ftt
12 x 1.25 mft 55 N.m (5.5 kg-r(, 40 tb-ft)
1 0 . Removethe pulleybolt and the crankshaftpulley.Remove the two rearboltsJromthe centerbeamto allow the engineto drop down and give clearancetoremove the lower cover,
O-RING Replace.
1 2 x 1 . 2 5m m 65 N.m {6.5 kg-m, 47 tb,ft) SEALS RUBBER whsn Replace damagedor deterio.ated.
SEAL RUBBER Replace when damagedor detaiorated.
RUBBER SEALS Replace when ol MIDDLE COVER oamageo

Semove any o .
6x1.0mm 12 N.m (1.2 kg-m.9 lb-ft)
BOLT PULLEY m 1 4x 1 . 2 5 m kg-m,159lb-ft) 220N.m(22.O

Apply engineoil to the bolt threads, but not to the surfacthat contacts the washer. CRAI{KSHAFT PUI.LEY Removeany oil. ADJUSTIf{GNUT 6 x 1 . O m m 1 2 N . m { 1 . 2k g - m , 10 r 1.25 mm 45 N.m {4.5 kg-m, 9lb-ft) 33lb-ft)
TIMII{G BELT Inspoction, pago 6-60 Adiusting, page 6-60
6-64
13. Lockthe timing belt adlusterarm in placeby installing one of the 6 x 1 .O mm lower cover mounting bolts, 14. Loosenthe timing belt adjustingnut. Pushon the pulleyto removetensionfrom the timing balancer belt, then tighten the adjustingnut. '15. Removethe timing balancerbelt. NOTE: lf you are removing only the timing balancer belt, go to step 21 . li you are removingboth belts, continuewith this procedure.
16. Loosen6 x 1.O mm lock bolt and the adjustingnut. Pushon the timing belt adjusterpulleyto removetension trom the belt, then tighten the adjustingnut. 17. Removethe timing blt. 18. lnstallthe timing beh in the reverseorderof removal. - Beforeinstalling timing belt, positionthe crankthe shaft and camshaft pulleys as shown on page 6-62. 19. Per{orm the timing belt tension adiustment {page
6-60t.
TIMING BELT ADJUSTER ARM ADJUSTING t{UT 45 N.m(4.5 kg-m,33 lb-ft)
20. Tightenthe 6 x 1.Omm bolt to lock the timing belt adrusterarm.
(cont'd)
6-65

21 , Make surethe crankshaftis positionedwith the No. 1 piston at TDC. with shaft pulleY 22, Alignthe grooveon the front balancer pointeron the oil pump housingas shown. the 23. Align the rearbalancershaft pulleyby usinga 6 x 1OO mm bolt or equivalentas an alignmenttool. Scribea line 74 mm (2.9 in) Irom the end of the bolt. holeto the scribed lnsertthe boh into the maintenance line. 24. Loosenthe adjusting nut and verifY that the timing balancerbelt adiustermoves freely. 25. Installthe timing balancerbelt. Removethe 6 x 1OO mm bolt from the rear balancershaft.
74 mm (2.9 in)
26. Tu(n the crankshaft pulleYabout one turn counterclockwise. then tighten the adiusting nut to the specltied torque. NOTE: Both belt adiusters are spring-loaded to properlytension belts.Do not applyanyextra presthe sure to the pulleYsor tensionerswhile performingthe adjustment. REAR BATANCER
6 r 1OO BOLT mm
Rplace. 12 mm SEALI G AOLT 30 N.m (3.0 kg-m, 22lb-ft) NOTE: Tighten the bolt after installingthe belt.
6 x 100 rm BoLT
ADJUSTING ]{UT
Align the g.oove oI the front driven pulley with the pointer on the oil pump housing
TIMII{GBALAT{CER EELT DN|VEIT PULI..EY
BALAI{CER BELT ORIVEPULLEY Set the crankshaft at TDC.
6-66
27. Removethe 6 x 1,Omm bolt from the timing belt adjuster arm. 28. Removethe crankshaftpulley. 29, Install lowercover. the 30. Installa rubberseal aroundthe adiustingnut. Do not loosenthe nut.
31. Installthe middlecover. 32. Installthe crankshaftputley. 33. Coat the throads 8nd seating face of the pulley bolt with engine oil. Install and tighten to the specified toroue. Spocifiedto|ql|3: 220 N.m {22.0 kg-m, 159 tb-ft)
RUBBER SEAL Replacewhen damagedor deterioratd.
MIODLE COVER
RUBEERSEAL Replac when damagedot deteriorated.
RUEBER SEALS Repl6c6 when damagdor dsteriorated.
6 x 'l.Omm 1 2 N m ( 1 . 2 k s - mI,l b , f t )
PULLEY EOLT 1 4 r 1 . 2 5m m
22ON.m 122.0 ks-tn 159lb-ft) CRANKSHAFT PUI.LEY Bemove oil. any 10 x 1.25rm 45 N.m(4.5 kg-rn, lb-ftl 33
6 x 1.Orrn 12 N.m ll.2 kg-m,I lb-ftl
6-67
Valve Clearance
Adjustment
NOTE: . Valvesshouldbe adjustedcold when the cylinderhead (38oC). is temperature lessthan 1oOoF . After adjusting,retorquethe crankshaftpulley bolt to 220 N.m (22.0 ks-m, 159 lb-ft) 1. headcover Remove cylinder the INTAKE 4, Adjust valves on No. 1 cylinder. Valve Cl6a?anca: in) lntak: 0.07-O.11 mm (O.0O3-0.0O4 Exhaust:0.15-0.19 mm (0.006-0.007 in) Loosenlocknut and turn adjustingscrew until feeler gaugeslides back andJonhwith slightamountofdrag.
27 N.m{2.7kg-m. lb-ftl 20 Apply ongine oil.
2.
"UP" markson the camshaft Set No. 1 pistonat TDC. pulleysshouldbe attop. andTDC Arooves the camon shaft pulleysshould align with cylinderheadsurface.
ag8in.Repeat Tightenthe locknut andcheckclearance adjustmentif necessary.
Number 1 fiston at TDC:
,,UP" MARKS
TDC MARKS Align the marks on the pulleys.
6-68
6.
(C8mshaft Rotatecrankshsft 18Oocounterclockwis pulleystums 9Oo).The "UP" marks should b6 at xhaust side. Adjust valveson No. 3 cylindor.
8.
RotatecrankshaftI8Oo counterclockwise bring to No.2 Distonto TDC. The "UP" marks shouldbe at intake side. Adjust valveson No. 2 cylinder.
filumber 3 Diston at TDC:
Number 2 dston at TDC:
,,UP" MARKS
7.
Rotatecrankshaft18Oocounterclockwise bring to No. 4 piston to TDC. the TDC groovesare onc agsin aligned.Adjust valves on No. 4 cylinder,
Numbor 4 piston 8t TDC:
6-69
Gylinder HeadA/alve Train lHz2!-l engine)

Camshafts Inspectbn ............ 6-93 wEc Vdves, VafueSpringsand ValveSeals Troubleshooting Flowc*rart Removal .............. 6-95 WEC Solenoid Vdve ................ 6-75 Vdve Springand Vdve Seal lrutalation Sequence................. WEC Pressure 6-101 Switch... . . ....... . .. 6-77 Vdve lnstallation VTEC SolnoidValve Inspoction...... 60 ... 6-102 Vaho Seats Rocker Arms Reconditioning ......6-97 ManualInspection . . . . . . . . . . . . .. . . . . . . . . . 61 . Vdve Gukles Inspeabn UsingSpecial Too|s........61 Valve Movernent ........................, Inspectbn 6-98 . .... .... . .. 6-92 Replacemst..... ..,.6-99 Cylinder llead Reaming .........,.... Removal 6-t0O .............. 6:l TimingBdt and nming Balancer Warpage......... Bat .....6-98 ltusratod lndex ...............,..... .... . Instalhtion . 6-107 ...........6-103 Feplacemem..... Rocker Armg and Shafts ....6-109 TimingBlt Removal .............. 6g Inspection Locations. . . . . . . . . ............6-108 ....6-90 TimlngBdancerBeh Clearance . .. ..... .....6-91 Inspoction Installation ............6-10g ...........6-102 Vaho Cbarance Lost motion AssemHies Adfu3rnora Inspection ..........6-1tE ............ 6-92 Special Tools ...........6-72 lllustrated .............................. lndex &73
Ref. No.
Tool Number
Descfption vaNe Gu\de Reame(, 5.5 mm Air Stopper Tappet Adiuster Tappet Locknut Wrench Attachment Valve SpringComprssor Extension Timing Belt Slider Valve Guide Driver, 5.5 mm Valve Spring Compressor Attachment
Oty 1 1 1 1
Page Rotorcncr
o
@ @ @
\!,
OTHAH_PJ701OA or O'?HAH-Pl'lO1OB OTLAJ_PR3O2OA oTMAA-PR70t10 07MAA-PR70120 OTMAF_PR90IOA 07NAG-P130100 07742-O010100 o7757-PJ10l0A
6-100 6 - 8 1 ,8 2 6 - 11 5 6-115 6-95 6-106 6-99, 100 6-95
P
--!_rr--_--__---b
il
o
U
@
:r-----------r-blrrrlllsaf
A---J
\9
q:\ "_-___e.dD/
@
6-72
lllustratedIndex
CAUTION: To avokl damaging the cylinder h6ad, wait until the engine coolant tmporatur dlope below IOOoF (38oC) before removing h. NOTE: a Use new O-ringsand gasketswhen reassembling. . Use liquidgasket, Pan No. 08740-OOO1. a Clesnthe oil controlorifice betoreinstalling. I Prio,to r"""sembling, clean all the parts in solvent.dry them, and apply lubricantto any contact pans.
PLUGWINE COVER x 1 . 0m m 1 0 N . m ( 1 . 0k g - m , l b - t t ) 7 CLAMP
CYLINDER HEAD COVER 6 x 1 . 0m m 1 ON m ( 1 . 0k g - m , 7 l b ' f t ) WASHER Apply liquid gaskt to these pornts. I r 1 . 2 5m m 26Nm{k2.6kg-m, 't lb,ftl 9 6x1.Omm 1 2 N . m { 1 . 2k g - m , 9tbft) CAMSHAFTHOLOER
RUBBEB SEALS
Replacewhn or deteriorated.
6r t.Omm 1 2N . m( 1. 2 k g , m )
RUBBER CAP Replacewhen damaged or dete orated.
8 x 1.25 mm 18Nm(1.8kg-m 13 tb-ft)
AKE CAMSHAFT page 6-93 page6-105 Installation, Replace. CAMSHAFTPULLEYS Removal,page 6-86 page6-105 Installation.
DISTBIBUTOR
KEYS
wEc
SOLENOID VALVE
5 x kl.0 mm 12 N . m ( 1 . 2k g - m I tb-ft) VTEC SOLENOID VALVE FILTER Replace.
1 0 x 1 . 2 5m m 5 1 N . m ( 5 . 1k g - m , 37 tb-ft)
EXHAUST CAMSHAFT
O-RING Replace. OIL CONTROL ORIFICE Clean. BACKCOVER 6x1.0mm 1 2 N . m ( 1. 2 k g m
'lO x 1.25 mm 45 N m (4.5 kg m, 33 tb ftl 8 x 1.25 |nrl 22Nm(2.2koJn-
qo.'
r o ru--ttt
I lb{tl
enctrue uourur
BRACKET B
{cont'd)
6-73
Index lllustrated
(cont'd)
NOTE: Cleanthe rocksr shaft orificeswhen installing.
CYLINDER HEAD BOLTS 1 2 x 1 . 2 5m m 100 N.m {10.0 kg-m,72 lb-ft) Apply clean engineoil to threads and underthe bolt heads.
EXHAUST VALVE SPRIG NI{ER
ROCIGRABM ASSEMBLY IPRIMARY,MIO, SECOI{DARY)
VALVE KEEPRS
VALVEKEEPERS
,f,"*'*o"'o'n"
VALVE INTAKE INNER SPRING VALVE INTAKE SPNING OUTER
pags6-95 Replacement, O.RINGS Replace.
VAL EXHAUST
OUTER SPRING SEALINGBOLTS20 mm 60 N.m (6.0 kg-m,43lb-ftl
WASHEB Replace.
SHAFTS ROCKER
I
VALVESEAL VALVE MOTION LOST ASSEMBLY EXHAUST ROCKER SHAFT ORIFICE Clean. i HEADGASKET CYLINDER GASKETI {METAL Replace. DOWEL PINS
SPRING SEAT ALVE GUIDE Inspection,page 6-98 page 6-99 Replacement, page6-10O Roaming, LOSTMOTION ASSEMBLY
INTAKE BOCKER SHAFT ORIFICE Clean.

HEAD CYI"INOER Removal,page 6-83 Roconditioning vslve sst, page 6-97 Warpage,page 6-98 Installation,page 6-103 EXHAUST VALVE INTAKE VALVE Rplacement, Oimension,pag 6-95 Reconditioning valve seal, pago 6-97 Adiustment, page 6-1 '15
NOTE: Do not installthe oil control orifice.
6-74
VTEC
Troubleshooting Flowchart - VTEC SolenoidValve
-f6il lttll Maffunction Indicato. Lamp(MlL) indicates Cliagnostic Trouble Code(DTC) 21:A problem the \rrEC in Solenoid ValvecircNJit,
-r-' ---.1116l -l 21l----iMIL hr! bon ,aoon6d on. With srvlc chock connoctor Fmpod lp.go 11-42), cod6 2 1 i8 indhatod.
Do tho onglno c-ontrol modole (ECMI Rosot Plocoduro (p.go 11-43).
Wann up ongino to normd oprating tompo.ature lradiator t6n como! onr.
*Road Test: Acceleratein 2nd gear to an onginespgedover 6000 rpm. Hold that enginespedfor at least two seconds. Ropeatthis test at least threo times. Intorrnlttaot lailuro, 3y8tom ir OK at thi! tim6. Ch6ck tor poo. connoctiona o. 10036 wiro. at VTEC aolonoid valve and ECM,
Do thg RoadTest.r
ls MIL on and does it indicate code 21?
Dbconnoc-t tho 1P connoctd from tho VTEC aolonold vdv6.
Ch6d( lor cootinuitv betwoon lP connoctoa torminal and body
ls there 14-300?
lTo page6-761
(cont'd)
I
VTEC
-VTEC Solenoid Valve(cont'd) Flowchart Troubleshooting
{Frompage 6-75} Reconnoct 1P connoctof to VTEC solonoidvalv6. Conngct tho ECM tost hamds lo the moin ha.n$t
Measuro the rosfutanco botween A4 trmlnaland 426 t6rminal.
ls there14-30 0?
Chd( lor ogdt or !ho.l In wlto batw.on ECM lnd VTEC lohnold vdvg.
substituts a known{ood ECM and rccheck. ll symplom/indlc'tion goos away toplaco thc odginal ECM.
6-76
Troubleshooting Flowchart@'l
VTECPressure Switch
Lsmp{MlLlindicates l2rl I Uafun"tionIndicator Diagnostic Troubte CodelDfcl 221 A Droblem in the VTECPressure Switch circuit.
- f-;;r ta I
r.-l !r{=r j-
MIL h6 baan rcponod on. Wlth ..wlca chccl corn.cior Fmp.d {p.gr I 142). Cod. 22 l! Indlcltrd.
Do the ongine control moduls (ECMI Bgset Procedure lpags 11-43).
Warmup engine normaloperto ating tempmturlradiEtorfan comes onr.

Do the RoodTest.'
*Ro6d Test: Accelorgte in 2nd 96.r to on gngine spoed ovfl 6000 rpm. Hold that engino speod for at loast two sconds. Repsat this test 6t lgagt thr6 timos. lr tmltt nt dura, !y!t!m b OK rt lhl! tlmc. Chlck td poor conn.ctlionr ot loota wklr rt VTEC prct.or. rwltch lnd EM,
VTECPRESSURE
Tu.n the ignition switch OFF.
Digconnoct the 2P connoctor from th VTEC oressuro switch.
Chsck continuivbstwoen for tho preasurs 2 terminals the VTEC on switch.
Turn the ignition switch ON.
Mga6urcthe voltags betw66n the 8LU/BLK wire 6nd body grolnd.
{To pags 6-78)
(cont'd)
VTEC
FlowchartTroubleshooting
(Frompage 6-77)
Switch (cont'dl VTECPressure

Inspoct lor an opon oa thort to ground ln th. BLU/BLKwiro b.tw6n tho 2P connccto. tnd D6 t.rmlnll ol th. EcM. It wko b oK, rub.iltuto r known-good ECM and ictort.
VTECPRESSURE
swtYcH
ls there approx. 10 V?
Measurs the voltage across the 8LU/BLKand BLK wires in 2P connector.
ls ther6 approx. 10 V?
Rgpolropon d.ori In BLK wko botwcn lha 2P connoctor gnd body ground.
Turn the ignitionswitch OFF.
1 0v ?
Reftove 10 mm soaling bolt nd connect oil prgss!re gauge.
GAUGE OIL PRESSURE COMMERCIALLY AVAILABLE
Connoct a tachomster {se section 1'1).
Start the ngine and warm it uP to normsl operatingtemperature. WASHER Replaco. Check oil prossure at engine 'l,OOO, 3,0OOand 5,0OO speedof rpm.
ri
ls pressurebelow 50 kPa (O.5 kg/cm', 7 psi)7 'l th P connectorfrom Disconnect the VTEC solenoid valve,
timo as shon NOTE: Keepmeasuting becausgengineis running as Dossible with no load (lessthan one minutel.
EOLT SEALING GAUGE JONT ADAPTOR 20 N.m (2.Okg-ln, SNAP.ON MT26-17 t 4 tb-ftt 10 x l.O mm
In3pocl tho VfEc tol.nold v.lv!.
. Use new washr when installing the sealing bolt.
F.
iiri ;i
Aftach the battory positive termitermin6l nal to the GRN/VVHT {To pge 6-79)
6-78
(From page 6-78)
Start th6 engine nd check oil p.essure at 5,OOOrpm. PRESSURE GAUGE COMMERCIAI.IYAVAILAALE
WASHER R6place.
NOTE: Keep rl|ossuring timg as short as poasiblebgcause enginis running with no losd (l6ssthan one minute).
SEALIIIGBOLT 20 N.ln l2.O kg-ln, 14 tb-frl
S]{AP-ON MT26-17 10 r 1.0 rnm . Usonew washgrwhen installing sealing the bolt.
ls p.essure above 4OO kPa (4 kg/cm', 57 psi)?
Inrpoct tho VTEC rol.nold vCv..
Turn the ignition switch OFF.
Reconnect the 2P connctor to the VTEC Dressureswitch.
Install the tgst hamess (page 11-251.
Stsrt the engins and run above 5,OOO rpm. Measurethe voltage between D6 l+l and O22 l-l terminal ol the ECM.
Subrlhute a known,good ECM .nd r.chock, It rymptoh/lndic.tlon gooa lwsy rcplsce tha o.iginll ECM.
6-79
t-
WEC
WEG SolenoidValve InsPection
the 1P connectorfrom the VTECsolenoid Disconnect valve. 2. Measureresistancebetween the terminal and body grouno. Resistance: approx 14-30 ohms 1. 4. lf the filter is not clogged, push the VTEC solenoid valve with your finger and check its movement' o lf VTECsolenoidvalve is normal,checkthe engine oil oressure.
6x1.0mm 12 N.m 11.2kg-m,9lb-ft)
removethe lf the resistanceis within specifications, the cylinder head, and VTEC solenoid valve from check the VTECsolenoidvalve filter for clogging. o lf there is clogging,replacethe engineoil filter and the engineoil. ;.1
Fl
' Il
r t
VALVE VTEC SOLENOID
VALVE VTEC SOLENOID FILTER Replace.
6x1.0mm g l 2 N . m ( 1 . 2k g - m , l b ' f t )
6-80
Rocker Arms
ManualInspection
Removethe cylinderheadcover. o Push the mid rocker a.m on the No, 1 cylinder manually. o Checkthatthe mid rockerarm movesindependently of the primaryand secondaryintake rockerarms. MID ROCKER ARM a . 1. 2. Btoro using the spodd tool (Valv! lmpction Tooll, mak6 sure that tho aL pnesauro gauga on th6 air com_ pressor indkrat.s ovor 250 kpa (2.S kg/cmr, 36 p3l). Inspect th valv clearance before rockr arm inspoctbn. Covcr thc dming bah with a lhop towol to fotoct thc beh frcm o0 roakhg, Check th. mH rocksr e]m of 6sch xilton Et TDC. Removethe cylinderhead cover. Plugthe relief hole with th speciattool.
Inspection UsingSpecial Tools
EXHAUST
4.
Checkthe mid rockerarm of each cylinderat TDC. a lf the mid rocker arm does not move, rmovethe mid, primaryand secondaryrocker arms as an assembly and check that the pistons in the mid and pfimary rockerarms move smoothly. o lf any rocker arm needs .eplacing, replace the primary,mid, and secondaryrockerarms as an as_ semblv.
(cont'dl
6-81
Arms Rocker
3.
Tools(cont'd) UsingSpecial Inspection

Removethe bolt and w8sherfrom the inspectionhole and connectthe valve inspectiontool. 4. Loosenthe regulatorvalveon the valveinspectiontool to . and applythe specifiedair pressure the rockerarm pistons. Sp6dfied A Pr$sui: 250 kPa (2.5 kg/cm', 36 psil - 5Oo kPa (5.0 kg/cm', 71 Fil VALVE REGULATOR and Pullthe lever turn to adiust. rockMakesurethat the intakeprimaryand secondary connectedby the pistonsand er armsaremechanically that the mid rocker arms do not move when pushed manuallv. MID ROCKER ARM
MOTION LOST ASSEMBLY m 1 0x 1 . O m ADAPTER S]{APONMT26-17 o. EOUIVAEI{T of o lt any mid rockerarm independently the primary and secondary rocker 8rms, replace the rocker arms, as a ser, Removethe tools.
'f
BOLT SEAUNG 1 Ox 1 . 0m m 20 N.m(2.0kg-m, 14 lb-ft)
,,1
oI Checkfor smooth operation the lost motion assemslightlywhen the mid rockerarm bly. lt is compressed deeplywhen the mid is lightlypushedand compressed is stronglyPushed. rockerarm . ReDlace the lost motion assembly iJ it does not move smoothly. check that the malfunctionindicator After insDection, lamo lMlL) does not come on.
6-42
CylinderHead
Removal
Engineremovalis not requiredlor this procedure. 1 . Disconnect the negative terminal from the battery. Drainthe enoinecoolant(seesection 1Ol. a Removethe radiator cap to speed draining
J.
@E
. MalG surs Fcks and salaty stands re dac.d p(opody ard hoist brack6is ar attachod to co.roct positions on ths engln6. . Mako sur the car wlll not loll off stards and fall while you aro working undor it.
Relieve fuel pressure. @ Do not moke whllo wor{ng on ft,"l sFtm, k3p opan f!|m or rFrt away from work Eroa. Drain fr.rCor{y lnto an apFovd contakrr.
CAUTION: . Uss tender covors to avokl damaglng paintad surfaces, o Undug rhe wiing connoctoB ceefuf,y whte holdlng th connctor ponion to avokt damage, a Ma.k aI wiing and hosos to avoH misconnectbn. Also, bo sur that they do not contact othor widng or hosa3 01 interfere whh othr DarB. . To avokl dsmaging the cytrder hrad. wait until tho coolanttemprature dropobelow IOOoF(38oC)engine bforo bosening the rotaining bolts, NOTE: . Inspect the timing belt belore removing the cylinder head. a Turn the crankshaftpulleyso that the No, 1 piston is at top dead center (page6-1061. a Mark allemissionhosesbeforedisconnecting them. NOTE: The radiomay have a coded theft protectioncircuit. Be sure to get the customer'scode numberbefore - Disconnecting b8ttery. the - Removingthe No. 43 (1O A) tuse (ln the under-hood fuse/relavboxl. - Removingthe radio. After service,reconnectpower to the radio and turn it on. When the word "CODE" is displayed.enrerthe customer's s{igit code to restoreradiooperation.
4.
Removethe intak air duct, Removeth fud feed hose and evaDorative emission (EVAP)controlcanistor hosfrom the intakemanifold.
POSITIVECRANKCASE
o.
Removethe throttle cable from the throttle body, NOTE: a Take care not to bend the cablewhen removing it. Always replaceany kinkedcable with a new one. a Adjust the throttle cable when installing(see s e c l i o n1 1 ) .
ADJUSNNG NUT
{cont'd)
6-83
"t.
Head Cylinder
(cont'dl Removal
7. Removethe fuel teed hose, the tuel return hose and the brakeboostervacuum hose. FEEO HOSE FUEL 9. Remove the engine ground cable lrom the cylinder head cover.
10. Disconnect the alternator terminal and connector, flom the cylinder , thsn removetheenginewire harness h9d cover.
6 x 1 . 0m m 5.8lb-ft) 8 N.m(O8 kg-m,

l ,}
6 x 1 . 0m m
10 N.m (1.0 kg-m.7 lb-ft)
1 1. Rdmovethe power stsering (P/S)pump bolt and pump. a Do not disconnecl the P/S hoses.
a a a a a a
fo
a a o o o o a a o a a a
connectors the Remove Jollowingenginewire harness and clamps from the cylindet head and the intake manifold: Fourfuel injectorconnectors lntake air temperature{lAT) sensolconnector ldle air control (lAC) valve connector Throttle position {TP)sensorconnector valve lift sensorconExhaustgas recirculation(EGR) nector Groundcableterminals Enginecoolanttemperature(ECTIswitch B connector Heatedoxygen sensor(Ho2S)connector ECTsensorconnector ECTgaugesendingunit connector lgnition control module (lCMl connector sensorconnector CKP/TDC/CYP sensor {VSS}connector VehiclesDeed lgnitioncoil connector VTECsolenoidvalve connector VTECpresserswitch connector Intake 8ir bypasssolenoidvalve connector ECTswitch A connector Knock sensorconnector
u'o-n, li,l.3u,ll*n-..'
LOCKNUT k 1 5N . m( 1 . 5 g - m , 1't rb-ft)
BELT P/SPUMP
8 x 1.25 mm 22 N.m (2.2 kg-m. 16 rb-ftl
6-84
I
I
I
1 2 .Bemovethe ignitioncoil.
RESISTANT BOLT *: CORROTION
* 8x1.25mm 22 N.m (2.2 kg-m, 16 lb-ft) 16, Femove the bracket and intake manifold.
* 8x 1.25mm 22N,n 12.2 kg-r'|,, 16 tb_ft)
1 3 . Remove the emission vacuum hoses and water

bypasshosesfrom the intakemanifoldassembly. 1 4 . Remove radiStorupperhose and heaterhosetrom the the cylinderhead. 15. Removethe water bypass hose and the thermostat housing. o-Rt]{G Replace.
'17.
Removethe selflocking nuts and disconnectthe ex, haust manitoldand exhaustpipe A. Remove the heat insulator, brackets and exhaust manifold.
'18.
BBACKETS
6-85
CylinderHead
(cont'd) Removal
1 9 . Rmovethe cylinderheadcover. 20. Removethe middlecover.
Use a wrench to loosen the maintenancebolt lf it cannot be loosenedwilh an open-endwrench, a box wrench can be used after pullingout the lock pin NOTE: Useof a tool shotildbe limhedto initialloosening only. 22, Loosen the maintenanceboh by hand until it stops' bracketis now tixed. The auto-tonsioner NOTE: bolt afa Neverusea tool to loosenthe maintenance ter initisl loosening. a ll tha auto-tensioner has been extendsd 8nd the timing beh cannot b installd,remove the autotensionsr,@mpressit and lainstsllh (page6-1 12). CAUTION: Do not caimp oi b.nd tho tlr$ng bdt mors fran 9Oo or bss thtn 25 mm | 1 in) h damcter' 23, Removethe belt from the camshaftpulleys.
G4?
No Good
24. Removethe camshaftPulleYs'
PULLEYS CAMSHAFT
MAINTENANCE
AOLT
Auto-tonsioner funstistl.
;*,6r*;i*
MAINTENAI{CE BOLT
Auto-tensaoner fixed in plac6.
6-86
25. Loosenthe rockerarm adjustingscrews,then remove

the camshaft holdersand camshafts
27, Rmove ihe cylinder head bolts, then remove the cylinder head. CAUTION: To p.event warpag, unscrw the bolts in soqunce 1/3 tutn at a time; rspeat the sequonce until all bohs aro loossned. CYLINDER HEAD SOLT LOOSENING SEOUENCE
ADJUSTINGSCREWS
ADJUSTINGSCREWS
24. Rsmovethe side enginernount bracket B and timing

bh back cover. NOTE: Separate cylinderheadfrom the block with a the flat tip screwdriveras shown.
x 1,25 mm 45 N.m (4.5 kg-m, 33 rb-ft)
'lO
8 x 1.25 m m 22Nm12.2kg-n', 16 tb ft)
6-87
RockerArms and Shafts

Removal
Loosenthe adjustingscrews, then remove the bolts and the rockerarm assemblY NOTE: a Unscrew the camshaft holderbolts two turns at a time, in a crisscrosspattem, to preventdamag'ng the valvesor rocker arm assembly. a when removingthe rocker arm assembly,do not remove the camshaft holder bolts. The bolts will keep the camshaft holders, the springs and the rockerarms on the shafts.
INTAKE
No.4
No.3
No.2
No.1
i t
2.
Removethe VTECsolenoidvalve 8nd fiher.
No.4
No.3
No.2
wEc solEflolD VALVE
EXHAUST
,i"
VTECSOLENOID FILTER VALVE Replace.
6 x k 1 . Om m 1 2 N . m { 1 . 2k g - m , I tb-ft)
6-88
3.
Hold the rocker arms together with a rubber band to preventthem trom separating.
Screw 12 mm bolts into the rocker arm shafts. Remove each rockerarm while slowly pullingout the inlake and exhaustrockerarm shafts.
RUBBER BAND
BOCKER ARMS
12 mm EOLTS
4.
Removethe intake and exhaustrockershaft orifice.

ROCKER SHAFT
NOTE: The shapesof the rockershaft ori{icesof the intakeand exhaustare difterent. ldentify the parts as they areremovedto ensurereinstallation the original in locations.
6-89
Arms and Shafts Rocker

Locations
h8s ban imrtod CAUTION: Attd hstafling the ]ockor shrtt odfic.. try to tum ihe locker shaft to mak sura that iho oriffco plsce' it ehorld not tum' in th6 holo ot rodcr shaft conectlY. lf th. odfica b in NOTE: in a ldentify parts as they are removedto ensurereinstallation originallocations' . Inspectrockershafts and rockerarms (pages6-93 and 941. a Rockerarms must be installedin the same positionit reused. o Cleanthe intakeand exhausttocket shaft orificesbetoreinstalling. I clean all the parts in sopent, dry thern and apply lubricantto any contact surfaces, erior to reinstalling,
ARM ROCKER ASSEMBLIES TNTAKE
m , |/ I
No.3
cyLtNoER NUMBEB
|
No.2
t /
No.1
BOLTS mm 20 SEALING TNTAKE ROCKER 60 N.m{6.0ks-m,43lb-ft} SHAFT
ri
i
I I
ll
rl i
No.4
No.3
No.2
*oi,
RUBBER BAND
\
t
EXHAUSTROCKER ARM ASSEMBLIES
\
\ NUMBER CYLINDER
6-90
Rocker Arms and Shafts

Clearance
Measure both the intake rocker shaft and exhaust rocker shaft. 1, Measurediameterof shaft at first rockerlocation. 3. Measureinsidediameterof rocker arm and check tor out-of-roundcondition.
Rocksr Arm-to-Shatt Clearance: l sko and Erhaust Standard {Nw}: 0.025-0.052 mm (O.OO1O 0.OO2O in) Swice Limit: O.08 mm (0.003 in.)
2.
Zero gaugeto shaft diameter.

Surfaceshould be smooth.
Repeatfor all rockers. - lf over limit, replace rocker shaft and all ove.tolerancerockerarms. NOTE: lf any rocker arm needsreplacement, replace all three rocker arms in that set (primary.mid. and secondarvl.
MICROMETER
6-91
Arms Rocker
Inspection
the NOTE: When reassembling primaryrocker arm, careol to fully applyair pressure the oil passage the rockerarm. 1. arm piston.Pushit manually. the Inspect rocker - ll it does not move smoothly, replacethe rocker arm assemblY.
Lost MotionAssemblies
Inspection
Removethe lost motion assemblyfrom the cylinder head and inspect it. Pushingit gently with the linger the will causeit to sink slightly.Increasing force on it will causeit to sink deeper. - lf the lost motion assembly doesnot move smoothly, replaceit.
il
ARM PRIMARYROCKEN
ASSEMBLY LOST MOTION
Check piston movement
a Apply oil to the pistonswhen reassembling. a Bundlethe rocker arms with a rubberband to pre-
vent them from separatlng.
6-92
Camshafts
Inspection
NOTE: Oo not rotate camshaftduring inspection. 1. Removethe .ocker arms and rockershafts, 4. NOTE; Rockerarmsmust be installedin the sameposition if reused. 2, fut the camshafts,camshaftholdersand holderpipes on the cylinder head, then tighten the bolts to the specitiedtorque. Specified tolque: @-@: 8x 1.25mm 26 N.m (2.6 kg-m, 19 tb-ft) @-@: 6x 1.Omm 1 2 N . m ( 1 . 2k g - m ,I t b - f t ) Zero dialindicatoragainstend of camshaft.then push camshaft back and torth and readthe end play. CamshaftEnd Play: Standa.d 5 {New): O.O5-O.'1 mm {O.OO2-O.006 in) SrvicoLimh: O.5 mm lO.O2in) Seat camshafts by pushingthem toward distributor end ot cylinderhead.
Removethe camshaft holdersand holderoiDes trom the cylinder head. . Lift camshaftout of cylinderhead.wipeclean,then inspect lift ramps. Replacecamshaft if lobes are pitted, scored,or excessivelyworn. . Cleanthe camshaftholdersurfacesin the cylinder head,then set camshaft back in olace. a Insertplastigage strip acrosseach journal. o Installthe camshaft holdersand holder oiees and torque bolts to the values and in the sequence shown in left column.
(cont'd)
6-93
Gamshafts
Inspection(cont'd)
Measure widest portion ot plastigage on each journal. Camshaft-to-Holder Oil CNearance: StandardlNowl: 0.050-O.089 mm (0.0020-0'0035 in) ServiceLimh: O.15 mm (0.006 in) Measurecam lobe height.
lnsooct this arca tor wear.
INTAKE Pf,I MID SEC
EXHAUST
7.
it
is oil lf camshaft-to-holder clearance out of tolerance: a And the camshaft has alreadybeen replaced,you must replacethe cylinderhead. o lf camshsft has not been replaced,first check total runout with the camshaft supported on Vblocks. Camshatt Total Runout: Standad {Newl: O.O3mm {O.OOIin} max. Servica Limit: O.O6 mm (0.0O2 Inl
\
T/B T/B
t,
SEC MID
PBI
T/8
Pql: PRIMARY MID: MID T/8: Tlill G BELT
SEC:SECO DARY
Cam l-obe Holght Standrd (Ncwl:
II\ITAKE
PRIMARY MID 34.041 mm ( 1 . 3 4 0 2i n )
EXHAUST
33.745 mm ( 1 . 3 2 8 5i n l
36.856 mm (1.451O ) in
34.971 mm ( 1 . 3 7 6 8i n )
SECONDARY
Rotate camshaft while measuring
36.323mm in {1.43OO l 34.683mm i { 1 . 3 6 5 5n }
- lf thetotalrunout ot the camshaftis within tolerance, replacethe cylinderhead, - lf the total runoutis out of tolerance, the replace clearance camshaftand recheck.It the beanang is still out of tolerance. replacethe cylinder head.
6-94
Valves, Valve Springs and Valve Seals

Removal
NOTE: ldentify valves and valve sprinos as they are removed so that each item can be reinstalledin its original position. 1. Using an appropriately-sized socket and Dlastic mallet. lightly tap the valve retalner to loosen the valve keepersbefore installingthe valve spring compressor. 2. Install spring compressor. Compress spring and remove valve keeDef.
VALVESPNI G COMPRESSOR ATTACHMENT EXTENSION OTMAF_PR90lOA
VALVESPRING COMPRESSOR ATTACHMENT 07757-PJ1010A
PLASTICMALLET
SOCKET
{cont'd)
6-95
Valves, Valve Springs and Valve Seals

Removal (cont'd)
3. lnstallthe specialtool as shown. Valve Dimemions:
VALVE GUIDESEALREMOVER LISLE P/t{ 579oo or KD 3350 AVAILABLE COMMERCIALLY
lntako Valvo A Stsndrrd (Now): 34.9O-35.10mm
(1.374- 1.382 In) mm B Standard (Ncwl: 105.rO- 1O5.7O l 1 4 . 1 5 0 - 4 . 1 6 1n l

4. Removethe valve seal. C StEndard {t{ew}: 5.475-5.483 mm
(O.2156-0.2159lnl
;r
5.W 10.2144lnl C Ssrvlco Limit: D Standard (Newl: 1 . 0 5 - 1 . 3 5m m

D Scruico Limit:
(O.O41-0.O53 In) Inl 0.86 mm (O.O34
ExhaGt vllvc A Standard {Nsw}: 29.90-3O.1O mm
( 1 . 1 7- 1 . 1 8 5 n l 7 i (4.134-4.1116 inl
B Standard (t{ow,: 105.OO105.30mm C Standard (Ncw): 5.475-5.485 mm
(O,2156-0.2159In) (O.O05-O.o78 In) 1.45 mm (O.O57 inl
iri
Inl C Service Llnh: 5.rt45 (O.21.14 (Ncwl: 1 . 6 5 - 1 . 9 5m m D Stand8rd

D Srvico Limit;
6-96
Valve Seats
Reconditioning
Renew the valve seats in the cylinder head using a valve seat cutter.
VALVE SEAT
PRUSSIANBLUE COMPOUI{D
o.
The sctual valve seating surface, as shown by the blue compound, should be centered on the seat. a lf it is too high (closer to the valve stem), vou must make a second cut with the 600 cutter to move it down, then one more cut with the 45o cutter to restoreseat width. a lf it is too low (closeto the valve edge),you must make a second cut with the 3Oo cutter to move it up, then one more cut with the 45o cutter to restore seat width, NOTE: The final cut shouldalways be made with the 45o cutter. Insert intake and exhaust valves in the head and measure valve stem installed height. Intak Valv. Stsm lmtallod Height: Standa.d {Now}: 37.465-37.935 mm (1.4750- 1.4935 int So.vic Limit: 38.185 mm {1.5033 inl Exhalst Valve Stom Installad Height: Standard(Newl: 37.165-37.635 mm (1 .rt632- 1.rt817 in) Servicol-imit: 37.885 mm (1.4915 inl
NOTE: lf guidesare worn (page6-98), replacethem (page 6-991 before cutting the valve seats. Carefullycut a 45o seat, removing only enough material to ensure a smooth and concentric seat. Bevel the upper edge of the seat with the 30" cutter and the lower edgeof the seatwith the 60o cutter. Check width of seat and adjust accordingly. Mak one mor very light pass with the 45o cutter to remove any possible burrs caused bv the other cutters. Valvo Soat Width (lntake and exhaustl: Standard(N6w): 1.25- 1.55 mm (0.0r1!l-0.061 inl Sorvice Llmit: 2.0O mm 10.079 in)
SEATWIDTH
VALVESTEM INSTALLED HEIGHT
5.
After resurfacing the seat, inspect for even valve seating; Apply PrussianBluecompound to th valve fEce, and insert valve in originallocation in the head, then lift it and snap it closed against the seat several tames.
8.
lf valve stem installedheight is ove. the servicelimit, replace valve and recheck. lf still over th service limit, replacecylinderhead;the valve seat in the head is too deeD.
6-97
Cylinder Head
Warpage
(page6-93) oil NOTE: lf camshaft-to-holder clearances are not within speci{ication,the head cannot be resurfaced. are oil lf camshaft-to-holder clearances within specifications, check the head tor warpsge in) . lf warpageis lessthan O.05 mm (0.OO2 cylinder head resurlacing is not required in) o lf warpageis between O.O5mm (0.OO2 and O.2 mm (O.OO8 resurlacecylinderhead. in), limit is 0.2 mm (o.oo8 in) based a Maximumresurface '132.0 mm (5.20 in). on a height of
Valve Guides
Valve Movement
Measure the guide-to-stem clearance with I di6l indicator while rocking the stem in the dirsction of normal thrust (wobblemethodl. lntako valvo Stsm-to-Guldo Clearancc: Standard(Now): 0.05-O.11 mm tO.O02-0.OO4in) 0.16 mm (O.OO6Inl Servic6 Limit: Exhaust Valvo Stem-to-Guldc Cloarancc: standard (Now): 0.1O-0.16 mm (O.oO4-o'006 inl 0.22 mm (O'OO9Inl Sarvice Limh: vrlvs anondcd 10 mm out trom t!|t'
PRECISION STRAIGHTEDGE
.rl .,il
Measurealong edges, and 3 ways acrosscente..
a lf measursmentexceedsthe servicelimit, recheck using a new valv6. a lf measurement is now within th service limit, reassemble using a new valve. a lf measurementstill exceeds limit, rechack using altrnate method below, then replsce valve and guide, if necssary. NOTE: An ahernate method of chcking guide to stem clearanceis to subtract the O.D. ol the vslve stem, measuredwith a micrometer, from the I'D of the valvs guide, measuredwith an inside micromter or ball gauge Take the measuromentsin three plsces along th valve stem and three placas inside the vslve guide. The difference between the largest guids measursshouldnot ment and the smalleststem measuremnt exceed the service limit. lntako Valvo Stam-to-Gddo Clcalanco: Standard{Now): O.O25-O'055 mm t0.O01O-O.0O22in) 0.O8 mm lO.0O3 inl Sorvlce Limit:
Cylindol Head Hoight: Standard(New): 141.95-142.05 mm (5.589-5.593 in)
Exhaust valvo Stom-to-Guida Cbarlncai Standard (New): O.O50-O.080 mm (0.o020-0.0O31 inl 0.1 1 mm (0'0O4 Inl Sorvice Limit:
6-98
Replacement
l. As illust.ated in the removalsteps o{ this procedu.e, use a commercially-available air-impactdriver attachment modifiedto tit the diameterof the valve guides. In most cases,the same procedure can be done using Valve GuideDriversand a conventionalhammer. Tool numbersare at the end of this procedure.
4.
Workingfrom the camshaftside,use the driverand an air hammer to driver the guide about 2 mm (O.1in) towa.dsthe combustion chamber. This will knock off some of the csrbon and make removal easier. CAUTION: a Always wear satoty goggles or a tace shield whon using th ai. hammot. a Holdthe air hamnrerdhectly in line with th valvo guide to prevnt damaging the driver.
VAI.VE GUIDEDBIVER Y AVAIIAALE
5.3 mm lO.2'l in)
tl_r l
10.8 mm 10.42 Inl
l r
Turn the head over and drive the guide out toward the camshaftside of head.
Removal Installation and VALVEGUIDE DR|VER, ftm 5.S 07742-d)10100
2 . Select the proper replacementguides and chill them

in the freezer section of a retrigerator for about an hour. Use a hot plate or oven to evenly heat the cylinder head to 3OOoF(150oC). Monitor the temoerature with a cookingthermometer.
VALVEGUIDE DRIVER, COMMERCIAIIY AVAILABTI
lf a valve guide still won't move, d,ill it out with a 8 mm (5/16 inchl bit, then try again. CAUTION: a Do not us6 a torch; lt may warp th6 hoad. a Do not get tho h6ad hotter rhan 3OOoF(150"C); xcesslvo heat may looron tho valvo soats, a To avoid burns, uso hoavy glovos whon handling tho hEted cylindsr head.
<reDi-k
{cont'd}
CAUTION: Drill guidos only in extrcmo cass; you could damagotho cyllndr head lftho guide breaks, 6. Remove new guide(sltrom ths refrigerator. th one at a time, as vou need them.
6-99
Valve Guides
7. Slip a 6 mm (0,2 in) steel washer and the correct driver attachment over the end ol the driver (the washerwill absorbsome ot the impact and extend the lite ot the driver).
Reaming
NOTE: Fo. nw valve guidesonly. 1. Coat both reamerand valve guide with cutting oil. Rotate the reamer clockwise the full length of th valve guide bore. Continue to rotate the reamer clockwise whil removing it from the bore. 4. Thoroughly wash the guide in dstergent and water to removeany cutting residue. Check clealancewith a valve (page 6-98). a Verify that the vslve slides in the intake and exhaust valve guides without exerting pressure.
/--Tr-1-l--lDRIVEB
6 mm 10.2in) WASHER
al;\ Y
-r
rnr \---jY
ATTACHMENT
8 . tnstallthe new guide(s)Jromthe camshaftside oJ botthe head;driveeachone in untilthe attachment toms on the head.It you have 8ll sixteenguidesto do, you may have to reheatthe head one or two more times.
VALVE GUIDEDRIVER, 5 . 5m m 07742-@10100
9*6W )/>-A()
5.5 mm OTHAH-PJTOIOA oTHAH-PJ70108
Valvo Guid6 Installd Hoight: Standard {New): lnrak: 12.55-13.O5 mm (O.494-0'514 in) Exhaust:12.55- 13.O5 mm (O.494-O.514Inl
VALVEGUIDE
6-100
Valves, Valve Springsand Valve Seals

ValveSping andValveSealInstallation Sequence
NOTE: Exhaustand intakevalve sealsare NOT interchangeable, VALVEKEEPERS e{t' A\---.'---.,-VALVE SPRING RETAINER
v
NOTE: Pt.c. the ond ot valvo .prlng whh clo3.ly wound coll! row..d tho cyllndor herd.
VALVE SPRING OUTER
VALVE SPNNG INNER
II{TAKEVALVE SEAL {WHITESPRING} Replace.
:,.^,7
NOTE: In6tallthe valve spring seats before installingth6 valv seals. VALVE GUIDESEALINSTALLER KD-2899
NOTE:Usesmalllo ndol tool.
wre
6-101
Valves,Valve Springsand Valve Seals

Valve Installation
When installing valves in cylinder head, coat valve stems with oil bejore insertinginto valve guides, and make sure valvesmove up and down smoothly. Whenvalvesand springsare in place.lightly1apthe end ol each valve stem two or three times to ensureproper grip seating of valve and valve keepers (use hammer. bottom). NOTE: Tap the valvestem only alongits axisso you do not bend the stem.
Arms Rocker
lnstallation
1 . lnstallthe rockerarms in the reverseorderof removal: o Valve adjustinglocknuts should be loosenedand adjustingscrew backedoff betore installation. o The comDonentDans must be reinstalledin the originallocations. Installthe lost motion assembly.
3 . Installthe rocker arms while passingthe rocker arm

shaft through the cylinderhead. NOTE: Removedthe rubber band after installingthe rockerarms.
Il
I
4.
lnstallthe rockershaft orifices.lf the holesin the rocker 8rm shaft and cvlinderheadare not in line with each other, threadsa 12 mm boh into the rockerarm shaft and rotate the shaft. NOTE: a The shapesof the rockershaft orificeslor the intale and exhaustare different.The oriticesmust be installedin the originallocations. o Cleanand installthe rockershaft oriticeswith new O-rings. EXHAUST ROCKER SHAFT ORIFICE
ri
6-102
Cylinder Head
lnstallation
Install the cylindr head in the reverse ord6r ol removal: a Always use new hadand manifoldgaske$. . The cylinder head gaskt is a m6tal gasket. Take care not to bend it. . Rotate the crsnkshaft, s6t the No. 1 piston at TDC (pase&106). Installthe cylinderhesd gasketand dowd pins on the cvlindrhead. 3. Tighten the cylinder head bolts sequentiallvin thr6e steps. lst stop torquo: 40 N.m (4.0 kg-m, 29 lb-ft) 2nd stop torquo: 70 N.m {7.Okg-m, 51 lb-ftl &d stp torque: 10O N.m {10.Okg-m, 72 lb-ftl NOTE: o We recommendusinga beam-type torque wrench, When using a preset-typetorque wrgnch, be sure to tighten slowly and not to overtighten. . lf a bolt makesany noisewhile you 8re torquingit, loosenthe bolt and retightenit from the lst step.
CYLINOER HEAO
CYUNDER HEADBOLTS TOROUE SEOUENCE
DOWEL PIN
oowEl n
CYUI{DER HEADBOLTS 12 x 1,25mm 1OO (10.0kg-m. lb-ftl N.m 72 Applyclean ngino oilto bolt thrsads underboltheads. 8nd
{cont'd)
6-103
CylinderHead
Installation(cont'd)
4. lnstall the intke manifold and tighten the nuts in a crisscrosspattern in 2 or 3 steps, beginningwith the Innernuls. INTAKE MANIFOLD GASKET 6. lnstallthe camshaftsand camshaft oil seals. NOTE: o Installthe camshaftswilh keyway facing up. . Installth oil s8al with the springside fscing in. . The dl seal housingsurfaceshouldbe dry. 7 . Cleanand installthe oil controlorificewith new O-ring in the oil passageof the No. 3 camshaft holde..
I x 1 . 2 5m m 22Nm{2.2kg-m, 16 lb-ft)
I x 1.25 mm 2 2 N . m1 2 . 2 l . g - m , 16 tb-ft)
ERACKET
;;;-a
o-RrNG
ReDlac.
Instsllthe exhaustmanifoldand brackets.Tightenthe nuta in a crisscrosspattern in 2 or 3 steps, binning with th innernuts, EXHAUST MANIFOLD GASKET Replace.
8 x f.-$.mm ks-m, 32 N.m-|C.2 23 tb-ir) 8xL25mm kg-m, 22 N.m12.2 16 tb-ft)
Apply liquidgasketto the headmating surtaceof the No. 1 and No. 5 camshaftholderson both the intake and exhaustside. Confirmthat the csmshaft kvway are face up, then plscethe holders,togetherwith the No. 2. No. 3 and No.4 camshaftholders,on the cylinderhead. NOTE; The arrows markedon the camshaft holders shouldpoint to the timing blt.
CAMSHAFTHOLDERS
I
I
No.5
I
6x1.Omm 10N.m ( 1 . 0k g - m , 7 tb-ft) ' 1 0x 1 . 2 5m m 45Nm14.5kg-m, 33 tb-ft) SEI.f,-LOCKING NUT l O x 1 . 2 5m m 55 N.m (5.5 kg-m, 40 tb-ft) Replace. 8 x 1.25 mm 22Nm(2.2kg-m, 16 lb-fr)
FA l t t
We)
i I A ,:)t Bqt fr
\t \t ta/\el
o.4
No.3
No.2
t{o.l
n A
K-
ffil"t
BFl f'q ffiTn
M H S
EXHAUST
IITTAKE
APPIvliquid gasket to tne shadedareas.
6-104
9.
Temporarily tighten the bolts ot the camshaft holders and the camshaftholderoioes.
1 1. Tightenthe bolts in the sequenceshown below.
1 0 . fush the camshaftoilseal securelyagainstthebaseof

the camshaft holder.
O-@:8x1.25mm 26 N.m (2.6 kg-m, 19 lb-ft) @-@:6x1.Omm 12 N.m (1.2 kg-m,9 lb-ft} 12. Installthe backcoverot the timingbelt. 13. Installthe pulleys. camshaft
..
KEY
W&
,7*,
CAMSHAFTPULLEY
1 0 r 1 . 2 5m m 51 N m 15.'kg-m,37lb-ft) 1
6-105
CylinderHead
(cont'd) Installation
1 4 . Installthe timing belt in the reverseorder of removal. Adjust the valve clearances lpage 6-1 151 - Beforeinstalling timing belt, positionthe crankthe shaft and camshaft pulleysas shown TDC CAMSHAFT POSITION: ,,I" MARKS 16. Installthe timing belt. NOTE: a It the autotensioner has been extended and the timing belt cannot be installed.remove the autotensioner.@mpressit ard reinstallit {page6-1 12}. . Take care not to damagethe timing belt when installingit.
TDC MARKS TDG POSITION : CRANKSHAFT
17. Tighten the maintenance bolt to make the autotensionertunctional. NOTE: Turn the maintenancebolt bv hand until it stoos.
TDC MARK ON
THEFI.YWHEEL
1 E
lnstallthe specialtool on the intake camshaftpulley. EXHAUST CAMSHAFT PtJLLEY
Auto-tensioner tixd in ploce.
Auto-tensioner lunctional.
6-106
Timing Belt and Timing Balancer Belt

lllustrated Index
NOTE:
a Reterto page 6-1OO positioningcrankshaftand pulley beforeinstallingtiming belt. tor o Beforeremoving,mark directionof rotationon each belt. ADJUSTING NUT 'lOt 1.25mm MIDOLE
45 N.m (4.5 kg-m,33lbJt)
RUBBER SEALS Replace when damagedor deteriorated.
RUBEER SEAL Replace when damaged or deteriorated. CRANKSHAFT PULLEY Removeany ojl.
CAP NUT 6xl.Omm 10Nm{1.0kg-m,7lb-ft)
WASHER
PULLEY EOLT 1 4 r 1 . 2 5m m 220 N.m {22.Okg m, 159 lb-tt} Applyengine oilto the bolt threads, but not to the surtacethat contacts the
LOWER COVER
Romovethe five bolts. RUBBER SEALS Replace when damaged or deteriorated. 6x1.Omm 'l2 N.m (1.2 kg,m, 9 lb-ft) CAMSHAFTPULLEYS 1 Ox 1 . 2 5m m 5 1 N . m ( 5 . 1k g - m , 37lb-ftl
POWER STEERING BELT Adiushent, sction 17
ALTEBNATOR
Adjustment,section 23
TIMINGEELT page6-108 Inspectaon, Installation,page 6 109
AUTO.TEI{SIONER AI'JUSTING BOLT 68 N.m (6.8 kg-m,49 tb-ftl Apply liquid gasker to the bolt lhreads installedin the blockside. TIMING BALANCER BELT page6-'l08. Inspectaon,
lnstall with concave surtacefacing in. Remove any oil.
6-107
Timing Beft
lnspection
1. the Disconnect alternatorterminaland the connector' then removethe enginewire harnessfromthe cylinder head cover. headcover Remove cylinder the Removethe middlecover. Inspect the timing belt for cracks and oil or coolant soakang. NOTE: a Replace belt if oil or coolant soaked. the . Removeany oil or solventthat gets onthe belt.
Timing BalancerBelt
Inspection
1. the Disconnect alternatorterminaland the connector, fromthe cylinder then.emovethe enginewire harness headcover. Removethe cylinderheadcover Removethe middlecover. Removethe crankshaftpulley. Removethe lower cover. Installthe crankshaftpulleY. Inspect the timing belt for cracks and oil or coolant soaking. NOTE: . Replace belt if oil or coolant soaked. the a Removeany oil or solventthat gets on the belt.
2. 3. 4.
2. 3. 4. 5. 6. 7.
Inspect this areafor wear,
Inspectthis areator wear,
Rotatepulloy and inspect belt.
pulley to bolt crankshaft retorquethe Afterinspecting, ks-m,159lb-ft). 220 N.m(22.O

.{d.,
retolquethe ctankshaftpulleybolt to After inspecting, 220 N.m (22.Oks-m, 159 lb-ft). NOTE: Reterto page 6-1 l3 for timing balancerbelt tension adiustment.
6-108
TimingBelt and TimingBalancer Belt

Replacement
CAUTION: Inspct th wstr Frmp whon roplacing tho timhg boh (pag61O-121. NOTE: Turn the crankshaftso that the No. 1 Distonis at TDC {page6-106}. 1, Removethe splashshield. Removethe mounting bolts, nuts and belt from the power steering(P/S)pump. NOTE: o Do not disconnectthe P/S pipe and hose. o After installing,adjustthe tensionof the P/Spump belt (seesection 171. LOCKNUT
15Nm(1.5kg-m,
l l
MOUNTING EOLTS
SPLASH SHIELD 2. Disconnectthe connector, then remove the cruise control actuator, NOTE: a Oo not disconnectthe control cable. a Takecarenot to bendthe cablewhen removingthe actuator,Always replace kinkedcablewith a new a one. CBUISE CONTROL ACTUATOR
8 x 1 , 2 5m m 22N,m 12.2kg-m,
P/SPUMP BELT
16 tb-ft| Disconnect ahetnatorterminaland the connector. the then removethe engine wire ha.nessfrom the body srde. Loosenthe ahernatormounting bolt, nut and th adjusting nut, then removethe alternatorbelt. NOTE: After installin, adjustthe tensionof the atternstor belt (seesection 23).
ALTERNATOR COI{NECTOR
6x1.0mm 10 N.m ('l.Okg-m, 7 tb-fr)
MOUNTNG AOLT 1Ox 1.25 mm 45 N.m (4.5 kg-m, 33 tb-ft)
CONNECTOR
TERMINAL
AL MOUNTINGNUT BELI 8 x 1.25 mm 22N m 12.2kg-m, 16 tb-ft) (cont'dl
6-109

Bemovethe cylinderhead cover. Removethe middlecover. Removethe side enginemount. m 1 2x 1 . 2 5 m k 5 5 N . m{ 5 . 5 g m , 40 rb-ft)
1 0 .Removethe crankshaftbolt and the pulley.

Removethe two rear bolts lrom the center beam to to allow the engineto drop down and give clearance removethe lower cover. 1 1 .Removethe adiusterrubber seal. Do not loosenthe adjustingnut.
1 2 . Removethe lower cover. 1 3 . Loosenthe adjustingnut. Pushon the pulleyto remove

belt, then tightenthe tensiontrom the timing balancer adjustingnut.
il
t , l l
il
1 4 . Removethe timing balancerbelt.
12 x 1.25 fifi 65Nm(6.5kg-m, 47 tb-fr)
tD.
Removethe timing belt.
1 6 . Removethe auto-tensioner.
9.
Removethe dipstick and the PiPe
6x1.0mm 1 2 N . m( 1 . 2k g - m ,9 tb ft)
Replace.
6-110
HEAD CYLINOER COVER
TIMING BELT Inspection,page 6-108
6x1.Omm 9 12 N.m(1.2kg-m, lb-ft)
MIDOLE COVER
TIMINGBALANCER BELT page6-108 Inspection, ADJUSTIT{G NUT l 0 x 1 , 2 5m m 45 N.m {4.5 kg-m, 33lb-tt)
RUBBER SEAL Replace whendamaged or deleriorated.

AUTO.TENSIONER
rullEY BOLT
1 4 x 1 . 2 5m m 220 N m (22.0 kg-m, 159 lb-ft)
RUBBER
Replacewhen damagedor deteriorated. 6t1.0mm 12Nm(1.2kg-m, 9 tb-ft)
PULLEY
Remove any oil.
6-111
Belt Timing Belt and Timing Balancer

Replacement {cont'd}
1 7 . Installthe timing belt in the reverseorder ol removal. - Beforeinstalling timing belt, positionthe crankthe shaft and camshaft pullevsas shown ,,T" MARKS NOTE: Take care not to damagethe threads or the gasketcontacl surfacewith the sctewdriver'
MAINTENANCE BOLT
FLAT BLADE SCREWDRIVER
STOPFER P/N 14540-Pl3-003
and 2 1 . Removethe screwdriver reinstallthemaintenance bolt. NOTE: Be sureto ube a new gasket.
i MAINTENANCE BOLT I N.m(0.8kg-m, 6lb{r)

Replace.
TDC MARK the auto-tensionerwith the maintenancebolt bolt. .l , pointingup. Loosenand removethe maintenance carefullyso the NOTE: Handlethe auto-tensioner the oil insidedoes not spill or leak. Replenish autotensionerwith oil if any spills or leaks. The total capacityis 8 cc {1/4 ii oz). in 19. Clamp the boss oJ the auto-tensioner a vise. Use oJ wood or a cloth to protect the boss, Dieces NOTE: Do not grip the housingot the auto-tensioner. 20. lnsert a flat blade screwdriverinto the maintenance 3-OO3) the on hole. Placethe stopper {P/N 1454O-P1 auto-tensionerwhile turning the screwdriver clockthe wise to comDress bottom.
8 x 1 . 2 5m m 22 N.m (2.2 kg-m, 16 rb-ft)
Make sure no oil is leakingaround the maintsnance on bolt. Installthe auto-tensioner the engine. NOTE: Make sure the stopperstays in place.
STOPPER P/N
t
'
I
;
6-112
23. Removethe stopper.

ADJUSTER
26. Align the rearbalancershsft pulleyby usinga 6 x 10O mm bolt or equivlentas an alignmenttool. Scribea line 74 mm (2.9 in) trom the end of th boh. Insertthe bolt into the maintenanc holeto the scribsd line. 27. Loosen the adjusting nut and verify that the timing balancerbelt adiustermoves freely. 28. Instsll the timing balancerbelt. Removethe 6 x 10O mm bolt trom the rear balsncershsft. 29. Turnthe crankshaftpulleyaboutoneturn, then tighten the adjustingnut to the specifiedtorque.
P/N 14540-P't3-OO3
24. Make surethe crankshaftis positionedwith the No. 1

cylinderat TDC.
NOTE: Both belt adjusters are spring-loaded to properlytension belts.Do not applyany extra prosthe sureto the pulleysor tsnsionerswhile performingtha adjustmenl.
REARBALANCER SHAFT
25. Align the grooveon the front balancer shaft pulleywith

the pointeron the oil pump housingas shown.
74 mm 12.9in)
6 r 100 mm BOLT
12 mm SEALINGBOLT 30 N.m {3.0 kg-m, 22lb-ft} NOTE:Tighten the bolt after installingthe belt.
Align the groove of the tront driven pulley with the pointer on the oil pump housing.
REARTIMING BALANCER EELT DRIVENPULLEY
BALANCER BELT
DRIVE PULLEY Setthe crsnkshaft TDC. at
(cont'dl
6-113
Timing Belt and Timing BalancerBeh

30. lnstallthe lower cover. 3 ' 1 Installa rubberseal aroundthe adjustingnut. Do not .
loosenthe nut. 32. Installthe middlecover. pulley. crankshaft 33. Installthe 34. Coat the threads and seating face of the pulley bolt with engine oil. Install and tighten to the specified torque. Spocifiedtorquo: 22O N'm (22.Okg-m. 159 lb-ft)
MIDDLE COVER
6x1.Omm 12 N.m (1.2 kg-m,9 lb-ft1
I
i
SEALS RUBBER when Roplace or damaged deteriorated.
t{UT AD.'USTING 1Ox 1.25tnm 33lb-ft) 45 N.m(4.5kg-m, RUBBER SEAL Roplace whgndarnged or deteriorated.
A'LLEY EOLT 1 4 r 1 . 2 5m m 220 N.m {22.0 kg-m, 159lb-ft) Apply engineoil to the bolt thrsads, but not to the surfacethat contacts the washer.
-ldl
ii li
I
f,
6x1.Omm '12N.m(1.2kg-m, lb-ft} I
ALTEN ATORBELT Adiustmnt,soction23
PULLEY
6-114
ValveClearance
Adjustment
NOTE: . Valvesshouldbe adjustedcold when the cylinderhead temperatureis lessthan 1oOoF(38oC). . After adjusting,retorquethe crankshaftpu ey bolt to 22ON.m (22.Okg-m, 159 lb-ft). 1. Remove cvlinder the headcover. 3. Adjustvalveson No.1cylinder. Valve Cloalance: Intaks: O.15-0.19 mm {0.0O6-0.O07in} Exhaust:O.17-0.21 mm (O.O07-O.OO8 in) 4. Loosenlocknut and turn adjustingscrew until feeler gaugeslidesbackandfonh with slightamountof drag. TAPPET ADJUSTER o7MAA-PR70'110
INTAKE
2.
Set No.l pistonat TDC. "f" markson the pulleys should be at top. and TDC grooves on the pulleys shouldalign with cylinderheadssurface.
20 N.m(2.O kg'm, 14 tb-ft)
WRENCH oTMAA-PR70120
Number pistonat TDC: 1
Tightenthe locknutandcheckclearance again.Repeat adjustmentit necessary.
FEELEN GAUGE
TDC MARKS Alignthe marks on the pulleys
(cont'dl
6-115
Valve Clearance
Adjustment lcont'd)
6. Rotate crankshaft 180o counterclockwise(camshaft pullevsturns 9Oo). The "f" marks should be at exhaust side. Adjust valves on No.3 cylinder' 8. Rotate crankshaft 18Oo counterclockwiseto bring "i" marks shouldbe at inNo. 2 piston to TDC. The take side. Adjust valves on No. 2 cylinder.
at Numbd 3 glston TDc:
Numbrr2 Di.tonat TOC:
,,I,, MARKS
1
I
7. Rotate crankshaft 1800 counterclockwiseto bring No. 4 pistonto TDC, The TDC groovesare once again aligned.Adjust valves on No. 4 cylinder. Number Dl.tonat TDC: 4
li
ld
l
I I
6-116
EngineBlock
Speciaf Toofs ..................................7-2 lllustrated Index................ ............. 7-3 Flywheeland DrivePlate Replacement ,.........,,..................7-7 ConnectingRod and Crankshaft EndPlay ..........7-7 Main Bearings Clearance ....,,..7-g Selection .........7-9 ConnectingRod Bearings Cfearance ....,,..7-10 Sefection .........7-11 Crankshaft, BalancerShafts and Pistons Removal ........,,7-12 Crankshaft Inspection .......7-15 Pistons Inspection .......7-16 fnstallation ......7-25 CylinderBlock fnspection ..,....7-17 Bore Honing lH23A1,H22Al enginesl ................7-18 BoreHoning(F22A1 engine)............................... 7-19 Piston Pins Removal ..........7-19 fnstallation ......7-20 fnspection .......7-21 ConnectingRods Sefection .,.,,,,..7-2O Piston Rings EndGap ...........7-22 Repf acement ,.............,.,........,,...7-23 Ring-to-Groove Clearance ........7-23 Afignment .......7-24 Crankshaft Seal Oil fnstaf lation ......7-25 Crankshaft and Balancer Shaft Oil Seal Installation(engineremoval is not requiredl ....7-30 Crankshaft and balancershafts fnstration ,.......,7-26 BalancerShafts fnspection .......l-91
SpecialTools
R.l. No.
Tool Number
D6cripiion PistonPin BaseInsert PilotCollar GuideAttachment Hub Assembly PistonBaseHead Se8lOriver RingGearHolder 30 Attachment, mm l.D. Driver Driver Attachment PistonPin DriverShaft PistonPin DriverHead Piston Ease Piston BaseSpring
Oty
Pag6Rdorence 1-19,20 7 -19,20 7-30 7 -19,20 7-30
O o
oTcAF PH6o3oo 07GAF PH7ol00
O
@ @ @ O @ O @ @ @ @
I
| I | | | I | | | | I
-seoozoo orcar
I
t
1 l
oTHAF-PL2o1o2 oTLAD PT3oloA o;Lnr - lvootooor 07924 PD20oo3 07746 oo3o3oo 07749 ooloooo 07948-sBoo101 07973 PEoo3lo 07s73 PEoo32o 07s73 6570500 07973 6570600
7-30 1-25,30 7- 2 5 , 3 0 7-19,20 7-'t9,20 7 -19,20 1-19,20
i
o
!1
ti
I
t
.'
(0
7-2
lllustratedIndex
I Lroric"t" "tl inrernal partswith engineoil during reassembly.
6x1.0mm 12 N.m 11.2
OIL SCAEEN 6x1.Omm 12 t{.m 11.2kg-m. GASKET Roplace.
6x1.0mm 12 N.rnlt.2 kg-m,9lb'ftI
BAFFLEPLATE
11 x 1.5mm 75 N.rn {7.5 lg-m, 54 tb-ttl Applyengineoilto the bolt throada. NOTEr Aftor torquing o6chcap. to turn crankshaft check Ior binding.
AEARINGCAP BRIOGE
DOWEL PIN
-rx
TOROUE CONVERTER COVER IA/T)
12 x 1.0mm 75 N.m 17.5 kg-m, 5t tb-ftl Torquesequence, page7-7 WASHER DRIVEPLAIE {A/T) Checkfor cracks. CLUTCH COVER (M/T) 6 t 1 . Om m 12 N.m (1.2 kg-m, 9 rb-ftl
DOWEL PINS
FLYWHEEL
12 x 1.0mm 105N{n (10.5kg-m, 76lb-ft, page7-7 Torquesequence,
(cont'd)
7-3
lllustrated Index
(cont'dl
I Luuri"ut""tl internalpartswith engineoil duringreassembly.
CRANI}IAFT Endplay,Page7'7 Runout.Tapor 6nd Out-of-Round, Page7-15 Installation,Page7-26
NOTE: Apply liquid gasketto the mating surfacesot the right them side coverand oil pump casebetoreinstalling part No. 08718 0001 Useliquidgasket,
MAIN BEARINGS page7-8 Oilclearance, page7-9 Slection, must NOTE:New main boarings be selectedby matchingcrank and markings. blockidentification
:l
ll
Groovedsidestac outward. NOTE: Thrust washerthicknoss is lixed and must not be changed by grindingor shimming. 8 x 1.25mm 25 N{n {2.5 kg-m, 18 tb-frl O.RINGS Replace.
CRAI{KSHAFTOIL SEAL Install6tion,pag* 7-25and 30
OIL CRANKSHAFT SEAL psges7-308nd 8-'11 Installation, Replace. THRUSTWASHER AALANCER DRIVEN GEAR RIGHTSIDE @VEB Apply liquid g88ktto block mating surface. Gr1.0mm 12Nrn (1.2 9IEftI Apply liquid g8skstto the boft threads.
I
'I l
il
PIN OIL PUMP Se page8-9 Apply liquid gssk6t to block mating surtace.
il
6x1.0mm kg-m,9 lb"ftl 12 l$m 11.2 Apply liq!id gasketto the bolt threads. BALANCER SHAFTOIL SEAL pages 7-30and 8-11 Installation, Reolace. BELT TIMINGBALANCER PULEY DRIVEN
7-4
OII-JET BOLT ito N.rn {a.0tg-m, 29 lb-ftl page 8-8 Inspection, H22Al engincl
OIL JET Handlethe nozzlewith care.Do not damage or detormed. Inspection, page 8-8
REARBALANCERSHAFT End play, p6ge 7-31 Runout.Tapor and psges 7-31,32 Out-of-Round, Inst6llation,pag 7,26
BALANCR SHAFT BEARINGS page Inspction, 7-31
BETAINER NOTE: Retainerthicknossis tixed and must not bs changedby or Orinding shimming.
BALANCER
(cont'd)
7-5
lllustratedIndex
lcont'd)
I parts oil withengine orr'nn,"u""".b'J;ron lruri""t" "tl internal
INSTALLATIONDIRECTION EXHAUST
by must be selected matching NOTE; New rod bearings markings identification rod connecting and crankshaft (pages -101l). 7 ,
1r;--..l@ ft##**if{*{"}H
PISTONPIN page7-19 Removal, page7-20 Installation page7'21 lnspection, ROO CONNECNNG Endplay,page7-7 Selection,page 7-20 7-21 Smallend measurement, Page
\3 -/ (3 \7 \7
A ?A Ae-l / A
\9,-// \Eo.J '\r' '\7
INTAKE PISTON page7-12 Removal, page7-16 M6asurement, properclearance, NOTE:To maintain matchthe lefter on the piston top with the lettor for eachcylinder stamped on the block. On the block On the pistontop A or I No letter <Bor'l
BL(rcK ENGINE p6oo7'17 Cylinder boreinspection, Warpageinspection,Page7-17 7-18,19 Cylinder borehoning,pag66 Inspecttop of each cylinder bore tor carbon build-up or ridge before removing Pigton. pagB7.14 Removeridge if n6cessary,
ROD CONNECTING BEARINGS page7-10 Clearance, page7 11 Selection,
CAP RODBEARING CONNECNNG Installation,page7-26 is rocess cap so the bearing NOTE:Install in on the samesideasthe recess the rod
RODNUT..-_.-....-__-.} CONNECTING 9 x 0.75 mm kg-m, 34 lb-ft, 47 N{n (i1.7 After torquing each bearingcaP, to rotate crankshaft checklor binding.
e
No.4
CYUNDER BORESIZES (A or l, B or rl) NOTE: To maintain proper piston clearance, rnatchthese lefterswith the letterson the pistons.The letters on the block readfrom left to right, No. 1 throughNo. 4 cylinders. On the block On the pistontop A or | --------------- > No letter B or,l --------------- > B
7-6
Flywheel and Drive Plate

Replacement
ManualTransmission:
Remove the eight flywheel bolts, then separatethe flyw h e e l f r o m t h e c r a n k s h a f f l a n g e .A f t e r i n s t a l l a t i o n , t tightenthe bolts in the sequence shown.
RINGGEAi
Gonnecting Rodand Crankshaft

End Play
ConnectingRod End Plsy: Standard (Newl: 0.15- 0.30 mm {0.006 0.012in) SorviceLimit 0.40 mm 10.016 inl
CONNECTING ROO
07LAB PVtDl(x)
or 0792it - PO20O03
BINGGEAR HOLDER 07LAB Pv(xrltx) or 07924 PD2qr03
aoo
\o;
. .
lf out-of-tolerance, install a new connecting rod. lf still out-of-tolerance,replacethe crankshaftlpages 7-11and7-26]..
Pushthe crankshaft firmly away from the dial indicstor. and zerothe dial againstthe end of the crsnkshaft. Then pull the crankshaft firmly backtoward the indicator; dial readingshouldnot exceed servicelimit.
Inspgctring gear teoth for w6ar or damage. 12x 1.0mm 105 N.rn 110.5 kg-m, tG lb-ft,
AutomaticTransmission:
Removethe ight drive plate bolts, thon separatethe drive platefrom the crankshaft flange.After installation. tightenthe bolts in the sequence shown.
SCREWDRIVER
/ AXid-*a\Ao
CrankshaftEnd Phy: Standard lNqwl: 0.10- 0.35 mm (0.004 0.014in) Ssrvice Limit 0.45 mm {0.018inl . lf end play is excessive than the servicelimit, inspect the thrust washersand thrust surfaceon the crank, shaft.Replace partsas necessary.
NOTE:Thrustwasherthickness fixed and must not be is changedeitherby grindingor shimming. Thrust washersare installedwith groovedsidesfacing outwaad.
7-7
Main Bearings
Clearance
L o T o c h e c k m a i n b e a r i n g - t o - j o u r n a li l c l e a r a n c e , removethe main capsand bearinghalves C l e a ne a c h m a i n i o u r n a l a n d b e a r i n gh a l f w i t h a cleanshoptowel. acrosseach main jourPlaceone strip of plastigage nal. NOTE:lf the engineis still in the car when you bolt the the main cap down to checkclearance, weight and flywheelwill flattenthe plastF crankshaft of the gage further than just the torque on the cap bolt. and give you an incorrectreading.For an accurate r e a d i n g , u p p o r tt h e c r a n kw i t h a j a c k u n d e r t h e s c o u n t e r w e i g h t a n d c h e c ko n l y o n e b e a r , n ga t a s time. 4. R e i n s t a ltlh e b e a r i n g sa n d c a p s ,t h e n t o r q u e t h e bolts. 75 N.m {7.5kg-m,54lb-ft) during inspecNOTE:Do not rotatethe crankshaft tron. 5. Removethe cap and bearingsagain,and measure the widest part ot the Plastigage. Oil Main Bearing-to-Journal Clearance: Siandard {Newl: mm No. 1. 2: 0.021 0.0i15 {0.(xn8 - 0.0018in) inl SqrviceLimit 0.050mm (0.0020 mm 0.025- 0.0,19 No. 3 in} {0.0010 0.0019 inl ServiceLimii: 0.055mm 10.0022 0.013- 0.037mm No. 4 10.0005 0.d115in) in) ServiceLimit: 0.050mm {0.1X120 o.(xlg- 0.033mm No. 5 (0.0004 0.0013 in) inl ServicaLimii: 0.040mm (0.0015 measures too wide or too narrow, lf the plastigage (removethe engine if it's still in the car). remove and remove the upper half of the the crankshaft, bearing.Install a new, complete bearingwith the the color as shown on the same color code (select the next pags),and recheck clearance. CAUTION: Do not fi16,3him, or 3crapoth b.arings or the caps to adiu3t clearance. is shows the clearance still incor7 . lf the plastigage rect,try the next largeror smallerbearing(the color listedaboveor belowthat one),and checkagain. cannot be obtained NOTE: lf the groper clearancs largeror smallerbearings, by usingthe appropriate the and reDlace crankshaft startover.
STRIP PLASTIGAGE
l.
7-8
Selection
CAUTION: lf the codes ars indecipherabls bcauso of an accumulationof dirt and dust, do not scrub them with a wiro brush or scraper,Cleanthgm onlv wiih sol. vent or .totrgont. CrankshaftBors Code Location {Numbers,Lettgrs or Bars} Numbersor Lettersor Bars have been stampedon the end of the blockas a code for the size of each of the 5 main journalbores. Use them, and the numbersstampedon the crankshaft (codes main journalsize), choosethe correctbearfor to
Ings.
Main Journal Code Locations (Numbers or Bars) H22Al engine:
Main JoumalCodeLocations lNumbers Ba'sl or
H23A1.F22Al engines: The Main Journal Codesare stampedin one of the following locations. Main Jou.nalCodoLocations (Numbals Bar3) or
No. 5 JOURNAL {FLYWHEEL ENDI
END} IPULI.TY BcaringDosign
PROJECTION
LOWER Berring ldentitication Colorcodeis on the edgeofthe bearing. ----------> Smaller bearing (Thicker) ---------------Largercrankbore Main Journrl Coda Locationi {Numbersor Br.!} No. 5 JOURNAL IFLY WHEELENDI No. 1 JOURNAL (PULLEY ENDI
No. 1 CRANK WEB Smaller main iournal Smaller bearing (Thicker) NOTE:When usingbearing halves of different colors, it does not matter whichcolor is usedin the top or bottom.
Rod Bearings Gonnecting

Clearance
rod the Remove connecting cap and bearinghalf. Cleanthe crankshaftrod journal and bearing half with a cleanshoptowel. plastigage the across rod journal. Place the bearing half and cap, and torque the Reinstall nutsto: 1. 47 N.m (4.7 kg-m, 34 lb-ft) during inspecNOTE:Do not rotatethe crankshaft tion. 5. Remove the rod cap and bearinghalf and meassure the widestpart of the plastigage. ConnectingRod Bearing.to.Journll Oil Clearsnce: P'AAI ngin6: Standard (Newl: 0.021- 0.049mm 10.0008 0.0019in) 0.05 mm (0.002in) ServicLimh: H23A1,ll22Ai enginos: Standald {Newl: 0.027- 0.055mm (0.0011 0.0022inl 0.06 mm (0.002in) Ssrvice Limh: too wide or too narrow, measurss lf the plastigage removethe upper half ot the bearing,installa new, complete bearing with the same color code (select the color as shown on the next page),and recheck the clearance. CAUTION: Do not file, shim, or scrapothc boaring3 or tha cap3to adiust cloaranc. is shows the clearance still incorlf the plastigage rect,try the next largeror smallerbearing(thecolor listed above or below that one), and check clearanceagarn. cannot be obtained NOTE: lf the proper clearance largeror smallerbearings, by usingthe appropriate and reolace crankshaft startover. the
PLASTIGAGESTRIP
i I
H t;,
ili tit
il
it; 'll
:'l
I !:
7-10
Selection
CAUTION: lf th6 cod6s aro indscipherable because of an accumulationof dirt and dust, do not scrub them with a wirg brush or licrapor.Clsan them only with sol v6nt or detergent. ConnectingRod Journal Code Locations {Numbersor Bars) N u m b e r so r B a r s h a v e b e e n s t a m p e do n t h e s i d e o f each connectingrod as a code for the size of the big end. Use it, and the letters barsstampedon the crank or lcodsfor rod journal size),to choosethe correctbearings, ConnqtingRod Journal Code Locations (Lettersor Barsl H22A1engine:
ConnectingRod Journal Code Locliion! lLstterr or BrBl
Halfot numberor bar is stamped bearing on cap and the otherhalf is stampedon rod BoaringD6i9n
H23Al, F22Al cngincs: The Connecting Rod Journal Codesare stampedin one ol the followinglocations. ..,:-.
ConnoctingRod Journrl Codo Locltion3 {Latta'3 or B!1!}
PBOJECTION ConnectingRod Journd Coda Location3llatta.3 or B.rrl
No. 5 JOURNAL Eoaring ldantif ication Colorcodeis on the edgeol the bearing. .---..-----+ Largerbig end bore
No. 1 JOURNAL IPULTIY END}
(Thicker) Smaller bearing
Elue
Smaller rod journal
Smaller bearing lThicker)
No. I CRANKWEB
Shaftsand Pistons Balancer Grankshaft,

Removal
1. Remove right side cover. the 3. drivenpulleyas thown. Remove front balancor the
DOWELPIN
BALANCER DF]VENPULEY
HOI MANTE'{ANCE
I I
)
I
t1
;l
Ii
SCREWT'RIVER
il
2. gearcase. the Remove balancer
DOU'ELPIN 8 x 1.25mm kg-m, 18lb-ft) 25 N.m 12.5
shaft hole.thon Align the bolt hole and the bslancer insert a 6 x 100 mm bolt to hold the rear balsncsr shaft. drivengs8r. Remove bolt and the balancor th6
REARBALA]IIGEB SHAFT
6 x lm .nm BOLT
inl va mm {2.9
BALANCER GEARCASE DOWELPIN
REARBALANCERSHAFT
7-12
Rmove oil screen the and the oil pump. 7. Rsmovthe baffle plate.
8.
Removethe bolts and the bearingcap bridge,then removethe bearingcaps. CAUTION: To provent wsrpago. un3crew tha bolts in loqucnc 1/3 turn at a timc; ropcst tho srqucnco until rll bolt3 are loosGnod.
o|LscaEE
BAFFLEPLATE
MAIN BEARING CAP BOLTSLOOSENING SEOUENCE
7-13
Balancer Shaftsand Pistons Grankshaft,

(cont'dl Removal
are so 9. Turn the crankshaft No. 2 and 3 crankpins at the top. and the rod caps/bearings main caps/bear1 0 . Remove in ings.Keepall caps/bearings order. out of the engine,being careful 1 1 . Lift the crankshaft not to damagejournals. 15. lf you can teel a ridge of metal or hard carbon around the top of each cylinder,remove it with a ridge reamer. Follow the reamer manufactursr's instructions. CAUTION: lf the ridgo k not rcmoved, h mly dtmag6 the pistons a! thcy lrc purhod out.
Use the wooden handle of a hammer to drivo the pastons out.

CRANKSHAFT
'12. Remove then removethe the bolts and the retainer. shaft. front balancer shaftand the rearbalancer
CAUTION: . Tako caro not to dtmago thc contlct turflcc of tho motal g.!kot. . Whan romoving thc pirton/connactlng rod trka cara not to hit thr oil irt (H22Al cngine onlyl. . It th. oil ict nozzlo is drmlg.d or d.formld, rrplaco the oil iet .srombly {H22Al .ngin. only, page 8-81.
RETAINER 1 3 . Remove the upperbearinghalvesfrom the connecting rods and set them aside with their respective caps. the 1 4 . Reinstall main caps and bearingson the engine in properorder,
't1 Reinstallthe rod bearings and capsaftor . connecting

removing each piston/connectingrod assombly. 1 8 . Mark each piston/connectingrod 8ssmbly with its cylindernumberto avoid mixup on .eassembly. NOTE:The existingnumbsr on the connsctingrod does not indicateits positionin the engine,it indicatesthe rod bore size.
Crankshaft
Inspection
C l e a n t h e c r a n k s h a f to i l p a s s a g e s i t h p i p e w cleaners a suitablebrush. or Check keywayand threads, the
Out-of-Roundand Taper
o Measure out-of-round at the middle of each rod and main journalin two places. . The differgncebetyveen measurements each on journalmust not be more than th servic limit, Journal Oui-ot.Round: Standa.d (Ncw): o.qE mm {0.0002in} SorvicoLimit: O.q)6mm (0.0002inl
Alignment
a M e a s u r er u n o u t o n a l l m a i n i o u r n a l st o m a k e surethe crankis not bent, . The difference between measurementson each journalmust not be more than the service limit. CrsnkehaftTotal lndicatod Runouti Standard (Nw): 0.03 mm (0.001in) Ssrvico Limit: 0.04 mm (0.002in)
DIALINDICATOR Rotatecrankshafttwo comptete rovolutions. M6asursin two pl6cesat middl.
Suppon with lathetype tool or V-blocks.
Measu16 taper near edgs.
Measure taper at the edge of each rod and main journal. The difference between measurementson each journalmust not be more than the servicelimit. Journal Taper: St.ndrrd (Now): 0.005mm (O.(xXr2 m!x. int Scrvicc Limit 0.006mm (0.(xn2 in)
Pistons
Inspection
for Check Diston distonionor cracks. the piston NOTE:lf the cylinderis bored,an oversized must be used. 21 Measurethe piston diameterat a point F22A1: mm (0.8in),H23A1, 15 in) H22A1: mm (0.6 from the bottom of the skirt. e N O T E : T h e r e a r e t w o s t a n d a r d - s i z p i s t o n s( N o Letter(A) or B). The letteris stampedon the top of the piston. There letters are also stamped on the blockas cylinderbore sizes. Piston Diameter: F22Al engine: Standard lNewl: mm No Letter lA): 8i[.980- 8i1.990 (3.3457 3.3451inl 84.970- 84.980mm B: in) 13.3453 3.3,157 ServiceLimit: mm (3.3453in} No Letter {A}: 8i0.970 84.950mm (3.3449in) B: H22A1 enginss: H23A1, Standard lNewl: No Letter (A): 86.990- 87.003mm (3./1248 3.4253inl 86.980- 86.993mm B: inl {3.,[2/14 3.42,19 ServiceLimit: inl No Lettor {A}: 86.980mm {3.,12,14
B: F22Al sngino: 21 mm 10.8 inl 86.970 mm (3.,[2'10in] SKIRT DIAMETER
t C a l c u l a t e h e d i f f e r e n c eb e t w e e nc y l i n d 6 r b o r e on diameter (page7-17)and pistondiamet6r. Pbton-to-CvlinderClsrranco: F22Al engine: Standard (Nw): 0.020- 0.0/(, mm l0.00oB 0.0016in) mm {0.002in) 0.05 ServiceLimil: H2341,H22A1engines: Standard (Newl: 0.007- 0.030mm (0.0003 0.0012in) SorviceLimit: 0.04 mm (0.002inl
the servicelimit, is lf the clearance near or excesds inspectthe piston and cylinderblockfor excessive wear. OvorsizePiston Diamoter: F22A1engine: 0.25:85.230- 85.2/0 mm {3.3555 3.3559in} - 85.tlln mm {3.3653 3.3657in} 0.50:85.,180 H23A1.H22Al rngin.3: O.25t .230- 87.2,(l mm (3./8/02 3.,13{8in) 87 4. Coat ths clearance. Checkthe piston pin-to-piston piston pin with engineoil. lt should then be possible to push the piston pin into the piston hole with thumb Dressure, Piston Pin-to Piston Clctrtnco: F22Al engine: Standard (Newl: 0.012- 0.02amm (0.fi)05- 0.qt0o in) H23Al, H22Al ongines: Standard {Nw}: 0.012- 0.026mm 10.000t- o.(XllOin)
7-16
CylinderBlock
Inspection
1 . M e a s u r ew e a r a n d t a p e r i n d i r e c t i o nX a n d Y a t three levelsin eachcvlinderas shown.
in) 6 mm 10.2 Firrt Ma!!urcmant S.cond Mar!uramcnt Third Mer3uramant
Boro Taprr: Limil: {Diftorcncabotw.on lirst snd third maasuromcntl 0.05 mm {0.002inl . . l f m e a s u r e m e n t sn a n y c y l i n d e r a r e b e y o n d i OversizeBore ServiceLimit, replacethe block. l f t h e b l o c k i s t o b e r 6 b o r e d ,r e f e r t o P i s t o n (page7-16)afterreboring. Clearance Inspection
6 mm 10.2 inl
NOTE: Scored or scratchdcylinder bores must be honed. F22Al engine: 0.50 mm (0.020inl H2341,H2/IA1rngincr: 0.25 mm (0.010inl 2, Checkthe top of the block for warpage. Measurealong the edgesand acrossthe centeras snown.
SUNFACES BEMEASUBED TO
CYLINDER BORESIZES lA or I, B or rll Readth ltterstrom lelt-to'right for No. 1 throughNo.4 cylinders.
CYLINDER BONE
Cylindcr Boro Size: F22Al engino: Stendlrd (Ncw): A or l: 85.010- 85.020mm {3.3458 B ot ll: 85.000- 85.010mm (3.3i165 Sorvicr Limit: 85.070mm (3.3492in) H23A1,HPAI ongines: Stlndffd {Now,: A or l: 87.010- 87.020mm {3.4256 I or ll: 87.000- 87.010mm (3.'1252 Srrvicc Limit: 87.070mm {3.i|:l79inl
Enginc Block W..prge: Stlndlrd {Ncw): bclow 0.07 mm (0.003in} S.rvico Limit: 0.10 mm (0.(Xt4 inl
PRECISION SIRAIGHT EDGE
3.3/t?2in) 3.3i168 in)
3.4260in) 3.i1256 in)
OvoEizo: F22Al cngino: 0.25:85.250- 85.260mm (3.356:t 3.3569inl 0.50:85.500- 85.510mm {3.3661 3.3665in) H2341, H22Al 6nginsr: 0.25:87.260mm 13.4:l5i[ inl
7-1
CylinderBlock
H2241engines) BoreHoning(H2341,
l. rbv^ ,,
CAUTION: Thir cylinder linor ussr FRM (Fiber ReinlorccdMatall. Hono only !s diroctod below. 1. Masure cylinderboresas shown on page7-16. It the block is to be reused,hone the cylindersand remeasure bores, the To honecylinderbores; . Useonly a rigid hone. . Honingstone: GC- 600- J or finer stone (for nonf6rrous metals) . Pressure: 2OO 3OO kP; (2-3 kg-cm', 28 - 43 psi) . Honingrpm: 45 - 50 rpm . Honingthickness; in) Lessthan 0.02mm (0.0008 Do not hone mote than 20 cvcls . Honinglubricant Oil type . Roughness of VVV or 1.2S finishedsurfaces: . Honingpattern: 60 degrecross-hatch CAUTION: Cloantho honing stono oyory 5 cyclos.
3.
t W h e n h o n i n g i s c o m p l e t e , h o r o u g h l yc l e a nt h e Washthe cylincylinderblockof all metal particles. der bores with hot soapy water. then dry and oil to immediately preventrusting. NOTE: Never use solvent, it will only redistribute walls. the grit on the cylinder
2.
4.
are still presentin cylinder lf scoring or scratchgs limit, reborethe cylinboresafter horningto service der block. is NOTE:Some light verticalscoringand scratching if acceptable it is not deepenoughto catchyour fingernailand does not run the full lengthof the bore.
PistonPins
BoreHoninglF22A1 enginel
Measure cylinderboresas shown on page7-16. lf the block is to be reused,hone the cvlindersand remasurethe bores. Honecylinderboreswith honing oil and a fine (400 grit) stone in a 60 degree cross-hatchpattern, NOTE: . Use only a rigid honewith 400grit or finer stone suchas Sunnen, Ammco,or equivalent. . Do not use stonesthat are worn or broksn.
Removal
Assemble PistonPin Toolsas shown. the PISTON SASE HEAD OTHAF-PUM102
PISTON PIN BASE INSENT OTGAF PHq'3U'
tl
PFTONBASE 0tt3 - 65t0500 Adjust the length A of the piston pin driv8r. A: 51.5 mm (2.G1 inl W h e n h o n i n g i s c o m p l e t e , h o r o u g h l yc l e a n t h e t engine block of all metsl particles. Wash the cylinder bores with hot soapy water, then dry and oil immediately preventrusting. to NOTE; Never use solvent, it will only .edistribute the grit on the cylinder walls. lf scoring or scratches are still presentin cylinder bores after honing to the servicelimit, rgbore the cvlinderblock. NOTE:Some light vsrticalscoringand scratching is acceptableit it is not deep enough to catch your fingrnailand does not run the full lengthof the bore.
PISTON PIN DRIVERHEAD 0t9t3 - PE|D320
l l
H trl-
m--.--
or9r3 Fdto3ro
PISTOI{ DRlvEN PII{ SHAFT
PILOT OOLLAN o'GAF- PHt0100 Emboesed lacingup. mark
CYLINDEB HONE
NOTEiUEea hydraulicpro6s. When prossingpin in or out, make sure that th rgco$ad ponionofthe pistonoligns with tho liD3on th collar.
NOTE:
. After honing,cleanthe cylinderthoroughlywith soapy water. o Only a scored or scratchedcylindr bore must be honed. Placeths piston on the piston base and pressthe pin out with a hydraulic press.
7-19
Rods Connecting
Selection
Each rod falls into one of four toleranceranges(from 0 in) in), in 0.006mm (0.0002 increto 0.024mm {0.0009 ments) dependingon the size of its big end bore. lt's then stampedwith a numberor bar \'1,2,3, ot 4ll, t, ttl, the or Irl) indicating range. t, oI '1,2,3, ot 4/1, ttl,o( You may find any combination Irl in any engine. Normal Boro Sizr: 51.0 mm (2.01in) NOTE: Refernc numbersor bars are for big end bore the sizeand do not indicate positionof th rod in the engine. rod for cracksand heat damInspect connecting age.
PistonPins
lnstallation
1. prossfor installation. Usea hydraulic . the Wh6n pressing pin, in or out, bo sureto positlat on the piston againstthe tion ths recessod lugs on the base8ft8chment.
The arrow must laco the timing belt side of the 6nOine.
RODBORE CONNECTING NUMBERoi BAR BEFEBEITCE Half ot number is sttmpsd on bearingcap, ths other half on connectingrod.
Tho ma* must faco the timing beltsid6 ol th6 engin6.
2.
Adjust the length B of the piston pin driver. in) B: 51.5mm (2.G1 PIN HEAO PISTON DRTVER 0797:1 PEqB2o
PISTONPIIIIDBIVERSHAFT 07973- PE00310 Embossdmark
I ffi*r,"ron'n
PILOTCOLLAR 07GAF- PH701d) PISTONPIN BASE NSEBT 07GAF- PH6o3q) PISTONBASE HEAD 07HAF- P120102 PISTONBASE 07973 - 6705{X'
Inspgctbolts and nuts for strogscracks.
NOTE: Installthe assembledpiston and rod with t h e o i l h o l e f a c i n g t h e i n t a k em a n i f o l d ( E r ( c e p t H22A1enginel.
7-20
PistonPins
Inspection
Measure diameter the pistonpin. the of Pbton Pin Diamoter: Standard (Nawl: 21.994(0.86s9 Ov6rsizg: 21.997{0.8560 Measure pistonpin-to-piston the clearance. NOTE:Check pistonfor distortion cracKs. the or 22.(XX' mm 0.8561inl 22.003mm 0.866:linl l f t h e p i s t o n p i n c l e a r a n c es g r e a t e rt h a n F 2 2 A 1 i e n g i n e : 0 . 0 2 4 m m { 0 . 0 0 0 9i n ) H 2 3 A 1 ,H 2 2 A 1 engines:0,026 mm (0.0010 remeasure in), using an pistonpin. oversize Piston Pin-to.PistonClearanco: F22A1engine: Standird (Ncw): 0.012- 0.024mm {0.0005 0.q)(xt in, H2341, H22Al ongines: Stlndsrd lNewl: 0.012- 0.026mm
NOTE:All replacement pistonpins are oversize.
2.
Zerothe dial indicstor the Diston diameter. to Din
4.
Checkthe diferrencebetweenpiston pin diameter and connecting smallend diameter. rod Pbton pin-to ConnoctingRod Interfa.oncs: Standa.d (Ncwl: 0.013- 0.032mm {0.00OS 0.0013in)
7-21
PistonRings
EndGap
1.
Using a piston, push a new ring into th cylindor '15 bore - 20 mm {0.6- 0.8 in) from the bottom. M e a s u r et h e p i s t o n r i n g e n d - g a pw i t h a f e e l r gauge: lf the gap is too small,checkto see if you have the properringsfor your engine. lf the gap is too large,recheck cylinderbore the diameter against wear limitson page7-17. the lf the bore is over the servicelimit, the cylinder blockmust be rebored. Pistoo Ring End-Gap: F22Al ongio: Top Ring Standard (Newlr 0.20- 0.35 mm (0.008 0.014in) in) SorvicoLimil: 0.60 mm 10.024 ScondRing Slandard {N6wl: o.i(t - 0.55 mm (0.015 0.022 inl SorviceLimh: 0.70 mm (0.028inl Oil Ring Standard (Newl: 0.20- 0.70 mm {0.008- 0.028in} 0.80 mm (0.03'linl ServicLimit H23A1,H22Al engine3: Top Ring Standard {New): 0.25- 0.35 mm 10.010 0.014in) mm (0.02'lin) SorvicaLimit: 0.61t Socond Ring Standard (N6w): 0.60- 0.75 mm 10.02,t 0.030in) mm {0.035inl ServiceLimit: 0.90 Oil Ring Stsndard (Newl: TEIKOKUPISTONRINGmanufacturs: 0.20- 0.50 mm (0.fi)8 - 0.020inl RIKENmanufacture: 0.20- 0.70 mm (0.008- 0.028inl Srvics Limit: TEIKOKUPISTONRINGmanutactur: 0.60 mm (0.02i1 in) RIKENmanutaqture: 0.80mm (0.031 in)
RING PISTON
r.---iL i.i----
iiii
ENDGAP
Ovg6izo: F22Al lnginel 0.251 85.25mm (3.356inl 0.50:85.50mm (3.366inl H23A1. H22Al .nginc: 0.25:87.25mm (3.i|il5inl
7-22
Replacement
1. 2. Usinga ring expander, removethe old pistonrings, Cleanall ring groovesthoroughly. NOTE: . U s e a s q u a r e d - o fb r o k e nr i n g o r r i n g groove f cleaner with bladeto fit pistongrooves. . Top and 2nd ring groovesare 1.2 mm ( 0 . 0 5i n ) wide and the oil ring groove is 2.8 mm ( 0 . ll i n ) wide. . Filedown bladeif necessarv. CAUTION: Dq not uss a wire brush to clean the ring groovgs, or cut ring groove3 d9per with cloaning tools. NOTE:lfthe pistonis to be separated from the connectingrod, do not installnew ringsyet. Installnew rings in the proper sequence and position (page7-24). NOTE:Do not useold pistonrings.
Ring-to-Groove Clearance
After installing new set of rings. measurethe ring-toa grooveclearances: Top Ring Clarlnc6 Standard (New): 0.035- 0.060mm {0.0014 0.002,tinl SorvicoLimit: 0.13 mm (0.005in) Second Ring Clsaranco Standard (Now): 0.030- 0.055mm (0.fl)12- 0.fl122inl SorvicoLimit: 0.13 mm (0.005inl
RINGEXPANDER
PistonRings
Alignment
1 , lnstalltheringsas shown. I Rotatethe rings in their groovesto make sure they do not bind.
ldentifyrop and secondrings by the chamferon the edge.Makesurethey are in their propergrooveson the paston. NOTE: The manufacturingmarks must be facing upwaro.
TOP RING
MARK
SECOND RING
3.
Position ring end gsps 8s shown: the
RINGGAP SECOND
DO NOT position any rinOgap at piston thrust surfaces.
H22Al onginos: H23A1, Approx.90'
Appiox. 90" TOPRINGGAP DO NOT posilion any ring gap in linewith the oistonoin hole.
OIL RING GAP GAP OIL RINGGAP
Crankshaft Seal Oil

; Installatio I
| | .11 'E The sealsurface the blockshouldbe dry. on Apply a light coat of oit to the crankshaft and to the lip of the s6al.
Pistons
lnstallation
B e f o r e i n s t a l l i n gt h e p i s t o n , a p p l y a c o a t o f engine oil to the ring groovesand cylinder bores. 1. ll the crankshaft alreadyinstalled: is . Setthe crankshaft BDCfor eachcvlinder. to o Removethe connectingrod caps and slip short sectionsof rubber hose over the threadedends of the connecting bolts. rod . Installthe ring compressor, checkthat the bearing is securelyin place,then position-the piston in the cylinder and tap it in using the wooden handleof a hammer. a Stop after the ring compressor pops free and checkthe connectingrod-to-crank journal alignment beforepushingpistoninto place. . Install the rod capswith bearings, and torquethe nutsto: 47 N.m {4.7kg-m.34lb-ft) lf the crankshaft not installed: is . Removethe rod caps and bearings,install the nng compressor, then positionthe piston in the cylinderand tap it in usingthe wooden handleof a nammer. . Position pistonsat toD deadcenter, all
l.
Drivein crankshaft sealagainstright sidecover. oil NOTE:Drivethe crankshaft sealin squarely. oil DRIVER 07749 0or(xDo
2.
Install sealwith the part number sid6 facingout.
DRIVEB ATTACHMCNT 079ir8 SBlXtl01 C o n f i r mt h a t t h e c l e a r a n c e s e q u a l a l l t h e w a y i aroundwith a feelergauge. Cloarancc: - 0.8 mm (0.02- 0.03 inl 0.5
The mark muBttace the timing beltside of the engine. The arrow must tace the timing beltsideot the engine.
RIGHTSIDE COVER
0.5 - 0.8 mm
NOTE:Maintaindownward force on the ring comp r e s s o rt o p r e v e n tr i n g s f r o m e x p a n d i n gb e t o r e entering cylinderbore, the

Usethe woodnhandle of a hammorto push,or
NOTE:Referto pages7-30and 8-11for installation of the oil pump sidecrankshaft sear. oil
Shafts and Balancer Grankshaft

lnstallation
apply a coat of Betoreinstallingthe crankshaft, r e n g i n eo i l t o t h e m a i n b e a r i n g s . o d b e a r i n g s shaft bearings. and balancer Insertbearinghalvesin the cylinderblockand connectingrods. so Holdthe crankshaft rod journaisfor cylindersNo. 2 and No,3 are straightup. into the block,seatingthe rod Lowerthe crankshaft journalsinto connecting rods No. 1 and No. 4. lnstallthe rod capsand nutsfingertight. 6. Installthe thrust washers,main bearingcaps and bearingcap bridge. Check clearancewith plastigage(page 7-8), then tightenthe bearingcap boltsin 2 steps. ln the first step tighten all bolts in sequence,to about 30 N.m (3.0 kg-m, 22 lb-ft);in the finsl step to tighten in same sequenc, 75 N.m {7,5 kg-m.54 tb-ft). with engineoil. NOTE:Coatthe bolt threads
RODNo. 2
WASHERS
RODNo. a
CAUTION: Whlnovor any crankshaft or connccting rod baaring i3 roplacad, it ir nocosarY lftcr lc!sscmbly to lun tho cngin. Ei idling tpoed until it rcacho! normal opcrrting iamporltula. thcn Gon. tinue to run it lor approximataly 15 minut6. 7. Insenthe balancer shaftsinto the block,then install shaftand block. to the retainer the front balancer
I
\ 'l
seat journals into clockwise, Rotatethe crankshaft rods No, 2 and No.3, and installthe rod connecting capsand nuts fingertiqht. NOTE:Installcaps so the bearingrecessis on the in sameside as the recess the rod. (page with plastigage Checkrod bearingclearance 7-10), then torquothe capnuts. 47 N.m (4.7kg-m.34lb-ft) numbers on connectingrod are NOTE: Reference for big-endbore toleranceand do not indicatethe positionof pistonin the engine.
7-26
NOTE: . Useliquidgasket, parrNo.087t8-0001. . Checkthat the matingsurfaces cleanand dry are beforeapplyingliquidgasket. . Apply liquidgasket evenly,beingcareful cover to allthe matingsurface. . To preventleakag oil. apply liquid gasketto of the innerthr6adsof th6 bolt holes, . Do not install the parts if 20 minutes or more haveelapsed sinceapplying the liquidgasket. Insteadreapplyliquid gasketafter removingthe old residue, . After assembly, wait at least 30 minutes before filling th6 enginewith oit. 8. Apply liquid gasket to the block mating surfaee of the right side cover, then install it on the cylinder block.
Apply liquidgasket to block mating surface.
6 x 1,0 rnm 12 N.m (1.2 kg'm, 9 lb-ft) Apply liquid gasket to the bolt threads.
RIGHTSIDECOVER
BIGHTSIDECOVER: 9. Apply liquid gaskstto the oil pump mating surfac of the block,then installthe oil pump on the cylinder block. . Apply greaseto the lips of the oil seals. T h e n , i n s t a l lt h e o i l p u m p w h i t e a l i g n i n gt h e inner rotor with the crankshaft. When the pump i s i n p l a c e , c l e a n a n y e x c e s sg r e a s e o f f t h e crankshaftand the balancer shaft, then check that the oil se8llips are not distorted.
OIL PUMP:
Apply liquid gaskst along the broken line.
{cont'd)
7 -27
Shafts and Balancer Crankshaft

Installation (cont'd)
shaftwith a 6 x 100mm bolt, 12. Holdthe rearbalancer drivengear. then installthebalancer
6x1.0mm 12 N.m (1.2kg-m,9lb-ftl OIL SCREEN
SHAFT: REAFBALANCER
8 x 1.25mm 25 N'm {2.5 kg-m, 18 lb-trl
O.RINGS Applyengineoil. Replace. DOWELPIN 6x1.0mm OIL PUMP kg-m, 12 N.m 11.2 Applyliquidgasket to 9 tb-ft) block mating surface. Applyliquidgasket to the bolt threads. Applygrease the seallips. to
6 r lOOmm BOIT
74 mm 12.9 inl
10. Installthebaifleplate,then installtheoil screen. '11. Apply molybdenumdisulfideto the thrust surfaces of the balancergears as shown, before installing t h e b a l a n c e rd r i v e n g e a r a n d t h e b a l a n c e rg e a r case. Applymolybdenum EALANCER SHAFT disutfide. DRIVEN
REARBALANCERSHAFT
'13. Hold the front balancershaft with a screwdriver, belt drivenpulley. then installthetiming balancer SHAFT: FRONTBALANCER
BALANCERBELT DRIVENPULLEY
BALANCERDRIVEGEAR AALANCERGEAR CASE
7-28
14. lnstallthebalancar gea|. caseto the oil pump. NOTE:Align the groovo on the pulley sdg to the pointoron the gear casswhile holdingths rear balancer with 6 x 100 mm bolt, then install the gear casg.
DOWELPIN E x 1.25mm 25 N.rn 12.5 lg.m. 18 rb-ft|
16. Install the oil pan.
OIL PAN GASKET Replace.
Apply liquid gasketto here.
BALAI{CER DOWELPIN GEAR $SE

POINTEB
O.RING Applyengine oil, Roplace.
WASHER Replace.
6xl,0mm 12 N.m {1.2kg.h, 9 rb-ft}
Alignthe groov to pornter.
45N.m(4.5 kg.m. 33tb-ftt Donot overtighten, 1 1 . Tightenthe boltsand nuts as shown below, Torqu.: 12 N.m (1.2 kg-m, 9 lb.ft)
GROOVE
Checkalignmentof pointersafter installing gear the case. POINTER THEPUL1TY ON
NOTE:Tightenthe bolts and nuts in two stoosand torquethem in a criss-cross pattern.
7-29
Shaft Oil Seals and Balancer Crankshaft

Installation {engineremovalnot requiredl
and front balancershaft NOTE:The crankshaft shouldbe dry. oil sealhousingsurface the to Apply a light coat oJgrease the crankshaft, the lips ot the seals. balancer shaftand to Using the specialtool, drive in the crankshaftoil the sealuntil the driverbottomsagainst oil pump. When thg seal is in place.clean any excessgrease and checkthat the oil seal lip is off the crankshaft not distorted. 3. Using the specialtool, drive in the crankshaftoil seal into ths right side coverto the point where the clearancebetween the bottom of the crankshsft oil seal and right side cover is 0.5 - 0.8 mm (0.020.03in) lpage7-251. with NOTE:Align the hole in the driver attachment the pin on the crankshaft.
SEALDRIVER O'LAD - PI':IOIOA lnslall se6l with the part number sido facing out.
07749 (x)1|xno
2,
Using the specialtool, d.ive in the front balancer shaft oil seal until the driver bottomsagainstthe oil pump. When the seal is in pl8ce,clean any excess greaseoff the balancer shaft 8nd checkthst the oil sealliDis not distorted.
ATTACHMEITT, 30 mm l.D. 077t6 - @30300
DRIVERATTACHMEMT 079a8- SB@r01 lnstoll sealwiththe part number side facing out.
GUIDE HUBASSEMBLY ATTACHMENT

_ OTGAF
7-30
Balancer Shafts
Inspection
NOTE: Inspectthe balancershaft before removingthe right sidecoverand the balancer gearcase{page7-12). '1. Push the balancershaft firmly away from the dial indicator, and zerothe dial againstthe front end of the balancer shaft,then pull the balancer shaftfirmly backtoward the indicator. Froni BalancorShaft End Play Standard (Nsw): 0.10- 0.35 mm l0.00il 0.014in) Remove balancer the shafts(page7-12). NOTE:Clean the balancer shsfts, Inspect surfaceof the balancer the shaftjournaland balancer bearing. Replace there is wear,damageor discoloration if on the surfaceof the bearingor the balsncer shaftjournal. When replacing the rear No. 1 bearingbe sure to replace oil pump housingwith a new one. the NOTE;A mirro.-like surfaceis normat. Measure taperat the edgesof eachjournal. . The differencebetweenmeasurements each on lournal. Journal Tapor Standard (Newl: 0.005mm (0.0002in)
lf end play is excessive, inspectthe retainerand thrustsurfaces the balancer on shaft.
Rsar BalancorShrft End Play Stsndard(Nw):0.06- 0.18mm 10.002 0.007inl
lf end play is excessiv, inspect the thrust washer and thrust surfaces the driven qear and oil on pump Dody.
N O T E :T h e t h i c k n e s s f t h e r e t a i n e r( f r o n t ) a n d o t h r u s t w a s h e r ( r e a r )a r e f i x e d a n d m u s t n o t b e changed eitherby grindingor shimming.
{cont'd)
7-31
Shafts Balancer
(cont'd) Inspection
6. Measurerunout on the No. 2 journal of each balshaltsare not ancershaftto makesurethe balancer bent, Ealanc6rShaft Total IndicatodRunout Standrrd (Now): 0.02 mm (0.001inl inl Sewice Limit: 0.03 mm 10'001
Measurethe diametersof the balancershaft journ al s .
:
I
MEASURINGPOINTS
i
I
Journal Diamotr Stlndard (New) No, 1 ioutnal: mm Front: 12-722- 12..731 11.6820 1.6824inl 20.938- 20.950mm Rear: in} {0.824:l 0.82'18 No. 2 iourn.l: 38.712- 38.724mm inl l1.52al- 1.5245 No. 3 iourn.f : 31.722- 31.731mm (1.3670 1.3675 inl Limit: Scrvica No. I iournal: in) 42.71mm {1.681 Front: inl 20.92mm 10.82,1 Rcar: inl No. 2 iouinll: 38.70mm (1.524 in) No. 3 iournal:34.71mm (1.367 the pistons and the other Removethe crankshaft, oartsfrom the block,then cleanthe balancershaft i o u r n a l b e a r i n g so f t h e b l o c k a n d t h e o i l p u m p housingwith a cleanshoptowel. 9. if Checkthe surfaceof the bearings, there is wear. damage or discoloration,replacethe bearingsor the oil pump housing.
7 -32
1 0 . Measurethe inner diametersof the balancer shaft journalbearings.

MEASURE POINTS No. 2 BEARING IBLOCKI
Bearing Inner Diametor Standard {Nswl: No. I iournals: Fronl: 12.8OO- 12-82O mm (1.6850 1.6858 in) Rear: 21.flD - 21.013 mm {0.8268 0.8273inl No. 2 iournals: 38.800- 38.820mm (1.5276 1.5283 in) No. 3 iournals: 34.800- 3,1.820 mm inl {1.3701 1.3709 ServicoLimit: No. l iournals: Front: 42.8:lmm 11.686 inl R6ar: 21.02mm (0.828 in) No. 2 iournals: 38.tIl mm (1.529in) No.3 iournsls:3i1.83 (1.371 mm in) 11. Calculate shaft-to-bearings clearances. the oil BEARING - JOURNALO.D. = OtL CLEARANCE l.D. Boaring-to-shaftOil Cl.aranc Standard (Newl No. I iournal front and No. 3 iournsls: 0.066 0.118mm {0.0026 0.0046 inl No. 2 iournab: 0.076- 0.128mm (0.0030 0.0050in) No. 1 iournal rar: 0.050- 0.075mm (0.0020 0.0030in) S6rviceLimit: No. I iournal tront and No. 3 iournats: 0.12mm (0.005 inl No. 2 tournsls: 0.13mm {0.005 inl No. I iournal roar: 0.09 mm (0.004in)
No. 2 BEARING IBLOCK) BLOCK
DIALGAUGE
No. 1 REARBEARING IOIL PUMP HOUSINGI
7-33
EngineLubrication
Speciaf Tools.......... ...........9-2 lllustrated lndex........... .....8-3 Engine Oil Inspection ...................... 8-5 Replacement ....................................... 8-5 Oil Filter Rep|acement ....................................... 8-6 Oil Pressure Testing ......8-8 OilJet fnspection lHz2Al engineonly) ........ 8-8 Oil Pump Overhaul ......................... 8-9 RemovaUlnspection/lnstallation8-10 ......
SpecialTools
Rs{. No.
Tool Numbel OTLAD 07746 07749 07912 PT3O1OA 0010300 0010000 6110001
Drtcription SealDriver 42 Attachment, x 47 mm Driver Oil Filterwrench
Oty
PEg. Rctercnc. 8-11 8-1 1 8-1' I a-7
o
Ar
@ @
I
o
8-2
lllustratedIndex
NOTE: a Us new O-rings when reassembling. . Apply oilto O-ringsbeforeinstallation. . Useliquidgasket, PartNo. 08718 OOO1. . Clean the oil controlorificewhen installing. 8 x 1.25 mm CAUTION: Do not overtighten the drain plug.
OILPUMP Overhaul, pageI 9 Inspection, page8-10 Apply liquidgasket to blockmatingsurface. O-RINGS Replace. F22A1,H23At enginesj OIL CONTROL ORIFICE Do not install on the H22A1 it engine. Clean. O.RING Replace. F22Al engin: ENGINEOIL PRESSURE SWITCH 18 N.m (1.8 kg.m, t3 tb-ft) 1/8in. BSP{British standard pipetaper) 28 threads/inch. Use properliquidsealant. H23A1,H22At engin.s: KNOCKSENSOR 32 N.m 13.3kg-m, 23 tb-ftl
8 x 1.25mm 30 N.m (3.0 kg-m, 22tb-ft1
BALANCEN GEARCASE
O.RING Replace. DOWEL PIN
8 x 1.25mm 25 N'm 12.5 kg-m, i8 tb-ft}
ENGINE OIL COOI..ER {H23A1, H22Al ongin6)
DOWEL PIN GASKET

Replace. OIL SCREEN OIL FILTER 7/8 turn or 22 N.m l2.2lg-m, i6 tb-ft| Replacemg6lp6gs g 6 Replace every 7,500miles {12,000 or 6 months. km) H23A1,H22At engin$: ENGINEOIL PRESSURE SWITCH 18 N.m {1.8 kg-m, t3 tb-ftl
OIL PAN GASKET Roplace.
6x1.0mm 12 N.m 11.2 kg-m,9 tb-ft|
6x1.0mm 12 N.rn(1.2kg-m.9 tb-ft) WASHER Replace. DRAINBOLT 1 4x 1 . 5m m 45 N.m 14.5 kg-m,33 lb-ttl Do not overtighten.
OIL PAN
(cont'd)
8-3
lllustratedIndex
lcont'd)
NOTE: a Usenew O-ringswhen reassembling. . Apply oilto O-ringsbeforeinstallation PartNo. 08718 0001. . Use liquidgasket,
1 1x 1 , 5m m 75 N.m (7.5kg-m, 54 tb-ft} Applyengineoiltolhe bolt threads and th washers NOTE: Alter torquing each cap, to turn crankshaft chock for binding.
5x1.0mm kg-m,9lb-ft| 12 N.m 11.2
BAFF1TPLATE
EEARINGCAP BRIDGE
OIL JET BOLT 40 N.m {a.0 kg-m, 29 tb-ft) OIL JET with Handle nozzle the il care.Replace any pan is damagedor detormed. 6x1.0mm 12 N.m {1.2lg-m,9lb-ft}
CRANKSHAFT
THRUST WASHERS Groovedsidesface outward.
a-4
Engine Oil
Inspection
Checkengine oil with the engine off and the car parkedon levelground. Makecertainthat the oil level indicated the dioon stickis betweenthe upoerand lowe. marks. lf the level has dropped close to the lower mark. add oil until it reaches upDermarK. the CAUTION: In36rt thc dipstick cardully to avoid bonding it.
Replacement
CAUTION:Removs the drain bolt carofullywhile th6 ongine is hot oil m8y caus6scalding. L 2. W a r mu p t h e e n g i n e . Drainthe engineoil.
45 N.m{a.5kg-m, tb-ft| 33
WASHER R6placo.
R e i n s t a ltlh e d r a i n p l u g w i t h a n e w w a s h e r , a n d refillwith the recommended oil. CAUTION: Do not ov6rtight6n the drain bolt.
Requirement API ServiceGrade:Use "Energy Conserving ll" SG gradeoil. F22A1,H23A1engines:5 W- 30 preferred. H22Al engine: W - 30 preferred. 10 Capacity F22A1 enginel 3.8f (4.0US qt,3.3 tmp qt) change, including filter. 4 . 9 1( 5 . 2 S q t , 4 . 3 l m p t ) U q atter engine overhaul. H23A1 engine: 4.3f (4.5US qt, 3.8tmp qt) chang,includingfilt6r. 5.4f (5.7US qt, 4.8lmp qt) afterengineoverhaul. H22A1 engino: 4.8f (5.1US qt, 4.2 lmp qO change, including fitter. 5.9f (6.2US qt, 5.2lmp qt) aflerengineoverhaul, Every7,500miles {12.OOO or 6 months krn)
Change
{cont'd)
8-5
Engi n eOi l
The numbersin the middle of the API Servicelabeltell you the oil's SAE viscosityor weight. Selectthe oil for your car according this chart: to F22A1.H23A1engines:
Oil Filter
Replacement
o Ltter tte engine has been run. the exhaurt pipo will be hot; be caroful when working around the axhau3t pipo. Be careful when loo3oning the drain bolt while tho engino i3 hot, Burns can rosult becausothG oil lgm' peraturc is very high. R e m o v et h e o i l f i l t e r w i t h t h e s p e c i a lo i l f i l t e r wrench. the threadsand rubber seal on the new filInspect ter. Wipe off seat on engine block,then apply a light coat of oil to the filter rubberseal. NOTE: Use only filters with a built-in bypasssysrem.
Ambint Temperaturo
A n o i l w i t h a v i s c o s i t yo f 5 W - 3 0 i s p r e f e r r e df o r improved fuel economy and year-roundprotection in the car. You may use a 10 W - 30 oil if the climate in rangeshown on your area is limitedto the temperature the chart. H22A1engine:
Applyengineoilto rubbr sealbeforeinstalling.
Ambiont Temo6raturs
-20
An oil with a viscosity of 10 W - 30 is preferredfor improved tuel economy and year-roundprotectionin the car. You may use a 5 W - 30 oil if the climate in rangeshown on the your area is within the temperature chan. N O T E : T h e o i l f i l t e r s h o u l d b e r e p l a c e da t e a c h o i l change.
8-6
Installtheoil filter by hand. A f t e r t h e r u b b e rs e a l s e a t s .t i g h t e n t h e o i l f i l t e r clockwise with the specialtool. Tighten: 7/8 turn clockwise Tightoning torque: 22 N.m (2.2 kg-m, 16 lb-ftl CAUTION: lnstallation other than the abov procsdur6 could result in sgrious ongine damage due to oil l6ak.go.
eight numbers(1 to 8l are printedon the surfaceof the filter. The following explainsthe procedure tighteningfil, for ters usingthesenumbers. 1) Make a mark on the cylinderblock under the number that shows at the bottom of the filter when the rubbersealis seated. 2) Tightenthe filter by turning it clockwise sevennumbersfrom the markedpoint. For example,if a mark is made under the number 2 when the rubberseal i s s e a t e d t h e f i l t e r s h o u l d b e t i g h t e n e du n t i t t h e , number1 comesup to the markedpoint.
OIL FILTER WRENCH 07912- 611t)00r
Numberwhen rubber sealis seated.
Numberaftertightening.
Numberwhen rubber sealis seated

ENGINEOIL COOLER (H23Al, H22A1engine3l
4 8 1
8 1
Numberaftertightening
5.
After installation, the engine with oil up to the fill specified level,run the enginefor more than 3 min utes,then checkfor oil leakage.
a-7
Oil Pressure
lf the oil pressure warning light stayson with the engine running.checkthe engineoil level.lf the oil level is correct:
'1.
Oil Jet
fnspection engineonlyl lH22A1
Removethe oil jet (page8-4) and inspectit as folrows. Make sure that a 1.1 mm {0.04in} diameterdrill will go throughthe nozzle hole {1.2mm t0.05in) diameter). Insertthe other end of the same 1.1mm {0,04in} drill into the oil intake(1.2 mm (0.05in) diameter). Make sure the check ball moves smoothlv and has a strokeof approximately mm (0.16 4.0
In,.
Connect tachometer. a Removethe engine oil pressureswitch and install gauge. an oil pressure S t a r t t h e e n g i n e . S h u t i t o f f i m m e d i a t e l yi f t h e gauge registers oil pressure. no Repair the problem beforecontinuing. Allow the engine to reach operatingtemperature (radiator comeson at leasttwice).The pressure lan shouldbe: Engine Oil Tamp6rrture: 176'F {80'C) EngineOil Pressure: At ldle: 70 kP8 (9.7 kg/cm,, 10.0psi) minimum At 3,flt0 rpm: 350 kPa (3.5kg/cm,, 50 p3il minimum
Checkthe oil jet operationwith an air nozzle. lt should take at least200 kPa (2.0 kg/cm,,28 psi) to unseat checkball. the NOTE:Replace oil jet assemblyif the nozzl the is damagedor bent,
1!
I
:. '
lf oil pressure within specifications, is replace the oil pressureswitch and recheck. l f o i l p r e s s u r ei s N O T w i t h i n s p e c i f i c a t i o n s , inspect oil pump (pages the 8-10,11|.
I
.
ENGINE OIL PRESSURE SWITCH MOUNTINGHOLE {F22A1engino}
OIL PRESSURE GAUGE
I
i
I I
ENGINE OIL PRESSURE SWiTCH MOUNTINGHOLE lH23A1,H22Al cneinos) lH23A1,H22A1.ngin.!l
Mounting torque is critical.Be very precisewhen installing. Torquo: 40 N.m (4.0 kg-m, 29 lb-ft)
8-8
Oil Pump
Overhaul
NOTE:
Usenew O-ringswhen reassembling, Apply oilto O-ringsbeforeinstallation. Use liquidgasket, PartNo.08718 0001.
6x1.0mm 7 N.m {0.7 kg-m, 5.1 lb-ftl PUMPCOVER
OOWEL PIN
OUTER ROTOR page 11 Inspection, 8-10,
6x1.0mm 12 N.m {1.2kg-m,9lb-ft}. Apply liquid gasker to the bolt threads,
INNERROTOR page8-10,t 1 Inspection,
OIL SEALS Replace.
PUMPHOUSING pageI 10.11 Inspction,
8-9
Oil Pump
Removal/lnspection/lnstallation
t o 1 . D r a i n h ee n g i n e i l . 2. Turn the crankshaft that the No. 1 pistonis at top so d e a d c e n t e r( F 2 2 A 1e n g i n e :p a g e 6 - 2 8 ,H 2 3 A 1 engine:page6-62,H2241engine:page6-106). the belt Remove timing belt and the timing balancer (F22A1 engine:page6-29,H23A1 engine:page6-63, H22A1 engine:page6-'l07). Remove he timing belttensioner nd the timing t a belttensioner. balancer Bemovethe timing belt drive pulleyand the timing balancer belt drivenpulley(page7-12). 6. g R e m o v e h e b a l a n c e . e a r c a s ea n d t h e b a l a n c e r t drivengear(page7-121. Remove oil pan and the oil screen. the R e m o v et h e m o u n t i n gb o l t s a n d t h e o i l p u m p assemory.
t
9. Removethe screwsfrom the pump housing,then separate housingand cover. the '10. rotor radial clearance Checkthe inner-to-outer on the oumo rotor. lnner Rotor-to-OuterRotor RsdialClea.anc Sland8ld (Newl: 0.02- 0.16 mm (0.001- 0.006in) ServiceLimit: 0.20 mm 10.008 inl
ii
I
DOWELPIN OIL PUMP
lf the inner-to-outer rotor clearance exceeds the service limit, replace innerand outer rotors. the
O.RINGS Replace-
1'1. Checkthe housing-to-rotor axial clearancson the oumo rotor. Housing-to-RotorAxial Clcaranco Standard lNewl: 0.02- 0.07 mm (0.001- 0.003in) SorvicoLimit 0.12 mm 10.005 inl
Replace.
PUMP HOUSING
OUTERROTOR ROTOR OUTER
OIL SCREEN
lf the housing-to-rotor axial clearancexceeds t h e s e r v i c el i m i t , r e p l a c et h e s e t o f i n n e r a n d outer rotorsand/orthe pump housing.
8-10
12. Chck housing-to-outer the rotor radialclearance, Housing.to-OuterRolor RadialClrarsnc Stlnda.d {Nsw}: 0.10- 0.19 mm (0.004- 0.007in} SorvicaLimit: 0.21 mm (0.fi)8 in)
_ 077a6 00,t0300
,rJ:|xaTmm
Rsassemblethe oil pump, applying liquid thrcad lockto the pump housingscrews. 1 7 . Check that the oil pump turnsfreely, ?8. Installa dowel pin and the new O-ringon the pump, NOTE:
a Useliquidgasket, Pan No. 08718 0001. a Check that the matingsurfaces cleanand dry are
l f t h e h o u s i n g - t o - o u t erro t o r r a d i a l c l e a r a n c e exceedsthe service limit, replacethe set of inner and outer roto.sand/orthe pump housing.
1 3 . Inspect both rotors and the pump housing for scoring or other damage.Replaceparts if necessary. Remove old oil sealsfrom the oil pump. the
t5.
beforeapplyingliquidgasket. Apply liquidgasketevenly,in a narrowbeadcenteredon the matingsurface. . To preventleakage oil, apply liquid gasketto of the innerthreadsof the bolt holes, . Do not install the parts if 20 minutes or more haveelapsed sinceapplyingliquidgasket. Insteadreapplyliquid gasketafter removingthe old residue. . After assembly, wait at least 30 minutes before filling the enginewith oil. 19. Apply liquidgasket the oit pump and insta it. to . Apply greaseto the lips of the crankshaft seal oil and the balancershaft seal.Then, installthe oil pump Inner rotor onto the crankshaft. When the pump is in place,cleanany excess greaseoff the crankshaftand the balancer shaft, then check that the oil seal liDsare not distorted.
Gentlytap in the new oil sealsuntil the special tool bottomson the pump. NOTE:The oil sealsalon can be reolaced without romovingth oil pump usingthe specialtool.
Apply iiquidgasket alongthe brokenline.
(cont'd)
8-11
Oil Pump
Removal/lnspection/lnstallation {cont'd}
23, Hold the rear balaocorshaft with the 6 x 100 mm drivengear. bolt,then installthe balancer
Apply grease to the seallips. 6 x 10 mm 12 N.m 11.2kg-m, 9 lb-ft| OIL PUMP Apply liquidgasket the to Applyliquidgasket bolt threads. to block mating surface.
REARBALANCER:
O.RINGS Applyengineoil. Replace.
I x 1.25mm 25 N.m {2.5 kg-m, 18lb-ft}
6 x 100mm EOLT
6x1.0mm 12 N.m (1.2kg"m, 9 tb-ttl t4 mm 12.9inl
OIL SCREEN
Install the baffleplate. 2 1 . Install oil screen. the Apply molybdenumdisultideto the thrust surfaces of the balancergears.as shown, before installing t h e b a l a n c e rd r i v e n g e a r a n d t h e b a l a n c e rg e a r
case. Apply molybdonum disulfide. BALANCER DBIVEN GEAR REANBALAI{CERSHAFT
24. Hold the front balancershaft with a screwdrivr, blt drivnpull6y. then installthe timing balsnce. FRONTBALANCER:
BALANCER DRIVE GEAR
8-12
gear caseon the oil pump. 25, lnstallthebalancer NOTE;Align the groove on the pulley edge to the pointeron the gear casewhile holdingthe rear balancerwith the 6 x 100mm bolt,then installthe gear case.
DOWELPIN 8 x 1.25mm 25 N.m 12.5kg-m, 18 lb-ftl
27. Install the oil pan.
OIL PAN GASKET Replace.
Apply liquid gaskthere.
BALANCER GEARCASE
DOWELPIN
O.FING Apply6nginoil. Replace.
WASHER Replac6.
6x1.0mm
POINTER Alignthe O.oove to pornter,
DRAIN EOLT ils .m 14.5 ks-m, 33 tb_ft) Donotovertightsn.
24. Tightenthe boltsand nuts as shown below. Torquo: 12 Nfl (1.2tg-m,9 lb-ft)
GROOVE
26. Checkalignmentof pointersafter installing gear the case. POINTER THE ON PULLEY
a -------_
POINTER ON THEOIL PUMP
NOTE:Tightenthe bolts and nuts in two stepsand pattern. torquethem in a crisscross
8-13
Intake Manifold/Exhaust System

Intake Manifold R e p l a c e m e n.t. . . . . . . . . . . . . . . . . . . . . . .9 . .2 . . . .- . ExhaustManifold R e p 1 a c e m e.n .t . . . . . . . . . . . . . . . . . . . . . .9 . .4 . . . .- . ExhaustPipe and Muffler R e p | a c e m e n . . . . . . . . . . . . . . . . . . . . . . . . . 9.-.7. .t . .
Intake Manifold
Replacement
NOTE: Use new O-ringsand gasketswhen reassembling.
a Chock tof folds or scratchos on ths surlace of th6 gaskot. a Replaco with a new gasket it dsmaged. H2341, H2241 engines: 22 N.m (2.2 ks-m, 16 lb-tll
STARTINGAIR VALVE 6xl.0mm 12 N.m 11.2 kg-m, 9 lb-ft| IDLE AIR CONTROL 8 r 1,25mm
INTAKE MANIFOLD CHAMBER Replacoif cracked or if mating surfaces are damaged.
{tAc}val-vE
8 x 1.25mm 22 N.m 12.2 kg-m, 16 lb-ft}
THROITLE BODY
d
O-RINGS Replace.
GASKET Replsce.
INTAKE AIR BYPASS FAST IDLE TXERMO VALVE
IIAB}VALVEBODYASSEMELY
Replace crackedor if if mating surlaces are oamageo.
6 x 1 . 0m m 12 N.m ('1.2kg-m,I lb-ttl
8 r 1.25mm 22 N.m 12.2 kg-m, 16 lb-ft)
GASKET Replace.
|l['sJ!'J[*%''
(fAT) SE[{SOR ./ O.RING Replace.
Y"Sft
EXHAUST GAS NECIBCULATIOI{ VALVE IEGR}
INTAKE
Replace crackedor it if mating su aces are damaged.
8r1.25mm 22 N.m (2.2 ks-m,l6 lb-tt) GASKET Replace.

8x1.25mm 22 N.tn 12,2 kg-m, 16 lb-ftI
8 x 1.25mm 22 N.m 12.2 kg-m, '16 lb-ftl
INTAKE MANIFOLD BRACKET
9-2
NOTE: Use new O-ringsand gasketswhen reassembling. CAUTION: a Check fol tolds or scfatchos on tho surfac6 ot the gaskst. a Roplsco with a nw gasket if damaged. F2241 engino:
8 x 1.25mm
FAST IDI-ETHERMO VALVE

I x 1.25mm 22 N.m 12.2 kg-m, 16 lb-ftl
22 N'm 12.2ks-m, 16 lb-ftl
STARTINGAIR VALVE O-RINGS Replace.
IAC VALVE
6 x 1.0 mm 12 N.m 11.2 kg'm, 9 lb-ft} 6 x 1.0 mm 12 N.m 11.2 kg-m, 9 lb-ttt INTAKE MANIFOLD CHAMBER Replaceif cracked or if mating surfaces are damaged. O.RINGS Replace.
THROTTLE BODY 8 x 1 . 2 5m m 22 N.m 12.2kg-m, 16 tb-ftl
GASKETS Replace.
8 x '1.25mm 22 N.m 12.2 kg-m, 16 lb-ft) EGR VALVE
GASKETS Replace.
8 r 1.25mm 22 N.rn 12,2 kg-m, 16 lb-ft)
8 x 1.25mm 22 N.m 12.2 kg-m, 16 lb-ft)
INTAKE MANIFOLD BRACKET
9-3
Exhaust Manifold
Replacement
NOTE: Use new gasketsand seltiocking nuts when reassembling' CAUTION: a Check for folds or scratchas on the sutfaca of tho gasket' a Rsplace with 6 new gaskot il damagod. H23A1 engine:
NUT SELF-LOCKING I x 1.25mm 32 N.rn (3.2 kg-m, 23 lb-ft) Replace.
GASKET R6place.
8 r 1.25mm 22 N.n 12.2 kg-m, 16 lb-ft)
MA IFOID EXHAUST BRACKET
lO x 1.25mm 45 t{.m (4.5 kg-m. 33 lb-ft} GASKETS Roplace. r 1.25mm 22 N.m 12.2 kg-m, l6 lb-ftl
1 0 r 1 . 2 5m m 45 N.m t4.5 kg-m.33 lb-ft)

6 x 1.0 m]n 12 N.m ll.2 kg-m. 9 lb-ft) T INSULATOR
NUT SELF-LOCKING 10 x 'l,25 mm 55 N.m t5.5 kg-m,40 lb-ftl
6 x 1.0 mm 10 N.m (1.0 kg-m, 7 lb-ft)
9-4
NOTE: Use new gasketsand selflocking nuts when reassembling. GAUTION: a Check tor folds or sclatches on th surfacs of the gaskt. a Replacewith a new gaskot if damaged. F2241 ongine:
GASI(ET Replace.
EXHAUST
SELF.I.OCKING 1{UT 8 x 1 . 2 5m m
32 'm 13.2 kg-m, 23 lb-ft| Replace.
,.(
HEATED OXYGEI! SENSOR {HO2Sl

45 N.m 14.5 kg-m, 33 lb-ft) Be carelul not to
EXHAUST MANIFOI.D BRACI(ET
8 x 1.25mm 22 N.m 12.2 kg-m, 16 lb-ft)
GASKET Replace.
10 x 1.25mm 45 N.m {4.5 ks-m, 33 lb-ft}
SELF.I-OCKIl{G NUT 10 x 1.25mm 55 N'm 15.5 kg-m. 40 lb-fi) Replace.
HO23 CONNECTOR
COVER
HEAT INSULATOR lCars equippedwith air conditioningl
6 x 1 . Om m 10 N.m (1.O kg-m, 7 lb-fil
9-5
Exhaust Manifold
Replacement
nuts when reassembling. NOTE: Use new gasketsand self-locking CAUTION: a Chock tor folds or scratchoa on tho surface of the gasket. a Replaco with a now gaskot it damaged. H22A'l ongino:
lr I
t{UT SELF.LOCKING 8 r 1.25mm 32 N.m {3.2 kg-m, 23 lb-ft) Replace. EXHAUST MAf{IFOLD
GASKET Replace.
COVER
1 0 r 1 . 2 5m | n 33 lb-tt)
.m 14.5 lg.|n,
GASKETS R6place.
8 x '1.25mm 22 N.m 12.2 kg-m, 16 lb-ft)
HEATINSULATOR
SELF-LOCKII{G NUT 10 x 1.25mm 55 N.m (5.5 kg-m, il.O lb-ft) EXHAUST PIPEA 8 x 1.25mm 22 N.m 12.2 ks-m, 16 lb-ft1 6 x 1.0 mm 10 N.m (1.0 ks-m, 7 lb-ft|
9-6
Exhaust Pipe and Muffler

Replacement
NOTE: Use new gasketsand self-locking nuts when reassemblino.
6 x 1 . 0m m 10 N.m {1.Okg-m.7 lb-ftl

HEAT SHIELD SELF-LOCKING NUT 1 2 x 1 , 2 5m m 55 N.m {5.5 kg-m,4O lb-ft| Replace.
\
EXHAUST PIPETIP
THREE WAY CATALYTIC COI{VERTR TTWCI TOROUE SEOUENCE
MUFFLER
\ GASKET Replace.
EXHAUSTPIPEB
45 N.ln 14.5 kg-m, 33 lb-ft| Be carefulnot to damage.
SEI.F.LOCKING NUT 10 x 1.25mm 34 N.m {3.4 kg-m, 25 tb-ftl Replace.
oor*rrr\
Replace. V
3
SELF-LOCKING NUTS I x 1,25mm 18 N.m (1.8 kg-m, 13 tb-ftl Replace.
GASKET
SELF-LOCKING NUT 10 x 1.25mm 55 N.m (5.5 kg-m,40 lb-ttl Replace.
SELF-LOCKING NUT 10 x 1-25mm 34 N.m (3,4 kg-m, 25 lb-ttl R6place.
I
9-7
Cooling
Radiator fffustrated Index......... . 1O-2 R e p | a c e m e.n t . . . . . . . . . . . . . . . . . . . . . . 1. . .-.5 .. .O . EngineCoolantRefilling a n dB l e e d i n g . . . . . . . . . . . .0 - 6 1 C a pT e s t i n g . . . . . . . . . . . . .1 . - 7 .0 Testing ..... 1O-7 Thermostat R e p | a c e m e.n . . . . . . . . . . . . . . . . . . . . . . . 1.O.-.8 .t . . . Testing ..... 10-9 Water Pump lllustrated Index......... . 1O-1O fnspection . 10-12 Repfacement .............. 1O-12
Radiator
lllustratedIndex
sy"t". is under high pressurewhon engino @ is hot, To avoid dangel ot releasingscaldingcoolant, remove cap only when engine is cool. Total Cooling System capacity {lncluding hoater and resrvoir) F2241 engin: ", : .1 | l7 .5 US qt, Manuaf Automatic: 7 .O | (7 .4 US qt, H23A1 sngin: Manuaf : 7 ,4 (. 0,A US qt, Automatic: 7 .3 I 17.7 US qt. H2241 engin: Manual: 7.6 | (8.O US qt, CAUTION: Whn poudng ongino coolant, be suts to shut the relay box lid and not to spill coolant on the electlical parts or tha paintsd po ion. lf 8ny coolant spills, rinse it off immdiately. NOTE: a Checkallcooling systemhosesfor damsge,leaks or deterioration and replaceif necessSry. a Check all hoss clamps and retightenif necessary. a Use new O-ringswhen reassembling. RADIATOR Engine coolant
6.2 lmp qt) 6.2 lmp qt) 6.5 lmp qtl 6.4 lmp qt) 6.7 lmp qt)
Reselvoircapacity:O.6 t {0.6 US qt, O.5 lmp qt)
p6ge 'l0-6 Refilling and bleoding. Leak test, page 1O-7 Inspect soldered joints and seamsfor leaks. Blow out dirt from between core fins with compregsedair. l{ insects,etc., are clogging radiator, wash them off with low oressule water.
RADIATOB CAP Pressure testing,pago 1O-7
6 x 1.0 mm 1 0 N . m { ' l . Ok g - m , 7 tb-ft)
FLUID (ATF) COOLER
FAN MOTOR
6 r 1 . 0m m ' l ON . m( 1 . 0rg-m, 7 tb-ttl
o.
O-RING DRATNPLUG Replace.
;t'i.*:l:XS[YJ,,,
Replace.
FAN COOLING
FAN SHROUD
10-2
Engino Ho86 Connoctions:

IOLEAIR CONTROL {IACI VALVE FAST IDLE THERMO V THERMOSTAT HOUSING
F22A1 engine:
\
HEATER OUTLET
LOWERHOSE
CONI{ECTINGPIPE BYPASS HOSE Replace.
HEATER INLET HOSE
H23Al engine:
IAC VALVE
POSITIVECRANKCASE VENTILATION(PCV} PIPE
EYPASS HOSES O.RING Replace. OIL COOLER BYPASS HOSE
HEATER
O-RING Replace.
* 8 x 1 . 2 5m m PIPE CONNECTING 22 N'm kg-rn, OIL COOLER 12.2 16 tb-ft) BYPASS HOSE COOLER
r:: CORFOSION RESTSTANT BOLT
(cont'd)
10-3
Radiator
lllustratedIndex (cont'd)
Engin Hose Connections:
H22A'l ngin:
THERMOSTAT HOUSING
INLET HEATER HOSE
OUTLET HEATER HOSE

PIPE CONNECTING
O-RING COOLER Replaco.
* 8 x 1 . 2 5m m 22 N.m 12.2kg-m, 16 tb-ft}
RESISTANT BOLT *: CORROSION
10 -4
Replacement
1 . Drinenginecoolant. Romovethe upper and coolor hoses.
a
5. radiatorhoses,and ATF
Removethe fan shroudassemblies and other parts from radiator.
Instsllthe radiatorin the reverseorder of removal: NOTE: a Set the upper and lower cushionssecurly. a Fillthe radistorwith engine coolantand bleedthe ai''.
Disconnect the fan motor connectors. Rmovethe radiatorupper brackets,then pull up the radiator.
4.
6 x 1.0 mm 10 N.m (1.0 kg-n, 7lb-ft1
RADIATOR
page 1O-7 BADIATOR CAP Testing,page 'lO-7
6x1.0mm 10 N.m ll.O kg-m,7 lb-ft} UPPER I{OSE
UPPER BRACKET ANDCUSHION
:tt'l13l3l=.--_g
I x 1.0 mm lO N.in (t.O kg-m.7 tb-frt @
F/o "l
sng 7.r.
d
FAN MOTOR CON'VECTOR
owE CUSHTON R
ATF COOLER HOSE$ O-RING Replace. LOWERHOSE
HOSE 1 RESERVOIR \
DRAIN PLUG
RESERVOIR
10-5
Radiator
Engine Coolantnefill\ and Bleeding
CAUTlOttl: When pouting enginocoolaisQgsuro to shut th6 ralay box lid and not to lst coolanl spill on tho electrical part6 or lh paint. lf any coolant spills, rinse it off immodiat6ly. 1. Set the heatertemperaturelever or conttol dial to maxamum heat. 2. 3. Removethe engine splashshield. When the radiatoris cool, removethe radiatorcap. Loosenthe drain plug, and drain the coolant. Removethe drain bolt trom the rear side of the cylinderblock to drain the block and heater, Apply liquidgasketto the drain bolt threads,then reinstall the bolt with a new washer and tighten it securely. Tightenthe radiatordrain plug securely. Fillthetank reservoir. Remove, drainand reinstallthe the MAX mark with water, then up to the haltway to MAX mark with anti-freeze. Mix the recommendedanti-freezewith an equal amount ol water in a clean container. NOTE: a Use only genuineHonda anti-Jreeze/coolant. a Fof best corrosionDrotection, coolant concenthe year-roundat 50 tration must be maintained less concentrations than 50% minimum.Coolant may not provide sutficient protection againstcorrosion or treezing. a Coolantconcentrationsgreaterthan 60% will impaif cooling efficiency and are not recommended. CAUTION: a Do not mix dilferent brands of anti-freoze/ coolants. a Do not uso additional rust inhibitors or anti-rust products; they may not be compatible with tho gnuine coolant. Engine Coolant Refill Capacity: including reservoir {0.6 t {0.6 US qt, 0.5 lmp qt}l and heatar{0.6 f (o.6 US qt, 0.5 lmp qt)|. F22Al engine: Manual: 3.5 I (3.7 US qt,3.1 lmp qt) Automatic: 3.4 f {3.6 US qt, 3.0 lmp qtl H23Al engine: Manual: 3.8 X (4'O US qt, 3.3 lmp qrl Automatic: 3.7 t {3.9 US qt, 3.3 lmp qt} H22Al engino: 4.O f 9.2 US qt, 3'5 lmp qt) : Manuaf
9 . Loosenthe air bleed bolt in the thetmostat housing,

then fillthe radiatorto the bottom of the tiller neck with the coolantmixtu.e. Tightenthe bleedbolt as soon as coolant stans to run out in a steadv stream without bubbles. BLEED BOLT
4.
5.
6. 7,
8.
DRAII{ BOLT
60 N.m {6.0 kg-m,43 lb-ft} Applvliquidgasketto the boltthreads wheninstalling. 1O. With the radiatorcap oft, start the engineand let it fan run until warmed up (Radiator goes on at least add twice). Then,if necessary, more coolantmix to bring the level back up to the bottom ot the filler neck. 11. Put the radiatorcap on tightly, then run the engine again and check tor leaks.
10 -6
Cap Testing
Removethe radiatorcap, wet its seal with engine coolant,then insmll it on the pressure tester. Apply a pressure f 95-125 o k g / c m , ,1 4 - 1 8 p s i ) . Check for a drop in pressure.
4.
kpa (0.9b-1.25
lf the pressuredrops, replacethe cap. RADIATOR PRESSUBE TESTER COMMERCIALLY AVAILABLE
ADAPTOR {for smallcap)
Testing
1. Wait until the engineis cool. then carefullyremove the radiator cap and fill the radiator with engine coolant to the toD of the filler neck. 2, Attach the pressure testerto the radistorand apply a pressure f 95-125 kPa (0.95-1.25 kg/cmr, o 14. 18 psi). Inspect for enngine coolanl leaks and a drop in pressure, Removethe tester and reinstall the radiatorcao. NOTE; Check for engineoil in the coolant and/or coolant in engineoil.
RADIATOR PBESSURE TESTER

COMMERCIALLY AVAILABLE
3.
4,
10-7
Thermostat
Replacement
NOTE: Use new O-ringswhen reassembling. F22A1, H23Al engin6s: ELEED BOLT 10 N.m lt.0 kg-m,7 lb-ftl
6 x 1.0mm '12 N.m (1.2 kg-m, 9 lb-ft)
ENGIfTE COOLANT (ECT} TEMPERATURE A SWITCH 28 t{.m (2.8 ks-m, 20 lb-ft|
CONNECTING PIPE
6 x ' l . Om m 12 N.m l'1.2kg-m,9 lb-ft} RUBBER SEAL Replace. THERMOSTAT Install with pin up.
AT COVER
H22Al enginor BLEED BOLT 10 N.m (1.0 kg-m.7 lb-ftl
A ECTSWITCH 28 N.m {2.8 kg-m,20 lb-ft|
THENMOSTAT Instali with pin up.
6x1.0mm '12 N'm 11.2 kg-m, 9 lb-ttl
AT COVER
10-8
Testing
Replacethe thermostat if it is open at room temperature, To test a closed thermostat; 1. Suspendthe the.mostatin a containerof wate. as snown. 2. Heat the water and check the temperaturewith a thermometer. Checkthe temperature which the at thermostatfirst opens.and at which it is fully open. CAUTION: Do not l6t the thelmometor touch tho bottom of hot containor. 3. Measurelift height ot the thermostat when fullv ooen. STANDARD THERMOSTAT Lift h.ight: above 8.0 mm {O.31 in.} Stans oponing: 169 - 176oF {76-8OoCl Fully open: 194oF (9OoC)
THEBMOSTAT
10-9
Water Pump
lllustrated Index
NOTE: Use new O-ringswhen reassembling. F22A1, H23Al onginsE:
WATER OUTI.ET HOUSING Apply liquidgasketto cylindrhead mating surface.
ENGINECOOLANT {ECT) TEMPERATURE SENSOR '13lb-ft) 18 t{.m (1.a kg-m'
ECTGAUGE
SEI{DINGUNIT
9 N.m lO.9 kg-m,6.5 lb-ft|

x 'l,O mm 12 N.m (1.2 kg-m, 9 tb-fr)
t{Gtl{E OILCOOLER (H234l engine)
B
28 N.m {2.8 kg-m, 20 tb-ft| ECT SWITCH A 2a .m (2.8 kg-m, 20 lb-ft) BLEEDBOI.T 10 x 1.25mm 1 O N . m 1 1 . 0k g - m , 7 tb-trl
6 x l.O mm 12 N.m (1.2kg-m, I rb-ft)
O-RINGS Replace.
*8 x 1.25mm 22 N.m 12.2 kg-n, 16 tb-fr)
6 x 1 . 0m m 1 2 N . m( 1 . 2k g - m , 9 rb-ft)
DRAIN BOLT 60 N.m 16.0 kg-m, 43 rb-frl Apply liquid gasket to bolt threadswhen installing. O-BING Repl6ce.
CONI{ECTINGPIPE (F22A1 enginel
BOLT RSISTANT *: CORROSION
10-10
H22A1 cnglne:
ECT SEI{SOR 18 N.m (1.8 kg-m, 13lb-ft} 6 x 1.0 mm 12 N.m {1.2kg-m, 9 rb-ttl
ECTGAUGE UNIT SENDIT{G 9 N.m lO,9kg-m, 6.5 rb-ft| ECTSWITCH B 28 N.m (2.a kg-m,20 lb-ftl
6 r 1.0 ir|m 1 2 . m 1 1 . 2k g - m , glb.ft)
BLEEDBOLT 10 x 'l.25 mm lO N.m {l.O kg-m, 7 tb-ftl
E GINE OIL COOLER
28 N.m 12.8kg-m, 20 rb-frl WATEFR,MP
o-Rtt{Gs
Replace.
*8 x 1.25mm 22 N'm 12.2 kg-m, 16 lb-fr)
CONNECTING PIPE
6 x l.O mm 12 .ln lt.2 kg-m. 9 lb-ft}
*: CORROSION RES|STANT BOLT
10-1 1
Water Pump
Inspection
Removethe timing balancerbelt and timing belt (F22A1 engine: page 6-29, H23Al engine: page 6-63, H22A1 engine:page 6-109) check that the water pump pulleY turns freely. Check for signs ol seal leakage. NOTE: Smsllamountof is normal. "weeping" Irom bleedhole
Replacement
Removethe timing balsncerbelt and timing blt (F22A1 engine: page 6-29, H23A1 engine: page 6-63, H22A1 engine:Page6-1091 Unscrew the bolts, then remove the water pump'
6x1.Omm 12 N.m {1.2kg-m. 9 tb-ft|
O.RING R6place.
I
,
HOLES BLEED 3. Install the water pump in the reverse order of removal.
HOLE BLEED
RUBBER SEAL Apply liquid gaskst to the water pump mating surtace.
10-12
Fuel and Emissions

S p e c i aT o o l s l . . . . . . . . . . . - . . .1 ' l - 2 . ComoonentLocations I n d e x. . . . . . . . . . . . . . . . . . . . . . .1 1 - 3 System Description V a c u u m o n n e c t i o n . , . . . . . . . . . . . . . , . . . . . . .1-. 8. C .s 1. , E l e c t r i c a l o n n e c t i o n.s . . . . . . . . . . . . . . . . . . , . . .1 . .- 12 C . .1 S y s t e mC o n n e c t o r s . , . . . . . . . . . . , . . . , . . . . . . . . . .l.- 2 O . 1 . Troubleshooting T r o u b l e s h o o t i n gu i d e . . . . . . . . . . . . . . . . . . . . . . .1. .- 4 0 G .1 S e l f - d i a g n o s tPc o c e d u r e s , , , . . . . . . . . , . , . . .1 '. l.- 4 2 ir . H o w t o R e a dF l o w c h a r t s. . . , . , . . . . . . . . . . , , . ,1 1 - 4 7 . .. 1-113 ' t- ' l 1 4 1 - 11 4 1-1 6 1 1-'t21 't-122 1-123 1-124 t-tzo 1 -1 3 0
Fuel Injectors Iniector Resistor Fuel Pressure Regulator Fuel Filter
PGM-FISystem
System Description ....... 1 1-48 Troubleshooting Flowchans E n g i n e i l l N o t S t a r t. . . . . . . . . . . . . . . . . . . . . . . .1-. S.0 W 1. . E n g i n e o n t r o lM o d u t e. . . . . . . . . . . . . . . . . . . . . . .1.1- 5 1 C . . H e a t e d x y g e n e n s o r , , . . . . . . . . . . , . . . . . . 1.1-. 5.6 O S . . . H e a t e d x y g e nS e n s o r e a t e r. . . , . . . . . . . . . ,1 1 - 5 8 O H . F u e lS u p p l y y s t e m . . . . . . . . . . . . . . . . . . . . . . .1 1. .6 2 S . .. - .. ManifoldAbsolute Pressure Sensor .,...... l1-64 Top Dead Center/Crankshsft position/ C y l i n d e P o s i t i o n e n s o r . . . . . . . , . . . . ....., . ' l 1- 7 O r S EngineCoolantTemperature Sensor ....... 11-72 T h r o t t l eP o s i t i o n e n s o r. . . . . . . . . . . . . ...... .- . .- 1 ' l- 74 S I n t a k eA i r T e m p e r a t u rS e n s o r . . . . . . . . . . . . .1 1 - 7 6 e . . B a r o m e t r iP r e s s u r S e n s o r. . . . . . . . . . . . . . . . . 1.l - 7 8 c e . l g n i t i o n u t p u tS i g n a l. . . . . . . . . . . . . . . . . . . . . . . .I. . .- 8 0 O 1 V e h i c l e p e e dS e n s o r. . . . . . . . . . . . ...... . . . . . . . . 1 1 - a 2 S . E l e c t r i c a lo a dD e t e c t o r. . . . . . . . . . . . . . . . . . . . . . .1 - 8 4 L 1. Knock Sensor l E x c e p tF 2 2 A 1 e n g i n e { S ).l . . . . . . . . . . . . . . . .1- 8 8 I A / T F l S i g n aA / B . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1 - . .0 t . ..9 .
Intake Air System

System T.oubleshooting Guide 11-13r System Description 11-132 Air Cleaner 11-133 Intake Control Svstem lExcept F22A't engine(Sll 1-134 Throttle Cable 1-138 Throttle Bodv 1-1 9 3 Intake Air Bypass Control System lExcepr F22A'l engine(Sll 1-143 I n t a k eM a n i f o l d F 2 2 4 1 e n g i n e ( S l . . . . . . . . . . . . . 1 - 1 8 ] I 4
EmissionControl System
System Troubleshooting Guide .... 1-149 System Description 1-1 0 5 TailpipeEmission 1-150 T h r e eW a y C a t a l y t i c o n v e n e r. . . . . . . - . . . . . . . . . .1 - 1 5 1 C E x h a u s G a s R e c i r c u l a t i o nv s t e m . . . . . . . . . . . . . 1 - 1 5 3 t S PositiveCrankcase VentilationSystem .,.,.,.. 1 - 1 9 5 Evaporative EmissionControls 1-160
ldle Control System

S y s t e mT r o u b l e s h o o t i n gu i d e . . . . . . . . . . . . . . . . I .1- 9 2 G . System Description ....... 1 1-93 Troubleshooting Flowcharts l d l eA i r C o n t r o V a l v e . . . . . . . . . . . . . . . . . . . . . . . .1 . .- 9 6 l .1 A i r C o n d i t i o n i nS i 9 n a 1 . . . . . . . . . . . . . . . . . . . . .I. .1- 9 8 g . . A l t e r n a t oF R S i g n a l r .. I1-1OO AutomSticTransaxle G e a rP o s i t i o S i g n a l. . . . . . . . . . . . . . . . . . . . 1 1- 1 0 2 n . S t a r t e .S w i t c h S i g n a l. . . . . . . . . . . . . . . . . . . . . . . . .1 1. 10 4 .. B r a k e w i t c hS i g n a l. . . . . . . . . . . . . . . . . . . . . . . 1.1-.10 6 S . . .. Power SteeringPressufe Switch Signal ... 1l-108 F a s tl d l eT h e r m o a l v e. . . . . . . . . . . . . . . . . . . . . . . I .1 - . .0 9 V . ..1 S t a r t i n A i r V a l v e. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1-.1 1. . g . . ..O l d l eS p e e d e t t i n g . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.-.l. .1 S . 1. j .
Special Tools
Rel. No.
Tool Number A973X_041_XXXXX KS-AHM_32 OO3 OTLAJ PT30l OA 07JAZ-OO1000B 07406-OO40001
Dascription Vacuum Pump/Gauge DigitalMultimeter Test Harness Vacuum/Pressure Gauge0-4 Fuel Pressure Gauge
I O'ty I 1
Pag Roforence 1 1 - 6 8 ,1 3 5 , 1 3 9 , 144, 154, 162, 165 11 - 4 5 ,5 8 , 6 3 11 - 4 5 1 1 - 1 6 41 6 5 , 1 ' l - 1 1 5 ,1 2 2
o
,ar
@
/A
in. Hg
\a)
\9
11-2
ComponentLocations
Index
H23A1 engine (USA: Si/Canada: SRI:
Troubleshooting, page 1 1-84 EXHAUST GAS RECIRCULATION {EGR) VALVE LIFT
ELECTRICAL LOADDETECTONIELOI (TPI THROTTTE POSITIOI{ SENSOR MANIFOLO ABSOLUTE

page 1 I-74 Troubleshooting, FAST IDLE THERMO VALVE Inspection p a g e1 1 - 1 O g PRESSURE IMAPI SENSOR Troubleshooting, page 1 1-64, 68 IDLE AIR CONTROL(IACI VALVE Troubleshooting, page 1 1-96 EVAPORATIVE EMISSION (EVAP} PURGECONTROL SOLENOIDVALVE page 1 1-162 Troubleshooting, STABTING AIR VALVE Description, p a g e1 1 - 1 1 0
sEr{son
Troubleshooting, p a g et l - 1 5 3 IGNITIONCONTBOLMODULE (ICM) page |'l -80 Troubleshooting, INTAKE CONTROL SOLENOIDVALVE Troubleshooting,
\ \. oaqe 1135 1 TOPDEADCEITTER/ } \. //' CRANKSHAFT POSITION/ CYLII{DERPOS]TION
ITDC/CKP/CYP' Troubleshooting, page11-70
IIIIJECTOB RESISTER Testing,page 11-'121
'trt
?,{oL
AKE AIR IIATI SENSOR Troubleshooting, p a g e1 1 - 7 6
TURE
ENGINECOOLANT TEMPERATUBE {CT) SENSOR Troub16shooling, page 11-72 KNOCK SENSOR{t(Sl page 1 1-88 Troubleshooting, INTAKE AIR BYPASS {IAB} VALVE Testing.page 1 1-146
EXHAUST GAS RECIRCULATION {EGR} VACUUM CONTBOLVALVE Troubleshooting, p a g e1 1 - 1 5 3
HEATED OXYGEN SENSOR tHO25) Troubleshooting,

p a g e 11 - 5 6
EXHAUST GAS RECIRCULATION {EGR)CONTBOL SOLENOIDVALVE page 1 1-153 Troubleshooting,
(PSP}SWITCH POWER PRESSURE page 1 1-108 Troubleshooting, VALVE INTAKE AIR BYPASS IIAEI CONTBOLSOLENOIO page 11-144 Troubleshooting,
11-3
Component Locations
lndex
H22Al ongino {USA: Si VTEC/Canada:sB-v)
LOAD DETECTOB{ELD) EI-ECTRICAL Troubleshooting, IDLE AIR CONTROL{IAC) VALVE p a g e1 1 - 8 4 Troubleshooting, 11 - 9 6 XHAUST GAS RECIRCULATION IEGRI POSITION SENSOR ITPI THBOTTLE VALVE LIFT SENSOR Troubleshooting, 11-74 Page page 1 1-153 Troubleshooting, FAST IDLE MANIFOLOABSOLUTE THERMO INTAKECONTROL PFESSUNE IMAP} SENSOR VALVE VALVE SOLENOID Troubleshooting, lnspection Troubleshooting, page '11-64,68 p a g o1 1 - 1 O g p a g eI 1 - 1 3 5 EVAPOBATIVEEMISSION (EVAP} PUFGECONTROL SOLET{OID VALVE page 1 1-162 Troubleshooting,
IGNITIONCONTROLMODULE (|CM} page 1 1-80 Troubleshooting,
ToP DEAOCENTER/ .. \ CR} .KSHAFT^POSITION/ \

CYLINDERPOSITIOl{ SENSOR {TDC/CI(P/CYP} Troubleshooting, page 'l 1-70
AIR STARTII{G VALVE Description, p a g e11 - 1 0 1 INJECTOR RESISTER p T e s t i n g ,a g e1 1 - 1 2 1
INTAKEAIR TEMPERATURE 0AT) SEI{SOB Troubleshooting, page 1-76 1
ENGIf{ECOOLANT Troubleshooting, page 11-72
(ECTI TEMPERATURE SENSOR
(EGRI RECIRCULATIOT{ VALVE VACUUMCOI{TROL page Troubleshooting, 11-l53

IEGRI EXHAUST GAS RECIRCULATION CONTROLSOLENOIDVALVE page 1 1-153 Troubleshooting, (PSPI SWITCH PRESSURE POWERSTEERING p89e 1 1-1OB Troublshooting,
GAS
KNOCK SEI{SOB {KS} Troubleshooting, page 11'88
HEATEDOXYGEN SENSOR tHO2S) Troubleshooting, page 1-56 1

INTAKE AIR BYPASS (IAB) VALVE 'l1-146 Testing.page
INTAKE AIR BYPASS {IABI CONTROLSOLENOIDVALVE page 1 1-144 Troubleshooting,
11-4
F22Al ongins (S):

IDLE AIR CONTROL{IAC} VALVE Troubleshooting. p a g e1 1 - 9 6 MANIFOLD ABSOLUTE THROTTLEPOSITIOT{ PRESSURE ITP) SEITISOR {MAPI SENSON EXHAUST GAS BECIRCULATION {EGRI Troubfeshooting.page 1 1-74 Troublsshooting. VALVELIFTSEI{SOR page 11-64, 68
ELECTRICAL LOAD DETECTOR {ELDI Troubleshooting. psge11-84
pago Troubleshooting. 11-,|53 IGNITION TBOLMODULE CO IICM} pag6 Troubleshooting. 11-80\\ TOPDEADCENTER/ CRAN(SHAFT POSITIOI{/ CYLINDER POSITION {TDC/CKP/CYP}
Troubleshooting. p a g e1 1 - 7 O
(EVAP) EVAFORATIVE EMISSION PURGE CONTROL SOLENOID VALVE Troubleshooting. 11-,|62 page FASTIDLE THERMO VALVE page11-110 Inspoction, II{JECTOR RESISTER
Testing, 11-121
STARTII{G AIR VALVE Description, p a g e1 1 - 1 1 0 I TAKE AIR TEMPERATUR: (IAT} SENSOR Troubleshooting. page 1'l-76
ENGINECOOLANT (ECT) SENSOR TEMPRATURE Troublshooting, page 11-72
EXHAUST GASRECIRCULATION IEGR) VACUUiI CO TROLVALVE page11-153 Troubleahooting, . ,-/ / '-''./ (EGRI EXHAUST GAS RECIRCULATIOI{ CONTROL VALVE SOLEiIo|D page11-'l53 Troubleshooting,
POWER STEERII{G PNESSUREIPSPI SWITCH Troubleshooting, pago 1 1-1OB
HEATEO OXYGEI{
(Ho2st sEr{soR
Troubleshooting, page 1 1-56
11-5
ComponentLocations
Index
EMISSIOI{ EVAPORATIVE {EVAPITWO WAY VALVE page11-165 Testing,

FUEL FUEL FIITER page 1 1-123 Replacoment,
Tosting,p6ge 'l t -125 paoo 11-125 Roplacemgnl, FUELFILL CAP I
FUEL ruMP
EVAPORATIVE EMISSION CONTROL CAI{ISTEB IEVAP) page Troubleshooting, 11-'162
TAI{K
Replacemgnt, p s g 11 - 1 3 0
FUEL REGULATOR PNESSURE page11-122 Testing, p.g6 11-123 Rphcomont,
FUEL VAPOR HOSE
FUEL RAIL
I]{JECTORS
Troubleshooting, ptgo11-116 page 11-1 19 Replacomedt,
11-6
AIR CLEANER{ACL) Oisass6mbly. p a g e1 1 - 1 3 3
THROTTLE BOOY page11,139 Inspection, page Disassembly, l l -141
II'ITAKE cot{TRoL
II{TAKEAIB
DIAPfIRAGM (Exclpt F22A1 .ngin.l Troubloshooting p a g 1 1 - 1 3 5
lnspection/Adjustment, page 1 1- l38 Installation, page 1 1-'l 38
POSITIVECRAI{KCASEVENTILATIOI{ (FCV) VALVE pago 1 1-159 Inspction.
PGM-FI MAII{ RELAY RolayT6sting,page 'l 1-126 page 1 1-128 Troubloshooting,
ENGINECO TROL MODULE {ECMI Sell-diagnostic Procedures.page 1 1-42 Troubleshooting.page 1 1-50 page 11-45 Romoval,
(2PI SEBVICECHECK CONNECTOR Sff-diagnosticProcedures,page 1 1-42
11-7
System Description
Vacuum Connections
SR} H23Al engine{USA: Si/Csnada: SR-V} H22Al engine{USA: Si VTEC/Canada: EMISSIOI{ EVAPORATIVE IEVAPI PURGE COI{TROL VALVE SOLEI{OID EMISSION EVAPORATIVE VALVE DIAPI.IRAGM CONTROL R'IRGE {EVAP)
EMISSIOI{ EVAPORATIVE {EVAPI COI{TROLCANISTER
TO EVAPORATIVE EMISSION {EVAPITWO WAY VALVE EXHAUST GAS RECIRCULATION IEGR) VALVELIFTSENSOB EXHAUST GAS RECIRCULATION IGR) VALVE MAI{IFOLDAESOLUTE PREESURE API 8E1{8OR I STARTII{GAIR VALVE I TAKE AIR BYPASS VALVE IIABI CHECT
INTAKE CONTROL SOLENOID VALVE
FRONT VEHICLE FUEL OF
:?'
REGULATOR
AIR BYPASS INTAKE IIABI CO TROL VALVE SOLEI{OID TO
INTAKE AIR BYPASS IIAB} COI{TROL OIAPHRAGM
CRUISECOI{TROL ACTUATOR
EXHAUST GAS RCCIRCULATIO VACUUM IEGR) CO TROLVALVE

(EGR)
EXHAUST GAS CONTROL DIAPHRAGM
SOLEI{OID VAIVE CONTROL
11-8
F22Al ongine (S):
EVAPORATIVE EMISSION IEVAPI CONTROI.CANISTER EVAPORATIVEEMISSION (EVAPI PUBGECONTROLDIAPHRAGMVALVE
EVAPORATIVE EMISSION {EVAP} ruBGE COTITROL SOLENOID VALVE
TO EVAPORATIVE EMISSION {EVAPITWO WAY VALVE
EXHAUST GAS RECIRCULATION IEGR} VALVE LIFT SENSOR
MANIFOLD AESOLUTEPNESSURE (MAP} SENSOR
GAS EXHAUST RECIBCULATION VALVE IEGR}
STARTII{G AIR VALVE
(EGR} EXHAUST GAS NECIFCULATION VALVE VACUUMCOI{TROL
FUEL PRESSURE REGULATOR
TO CRUISE CONTROL ACTUATOR

(EGR} EXHAUST GAS BECIRCULATIOI{ CONTROLSOLEI{OIDVALVE
11-9
System Description
Vacuum Connections
SR) H23A1 ongino (USA: Si/Canada: SR-V} H22A1 ongine{USA: Si VTEC/Canada:
(Ho2s) \--J@ oxycEN sENsoR o) HEATED
ABSOLUTE PRESSURE {MAPISENSOR O MANIFOLD (ECT) TEMPERATURE SENSOR COOLANT O ENGINE (IAT} AIR @ TNTAKE TEMPERATURE SEI{SOR @ KNocK sENsoR(Ksl @ |DLEAtR co rRoL flact vALvE SCREW O IDLEADJUSTING VALVE @ FASTIDLETHERMO AIR @ STABTING VALVE [rtJEcToR @ FUEL FILTEB @ FUEL PRESSURE REGULATOF @ FUEL PUMP @ FUEL TANK @ FUEL @ AIRCLEANER @ RESONATOR (IAB}COIIITROL DIAPHRAGM AIR BYPASS @ INTAKE VALVE AtR SOLENOID @ TNTAKE BYPASSflABl CONTROL
TANK AIR BYPASS IIABIVACUUM @ II{TAKE VALVE ArR 0AB)CHECI( @ ra{TAKE BYPASS DIAPHRAGM COI{TROL @ II{TAKE SOLENOTD VALVE COIT|TROL @ tt{TAKE VACUUM TANK @ I TAKECONTROL CHECK VALVE CONTROL @ INTAKE (TWCI WAY CATALYTTC CONVERTEn @ THREE VENTILATTON {FCV)VALVE @ postT|vE CRANKCASE (EGRI GASBECTRCULAIION VALVE @ EXHAUST (EGR} GASRECIRCULATION VALVELIFT @ EXHAUST SENSOR (EGRI GAS REC|RCULAT|OII VACUUM @ EXHAUST VALVE CONTBOL GAS RECTRCULATTON CONTROL {EGR} @ EXHAUST VALVE SOLENOID (EVAP} CAt{ISTER EM|SS|OT{ CONTROL @ EVAPORATTVE (EVAP) PURGE COI{TROL EMTSSION @ EVAPORATTVE VALVE SOLENOID PURGE CONTROL EMTSSTON {EVAP} @ EVAPORATTVE VALVE DIAPHRAGM @ EvapoRATtvEEMtsstoN{EvaPl rwo wAY vALvE
11-10
F22A1 ongine
oxYGEr{sEr{soR(Ho2sl O HEATED pREssuRE ABSOLUTE O MAr{rFoLD tMApt sENsoR coolA T TEMPERATUBE sEI{soR @ ENGINE tEcTI (IAT) AIR TEMPERATURE sEI{soR @ II{TAKE O |DLEAtR co rRoL 0Acl valvE @ IDLEADJUSTI G scREw VALVE @ FASTIDLETHERMO ArR @ START|NG vALv I @ FUEL JEcToR FILTER @ FUEL PRESSURE REGULAToR O FUEI. PUMP @ FUEL TANK @ FUEL @ AIR CLEANEn @ RESOI{ATOR
way caTALyTrc coNvERTEn fiwcl @ THREE (Pcvt cRAl{KcasE vEr{TrLATror{ valvE c) posrTlvE (EGR} GAs @ EXHAUST REcrRcuLATtOr{ valvE (EGR} GAs @ EXHAUST REcrRcuLATror{ valvE L|FT (EGRI GAsREctRcuLATtot{ vAcuuM @ ExHAUsr COI{TROL VALVE (EGR} GAs @ EXHAUST BEcrRcuLATror{ coNTRoL
SENSOR
SOLEIIOID VALVE (EVAPI EMISSION cO TRoL CAI{ISTER @ EVAPORATIVE EMTSSION PUnGE COI{TROL TEVAP) @ EVAPORATTVE SOLENOID VALVE EMrssroN(EvAp)PURGE conrRol @ EvApoRATrvE DIAPHRAGM VALVE EMtsstoN(EvApl Two wAy vALvE @ EvapoRATrvE
11-11
System Description
Electrical Connections
FUEL PUMP
'1_
CYP SEI{SOR TDC
sEf{soR
CKP
sEitsoR
wEc
PfiESSURE
swtTcH
SERVICE CHEGX
cot{t{EcroR
col{DEl{SOR FAl{ RELAY
A/C
swtTcH
GAUCE ASSEMSIY
i FUsEs
t10 c) clocx RADro al. tlOO @ SATTERY At. @ rGsw tso A). (15 @ sToPHORir Al. BOX @ FUSE tr$ Alr
o. 4 BACKUP(10 A) ECUGcill (15 Al t{o. 13 ttlETER Al {1O FAt{ t15 At. cot{oEI{sER REIAY110At o. 11 nEARDEFROSTER SIG l{o.2 ATARTER AL 17.5Al
A/T GEAR POStTtOt{
swtrcH
L _ _ _ _ _ _ _ _ _ _ _ _
': in the UI{OER-HOOO FUSE/RELAY BOX
at-tz
sE son
TP 8EI{SOR EGR vAt-vE LIFT SEI{sOR
TIAP
SOLEOIDVALVE r--=-l H22Al .nglnc)
Gn co TnoL solEftolo valvE EVAP PUNGE CO TNOLSOLEI{OID VAIVE IAB CO[{TROLSOlEtrtOtOVALVE INTAXE COITROL AOLETTOID VALVE
o o o o o o o o o o o o o o o o o o o o o o o o o o
o o o o o o o o o o o o o o o o TERMI AL LOCATIONS
o o o o o o o o o o o o o o o o o o o o o o
(cont'dl
11-13
System Description
(cont'd) Electrical Connections
Cttt
HO23
YEIiTLK
oR /wlft
nco/Btu-
E I
WHT/GRt{ WHT/RED-
w,si
,arn*"rfl
1l
q101
---J------'l vrr.rvyxr ---l RD,srx lrP sE SoR I

GRx/wHTr _!l________J
cl13
---------.r-T------------'l
__jl.:l*r1l
tto prg. 1I -16l
lTo p.gp t1-151
lTo p.!. 11-15)
11-14
11-141 c425
( F r o r n . g . 1 l - 1 4 1 l F r o mp . g . 1 1 - j 4 ) p
c 133 :-:wHT---_----
TDC/CXP/CYP SEI{SOR
c102
nroisrxl-[dfiiiJidi5il BRn---l-[I:jl__l
clo3
nronu---1-f iiliifididil
BLU]lltro. 3l I
c1(x
--j-liiiiili6i5i-l n:omx -l
YEL lr o. a) cl11
c105
srr'---1-ffii----l RED/GR'{ ]-E!lf9r-___l

ct 09
sLxryel ---- iid--]

ox{
I| lsolCtoro I | vatvE I lErccpt F22A1 .ngin.)
cl22
Hiiii;l I."' ".n"o* |

c10g
$ffiElfl | ,"r senson I

BED^^rHrlJ-----l VALVE I wxrierr I I EGR cRil/wHr,l I tlFr sEI{soRI
System Description
(cont'dl Connections Electrical
c31O-..._at-K/YEt---l lci co liol ----llj95:g:i1:l
RED,
sa".;-l ffi#ffll
TO COi{DEiISER FAI{ Bt-u/RED_____'
-----i Toa/cHcRoMPnEssoR RED/8LU

-----> TO A/C SYVITCH
-l I r^ra co|rnol I I lsor.Er{oro I llJ !!E-J

lErc.Dl F2241 f,{arl
J I6ERVTCE llcHEct(
ll-99!!!9r98--J
t-Jl r T GRX/RED
I |
C43LT GFI{/RED_Il DATA Lt K I BLI(/RED-l I cO ECTORI
[E+_
REDiErx
E<-YEL/BLU
TCil lA/Tl ORIIl PI{K [T GN[{/BLX
11-16
UI{DED.HOOO FUSE/RELAY BOX
BATTERY {1(x)A) tG sw l5o Al FUSE 8OX liro Ar CLOCK RADIO A) {10 sToP HOR[{ Al t15 WHTA'EL
Ut{DED-HOOD
FUSE/RELAY c421 c422

WHT/RED
WHT/YEL c424 WHT/YEL c420

ATKATEL
BIK
Grl03 BATTERY
PGM.FI
YE|-/SL(
YEL/BLK
GRI/BLKt
E<--BLK
FUEL
fl_
Eszzaer-x ll
G52r
v:l- _-____j-1
-C537
____h
pUMp
(PJ
swrTcH
tc tTtON
UI{DER.DASH FUSE/REI.AY BOX iECMI At tls c) ECU stcilAl @ Ito. 2 STAKTER t7.5Al UP @ o.4 BACK t10 Al tlo O o. 13 METER A)
TO M/T: STARTER CUTRELAY A/T: A/T GEAR POStTtot{ SYVITCH c466 c471
BLU/RED
GRiUwHT'
GRt{/WHTI GRI{MIHT
c479..-........................"-.".-.rHrljl GRr{^ BRAKE I
FUSE/RELAY BOX
wnrrrer-ll_llcH
lTo p!96 11-18,
l
(cont'd)
11-17
System Description
(cont'dl Connections Electrical
l F . o mp ! g ! 1 1 . 1 7 1
GAUGE ASSEi'BLY
N |-'FFGEF_I
ll ltrlswmcx
I I HPOSmOI{
c4a4 - cr39
c13a cRr/YEL-wEc solEl{olD VALVE lH22A'l.n!rn.l
swrTcH
tH22.A1
ri
11-18
System Description
System Connectols lEngine Compartment]
SR-V} H22Al engine{USA: Si VTEC/Canada: SR) H23A1 ongine{USA: Si/Canada:
ENGINE WIRE HARTTESS MAIN WIR HARNESS
11-20
c114
cll5
c117
c122
rF|-r l l l 2 1 |3
IO) IGRN^^/HTZ
lEilwlr-O loRt,M/Hr ldlYE BLK
I i
l-6''I"*t----.',
lO IBL(,"/eL
l6F'it------1
C137 lH22Al onglnql
C138 (H22Al .nginol
c420
tr
l-6'l6iNrEi-----'l
lrJ
c422
l l j 2 1 3 l
r-FF-r
2
7
9 10 1 1
----l r'-T"*
f5-lwxr
2IBLX/GRI
REO/6LU 3 FEOr'GFN 5
I -- ---1
LX tASSt
LKI''EL IA65)
NOTE: Diflerent wi,es with the same color have been given a number suffix to distinguish them {for example YEL/BLK1 and YEL/BLKz not the samel. are l: Relatedto Fuel and Emissions Svstem.
System Description
(cont'd] Compartment] SystemConnectors [Engine
SR-V) H22Al engine (USA: Si VTEC/Canada: SRI H23A1 engine (USA: Si/Canada:
6'
!,,-
.lv
c432 c135
MAIN WIRE HARNESS
c4a4 c139
ENGINEWIRE HARNESS
11-22
c426
c429
c/*12 (M/Tl
C484 (H22Ai onglnrl
{,t(
IBLUI"'EL IT
lO--lCiNrEL
--l
'It,,YEL
RED/II.U
Diffotent wirs with the same color hsve baen given a number suffix to distinguish them (for example YEL/BLK1 and YEL/BLK, are not the same). O: Rlated to Fuel and Emissions Svstm.
\oTE:
(cont'd)
11-23
System Description
(cont'd] SystemConnectors lEngineCompartment]
H22A1 engine (USA: Si VTEc/Canada: sR-vl SRI H23Al ongina (USA: Si/Canads:
LEFT GIT{E E COIIPARTIIIENT WIREHARI{ESS
HARNESS
11-24
ct 02
c103 tr---T---ll ti 2tl tl
c 104
c105 t--T----rl ll 2 | 1 ll
tr-r-rl 2tl
tl
tr---r---rl ll 2 I 1 ll
---|6'TREo/BIK - - - j@ leRN
to) tRED/Blx
lZiTREp-l
l6TnED/aLi--------f6-lilu
-'l lSTiED/ELr ---] l6ltrL
c106
c107
c108
cl 09
clt1.
c310
c320
c321
r+
l l l 2 l
NOTE: Difterentwi.es with the samecolor have beengiven a numbersuffix to distinguish them (tor exsmpleyEL/BLKI and YEL/BLK, are not the same). O: Related Fuel and Emissions to Svstem.
System Description
(cont'd] SystemGonnectors [EngineCompartment]
F22Al ongino{Sl:
ti
MAIN WIRE HARNESS
HART{ESS
11-26
clr3
cl14
c 11 5
c117
c122
l 1 l 2 1 3 l
rf:lr
loFii'c420
16loRNi------l lO IBLK/YEL I ---l
c421 r--Fl_____1
E
c424
1
lrl2l3l
FT-,--__l 2
l l8r(/GFN
16lwii-.
2
8 9
10 tt
1 2
REO/6LU
3
5
I
I
ALK/YEL IAAS)
10
NOTE: Differentwires with the same color have beengiven a numbersuffix to distinguish them (for exampteyEL/BLKr and YEL/BLK2 not the samel. are O: Related Fuel and Emissions to Svstem.
System Description
F22A1angino lsl:
(cont'd] SystemGonnectors [EngineCompartment]
MAIN WIBE HARNESS

ENGI'{E WIRE HARI{ESS
11-28
c426
c432 (Mtf I
ALK/BIU RED/6LK LU'EL ALK/iED FEO' 8LU YEL
BLI.I/GiN
c432 lA/Tl
'LU/GRIiI
BfiI'I/6LK
a
HT
NOTE: Different wires with tho same color have been given a number suffix to distinguish them (for example yEL/BLK1 and YEL/BLK2 not the sam). are O: Related to Fuel and Emissions Svstem.
System Description
F22A1 engine{S):
(cont'd) [EngineCompartment] SystemConnectors
'j
11-30
ct ol
cl02
J r-----r 1I I----T-----rI
c103 -J r-----rl-
c104
c105
tffJl
tErll
ll 2 | 1 ll
Il2 | 1 ll
c106
c107
c108
c111
c3lo
c320
l 1 l 2 l
NOTE: Oifferent wires with the same color have been given a numbe. sulfix to distinguish them (tor exampte YEL/BLKi and YEL/BLK, are not the same). .-r:Related Fuel and Emissions to Svstem.
System Description
System Connectors [Dash and Floor] lcont'd)
DASHBOARDWIRE HARNESS MAIN WIRE HARNESS
I-EFTENGINE COMPARTMENT WIRE
LEFT SIDE WIRE HARNESS
11-32
c442
c443
c445 (A/Tl
4 2 3 8 9 llol11
c451
r-----.-t
| 1 1 2 |
| 1 l / 1 3| r------y.____J__l
r-EFr
I r_____lz_____r_J I
ll;Tvrtl
BLKIVHT
I(, ]LTGRN/RED I lO lBLx/Ro . 2 3 GRNTYEL 5 12 ALK
lElwH------l
t 2 t
| 3
I
I
t o YL
c461
c463
c466
l1l2l3l
2 3
BLX/GFN"
12 l 3 RIO/SLK
BLU/REO q) RED/ALU 3 YEL/BLK
@ BIU/BLK
15 16
YL 7 8 I
aLu
BCU,IYEL
1o
1A 1 9 RED/YEL 20
BLK/ryEI FED/GRN
c469
BIU/REO YEL/BLU 6LU 8L( YEL
2 10 12 1 3 BLU BLK/tEL 8
ALK L&'YEL BLK,YEI BLK/YEL
12 1 3 ALK
BLK/REO 1A 1 9 BLK,YEL 20
YEL/BCO YL/8LK
NOTE: Differentwi.es with the samecolor have beengiven a numbersuftix to dastinguish them (for exampleYEL/BLK1 and YEL/BLK, are not the same). O: Relatedto Fuel and Emissions Svstem. * : Canada * *: Canada(with heatedseatsl
11-33
System Description
SystemConnectors [Dashand Floor](cont'd
OASHBOARDWIFE HARNESS
MAIN WIRE HARI{ESS
11-34
c479
c601
c612
I 4 X ,/t7 I 9 t 0 1 1 l2lxh3 1 4 1 5 1
RED/BLK
2 3
YEL LIJ/FEO 12 BLK ALU r 6 ALK/RED 6 AtK'/EL 3 1t 12
GRA/YEL
GFN
GiN/ALU
l 6 BLK
c614
2 BLK/ryEL 3
ALU'
1 17 YEL' t9 20 GFN/BLK 21 GhN/REO
22 a
REO BLU/FEO 26 2 7 RED/BLK YEL
1 2 YEL/iED 13 15
3(
NOTE: Ditferentwires with the same color have beengiven a numbersuffix to distinguish them (for exampleYEL/BLK1 and YEL/BLK,a.e not the same). O: Related Fuel and Emissions to Svstem. *: Canada
System Description
System Connectors [Dash and Floorl (cont'dl
OASHBOARD WIBE HARNESS
MAIN WIRE HARNESS
11-36
c404
c411 (A/Tt
c415 {ECM-A}
1t 2
12
3
giN/BLK 15 YEL/BLU RED/gL( LI GFN]BLK 19 20 22
r5
YEL RED H?2rl GRNTYI! ri?rul I
ta
I
8
I
YEL/GFN I LK/8!U BLK'
AED/BLU
20
c4t6 (ECM-BI
c417 tECM-D)
311'r9 7 5 3 1 ldl/rfl 210 8 4 2

YEL/BLK BLU/FED WHI/YEL
GRN/IYHT'
['
(}
AEo/BLlr"'
BRN,IVHT BLU/ALK
l@
I(' a0//EL i1a l{il
@ LT3{urtr22lrmnr
8LU/GAN BLU/^rlt
REO/ALK
NOTE: Differentwires with the same color have beengiven a numbersuffix to distinguish them {for exampleYEL/BLK1 and YEL/BLKr are not the same). to O: Related Fuel and Emissions Svstem. * * * : E x c e p tF 2 2 A 1 e n g i n e
System Description
SystemConnectors lFuel Pump](cont'd)
11-38
c537
E
NOTE: Ditfe.ent witos with the same color have been given I number suffix to distinguish them (for example YEL/BLKr and YEL/BLKz not the same). are O: Related to Fuel 8nd EmissionsSvstem.
11-39
Troubleshooting
TroubleshootingGuide
NOTE: Across each row in the chart, the systems that could be sourcesof a symptom are ranked in the o.der they should be inspectedstartingwith O. Findthe symptom in the left column, read acrossto the most likely source,then refer shows the systemis OK, try the next most liklysystemO, etc, to the pagelistedat the top of that column,It inspection
SYSTTM at'iclNE CONTROI MOOULE 50
MALFUNCTION INDICAIOR LAMP IMIII" TURNS ON MAIFUNCTION INOICATOB LAMP IMILl" BLIN(S ENGINE WON'T STAFT OIFFICUITTO STAFT ENGINE WHEN COID WHEN COLO FAST IDLE OUT OF SPEC. ROUGHIOLE IDTING HIGH HEAIEO OXYGEN SENSOR 56, 54, 62 TOPDEADCENIER/ TNGINC THNOTTLE EANOMEIRIC IGNITON COOTANT TEM. ABSOLUTE PO9TtOtl PitssuSE OUTPUT FCi^TURE PNESSUfiE POSITON/CYUNDES sc soR sfNsoR stcNA! SENSOR SENSOR POSftOt'tsE|so8 fuiE sEt{sof
vtHtclE SPfED
sE[son
a2
64, 6a
70
or-Ll
.o:
:i6):
lll or Lll
-mi
O or-8.o.:ft
-r.tr-
76
7A
80
:r6t: :r6t1 -mi rg: lrm.t: /---\ /---\

\.--r-r
\
EorEl
- --i-r t - \.--l- r t / - - t r t l - - t t l t t -t __i.

---'_-\
/ \ /'_-i\
-t---i- l- \.--1-, t15 \ -l_--l-\ t? / /
@
IBU)
@ @ @
o
@
@ @ @
a9
'
:l
IBU)
FREOUENT STALLING
'lr
@
ROUGH RUNNING EMTSSTON TEST LOSS OF
@ @ @ @
@ @ @
@ @
ANCE
lf codesother then those listedaboveare indicated, count the numberof blinksagain. It the MIL is in fact blinking these codes, reDlace the ECM. @ tt ttr" MIL is on while the engineis running,jump the servicecheck connector.lf no code is displayed(MlL stays on steady),the back-upsystem is in operation. Substitutea known-goodECM and recheck.lf the indicationgoes away, replacethe originalECM. ** USA: Canada: '6+rr-trMALFUNCTTON -[tgltCHECK ;ND;CATOR ENGTNE ;t-\+: , LAMP {MILI LIGHT '** E x c e p tF 2 2 A 1 e n g i n e( s ) SR-V) engine (USA: Si VTEC/Canada:
11-40
IOLECONTFOL ELECTRICAL LOAO uFrE|lcTnoMc LIFT ELECNOMC DETCCTOR :o{TnoL soLENoto :OIITROL PiESS!iI 84 6-75 677 XNOCK SENSOF IOIEAIF CON'FOL OTH'i IDL' c0NTROTS
FUELSUPPTY FUEI INJECTOF 116 OTHER FUEL
EMISSIONCONTFOL ETH USI GAS INIAKT
nEcncu. c0[TioL sYstE
SIGNAL A
SIGNAL 8
OTHER EMtSS|ON
coNTiots
149
8a
90
90
96
92
r13
131
153
tf
-q.
\.--r-l
rgt22 | /-....-.
/ - \
D E
ffil /---\
-r6t/_l-\
-r6t\.--.1z --"i--
- ' .
-t 20 -t 2r I 1 /---,_-. , -_-i-- \
-t 23I 11361,lrt-
- l r 6I
| | 2t\ -
o o
@
@ @ @ @ @
o o o
@
o o
o
@
@ @
o
@ @
11-41
Troubleshooting
Self-diagnosticProcedures
When the MaltunctionIndicatorLamp (MlL) has been reponed on, do the following: 1. Connectthe servicecheckconnectorterminalswith a jumperwire as shown (the servicecheck connectoris located behindthe center console).Turn the ignitionswitch on.
OATA LINK
co itcToR{3Pl
Do not attach wire. the jumper
JUMPERWIRE
CHECK SERVICE (2P) CONNECTOR
a TroubleCode (DTC):The MIL indicates code by the lengthand numberof blinks.The MIL 2. Note the Diagnostic codes,one atter another.Codes 1 through componentproblemsby blinkinqseparate can indicstesimultaneous by shon blinks.Codes10 through43 are indicated a seriesof long and shon blinks. I are indicated individual by The numberof long blinks equalsthe first digit, the numberoJ short blinks equalsthe seconddigit.
USA: MALFUNCTION INDICATOR LAMP {MIL} CANADA: CHECK ENGINE LIGHT
S6pa1.t. Ptobl.mr: Shon l-1 -jl-rLtU-X-r- r]r1.f1--JlrrL = Soe DTC 1 = Seo OTC 3
X{ILong sho.l SimuhanoouaProbloms: J rJTxrL-----n l'lr]rL Jltll-r-r]f1J-1l-LnnrL --n-trxrrl_ J-lt-x-L-J
= scoDTC13
= 566 DTc 1 and 3 = 566 OTC 3 and 4 = Soo DTC 3 and 14
11-42
ll.
EngineControl Module {ECM}ResetProcedure 1. Turn the ignitionswitch off. 2. Remove the the CLOCKRADlO ( 1O A) f use f rom the under-hood tuse/relav box for 1O seconds resetthe ECM. to NOTE: a Disconnecting CLOCKRADIO(10 A ) fuse also cancelsthe radio preset stationsand the clock setting. the Make note of the radio presetsbefore removingthe fuse so you can.eset them. a The radio may have a coded theft protectioncircuit. Be sure you get the customer's code numberbefore removing the CLOCKRADIO{10 A) fuse.
(this procedure t . FinalProcedure must be done sfter any troubleshooting) 1. Removethe jumper wire. NOTE: lf the servicecheck connectoris jumped, the MIL will stay on. 2, Do the ECM ResetProcedure. 3, Set the radio presetstationsand the clock.
11-43
Troubleshooting
Self-diagnosticProcedures(cont'dl
DIAGONOSTIC TROUBLE coDE (DTC)
SYSTEMINDICATED
Page 11 - 5 0
I t-50
ENGINE CONTROL MODULE(ECMI
(HO23) HEATED OXYGEN SENSOR

5 4 (MAP SENSOR) MANIFOLD ABSOLUTE PRESSURE (CKPSENSOR} CRANKSHAFT POSITION (ECTSENSORI ENGINE COOLANTTEMPERATURE (TP SENSOR} THROTTLE POSITION (TDC SENSOR} TOP DEAD CENTER POSITION N o , 1 CYLINDER POSITION {CYP SENSOR)
11 - 6 4 , 68 11-70 11-74 11-70 11-70
6
7
I 9 10 't2 13
14
tc to
(IAT INTAKE TEMPERATURE SENSOR} AIR EXHAUST GASRECIRCULATION VALVELIFTSENSOR) IEGR

(8ARO SENSOR) EAROMETRIC PRESSURE (IAC VALVE) IDLEAIR CONTROL IGNITION UTPUT IGNAL O S FUELINJECTOR VEHICLE SPEED SENSOR IVSS)
11-76 11 - ' l 3 5
11-79 11 - 9 6 11 - 8 0 11-116
1' 1-82
'I 1-84
20
'.1
(ELD) ELECTRICAL LOADDETECTOR

VARIABLE VALVE TIMING& VALVE LIFT ELECTRONIC CONTROL {VTEC} SOLENOID VALVE*' VARIABLE VALVE TIMING& VALVE LIFT ELECTRONIC CONTROL {VTECI PRESSURE SWITCH** ( K N O C KS E N S O RK S } I
21
'tJ
6-75 6-77
22 23
4'l
11 - 8 8 11 - 5 8
11-62 *: ExceptF22A1 engine(Sl ": H22A'l engine{USA: Si VTEC/Canada: SR-V)
43
(HO2S) HEATED OXYGEN SENSOR HEATER FUEL SUPPLY SYSTEM
a lf codesotherthan those listedaboveare indicated, verify the code. It the code indicated not listedabove,replace is the EcM. a The MalfunctionIndicatorLamp (MlL) may come on, indicstinga system problemwhen, in fact, there is a poor or intermittentelectrical connection.First,check the electricalconnections, if clean or repairconnections necessary. a The MIL and D4 indicatorlight may light simultaneously when the code blinks 6, 7 and 17. Checkthe PGM-FIsystem accordingto the PGM-FIsystem troubleshooting, then recheckthe D4 indicatorlight. lf it lights, see page l4-36. a The MIL does not come on when there is a maltunction in the A/T Fl signalor slectricsl losd detector circuits. However, it will indicatethe codes when the servicecheck connectoris iumDed.
11-44
lf the inspction a panicularfailurscode requires for the test harness,removethe right door sill moldingand the small coveron the right kick panel8nd pull the carpetbsck to exposethe ECM.Unboltthe ECMcover.With the ignitionswitch off, connectthe test harnss. Checkthe system according the procedure to described the appropriate tor code(s)listed on the following pages.
DIGITALMULTIMETER KS-AHM-32-003
o o o o o o o o o o o o o o o o o o o o o o o o o o
o o o o o o o o o o o o o o o o TERMII{AL LOCATIOI{S
o o o o o o o o o o o o o o o o o o o o o o
{cont'd)
11-45
Troubleshooting
Self-diagnosticProcedures(cont'd)
a Punctudng th6 insulation on a wile can causa poor or Intermittent eloctdcal connectlona, a For lasling at connectora othor than ths test harness, brlng tho taster probo into contact wltlr tho telmlnll tlom tho connoctor side of wiro harnoaaconnoctors in th engin companmont. For temelo connectoB,lust touch llghtly whh tho tostsr probe and do not insort th probe.
TERMII{AL
t,-l
l-rI
,i,1i -it1
11-46
How to Read Flowcharts

A flowchart is designed be used from start to final repair.lt's like a map showing you the shortestdistance.But beto ware: it you qo off the "map" anywherebut a "stop" symbol, you can easilyget lost.
TSTAR-T]
Eotaivpet
Describes the conditionsor situationto start a troubleshooting flowchart. Asks you to do something;perform a test, set up a conditionetc, Asks you about the resultof an action,then sendsyou in the appropriate troubleshooting direction. The end of a seriesof actionsand decisions. describes tinal repairaction and sometimesdirects a you to an earlierpart of the flowchart to confirm your repair.
Fdfibxl @
trroFl
(bold typel
NOTE: a The term " lntermittentFailure"is usedin thesecharts.lt simplymeansa systemmay havehad a tailure.but it checks out OK at this time. It the Maltunction Indicator Lamp(MlL)on the dashdoesnot come on, checkfor poorconnections (see illustration or loose wires at all connectorsrelatedto the circuit that you are troubleshooting below,. a Most of the troubleshooting flowchartshaveyou resetthe Engine ControlModule(ECM) and try to duplicate diagthe nostic troublecode (DTC).lf the problemis intermittentand you can't duplicatethe code, do not continuethrough the tlowchart. To do so will only result in confusionand, possibly,a needlessly replacedECM. a "Open" and "Short" are common electrical terms. An open is a break in a wire or at a connection.A short is an accidental connection a wire to groundor to anotherwire. In simpleelectronics, usuallymeanssomething of this won't work at all. In complexelectronics meansomething works, but not the way it's sup{likeECM's),this can sometimes poseoro. a It the electrical readings not as specified are when usingthe test harness, checkthe test ha.nessconnections before proceeding.
11-47
PGM-FISystem
System Description
MODULE ENGINE CONTROL {ECM)
Sensor TDC/CKP/CYP MAP Sensor ECT Sensor IAT Sensor TP Sensor HO2S
OUTPUTS
Fuel Injectors PGM-FlMain Relay(FuelPump) MIL IAC Valve Clutch Relay A/C Compressor
vss
F"*li"",---fl-ni-l-".M;l
rcM
BAROSensor StarterSignal ALT FR Signal Air Conditioning Signal A/T Gear PositionSignal BatteryVoltage(lGN. 1) BrakeSwitch Signal PSP Switch Signal EGR Valve Lift Sensor Knock Sensor* VTEC Pressure Switch* *
EVAP Purge Control Solenoid Valve HO25 Heater VTEC Solenoid Valve" @;bbc-t.d ALT EGR Control Solenoid Valve Fit"rJ,,"o,,"-',....-,,,"o.*-,,cont,ot,,cont.trr".**-_-lValve' IAB ControlSolenoid lntake Control Solenoid Valve*
--_]l
Eil,*"s c-,'d
B*k',p F;tb";-ll]]l fEcM
': ExcptF22A1 enqine ": H22A'l engine
't,
PGM-FI Svst.m multipon fuel injectionsystem The PGM-FIsystem on this model is a sequential Fuel Inlector Timing and Duration The The ECM containsmemo.iesfor the basic dischargedurationsat variousenginespeedsand manifoldpressures. memory,is further moditiedby signalssent from varioussansors duration,after beingreadout from the basicdischarge duration, to obtain the final discharge ldle Air Control ldle Air ControlValve (lAC Valve) is is When the engineis cold, the A/C compressor on, the transmission in gear (A/T only) or the alternatoris charging, the ECM controlscurrent to the IAC Valve to maintsincorrect idle speed. lgnition Timing Control lgnitiontiming o The ECMcontainsmemories basicignitiontiming at variousenginespeedsand manifoldpressures. for is also adjustedtor enginecoolanttemperature. is a A KnockControlSystemisalsoused.When detonation dotectedbythe knocksensor,the igntiontiming is retarded (ExceptF22A1 engine). Other Control Functions 1. Starting Control {uel iniectorduration. When the engineis started,the ECM providesa rich mixture by increasing 2. Fuel Pump Control main relay that supplies a When the ignitionswitch is initiallyturned on, the ECM suppliesgroundto the PGM-FI the current to the fuel pump fo. two secondsto pressurize fuel system. a When the engineis running.the ECMsuppliesgroundto the PGM-Flmain relaythat suppliescurrentto the fuel pump. main relaywhich cuts a When the engineis not runningand the ignitionis on, the ECMcuts groundto the PGM-FI currentto the fuel pump. 3. Fuel Cut-off Control is a Duringdeceleration with the th.ottle valveclosed.currentto the fuel injectors cutoff toimprove fuel economy 'l at speedsover ,1OOrpm. a Fuel cut-otf action also takes place when engine speed exceeds, F22A1 (S): 6,6O0 rpm. H23A1 (USA: Si/ of SR-VI: 7,7OOrpm, regardless the positionof the Canada:SR): 6,8O0 rpm. H2241 (USA: Si VTEC/Canada: throttle valve. to protect the enginetrom over-revving.
i:r
fii
11-48
4.
A/C Compressor Clutch Relay When the ECMreceives demandfor coolingfrom the air conditioning a system,it delaysthe compressor Jrombeing energized, and enrichesthe mixture to assuresmooth transitionto the A/C mode. Evaporative Emission(EVAP)purge ControlSolenoidValve when the enginecoolanttemperature betow 167 oF (75 "Cl IH22A'| engine(USA:Si VTEC/Canada: is SR-V):1bg oF (70oC)1, ECMsupplies groundto the EVAPpurgecontrolsolenoid the a valvewhich cuts vacuumto the EVAp purge control diaphragmvalve. IntakeAir Bypass(lAB) ControlSolenoidValve When the enginespeed is below 4,8OOrpm IH22A1 engine(USA: Si VTEC/Canada: SR-V):4,600 rpml, the IAB controlsolenoid valveis activatedby a signalfrom the ECM,intakeair tlows throughthe long intakepath, then high torque is deliveredAt speedshigherthan 4,8OO(or 4,600) rpm, the solenoid valve is deactivated the ECM.and by intake air flows through the short intake path in order to reducethe resistance airflow. in Intake Control SolenoidValve When the enginespeedis below 4,000 rpm, the ECM suppliesa groundto the intakecontrol solenoid valve. This opens the solenoidvalve sendingintake manifoldvacuum to the intake control diaphragm. ExhaustGas Recirculation {EGR)Control SolenoidValve when the EGRis requiredtor control of oxidesof nitrogen(NOx)emission,the ECM suppliesground to the EGR control solenoidvalve which suppliesfegulatedvacuum to the EGRvalve. Alternator(ALT) Control The system controlsthe voltagegenerated the altematorin accordance at with the electrical load and drive mode, and reducesthe engineload to improvethe fuel economv.
5.
6.
7.
8.
9.
ECM tail-safe/back-upFunctions 1. Fsil-safe Function When an abnormality occursin a signalfrom a sensor,the ECM ignoresthat signaland assumes pre-programmed a value fof that sensot that allows the engineto continueto run. 2. Back-uD Function When an abnormality occursin the ECM itself,the fuel injectors are controlledby a back-upcircuit indeDendent ot the system in order to permit minimaldriving. Self-diagnosis FunctionIMalfunctionIndicatorLamp (MlL]1 When an abnotmalityoccurs in a signalfrom a sensor,the ECM lights the MIL and stores the code in erasablememory. When the ignitionis initiallyturned on, the ECMsupplies groundtor the MIL for two seconds check the MIL bulb to condition.
3.
11-49
System PGM-FI
Will Not Stan Flowchart- Engine Troubleshooting
Watch the Mallunction Indicator Lamp (MlL)and turn th ignition swirch ON.
Did the MIL come on at all?
Porfo.m tioubleshooting on pago 11-51.
Portorm t.oubloshootingon pago 11-52.
Connectthe test harnessb6tw96n the ECM and connectors (see page 1 1-45).
V 1.O ?
Turn the ignitionswitch ON.
Measure voltage between body ground and the tollowing terminafs individually: A23, A24. R6psir op6n in wir6(61 botwoon ECM 6nd GlOl llocstd at thermoltat houringl that had mo.6 thsn 1.0 V.
ls there less than 1.O V?
Inspect tuel pressure (see page 11 - 1 5 ) . 1
Popair as nocoaaa.y {ago pag6 11 - t t 5 ) .
Portorm ignition systom chock {3o6 Baction 231.
11-50
Troubleshooting Flowchart - EngineControl Module (ECM)

Tho Maltunction Indlc.tor Lamp (MlLl nover com6! on l6vcn tor two sgcondsl aftei ignition i3 tuhgd on.
ls the low oil p.essure light on?
Inspect No. 13 METER110 A) fuse (in the under-dashfuse/relay oox,.
Connectthe test harnessbetween the ECM and connectors (se page 1 1-45).
R6palropan in YEL wir6 botwoon No. 13 METER(1O A) ture.nd gaugo alrombly.
o o o o o o o o o o o o o ooooo ooo I o@#qPt}| ooooooooooo

ooooo odooo ooo I oooooo oo
Turn the ignition switch ON. - RaDlocoth6 MIL bulb. - Ropairop6n in 8LU/WHT wire botwoon ECM lA13l and gaugs a88ombly.
ooooooooooo
ls the MIL on?
I LoooooooooooQo I
| t-.-----+-
423
|---TMeasure voltage between body ground and the tollowing terminals individuallv: A23, A24.
I ooooo999l1!9!t!1!!lg{ ooooooooooo I
L Le.. than 1 .0 V? --{
+-
a,
ls thsre less than 1.0 V?
Ropalr opon in wiro(sl botwson ECM and GlO1 {locatod at thormostat housing) that had moro than 1.0 V.
G101
Subrtituto a known-good ECM 6nd rechock, lf symptom/lndicatlon gooa away, raplaco tho origi nal ECM.
11-51
PGM-FISystem
TroubleshootingFlowchart - Engine Control Module IECM)
The Mallunction Indicator L6mP (MlL) 3tays on or com63 on allo. two soconoS.
NOTE: When there is no code stored,the MIL will stay on if the servicecheck connectoris jumped.
Connect the service check connector terminalswith a jumper wire {see page 11-42).
Does the MIL indicate any Diagnostic Trouble code (DTc)?
Go to rslf-diagnoatic ptocodutos lso6 pags 11401.

o oooooooo oooo I oooooooom ooooo ooooo oo ol oooooooo oooooooooo
Rmovethe iumper wire from the service check connoctor. Turn the ignition switch OFF. Try to start the engine. Connectthe test harnessbetween the ECM and conneclors {see p a g e1 1 - 4 5 ) . Turn the ignitionswitch ON. Measurevoltage between D4 (+) terminaland D21 l-) terminal.
D 4l + l r_S V? {A/T:
ls thereapprox.5V (A/T: 11 V)?
Connect the service check connector termanalswith a jumper ware.
Bopair shorl to body ground in BRN/ WHT wiro botwon tt|o ECM {t}4}, lrsnsmission Control Modulo lTCMl, ABS contrcl unit or 4WS control unit and seryico chock connoqtor. - Repairopen in BRN/WHTwite botwoon ECM (O4l and sorvico chock connoctor. - Repairop6n in BLU/WHTwite botwoon sorvico check connoctor and ECM {O211.
Mgasure voltage between D4 (.t ) terminal and D21 {-) terminal.
Removeand inspectthe NO. 4 BACKUP(10 Altuse in the underbox. dash fuse/relay
ls there spprox. 5 V ( A / T :1 1 V l ?
ls the fuse OK7
Remove the ,umper wire from the service check connector.
YES
{ T o p a g e1 1 - 5 3 )
lro page 11-53) 'NorE: After reDair, rhe servicecheck condisconnect nector iumper wire, test drive the car, and recheck the MIL for code.
11-52
11-52) Insp6ctthe ECU (ECM) (15 A) Iuse anthe underdash tuse/relay box.
Disconnect"A" con, nectorlrom the EcM.
Disconn6ct the 3P connector of each sengor one at a time: . MAP sensor . EGRvalve litt snsor . Throttle Position (TP) sensor
Substituto . known{ood ECM and rochock. lt lymptom/indication gooa awsy, roplaca the origin8l ECM.
ls the MIL ON?
Rprir rhort to body ground in BLU/WHT wlro betwoontho ECM {A131 th6 MlL. rnd
RoDlacatho aenaor that causod thc light to 9o our.
Doesthe MIL romainON?
"l;_-l
Connect the test harness. Oisconnoct the "O" connector Irom the ECMonlv, not the m6in wire hamess(seepage | 1-451.
I o o o o o o o o o o o o o I o o o o o o o o f , S & l * * * * No o o o o o o o o o o | D20
-l\:-----:J
I
|
Check tor continuity between body groundterminalsD'l9, D2O. - Bopair .hort to body ground in RED/WHTwiro bctwe.n ECM {Dl9} ond MAP 3onso.or EGR valve lift sonror. - Bopair shon to body g.ound in YEL/WHT wlre botw66n ECM lD2Ol and TP !on3or.
Continuitv?
ls thre continuityT
NO
Reconnect all the sensor connectors. Reconnectthe "D" connector to the ECM.
Turn th ignirionswitch ON.
(To page 1 1-54)
(cont'd)
11-53
PGM-FlSystem
Flowchart - Enginecontrol Module IECMI (cont'd) Troubleshooting
(Frompage 1 '!-53)
Measurevoltage between body terminal groundandthe tollowing A26, B2. individually: A26 82 l l
]L
Less than
'1.0 v?
ls rhere lessthan 1.0 V?
Repai. op6nin BLK/RED lA26) or (B2l.nd G101 llocatod BRN/BLK 6t thormoslat housingl.
A 2 5( . r ) 8 1 { + )
Measurevoltage between A26 81 I - ) andthe following: {+ ) and A25 (+).
BATTERY VOLTAGE?
- Repair opon in YEL/BLK wir6 betweon ECM (425, 81) and PGM-Fl main iolay. - Check PGM-FImain tolaY .nd wiring connoctors at PGM-FI main r6lav.
BATTERY VOLTAGE?
Substitute a known-good ECM and recheck. lf symptom/indication goes avray, replacethe otiginal ECM.
11-54
Y
PGM-FISystem
TroubleshootingFlowchart - Heated Oxygen Sensor (HO2S)
mr- _.-i- _ The MaltunctionSensor(HO2S)(MlL)indicatesDiagnosticTroublecode {DTC)1: A problemin th ri--ri HeatedOxygen IndicatorLamp circuit. ff'_
The HeatedOxygen Sensor(HO2S)detectsthe oxygen content in the exhaustgas and signalsthe ECM. In opration, the signalsfrom the sensorand variesthe durationduring which fuel is injected.The HO25 has an the ECM receives in the The heaterstabilizes sensor'soutput. The HO2S is installed the exhaustmanifold(H2341 engine internalheater, SR-VI:in the exhaust pipe A)' (USA: Si/Canada: SR). H22A1 engine(USA: Si VTEC/Csnada: HEATER TEBMINALS VOLTAGE IVI
SENSOR TERMINALS
lm;rl lrirl
-Y-.-i- Tha MIL hsa becn roDortod on. - Yvlth sorvico chack connoclor iumpod l.60 page I 142), codo 1 i3 indicatod.
- LEAI{ RICH- AIR. FUEL RATIO
Do the ECMResetProcedure {see p a g e1 1 - 4 3 ) .
Warm up engine to normal oPeF (the radiatorfan atingtmperature comeson),
Run enginetor 60 seconds.
Roadtest with the manualtrqlsmission in 4th geat I AfIt lA position). Starting st 1,600 rpm, accelerate using wide open throttl for at least 5 seconds.Then docelerte tor at least 5 seconds with the throttle completoly closed. Intormittont lrllur., systom l. OK al thb time. Ch.ck to,. poot connoctlons o. loorc wiror at C432 {locatod al tight shock towcr), C114 (HO2S)and ECM.
ls the MIL on and does it indicate code 1?
Go !o pagl. and prtorm tcat for p.fo 11-62). .-.3 l-
11-56
PGM-FISystem
Flowchart- HeatedOxygenSensor(HO2SlHeater Troubleshooting
:ml1:f,f-f -*-Y: TroubleCode (DTC)41: A problemin IndicatorLamp (MlL) indicatesDiagnostic The Mattunction the HeatedOxygen Sensor(HO2S)Heatercircuit.
-[6]- ]l-rTll
/ -]-\ 7.---:\
- Engino ia running, - Tho MIL hsr bcon roportodon. With rervica chock connoctol iumpod (soopage 11421, codo 41 ir indicalod.
(see Do the ECM RssetProcedure p a g e1 1 - 4 3 ) .
H23Al ongino {USA: Si/Clnada: SR) H22Al engin. {uSA: Si vTEc/Canada: SR-VI:
lrrtd$frqrttS$6,3ystom 13OK at thi! tlmo Itost drlvo maY bo nacrsrsryl. Chock lor poot connoctionr or 10036wirot rt C432 llocat.d at right shock toworl, C114 lHO2Sl and EcM.
10-r|o o?
DIGITAL MULTIMETER KS-AHM-32-003
the Disconnect 4P connectorfrom the HO25.
Me6sute tesistance betweon terminsls C and D on the HO2S.
ls there 1O-4O 0?
( T o p a g e1 1 - 5 9 )
DIGITAL MULTIMETEB KS-AHM-32-003
11-58
11-58)
Check lor continuity to body ground on telminalsC and D ot the HO2S.
H23A1 engino IUSA: Si/Canada: SRl. H22Al ongino (USA: Si VTEC/Canada:SB-V):
Check foi continuity between terminalD and terminals and B inA dividually. F22A1 ongine (S):
HO2S 45 N.m (4.5 kg-m,
At HO25 harness,measurevol, tage between YEL/BLK{+ I terminal and ORNMHT {- ) terminat.
ls there battery voltage?
YES
Disconnectthe "A" from the ECM.
connector
HO2S 45 N.m {4,5 kg-m, 33 tb-ftl
Meosure voltage bstween YEL/ BLK (+l re.minal and body ground.
At HO25 harness, measure voltage between YEL/BLK(+ )termi nal and ORN/WHT(- ) teiminal. Repair 3hon in ORf{/ WHT wire botwoen ECM (A6l and HO2S.
Ropairopon in YEL/BLK wiro botwoon HO2S and PGM-FImsin rolav. Turn the ignirionswitch OFF.
Reconnect HO25 connector. the
{To page 1 1-60}
{To page 1 1-60)
{cont'd}
11-59
PGM-FISystem iM-Fl
Flowchart - HeatedOxygen Sensor(HO2S)Heater {cont'd) Troubleshooting
(Frompsge 11-59)
"A" Connoct the tesl harness connector to the main wile haF ness only. not the ECM (seepage 11-45).
Connect an ammetet btween telminalsA6 { + ) and A26 (- ) ' Monitor over a 5 minutes period. ls the curront less than 0.1A?'
Subrtltut. a knownSood ECM lnd rochock. ll .ymptom/indication 9o6a away, roplaco tha origi_ nal ECM,
I
Reconnect the 4P connector to the Ho2s.
"A" Connect the test hahess connector to the main wi.e haF ness onlv, not the ECM (s.e page 11-45).
BATTERY o o o o o o o o o o o o o oo ooooooooooo VOLT
oooooooo oooooooo
ooooooooooo ooooooooooo
Turn th6 ignitionswitch ON.
Measurevoltage between A6 {+} terminsland A23 {- } terrninal.
Rep.lr opn in OR /WHl wir. bctwcrn ECM lA6) .nd HO2S.
Subllltuto 6 known-good ECM and$chock. ll symptomlindicat'roril'golr ay{ay, rsplaco tho otigil_ nal ECM.
11-60
F
PGM-FISystem
TroubleshootingFlowchart - Fuel Supply System
:r,*n-- \r-r-l13l -t
- - - | t
Troublecode (DTC)43: A problemin The MatfunctionIndicatorLamp (MlL) indicatesDiagnostic problemin the Fuel Supply System the HeatedOxygen Sensor{HO25) circuit or a
l@r rE.
- Tho MtL hc! b.cn roportod on . - Wlth rorvico chock connoctoi iurDod t!.3 p.Oe 1 142), codo 43 l. indicatod. ls the codo 43 accompaniod by the MIL and poor driveabilitY? Go to Fu.l Supply Systam (3.o p!9. l1-'1131. Fiom cod. 1 troubb'l 3hootlng lpag. I -561.
Do the ECM Reset Procedure lse6 page 1 1-43). warm up engineto normSloper' ating tompgrature {the radiatorfan comes on). rpm lor two Hold engineat 3,OOO mtnutes. (A/T:NorEposition.)
,,ti
i,l
ls the MIL on and doss it indicate code 43?
Intlrmlttdrt t ilurc, ly.tom is OK at thir dm (t6st drlv. may ba nocoalarYl. Chock tor ooor connactiona o. loor. wirst at C432 lloclt.d !t rtght rhock low.tl, C1f4IHO2S) and ECM.
Turn the ignition switch OFF. NOTE: . Use DIGITALMULTIMETER (KS-AHM-32-OO3) equival6nt. or . Use 2 Volt range.
Connect the test hamess bgtween the ECM and connoctors {see page 1'l-45).
With the ignitionswhch OFF,wait tor st least two minutes. Install a iumper wire on the test harnessbotween A6 and A26.
A26 WIRE JUMPER
Turn the ignition switch ON. Measure voltage between Dl4 A l+) terminaland 26 {- ) terminal as soon as the ignition switch is turned on, lTo page 11-63)
A26{-t
Voltaga .hould ttan tl 0.4-0.5 v wh.n thc ignltion .whch i. fit8t tunad oo, and dactaaso to b.low O.l V In L.t than two mlnut6a.
D 1 4( + l
11-62
lFrom page 11-62)
ls there 0.1 V or lss when the ignition switch is tirsr turned on?
Measurevoltage belween D14 { + ) t e r m i n a la n d A 2 6 ( - ) telminal.
ls there more than 0.1 V?
Disconnect the "D" connector trom the main wire harness.
Measurevoltage between D14 l {+} terminaand A26 {-) rer minal.
ls there more than 0.1 V?
Bop.ir rhon in WHT wlro b.tw.on ECM (Dl4l andHO2S.
Measu.e voltage at the engine wi.e harness side ot the HO2S connector between GRNMHT ( - ) a n d W H T( + ) .
Substitute a known{ood ECM and r6.hock. lf symptom/indlcation goos away, roplact the orlglnal ECM.
ls thre mor than 0.1 V?
Chock for oDcn in IIVHTwiro betw..n ECM (D141 and HO2S. lf wlrs ir OK, r6poir opcn in GBN/WHT wiro berw66n ECM (D221and HO2S. F2241 sngino {S): GRI{/
H23A1 ongin6 (USA: Si/CanadarSR), H22Al ongino (USA: Si VTEC/Conada:SR-V);
GRl{/ WHT
W H T( + )
IVHT - l
WHT
(+l
moro than
o.'t v?
DIGITAL MULTIMETER KS-AHM-32-OO3
HO25 45 .m (4.5 kg-m,33 lb-ft|
HO2S 45 N.m 14.5 kg-m, 33 lb-ft)
DIGITAL MULTIMETER KS-AHM-32-OO3
11-63
PGM-FISystem
t 1 6 l - /- l 3 l \/--l-\ ,
\ |
|
TroubleshootingFlowchart -Manifold Absolute Pressure(MAP) $gn5s1

- -l-- ---1- TroubleCode (DTC) 3: An electricsl The MalfunctionIndicatorLamp (MlL) indicatesDiagnostic {MAP) Sensorsystem. oroblemin the ManifoldAbsolutePressure
Troublecode (DTC) 5: Lamp {MlL) indicatesDiagnostic {-61--fr-r- The MalfunctionIndicatorthe ManifoldAbsolutePressure(MAP) SensorSystem' A mechanical (vacuumleak) in problem
/\ /---i\
/-
The MAP sensorconvertsmanifoldabsolutepressureinto electricalsignalsand inputs the EcM. CAVITY OUTPUT VOLTAGE (vl3.5 3.0 2.5 2.0
1.5
-16l/-\/
0.5
lar. Hll OAUOE N: DING
- Engin6 is watm ond running. - Tho MIL has b6nloPortodon - With soryico ch6ck connoctot jumpod (so pago 1'142), codo 3 is indicalod.
I
r',i i , l'
{see Do the ECM ResetProcedure p a g e1 1 - 4 3 ) .
I'iI
l l
Intgrmittont failuro, 3yltam is OK at this time ltort ddve may D6 noc{r!ry}. Chock tor Poor connoction! ol loose wiror at O163 (locatod undor loft 3ideol drshl, C32O IMAP 3.n3otl and ECM.
the Disconnect 3P connectorfrom the MAP sonsor.
(To psge l1-65)
11-64
l F r o mp s g e 1 1 - 6 4 )
Measure voltage between RED/ WHT (+) terminal and body ground.
D 1 9t r l D 2 1( _ l
ooooooooooooo ovooooooooooo I o oooo ooo I oooooooo
ft
Measure voltage between RED/ WHT (+ ) terminal and BLUMHT { - ) terminal. Ropai. op6n in BLU/ WHT wiro betwoon ECM {D21} and MAP s6n8l't.
Turn the ignirionswirch OFF. ls there approx. 5 V? Connect the test harness "D" connecto.to the ECMonly, notto the main wire harness (see page 1145).
Measurevollage between D19 l + ) t e r m i n a la n d D 2 1 ( - ) terminal. Measure voltage betweon WHT/ BLU {+ ) terminaland ELUMHT { - ) terminal.
Ropairopon in RED/WHTwiro botwcon ECM (D191 and MAP son3()r.
Sub3tituto a known-good ECM and rochock. lf 3ymptom/indication 9003away, .eplacotho original ECM.
Turn the ignitionswitch OFF. Reconnect the 3P connector to the MAP sensor. Connectthe test harnessbetween the EC|VI and connectorlsee page 11-45). Turn the ignitionswitch ON. { T o p a g e1 1 - 6 6 }
{To page 1 1-66)
(cont'd)
11-65
PGM-FISystem
(MAPISensor Pressure lcont'dl Absolute Flowchart- Manifold Troubleshooting
{Frompsge 11-65) (Frompage 1 1-65) MeasuG voltage bstween D'l7 (+l terminaland D21 (-) terminal.
"D" Connect the test harnss not to connectorto the ECMonly, the main wire harness {see page 11-45).
Sub.tituls . known{ood ECM rnd r.chock. lf 3ymptom/lndication goo! 6w!y, r.plact th. odgi nal ECM.
Measurevoltage betweon D17 ( + l t e r m i n a la n d D 2 1 { - ) tetmlnal.
ls there approx. 5 V7
- Roplir rhort In WHT/BLU wiro botworn ECf,l {D17) rnd MAP loflto], - R.prir opon in WHT/BLU wlrc botwo.n ECM (Dl7l.nd MAP 36nao..
Substltuto a known{ood ECM and rochock. lf aymptorn/indicrtion goo3 away, taplace tho original ECM.
11-66
PGM-FISystem
Sensor Pressure lcont'dlAbsolute {MAP} Flowchart- Manifold Troubleshooting
,g:
-g-
- The MIL has boon reponod on. - With sorvic chock connector jumpod ls6opago 1 142), code 5 is indicatod.
Do the ECM ResetProcedure {see p a g e1 1 - 4 3 ) .
Start the engine and keep engine speed at 2,000 rpm tor one minutewith the manualtransmas sion in neutral {A/T: @ or S position). - Intgrmitl6nt lailuro, 3y3tom is OK al this tlm6 lt$t ddvo mav bo nocoasaryl. - Chock vacuun ho3or, PiPo3 ond connoctionS. - Mako turo all conn9ctota ar6 30cu16, MAP SENSOR Turn the ignitionswitch OFF.
l l
'1i
r:ttl
Hrl
Disconnect#21 hose lrom the throtle body, connect vacuum pump to the hose and apply
VACUUMPUMP/ GAUGE A973X-041-XXXXX

#21 HOSE Connect a vacuum pump to the MAP sensorand apply vacuum.
Does it hold vacuuml
Connecta T-titling from a vacuum gauge between the throttle body and #21 hose.
Repairvscuum lsak in hoa routing betwaon MAP asn3or lnd rhrottlo body .
{ T o p a g e1 1 - 6 9 }
11-68
{Frompag6 1 1-68)
Start the engine.
ls there manifoldvacuum?
Connectths test harness between the ECM and connectors (see p a g e1 1 - 4 5 ) .
T-FITTING
D l 7 t + l D 2 1{ - }
Measurevoltage between D17 (.t ) terminal and 021 ( - ) lermrnal,
3V?
ls there approx.3 V?
Start the engineand allow it to idle.
Subltitute a known-good ECM and rocheck. ll symptom/indication 9063away, ropl6cotho o.iginal ECM.
11-69
System PGM-FI
Sensor Flowchart- TDC/CKP/CYP Troubleshooting
I
-Yt-._r-\ \
16l-
Tr-l-
TroubleCode(DTC)4: A problemin the Diagnostic Lamp(MlL)indicates The MalfunctionIndicator CrankshaftPosition(CKP)Sensorci,cuit. Diagnostic TtoubleCode{DTC)8: A problemin rhe Lamp(MlL)indicates Indicator The Maltunction (TDC)Sensorcircuit. Top Dead Center TroubleCode(DTC)9: A problemin the Diagnostic Lamp(MlL)indicates Indicator The fiilalfunction (CYP)Sensorcircuit. CvlinderPosition
- l r G./l - --_-1_/l 8l
/-i-\ / \
-116l--l e l/ --t-\ /---- \
\_
j_'-,2
\_
_/
timing fo. fuel injectionand ignitionof each cylinderand also detects enginespeed.The The CKP Sensordetermines The CYPSensordetects and when crank angleis abnormal. ignition timing at start-up(cranking) TDC Sensor determines to each cYlindet. the position of No. I cylinder for sequential fuel injection
-@Jtrl:;m:-;F;
.ir
- Tho MIL ha. bn Jooortod on. - lilfith loruice chck conn.ctol iumpd (3ooprgo 1142), codc 4. 8 rnd/or 9 aro indicstgd.
l,l
Do the ECM Resetprocedurelsee pago 1 1-43).
ls lhe MIL on and does it indi cate code 4. 8 and/or 9?
l ormittont l.ilur., syltom b OK at this timo ltelt driv6 may bo neco$aryl. Chock for Door connoctiona or loos6 wir.s at Al25 (locatod at dght shock towo.), Cl25 (TDC/ CKP/CYPionsorl .nd ECM. SRl, .,. H23A'l ongino{USA: Si/Canada: vrew rrom H22a1 engino
sa-vt, iiisr, si vlicrca"aaa
$jT'"'
Disconnect 8P connctorfrom the the TDC/CKP/CYPsensor.
( T op a g e1 1 - 7 1 )
11 -7 0
1 1-70)
Measurerosistancebetween terminals of the indicnted senso.. '9oo tsblg
SENSOR
oTc
SENSOF
ECM COLOF 815 416 ALU/GRN SLUTYEL
cxP ls there 350- 700 O? Roplacathe di.Mbuto. houalng {16o soction 231.
TOC
c
G
al3 at4
Bll
OFN/aLU
OFN
Bt2
Chck lor continuitv to bodv ground on both terminals of the indicatgd sensor. RoDlrc. th. di.trlbutor houling (soo aocdon 231.
Connect the test harness to the main whe harnossonlv, nottothe ECM (seepag 1 1-45).
8:16
350-7OOO?
Measurerosistancebetween trminals of the indicated sensoron test harness. 'see tablg
o oooooooooooo I oooooo ooooo oooooooo I oooooo
o l:1E$iq#Cittl o o o oo o oo oo o o ooooo oo oo o
B1l-
350-7ooo?
o o ooooooo o ooo I ooooo ooo r.sEt$di6dq oooooooooo o 350-7000? 812
ooooo oooooooo I ooooo0oo lfrlE#lls*llooooooooooo
ls there 35O-7OO 0?
R9pai.op.n In tho indicatad alnlor wi10a. '!oo trble
Check tor continuity to body groundon Bl 5, 813 or 81 1 termtnals,
Subltltuto a known-good ECM lnd r6chock. lt aymptom/indicrtion goor away, rcphca tho origin.l ECM.
11-71
PGM-FISystem
TroubleshootingFlowchart - Engine Goolant Temperature(ECTI Sensot -
f'at- lri-tl , - ---;--
TroubleCode (DTC)6: A problemin The MalfunctionIndicatorLamp (MlL) indicstesDiagnostic (ECT)Sensorcircuit. the EngineCoolantTemperature
as of The resistance the thermistordecreases the enresistor(thermistor). dependant The ECTSensoris a temperature gine coolanttemperatureincreases shown below. as
RESISTANCE (KO)
- -- hl 6 l -
/----,
r / -- -l- ! 5 l ---i-
-20
- The MIL has b6onroDongdon. - With sorvica ch6ck connoctol 'l ,ump6d l.oo pag 1421, c!d6 6 is indicatsd.
0 ,ro ao ao r roo 12o (rc, . 12 aa r0. !.ro 1ta 2r2 2.r r.fl
COOLANT TEMPERATURE ENGIT{E
Do the ECM ResetProcedure {see page 1 1-43).
Turn the ignition switch ON,

j
ls the MIL on and does it indi cate code 6?
Intermittnt failure, systgm i3 OK at thir timo lt6st d.ivr m.y b. n6ce!l|'yl. Chock tor poor connootions or looro wir6 at 9125, 9126 (locrtod at righl shock toworl, Cl22 IECT lenrotl, AIf: C411 (TcMl and ECM.
Warm up engine to normal oper(th radiatorfan ating temperature comeson).
the Disconnect 2P connectorfrom the ECT sensor.
Measureresistancebetween the 2 terminals on the ECT sensor.
ls there 2OO-4OO0?
{To pagc 1 1-73)
11-72
( F r o mp a g e 1 1 - 7 2 )
Measure voltage between YEL/ BLU and body ground.
GBN/ wHT
YEL/BLU
ls there approx. 5 V? Measure voltage between YEL/ BLU (+ ) torminaland GRNA/VHT (- ) terminal. Repair opn in GRN/ WHT wlra brtw.on EGM (D22) and ECT tonaoa.
Turn the ignitionswitch OFF. ls there approx. 5 V? A/T only Disconnect the 22P connector trom the TCM. Subrrituto r known{ood ECM and iocheck. lf lymptom/lndlcrtion goaa aw!y, rol aco tha original ECM.
YES
NO
I
I
I
Connect the test harness "D" connectorto the ECMonly, notto the main wire harnsss lse page 11 - 4 5 ) .
v? T-5 O13l+l
D22 t-l
Measurevoltage belween D13 ( + l t e r m j n a la n d D 2 2 ( - ) rermtnat.
NO
Subatituto a known-good ECM and rechock. lt symptom/indication goos away, r6pl6cothe original ECM.
Ropairopen or rhon in YEL/BLU wir. betwoon ECM lDl3l snd ECT sensor.
11-73
PGM-FISystem
TroubleshootingFlowchart - Throttle Position (TP) Sensor
lf1=lllfifl .:. : TroubleCode IDTC) 7: A problemin The MalfunctionIndicatorLamp (MlL) indicatesDiagnostic the Throttle Position{TP) Sensorcircuit.
lt The TP Sensoris a potentiometer. is connectedto the throttle valve shaft. As the throftle positionchanges,the TP Sensorvariesthe voltage signalto the ECM.
ERUSH HOLDER
VOLTAGE OUTPUT NI
BRUSH
5 4 3
RESISTOR
lr6t1
-Yr
:.t1
-tTERMINAL
2 1 o.5 0 THROTTLE
- Engino b running. - Tho MlLhas beonreDortedon. - With sorvico check connoctot iumpsd ls6opage 1 142), codo 7 is indicatod.
;;ii-
oPEt{rNG
THROTTLE
INNER BRUSH
(see Do the ECM ResetProcedure p a g e1 1 - 4 3 ) .
ls the MIL on and does it indicatecode 7?
Inlormittont Iailure, systom b OK at this timo lt6st d.ivs m6y b6 nocossaryl. Chock tor Dooi connections or loos wiros at O125, g*13 llocatod at right shock rowerl, C113 (TP sonsorl, A/T: C4'l l ITCMI and ECM.
Disconnect 3P connectorfrom the the TP sensor.
Measure voltage between YEL/ WHT (+ ) terminal and GRNMHT (- ) terminal. Measure voltage between YEL/ WHT (+) rorminal and body grouno, YEL/ RED/ GNN/ WI{T BLK WHT (To page 'l1-75)
YES
{ T o p a g e1 1 - 7 5 }
11-7 4
(F om p8O11-741
(Frompage 1 1-74) Repaii opon in GBN/ WHT wiro botwo6n ECM (D221 End TP 30n3('t.
ls there 6pprox. 5 V? Turn the ignition switch OFF. Turn th6 ignition switch OFF.
Connoct testharness th btween tho ECM snd connectors{see p8ge11-451.
Connoct the test hamess b9tw6n the ECM and connoctors lse p a g e1 1 ' 4 5 1 .
Measure voltage betwgen D2O ( + ) t e r m i n a la n d D 2 2 { - ) terminal. Turn the ignhion switch ON. ls there aoo.ox. 5 V? Rop.ir op.n in YEL/ WHT wlra bolwoon ECM {D2O} a.|d TP aonlot,
Measurevoltago btween Dll {+) trminaland D22 (-, terminal.
Subltltut. . known{ood ECM .nd r.ch.ck. It piclcribcd voltage i! now lvoilabl., rrphco tho orlgin.l ECM.
o o o o o o o o o o o o o I o o o o o o o o E f f n f f i n S Ho o o o o o o o o o o Fl o o o o o o o o o oo o o I o o o o o o o o ooooooooo
D 2 0t + l D 2 2 l - l
tsv,J
0.5 V at tull close throttle? 4.5 V at lull open throttle? ls voltago 0.5 V at full clos throttle, and approx.4.5 V 8t full open throttls? NOIE: There should be a smooth transition from O.5 V to approx.4.5 V as the throttle is depressgd.
Diaconngct the 22P connecto. from th6 TCM.
Sub.litulc ! known-good ECM .nd rochsck. lf symptom/lndic.tlon goat rway, ropl.c. the odginll ECM.
ls voltageO.5 V at full clos6 throftls, and 4.5 V at full open throttl? NOTE: Thero should be a smooth transition from 0.5 V to 4.5 V 8s the throftlo is dpressed.
- Roplac6 the TP lonaoa. - Rapairoponoarhon in RED/BLKwiro betw.n ECM {Dl 11, TCM and TP r.n!or.
11-75
PGM-FISystem
(lAT) Sensor Troubleshooting Flowchart- IntakeAir Temperature
f6l F l---:Diagnostic TroubleCode(DTC)1O:A problem the in The Maltunction Indicator Lamp(MtL)indicates (lATl Sensorcircuit. Intake Air TemDerature
The IAT Sensofis a temperature dependant resistor(thermistor). resistance The ofthe thermistor decreases the intake as air temoeratureincreases shown below. as
(KO} RESISTANCE
THERMISTOR
. 12 aa ro4 1aolta :12 t a |.Fr
INTAKEAIR TEMPERATURE
IA7 SENSOR
GR N'VHT
:[611:frnl --i/ --T/ \ \
i:
- Tho MIL har b6onropon6d on. - Wlth s6rvico chock connoctol iumpod {3opago 1142}. cod6 10 is indicsrod.
(see Do the ECM ResetProcedur p a g e1 1 - 4 3 ) .
Turn the ignitionswitch ON. Intermitl.nt tailu.o, sydom iB OK at thir tims (tost ddvo may bo noc6ssttyl. Chock for poor connoction! ol loo!. wircr .t O+25, 9126lloclled ot right .hock towor), CiOS llAT sonsorl and ECM.
ls the MIL on and dos it indicatecod6 10?
Disconnect 2P connectortrom the the iAT sensor.
Measureresistanc6between the 2 terminalson the IAT sensor,
ls there 0.4 -4.0 k0?
lro page 11-771
11 -7 6
(Frompag 1 1-76)
Measurevoltage between RED/ YEL (+) terminal and body ground.
ls th6re approx. 5 V?
Mgasure voltage betweon BED/ YEL (+ ) terminaland GRNMHT {- ) terminal. Ropair opcn in GRN/ WHT wlr6 botwoon ECM (D221 and IAT lon301.
li there approx. 5 V?
Connect the test hamess "D" connectorto the EcM only, notto the main wire harness lsee page 11-45).
Subrtitut. . known-good ECM and rochock. ll lymptom/indicatioh goe! aw!y, r6pl.ce th. orlglnel ECM.
Measurevoltage between Dl5 {+} terminafand D22 l-) terminal.
ls ther6 approx.5 V?
Ropair oponor lhort in REOrYEL wirebotween ECM{D15}.ndIAT aona{tr.
Substilute a known-good ECM and .ochock. lI symptom/indication go6s awsy, roplac6tha original ECM,
11-77
PGM-FI System
lmil .(-frrf: .+.
(BARO) Sensor Pressure Troubleshooting Flowchart- Barometric

in 13: Diagnostic Trouble Code(DTC) A problem the Indicator Lamp{MlLlindicsts ThsMalluncrion (B B a r o m e t rPc e s s u r e A R O ) e n s o r . ir S
is The BARO Sensor builtinto the ECM.
-\ 13\/--i- Tho MIL hsr boon r.ponod on. - With sr|.ico chack connacto. iumpcd l!.o p.06 I 142), cod 13l! Indlcstod.
Do the ECM RsotProc6dlre (se6 page 'l1-43).
ls the MIL on and do6s it indicatecode 13?
Int.rmltt.nt f.llut . lyltgm Ir OK at thlr tlm. lt6!t drlv. mly b. nacoar!ry1.
Subrtituto a known{ood ECM .nd rcchock. lf symptom/indlc!tion goo! away, r6phca tha odolnsl ECM.
11^78
i t
PGM-FISystem
TroubleshootingFlowchart - lgnition Output Signal
i151 : :16: in Trouble Code(DTC)15: A problem the Diagnostic Indicator Lamp(MlL)indicates The Malfunction lgnitionOutput Signalcircuit.
H23Al ongine IUSA: Si/Caneda:SRl, H22A1 ongino IUSA: Si VTEC/ Clnada
sR-v):
- Tho MIL ha5 beenroponod on. - With sorvice chock connoctot iumpod {! p.g 1142), code 15 is indic.ted.
(see Do the ECM ResetProcedure p a g e1 1 - 4 3 1 .
NOTE: lf the engino won't stari. it mav take 20 seconds of cranking to set the code. lntrmittant failute. tYllam i! OK .t this timo (t.!l drive may bo nac6slary). Chcck for poot connactions or looso wi.or ot C433 {locrtod at .ight shock towet). Ct2S llgntdon Conlrol Modulo llCMl) and ECM.
ls the MIL on and doos it indicatecode 15?
Measure voltage betwegn YEL (+ ) terminland body ground.
YES { T o p a g e1 1 - 8 1 } (To page 1 1-81)
1 1 -8 0
Turn the igniitionswitch OFF.
Reconnectthe 2P connector. ls the ignirioncoil OK? Connectthe test harnessbetween the ECMand connector(seepage 11-45).
- Repsii opon in YEL wiro botwoon tho 2P oonngcto. and ignition coil, - Ropaii opon in BLK|'EL wi.o botwoon tho ignition coil ond ignition $witch.
Measurevoltage individually bet w e e nA 2 1 ( + ) , A 2 2 { + l t 6 r m i nals and A26 t-) terminal.
1OV? ---r A 2 1{ + } oooooooooooo
oooooooooooo
A 22l+t 426 l-l 1 0v ?
t-J
ls th6ro approx. 10 V?
- Roolocs lho lCM. - Repair opon oi lhon in YEL/ GRN wir. botwon ICM lnd ECM {A2l or A221. NOTE:lf the YEL/GRN wire was shorted. the ICM may be damag6d.
Substituto . known-good ECM and roch.ck. lf symptom/lndic.tlon goos awsy, .oplacoth6 original ECM.
11 - 8 1
PGM-FISystem
Troubleshooting Flowchart- VehicleSpeedSensor(VSSI
-c+l --lKgll- :'; rI r'' lin Diagnostic TroubleCod(DTC)17: A problem the The Maltunction Indicator Lamp(MlL)indicates vehicle speed sensor {vss) circuit.
The VSS generates pulsingsignalwhen the front wheels turn. a

- Th6 MIL has bo6n rportodon. - With sorvico ch6ck connoctor iumped ls6opage I 142), cod '17 is indicatod.
(see Do the ECM RestProcedure p a g e1 1 - 4 3 ) .
Road test necessary. With manualtransmission 2nd in gear (A/T: E position)accelerate to 4,000 rpm, thn decelerateto 1,5OO rpm with throttle tully croseo. Intormlttont lallurc, 3ystcm ls OK at this tim. Chock tor Door connoctiona ol loose wir6s at C433 {locrtod at .ight shock tow6.). Cl15 {VSSI and ECM,
rl
Block rear wheels and set the parkingbrake.Jack up the front oI the car and support with salety stands.
@emr ro.l wheel
beloro jacking up front ot cat,
Turn the ignitionswilch OFF.
Connectthetest harnessbetween the ECM and connectors (see p a g e1 1 - 4 5 ) .
o oooooo ooo ooo I oooooooo &ruffi ooooooooooooo I oooooooo EEwryl A 2 6l - ) 8 1 0( + ) O - 1 2v ot O *5.o v?
ooooooooooo oooooooo ooo
Block the right front wheel and slowly rotate left lront wheel and measurevoltage between B1O { + } t e r m i n a la n d A 2 6 { - ) Iermrnat.
NOTE: Transmission @ position{A/T). in
Does voltage pulse 0 V and '12 V lH22A1 engine{USA: Si VTC/Canada: SR'V)5.0 V)?
Substituto a known-good ECM and rochock, lf symptom/indication gooaaway, roplacoth6 original ECM.
( T o p a g e1 1 - 8 3 )
11-82
(From page 1 'l-82)
Disconnoctthe B connector trom the ECM only, not the main wire harngss.
Block the right front wheel and slowly rotate left front wheel and masurevoltage between 810 (+) terminaland A26 (-) tefmrnal.
Does voltage pulse O V 8nd 12 V lH22A1 engine (USA: Si VTEC/Canada: SR-V):5.0 VI?
Sub.tituto r known{ood ECM .nd r.ch.ck. lf lymptom/indication goar rway. roplace tho original ECM.
- Reprir 3hort in ORN wi.e b6twoon ECM (8101and tho VSS, Tianlmission Control Modulc, spo6domotor, 4WS control unit, or cruiso contrcl unit. - Ropoiropon in ORN wire b6two6n ECl, {8101and VSS. - lf wlr i8 OK. tort th VSS {!oo .oction 23t.
11-83
PGM-FISystem
(ELD) TroubleshootingFlowchart - ElectricalLoad gs1s61q1
tf
- --r--' I 20 l-
in Trouble Code(DTC)20: A problem the Diagnostic Lamp(MlL)indicates Indicator The Malfunction Etectrical Load Detector(ELD)circuit.
With sorvice chock connoctor jumpcd (3oepago 1142), code 20 is indicatod.
Do the ECM Resetprocedure{see page 1 1-43).
Start engineand keep enginerpm at idle. Turn on headlighls. Intormitlgnl lalluro, system is OK at this timo {to.t ddv m.Y bo nocoa!4ry1. Chock tor ooor connociion3 ot looso wlr6s at C420 IELD) 8nd ECM.
Doesthe MIL indicatecode 20?
Turn the ignitionswilch OFF.
,i
Remove the undeFhood tuse/ relay box and remove the fuse/ relay box lower cover,
it
( SLKTYEL+ }
Measure voltage between BLK/ l Y E L ( + ) t e r m i n aa n d B L K ( - l terminal. Measure voltage between BLK/ YEL {+) terminal and body ground.
LOWERCOVER
ls there battery vollage?
Roplir opon In BLK rvk. batwcan tha 3P conn ctor and erc3 llocatcd undor middlo ol dashl.
Ropairopon in BLK/YELwlto botweon ECU IECMI {'15Al fu3o {in tho undor-dash tuso/rolay boxl and lho 3P connector. (To page 1 1-85)
11-84
{Frompsge 1 1-84}
Measure voltage between GRN/ 8LK terminl and body ground. Rep.ir opon or short in GRN/BLK rvi. brtwoon ECM lDlO) and tho 3P connoctoa. It wiro is OK, aubstitut6a knowngood ECM and ..chock.
ls there 4.5- 5.0 V?
GRI{/BLK ) I+
LOWER COVER
Connectth6 tst hsmossbetween the ECM and conneclors (see p a g e1 1 - 4 5 ) .
{To poge 1 1-86}
(cont'd)
11-85
PGM-FISystem
TroubleshootingFlowchart - ElectricalLoad Detectol (ELDI (cont'd)
Condition Headlightswitch, first position (.) Headlightswitch, second position( a) Voltage 1 . 5 - 3 . OV
V 1.0-2.O
Underthe conditions listd in the chart to the right, measure vol_ tage between D1O {+ } terminal and A26 (- l terrninal.
'
it
Substituto a known{ood ECM and recheck, ll symptom/indication goos away. 6phco tha otiginel ECM.
11-86
PGM-FISystem
t-7=.l_lltlllll-r#-l .l l-
Flowchan- KnockSensor(KSl [ExceptF22A1 engine(S]l Troubleshooting

TroubleCode (DTC)23: A problemin The MalfunctionIndicatorLamp (MlL) indicatesDiagnostic (KS) circuit. the Knock Sensor
-e-tm- Thc MlLhas boenroponed on. - With !6wico chack connoctol lumpd l..o pago I 1421, codo 23 is indicatod.
Do tho ECM RestProcedurslse p a g e1 1 - 4 3 ) .
Warm up the sngine to normsl opgratingtempotature (tho radiator lan comgs on).
Hold engine8t 3,OOo 4,0OOrpm tor 1Osecondswith manualtransmiesion in neutral {A/T: lll or lq position). Int.mittonl l.llur., sy.t.m b OK at thir tim. (tod driv. maY bo nocolaorYl. Chack for poot conncctlon! ot loolq wlro3 al O+32 (loortrd rt right shod( tow.r), Cl l2lKS) and ECM,
ls the MIL on and does it indicats code 23?
Turn the ignition swirch OFF.
Connect the test harness to the engine wire harneasonly, not to the ECM (seepage 1 1-45),
t_ Continuity?
o3
Ch6ck lor continuity between D3 trminal and body ground.
wite bcRop6ir.hon in RED/BLU trY.en ECM lD3l snd th. KS.
(To page 11-89)
1 1-88
Check tor continuity on RED/BLU wire betweenD3 terminaland 2p connectorof enginewhe harness.
lContinuity? Ropairopon in RED/BLUwiro botwoon ECM lD3) and tho KS.
Warm up tho engineto normal operating temperature {theradia, tor fan comgs on).
Hold engineat 3,OOO-4,OOO rpm lor 1Osgcondswith manualtransmissionin noutral (A,rf: @ or @ oosr!onl.
Subslituto a known-good ECM and rsch6ck. lt symptom/indic!tion goos aw6y, .oplacothe original ECM.
32 N.m 13.2ks-m.23 lb-ftl
11-89
PGM-FISystem
Flowchart- A/T Fl SignalA/B (A/T only) Troubleshooting
TroubleCode (DTC)30: A problemin ---l-The MalfunctionIndicatorLamp (MlL) indicatesDiagnostic -l 30 lControl Module {TCM) and ECM. A/T Fl Signsl A circuit between Transmission tne (MlLl indicatesDiagnostic TroubleCode {DTCI 31: A problemin r;;--] The MaltunctionIndicatorLamp I Jr l- the A/T Fl SignalB circuit between Transmission control Module {TCM) and ECM.
\.----_/\r---:-/
- l 3 0l - o , - l 3 l l ------ ---j\
With 3orvico chock connactor jumpod, (ra. pagc 1142), codo 30 .nd/or 31 arc indicatod.
Do the ECMR6setProcedure {see p a g e1 1 - 4 3 ) .
Test drive necessarv. Drive th3 car for severalmiles so that the transmission upshiftsand downshifts soveral times. lhtdmittont failurs, gylt.m i. OK ai thir tlmo. Chock for poot connoction! or loo.. wiro. at C4ll (TCMI snd ECM,
l
I I
Does th MIL indicat code 30 and/or 31?
r'l Turn the ignition switch OFF.
Connect the test harnssg to the msin hrnessonly, nottothe ECM 'l1-45). {see page
Disconnect the 22P connector from rhe TCIV. Conlinuity? Check for continuity between 93 and/or 84' terminal and body grouno.
+
Continuity *r codo 31 {A/T Fl signal B) RoDairrhort in ORN or Pf{Kr wilo botw.n ECM {B3 or B4r I .nd rh. TCM.
NO
( T op a g e1 1 - 9 1 )
11-90
(Frompsge 11-9O)
Check lor continuity on ORN or PNK'wire between 83 or 84* and 22P connectorot rhe TCM.
Ropsiiopon in ORI{ or P{lK. wir6 botween ECM {8:} o?84. I and rhc TCM. Subltitute a known{ood ECM and rochack. lt lymptorh/indication gogs rway, roplaca tha original ECM.
11-91
ldle Control System

Guide System Troubleshooting
NOTE: of that couldbe sources a symptomare rankedin the orderthey should a Acrosseachrow in the chart,the sub-systems refer startingwith @. Findthe symptomin the left column,read aclossto the most likelysource.then be inspected, the system is OK' try the next system @' etc' to ths page listed at the top ot that column. lf inspectionshows Trouble and the MalfunctionIndicatorLsmp (MlLl does not blink Diagnostic a lf the idle sDeedis out ot specificstion go to inspectiondescribed page 11-95. on Code {DTC) 14,
PAGE
SYMPTOM
ALIER, IOLE coNDr- NATOs ADJUST I D I E A I R CONTROL l s u s - s Y s T M ING FR TIONING SIGNAL S I G N A I SCREW -'\ 100 96 98 ttl
STARTER ERAKE STEERING FAST IDLE STAFTING
swtTcH swtTcH PFESSUNE THERMO srGt'rALSIGNAL SIGNAL

l04 106 104
HOSES AND CONNEC. TIONS
102
l09
110
TO DIFFICULT START WHENCOLO ENGINE WHEI.{ COLDFASI IDLEOUTOF SPEC.(1 ,000- 2,000rpm) ROUGH IDLE
O
@ @ @ @ @
o
@ @ @
TOOHIGH WHENWARMRPiN
load)
o o
@
WHEN T00 Low

liomr in ON
o
\,
@ @ @
o
@
FREOUENT STALLING
WARMING WHII,E UP AFTER WARMING
o
@
TEST FAILS EMISSION
11-92
System Description
The idle speed of the engine is contro ed by the ldte Air Control ACI Vatve. The vElve chsnges th smount of air bypassing into the intake manifold in responseto electric current contro ed by the ECM. When the IAC Valve is activated,the valve opens to maintainthe proper idle speed.
TO PGM.FI MAIN RELAY
.,\ \r-
vARtous
SENSORS
STARTITIG AIB VALVE
FAST IOLE THERMO VALVE
11-93
ldle Gontrol System

System Description(cont'd)
to 1. After the enginestarts,the IAC valveopensfor a certaintime. The amountof air is increased raisethe idle sp6d 'l about 50- 3OOrPm. 2. When the engine coolant temperatureis low, the IAC valve is openedto obtain the prope. fast idle speed. The amount of bvoassedair is thus controlledin relationto the enginecoolanttemperature'
IDLE SPEEO {rpml
104
140 60
&
11-94
l.
When the idlespeedis out of specification the MalfunctionIndicator and Lamp(MlL)does not blinkDiagnostic Trouble Code lDTC) 14, check the following items: . Adjust the idte speed (page I 1- l 1 I ) . Air conditioning signal (page 11-99) . A L T F R s i g n a t p a g e1 1 - 1 0 0 ) { . A/T gear positionsignat{page 11-1O21 . Starterswitch signal (p8ge 1j-1O41 . Brakeswitch signal(page 11-106) . PSPswitch signat(page t 1-108) . Fast idle thermo valve (page l.l_109) . Starting air valve . Hosesand connections . IAC valve and its mountingO-fings It the above items are normal,substitutea known-goodIAC valve and readiustthe idle speed {page 11-l1l). . lf the idle speed still cannot be adjustedto specification (and the MtL does not blink code 14) sfter IAC valve replacement, substitutea known-goodECM and recheck.ll symptom goes away, replscethe originalECM.
2.
11-95
ldle Control System

TroubleshootingFlowchart - ldle Air Gontrol (lAC) Valve
-r---i -tgll - - -;lr l_ I TroubleCode (DTC) 14: A problemin The MaltunctionIndicatorLamp (MlL) indicatesDiagnostic the ldte Air controt {tAc) vatve circuit.
to the throttle body in response a currentsignalfrom the ECM in The IAC Valve changesthe amount of air bypassing proper idle speed. order to maintainthe
TO INTAKE MANIFOLD FROM AIR CLEANER
VALVE
SPRING
--t6t- :Frl ---r-l- Tho MIL has boen r6portodon. - With sgrvico check connoctor jumped lsopago 1 1421, codo l4 is indicatod.
(see Do the ECMResetProcedure p a g e1 1 - 4 3 1 .
ls the MIL on and does it indicale code 14?
With lhe engine running and the accelerator pedal released, disconnect the 2P connector lrom the IAC valve.
Remove the 2P connector ttom the IAC valve.
ls there a reduction in enginerpm?
Substhute a known-good IAC valve and retost.
Intormitlant lafluro, ay8tom is OK dt this timo {to3t d.iving may bo nocassa,yl. Chock tor ooor connoction or looso wiros at c+25, C433 (locarod at right ahock towoil. C106 llAC valvo) and ECM.
( T op a g e1 1 9 7 )
11-96
(Frompage 1 1-96)
Measure voltage between the YEL/BLK wire 8nd body ground.
Rop6iropen in YEL/BLKwiro botwoon ths IAC valvc.nd PGM-FI main relay. Turn the ignition switch ott and reconnectthe 2P connectorto the IAC valve.
Connect the test hamess "A" connector to the main wire harness only. not the ECM lsee page 11 - 4 5 ) .
Mofientarily connect Ag terminal to A26 terminsl several times. Subrtitut . known{ood ECM .nd r.to.t. lt rymptom/ktdicrtkrn gooa away, raplaca tho original ECM.
Doosthe IAC valve click?
Ropairopon or .hort in BLX/aLU wirc b.tw.on IAC v.lvo and ECM (A9l . It tho wlr. i! OK, r6pl.co th6 IAC valv6.
ldle Control System

Troubleshooting Flowchart Air Conditioning Signal
system. This signalsthe ECM when there is a demandfor coolingfrom the ai. conditioning
Connectthe test hatnessbetween the ECM and connectors. "B" connectorfrom Disconnect the main wire harness only, not the ECM (seepage 11-45)
Turn lhe ignitionswitch ON.
A26 t-t
Measurevoltage between 85 (+) terminaland A26 (-) terminal.
Substituto a knowngood ECM and ]e fieck. It prssc bod voltago i3 now availablo, rapl6c6 th6 origln.l ECM.
Reconnect "8" connector to the main wirc harness. Clicklng?
Momentarily connect A15 terminal to /q26 trminal several times. ls thsre a clicking nob ftom the A/C comprc$or clulch?
Connecrrho RED/BLU torminrl ot ihe 4P conneclor on tho A,/C clutch rolty to body g.ound.
Vigw from wire harness side
13thorc I clicking noiaetrom the A/C comore6sor clutch ?
S6a alr condltlonat inrpaetlon lrac toction 22t.
Ropairopen in RED/BLUwlr6 borwo.n ECM {A 15} rrd A/C drnc*l relay. { T o p a g e1 1 - 9 9 }
11-98
(Fromp8g6 1 1-98)
r-
Lo!! rhan 1.0 v? --------.1
I
| I
es t*t
| ooooooo ooooo o looooc looooooooooooQ I ooooc r---------------A26 t_l I

Measure voltage between 85 (+) terminaland A26 {-) terminal.
ls voltagelessthan 1.O V? Air conditioning iignal i3 OK. Substituto a known-good ECM and rodrock. ll proscribod voltago is .row availoblo, rsplacg tho original ECM.
Ropairopen in BLU/BLK wiro botwoon ECM lB5l and A/C awitch.
11-99
ldle Control System

TroubleshootingFlowchart- Altelnator (ALT) FR Signal
This signalsthe ECM when the alternatoris charging.
Inspoction ol ALT FR sign.l.
Connectthe test harnessbetween the ECM and connectors. "D" connector from Oisconnect the main wire harnessonly, not the ECM (see page 11-45). 4.5 V? Turn the ignirionswitch ON.
A26 t-l
Measure voltage between D9 (+) rerminal and 426 (-) termrnat,
ls thereapprox.4.5 V?
Subltitut. a khown{ood ECM and r..hock. lf pr.rcribed voltlgo ir now availabl., rophce lh. ottginel ECM.
'l
Turn the ignitionswrtchOFF.
li
"D" Reconnect connector to the main wire harness.
Warm up engineto normaloPer ating temperatu (the radiatortan comes onl.
Vohfo
D 9l + l
Measure voltage between Dg l+) terminal and A26 {-) terminal.
ooooooooooo
ooooooooooo
Does the vohage decreasewhen heedlighls and rear dfogggr 8re turnedon ?
(see Do the ECM ResetProcedure p a g e11 - 4 3 ) .
ALT FR sign.l is OK.
(To page 'l 1-10'l)
(Frompage 1 1-1OO) "O" connector Disconnect trom ECM only, not the main wire harness.
NOTE: The radio may have a coded theft protection circuit. Be sure you get the customer'scode number before disconnecting the battery cable.
Disconnecl the negative banery cable trom the battery.
Check tor continuity between D9 trmanaland body ground.
Disconnect GRNconnector from the ALT.
Check tor continuity between D9 trmin.l and body g.ound.
Check for continuity betwoon Dg terminaland body ground.
Ropair3hon in WHT/REDwiro botwoon ECM (Dgl snd ALT.
Ropoi.opn in WHT/REDwiro b6twon ECM lDgl and ALT.
11 - 1 0 1
ldle Control System

(A/Tl Geat PositionTroubleshootingFlowchart - AutomaticTransaxle Signal(A/T only)
is This signalsthe ECM when the automatictransmission in @ or@] position.
Tum the ignition switch ON.
Observethe A/T gear position indicator and select gach Position separately. S6e A/T goar position indicatoi inspecdon (soction 141.
Ooesrhs indicatorlight ProPrlY?
Turn the ignitiongwitch OFF.
Connectthe test harnessbetween the ECM and connectors. "B" connector trom Disconnect the main wire hamess only, not the ECM (see page 11-451
5V?
87(+)
Turn the ignitionswilch ON.
A26 (-l
Measure voltage between 87 {+} terminal and A26 (-} terminal. Subltituto a known-good ECM and rech.ck. ll prsc.ibod voltago b now avriloblo, taplaco the original ECM.
Turn the ignition 3wilch OFF.
"8" connector the to Reconnect main wire harness.
(To page 1 1-1031
11-102
( F r o mp a g e1 ' l - 1 0 2 ) L6s8 than 1.O V7 --.-87 l+l
ooooooooooooo
oooooooooooo
A26 t-l
Measurevoltago botween 87 (+ ) terminal and A26 (-) tellninal gith the trsnsmission in LNI and lll position individually. Ropair opon in LT GBN wir. betwoon ECM lB7) .nd gaug6 aelombly.
ls there lessthan 1.0 V?
12V7Measure voltage btween 87 {+l terminal and A26 (-) ter, minal with the transmission in gear. Ropalr rhort ir| LT GRN wir6 b.tw.cn ECM {87} and gaugo .rlombly.
ls ther approx. 12 V7
A/T gear poritlon .lgn.l i. OK.
11-103
ldle Control System

Troubleshooting Flowchart -Starter
This signalsthe ECM when the engineis cranking.
Switch Signal
BATTERY
between Connectthe test harness the ECM and connectors {see p a g e1 1 - 4 5 )
ooooooooooooo oooooooooooo A26 (-t

NOTE: a M/T: Cluich pedal must be deoressed. o Ait: Transmission in @] or @ posltlon.
Measurevoltage between Bg (+) terminal and ,426 (-) terminal when the ignitionswitch in the start posrton.
ls there battery vollage ?
SIGNAL Insoect 2 STARTER No. (7.5 A) fus (in the undr-dash fusefielav boxl.
wlr. b.Rap.i. opon In BLU/RED tw.sn ECM (B9l rnd t{o. 2 SIGNAL STARTER 17.5Al lur!'
Startr switch signol i3 OK.
ldle Control System

TroubleshootingFlowchart - Brake Switch Signal
This signalsthe ECM when the brake pedal is depressed.
Inspoclion ol Brak6 Srvhdi Signal.
Are the brake lights on without depressingthe brake pedal?
Inapoct th6 br!k6 3wltch (!o aoction 19).
Oo the brake lighB come on7
InspectSTOPHORN('l5 A) luse (in th under-hood Iuse/rel8y boxl.
Connect the t6st harnoss to the main wire harnssonlv, nottothe ECM (see page 11-45).
- Roprir op.n In WHT^'EL wlrc b.twoon bruks lwitch lnd STOP HOR[{ 115 A} tu!o. - Inrpgcl tho b'r6ko rwltch l!o. lection l9l.
( T op a g e1 1 - 1 0 7 1
( F r o mp a g e 1 1 - 1 0 6 )
Measure voltagebetweenD2 (+) lerminal and A26 (-) terminal with the brake oedal deDressed.
BAI-TERY VOLTAGE?
02 t+l
ls there bane.y voltage t
Roplir opon in GRII/WHT wlro betwoon th. brakq lwltch rnd ECM {D2t.
Br.k. .wilch lional i. OK.
11-107
ldle Control System

I TroubleshootingfFlowchart l ,uurEJl l ! ! t l , rl I I l g lt.,Yvvrrql
(PSP) Switch Signal PowerrSteeringPressure rvYYtEI
This signalsthe ECM when the power steeringload is high.

Inrp.clion ol PSP twltch Signal
ooooooooooooo
between Connectthe tst harnes6 the ECM and connectors (see p a g e1 1 - 4 5 ) .
oooooooo
oooooooooooo oooQoooo
ooooooooooo oooooooooo
Tu.n tho ignilion swilch ON.
Moasurevoltage btween 88 {+} torminsland A26 (-l terminsl. Disconnect 2P connectorfrom the the PSPswitch. ls rhere more than 1.0 V?
Tum rtaaring whool slowly.
ls ther6 more than 1.0 V?
M66sure voltage betw66n BB (+) t6rminal and A26 {-} torminsl whilo stggring wheel is turning.
Repairopon in RED/GRN wir6 b6tw6on ECM (88) snd PSPswitch or BLK wir. bolwog.i PSP.wilch a n dG l O l .
PSP 3wirch slgnal i! OK.
Disconnect 2P conneclorfrom the the PSPswitch.
swtTcH
Measurevoltage between 88 {+ ) terminaland 426 l- l terminal.
wilo boRooairshon in RED/GRN twoon ECM {88) and P1SP switch. lI wire is OK, substituto a knowngood ECM and rochock. lf proscdbodvoltege ir now availabl6, roplace tho original ECM.
11-108
Fast ldle Thermo Valve

Description
To preventerraticrunningwhen the engineis warming up, it is necessary raisethe idls speed.The fast idle to thermo valve is controlledby a thermowax plunger. When the engineis cold, the enginecoolant surrounding the thermowax contractsthe plungef,allowingadditionalair to be bypassedinto the intake manifoldso thst the engineidlesfaster.When the enginereachesope.ating temperature,the valve closes.reducingthe amount of air bypassinginto the manitold.
lnspection
H23A1 engino(USA: Si/Canada: SR), H22Al 6ngin (USA: Si VTEC/Canada:SR-V) NOT: The fast idle thermo valve is factory adiusted; it should not be disassembled. 1. Removethe intakeair duct from the throttle bodv. 2. 3. Stan the engine. Put your finger over the lower port in throttle body and makesurethat there is air flow with the engine cold {engine coolant temperature below 860F,
300c).
FAST IDLE THERMO VAIVE thermo valve and
12 .m (1.2 kg-m, 9 lb-ttl
4.
Warm up the engine (the radiatorfan comes on). Check that the valve is completelyclosed. lf not, air suctioncan be telt at the lower gort in the throttle body. a lf any suclion is felt, the valve is leaking.Check engine coolantlevelandforair in the engine cooling system (seesection 1O). lf OK, reDlacethe tast idle thermo vslve and recheck.
11-109
ldle Control System

Fast ldle Thermo Valve (cont'd)
F22A'l onginelS): NOTE: The tast idle thermo valve is factory adjusted; it should not be disassembled. 1. 2. 3. Removethe cover of the fast idle thermo valve. Start the engine. Put your fingeron the valveseat areaand makesure thst ther is 8ir flow with the enginecold {engine coolanttemperature below 86oF, 30oCl and idling.
Starting Air Valve

Description
the Whencranking engine,the startingair valvesuppliss additionalair to the intake maniJoldto ease engine starting.
I
i I
i
DIAPHRAGM
I
TO INTAKE MANIFOLD lf not, replacethe tast idle thermo valve and retest. 't2 N.m (1.2 ks-m.I lb-ttl
ADDITIONAL AIR FROM AIR CLEANER
4. 5.
radiatortan fan Warm up the engine (the radaator comes on). closed.lf not, air Checkthat the valveis completely suction can be {elt in the valve seat area. a It any suction is felt, the valve is leaking. Checkenginecoolantleveland for air in the engine coolingsystem (see section 'lO). It OK, replacethe fast idle thermo valve and recheck.
1 11 - 1 0
ldle Speed Setting

lnspection/Adjustment
NOTE: (Canada) Pull the parkingbrake lever up. Start the engine,then checkthat the headlights olf. are 1. Startthe engineand warm it up to normaloperating temperature(the radiatorfan comes on). Turn the ignitionswitch OFF. Connecta tachometer. Disconnect 2P connectorfrom the ldle Air Conthe Adjust the idle speed, if necessary, turning by the idle adjustingscrew. IOLEADJUSTING SCREW
2. 3. 4.
7 . Turn the ignirionswitch OFF. Reconnect 2P connectoron the IAC valve.then the (1OA) Iuse in the under-hood remove CLOCK RADIO fuse/relaybox tor 1O secondsto reset the ECM. Restartand idle the enginewith no-loadconditions for one minute, then check the idle speed. NOTE: {Canada)Pull the parking brake lever up. Start the engine,the checkthat the headlights are off. pedalslightly Start the enginewith the accelerator depressed. the rpm at 10O0,then slowly Stabilize releasethe pedal until the engineidles. Checkidlingin no-load conditions: headlights, blower fan, reardefogger,radiatorfan, and air conditioner are not operating. ldle speed should be; H23A1 engine (USA: Si/Canada: SRI: ldle speed shoul.dbe; H23A1 engine(USA: Si/Canada: SRI: M/T 7OO I 7OO 1 50 rpm 50 rpm {in @ or @ position)
H22Al engine (USA: Si VTEG/Canada: SR-V): 7OO 1 50 rpm F22Al engine {S}: Mfi AlT 7OO t 7O0 1 50 rpm 50 rpm (in S or @ position)
M/T
A/T
55O t 50 rpm 55O + 50 rpm {in S or @ position}
H22A1 engine {USA: Si VTEC/Canada: SR-V): 55O 1 50 rpm F22Al engine (Sl: M/T 55O I 550 t 50 rpm or @ position) (cont'd)
NT
50 rpm (in I
11-111
ldle Control System

ldle Speed Setting (cont'dl
1O. ldle the enginefor one minute with headlights{Hi} and rear defoggerON and check the idle speed, ldl speod should be; SR}: H23A1 engine {USA: Si/Canada:
M/T A/T
78O t
50 rpm or @ posirionl
78O 1 50 rpm {in S
SR-V): H22A1 ongino (USA: Si VTEC/Canada: 79O t 50 rpm F22Al engine {S): l\illT Afi 77O t 50 rpm
770 I 50 rpm (in S or E position)
1 1 .Turn the headlightsand rear defoggeroff. ldle the enginefor one minute with heatertan switch at Hl and air conditioneron, then check the idle speeo. ldlo speod should be;
I I
: ri ,
SRI: H23Al engin (USA: Si/Canads:
M/T NT
78O t 50 rpm
78O t 50 rpm (inI
or E position)
SR-VI: H22A1 engin (USA: Si VTEC/Canada: 79O 1 50 rpm F22A1 engina (S): M/T 77O i 50 rpm
NT
770 t 50 rpm lin S or @ Fosition)
NOTE: lf the idle speedis not within specification, Guideon page 1'l-92. see SystemTroubleshooting
11-112
t
FuelSupply System
System TroubleshootingGuide
NOTE; Across each row in the chart,the sub-systems that could be sourcesof a symptom are rankedin the orderthey shouldbe inspectedstartingwith O. Findthe symptom in the left column,read acrossto the most likelysource,then referto the page listedat the top of that column.It inspection shows the systemis OK, try the next most likelysystem !), etc.
PAGE
SU8-SYSTEM
------SYMPTOM ENGINE WON'T START OIFFICULT STARTENGINE TO WHEN COLD HOT OR ROUGH IDL MISFIFE OR ROUGH RUNNING FAILS POOR PERFORMANCE EMTSStON
FUEL FUEL FUEI. PRESSURE FILTER INJECTOF REGULATOR

116
FUEL PUI\4P 124
PGM-FI MAIN RELAY
coNTAtrl NATED FUEL
122
123
126
o
O
@ @ @
@ @
Loss 0F
POWER WHILE WARMING UP AFTEF WARMING UP
o
o e
FREOUNT STALLING
Fuel with din, water or a high percentage atcoholis considered of contaminated.
11-113
Fuel Supply System

System Description
The tuel supplysystem consistsof a Jueltank, in-tank high pressure fuel pump, PGM-Flmain relay,fuel filter, fuel pressure regulator,fuel injectors,injectorresistor, and Juel deliveryand return pipes and hoses. fuel This systemdeliverspressure-regulated to the fuel iniectorsand cuts the fuel deliverywhen the engineis not running.
FuelPressure
Relieving
@ a
Do not smoke while working on the fu6l systm. Keep open llames or sparks away ftom your work alea. a Be sure to relieveluel pressulewhile the ngins is off.
NOTE: Beforedisconnectingluel pipes or hoses,release pressure the 6 mm servfrom the system by loosening ice bolt on top of the fuel rail. 1. Disconnect batterynegative the cablefrom the battery negativeterminal. NOTE: The radiomay havea codedthett protection circuit. Be sure you get the customer'scode number before disconnecting the battery cable. 2. 3. Removethe fuel fill caD. Use a box end wrench on the 6 mm servicebolt at the fuel rail,while holding special the banjobolt with anotherwrench. Placea rag or shop towel over the 6 mm servicebolt. Slowly loosenthe 6 mm servicebolt one complete turn.
12 N.m {1.2 kg-m, 9 lb-ft)
4. 5.
NOTE: gaugecan be attachedat the 6 a A fuel pressure mm servicebolt hole. a Always replace the washerbetweenthe service bolt and the specialbanjobolt, wheneverthe service bolt is loosened. a Replace all washers whenever the bolts are removed.
11-114
Inspection
( 1 . R e l i e v eu e l p r e s s u r es e ep a g e 1 1 - 1 1 4 1 . f 2. Removethe servicebolt on the fuel rail while holding the banjobolt with anotherwrench. Attach the tuel pressuregauge. Start the engine. *Measurethe fuel pressure with the engineidlingand vacuumhose ot the fuel pressure regulatordisconnected from the fuel pressure regulatorand pinched. Plessur should be; H23A1 ongine (USA: Si/Canada: SR), F22Al engine (S): 2 5 5 - 3 O 5 k P a( 2 . 5 5 - 3 . O 5 k g / c m 2 , 3 6 - 4 3 p s i ) H22A1 engine (USA: Si VTEC/Canada: SR_V): 23O-2AO kPa 12.3-2.8 kg/cmr. 33-4O psi) 4. Reconnect vacuum hose to the fuel Dressure regulator. Prssureshould b: H23Al engine (USA: Si/Canada: SR). F22A1 ongine (S): 195-245 kPa (1.95-2.45 kg/cm2,28-35
a lf the fuel pressure not as specified. is first checkthe fuel pump(seepage1 1-125).lf the pumpis OK, check the following: lf the fuel pressure higherthan specified. is inspect loti a Pinchedor cloggedJuel return hose or pipe. a Faultyfuel pressure regulstor {seepage 11-1221, lf the fuel pressure lower than specifiedinspect, is for: a Cloggedfuel filter. a Faultyfuel pressure regulator {seep age 11-1221, a Leakagein the tuel pipes or hoses.
3.
psi)
H22A1 engine (USA: Si VTEC/Canada: SR-V): -2.2 kg/cmr. 24-31 psi) 17O-22O kPs 11.7
PRESSURE REGULATOR ': lf the engine will not stan, turn the ignition switch on, wait for two seconds,turn it otf then back on again and read the iuel pressure.
11-115
Fuel Supply System

Fuel lnjectors
Flowchart Troubleshooting
Troublecode (DTc) 16: A problemin The MalfunctionIndicatorLamp (MlL) indicatesDiagnostic the Fuel Injectorcircuit. The Fuel Iniectors are a solenoid-actuatedconstant-stroke pintle type consisting ol a solenoid, plunger needle valve and the tuel coil, the valve lifts up and pressurized is injected.Because neeto When currentis applied the solenoid housing. by pressure constant,the injectionquantityis determined the lengthof time that the valvo are dle valve liJtand the fuel to is open (i.e.,the durationthe current is supplied the solenoidcoil).The FuelIniectoris sealedby an O-ting and seal ring at the top and bottom. These sealsalso reduceoperatingnoise.
PLUNGER
SEAL BII{G
- __l=-
\.__.,:_
FUEL INJECTOR INSULATOR
-tFJ- ;ull:
- Th6 MIL has boonrooortodon. - With sorvice chock conncctor iumpod {s6pago 11421, codo 'l6 is indicatod.
(see Do the ECM ResetProcedure p a g e1 1 - 4 3 ) .
NOTE:lf enginewill not start, it may take to 10 seconds cranking set the code. of Into.mittent lailuro, 3yst6m ir OK at this tim (to3t drivo moy bs nocossary). Chock fo. Door connoctiona ot looso wires at C433, C425 llocatod ar right shock towotl, C1O2, ClO3, ClO4, C1O5 (tuel ini.ctoBl, Cl07 {iniocto. risto.), and ECM.
ls the MIL on and does it indi cate code 16?
'1-1 (To page '1 171
11-116
r f
2P CONNECTOR Starl engingand lislenai 6ach luel injector a clicking ror sound.
Disconnect 2P connectorfrom the the fuel injector that dogs not click.
Measure rgsistancebetween the 2 terminals of luol injector.
l s t h e r e1 . 5 - 2 . 5 O ?
Ropl.c. th6 tu.l inictor/inioctor! thlt aro not 1.5-2.5 O.
FUEL IITJECTOB
Measuro voltaoebetweenREO/ 8LK { + } terminalin rhe 2P conngctorand body ground.
Tu.n tho ignition switch OFF.
Measure voltsge between YEL/ BLK {+) terminal and body ground.
(To page 1 1-118)
{To page 1 1-l 18)
11-117
Fuel Supply System

Fuel Injectors(cont'dl
{Frompage 1 1-'l17} ( F r o mp a g e 1 1 - 11 7 ) Rgpair op6n in tho YEL/BLKwire botws6n the inioctor resistot and tho PGM-FImain ,olaY. Testthe injectorresistor(seepage 11-1211.
Reconnect the 2P connector to the tuel iniector. Bpair op6n RED/BLK wiro botwen lhe 2P connocto. end inioctor roaistor.
Connectthe test harnessbetwoen the ECM and connectors (see p a g e1 1 - 4 5 ) .
Measure voltage between A23 {-) terminal and following termrnal: . No. 1 tuel iniector: A1 {+) terminal. . No. 2 fuel iniector: A3 (t)terminal. . No. 3 fuel injector: A5 {+ | terminal. . No. 4 tuel injector: 42 {+) terminal.
13. rott.*t
A 1 { + } lA 5 l + )
$Li6iiitl'-oooooooooo oooooooo
oooooooooooo oooooooo
ooo ooo ooooo ooooooooooo
Ropairop6n in tha wire batwoon the ECM(A1, A3, A5 or A2) and tho luol inioctor.
Substilute a known-good ECM and rechock. ll symptom/indication goos away, roplacetho origi nal ECM.
11-118
Replacoment
@@
l
oo not smoke when working on tha fuel system. Keep open llam6s away from your wolk a.sa,
Relieve fuel pressure(see page 11-114).
2 . Disconnect connectorsfrom the fuel injectorsand IAC valve. the

Disconnect vacuumhose trom the fuel pressure the regulator and EGRvalve,and the luel returnhosefrom the fuel pressureregulator. NOTE: Placea rag or shop towel over the hoses before disconnecting them. 4. 5. 6. 7. Disconnect the tuel hose from the fuel rail. Loosenthe retainernuts on the fuel rail and harnessholder. Disconnect the PCV valve and fuel rail. Removethe fuel injectorstrom the intake manifold.
SEALING WASHER Replsc6.
00
00
CUSHION RING Replace.
8. 9.
Slidenew cushionrings onto the fuel injectors. Coat new O-ringswith clean engineoil and put them on the fuel injectors.
1O. Insertthe fuel iniectorsinto the fuel rail first. 'I 1. Coat new seal rings with clean engineoil and press them into the intake maniforo. (cont'd)
11-119
Fuel Supply System

Fuel Injectors lcont'dl
12. lnstallthe tuel injectorsand fuel rail assemblyin the manifold' CAUTION: a To prevent damag to ths O{ings, install the lul inioctors In th fuol rall first. then inslall thm in tho intaks manifold.
FUEL RAIL
13. Align the center line on the connectorwith the mark on the Juel rail. '14, Install and tighten the retainernuts. 15. Connectthe Juel hose to the fuel rail with new washers. 16. Connectthe vacuumhoseto the tuel pressure regulator and EGRvalve,and the fuel returnhoseto the tuel pressure regulator. 17. Installthe connectorson the fuel injectorsand IAC valve. the 6 mm servicebolt washer and tighten the bolt. 18. Replace two seconds, 19. Turnthe ignitionswitch ON. but do not operatethe starter.After the fuel pump runsfor approximately in this two or three times, then check whetherthere is any tuel leakage. the luel pressure the fuel line rises.Repeat
11-120
InjectorResistor
Description
The resistorlowersthe currentsupplied the fuel to injectorsto preventdamageto the fuel injectorcoils. This allows a faster responsetime of the fuel inrectors,
Testing
1. 2. Disconnectthe injectorresistorconnector. Check for resistance between each of the inisctor resistor terminals D, C 8nd B) and the power tr{E, minal (A). Resistance should be: 5-7 O
LLLLL
FUEL a Replace injectorresistorwith a new one if any the of the resistances outsideof the sDecification. are
11-121
Fuel Supply System

Fuel PressureRegulatol
Description
The fuel pressureregulatormaintainsa constant fuel pressure the fuel injectors.When the differencebeto exceeds and manifoldpressure tween the luel pressure is 300 kpa (3.0 kg/cm' , 43 psi), the diaphragm pushed uDward,and the excessfuel is fed back into the fuel tank through the return line. CLOSE INTAKE MANIFOLD VACUUM
Testing
Do not smokdurlngtho test. Kap Iry opan flamesaway lrom your work area.
gaugeto the serviceport of 1 . Attach a fuel pressure t h e f u e l r a i l ( s e ep a g e 1 1 - 1 1 5 ) . Pressurs should be; SR), H23A1 engino (USA: Si/Canada: F22A1 engino (S): 255-3O5 kPa (2.55-3.05 kg/cm2,36-43 psi) H22Al engino (USA: Si WEC/Canada:SR-VI: 23o-2ao kPa (2.3-2.8 kg/cm2.33-4o psil {with the fu6l pressuro logulator vacuum hose disconnectod and pinchedl
INTAKE MANIFOLD VACUUM
DIAPHRAGM
REGULATOR PRESSURE 2. Reconnect the vacuum hose to the fuel ptessure regulator. rises when the vacuCheck that the fuel Dressure is regulator disconum hose from the tuel pressure nected again. lf the fuel pressuredid not rise, replacethe fuel pressure regulalor.
ar t FUEL \INLET
3.
FUELRETURN
11-122
Fuel Filter
Replacement E@ oo not smok6 whilewolking fuelsyson
tm. Keep open flame arvay from yout work area. 1. Placea shop towel unde. the tuel pressure regulator, then relievefuel pressure(see page 1l-114). 2. 3. Disconnect the vacuum hose and fuel returnhose. Removethe two 6 mm mounting bolts.
O,RING Replace
Replacement
oo not amoko whib working on fuol sys@ tem. Kesp open flame away ftom yout wolk atea. The fuel filter should be replacedevery 4 yea.s or 60.OOO miles(96,000 kml, whichevercomesfirst or whenever the fuel pressure drops below the specifiedvalue IH23A1 e n g i n e ,F 2 2 4 1 e n g i n e :2 5 5 - 3 O 5 k P a , 2 . S 5 - 3 . 0 s kg/cm' , 36-43 psi (H22A1 engine: 23O-280 kpa, 2.3-2.8 kg/cm2,33-40 psi) with the fuel pressure regulato. vacuumhosedisconnected and pinchedlafter making sure that the fuel pump and the fuel pressure regulatorare OK. 1. 2, 3. Placea shop towel under and aroundthe fuel rail. R e l i e v eu e l p r e s s u r es e ep a g e 1 1 - 1 ' 1 4 ) . ( f Remove the 12 mm banjobolt and the fuel feed pipe trom the fuel filter. Removethe fuel Jilterclamp and fuel filter. When assembling, use new washers,as shown. 28 N.m (2.8 ks-m,20 lb-ft) FUEL PRESSURE REGULATOR
VACUUM HOSE
4. 5.
NOTE: a Replace the O-ring. a Whenassembling fuel pressure the regulator, apply clean engineoil to the O-ringand assemble it into its proper position, taking care not to damagethe O-ring.
NOTE; Cleanthe flaredjoint of high pressure hoses thoroughlybefore reconnecting them.
11-123
Fuel Supply System

Fuel Pump
Description
savingspaceand simplifyinsidethe tuel tank. therebY design,the iuel pump is installed of Because its compactimpeller ing the fuel line system.
FUEL PUMP CROSS SECTION(Side vtew) rFrrFFvar VALVE RELIEF vF FUEL COVER PUMP
FUEL pUMp CROSS SECTION(ToD viowl

DISCHARGEPORT
,
IMPEI.LER
POBr rNrET
CASING
VALVE CHECK COIL ARMATUBE
GROOVES
CASING FUEL PUWIP
IMPELLER
the flow pump,a telietvalvetor protecting fuel linesystems, of The fuel pumpis comprised a DC motor, a circumterence port. The fuel pump assemblyconsistsof an check valve for retainingresidualpressure, inlet port, and a discharge a pumpingchamber), and the fuel pump cove,. the imoeller(drivenby the motorl, the fuel pump casing{which forms the OPERATION "o telaYactuatesthe fuel pump' and the motor turns tlle impeller' (1) When the engineis stsrted, the PGM-FImain relav actrrates by pressureis generated the numerousgroovesaroundthe impeller' Differential (2) Fuetenteringthe inlet port flows insidethe motor from the pumpingchambefand is torced throlgh the dischargo side of the fuel line, the reliefvalve will open oort via the check valve. lf fuel Jlow is obstructedat the discharges the fuel to the inlet port and prevent excessive fuel pressure' to bypass However,a checkvalveclosesby springactionto retain (3) Whe; the enginestops,the fueipump stops automatically. to restart more easily' in the residualpressure the line. helpingthe engine
11-124
Testing
Do not smokeduringthe test. Kepopon E@E flame away from your work area,
lf you suspecta problemwith the fuel pump,checkthat the tuel pump actuallyruns;when it is ON, you will hear somenoiseif you holdyour ea. nearthe tuel till port with the fuel fill cap removed.The fuel pump shouldrun for two secondswhen the ignitionswitch is first turnedon. lf there is no noiseat the fuel fill port, check as follows; 1. Removethe accessDanelin trunK,
Replacement @@l
tam. Kep open flsmes away ttom yout wotk area. 1 . R e l i e v eu e l p r e s s u r es e ep a g e 1 1 - 1 1 4 ) . ( f 2. 3. 4. 5. Removethe accesspanel in t.unk. Disconnect the 2P connectorJrom the tuel pump. Removethe fuel pump mountingnuts. Removethe tuel pump from the fuel tank.
6 N.m (O.6 kg-m, 4 tb-ftl
Donot smoke whilowolking fuetsyson
CAUTION: B sure to turn tha ignition switch OFF betore disconnecting tho wiles. 2.
?
Disconnect the 2P connectorDisconnectthe PGM-Ftmain relay conneclor and connect the BLK/YEL wire and yEL @ wirc with @ a jumper wire.
FUELPUMPUNIT
\< \ ..-\
pcm-H
MA|N
I
28 N.m (2.8 kg-m, 20 tb-ftI
BLK/ YELG)
JUMPER 'WIRE
YEL)
Check that battery voltage is available the fuel at pump connectorwhen the ignitionswitch is turned ON (positive probeto the yEL wire, negativeprobe to the BLK wire).
YEL +} { lf battery voltage is available,replacethe fuel

DUMO.
lf there is no voltage, check the fuel pump grouno and wire harness(see page 1j- 128).
11-125
Fuel Supply System

Main Relay PGM-FI
Descdption
main relayactuallycontainstwo individual The PGM-Fl retavs. The relay is located at the left side of the cowl. the ignitionis on which whenever One relayis energized supplies the battery voltage to the ECM, power to the fuel injectors,and power for the secondrelay. The second rlay is energizedlor 2 seconds when the ignitionis switched on, and when the engineis running which suppliespowet to the fuel pump.
Relay Testing
NOTE: lf the car starts and continues to run, the PGM-FImain relay is OK 1. 2. Removethe PGM-Flmain relay. Attach the b8ttery positivete.minalto the No' 6 terminal and the batt8ry negativeterminalto the No. main relay.Then checktot I terminalof ths PGM-Fl the No. 5 terminal 8nd No' 7 tetcontinuity between minal of the PGM-FImain rlaY. a It there is continuity.go on to step 3. a ll there is no continuity, replacethe relay and
FGM.FI MAIN RELAY
TO IGN.1
TO 8AT C)
TO GROUND
to EcM (A25,Btl
TO ST. SWTTCH
TO ECM{A7, 8} 3.
TO FUELPUMP
Attach the battery positive terminal to the No' 5 tsrminal and the battery negative terminal to the No. 2 terminslof the PGM-Flmain relav.Then check that there is continuitybetweenthe No. 1 terminal8nd No. 3 terminalot the PGM-FImain relay. a lf there is continuity, go on to step 4. a lf there is no continuity, replacethe relay and relesl.
4.
Aftach the baftery positive terminal to the No. 3 terminal and the batterY negative terminsl to the No. 8 terminalof the PGM-Flmain relav. Then check that there is continuitv between the No. 5 terminsl and No. 7 terminalof the PGM-Flmain relay' a lf there is continuity,the relay is OK. a lf there is no continuity, replacethe relay and retesl (cont'dl
11-126
! t
FuelSupplySystem
PGM-FlMain Relay(cont'd
- Engino will not 3tan. - InlDcction ot PGM-FI rclay.
Check for continuitY between BLK terminal @ and bodY ground. Ropairopon in 8LK wirc b6tw.en PGM-FImain relay and GlOl {locatod at th6amostot housing).
Measure the voltage between YEL/BLU terminal O and bodv gtouno. - Roplace tho No. 4 BACK UP {10 Al tu36 {in tho undordash fu3o/rolay borl. - Ropoir op6n in rho YEL/BLU wire btweon tho NiM-Fl rnain relay and ths No. 4 BACK uP {10 Al lu8o.
Measure the voltago between BLK/YEL terminal @ and body glouno, - Roolaco th. ECUIECMI {15 A} tuis {in tho und6r{eh tut /rolay boxl. - R6pai opgn In tho BLK/YEK wiro btween d|o FGM-FI tnein r6laYand tho Ecu (ECM) {15 Al fu3e.
PGM-FI MAIN RELAY
Turn the ignition swilch to the START position.
Measure the voltage betwen terrninal@ and body BLU/RED ground.
NOTE: . M/T: Clutch pedal must be depressed. in a A/T: transmission I n I or [E position.
BLK @
ls there baltery voltage?
- Replaco lhc No. 2 STARTER SIGNAL {7.5 A} furo lin tho undor-dashf uso/ralay borl. - B.p.ir op.n in tho BLU/RED wiro b.twoon th6 FGM-FI rtain r6lay .nd lh. ignition twitch
(sr).
BLK)
YEL)
( T op s g e I ' l - 1 2 9 )
11-128
11.12Al Turn the ignitionswitch OFF.
Connectthe test harnessbetwgen the ECM and connectors. Disconnoct "A" connector from the ECMonlv, not the main wire harness(see page 11-451.
Check tor continuity between GRN/BLK terminal @ and rhe followingterminals; A7. A8.
R6palropen in GRN/BLKwlr. btwoon ECM lA7, A8l and PGM-FI main rohy.
Turn the ignitionswirch ON.
Measure the voltage between 423 1-) terminaland the tollowing terminals: A25 (+) 81 lf). R.pair opon in tho YEL/BLKO rvi 6 botwoon th. ECM (A25, 811 lnd PGM-FIh.in iohy. R.pl.c. PGM-FImain r6lay.
ls there battery vokage?
Turn lhe ignilion switch OFF.
o o o o o o o o o o o o o o ooooooo lfitoHruffs{sl ooo ooooo ooo o oooo ooooo ooo I oo oooo oo ooooooooooo
Connect a voltmeter between A7 l+l te.minal and A23 l-) rer mtnat.
ls there battry voltage tor lwo seconds when the ignition switch is first tu.ned on?
Subrtltulc 6 known-good ECM and raatrock. ll p.eacriH voltago b now svail.Hg, rgf aco tho original ECM.
Chock th. PGM-FI mlin r.l6y (.eo pag. l1-126).
1-1 29
FuelSupplySystem
FuelTank
Replacement
@ 1. 2. 3. 4. Do not smoke while working on fuel systm. Keep open llame away from your work area.
Ir
Block front wheels. Jack up the rear of the car and supportwith jackstands. Removethe drain bolt and drain the fuel into an aoorovedcontainer, Removethe accesspanel. Disconnect from the fuel gaugesendingunit and the fuel pump,then removethe fuel feed line and the connectors return hose. CAUTION: Be sur to turn the ignition switch OFF before disconnecting the wires.
5. Removethe fuel hose protectors. 6. Oisconnect the hoses. CAUTION: Whon disconnocting the hos6s. slide back ths clamps, then twist hosos as you pull to avoid damaglng them. 7. Placea iack, or other support,underthe tank. 8. Removethe strap bolts and nuts. and let the strapsfall free. 9. Removethe fuel tank, NOTE: The tank may stick on the undercoatappliedto its mount. To remove,caretullypry it off the mount. 1O. lnstalla new washer on the drain bolt and the fuel pump line, thn installpans in the reverseorderol removal.
ks-m.28 lb-ft| 38 N m 13.8 CAUTION: Cloanthe flared ioint of high prossu.oho8e3 thloughly botoro .oconnecting thom.
FUEL PUMP GAUGE SENOINGUNIT FUELTANK WASHER Rplace DRAII{ BOLT 50 N.m (5.o kg-m, 36 lb-tt)
3a N.m (3.8 ks-m. 28 lb-ft|
11-130
Intake Air System

NOTE: Acrosseach row in the chan, the sub-systems that could be sourcesof a symptomare rankedin the orderthev shouldbe inspectedstartingwith O. Findthe symptom in the left column, read acrossto the most likelysource,then refer to the page listed at the top of the column. lf inspectionshows the system is OK, try the next system @, etc.
SYMPTOM WHEN COLD FAST IDLEOUT OF SPEC W H E NW A R M I D L ET O O H I G H LOSSOF POWER *: Except F224 1-engine{S)
11-131
Intake Air System

System Description
(ACL).intakeair pipe, intakeair duct, Throttle The systemsupplies lor all engineneeds.lt consistsof the Air Cleaner air *intakecontrol Bodv {TB},ldle Air Control(lAC)Valve,tast idlethermo valve, *lntake Air Bypass(lAB)ControlSystem, additional silencing air is drawn intothe system. as in A system,and intakemanifold. resonator the intakeair pipeprovides *: Except F22A1 engine (S)
.IAB CONTROL SOLENOID VALVE
.tA8 VACUUM TANK
?!t'----_'o
ECU|ECM){'r5 A' FUSE
Xll'----'oPGM.FIMAINRELAY
VARIOUS SENSORS INTAKE AIR DUCT
r|AB CONTROL DIAPHRAGM
BODY :II{TAKE
CONTROL SOLENOID VALVE
FAST IOLE THERMO VALVE
SLK/ YEL WHT
(15 . TO ECU{ECM} AI - FUSE

RESOI{ATOR
INTAKE AIR PIPE
.If{TAKE CONTROL CHECK VALVE
-1 32
Air Cleaner{ACL}
Air Cl6anel (ACL) Element Raplacemont
ACL HOUSINGCOVER
ACL HOUSING
ACL ELMENT Roplacvery 3O,OOO miles (48,OO0 kml or 24 months. 'l5.OOO Cleanair cleanerelementeverv (24,OOO mil6s kml or 12 months under conditions, rough or muddv roads.
INTAKE AIR DUCT
11-133
Intake Air System

Intake Control System [Except F22A1 engine (S)l
Description
The intake control svstem decreases intake noise. air
INTAKE CONTROISOLENOIDVALVE
BLK/ ------? - TO ECU (ECMIll5 Al FusE YEL
II{TAKE CONTROL
VACUUMT
INTAKE CONTROL CHECKVALVE
BLK
I =
RESONATOR
When the engine speed is below 4,OO0rpm, the ECM provides ground for the intako control solenoid valv6. This opens the solenoidvalve sendingintake manifoldvacuum to the intake control diaphragm.
11-134
Troubleshooting Flowchart
VACUUMPUMP/GAUGE -XXXXX A973X-O41
AKE CONTROL SoLENOTO VALVE
St.n onginernd allow to idle.
Remove the #8 vacuum hos6 from the hose joint and connect a vacuum gaug to the solenoid
Oisconnect lhe lower vacuum hosofthe solonoidvalv6from the air chamb6r and connecl a vacuum gau96 to th hos6. Chcck tho v.cuum lina tor profEr conn6ctlon, crack!, blockrg! or dtr;onn*tod ho!o. Closn manltold m.t. Disconnect th 2P connector from the intake control solehoid
Measurs votiag botwson BLK/ YEL (+ l terminaland WHT (- ) tornanal.
INTAKE
CONTROL SOLENOID VALVE
ls there battery vollag?
R.pl.co th. Intlko control aobndd volve.
Measure voltage betwen BLK/ YEL {+l torminal and body ground.
{To page 11-136)
(To page 1 1-136)
(cont'dl
11-135
Intake Air System

Intake Control System lExcept F22A1 engine (S)l {cont'd}
{ F r o mp a g o1 1 - 1 3 5 } lFrom psge 1 1 - 1 3 5 ) Ropairopoo in BLK|/EL wi.o botwoon tho 2P connoctor and ECU (ECMI (15 Al tuso lin tho undo.-dsshfus/r6l6y box).
Turn the ignirionswitch OFF.
Connectthe test harnessbetween the ECM and connectors (see page 1 1-45). Turn the ionition switch ON. Connect a jumper wire between A19 terminaland A26 terminal.
Ropair opon in WHT wiro betwoon ECM lA19) and tho 2P connectot.
Substituto s known-good ECM and .ochock. lf symptom/indication goos away, replgceth6 odginal ECM.
Turn the ignilion swilch OFF.
Check for continuity to ground
(To pago 1 1 - ' t 3 7 ) { T o p a g e1 1 ' 1 3 7 )
11-136
(Frompage 11-136)
lFrom psge 1 1-136)
R6pai. ahort lo ground in WHT wira b6twen ECM {A19).nd rhe 2P connoctot.
Subltitute a known-good ECM and rechock. lf symptom goaa away, .oplaco tho originsl ECM.
Connect a vacuum pump to the #8 vacuum hose.
Does it hold vacuumT
Chack dr vecuum line for propor connaction oa diaconnected noaa. lf OK. '.plac6 tho inllk. control dl.phrlgm.
l aha contol ayatam b OK,
11-137
Intake Air System

Throttle Cable
Inspection/Adjustment
1. Warm up the engineto normaloperating temperature (the radiatorfan comes on). 2. Check that the throttle cable operates smoothly with no bindingor sticking.Repairas necessary. Checkcablefree play at the throttle linkage.Cable d e f l e c t i o n h o u l db e 1 O - 1 2 m m ( O . 3 9 - 0 . 4 7 i n . ) s
lnstallation
1. Fully open the throttle valve,then installthe throttle cablein the throttle linkageand installthe cable housingin the cable bracket. Warm up the engine10 normaloperatinqtemprature (the radiatortan comes on).
2.
3.
DEFLECTION 10- 12 mm 1O.39-O.47 in.)
Hold the cable sheath. removingall slack from the cable. Turnthe adiusting untilit is 3 mm (0.12 in.)away nut from the cable bracket. Tightenthe locknut. The csbledetlectionshouldnow b e 1 O - 1 2 m m ( O . 3 9 - O . 4 7i n . ) .l f n o t ,s e ei n s p e c tion/adjustment.
CABLE ARACKET
It deflection not within specs,loosenthe locknut. is turn the adjusting untilthe deflection as specinut is fied, then retightenthe locknut, 5 . With the cableproperly adjusted, checkthe throttle valve to be sure it opens fully when you push the accelerator to Dedal the tloor. Also checkthe throttle valve to be sure it returnsto the idle position pedal. wheneveryou releasethe accelerator
38
Throttle Body
Description
type. The throttls body is ot the single-barrel side-dratt The lower portion oJ the throttle valve is heated by engine coolant which is fed from the cylinder head.The idle bypass 8ir adjustingscrew which increases/decreases Emission and the EvaDorative {EVAP)ControlCsnister port are locatedon the top ot the throttle body.
IDLEADJUSTING SCREW
Inspection
CAUTION: Do not adiust the throttls stop screw, It i3 presot at tho tactory. 1. Stan the engineand allow it to reachnormaloper ating temperature(the radiatorfan comes on). 2. ' contro Disconnect the vacuum hose (to the EVAPc o n t r o l trom the top of the throttle body; connec canister) connect I vacuum gaugeto the throttle body.
VACUUM PUMP/GAUGE A973X-04t -XXXXX
3 . Allow the engineto idle and check that the gauge

indicatesno vacuum. a lf there is vacuum,check the throttle cable (see p a g e11 - 1 3 8 ) . 4. Checkthat vacuumis indicated the gaugewhen on the throttle is opnedslightlyfrom idle. a lf the gauge indicates no vacuum, check the throttle body port. ll the throttle body port is clogged,cloan it with carburetorcleaner. Stop the engine and check that the throttle cable operatessmoothly without bindingor sticking. a It there are any abnormalities the abovesteps, in check for: - Excessivewear or play in the throttle valve sh8tt. - Sticky or binding throttle lever at full close position. - Clearance between throttle stop screw and throttle levr at full close oosition,
11 - 1 3 9
Intake Air System

Throttle Body (cont'd)
THROTTLE LEVER
There should be no clearance.
THROTTLE STOPSCREW (Non-adiustable)
play in the Replace throttlebody if there is excessive the throttle valve shatt or if the shatt is bindingor sticking.
11-140
Throttle Body
Disassembly
GASKET Rgplaco
THROTTLE CABLE
(2.2 kg-m, 16 lb-ft}
A/T THROTTLE CONTROL CABLE
11-141
r
Intake Air System
Throttle Body (cont'd)
a The throttle stop scrw is non-adiustable, a Aftd rrllrombly. adiust tho throftle cabl {seo pag6 'l 1-138}. and A/T throttlo control cable (s66 section 141tor cars l whh A/T. F22A1 angine (S):
IDLEADJUSTING SCREW
H23Al ngino (USAr Si/Can8d8: SR), H22Al engine (USA: Si VTEC/Csnada: SR-VI:
FAST IDLETHEBMO VAVLE pago1'l-110 Inspection,
('1.2kg-m, 9 lb-lt)
11-142
lntake Air Bypass (lABl Control System fExcept F22A1 engi,ne(Sll

Description
Two air intake paths are providedin the intake manifoldto allow the selectionof the intake path most tavorablefor a given enginespeed. Optimum perlormance at any RPM is achieved by c\osing and opening the \ntake Air ByDass(tA,Bl\ratves. High torque at low RPM is acheivedwhen the IAB valves are closed, whereashigh powe, at high RPM is achievedwhn the IAB valves are ooened.
tA8 CHECK VALVE
IAB CONTROL DIAPHRAGM
9i['-_-------> I$.i"u
(15 tEcM] A]
tA8 CONTROL SOLENOID VALVE
IAB VACUUMTANK
VARIOUS SENSORS
IAB CONTROLSOLENOIDVALVE OFF
ET{GINE RPM IS ABOVE 4,800 rpm (H23A1 onginel or 4,600 .pm (ll22Al nginol
(cont'd)
11-143
IntakeAir System
(lABlGontrol System F2241engine (cont'd)lntakeAir Bypass [Except {S}]
In.poction ot IAB Control Sy.t.m #13 VACUUM HOSE
COI{TROLDIAP}IRAGM
Stan ongino lnd allow to idl.
Remove # vacuum hose trom the lAg control diaphragm hd connecl vacuum gauge to th6 nose,
'l3
VACUUM PUMP/GAUGE A973X-O4t-XXXXX
/f
Disconnect 2P connectorfrom the the IAB control solnoid valve.
Measure voltagg between BLK/ YEL (+) terminaland PNK (-) terminal.
IAB COI{TROL SoLENO|O VATVE
' t
I
I I
I I I I
Pl{K
ls tho.o banory vohrgo ?
Rcp.lr th. block.g. or vlcuu|n lark bltwaan lh. intlk m.ntlold .nd d!ph.!gm, it vrqrxn l! OK, r.pl.c. the IAB contrcl lolcnold vllva.
Matturu voh.ge btwen BLK/ YEL (+) t.rmin.l and bodv gaouno, R.p.lr op.r| in BLK|rEL wlre bctwaon th! 2P connaclor lnd ECU IECMI (15 Al tur. {ln tha undardrah lura/.chy boxl.
13there bancry vohage ?
Turn the nrtion swilch OFF.
(To page 1 1-145)
(To page 1 'l-145)
11-144
(Frompage 1 1-1441
{Ffom page 1 1-144)
Reconnect the 2P connector to the IAB control solenoid valve.
Connect the tost harness to the mainwire harness only {seepage 11 - 4 5 ) .
Turn the ignitionswitch ON and connect a jumper wiro between A17 terminaland A26 torminal.
Does the solenoid valve click
Rop.ir opon in P K wlro botwoon ECM {A17) ond tho 2P connctor. lf tho wiie i. OK, ,oDlac6. th6 IAB cootol 8olongid
Substhuto a known-good ECM and .echack. lf proacriH vohlgo i3 now sveilabloroplacetho originll ECM.
Disconnect 2P connectorfrom the the IAB controisolnoidvalve.
Turn the ignilion swatchOFF.
Check for continuity to ground on rhe PNK wire. IAB control syrtom i! OK. Ropair short to giound rt PNK wir6 b6twoen ECM {A17) and tho 2P conneclol. Substituts a known-good ECM and rachock. lt symptom goos away, rcplaco the original ECM.
11-145
Intake Air System

(lABlControl System Intake Bypass Air F22Al engine (cont'd} {S}l lExcept
IAB Valve Testing
CAUTION: Do not adjust the IAB valve full-close5c1w. It was preset 8t the factory. 1. 2. 3. Check the IAB valve shaft for bindingor sticking, Check the IAB valve for smooth movement. With the engineOFF,ctreckthat @ of the bypass valve is in close contact with the stoDper.
4.
With the engine at idle, check that (9of the IAB valve is in close contact with the full-closescrew.
a ll sny fautt is found, clanthe linkagoand shafts with calbuistor clssner. still exists after cleaning,disassemlf the Droblem ble the intakemanifoldand check the IAB valve ( s e ep a g e 1 1 - 1 4 7 )
11-1 4 6
fntake Air Bypass (lAB) Control System lExcept F22A1 engine (S)l
22 N.m 12.2kg-m, 16
e s H lle s
E
22 N.m (2.2 kg-m,16 lb-ttl
IA8 VALVE
@ ^ ^
IAB tCONTROL
@-,rrn.^
{2.2 kg-m, 16 tb-frl
SOLENOIDVAI-VE
11-147
Intake Air System

fntake Manifold 1F22A1engine (S)l
e
22 N.m (2.2 kg-m.
16 rb.ftl
-l9
HEn
@
* ^\,,^^
NOTE: Acrosseach row in the chan, the sub-systems that could be sourcesof a symptom a.e rankedin the orderthey should be inspectedstartingwith O. Find the symptom in the left column,read acrossto the most likelysource,then referto the pagelistedat the top of that column.It inspection shows the system is OK, try the next most likelysystem @. etc.
PAGE
SUB-SYSTEM THREE WAY

CATALYTIC CONVERTER
POSITIVE EXHAUSTGAS CRANKCASE RECIRCULATION VENTILATION SYSTEM SYSTEM

t55
EVAPORATIVE EMISSION CONTROLS 160
SYMPTOM
t 5 l
159
ROUGHIDLE
o
WARMINGUP MISFIRE OR ROUGH RUNNING
FREOUENT STALLING
o
o o
@ @ @
POOR PERFORMANCE
FAILS EMTSSTON TEST LOSSOF POWER
11-149
EmissionGontrol System
SystemDescription
The emissioncontrol system includesa Three Way Cata(TWC),Exhaust lytic Converter GasRecirculation IEGR) system, Postitive CrankcaseVentilation (PCV) system Emission(EVAP)control system. The and Evaporative emission controlsystemis designed meet federaland to state emissionstandards,
Tailpipe Emission
lnspection
Do not smoke during this procedure.Keep @ any open flame away ltom your wotk alea. 1. Start the engineand warm up to normaloperating by temperature driving on the road. Connect a tachometer. Check and adjustthe idle speed,if necessary(see p a g e1 1 - 1 1 1 ) . to the CO meter according Warm up and calibrate instructions. the meter manufacturer's heaterblower, Check idle CO with lhe headlights, rea. window defogger,coolingfan. and air conditioner oft. CO meter should indicateO.1 % maximum,-
11-150
ThreeWay CatalyticConverter(TWC)
Description
The ThreeW8y CatalyticConverter(TWC) is used to convert hydrocarbons (HC),carbon monoxide(CO),and oxides of nitrogen(Nox) in the exhaustgas to carbon dioxide {co2), dinitrogen(N2)and water vapor.
HOUSING
WAY THREE CATALYST
FROI{TOF VEHICLE
11 - 1 5 1
Three Way Catalytic Converter (TWC) (cont'd)
Inspection
lf sxcessiveexhaust systgm back-pressureis suspected, .emove the TWC from the car and make a visual check for plugging, meltingor crackingof the cstalyst. Replace the TWC if any of the visiblearea is damagedor plugged.
34 N.m 13,4 kg-m,
SD
SN
HEAT SHIELD 34 N.m 13.4 kg-m, 25 lb-ft) 10 N.m 11.O kg-m, 7 lb-ft)
IJ
ia"\
FRONTOF VEHICLE
11-15,2
(EGRI Exhaust GasRecirculation System

\ l / -lra-ll-
l lf;-f \ . L-l!J _
The MalfunctionIndicatorLamp (MlL) indicatesDiagnostic TroubleCode (DTC) 12: A problemin (EGR)system. the ExhaustGas Recirculation
The EGRsystem is designed reduceoxidesof nitrogenemissions to {NOx)by recirculating exhaustgas throughthe EGR valveand the intakemanifoldinto the combustion chambers. is composed the EGRvalve.EGRvcuum cont.olvalve. lt of EGRcontrol solenoidvalve, ECM and varioussensors. The ECM memorycontainsidealEGRvalve lifts tor varyingoperatingconditions. The EGRvslve lilt sensordetectsthe amount of EGRvalve lift and sendsthe informationto the ECM. The ECM then comparesit with the jdeal EGRvalve lift which is determined signslssent from the other sensors.lf there is any di{ferencebetween the two, the ECM by variescurrent to the EGRcontrol solenoidvalve to further regulatevacuum appliedto the EGRvalve.
EGR CONTROL sol-Et{otD VALVE
---l> BLK/YEL EGB VACUUM CONTROL VALVE RED/ EGRVALVE 5-J WHT LIFTSENSoR I.+-WHT/BLK
ECUIECMI A} {15
BLK
{cont'd)
11 - 1 5 3
System{cont'd) Exhaust GasRecirculation {EGR)
--J-h6l\ ---r-l
-.-_:-
-l12l/--\
- lho MIL has boon roportedon. ' With rsNico chcck connoctot iumpedlsoopa06 1142), cod. 12 is indicatod.
Do the FCM ResetProcedure {see p a g e1 1 - 4 3 1 .
Roadtost necessary: Warm upthe engine to normal operating temperature {the radiator fan comes on). Drive the car on lhe road for approx. 10 minutes.Keep th6 engine speedin the 1.700-2.500 rpm.
VACUUMPUMP/ GAUGE 4973X-04't -XXXXX
I I
| Intormitlrnt t llur6, .yltom ir OK at thi! tlm.. Chock for poor connaction! ot loo.. wlr.s at Ot25, gl28llocatod at rlght ihock towqr), C463 (locatod at loft .ida und.r dashl, C1 17 (EGR vllvo lift $n.or), C31O GGB comrol .olonoid vrlv.l and ECM. #16 HOSE
With the engineat idle, disconnect the # 16 hosefrom the EGR valve and connect a vacuum pump/gauge to the hose.
ls there any vacuum?
Disconnoct2P connoctorfrom the EGR control solgnoid valve and checkthe # 16 hosgfor vacuum again.
EGRVALVE
to Move the vacuum pump/gauge
# 16 HOSE
EGR VALVE LIFTSENSOR
{To page
EGR VALVE l T o p a g e1 1 - 1 5 5 1
1 1 -1 5 4
{Frompage 1 1-154}
(Frompage t 1-154) Check vacuum hoso rouling of the ontiro EGR system. It hoss routing ir OK, roplac. EGR control 3olenoid
With the engineat idle, apply 2O0 mm Hg (8 in Hglof vacuum the to EGRvalve.
ls there any vacuum?
Turn the ignitionswitch OFFand disconnect the "A" conngctor from the ECM.
Checktor continuity to ground on REDwire of the 2P connector. Ropairsho.t in REDwir6 botween EGR control solonoid valvo ard ECM {A11t. Substitut. a knownood ECM and rot$t. It symptom/indication goos away, roploco tho odginol ECM. EGR CONTROL SOLENOID VALVE Ooesthe enginestall or run rough and does the EGR valve hold vacuum?
Disconnect 2P connectorfrom the the EGRcontrol solenoid valve.
Measurevoltage between BLK/ YEL(+lterminalon the mainwire harness and body ground. Repairopon in BLKrYELwir6 botween th6 EGR contrcl iolenoid v6lv. .nd ECU (ECM)(15 Al fuso (in tho und6r{a.h turo/,olay borl.
Reconnectthe vacuum pump/ gaugeto the # |6 hose.
( T op a g e11 - 1 5 6 )
{cont'd)
11 - 1 5 5
GontrolSystem Emission
(EGRI System(cont'dl ExhaustGas Recirculation
{ F r o mp a g e '11-1551
Connect battery oower lerminal to the A terminal of the 2P connector. While watching the vacuum gauge, ground the B terminal.
ls there approx.2OOmm Hg (8 in.Hg)within 1 second?
Turn the ignitionswitch OFFand inspectthe # 16 and #24 hoses for leaks, restrictions, or misrouting.
Turn the ignition swith OFF and reconnect the 2P connector,
Are the hoses OK?
EGRVALVE LIFT
VACUUM EGR VALVE CONTROL
COI{TROL EGR VALVE SOLENOID
(
Disconnect the lower hose on EGR control solenoid valve and connect a vacuum gaugeto the hose.
PUMP/ VACUUM GAUGE A973X-O4t -XXXXX
3P Disconnect connectorfrom the EGR valve lift sensor. Roobca the EGB vacuum control valvg.
ls there 150-250 mrn Hg 16- 1o in.Hg) ol vacuum?
Measure voltage between RED/ wHT (t ) terminal and GFN^dHT {- ) terminal. Measure voltage betwen RED/ WHT {+} terminal and bodv ground.
( T op a g eI l - 1 5 7 )
l T o p a g e1 1 - ' l 5 7 1
11-156
{Frompage 1 1-156}
't {Frompage 1 - 1 5 6 ) Ropair open in GRN/ WHT wii. botweon EGR vrlv6 lift sonsor ond ECM (D22). Connect the test harness "D" connectorto the ECMonly. not to th6 main wire harness (see pags 11 - 4 5 ) .
Measure voltage botween D19 (+) terminaf and O22 l-l terminal. Rgpair opon in RED/ WHT wir. batwoon EGR valv. litt !.n3or .nd ECM (Dl91. Subrtituto a known{ood ECM and .ech6ck, lf symptom/lndiction go6i away, ,ophc6 rha original ECM.
Reconnoct the 3P connector to the EGRvalve lift sensor.
D 1 2t + t D 2 2 t - l
Connectthe test hmessbelween the ECM and connectors (see p a g e1 1 - 4 5 ) .
1.2 V wirh no vacuum appli.d? 4.3 V rvith 2OO mm Hg (8 in.Hol of vacuum appliod?
Measure voltage between O'l2 f+) terminaf and D22 l-) terminal.
ls the voltageapprox. 1.2 V with no vacuum applied and approx.4.3 V with 2OOmm Hg {8 in Hg) of vacuum applied to the EGR valve?
Ropair opon or lhort in WHT/ BLK wir. botwo.n EGR valvo lift !.n.or and ECM {D12}. ll YYi.o OK, r.Dlac. th. EGR b
(To page 1 1-158)
(cont'd)
11-157
(EGR)System (cont'd) ExhaustGas Recirculation
( F r o m a g e1 1 - 1 5 8 ) p
,:
Does the voltageconsistenly as increase/decrease the vacuum increases/decreases?
Connecl 41 1 terminalto 426 teF minal with a jumper wire.
Did the enginestall or run rough?
Ropair open in RED uviro botwoon ECM lAl ll and EGRconlrol3donoid valv6.
Substitute a known-good ECM and rechck. ll symptom/indication goes away, replacthe original ECM.
11-158
Positive CrankcaseVentilation (PCVI System

Description
The Positive CrankcaseVentilation (PCV) system is designedto preventblow-by gas from escapingto the atmosphere.The PCV valve contains a springjoaded plunger. When the enginestarts.the plungerin the PCV valve is lifted in proportionto intake manifoldvacuum and the blow-by gas is drawn directly into the intake manifold.
Inspection
1. Checkthe PCVhosesand connections leaksand for clogging.
PCV HOSE
BREATHER PIPE
VALVE
- : BLOW-BYVAPOR Cf I FRESHAIR
At idle,makesurethere is a clickingsoundfrom the PCV valve when the hose betweenPCV valve and intakemanifoldin lighttypincfiedwirh your fingers or olrers.
Ll\l
.t
Gently pinch here
lf thereis no clickingsound.checkthe pCV valve grommetfor cracks or damage.ll the grommet is OK, replacethe PCV valve and recheck.
11 - 1 5 9
EmissionControl SYstem
EvaporativeEmission(EVAPI Controls
Description
The to the amountof fuel vapor escaping the atmosphere' to emissioncontrotsare designed minimize The evaporative system consistsof the following components: A. Evaporative Emission (EVAPI Control Caniatot be purgedfrom An EVAPcontrol canisteris used tor the temporarystorageof fuel vapor until the fuel vapor can burned the EVAP control canisterinto the engineand Vapor Putgo Control System EVAPcontro|canisterpurg|ngisaccomp|ishedbydrawingfreshairthroughtheEVAPcontro|canisterandintoa portonthethrott|ebody.Thepurgingvacuumiscontro||edbytheEVAPpurgecontro|diaphragmva|veandthe EVAP putge control solenoidvalve VALVE OFF AFTER SOLENOID CONTROL EVAP PURGE ENGINE STARTING
ABOVE I67OF (75OC) ENGINE COOLANTTEMPERATURE S e n g i n e( U S A :S i V T E C / C a n a d a :R - V ) :1 5 8 " F ( 7 O o C ) 1 [H22A1
Fuel Tank Vapor Conttol SYstem in When fuel vapor pressure the fuel tank is higherthan the set value of the EVAPtwo way valve,the valve opens the flow of fuel vapor to lhe EVAPcontrol canister. and regulates
11-160
EVAP PURGE
cot{TRoL
SOLENOID VALVE
TO ECU(ECM) {15 A} FUSE
FUEL FILL CAP
FUELTANK
FRE SH
EVAP CONTROL CANISTER
11-161
EvaporativeEmission{EVAP) Controls (cont'd
FLowchart Troubleshooting
EVAP CONTROL PURGE OIAPHRAGMVALVE
# 3 VACUUMHOSE
Disconnect #3 vacuum hose from the EVAP purge control diaphragmvalve (on the EVAPcontrol canister) 6nd connect a vacuum gaugelo lhe hose.
VACUUMPUMP/GAUGE A973X-041-XXXXX
Start the ongine and allow it to idle. NOTE: Enginecoolant temperature mustbe below 158oF{70oC}
EVAP CONTROL CANISTER
Measure voltage between BLK/ YEL (+ ) terminaland REO/GRN (- ) terminal. Inspoct vacuum hoso routin9. lf OK, .oplaco EVAP purge control solenoid
ls there battery vollage ?
Measure voltage betwgon BLK/ YEL (+) terminal and body ground.
(Topage11-163)
{To page 1 1-'163)
11-162
( F r o mp a g e 1 1 - 1 6 2 )
l F r o mp a g e1 1 - 1 6 2 ) Ropairopon in BLK/YEL wir6 betwoon ECU (ECM) (15 Al lus6 lin tho undordash fuso/rolay boxl 6nd ths 2P connoclor.
Warm up the engine to normal operating temperature {th6radiator fan comes on).
ls there battery vohage ?
lBpoct RED/GRN wlro tor an opn beiwen ECM (4201 end tho connocrot. lf wir6 is OK. substitut6 a knowngood ECM and rcchock. lf symptom gos away, ioplaco tho original ECM. Hold engineat 2,OO0rpm.
Check for vacuum at rF3 vacuum hose after starting the engine.
ls theremanifoldvacuum? InSD6ct vocuum hose routing. It OK. r6placo EVAP purge control 3olenoid
ls there manifoldvacuumT
Insp6ct lor . short in RED/GRN wiro b6tw6on ECM lA2O) and tho conn6ctol, ll wir6 is OK, sub3titutoa knowngood ECM and rech6ck. lt 3ymptom goo3 away, r6placo tho original ECM.
(To page 'l 'l - 164)
(cont'd I
11-163
EvaporativeEmission(EVAP) Controls {cont'd)
{Frompage 1 1-1631 VACUUM PRESSUNE GAUGE0-4 in. Hg o7JA2 -OO10008
Connect a vacuum gauge to EVAP control canister purge air nose,
Does vacuum appgar on gauge 'l within minute?
Connect a vacuum gauge to the purge hose and raise lhe ngine sDeed 3,5OOrpm. to
Soo EVAP two way valvo tost to comoloto. Evaoorativo ombsion control! aro
Inlpacl tho purgo hoas ..d throt r body po.t tor pinch or blockag..
oK.
Rsol6c6 th6 EVAP conttol caniator.
11-1 6 4
EVAP Two Way Valve Test

1. 2. Removethe fuel fill cap. Removevapor line lrom the fuel tank and connect to T-tittinglrom vacuumgaugeand vacuum pump as snown.
VACUUM/PRESSURE GAUGE 0-4 in. Hg 07JAZ-0010008 VACUUM PUMP/ GAUGE A973Xo4'l -
xxxxx
F
T-FITTING
3.
while walching Applyvacuumslowly and continuously the gauge. momentarily 5 to 15 mm at Vacuumshouldstabilize H g ( O . 2t o 0 . 6 i n . H g ) . (valveopens)below 5 mm a lf vacuum stabilizes H s ( 0 . 2 i n . H g )o r a b o v el 5 m m H g { o . 6 i n . H g l , installa new valve and retest.
4.
Move vacuum pump hose from vacuum to pressure tifiing, and move vacuumgaugehosefrom vacuum side as shown. to oressure
the Slowly pressuraze vaporline while watchingthe gauge. at Pressure should stabilize 1O to 35 mm Hg {O.4 to 1.4 in. Hg). (valveopens) a It pressure momentarily stabilizes t a t 1 Ot o 3 5 m m H g ( O . 4 o 1. 4 i n . H g ) .t h e v a l v e is OK. a lt pressure below 1Omm Hg (O.4in. Hg) stabilizes l o r a b o v e3 5 m m H g ( 1 . 4 i n . H g ) , i n s t a l a n e w valve and retest.
11-165
Transaxle
Clutch ...........12-1 Manual Transmission ............................ 13-1 Automatic Transmission .................. 4-1 .....1 Differential Manual Transmission ......................... 15-1 Automatic Transmission ................... 0 15-1 Driveshafts ... 16-1
Clutch
Special Tools.......... ...........12-2 fffustrated Index........... .....12-3 ClutchPedal Adjustment .................... 12-4 ClutchMasterGylinder RemovaUlnstallation ....12-5 SlaveGylinder Removal .... 12-6 Installation ..................... 12-6 Release Bearing Disassembly/f nspection.................... 12-7 fnstaf lation................;.... ..................... 12-7 Pressure Plate RemovaUlnspection ......12-8 GlutchDisc Inspection ...................... 12-9 Flywheel fnspection/Removal ...... 12-10 Flywheeland ClutchDisc lnstaf lation ..................... 12-10
SpecialTools
Re{.No I Tool Numbqt O T J AF 07LAB 07924 07LAF 07936 PM7011A PV00100 or PD20003 PT00110 3710100 ClutchAlignmentDisc RingGearHolder ClutchAlignmentShaft Handle 12-8 1 2 - 89 , r 0 , 12-4,10 1 2 - 8t 0 .
g
o
6,
B
@
12-2
lllustratedIndex
NOTE: a Whenever transmission removed, the is cleanand grease the release bearingslidingsurface. a When partsmarked"*" are removed, clutchhydraulic the systemmust be bled. . Bleedthe clutchhydraulic system(seepage 12-6). . Inspect hosesfor damage,leaks, the interference, twisting. and
PEDAL PIN r19 N.m lt.g kg.m, la lb-fil
8 x 1.25mm 22 N{n 12.2 kg-m, 16 lb-ft)
6x1.0mm 10 N.m {1.0lg.m,
7 rb.ftl
.RESERVOIF .CLUTCHMASTER CYLINDER R6moval/lnstall6tion. pag6 12-5
.rg runrfl.g tg-m, 14lb-ft1

8 x 1.25mm 22 N.ln {2.2 kg-m, 16 |b-ft)
'15 N{n l'1.5kg-m, 11 tb-ft|
.OIL BOLT 30 t&n {3.0kg-m, z2tb-ftI
WASHER R.pl|c..
Y*
\_-/
l/A+,
'REsERvolR HosE
Pro
CLUTCH DAMPER
(fr&..]{{r+--->
I x1,25 mm ..-
7 ^r*V " lJYr-'

n x r.o mm 10N.m{1.0ls-m, 7 tb.ft}
'Fr
| \\l t \\
^*i!-
rg.m, IJUz tt.r"tz.z

r15 N{n {1.5rg-., lt tb-ft|
virh.
V
tW
/
\ ^
r15 N{n 11.5 kg-ft, 11 tb.ftl
RET-EASE SEANING p8go Romoval, l2-7 pago12-7 Inspoction,

page12-7 Installation,
DOU'EL PIN
FLYWHEEL page Inspection/Removal, 12-10

page12-10 Installation, CLUTCH DISC page12-9 Inspection, psge 12-10 Installation, PRESSURE PLATE pa96 12-8 Femoval/lnspection, page12-10 Installation, RELEASE FORK page12-7 Removal. page12-7 Installation, *CLUTCH 15 N{n (1.5kg-m, 11 tb-ft}
TRANSMISSION See section 13
TSLAVE CYLINOER R e m o v a l / l n s t a l l a t i o n p a g e 12 ' 6 ,
12-3
GlutchPedal
Adjustment
NOTE . To checkthe clutchpedalswitchA and B, seesection . The clutchis self-adjusting compensate wear. to for Threadthe clutchpedalswitchA in until it contacts the clutchpedal. Turn the clutchswitchA in 114 '12lurn further. TightenlocknutA.
7.
CAUTION: ll thro is no cl6aranc6betwon tho mastel qylindor piston and push rod, the releasebearing is held lgainrt tho diaphrrgm spring, which can result in clutch slippago or other clutch problms. 1, L o o s e nl o c k n u tA , a n d b a c k o f f t h e c l u t c h p e d a l switchA or bolt until it no longertouchesthe clutch peoal. LoosenlocknutC, and turn the push rod in or out to g e t t h e s p e c i f i e d t r o k ea n d h e i g h t a t t h e c l u t c h s Deoat. TightenlocknutC,
LoosenlocknutB and clutchpedalswitchB.
8 . Measursthe clsarance between the floor board and clutchpedal.lvith clutchpedalfully depressed, the
q
2.
Release clutchpedal '15- 20 mm (0.59- 0.79 the p i n ) f r o m t h e f u l l y d e p r e s s e d o s i t i o na n d h o l d i t there. Adjust the positionof clutch pedalswitch B so that the engine will start with the clutch pedal in this position. 112-tu'n
3.
10. Thread the clutch pedal switch B in 114further, 11. TightenlocknutB.

LOCKNUT C 15 N.m 11.5
tl tb-ft}
LOCKNUT B 10N.m{1.0 kg-m,7 lb.ftl

CLUTCH PEDAL SWITCH B
CLUTCII PEDAL SwlTCHA

PUSHROD
L(rcKNUT A
10 l,I.|n(1.0kg.m, 7 lb.ft)
CLUTCH MASTERCYLINOER
Padrl in contld
whh awhch
CLUTCH ASSISTSPRING
-6El
@ @ @ @
(STROKE PEDALI:135- 1ir5mm (5.31- 5.71 in) 8t (TOTALCLUTCHPEDALFREE PLAY):9.0 - 15.0mm 10.35 0.59 in) includo ths psdal plsy 1 - 7 mm t0.0t - 0.28 in). PEDAL HEIGHT): mm (7.48in) 190 ICLUTCH PEDALDISENGAGEMENT HEIGHT): mm (3.70in) minimum to the ftoor. 9,[ ICLUTCH
2-4
ClutchMasterCylinder
Removal/lnstallation
CAUTION:Avoid spilling brake fluid on paint.d surtacos,as it may damagoths tinish. NOTE:Plug the end of the resrvoirhose,and cap the end of the clutchpipe,with a plug and cap suchas those discardedfrom an A/C kit. 1. Removethe reservoirhose from the clutch master c v l i n d e ra n d d r a i n t h e b r a k ef l u i d i n t o a s u i t a b l e contarner, NOTE:The brakefluid csn be suckedout through the top ot the reservoir with a syringe. 2. from the enginecompartment Remove reservoir the bulkhead. Disconnect clutch pipe from the clutch mastsr the cylinder. CLUTCH PIPE
19 N.m 11.9 kg-m, la lb-ttl 6x1.0mm
5.
Remove clutchmastrcvlinder. the
3.
10ll.rn 11.0 ke-m, 7 tb-ft)
CLUTCHMASIER CYLINDER
6.
Install the clutch mastor cylinder in the revrse order of removal. NOTE: Blsed the clutch hydraulic systom (see psge 12-6t.
RESERVOIR CLUTCH RESEBVOIR HOSE MASTER CYLINDER Pry out the cotterpin, and pull the pedal pin out of the voke.Remove nuts. the
COTTERPIN Replac. PEDALPIN
-6rl
NUTS
13 N{n (1.3kg.m,9lb-ft|
2-5
SlaveCylinder
Removal
Disconnect clutchpipefrom th slavecylinder. the CAUTION: Avoid spilling braks tluid on the paintod 3u.facos,as it may damagoth tinish. NOTE:Plug the end of the resrvoir hose,and cap the end of the clutchpipe,with a plug and cap such as those discardedfrom an IVC kit. Remove slavecylinderfrom the clutchhousing. the
CLUTCH PIPE 15 N'm {1.5kg-m.
lnstallation
-6ll, (P/N08798 SuperHighTemp LJrea Grease 9002). : BrakeAssemblyLubeor equivalent rubber grease.
1 . Install the slave cylinder on the clutch housing.

Connect the clutch pipe.
CLUTCH PIPE
SLAVE CYUNDER
l,
BLEEOER SCREW 10 N{n (1,0kg-m,
7 tb-ft|
8 x 1,25mm 22 N.m {2.2 kg-m, 16 tb-ft| (P/N08798-
-#,1
BOOT
Relhovand chocktor signs of leaking and deterioration.
(BraksAssembly Lub6)
3.
Bleed the ciutch hydraulic system:
Attacha hoseto the bleederscrewand suspend the hosein a container brakefluid. of Makesurethere is an adequate supplyof fluid at the mastercylinder, then slowly pump the clutch pedaluntil no more bubblesappearat the bleeder hose. a Refillthe mastercvlinder fluid when done. a Useonlv DOT3 or 4 brakefluid.
12-6
Release Bearing
Disassembly/lnspection
Remove boot trom the clutchhousing. the Remove the release fork from the clutchhousingby squeezingthe releasefork set spring with pliers. Remove release the bearing.
lnstallation
N O T E :U s e o n l y S u p e r H i g h T e m p U r e a G r e a s e( P / N 08798 9002). Install the release fork set springon the release tork. RELEASE FORK RELEASE FORK SPBING SET
-#l
RELEASE FOBK
{P/N08798-
-6El
{P/N08798*
With the release fork slid betweenthe release bearing pawls, installthe releasebearingon the mainshaft while insening the releasefork through the hole in clutchhousing. Align the detentof the release fork with tlle release f o r k b o l t , t h e n p r e s s t h e r e l e a s ef o r k o v e r t h e release fork bolt souarelv.
RELEASE FOBK RELEASE FoRK SETSPRING RELEAS BEARING
(P/N08798- 9002t
RELEASE FORK SET SPRING
CLUTCH HOUSING
Checkthe release baringfor play by spinningit by h an d . CAUTION: Tho reloass besring is packed with groas.Do not wa3h it in solvsnt.
BELEASE FORKBOLT 30 N.rn {3.0 kg-m, 22 lb-ftl
f-
Installthe boot, being sure that there is no clearance:release fork-to-boot, and boot-to,clutch housing, .Move the releasefork right and left to make sure that the release fork fits properlyagainstthe release bearing, and that the release bearingslidessmoothRCLEASE BEARING
play, replacethe releasebear lf there is excessive ing with a new one.

FORK RELEASE
12-7
Plate Pressure
RemovaUlnspection
springfor wear Inspect fingersof the diaphragm the area. at the release bearingcontact as Assemble specialtools shown. the N O T E :A s s e m b l e h e C l u t c hA l i g n m e n tD i s cw i t h t springas shown. side "A" facingthe diaphragm springfingersfor heightusrrg Check diaphragm the and a feelergauge. the specialtools Standard(New): 0.6 mm {0.02in) max. 0,8 mm {0.03in) ServiceLimit: To prevent warping. unscrew the pressure plate mounting bolts in a crisscrosspattern in several steps.then remove the pressureplate.
PRESSURE PLATE
CLUTCH ALIGNMENT
Dtsc
plate surfacefor wear, cracks, Inspectthe pressure a n db u r n i n g .

FEELER GAUGE
OTJAF PM7O11A
1.
Inspectfor warpage using a straight edge and a feelergauge. NOTE:Measureacrossthe pressureplate at three pornts. in) Standard (lrl6wl: 0.03 mm (O.0Ol max. 0.15 mm (0.006in) Sorvicc Limit
FEELER GAUGE
SHAFT CLUTCH ALIGNMENT 07LAF- PTOo110 HANDLE 07936- 3710100
4.
Install the special tools as shown.
45 N.m (4.5kg-m, 33 tb-ft)
HANDLE 07936 3710100
* /
/ '
CLUTCH L I G N M E N T IA SHAFT 07LAF PT00110 RINGGEARHOLDER ENGINEBLOCK 00 07LAB- PV001 07924- PD20003 RING GEAR HOLDER ADJUSTER NUT AOJUSTEB BOLT BOLT STRAIGHT EDGE
WASHER
12-8
ClutchDisc
Inspection
L 2.
Remove clutchdisc. the lnspect the lining of the clutchdiscfor signsof slipp i n g o r o i l . R e p l a c e t i f i t i s b u r n e d b l a c ko r o i l i soaked.
Measurethe depth from the lining surfaceto the rivets,on both sides, Rivt Dspth: StandardlNewl: 1.3mm {0.05in) min. SrvicoLimit: 0.2 mm (0.01in)
xi (
@
CLUTCH OISC
CLUTCH DISC 3. Measure clutchdiscthickness. the Clutch Disc Thicknss. Standard(New|: 8.4- 9.1 mm {0.33 0.36in} ServiceLimit: 6.0 mm 10.24 inl
12-9
Flywheel
Inspection/Removal
1,
Flywheeland ClutchDisc
lnstallation
.-Alignthe hole in the flywheel with the crankshsft Installthe mountingbolts dowel pin and assemble. only tingertight. Installthe specialtool. then torque the mounting p b o l t s i n d c r i s s c r o s s a t t e r n i n s e v e r a ls t e p s a s shown.
the Inspect ring gearteethfor wear and damage, Inspectthe clutch disc mating surfaceon the flywheelfor wear,cracks, Sndburning. Measurethe flywheel runout using a disl indicator through at least two full turns. Push the flywheel thrust towardsthe engineto take up the crankshaft washerclearance. w N O T E :T h e r u n o u t c a n b e m e a s u r e d i t h e n g i n e installed. Standard lNowl: 0.05 mm {0.002in) mrx. in) 0.15 mm {0.(X)6 ServiceLimit the the servicelirnit, reDlace lf the runout exceeds flywheel. (}
2.
FLYWHEEL
rLvwxeel
07LAB PV00100 MOUNTTNG or BOLTS 07924 PD2fi)O3 tO5N.rntj9.5 k,-m, ?G tb-ft1
l "
4. R e m o v et h e e i g h t f l y w h e e l m o u n t i n g b o l t s i n a crisscrosspattern in ssveral steps, and remove the flywheel. FLYWHEEL
I n s t a l lt h e c l u t c h d i s c u s i n g t h e s p e c i a lt o o l s a s shown.
FLY\AIHEEL
HANDI.I 07936- 3710100
CLUTCH DISC
CLUTCH ALIGNMENT SHAFT 07LAF- PT|X)I10
RII{GGEARHOLDER o?LAB- PVO010O ol 0?924 - PD2o003
(P/N08798- 9002)
4.
Install the Dressure Dlate.
Pf,ESSUREPLAIC
patternas Torquethe mountingbolts in a crisscross shown.Tightenthem several stepsto preventwarping the diaphragm spring.
MOUNTINGBOLTS 26 N.m (2.6kg-m, 19 lb-ft|
6.
Remove soecial the tools.
12-11
ManualTransmission
Tools... Speciaf ........... 13-2 Maintenance Transmission .............................. Oil 13-3 Back-up Llght Switch Replacement .,.,,.... 13-3 Transmission Assembly Removal ................. 13-4 Gearshift Mechanism Overhaul ................ 13-9 lllustrated Index ................................... 13-10 Shift Arm Assembly fndex ................ ......13-12 Disassembly/Reassembly ............... 13-13 Transmission Housing Removal ................. 13-15 ReverseShift Fork Glearance Inspection,,,....,.............., 13-1 6 Reverseldler Gear Removal ................. 13-17 Mainshaft, Countershaft Removal ................. 13-17 Mainshaft lndex ............... ....... 13-18 Clearance Inspection ......,................ 13-19 Disassembly .......... 13-20 Inspection .............. 13-21 Reassembly ........... 13-22 Countershaft fndex ................ ......13-23 Cfearance fnspection....................... 13-24 Disassembly .......... 13-25 Inspection .............. 13-26 Reassembly ........... 13-25 Shift Fork Assembly Disassembly/Reassembly ............... 13-28 Clearance Inspection ....................... 13-29 SynchroSleeve,SynchroHub Inspection Installation ............. 13-30 SynchroRing,Gear Inspection .............. 13-31 MainshaftBearing/Oil Seal Replacement .....,.,, 13-32 Countershaft Bearing Replacement ......... 13-33 MainshaftThrust Shim Adiustment ............ 13-34 Transmission Reassembly ........... 13-37 Transmission Assembly Installation ............. 13-40
NOTE:The radio may havea codedtheft protection circuit.Be sureto get the customer's code numberbefore - Disconnecting battery. the - Removing No. 43 {10A)fuse in the under-hood the fuse/relay box. - Removing radio. the After service, powerto the radioand turn it on. reconnect Whenthe word "CODE"is displayed, enterthe customer's 5-digitcodeto restore radiooperation.
SpecialTools
R{.No.
Tool Number 07GAJ07GAJ*07736 07746 07746 07746 07746 07749 07947 Pc2o' r'r0 PG20130 A010004 0010300 0010500 0030100 0030400 0010000 6890100
Description Holder Mainshaft Mainshaft Base Adjustable BearingPuller,25 40 mm 42 Attachment, x 47 mm Attachment. x 68 mm 62 Driver,40 mm l.D. Attachment mm LD. 35 Driver SealDriver
Oty 1 1 ,l 1 ,| 1 1 1 1
PagReferonc
tJ-JO, J/
o
@
/a\
@ @ @
13-32.33 't3-22,21 ,32 13-32.33 't3-22 13-22 13-22,21 ,32,33 't3-21
o @ o
* Must be usedwith commerciallv SlideHammer. available in x 16 thread/in 3/8
13-2
Assembly Transmission
Removal
@ 3uro Makr
4.
iacks and safoty 3tlnds aro placed proper' ly, rnd hoi3t brlckot! aro sftached to corroqt posi' lion on tho cngins. Apply parking brako and block roar whool3 30 car will not roll off stand3 lnd fdl on you whilo working uodor it.
Removethe intakeair duct and air cleanerassemDtv.
CAUTION: U3o lcndrr coveB to 8void dEmlging print' ed surfaces. NOTE: The radio may have a coded theft protection circode numberbefore cuit.Bo sureto get tha customer's - Disconnecting the battery. - Removing No. 43 (]0 A) fuse. the fuse/relay box) {Under-hood - Removing radio. the After service,reconnectpower to the radio and turn it on. " C O D E "i s d i s p l a y e de n t e rt h s c u s , When the word tomer's5-digitcodeto restoreradiooperation. 1. Disconnect negative(-) and positive(+) cabls the from the b8ttery,then remove the battery. oil Drainthe transmission (seepage13-3). Removethe battery base and bsse stay, Removethe intakecontrol vacuumtank and brackt, Do the NOTE: not disconnect hoses, INTAKE OONTROL
fti
2. 3.
13-4
6. Disconnect the starter motor cables,then remove the startermotor. 7. Disconnect back-uplight switchconnectors the and groundcable. transmission 8. Remove wire harness the clamp. WIRE
HARNESS
1 1 .Disconnect vehiclespeedsensor(VSS)connecthe tor and removethe VSS/power steeringspeedsensor, but leaveits hosesconnected.
vss coNNEc?oR
LIGHT BACK.UP SWITCH
POWER STEERING SPEED SENSOR
STARTEB MOTOR
STARTER MOTOR CABLES TRANSMISSION GROUND CABI.T O-RING Replace.
12. Remove slavecylinder. the 9 . Shiftthe transmission into reverse. 1 0 . Firstremovethe cablebracket, then disconnect the from the top housingof the transmission. cables NOTE:Removeboth cablesand the bracket together. CAUTION: Take crre not to bond ths cables.
Do not aamovo.
NOTE: . Do not operatethe clutch pedal once the slave cylinderhas beenremoved. . Takecarenot to bendthe clutchpipe.
HOSE CLUTCH
WASI{EB
WASHER Inspect for '}{FT CAALE
and
Replace. STEEL PLASTIC I WASHER WASHER Inspectfor wear and oamage. SLAVECYLINDEB
(cont'd)
13-5
(cont'd) Removal
1 3 . R e m o v t h e c l u t c h d a m p e r m o u n t i n g b o l t s , a n d raisethe clutchdamDer. Remove cotterpins and ball joint nuts,then septhe arate the ball joints and lower arms on both sides (seesection'18). the right damperfork bolt. 1 6 . Remove
CLUTCH OAMPER
't1. Remove the right radius rod.

BOLTS SELF.LOCKING Replace. SELF.LOCKING NUT
Replace.
I,
l '
36i'J'--* NUr
MOUNTINGBOLTS a.
DAMPER NUT SELF.LOCKING Replace.
COTTERPIN Replace.
stay. the 14. Remove rearenginemount bracket
shaft (see and intermediate 18. Remove the driveshafts 16). section w f N O T E : C o a t a l l D r e c i s i o n i n i s h e ds u r f a c e s i t h Tie cleanengineoil or grease. plasticbags over the driveshaftends.
REAR ENGINE MOUNT BRACKET S?AY
SHAFT INTERMEDIATE
13-6
19. Remove centerbeam. the
21. Remove the intakemanifoldstav.
INTAKEMANIFOLO STAY
20. Remove front enginestiffener the and clutchcover.
22. Removethe rear beam stiffener.
REARBEAMSTIFFENER
13-7
(cont'dl Removal
mounthe 23. Remove three rearenginemount bracket ting bolts. housingmounRemove two uppertransmission the ting bolts.
! :
and raise Placea floor jack under the transmission just enoughto take weight oft of the transmission the mounts. mount and mount brackRemovethe transmission et.
UPPERMOUNTING BOLTS
27. R e m o v et h e t h r e e l o w e r t r a n s m i s s i o nh o u s i n g mountingbolts.
MOUNNNG BOLTS LOWER
MOUNT BRACKET
away ftom the engine until it 28. Pull the transmission clearsthe mainshaft.
13-8
Gearshift Mechanism
Overhaul
NOTE: . Inspect parts wearanddamage rubber for whendisassembling. . Check the newcotter is seated pin that firmly.
6x1.0mm 10 N.rn (1.0 kg-m, 7 tb-ft) SELECT CABLE
CHANGE WIREPLATE Replace.
tr
6x1.0mm l0 N.m {1,0kg-m, 7 tb-ftt
COTTER PIN Replace.
l',
@---=.6x1.0n '10N.m kg-n kg-m,7 lb-ft} 11.0
PLASTIC WASHER Inspectfor damsge.
sELF-LocKrNG NUT
Replace. '10N.m (1.0 kg-m, 7 lb-ft|
CHANGE LEVER LINKAGE

CHANGEI,.EVER CHANGE LEVER O-RINGS Feplace. CHANGEBALL
\ \ - -
\-ry \ \\\ N \
I L
&
WAVE *ou.)@o\
WASH WASHER SELF.LOCKING SELF.LO NUT Replace. CHANGE BALL HOLOER
CHANGELEVER
Ptvot
PIVOT CHANGE GUIDE 6x1.0mm kg-m, 10 N.m 11.0 7 tb-ft) SHIFTLEVER BRACKET
FLOATING COLLAR
13-9
lllustratedIndex
disassembly Referto the drawingbelowfor the transmission air. Cleanall pans thoroughlyin solventand dry with compressed
reassembly. oil Luuri""t""tl partswith before

use liquidgasket(P/N08718 0001) between the major housings; usesno gaskets This transmission (seepage 13-14.39). housingis disassembled. the Alwayscleanthe magnetO whenever transmission
t
.>_._------.\\ _._i---.---'l
__----.--
.-.-_.-.-_---
/---ry
o CLUTCHHOUSING o
oll SEALReplace. . Seesection15 an 14 x 20 mm DOWELPIN OIL GUIDEPLATE BEARING NEEDLE . Inspect wear and oporation. for 0 RETAININGPLATE 7 MAGNET IDI.IR GEARSHAFT @ REVERSE IDLER GEAR @ REVERSE @ OIL SEALReplace.
o BALLBEARING '
for Inspect wear and operation.
WASHER @ SPRING @ WASHER SHIFI FORK @ REVERSE
G' SHIFTFORKASSEMBLY . Index,page 13-28 ASSEMBLY G' MAINSHAFT . lndex,page13-18 ASSEMBLY E) COUNTERSHAFT ' Index, pago13-23 ASSEMBLY CD DIFFERENTIAI. Seesection15
13-10
L
q
6
l_
_l I 'ei ,w
H '
0n
I I
sHrM @ THnusr
@ @ @ @ @ Ql @
E9 SHIFTARM ASSEMELY . Index, page13-12 PLATE E4 OIL GUTTER

. S e l e c t i o n ,p a g e 1 3 - 3 4
oIL GUIDE PLATE WASHER Replace. BACK-UP LTGHT swITcH sErflNG scREw WASHER Reptace. SPRTNG 30 mmt lL. srEELEALL s/16inl {D.
HANGER 9 TRANSMISSION @ 28 mm SEALINGBOLT 60 32 mm SEALING BOLT 6D waSHER Reptace. IDIEN GEAR ' BEVERSE SHAFTBOLT T8]OIL SEAL . Seesection 15 .'9 OIL DRAINPLUG WASHER Replace. a{o)
(' @ Q} @
OIL FILIfR BOLT WASHER Replace. TRANSMISSION HANGER TRANSMISSIoN HoUSING
13-1 1
Shift Arm Assembly

lndex
NOTE: in with the transmission the car. . The shift arm covercan be removedand installed with grease. . Lubricate movingand slidingsurfaces all . Turn the boot so the hole is facingdown
LEVER SELEGT
08798 - 9lD2l
-G1
6x1.0mm 12 N.m {1.2kg-m, 9 rb-ftt
OIL SEAL Replac. SHIFTARM . Inspoction, page 13_29 8x1.0mm 29 N.m 12.9kg-m, 2'l tb-ftl
SHIFTARM COVER
PIN RETURN SELECT 6x1.0mm '12N.m 11.2 kg-m, 9 tb-ft} 5TH/REVERSE SELECT SPRING INTERLOCX
6xl.0mm kg-m, 15 N.m 11.5
WASHEB LOCK Replace.
11tb-ftI
BOLT
sE[rcT
RETURN SPRING ARM SELECT
/N 08798-
-6ll
OIL SEAL Replace.
4xBmm DOWELPINS
13-12
Disassembly/Reassembly
NOTE:Duringreassembly, greaseall slidingparts. 1. Remove shift arm coverassembly. the 6x1.0mm 12N.m(1.2 kg-m,9lb-ft|
SHIFTARM COVER ASSEMALY
4.
Remove the reverse lockcam.

6x1.0mm 15 N.m (1.5kg-m,11 lb-ftl
{x8mm DOWEIPINS
R e m o v et h e s p r i n g p i n , t h e n r e m o v e t h e s e l e c t lever,selectarm and springs. Remove selectreturnpin. the

SELECT ARM ,/
5.
Remove oil seal. the
OIL SEAL Rplace.
5x22mm PIN SPRING
-'
SELECT RETURN SPRIMi SELECT RETURN PIN 6x l.0mm 12 N.m 11.2 kg-m,9lb-ft| 5TH/REVERSE SELECT SPRING
SELECT LEVER
.JG
(cont'dl
13-13
Shift Arm Assembly

(cont'dl Disassembly/Reassembly
gend the tab of the lock washer,then remove the bolt. bolt. Remove interlock the NOTE: Apply liquid gasket(P/N 08718the threadsbeforereassembly. 0001)to 9. orderof in the shift arm assembly the reverse Install removal. NOTE: . Use liquidgasket(P/N08718 0001). o Remove din oilfrom the sealingsurface. the of . Sealthe entirecircumference the bolt hole to preventoil leakage. . lf 20 minutes have passedafter applying liquid t g a s k e t ,r e a p p l yi t a n d a s s e m b l e h e h o u s i n g s a n d a l l o w i t t o c u r e a t l e a s t 3 0 m i n u t a sa f t e r with oil. beforefillingtransmission assembly
8x1.0mm 29 N.m {2.9kg-m, 21 tb-ft)
o
\ .oi* *os".^
Replace.
--: LIOUID GASKET
8.
the Remove shift lever,shift arm. and interlock. NOTE:Turn the boot so the hole is facingdown,
13-14
Transmission Housing
Removal
NOTE: . lf the transmissionhousing or clutch housingwere replaced, bearingpreloadmust be adjusted. the o Place the clutchhousingon two piecesof wood thick enough to keep the mainshaftfrom the hitting the workbench. '1. Remove (seepage 13the shift arm coverassembly 131. Remove the reverse idlergear shaftbolt. Remove the settingscrews,then removethe washers,springs. and steelballs.
STEELBALLlD.5/16 in)
Remove 32 mm sealingbolt. the 7. Expandthe snap ring on the countershaft ball bearing and remove it from the groove using a pair of snap ring pliers. Separate the transmission housingfrom the clutch housingand wipe it cleanof the sealant.
SNAPRING
r-^
-/
Replace. WASHER SETTINGSCREW
9.
Removethe 28 mm sealing bolt, then removethe oil gutterplate. NOTE:The transmission housingcan be removed with the oil gutter plate in the transmissionhousing. 28mm SEALTNG BOLI
OIL GUTTER PLATE
4.
Remove back-up the light switch. Remove the l0 mm bolts and 8 mm bolts in a crisscross pattern in severalsteps.
OIL GUTTER PLATE
LIGHT BACK.UP
swlTcH
13-1 5
Reverse Shift Fork

Inspection Clearance
1. Measurethe clearancebetween the reverseshift fork and 5th/reverse shift piecepin. A: 0.05- 0.35 mm 10.002 0.01i|in) B: 0.,1- 0.8 mm {0.016 0.031in) ServicoLimit; A: 0.5 mm (0.020inl in) B: 1.0mm {0.039 Standard:
l.
Measurethe clearancebetween the reverseidler gear and reverse shiftfork. 0.5 - 1.1 mm (0.020- 0.043in) Standard: Srrvico Limit: 1.8 mm (0.071inl
lf the clearance exceedthe service limit, measure shiftfork. the width of the groovein the reverse Stand8rd:A: 7.05- 7.25 mm (0.278- 0.285inl -0.303 inl 8: 7.4- 7.7 mm (0.291
4.
lf the clearance exceeds the servicelimit, measure the width of the reverseshift tork. Standard: 13.0- 13.3mm {0.512- 0.52'l in)
REVERSE SHIFTFONK
REVERSE SHIFT FORK
lf the width of the groove exceedsthe standard, replace reverse the shiftfork with a new one. It the width of the groove is within the standard, reolace sth/reverse shift Diece with a new one. the
l f t h e w i d t h e x c e e d st h e s t a n d a r d ,r e D l a c e h e t reverse shiftfork with a new one. l f t h e w i d t h i s w i t h i n t h e s t a n d a r d ,r e o l a c et h e reverse idlergearwith a new one.
13-16
Reverse ldler Gear

Removal
1. Remove reverse the shift fork.
Mainshaft, Countershaft
Removal
1.
Remove and countershaft assemblies the mainshaft with the shift forksfrom the clutchhousinq. NOTE:Tape the mainshaftspline before removing the mainshaft and countershait assemblies.
REVERSE SHIFT MAINSHAFT ASSEMBLY
COUNTERSHAFT ASSEMBLY
Tapethe mai shattspline. SPRING WASHER
Remove idler gear shaftand the reverse the reverse idlergear.

CLUICH HOUSING
2.
Remove differential the assembly.
DIFFERENNAL ASSEMBLY
REVERSE IDLER GEAR SHAFT
13-17
Mainshaft
lndex
I air, dry B"for" """"mbling. cleanall partsin solvent, them with compressed then coatthem with cleanoil.
RING STOPPER 3RD/irTH SYNCHRO HUB 3RD/4TH SYNCHRO SLEEVE HUB 3RD/irTH SYNCHRO page'13 30 Inspection,
TAPERRING
1,.
NEEOLE BEARING Check wear and ooeiation. SPACERCOLLAS SYNCHRO RING page13 31 lnspection, SYNCHRO SPRING sTH SYNCHRO HUB page13-30 Inspection, sTH SYNCHRO SLEEVE page13-30 Inspection, SYNCHRO SPRING SYNCHRO RING page13-31 Inspection,
SYNCHRO SPRING SYNCHRO RING
SYNCHRO SPRING
" o oro /
SYNCHNO RING page13-31 Inspection, 3ROGEAR page Inspec!on, 13,19,31 NEEDLE BEARING Check wear and operation. MAINSHAFT page13?1 Inspection,
13-18
NOTE:lf replacementis required,always replacethe synchrosleeveand hub as a set. 1 . Support the bearing inner race with a socketand push down on the mainshaft. Measure clearance the between 2nd and 3rd gears. 0.06- 0.21 mm {0.002- 0.008in) Service Limit:0.3mm 10.012 inl I Stands.d:
Measurethe clearancebetween 4th gear and the soacer collar. Standard: 0.06- 0.21 mm {0.002- 0.fl18 in} ServiceLimit: 0.3 mm {0.012in}
5.
lf the clearance exceeds the servicelimit, measure distance on the spacer collar. @ 26.03- 26.08mm (1.025- 1.027in) Standard: Limit:26.01mm {1.024 Service inl
lf the clearance exceeds the servicelimit. measure the thickness 3rd gear. of Transmission Type Standard Service Limit M215.M254 M2F4 6.
6J-l-l L+
SPACER coLLAR ----+l_J
1,
.nrcean
S|DE
-32.41 mm 34.92 34.97mm 32.42 - 1.2'18 inl { 1 . 3 7 - 1 . 3 7 7n ) i 1'1.276 5 32.3mm .27 11 2 inl 34.8mm ( 1 . 3 7 0n ) i
lf distance is lessthan the servicelimit, roplace O the spacer collarwith a new one. tf distance@ is within the service limit, measure the thickness 4th gear. ot M215,M254 M2F4
3RD GEAR
Transmission Type Standard Service Limit
30.92 30.97 mm 3 1 . 4 2 3 1 . 4 7 m m inl ( 1 . 2 3 7 1 . 2 3 9n ) i 11.217 1.219

30.8mm ( 1 . 2 1 i3 ) n
I
3 1 . 3m m inl l'1.232
El r| ^J-_-6
lf the thickness 3rd gear is lessthan the service of limit,replace gearwith a new one. 3rd lf the thickness f 3rd gear is within the service o limit, replacethe 3rd/4thsynchro hub with a new one.
t,A
\--t 1 I
. .THGEAn
l lf the thickness 4th gear is lessthan the service of limit, replace gearwith a new one. 4th lf the thickness f 4th gear is within the service o limit, replacethe 3rd/4thsynchro hub with a new one. (cont'd)
Mainshaft
Inspection{cont'dl Glearance
Measurethe clearancebetweenthe spacer collar and 5th gear. 0.06- 0.21mm (0.002- 0.008in) inl SsrviceLimit: 0.3 mm 10.012 Standsrd:
Disassembly
CAUTION: Removethe synchro hubs using a press and steel blocks as shown. Use of a iaw.typ puller can damagethe gsar teeth, Removethe ball bearingusing a bearingpuller as shown.
BEARING PULLER
BALLBEARING
lf the clearance exceeds the servicelimit, measure collar. distance on the spacer @ 26.03- 26.08mm in) {1.025 1.027 Limit: 26.01mm {1.02'l in) Sorvice Standard:
SPACER COLLAR BAI-L BEARING STOPPER RING
sTHGEAR SIDE lf distance is lesathan servicelimit, replacethe ) spacer collarwith a new one. lf distance@ is within the service limit, measure thickness sth gear. of -1.219inl Standard: 30.92 30.97mm (1.211 Limit: 30.8mm 11.213 inl Service
5TH GEAR
MAINSHAFT
lf the thickness sth gear is lessthan the service of limit, replace gearwith a new one. 5th lI the thickness f 5th gear is within the service o limit, replace sth synchrohub with a new one. the
13-20
lnspection
S u p p o r t s t h g e a r o n s t e e l b l o c k sa s s h o w n a n d the Drsss shaftout of the sth synchrohub. '1. Inspectthe gear surtace and bearing surface for wear and damage,then measurethe mainshaftat pointsA, B, and C. Standard: A {88ll bearing surlacol: B (Needlebearing surfaco): C (Ball bearing 3urface): Ssrvico Limit A: 27.940mm B: .37.930 mm C: 27.940 mm
27.987- 28.000mm ( 1 . 1 0 1-8 1 . 1 0 2 'i ln ) 37.98'l- 38.000mm (1.irgsit- 1.,t961in) 27.977- 27.99O mm ( 1 . 1 0 1-5 1 . 1 0 2 0n ) i (1.1000in) (1.4933 in) (1.1000 in)
I n s p e c t o i l p a s s a g e sf o r c l o g g i n g .
In the same manneras above,supportthe 3rd gear on stel blocks and pressthe shaft out of the 3rd/4th svnchro hub as shown.
lf any part of the mainshaftis lessthan the service limit, replace with a new one. it Inspect runout. for Standard: 0.02 mm (0.001in) max. in) Seivico Limit: 0.05 mm 10.002 N O T E : S u p p o r t t h e m a i n s h a f ta t b o t h e n d s a s snown.
lf the runout exceeds the servicelimit, reolacethe mainshaft with a new one,
13-21
Mainshaft
Reassembly
NOTE: Refer page13-18 reassembly for sequence. to 1. Support 2nd gar on steel blocks as shown, then i n s t a l lt h e 3 r d / 4 t hs y n c h r oh u b u s i n gt h e s p e c i a l tools and a pressas shown. NOTE:After installing, inspectthe operationof the 3rd/ 4th synchrohub set. (T..nsmi$ionTypol: M2L5, M2S4
PRESS
Installthe sth synchro hub using the spocialtools ano a pressas snown.
,40 ORIVER. mm l.D. 07746- (x)30100
HUB sTHSYNCHRO
1
3RD/4TH SYNCHRO HU8 3. lnstallthe ball bearingusingthe special tools and a pressas snown.
Typel: M2F4 {Transmis3ion
BCARING ATTACHMENT,35 mm l.D. 07745 - (x}301o0
ATTACHMENT, a2xaTmm 07?46 0010300
2ND GEAR
13-22
Countershaft
lndex
I air, B"for" """"mbling. cleanall partsin solvent, them with compressd then coatthem with cleanoil. dry
Replsce. LOCKNUT 130 + 0 + 130N.m + 0 + 13kg-m, 113 r 9a + 0 + 9a lb-ft
GEAB REVERSE
WASHER SPRING BALLBEARING Checkwear and oporation.
lSI/2ND SYNCHRO HUB Inspction,page 13-30
NEEDLE BEARING Checkwear and operation. FRICTION DAMPER Check war and d6mag. SYNCHRO SPRING ilTH GEAR RING SYNCHRO pa96 13-31 Inspection, 5TH GEAR
lST GEAR
3RD GEAR
page 3'l Inspection, 13-24, BEARING NEEDLE wearsndoporation Check THRUSTWASHER page13-?4 Solection,
2ND GEAR pag13-24, Inspoction, 31
NEEDI..E BEARING Chsck wear and operation. SPACER COLLAB pag13-24 Sel6ction,
OOUNTERSHAFT p8g 13-26 InsDection,
FRICTION OAMPER Checkwear and damage. page13-25 Removal, page13-27 Installation, INNERSYNCHRO RING page13-31 Inspection, SYNCHRO CONE OUTERSYNCHRO RING page'13-31 Inspction, SYNCHRO SPRING
13-23
Gountershaft
Clearance Inspection
l, Measurethe clearancebetweenthe 1st gear and thrustwasher. 0.04- 0.10mm {0.002- 0.0O'lin} ServicaLimit: 0.18 mm 10.007 inl Standard: 3. Measurethe clearance betwoenthe 2nd gear and 3rd gear. Strndlrd: 0.0,1- 0.10mm {0.002- 0.00il in) Sorvico Limil:0.18mm (0.007 in)
THBUST WASHER
2.
lf the clearance exceeds servicelimit. selectthe the appropriate thrust washerfor the correctclearance from the chartbelow,
4.
lf the clearanceexcesdathe service limit, selectthe appropriatespace.collar for the correctclearance from the chart below.
THRUSTWASHER Part Number 23921 PG1- 000 2 3 9 2 2 - P G 10 0 0 23923-PG1-000 D 23924-PG1-000 23925 PGl -000 Thicknaes 1 . 9 6 m ( 0 . 0 7 7 i1 ) m n 1.99mm (0.0783 in) 2.02mm (0.0795 in) 2.05mm (0.0807 in) 2.08mm 10.0819 inl
SPACER COLLAR
Prrt Numbcr
A 23917-P21-O10
Thickn..s
29.02 29.04 mm ( 1 . 1 4 2 51 . 1 4 3i 3 ) n
29.07- 29.09mm ( 1 . 1 4 4-5 1 . 1 4 5 i n ) 3
23918-P2'r-010
13-24
'1.
S e c u . e l yc l a m p t h e c o u n t e r s h a f t s s e m b l yi n I a benchvisewith wood blocks. Raisethe locknuttab from the groove ot the shaft and removethe locknutand the springwasher,
4.
Remove the friction damper trom the spacer collar using a prgss and a socket as shown.
PRESS
CHISEL
SPRING WASHER BENCH
vtsE
BLOCKS WOOD
Replac.
3.
Remove ball bearingusinga pressas shown. the
PRESS
ATTACHMENT
4TH GEAR
COUNTERSHAFT
STEEL BLOCKS
3-25
Countershaft
Inspection
'1. lnspect the gear surface and bearing surface for wear and damage,then measurethe countershaft at pointsA, B, and C. StandErd: A:38.fi10l1.i(t61 B: 39.984{1.5742 C: 24.987 {0.98:17 38.015mm f.il967 inl /{1.000mm 1.57'18 inl 25.000mm 0.9843in)
Reassembly
NOTE: Refer page13-23 reassembly to for sequence. 1, Installthe thrustshim, needlebearing,lst gear,friction damper,synchroring,and synchrospring. NOTE:Reassemble lst gear and frictiondamper th beforeinstallation.
SYNCHRO SPRING SYNCHRO RING FBICTION DAMPER lST GEAR NEEDI.E BEARING THRUSTSHIM
Limit:A:37.950 (t.t*t41 Sorvico mm in) B:39.930 (1.5729 mm inl C:2il.9il0 mm (0.9819 inl
Inspect wearand damage. for
COUNTERSHAFT
lf any part ot the countershaft lessthan the seris vice limit. replace with a new one. it Inspect runout. for St.ndard: 0.02 mm 10.001 in) SrvicoLimh: 0.05 mm (0.002in) 2. NOTE:Support th6 countershaftat both ends as snown. Installthe 1sv2ndsynchrohub by aligningthe frict i o n d a m p e r f i n g e r s w i t h 1 s t / 2 n ds y n c h r o h u b grooves.
lST/2ND SYNCHRO HUB
Rotate two complele revolutions,
It the runout exceeds the servicelimit, reDlace the countershaft with a new one.
13-26
Install Jriction the damperon the spacercollarusing the soecialtools and a Dress shown. as
Install the needlebearing, Installthe ball bearing using a specialtool and a pressas shown.
PRESS
PRESS
DRIVER 077 - 0010000
+
ATTACHMENT,42 x 47 mm 07746- (X)103q)
COLLAR SPACER
ffi!--;.+a'-,
1. 8. I n s t a l t h e 2 n d g e a r b y a l i g n i n g h e s y n c h r oc o n e l t fingerswith 2nd geargrooves.
o
Install springwasher. the S e c u r e l yc l a m p t h c o u n t e r s h a f t s s e m b l yi n a a benchvisewith wood blocks. Tightenthe new locknutto the correcttorque,thn stakethe locknut tab into the groove Torqus:130+ 0 + 130N.m (13.0 13.0kg-m, 9 4 + 0 + 9 al b - f t )
LOCKNUT Replace.
GROOVE
FINGER BENCH
vtsE
wooD Bl-ocKs
13-27
Shift ForkAssembly
I e,ior. reassembling, cleanall the partsin solvent, them and apply lubricant any contactparts. to ,o dry
5 mm PIN PUNCH
1ST/2NDSHIFTFORK
13-24
NOTE:The synchrosleeveand synchrohub should be replaced a set. as 1. Measure the clearance betweeneach shift fork and its matching synchrosleeve. Standard: 0.35- 0.65mm {0.014- 0.026in} ServiceLimit: 1.0{ mm {0.039in)
3.
Measurethe clearance betweenthe shift fork and the shift arm. Standard: 0.2 - 0.5 mm l0.fi)8-0.019in) SorvicLimit 0.6 mm (0.02i1 inl
sTH/REVERSE SHIFT PIECE
SIfEVE SYNCHRO
3ND/'TH SHIFTFORK
SHIFTFORK SHIFTARM
lf the clearance exceeds the servicelimit, measure the width of the shift arm. 2. lf the clearance exceeds the servicelimit, measure the thickness the shiftfork fingers. of Stlndard: 12.9- 13.0mm (0.508 0.5f2 inl
Standard: M2F4(Transmission Type) 3rd/4th shift fork (Transmission M2L5/M2S4 Type) 3rd/4th shift fork 7 . 4- 7 . 6m m (0.291 0.299in) 6.2- 6.4 mm |'0.244 0.252inl
iy
SHFTFORK lf the thicknessof the shift fork finger is less than the standard, replace shjftfork with a new one. the lf the thickness the shift fork finger is within the of standard, replacethe synchro sleeve with a new one.
SHIFTARM
lf the width of the shift fork finger is less than the replace shiftarm with a new one. standard, the lf the width of the shiftfork finger is within the standard, feplace the shift fork or shift piecewith a new ones.
SynchroSleeve, SynchroHub
Inspection
1.
lnstallation
Eachsynchrosleevehas three sets of longerteeth (120 apan)that must be matchedwith the three sets degrees of deepergroovesin the synchrohub when assembled. NOTE:Installing the synchrosleevewith its longer synchrohub slots will damage teeth in the 1sV2nd the spring ring.
gear teeth on all synchrohubs and synchro Inspect sleevesfor rounded off corners. which indicates
I n s t a l le a c h s y n c h r o h u b i n i t s m a t i n g s y n c h r o sleeveand checkfor freedomof movement. NOTE:lf replacementis required,always replace ths synchrosleeve and synchrohub as a set.
TEETH LONGER SYNCHRO HUB SLOT
SYNCHRO HUB
13-30
Synchro Ring,Gear
Inspection
1. Inspect synchroring and gear. the A: Inspect insideof the synchroring for wear. the B: Inspectthe synchrosleeveteeth and matching t e e t h o n t h e s y n c h r or i n g f o r w e a r { r o u n d e d off).
GOODWORN C: Inspect the synchro sleeve teeth and matching SYNCHBO
SYNCHRO
teethon the gearfor wear (rounde;$).

GOOO WORN
D: Inspect gear hub thrustsurface wear. the for
E: Inspectthe cone surfacefor wear and roughness. F: Inspect the teeth on all gearsfor unevenwear. galling,and cracks. scoring, 2. C o a t t h e c o n e s u r f a c eo f t h e g e a r w i t h o i l a n d p l a c et h e s y n c h r o r i n g o n t h e m a t c h i n gg e a r . Rotate rjng, makingsurethat it does not slip. the Measurethe clearance betweenthe synchro ring and gear all the way around. N O T E : H o l d t h e s y n c h r o r i n g a g a i n s tt h e g e a r evenlywhile measuring clearance. the Synchro Ring-to-Gear Clearance Standard: 0.85- 1.10mm (0.033- 0.0,|:|inl Servico Limit: 0.4 mm {0.015 in) Doubl Cone Synchro-to-Gear Clearance Standard: @:(Outer Synchro Ring to Synchro Con) 0.5- 1.0mm (0.020-0.039 inl @: (synchro Cone to Gear) 0.5- 1.0mm (0.020 0.039in) Synchro Ring to Gear) @:lOuter 0.95- 1.68mm (0.037- 0.066in) Ssrvice Limit: in) @:0.3mm (0.012 in) @:0.3mm (0.012 in) @:0.6mm (0.024 l f t h e c l e a r a n c ei s I e s s t h a n t h e s e r v i c e l i m i t , replace synchroring and synchrocone. the
INNEN SYNCHRO RING
SYNCI{FORING
SYNCHRO RING
13-31
Bearing/Oil Seal Mainshaft

Replacement
1.
C
4. side Drivethe new oil seal in from the transmission as usingthe specialtools shown.
Remove differential the assembly. l R e m o v e h e b a l l b e a . i n gw i t h t h e s p e c i a t o o l a s t snown.
3.
Remove oil sealfrom the clutchside. the
DRIVER 07749 001(x)00
3/8 in r( 16 thr.rd/in SLIDEHAMMER {Comm.rci.lly .v.il.blc)
ATTACHMEN?, U 2 x 1 7m m 07746 - (x)l0300
Aq,USTABLEBEARING PULER, 25 - 40 mm 07736- A01rDoA OIL SEAL Replacs.
Drivethe new ball besringin from the transmission side usingthe specialtools shown. as
BALLBEABING
AALLBEARING
ATTACHMENT, 62x68mm 077a6 - (X)105(x)
AALLAEARING
13-32
Countershaft Bearing
Replacement
1. platefrom the clutchhousing. Remove the retaining Position the oil guide plateand new needlebearing in the bore of the clutchhousing. NOTE:Position the needlebearingwith the oil hole facingup.
OIL HOLES BEARING NEEDLE
Removethe needle bearing with the specialtool, then removethe oil guide plate.
Drive the needlebearingin using the specialtools as shown. DRIVER 07749 (xll(xx)O
3/8 in x 16 throad/in SLIDEHAMMER (Commc.ciallyrvailrblel
ADJUSTAB1IBEARING PULLER, - i(, mm 25 0t736 - A01@0A
NEEDl-E NEEDLE BEARING
(cont'd)
13-33
Bearing Countershaft
Replacement(cont'dl
plsteand stakethe bolt headsin lnstallthe retaining plate. the groovein the retaining
6x1.0mm 12 N'm {1.2kg-m,9lb-ftl Replaco.
MainshaftThrustShim
Adjustment
1. Removethe thrust shim and oil guide plate from housing. the transmission PLATE otl GUIDE rHnr rcr qHlM
RETAINING PLATE
Installthe 3rd/4thsynchrohub, spacercollars,sth synchro hub, and ball bearing on the mainshaft, then installthe aboveassemblyin the transmission housrng. lnstallthewasheron the mainshaft. Measuredistance betweenthe end of the trans@ missionhousingand washer. NOTE: a Usea straightedgeand verniercaliper. a Measure three locations at and average readthe
Ing.
ENDot TRANSMISSION
HOUSING MAINSHAFT
WASHER
HUA 3RD/4THSYNCHRO SPACER COLLAR sTH SYNCHRO HUB SPACER BALLBEARING
1 3 -3 4
5.
Measure distance @ between the end of th clutch housingand bearinginnerrace. NOTE: . Usea straightedgand depthgauge. ! Measure three locations at and averagsthe readings.
78 mm THRUSTSHIM Part Numbor 23941 PK5- 000

Thiqkno!!
'1.20 mm (0.0472 in) 1.23mm (0.0484 in) 1 . 2 6 m ( 0 . 0 4 9 i6 ) m n 1.29mm (0.0508 in) 1.32mm (0.0520 in) 1.35mm (0.0531 in) 1.38mm (0.0543 in) 1.41mm (0.0555 in) 1.44mm (0.0567 in) 1.47mm {0.0579 in) 1.50mm (0.0591 in)
23942-PKs-000
a
23943-PKs-000
23944-PK5-000
D E
ENDof CLUTCH HOUSING
23945-PKs-000 23946-PKs-000 23947-PKs-000 23948-PKs-000 23949-PKs-000 23950-PKs-000 23951 PKs 000 23952-PKs-000 23953*PKs-000 23954-PK5-000 23955-PKs-000 23956-PKs-000 23957-PKs-000 23958-PKs-000 23959-PKs-000 23960-PKs-000 23961 PKs- 000 23962-PKs-000 23963-PKs-000
K L
BEARING
1.53 mm (0.0602 in)

1.56mm (0.0614 in) 1.59mm (0.0626 in) 1.62mm (0.0638 in) '1.65 mm (0.0650 in) 1.68mm (0.0661 in) 1.71mm (0.0673 in) 1.74mm (0.0685 in) 1.77mm (0.0697 in) 1.80mm (0.0709 in) 1.83mm (0.0720 in) 1.86mm (0.0732 in) '1.89 mm (0.0744 in) 1.92mm (0.0756 in 1.95mm (0.0768 in L98 mm (0.0780 in 2.01mm (0.0791 in 2.04mm {0.0803 in 2.07mm {0.0815 in 2 . 1 0m m ( 0 . 0 8 2 i7 n 2.13mm (0.0839 in 2.16mm (0.0850 in 2.19mm (0.0862 in)
M N
o
P
o
6. S e l e c tt h e p r o p e rt h r u s t s h i m f r o m t h e c h a r t b y usingthe formulabelow. NOTE: Useonly one thrustshim. Shim SoleqtionFormula: you Fromthe measurements made in steps4 8nd 5: -1. Add distance {step5) to distsnce (step4). @ @ -2. Ftom this number,subtract0.93 (which is the midpoint of the flex rangeof the clutchhousingbearing springwasher). -3. Take this number and compare it to the available shim sizesin the chart. (Forexample) B: 2.39 + C: O.22 = . ,.tr/ , /,/ 2.61 0.93 R
s
T
U
23964-PK5-000 23965-PK5-000 23966-PKs-000 23967-PKs-000 23968-PKs-000 23969-PKs-000 23970-PKs-000 23971 PK5 000 23972-PKs-000
23973-PK5-000
z
AB
AC
AD AE
AF AH AI AJ
= t*
23974-PKs-000 23975-PKs-000 23976-PKs-000

23977-PK5-000
Try the 1.68mm (0.0661 shim. in)
2.22 mm (0.0874 in)

2.25mm {0.0886 in} 2.28mm (0.0898 in) 2.31mm (0.0909 in) 2.34mm (0.0921 in) 2.37mm (0.0933 in) {cont'd)
AK
AL
AM AN
23978-PKs-000 23979-PKs-000 23980-PKs-000
13-35
MainshaftThrustShim
Adiustment(cont'd)
in Checkthe thrust clearance the mannerdescribed below, at NOTE:Carryout the measuremsnt normal room temperature. -1. Installthe thrust shim selectedand oil guide platein the transmission housing.
OIL GUIDEPLAYE
-7. Slidethe mainshaft baseover the mainshaft.

MAINSHAFT TRANSMISSION
-2. Install the spring w a s h e ra n d w a s h e ro n t h e ball bearing. NOTE: . Clean the springwasher,washerand thrustshim throughlybeforeinstallation. . l n s t a l l t h e s p r i n g w a s h e r .w a s h e r a n d t h r u s t shim properly.
-8, Attachthe mainshaft holderto the mainshaft as follows: NOTE: o B a c k - o u tt h e m a i n s h a f t h o l d e r b o l t a n d loosenthe two hex bolts. . Fit the holderover the mainshaft its liD is so towardsthe transmission. . Align the mainshaftholder'slip around the groove at the insideof the mainshaft splines, then tightenthe hex bolts. MAINSHAFT HOLDER EOLT
WASHER
aSttRrNGwasHER
in Installthemainshaft the clutchhousing. -4. Placethe transmission housingover the mainshaftand onto the clutchhousing. Tighten the clutch 8nd transmissionhousings with several mm and l0 mm bolts 8 Tap the mainshaft with a plastichammer.
l:vli ffir"
MAINSHAFT HOLDER O?GAJ PG2O11O
lla-F.
BASE MAINSHAFT 07GAJ PG20130 -9. Seatthe mainshaft fully by tappingits end with a plastichammer. -10. Threadthe mainshaftholderbolt in until it just c o n t a c t st h e w i d e s u r f a c eo f t h e m a i n s h a f t Dase. -1 1.Zero a dial gaugeon the end of the mainshaft.
13-36
Transmission
Reassembly
-12, Turn the mainshaftholder bolt clockwise; stop t u r n i n gw h e n t h e d i a l g a u g eh a s r e a c h e d t s i maximum movement.The readingon the dial gaugeis the amountof mainshaft end play. CAUTION: Turning iho mainshaft holder bolt mor than 60 dogrecs after tho noodle of ths d i a l g l u g a 3 t o p s m o v i n g m a y d a m a g ot h e transmission.
DIALGAUGE
Installthe differential assemblyin the clutch housing.

OIFFERENTIAL ASSEMBLY
MAINSHAFT HOLDER 07GAJ FG20110 -13. lf the readingis within the standard. the clearance is correct. lf the reading is not within the standard. recheckthe shim thickness. Strndard:0.100.16mm (0.00i1- 0.006in)
CLUTCH HOUSING Installthe springwasherand washerwith the angle against clutchhousingas shown the lnsertthe mainshaftand countershaft into the shift forks 8nd installthemas an assemblv. NOTE: Beforeinstalling the mainshaft and countershaft assemblies, tape the mainshaft splinesto protectthem.
MAINSHAFT ASSEMBLY
Tapethe mainshaft splrn6.
(cont'd )
13-37
Transmission
(cont'dl Reassembly
4. Installthe reverseidler gear and reverseidler gear shaft in the clutchhousing. 6. NOTE: the thrust shim according the meato Select madeon page13-34. surments Installthe oil guide plate and thrust shim into the transmission housing.
CLUTCH
TRANSMISSION HOUSING
5.
Installthe reverseshift fork in the clutch housing in with th sth/reverse shift piecepin positioned the slot of the reverseshift fork, NOTE: Check that the steelball is in the properposiIlon.
7.
housInstallthe oil gutter plate in the transmission ing. NOTE:Bendthe hook of the oil gutter plateinto the holeon the transmission housing. Installthe28 mm sealingbolt.
REVERSE SHIFTFORK
6x1.0mm 15 N'm 11.5 kg-m.11lb-ft,
NOTE:Apply liquid gasket(P/N 08718the threads.

28 mm SEALING BOLT 15 N.m 14.5 kg-m, 33 lb-ftl OIL GUTTER PLATE
0001)to
HOUSING TNANSMISSION
13-38
Apply liquid gasketto the clutch housing mating surface shown. as NOTE: . Useliquidgasket(P/N08718 0001). . Remove dirt oil fromthe sealing the surface. . Seal the entirecircumference the bolt hole to of preventoil leakage. . lf 20 minutes have passedafter applying liquid g a s k e t ,r e a p p l yi t a n d a s s e m b l e h e h o u s i n g s t a n d a l l o w i t t o c u r e a t l e a s t 3 0 m i n u t e sa f t e r assembly beforefillingtransmission with oil.
12. Lower the transmission housingwith the snap ring p l i e r sa n d s e t t h e s n a p r i n g i n t h e g r o o v eo f t h e countershaft bearing.
SNAPRING
---: Liquid g6k.t *: Dow6l pin
1 0 . Installthe14 x 20 mm dowel pins.

1 1 . Set the stopperring as shown. Placethe transmission housingover the clutchhousing,being careful to line up the shafts. NOTE:Align the long arm of sth shift fork with the hook on the stopperring.
1 3 . Checkthat the snap ring is securelyseated in the grooveof the countershaft bearing. DimensionA as installed: 3.60 - 6.32 mm l0.i,r2_ 0.249inl
1 4 . Install the 32 mm sealingbolt.
NOTE:Apply liquid gasket(PiN 08718the threads. 32mm SEAI-ING BOLT 25 N.m12.5 kg-m,18lb-ftl
0001)to
sNAperN.:
{cont') d
13-39
Transmission
Reassembly(cont'dl
tc,
lnstallation
1. the dowel pins. Install
pattern in several Torque the bolts in a crisscross stepsas shown. I x 1.25mm bolts: 28 N'm (2.8 kg"m, 20 lb-ft) 10 x 1.25mm bolts: ,15N.m (4.5 kg-m, 33 lb-ft|
1O mm BOLTS
O Or 8 x 50 mm bolts 8 Other: x /U'mm bolts idlergearshaft bolt. the reverse 16. Install 17. Installthe steel balls,springs,washersand settlng screws. BALL 5/16in) lD. STEEL
WASHER Beplace. G SCREW 22 N.m {2.2kg-m, 16lb-ft)
to Apply grease the pans as shown,then installthe fork (seepage 12-7). release bearingand release N O T E :U s e o n l y S u p e rH i g h T e m p U r e aG r e a s e (P/N08798 9002).
FORK RELEASE
FORK RELEASE SETSPRING
I
I
RELEASE FORK BOOT FORKBOLT kg-m, 22 lb-Itl 30 N.m 13.0
3. BOLT 18 13). through all the gears before 19. Shift the transmission installing it.
kg'm. 40 lb'ttl 55 N.m 15.5 shift arm cover assembly (see page 13-
fork boot. lnstalltherelease
1 3 -4 0
P l a c et h e t r a n s m i s s i o n n t h e t r a n s m i s s i o na c k , o i and raiseit to the enginelevel. Install three lowertfansmission the mountinqbolts.
7.
R a i s et h e t r a n s m i s s i o n , h e n i n s t a l l t h e m o u n t t bracket and transmission mount. NOTE: . T o r q u e m o u n t i n gb o l t s a n d n u t s i n s e q u e n c e snown. . Makesurethe bushings not twistedor offset. are
TBANSMISSION MOUNT
12 x 1.25mm 65 N.m 16.5kg-m.
O Tighren 10x 1.25 mm
O Tighten 10 x 1.25mm 39 N.m 13.9 kg-]n, tb-ft)
BRACKET 66 N.m (6.5kg-m, ia1lb-ft) O Tighton 10x 1.25mm 10 x 1.25mm 39 N.m (3.9kg-m, 39 N.rn 13,9 kg-m, 28 tb-ft) 28 rb-ft) O Tight.n t.mpor..ily @ Tighron 12x 1.25mm 65 N{n (6.5 kg-m, a7 lb"ftl 8. Install the th.ee rear engjne mount bracketmounting bolts.
O tidhron
6.
Install two uppertransmission the mountingbolts.
MOUNTINGBOLTS Replace. 12 x 1.25mm 55 N.m 15.5 kg-m, 40 lb-ft)
12 x 1,25mm 65 N.m (6.5kg-m, 4t lb-ft}
(cont'd)
(cont'dl Installation
9. lnstalltherearbeamstiftener. and clutchcover. the 11. Install front enginestiffener NOTE:Torque the front engine stiftenermounting sequenca. boltsfollowingthe numbered kg-m. 28 lb-ft) Torque: 39 N.m 13.9
3!, N.m {3.9 kg-rn, 28 tb-ft)
'10. Install the intake manifold staY.
INTAKEMANIFOLD STAY
12. lnstallthe centerbeam,
10 x 1.25mm 60 N.m 16.0 kg-m, 43 lb-ftl
13-42
Installthe intermediate shaft and driveshafts{see section161. 10x 1.25mm 39 N.m13.9 kg-m,28lb-ft|
1 7 . Install the rearenginemount bracket stay. NOTE: Loosely installthe stay mounting bolt and nut, then torque in the sequence shown.
SPECIALBOLT 10 x 1.25mm 39 N.m (3.9tg-m, 28 tb-ft,
10x 1.25mm 21 N.m {2.'l kg-m, 15 tb-ft|
1 4 . Installtheradiusrod. NOTE: Check for deteriorationor damage of the radiusrod rubberbushings. 1 5 . Connect the ball joint to the lower arm, then install t h e b a l l j o i n tn u t .
16. Installthe damper fork bolt, SELF.LOCKING BOLTS Replac. 12 r 1,25mm 105 N{n (10.5kg-m, ?6lb-ft| SELF.LOCKING NUT Replace. 12 x 1.25mm 55 N{r| (5.5 kg-m,
10x 1.25mm 39 N.m 13.9kg-m, 28 lb-ft)
18. Installtheclutchdamoer.
40 tb-ft|
ROD
Replace. / AALLJOINT NUT 14xZtmm 55 N.m 15.5 kg-m. 40 lb-ltl
/1*-
corrERPrN
SELF.LOCKING NUT Replace. 12x 1.25mm 65 N.m {6.5 kg-m, a7 lb-ft| I x 1.25mm 22 N.m 12.2 kg-m, 16 lb-ft|
(cont'd)
13-43
TransmissionAssembly
lnstallation (cont'dl
then installthe clutch pipe 19. Installthe slavecylinder, joint and stay. CAUTION: Take care not to bend the clutch pipe. 21. Installthe shift cable and selectcable to the shift leverand to selectleverrespectavely. CAUTION: Tako care not to bsnd the cabls. NOTE: firmly. ! Check that the new cotterpin is seated . Turn the boot of the shift leverso the hole is facI x 1.25 mm kg-m, 16 lb'ft} 22 N.m 12.2 Ing down. I x 1.25mm {P/N 08798- 90021 PIN COTTER ReplaceSTEEL WASHER PLASTIC WASHER SELECT CABLE CABLE
6x1.0mm 10 N.m {1.0kg-m, 7 rb-ft}
)
tP/N 08798- 9002) 8 x 1.25mm 22 N.m {2.2kg-m, 16lb-ft}
PIN COTTEB Replace.
BOOT SHIFTLEVER WASHER WASHER
groundcableand back-up the 22. Connect transmission light switchconnectors. steer20. Installthe vehiclespeedsensor(VSS)/power the then connect VSSconnector' ing speedsensor, I x 1.25mm kg-m, 14lb-ft) 19N.m11.9 clamp. 23. Installthewire harness 24. Installthe starter motor, then connect the starter motor cables.
S CONNECTOR
Mr"'
POWER STEERING SENSOR SPEED
N O T E : W h e n i n s t a l l i n gt h e s t a r t e r m o t o r c a b l e , makesurethat the crimpedside of the ring terminal is facingout (seesection23).

6x1.0mm
(il5 33 t io r'i'"'ii.i 11n--, 'o-ft1 45N'm ks-m, lb-ft|
l0 x 1.25mm
fnt$rtt ,"o""",..to"
GROUND CABLE
WIRE HARNESS- , CLAMP STARTER MOTOB CABLES
8 x 1.25mm 22 N.m (2.2kg-m, 16 tb-ft)
12 x 1.25mm 75 N.m (7.5kg-m, 54 tb'ft) 6x1.0mm 't0 N.m 11.0 kg-m,7 rb-ft)
13-44
25. Install the bracket and intakecontrolvacuumtank.

INTAKECONTROL
27. Installthebasestayand batterybase.
x 1,0mm 10 N.m 11.0 kg-m, 7 tb-ft|
BASE STAY
6x1.0mm 10 N.rn (1.0kg-m, 7 tb.ftl
BRACKET
I
Front
8 x 1,25mm 22 N.m (2.2 kg-m, 16 rb-ft}
26. Install the air cleaner assemblv and intakeair duct.
6x1.0mm 10 N.m {1.0kg-m,7 lb-ft|
24. Refillthetransmission with oil (seepage13-2). 29. Install the battery. then connect the battery positive (+) and negative cables the battery. (-) to 30. Check clutchoperation. the 3 1 . Shift the transmission and checkfor smooth operatron. 32. Check front wheel alignment the {seesection18).
{cont'd)
13-45
Installation (cont'd)
the 33. Loosen three mountingbolts of the front engine t mount bracket, hen torque the three mounting bolts. NOTE:Make sure the bushingsare not twisted or offset. BRACKET ENGINE MOUNT FRONT
13 -4 6
Automatic Transmission
Tools..... Speciaf ........14-2 OilPump Description ........ ........14-3 Inspection.......... ....14-101 C1utches.............................................1 Valve Bodv 4-6 Main PowerF|ow.......................................1 Disassembly/lnspection/Reassembly. 4-9 4-1 .....'l 02 Electrical Control Svstem................1 4-10 Secondary ValveBody Hydraulic Flow.................................,1 4-13 4-1 Disassembly/lnspection/Reassembly. .....1 04 Lock-up System...............................1 Regulator 4-22 Valve Body Hydraufic Contro1..............................1 4-28 14- 106 Disassembly/lnspection/Reassembly...... ThrottleValveBody EloctricalSystom 4'1 Disassembly/lnspection/Reassembly. .....1 07 Component Location .......,...................1 4-31 Servo Body Circuit Diagram. ........14-32 1+ 108 Disassembly/lnspection/Reassembly...... * Troubleshooting Procedures...,,,,.,,,,,,,1 4-g 1st/2ndAccumulator Body Symptom-to-Component Charr 14- 109 Disassembly/lnspection/Reassembly...... Electrical Svstem..............................1 Mainshaft 4-36 Electrical Troubleshooting +1 Disassembly/lnspection/Reassembly. .....1 1O Troubleshooting F|owchart...............,.... 14-38 Countershaft Mainshaft/Countershaft Sensors Soeed 4-1 Disassembly/lnspection/Reassembly. .....1 1 1 Replacement .........14-61 Remova1............. ....14-112 Lock-upControlSolenoid ValveA/B 13 lnstallation .,...........14-1 Test..........,......... ....14-62 One-wavClutch Repfacement .........14-62 +1 Disassembly/lnspection/Reassembly. .....1 14 Shift ControlSolenoid ValveA/B Secondarv Shaft Test.................... ....14-63 15 Disassembly/lnspection/Reassembly......14-1 Replacement .........14-63 Insoection.......... ....14-116 Clutch HydraulicSystom flfustrated fndex................... +1 17 ..............1 Symptom-to-Component Chart Hydraulic System.............................1 +64 * Road Test....... ...........14-68 StallSoeed Test....................................................1 4-71 FluidLevel +1 28 Countershaft Bearing Replacement...,.,..1 Checking/Changin9....................... ....1 +72 4-128 Secondary ShaftBearing Replacemen1...1 Pressure Testin9.................,,..,,..,...,.....1 Transmission 4-73 Housing Bearings 4-1 Removal/lnstallation ..................... 29 ....1 Transmission Transmission Transmission Reassembly ....... ....1+130 Remova1............. ....14-80 RightSideCover lllustrated lndex +1 36 Feed PipeInsta;;ation......................,.1 Right SideCover...............................1 Parking 4-86 BrakeStopper Transmission Housin9......................1 4-88 4-1s?6 Inspection/Adlustment ....................1 Torque Converter Housin9...........,,.1 4-90 ToroueConverter RightSideCover Disassemblv ..........1+'137 Remova1............. ....14-92 Transmission Transmission Housing Installation .............1+138 Remova|............. ....14-94 CooferFlushing.. ..,.14-142 Torque Converter Housing/Vafue Body shifr cable *Removal/lnstallation Remova|............. ....14-96 ..............,... 4-144 .,,,,,.1 *Adjustment...... ValveBodv ......14'146 * Gearshift Repair................. ....14-98 4'147 Selector .............,,..,,.,,,,,.,...,.1 Valve A/T GearPosition Indicator Panel *Adjustment...... Assembly........... ....14-99 .,'.1+148 ValveCaos ThrottleControlCable Description ...,.... ....14-100 Insoection.......... ....14-149 Adiustment........ ....14-150
'i45"Hgffi *i:|i'',i',
SpecialTools
Rot. t{o.
Tool Numbar 07GAB-PF5010O or 07GAB-PF50101 oTGAE-PG40200 oTHAC-PK4010A 07HAE-PL50100 07LAE-PX40100 OTLAJ-PT3O1OA 07406-@20201 07406-@20@3 07106-0070@0 07730-A010@A 07746-@10400 07746-OO10500 07746-0010600 07749-OO10000 07947-63zto5@ J38405-A
Dolcrlptlon MainshsttHoHer Clutch Sprino Compressor Assmbv Bolt HousingPullor Attachment Clutch SpringCompressor Attachm6nt Clutch SpringCompresaor Test Harnass Hoss} A/T oilPressure Hose {ReDlacement A/T OilPressureGsugeSt A/T Low Pressure Gauge AdjustableBesringPuller,25-40 mm Attschment, 52 x 55 mm Attachment, 62 x 68 mm Attachment, 72 x 75 mm Oriver Attachment Transmission CoolrFlushor
otv
1 1 1 I I I I 1 1 1 1 1 1 1 1 'I
PagoRoferanca
o
ri
1+92,1U 1+121,124 1+93 1+121,124 1+121,124 1+35,68 1+73 1+73 1+73 1+1n 1+18 1+127,'128 1+'127 1+127,14 1+127 1+142
o o o
@ @ @ @ '@ @ @ @
@ @
6,rmr--
o
@
\!,
0
'0
Must be used with commercially available in, x 16 throads/in.slid6nammer. 3/8
14-2
Description
The Automatic Transmissionis a combination of a 3-element torque converter 8nd tripls-shaft electronicaly controllod sutom8tic transmissionwhich provides 4 speedsforward and 1 speed reverse.The entire unit is poshionedin line with the engrne. Torqug Convarter, G6arsand Clutches The torque converter consistsof a pump,turbine and stator Sssembled a singlsunh, in Thsy are connectedto the enginecrankshsJtso they turn togethr as a unh as the engineturns. Around th outside of the torque convrter is a ring gear which meshes with the stsrtel pinion wh6n the engin ig bing st8rt6d. The antir torque converter assemblyservesas a flywheel while transmittingpower to the transmission mainshaft. The transmissionhas three psrsllelshatts: the mainshatt,the countershaft, and ths secondaryshaft. The mainshaftis in line with the enginecrankshsJt. The mainshaftincludesthe clutchestor 3rd. snd 4th, and gearsfor 3rd, 4th, R6vsrseand ldlor (Rsverse gesr is intogralwith 4th gear). The countershaftincludesthe lst-hold clutch and gearsfor 2nd, 3rd, 4th, Reverse,lst EndHler. Th6 secondaryshaft includes the 1st and 2nd clutches,andgesrstor 2nd, 1st and Hler. The 4th 8nd reverse garscan be lockedto the countershaft 8t its center, providing4th gear or Reverse,depending which on w8v the selectoris moved. Ths gears on the msinshaJtare in constsnt msh with thosa on ths countershatt and the secondaryshaft. When certain combinationsof gears illbe lMsDl9giol lre etglged by the clutches, power is tr8nsmitted from the mainshalt to the countershaft pro"ia" O.-l,f-O"-l,f , T and@oosirions. to EleqtronicControl The electroniccontrol system consistsof the Transmission Control Module{TCM),sensors,and 4 solonoidvalves.Shifting 8nd lock-upare l6ctronicslly controlledfor comtonable drivingunder allconditions, The TCM is locatedb8low the dsshboard, behindthe right sido kick panolon the psss6ng6r's sids. Hydr8ullcConilol The vslve bodiesincludethe main valve body. secondaryvafue body, servo body, regulatorvafue body, throttl vsve body and lst/2nd accumulatofbody.They 8re bohedto the torque converter housingas an assembly, The main vslve body containsthe msnualvalve, 1-2 shift valvs, 2-3 shift valvs, coolel relief valve, lock-up shift vafue, lock-up control valve, 3-2 kick-down valve, modul8torvatue.CPCvalve and oil pump gears, The secondaryvalvo body includesthe 4th exhaust valve, 3rd kick-down v8lve,3-4 shift vafu, servo control vslve, orific controlvalve andthe 2ndotificecontrolvalv6. The servo body contains the accumulator pistons 8nd servo valve. The rogulEtorvafus body contains the roguhtor valve, torque converter check valve, and lock-uptiming v8lve. The throttle valve body contains ths throttle valve B and relief valve. Fluidfrom the regulatorpasses throughthe manuslvatveto the variouscontrol valves. The clutchesreceiveoiltrom their respectivefeed pip6sor internalhydrauliccircuit, Shlft Control Mechanism Input from various sensors located throughout the car determinswhich shift control solsnoidvalve the TCM will activate. Activating 8 shiJt control solenoidvalve chsngesmodulator pressure,causingI shtft valve to move. This pressurizes line to a gear, one of the clutches,engaging that clutch and its corresponding Lock-up Machanlsm InL91l position,in 2nd, 3rd and 4th. andI D3 | positionin 3rd, pressurized fluid is drainedfrom the back of the torque converter througir an oil pass8ge,csusing the lock-up piston to be heH agsinst the torqus converter cover. As this takes phcs, th mainshaftrotates 8t the samespeedas the enginecrankshaft.Togetherwith hydrsuliccontrol, the TCM optimizesthe timingof the lock-upmechanism. The lock-upvatuescontrolthe rangeof lock-upaccording lock-upcontrolsolenoidvalves A and B, andthrottle valve B. to When lock-up controlsolsnoid vslves A and B activate, modulatorpressurechanges.Lock-up controlsolenoidvslvs A and B are mountedon the torque converter housing.and are controlledby the TCM, lcont'dl
14-3
Description
(cont'd)
Gaar Sobction
4th Thesetector tever sevenpositions:@PARKt, REVERSe, rueurnef-,1 11stthroush gear,"n0"", @ has o. Fl @ 1stthrough gear 3rd rangss,2l2ndgearandl llstge8r. 1 |
Position Dolcrlptlon Front wheelslocked;p8rkingpswlengsgsdwith parkinggesr on countershaft.Allclutches released. Reve.se;reverseselectorengaged with countershaftreversegear8nd 4th gearclutch locked. Allclutches released. to on Generaldriving; starts oft in lst, shifts automatically 2nd, 3rd, thsn 4th, depending vehiclespeed and throttle poshion. Downshift tEglgh 3rd, 2nd and 1st on decelerationto stop. The lock-up mechanism comes into operstionin LP1Jpositionin 2nd, 3rd and 4th speed. starts otf in For rapidacceleration highwayspeedsand genersldrivlng; at up-hillanddown-hilldriving; lst, shifts automsticslly to 2nd, then 3rd, dspsnding on vehicle speed and throttl position. DownshiJtsthrough 2nd to 1st on dscelertionto stop. The lock-up mechsnismcomes into operation in 3rd sDeed. For enginebrskingor better traction starting off on looseor slipporysurfaces;stsys in 2nd gsar,doos not shitt up or down. For enginebrsking;stays in lst ge8r,does not shift up.
@ernr I nl nevensr r.reurnnrI n-] oo-l I(1st onve

through 4th)
I o.lonve
Flst throush 3rdl
@secor.ro
f rrnsr
positionsthrough th use ol 8 slide-type,nutral-ssfetyswitch. St8rting is possible only in Ll,l andL!_.1 Automatlc TransaxlolA/Tl GoEl PoshlonIndlcatol A/T gear position indicator in the instrument panelshows what gear has been selectedwithout hsving to look down at the consore.
14-4
VA\
,IST CLUTCH
RINGGEAR
TOBOUE COT{VERTER
2I{D CLUTCH
COU TEASHAFT SPEED SE SOR
lST-HOLD CLUTCH
PARKINGGEAR
4TH CLUTCH
3RD CLUTCH
14-5
Description
Clutches
The four-speed automatic transmissionuses hydraulically actuated clutches to engageor disengage the transmissiongears. When clutch pressureis introducedinto the clutch drum, the clutch piston is Epplied. This presssthe friction discs and stsl plstes together. locking them so they don't slip. Power is then transmitted the through the engagedclutch psck to its hubgear. mounted Likewise,when clutch pressureis bledlrom the clutch pack, the piston releases triction discs and stsel plstes,snd thy are the tree to slidepast each other while disengaged. This allowsthe gearto spin independently its shaft, trsnsmittingno power. of 13t Clutch lst The lst clutch engges/disengages gear,and is locatedat the center of the secondaryshaft. to The lst clutch is joinedback-to-b8ck the 2nd clutch. The 1st clutch is suppliedclutch pressureby its oilfeed pipe within the secondsryshaft, 1st-hoH Clutch 'l The 1st-holdclutch engages/disengages st-holdor 1 1 i position,and is locatedat the end of the countershaft,just behind the torque converter housing. The I st-holdclutch is-supplied clutch pressureby its oil teed pipe within the countershsft. 2nd Clutch The 2id clutch engages/disengages gear,and is locatedat the center of th6 secondaryshaft, The hd clutch is ioined back2nd to-back to the 1st clutch. The 2nd clutch is suppliedclutch pressurethrough th socondaryshsft by a circuit connectedto th6 internal hydraulic circuit. 3rd Clutch The 3rd clutch engages/disengages geaf,and is locatedat the center of the msinshsft. 3rd The 3rd clutch is joinedback-to-back the 4th clutch. to The 3rd clutch is suppliedclutch pressurethroughthe mainshaftby a circuit connoctodto ths regulatorvalve body, 4th Clutch The 4th clutch engages/disengages gear, as well as reverse gear, and is located at the c6nt6r of the msinshaft.The4th 4th clutch is joined back-to-back to the 3rd clutch. The 4th clutch is supplied clutch proasuraby its oil feed pipe within the mainshaft. One-way Clutch The one-wayclutch is positionedbetweenthe countershaft lst gear and 3rd 968r,with the 3rd gsar splinedto th countsrshsft. The 1st gear providesthe outer racs surface, and the 3rd gear providesthe inner race surfacs, The on-way clutch locks up when power istransmitted from the mainshaft1st gearto the countershEft1st gear. _ The lst clutch and gearsremainengaged the 1st. 2nd, 3rd, and 4th gsr rangssin the ll1l, fQg,lor l ll oosition. in position. However, the one-wayclutch disengages when the 2nd, 3rd, or 4th clutches/gsErs aooliedin th@ are , I olorl2l This is becausethe increased rotationalspeedof the gesrson the countershstt overridesths locking"spe6d range" of th6 onsway clutch,Thereafter,the one-way clutch freewheelswith the 1st clutch still6ngaged.
COUNTERSHAFT 1ST GEAA LOCKS
FREE
NOTE: Viewlrom rightsidcovorsid.
14-6
COUNTERSHAFT 3RDGEAR MANSHAFT COUI{TERSHAFT 1ST GEAB 3RD CLUTCH 4TH CLUTCH MAII{SHAFT 4TH GEAR MAIITSHAFT REVERSE GEAR
MAII{SHAFT IDLER GEAR

COUNTERSHAFT 4TH GEAR
MAIl{SHAFT
REVERSE SELECTOR SEI.ECTOR HUB COUTTERSHAFT IDLER GEAR
FII{ALDRIVE lST.HOLD SECOI{DARY SHAFT

ARKINGGEAR
COUNTERSHAFT 2NDGEAR COUiITERSHAFT REVERSE GEAR

SECONDARY SHAFT IDLERGEAN
SECOI{DARY SHAFT 2NO GEAR 2ND CLUTCH
FI AL DRIVEI{ GEAR
14-7
Description
(cont'd) Clutches
Lock-up Clutch 1. Operation{clutchon) With th lock-up clutch on, ths oil in the chsmbor between the converter cover and lock-up piston is drsined otf, snd the converter oil exerts prssurethroughthe piston againstthe convertsr cover. As a resuh,the converter turbine is lockedto the the converter cover. The effect is to bypassthe converter, thereby placing car in direct drive.
tF"*"'ffil
The power flows by way of: Engine Driv plat Torqueconverter cover Lock-up piston Dsmperspring Turbine Msinshalt
PISTON LOCK.UP
DAMPERSPRING
J J J J
J J
MAINSHAFT
2. Operation(clutchotf) With the lock-upclutch off, the oil flows in the revers of CLUTCHON.As s resutt,the lock-up piston moves away from the converter cover andth torouo converter lock-uDis relasd, TURBINE
Engine tirive plate J Torque convrter cover J Pump J Turbine J Mainshaft
MAINSHAFT
14-8
PowerFlow
}K
E
tr'|
t^-l
sT
2ND 3RD
4TH
tr
TOROUE1STGEAR lST GEAF 1 S T E A F GEAF3RDGEAR G 2ND 4TH REVERSE PARKING coN- 'IST-HOLD l S T ONE-WAY 2ND 3RD GEAR GEAR VERTER CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH GEAR CLUTCH
X
X
X X X X
o
X
o
o
X X
X
X
X
o
X X X
o
X X X X X X X X X X
o o o
o
X
o -o -o
.o
o
X
X X X X X X
o
X
o
X X X X
o
X X X X X
E
f;t
Lil
t5l
2ND 3RD
tr
o o o o o
o .o
X
o
X
X X
.o
.o o
X
o o
X
o
X
X
X
X X
driving pow6r in not transmittsd as the one-wav clutch O: Operates, x: Doesn't operate, *: Akhough the 1st clutch engsges, sliDs.
COUNTERSMFT MAINSHAFT 1STGEAR 3RD GEAR 3RDCLUTCH MANSHAFT
GEAR 4THCLUTCH REVERSE COUt'ITERSHAFT 3RDGEAR 4TH GEAR

MAII{SHAFT / REVERSE IDLER GEAR
MAINSHAFT IDLER GEAR MAINSHAFT COUiITERSHAFT GEAR 2I{D

COUNTERSHAFT IDLERGEAR PARKI G GEAR
<-
coul{TERSHAFT
PARKI]'IG PAWL SECONOARY SHAFT
OIL PUMP
TOROUE CONVEBTER
FINAL GEAR lST.TIOLDCLUTCH SHAFT 1ST GEAR lST CLUTCH
SECONDARY SHAFT IDLERGEAR
2NDCLUTCHI
SECODARY SH/TFT 2NDGEAR COUI{TRSHAFT REVERSE OEAR REVERSE SELECTOR COUI{TERSHAFT

4TH GEAR
SERVO VALVE
14-9
Description
Electronic ControlSystem
Eloctror c Contlol Systom valves. Shitting8nd Control Module{TCM},sensors,and 4 solnoid The sloctroniccontrol system consistsot the Transmission lock-upars sloctronicslly controllsdfor comfortabledrivingundersllconditions, sida, behindthe right side kick panelonthe passengar's The TCM is locatedbslow the dsshboard, Shlft Control Gstting a signslfrom each sensor,the TCM determinesthe appropriategearand activatesshift controlsolenoidvavos A and/or to The combinationof drivingsignals shift controlsolenoidvafuesA and B is shown in the tsble below. valve \Shitt control solenoid Position(gesr) \ ON ON OFF OFF ON
trstt
@a'at os-ltrstt 1o.-ll
ON ON
OFF OFF OFF
I o.-llo.-lrznar o.-lts,ar 15.-ll
ON
ON OFF ON
(4th)
tr
Lock-up Contlol From sensor input signals, the TCM determineswhether to turn the lock-up ON or OFFand activates lock-up control solenoid valve A and/or B accordingly. The combinationot drivingsignals lock-upcontrolsolenoidvalves A and B is shown in th6 table below. to Solenoid valve A t*"*"-*----\ Lock-up OFF Lock-up,slight Lock-up,hstf Lock-up,full
LOCI(-Up during dec6leration
B
OFF Duty operstion OFF1) ON
urr
ON ON ON ON
ON ON
Duty operation OFF<J ON
14-10
Throttlo Position SonsorSignal Shift Control EnginoCoolam Senso. Sienal ENGINE IECM}
I U
Shlft Conlrol SolenoidValve A Shift Control Sobnoid Valve B
cot{TRoL MODULE
Sorylco Check Connector
Lock.up Control SoLnoid V.tue A Lock-up Control Lock-upControl Solonoid Valv6 B
EngineSpood
I]]]
II{TERLOCK CONTROL UNIT
Alr Conditioning Signal
'
BrakoSwitch Signal Main!haft/Countor$haft Spo6dSsnso. Signal
D.
Vohlclo SpedSeNor Slgnal
Dr
not"ao,Lret r
Solt-Diagnosi3 Signol
14-11
Description
ElectronicControl System (cont'd)
Clrcuh Diagramand Terminal Locstion
; -:.'
nr
r 1 r9 : n{FoTrt! 9osllroN r 2 ECT ENGIIE : COOLiTTTIMPIiATLJRI
'/;scs
ms|rtFlcoiTior
rocx utco{nol
A13lA1! A1
TCM TERMINALLOCATION
14-12
HydraulicFlow
No, 1 DESCRIPTION OF PRESSURE LINE LINE LINE LINE LINE LINE LINE LINE No. DESCRIPTION OF PRESSURE No. DESCRIPTION OF PRESSURE No, DESCRIPTION OF PRESSTIRF OILCOOLER LUBRICATION
6'
I
MODULATE (DUTY CONTROL)

l ST CLUTCH lST.HOLDCLUTCH lST.HOLDCLUTCH LINE 2NDCLUTCH 2NDCLUTCH LINE
30 31
4A
41
3RDCLUTCH
3RD CLUTCH 4TH CLUTCH 4TH CLUTCH
93
5
10
15 18
qA
4
L'
THROTTLE B
90 9l
s9
TOROUE CONVERTER
SUCTION
MODULATE
21 zc
THROTTLE B X TOROUE CONVERTER
BLEED
TOROUE CONVERTER 92 TOROUE CONVERTER
I N I Position As the enginetufns, the oil pump alsostarts to operate.Automatic transmissionfluid (ATFI is drawn from (g9l and dischsrged into (1).Then, ATF pressureis controlledby the regulatorvalve and becomesthe line pressure{1).The torque converter intet pressure(921 jnto (90). enters (94)of torque converter throughthe orifice and discharges The torque conve,ter check valve preventsthe torque converter pressurefrom rising. Underthis condition,the hydraulicpressureis not appliedto the clutchesas the manualvalv6 stoDsline oressure{l ). NOTE: When used,"lett" or "right" indicatesdirectionon the flowchart.
(cont'd)
14-13
Description
HydraulicFlow (cont'dl
I 1 lPositlon (1) to and line {4) Th6 linepressure becomes pressure at the manualvalve passes the lst clutchand lst accumulator. The power is transmittedonly during pressure(4) flows throughthe 1st-holdclutch and 1st-holdaccumulator. Then line the lst-holdclutch, deceleration through Fluidflows bv wav of : (31)+ 3-4 Shift Vslve-4th ClutchPressure - LinePressure l4)+ 1-2 Shift Vatve+ 2-3 Shift Valve- 3rd ClutchPressure (16)J 1st-hold (41)r Manual Clutch ClutchPressure Valve- I st-hold (6) pressure is supplied the 1-2and2-3 shift valves. to The modulator The line pressure(1)alsotlows to throttle valve B. NOTE; "left" or "right" indicatesdirectionon the flowchart. When used,
14-14
I 2 lPosition (1) The linepressure becomes linepressure as it passes throughthe manualvslve. then goesthroughline (2O) the 2nd {4) h to (1) clutch.Also.linepressure goesto the modulator valvethroughthe fiher andbecomes modulator (6l,Modulator pressure the pressure is not supplled the l-2, 2-3 and3-4 shift valves. {6) to (1) Linpressure alsoflows to throttlevalveB. NOTE: When used,"lett" or "right" indicatesdirectionon the flowchart,
{cont'd)
'14-15
Description
HydraulicFlow {cont'd}
I oglo.lEl Positio"
1. 1st Spod circuitis the sameas inI N lposition. The f low of f luidthroughthe torqueconverter The line pressure (1) becomesline pressure{4} and it becomesthe 1-stclutch pressure{10).The lst clutch prossureis the consequently, vehiclewill move as the enginepower is transmitted. aooliedto the 1st clutch and 1st accumulator; (1) becomesthe modulatorpressure(6) by the modulatorvalve snd travsls to 1-2 8nd 3-4 shift v8lvs. The line Dressure The 1-2 shitt vave is moved to the right side becausethe shift control solenoidvalve A is turned ofJ 8nd B is turned on by the TCM, This valve stops 2nd clutch pressureand the power is not transmittedto the 2nd clutch. Lins pressure{4)alsoflows to the servo valve and line pressure{1)slso tlows to throttle valve B NOTE: "left" or "right" indicatesdirectionon the flowchart. When used,
14-1 6
2nd Speed The flow of fluid up the 1-2 and 2-g shift valves ls the same as in the lst sped. As the speed of th6 car reachesthe prescribedvlue,the solenoidvalve A is turnad on by meansof the TCM. As a resuh, the 1-2 shift vav is moved to the left and uncoversthe port leading the 2nd clutch; the 2nd clutch is engaged. to Fluidflows by way of ; -Line pressure + 1-2 Shift Valve+ 2-3 Shift Valve-2nd ClutchPressure {4) {21)J Orifice-2nd ClutchPressure (20)-r 2nd Clutch The hydraulicptessurealsoflows to the 1st clutch. However, no power is transmittedbecauseof the one-wavctutch. NOTE: When used,"left" or "right" indicatesdirectionon the flowchart.
(cont'dl
14-17
Description
HydraulicFlow (cont'd)
3rd Spoed The flow of tluid up to the 1-2, 2-3 and 3-4 shift valves is the sameas in the 2nd speed.As the speedof the car roachesthe prescribedvalue,the shift control solenoidvalve B is turned oft (shift control solenoidvalve A remainson). The 2-3 shift to valve is then moved to the laft, uncoveringthe oil port leading the 3rd clutch. Sincethe 3-4 shitt valve is moved to the right to cover the oil port to the 4th clutch, the 3rd clutch is turned on. Fluidtlows by w8y of : -Line Pressure J 1-2Shift ValveJ 2-3 Shift Valve- 3rd ClutchPressure (31)J 3-4 Shift Valve (not controlled) (41 -3rd Clutch Pressure(30)-r 3rd Clutch The hydraulicpressurealsotlows to the 1st clutch, However, no power is transmitted becauseof the one-wayclutch as in the 2nd sDeed. NOTE: When used, "left" or "right" indicatesdirectionon the tlowchart.
E aFt
Thc prrt Asd shift
Fbn
Tho M
wh
NO
14-18
!he hft the
I Da lPoshion Fth Speed The flow of fluid up to ths 1-2, 2-3 and 34 shift vslves is the same as in the 3rd speed.As th sped of tho car reachesthe prscribed valu,the shitt control sol8noid vatueA is turned olt (shitt control solnoid valv B remsinsoff). As this takos place,3-4 shift valve is moved to th left and uncoverstho oil port leading ths 4th clutch, Sincathe 1-2and 2-3 to shift vslves are kept on the lft side,the fluid flows th.ough the 4th clutch; the power is trsnsmitted throughthe 4th clutch. Fluidflows by way of : -Line Pressure(4) J1-2 Shift Vslvo J 2-3 Shift Vslve-3rd Clutch Pressure(31) + 3-4 Shift Vslvs-4th Clutch pressuro (41)+ ManualVslve-4th Clutch Pressure(4O) 4th Clutch J Ths hydraulicprossurealsoflows to th8 1st clutch, However, no power is transmittedbecsuseof ths one-wsy clutch 8s in 2nd and 3rd sDeed. NOTE: When used,"left" or "right" indicatesdirectionon the flowchan.
Ed)
tin
(cont'd)
14-19
Description
HydraulicFlow (cont'd)
I R lPolhlon Th; tlow of fluid through th6 torque converter circuit is the same ss in the I N I position.The fluid {1)trom the oil pump flows the throughth manualvatveand becomesline prsssure(3). lt then flows throug-h 1-2 shift valv to the servo valve {3),causing the shift tork shsft to be moved in the rovorsedirection, this condition,the shift controlsolenoidvalve A is turned on whereasthe valve B is turned off 8s in 3rd speedinLqllor Undeq I D3 I position.As a resuh, tho 1-2 shift valve is also moved to th8 lsft. The Jluid (3') will flow through the seryo valve and m:Ei[alvalve to the 4th clutch; power is transmittedthroughthe 4th clutch, Rev6rsoInhibito!-.lE=ontrol When the I R I positionis selectedwhile the vehicleis movingforward at a speed over 6 mph (10 km/h), the TCM outputslst;i6;al (A: OFF,B; ON),and the 1-2shift valve is moved to the right side.Th6 line pressure(3)is interceptedby pow6r ia not transmittedas the 4th clutch and servo vatueare not operated. th 1.2 shift vave; consequntly, NOTE: "right" indicstesdirectionon the tlowchart. When used,"left" or
tr
The prst End Hot\
NOI Wix
14-20
ins
,J
I P I Poshlon The flow of fluid th.ough the torque converter circuit is the same as in fTl position.Tho line prsssuro {11bscomes the tine prsssure{31as it passesthrough the manualvatue.Then line pressure(3)*flowsthrough the l-2 shitlgrvs to the sarvo v8vs and the servo control valve,causingthe shift tork shatt to be movedto rhe reversepositionas in th R position. I I However,the hyd.auilcpressureis not supptied the crutches. to The power is not trsnsmittod. NOTE: When used,"left" or "right" indicatesdirectionon the flowchart,
rrd
CM
E
a
14-21
Description
System Lock-up
fluid is drainedjrom the back oJ the torque convsrtsr h l5r-l positionin 2nd, 3rd and 4th, andI 03 | position in 3rd, pressurized th;o6h an oil passage,causingthe lock-up piston to be held against the torquo converter cover. As this takes pl8cs, th mainshsttrotates at the samespedas the enginecrankshaft.Togetherwhh hydrauliccontrol, th TCM optimizosthe timing of in the lock-upsystem. Undercenain conditions,the lock-upclutch is appliedduringdecsleration, 3rd 8nd 4th sp66d. The lock-up systam controls the rangeof lock-up accordingto lock-up control solenoidvavs A and B,8nd throttle valve B' When lock-up control solenoidvslves A and B activate. modulstor pressurechanges.Lock-up controlsolenoidvalvos A 8nd B and are controlledby the TCM, are mountedon the torque converter housing, NOTE: When used, "left" or "right" indicatesdirectlonon the flowchart,
LOCKUP II coNrRoL ll S O L E N O II l D VALVE: ll A
1 L O C K u pC O N T R O L SOLENOTO LVE: VA
FEGULATOF
14-22
l,lo Lock-up The pressurized fluid regulstedby the modulatorworks on both ends of the lock-up shift vsfue and on the left side of the lockup controlvslvo. Underthis condition,the pressures working on both ends of the lock-upshift valveireequat. ttre stritt vatve is movsd to the right side bv the tensionof the v8tuespringalone.The fluid trom the oil pump willflow throught;e bft side of the lock-upclutch to the torque converter; i,e.,the lock-upclutch is in OFFcondition. NOTE; When used,"left" or "right" indicatesdirectionon the flowchart,
!BRi?'", I
v 1
;9ii?9P! !B:i,VBS",jffi?f"
I\4ODULATOR PRESSURE
T O R O U C O N V E R T E R CHECK ALV V
(cont'd)
14-23
Description
Lock-upSystem (cont'd)
PartialLoqk-up VslveB: OFF ControlSolenoid Valve A: ON Lock-up Lock-upControl Solenoid Tho The TCM switches the solenoidvalve A on to releasethe modulatorpressurein the lett cavity of the lock-up shift valve' pressurein the right cavity ot the lock-up shilt valve overcomes the spring forc8, thus the lock-up shitt valve is modulator movedto the left side, to The modulatorpressureis separated the two passages: lock-upclutch enters into right side-toengage Torque Converter InnerPressure: lock-upclutch enters into left side-todisengage Torque ConverterBack Pressure: The bici pressure(FA is regulatedby the lock-upcontrol vave whereasthe positionot the lock-uptiming valve is doterminad by tension ot the valve springand pressureregulated the modulator.Also the positionoJ the lock-up by the throttle B pressure, is determindedby the back pressuieoithe lock-upcontrolvalve and torque converter p.essurergulatedby the controlvalve end of th lockin check valve.With the lock-upcontrolsolenoidvalve B kept oJf, ihe modulatorpressureis maintained the left in other woios, the tock-upcontrol vave is moved slightlyto the leJtside.This slightmovement of the lock-up ,p--nt-iu"V"; in controlvalve causesthe back pressureto be lowered slightly,resutting partiallock-up' NOTE: "left" or "right" indicatesdirectionon the tlowchart. When used,
IOCKUP CONTfiOL SOLENOID
LOC(UP CONTFOL V S O L E N O I D A L v E :B
PRESSURE MODULATOR
TOROIJE CONVERTA
14-24
Half Lock-up Lock-up ControlSolenoid Vafue ON Lock-upControlsolenoid A: ValveB:ON The modulator pressureis releasedby the solenoidvalve B, causingthe modulator pressurein the lft cavity of ths lock-up controlvalve to lower. Also the modulator pressurein the leJtcavity ot the lock-uptiming v8lve is low. However the throttle B pressurois still low at thjs.time;consequently, the lock-uptimingvalve is kept on the righi side by the springforce. With the lock-upcontrolsolenoidvalve B turned on, the lock-up controlvalve is moved somewhat to tho lelt side,causing ths back pressure(F2)to lower. This allows a greater amount of the fluid (Fi ) to work on the lock-u; ;bich ;; 8s ro engage the clutch. The back pressure(Fa which stillexists preventsthe clutch from engaging fully. NOTE: When used,"left" or "right" indicatesdirectionon the flowchart.
ixi"iivflL
!3:i",3,3"J:'&?."
MODULATOR PRESSURE
VALVE
TOFOUE ONVERTER C CHECK ALVE V
(cont'd)
14-25
Description
Lock-upSystem (cont'd)
Ful Lock-up VaMe B: ON VaVe A: ON Lock-up ControlSolenoid Lock-uDControlSolenoid with the throttl opening. in the When the vohiclespeedfurther increases, throttle B pressureis increased accordance to The lock-upttmingvalve overcomssthe springforca and movesto the left side.Also, this vslve closesthe oil port leading the torou convrter chsck vave. Underthis condition,the throttle B pressuraworking on the right end ol the lock-upcontrolvalve becomesgleatsr than that on vatue B); i.e.,the lock-upcontrolvalve the left end (modulatorpressurein the lelt end has alreadybeen relessedby the solenoid is mov6d to ths l6ft. As this happ6ns,the torque convertar back pressureis releasedtully, causingthe lock-up clutch to bs Jully. ng8ged NOTE: "left" or "right" indicatesdirctionon the flowchart. When used,
coNlROL ll SOLENOID II VALVE: A ll
X LOCKUPCONTROI SOIENOIDVALVE: A
THROTTLE PRESSURE B
MODULATOR PRESSURE
TOROUE ONVERTER C C X E C KV A L V E
orr cooLEA
14-26
Dacoleratlon Lock-up Lock-up controlsorenoid Vatve oN Lock-up A; controrsoronoid (oNoFF) vatueB:Dutyoperation TheTCMswitches solsnoid vslveB on andotf iapidlyunder ceitainconCitions. slightlock-up halflock-up Tfre and regions 8re msintEined 8sto lockthe torqueconverter so properV. NOTE: "left" or "right" Whenused, indicatos direction the flowchan. on
33i,'î":i I
LOCXIJ
rocr(uP JI
MOOULATOR PRESSURE
TOROUE ONVERTER C CHECK ALVE V
F E L I E FV A L V E
14-27
Description
HydraulicControl
TheValvebodyinc|udesthemainva|Vebody,the'egulatorVa|vebody,thethrott|evalvebody,thesecondaryvslvbody,the body. servo body and the 1st/2ndaccumulator oilllows throughthe The oil pump is driven by splineson the right snd of the tolqus convener which is attachedto the engine' through the main valve body to the manualvalv and the servo bodv, dirocting ,"si,[i;, rriv" t" mainiiin specitieJ pies--sure oressureto eachof the clutches.
VALVE THROTTLE BODY
SERVO BOOY
VALVE REGULATOR BODY

SHIFTCONTROL VALVE SOLE]TOID ASSEMBLY
VALVE SECONDANY BODY MAINVALVEB(X'Y
VALVEB THROTTLE
LO[{G THROTTLE VALVE
l ST/2ltD ACCUIUIULATOR BODY
RELIEF VALVE
COrTROL LOCK.UP VAI.VE SOLENOID Ot purip ASSEMBLY
GEAR DRIVE OILPUMP
ORIVEiIGEAR
4TH ACCUMULATOR 3RD ACCUMULATOR

lST-HOLD ACCUMULATOR
sEnvo
VALVE
REGULATOR VALVE
LOCK.UPTIMING VALVE
CONVERTER TOROUE VALVE CHECK
1STACCUMULATOR 3RDKICK-DOWI{ VALVE

CPC VALVE
2]IDACCUMULATOR 2 D ORIFICE VALVE COT{TBOL VALVE
VALVE VAL MODULATOR

COOLER VALVE LOCK.UP SHIFT VALVE
1-2 SHTFT VALVE
34 SHIFT VALVE
co oRrFrcE TnoL
SERVO cot{TRoL VALVE
4THEXHAUST VALVE
MANUAL VALVE
VALVE 2-3 SHTFT
14-28
RogulatorValve The regulstorvalv8 maintainsa constant hydraulicpressuresent trom the oil pump to th hydrsuliccontrol svstem, while also turnishingoilto the lubricsting system and torque convarter. Oil flows through B and B', The oilwhich enters through B flows through ths vslve orifice to A, pushingtho regulatorvalve to the right. Accordingto the level ot hydraulicpressurethrough B, the poshion ot the valve changes,and the smount of th oil through B'from D alsochanges. This operationis conttnued,maintaining prossure. line
I{OT RUN II{G) IENGI]TE
GiIGI]TE RUN ING) To TOROUECOIWERTER
To RELIEF VALVE
Stator RoactionHydtaulc P1!ssur6Control Hydraulicprossuroincreaseaccordingto torque is performod by the regulatorvalve using stator torqus reaction.The stator shEft is spllnedin the ststor, and hs arm end contacts the ragulatorspringcap. whn the car is acclerEting climbing(Torque or Converter Range), stator to.que reaction acts on the stator shaft, snd the stator arm pushesthe rgulsto; springcap in the -) direction in proportion to the reaction.The stator roaction spring compressos,and the regulatorvalve movss to increasethe regulated control pressureor line prssure. Line prgssureis maximumwhen the stStor reactionis maximum.
REGULATOR VALVE
STATOR REACTION SPRII{G
REGULATOf, SPRING CAP STATOR SHAFTARM
STATON SHAFT
{cont'd}
14-29
Description
HydraulicControl (cont'd)
Thlottle V8tuo B Throttle vave B converts changesin the throttle openingto changesin transmissionhydraulic pressute.The end ot throttle vave B contscts the throttle cam which is connectedby a cable to the throttle body. The cable pullsthe cam which, in turn, moves the throttle valve B. The throttle valve B-to-camengagementis adiustablefor shitt smoothnessand lock-up.Throttle to valve B controlsthe accumulators, make smooth changesfrom one gearto snother.An assist tunction is used to lessenthe throttle load. ModulEtor Valv6 The modulstorvalve maintainsline pressureJrom the regulator,to the pressureshitt control solnoidvatuesA/B and lock-up accurateshi{t and lock-upcharacteristics. valves A/8, thus maintaining control solenoid 2nd Ollflce Contiol Vslvo For smooth shifting between 2nd and 3rd. the 2nd orifice controlvalve relievesthe 2nd clutch pressure. the the is As 3rd clutch Dressure incressed, 2nd orilice controlvalve movesto uncover the oil port relieving 2nd clutch pressure.
14-30
ComponentLocation
TRAl'ISMISSION CO]\ITROL (TCMI MODULE
BRAKE SWITCH (ECM} ENGINE CONTROI. MODULE

AUTOMATIC TRANSAXLE(A/TI GEARPOSITION SWITCH
LOCK.UP CONTROL SOLENOID VALVE ASSEMBLY
VEHICLE SPEED SENSOR {VSS}
THROTTLE POSITION SENSOR {TPI
COUNTERSHAFT SPEED SENSOR
ENGINE COOLANT TEMPERATURE {ECT}SENSOR MAINSHAFTSPEED SENSOR SHIFTCONTROL SOLENOID VALVE ASSEMBLY
14-31
Circuit Diagram
HOOD FUSE/FELAY UNDER8OX

t l o . 4 t( 1 5 4 i
tlo.32l100Al
No.43ll0A|
423 424 AIO A8
A2O D2 IRAI{SMISSION CONTROL MODULE {TCM} A19 A7 Ar8 A21
A17
A15
At3
All
A/T GEAR POSITIOI'I I DtCAT0R 8LK
G40r
4
G40l
8U(
14-32
SERVICE CHECX I CONNECTOR I
REO/BIX
I sENsoR +iHr*_ SENSOR
THROTTTE ENGINT POSInON CoOtANr
Dl8
A22
D9 013 Otl
Dt6
D6
D7
D5
A25
A26
TRANSMISSION CONTEOL MOOUIE IICM} 017 Dt5 D19 012 A6 A4 A5 A3
wHT/EU(
GRN/BL(
8LU,^TEL
r,oct( uPcoNTRot-sHtFr corTRolSO[TNODVALVE SOI-EI\OID VAI.VE
COUTIIERSHAFI SPEEDSENSOR
MAINSHAFI SPIED SENSOR
A3 A 5
A9 A11 A13A l 5 A 1 7Ar9 421
atr
A4 A6 A8 A ! C
A18 ^ tttta t'ltt ) aa, t

TCMT.nnin.lLocnbns
14-33
Procedures Troubleshooting
When the TCM sensesan abnormslityin the input or output systems, th | D4 lindicator light in the gsugeasseEUlLwillblink. with I jumper wire, the I Da lindicator Whn the Service Check Connector (locatedbehindthe center console)is-E6nnectod TroubleCode (DTC)when the ignitionswitch is turned on' light will blinkthe Diagnostic When the I D;l indicatorlight has beenreported on, connect the two terminalsof the ServiceCheck Connectortogether whh a iumperwire, Thon turn on the ignitionswitch and observethel Da lindicator light.
DATA LI'{K
coNiEcToR t3Pt
GAUOE ASSEMELY
JUiIPER
cAUTlOir:
Do not attadr tha lumper wlre,
3'S,Y,!"3reJl'ii['
short blinks,codes 10 throught 15 8re indicatedby a soriesof longand short blinks. Codes1 throuqh 9 are indicatedby individual the code, Onlong blink equals10 short blinks.Add the long and short blinkstogether to determinethe code. After dstermining Chart on pages1+36 8nd 37. refer to the electricalsystem Symptom-to-Component rhort
n
S.. DTC I Soo DTC 2 s.. DTC '14
L]
rhort
Some PGM-FIproblemswill also make the I D4 lindicator light com on. After repairingthe PGM-FIsyatem, disconnectth tuse/relavbox for more thsn 1Osecondsto reset the TCM memory. CLOCKRADIOfuse (1OA)in th6 under-hood NOTE; . PGM-Fl system muhipon tuel iniectionsystem. The PGM-Flsystsmon this modelis I sequenti8l . Disconnecting CLOCK RADIOfuse also cancelsthe radio antFthett code, preset stations 8nd the clock setting. Get the the customr'scode numbe. and make note oJ the radio presetsbefore removingthe Juseso you can .eset thm.
14-34
CAUTION: . Al SRS electrlcal whlng haro6sres are covorod with yelow outor insuhtlon. . Before dsconnoctlng the SRS wila harnoss, install th lhort connoclor(s)on tho ailbag(s)(so6soction 23 I. . Roplaceiho snllro affectod SRS harness assombly if it ha! sn opon circuit or damagodwlring.
. TCM Roset Procodure 1. Turnthe ignition switchoft. 2. Remove the No. 43 CLOCK RADIO fuse (10A) lrom the under-hood tuse/relaybox tor 10 secondsto reset the TCM. NOTE: Disconnecting No.43 CLOCK RADIOluse aho the cancelsthe radio anti-theft code, Drsetstations and the clock setting. Get the customer's code number 8nd mske note of the rsdio presets befors romoving the fuse so vou can resat them.
CLOCK RADIO FUSE
lf the inspctionfor a particularfailure code requiresthe usa ot Test Harnesa(07LAJ-PT3010A); 1, 2. 3, Removethe right door sill molding,door trim and right side kick psnel(seesection 20). Pullthecsrpetbackto expose TCM. the Connectthe wire harnessto the Test Harness.and/or connect ths Test Harness the TCM according the to to troublshooting lowchart. f NOTE: . OnV the A and D terminalsof the Test Harnessare usedfor A/T troubleshooting. . Unloss otherwise noted, use only the Digital Muhimeter, KS-AHM-32-003, tor testing.
DIGITALMULTIMETER KS-AHM-32-O03
UI{DER-HOOD FUSE/RELAY BOX . FinalProcodure NOTE: This proceduremust be done after any troubleshooting.
l.
Remove the iumper wire from the Ssrvice Chsck Connector. Resetthe TCM. Sst the rsdio preset stations and clock setting.
, o o o o o o o o o o o olio o o o o oo qo o o o o 6to o o o o r o o o ) c
14-35
Chart Symptom-to-Component
Syst Electrical
NumbsroI Da indicatorlight blinkswhile Ssrvice Check Connectoris jumped. I
Da indicator light
Possible Cause
Symptom
Referto page
Blinks
Disconnectedlock-up controi solenoidvafue A connector Shon or open in lock-up control solenoid vafueA wire Faultvlock-uocontrolsolenoidvalve A Disconnectedlock-up control solenoidvafue B connector Short or open in lock-up control solenoid valve B wire Faultylock-upcontrolsolenoidvalve B Disconnectsd throttle position (TP) sensor connector Short or oDenin TP sensorwire FauhvTP sensor Disconnected vehicle speed sensor {VSS) connector Shortor openin VSS wire FauftyVSS Short in A/T 9e8r positionswitch wire FauhyA/T gear poshionswitch
Lock-up clutch does not engage. Lock-up clutch does not disengage. Unstableidlespeed. Lock-up clutch does not engage.
14-38
Blinks
1+39
Blinks or OFF
Lock-up clutch does not engage.
1440
Blinks
1441
Blinks
' Failsto shi{t other than zrde4th gears. ' Lock-up clutch does not engage, Failsto shift other than 2ndo4th ge8rs, Lock-up clutch does not engage. Lock-up clutch sngages ahernateand disengages ' Failsto shitt (between 1 ste4th, 2nde4th or 2 nde3rd gesrsonly). ' Failsto shift (stuck in 4 th gear) ' Failsto shift (stuck in I st or 4th gears).
1442
OFF
geat position switch Diconnected Nf connector Open in A/T gear positionswitch wire FaultyA/T gear positionswitch
1444
Blinks
Disconnectedshift control solenoidvalve A connector Short or open in shift control solenoidvalve A wire valveA Fauhyshift controlsolenoid Disconnectedshift control solenoidvalve B connecror valve B Short or oDBnin shitt control solenoid Fsuhv shift controlsolenoidvalve B
1446
Blinks
14-47
Blinks
Disconnected countershaft speed sensor connector Short or opon in the countershaft speed sensorwir Fauhycountershaftspeedsensor
1+44
14-36
Numberof Dr indicslor light blinkswhile ServiceCheck Connsctoris iumped.
Da indicator light
Possible Csuse
Symptom
Referto pa9e
10
Blinks
Disconnected engine coolsnt temperature (ECT)sensorconnector Short or open in ECTsensorwire FauhvECTsensor Disconnected ignitioncoil connector Short or open in ignitioncoil wire Fauhyignitioncoil
14-50
11
OFF
1+51
't4
OFF
'Short or open in FAS wire be- ' Transmissionjerks hard {ORIVRED} tween the D16 terminaland ECM when shifting. ' Troublein ECM Disconnectedmainsh8ft speed sensor connector Shon or openin mainshatt speed sensor wire Faulty mainshaftsDeed sensor Transmissionjerks hard when shifting.
14-52
OFF
1+U
f the setf-diasnois to L91l indicatoflight does not blink,perform an inspectionaccording the tabtebelow. Symptom Da indicator light does not come on for 2 seconds atter ignhion is first turndon. D4 indicstorlight is on steady,not blinkingwheneverthe ignitionis on. Lock-upclutch does not have duty operation{ON-OFF). Lock-upclutch does not engage. Shift lever cannot be moved from doressed. P Check A/C signal with A/C on. Probable Cause
RBf. page
14-56
1+58 1+59
Dosition with the brake oedal Checkbrakeswitchsignal.
14-60
. It a customer describesthe symptoms f or codes 3, 6, or t t , inaicatorlight is not blinking,it wilt be necessaryto Jeqn" I Oo--l rcrsglg1lie symptom by tost driving,andthen checkingthe I D4 | indic8torlightwith the ignitionstill ON. o lf the aboveor stays lit continuously, TCM is tauhy. the ElJindic$gllight displsyscodesother than those liste-d . Sometimesthe light and the MalfunctionIndicatorLamp (MlL)/CheckEngine light may come on simuhaneously. Lgllind;cator It so, chsck the PGM-FIsystm accordingto the number ot blinkson the MIL/CheckEnginelight. then reset the memorv bv removingthe CLOCK RADIOfuse in the under-hoodfuse/relaybox tor more than 10 seconds.Drive the vehicle for several minutesat speedover 30 mph (50 km/h).rhen recheckthe MIL/CheckEnginetight. NOTE: . PGM-FI svstem The PGM-Fl system on this modelis a sequentiat muhiport fuel iniectionsystem. ' Disconnecting th CLOCK RADIOfuse also cancelsthe radio anti-thett code. preset stations and the clock setting. Get the cuatomer'scode numberand make note of the radiopresetsbefore removingthe fuse so you can reset them.
14-37
Electrical Troubleshooting
Soff-dirgnosis I I,a I indicstor lght blink. onc.-Possib16 Caus6 . Oisconn6ctdlock-up control valv6 A connector solnoid ' Short or open in bck-up controlsolnoidvslv6 A wire ' Fauhylock-upcontrol solenoid
Disconnect the 26 P connector trom the TCM,
NOTE: Vi6w f rom terminalsid6.
Turn the ignitionswhch ON.
Msasure the vohago betw6n th6 AO (RED/WHT) and A25 (BLK/RED) A26 (BRN/BLK) or terminals. Ropairthorl to power rouaca in REDMHT wlro botwo6n tho AO tormln l and the lockuDconlrol lolonold valvo A. Turn the ignitionswitch OFF.
Measure the resistance b6tw6n th A6 (RED/WHT) and A25 (BLK/RED) A26 (BRtl/ or BLKlterminals. Chcck for bo.o TCM cor|r|octorg. It nacollgry, lubrtftute a known-good aolenoid vtlvo assombly o. TCM ond rochock.
ls th6 resistanco 12-24 O ?
Diconn6ct th6 2P connector i.om the lock-up control sob. noidvalve assembv.
Check tor continuity betwon the A6 (BED/WHT) snd A25 GLKiRED)or A26 (BRIVBLK) tgrminsls. Bopah lhort to ground In RED /wHT wire betwoon tho AB tormlml and tho bck-uD control 3olonoldvrlva A. Mgasureth6 resistanceot the solenoid at the 2P connsctor (1+62). Chock for opon In RED/WHT wire between thc A6 tarmlnal and the lock-up control roLnold valve A.
fs the resistanc12-24 A?
Rophce the bck-up cofirol aolonoid vafuo a$ombly.
14- 3 8
Possibls C6use ' Disconn6ctod lock-up control aolono'xtvafu6 B connoctor . Short or oD6n in bck-uD coft trolsolenoidvafueB wko ' Fauhybck-up controlsolonoil vafueB
Diocomect the 26 P conn6cto. f.om the TCM.
Vi6w f rom terminalside.
Meaaur6tho vohago btwoon th6 A4 {WHT/BLK) and A25 (BLK/RED) A26 {BRIVSLK) or terminab. Rapllr ahort to Dowar aolrca In WHT/BLK wlr. b.twoon ths A4 t.rmlnal lnd th. loct. up control roLnold vrlva B. Turn tho ignitionswitch OFF.
6.\ 12-24 Q7 BRN/BLK-r-Y-WHT/BLK I V,, Voh.sa?
Mrsua th6 resistanc6 btweon th A4 {WHT/BLK)and A25 (BLK/REDI A26 lBFl! or BLKltormingls. Chad( tor loota TCM connoctoaa. ll nacaltary, tubttltuta r known-good toLnold vllva .t!.mbly or TCM !nd rachack.
ls th rsistance12-24 Q ?
Disconnctth6 ? connector lrom th lock-up cootrol solonoidvafueassernbv.
Ch6ck for continuity betw6en the A4 (WHT/BLKI 8nd A25 (BLK/RED) A26 {BRI,I/BLK) o. tsrminsb. Rapalr rhort lo ground In WHT/BLX wh. brtw.on thr A4 t.ri| ml rnd lha lock-uo control aoLnold valva B. Me63uretho rosistanceof th6 aolonoidat th6 2P connector t1+6,4. Ch.ck tor oD.n In WHT/BLK wlra baiwaon tho A4 tarmlnal ard th. lock-up control aob" nold v.lv.8.
ls tho rosbtance 12-24 O ?
R.pbc. th. bck-up control rcLnold vtlva r'!an|blv.
(cont'd)
14-39
Electrical Troubleshooting
(cont'd) Flowchart Troubleshooting
S.ltdlomrl! { Xr4| lndlc.tor leht bl|rb thr..-i6.r. Possibh Csus ' Disconnected throttl position {TP}sonsorconnoctor ' Shon or opn in TP sonsor ' FEulty TP sonsor
Turn the ignitiooswitch ON.
Chock whothor tho Malfunction Indicato. Lamp (MlL) blinkslsse soction 111.
ls th6 MIL blinking?
R.p.h th. PGM.FI Sy.t.m {r....ctlon l1}.
Disconnoct th6 26P and 22P connectorstrom th TCM. C o n n o c tt h 6 T 6 s t H a r n e s s "4" arfr "D" connoctora to the wire harno$ onv, not to the TCM 114-3$.
oooooooooooo oooooooooooo
ooooooooooo ooooooooooo 4 . 7 5 - 5 . 2 5V ?
Turn the ignhionswitch ON.
Mosgursths vohsg btwe6n the D1I ard A29A26 torm'F na|s.
ls the vohago4.75-5.25 V?
R.plli op.n or rhort In LT ORiUBLK wl.. b.tw..n th. D I I tcrmlnll aid thc ECM.
Appror.0.5V?
C o n n e c tt h 6 T e s t H a r n e s s "A" snd "0" conn6ctors to tho TCM.
A26
ooooooooooo
ooooooooooo
Turn th ignitionswitch ON,
Moasurotho voltago btwen th6 D7 snd A2tA26 torminal.
ls tho vohagbapprox.O.5V?
R.pdr op.n or thon In RED/ BLK wlrr b.twarn lh. D7 tcrmlnd lnd lha TP $naor.
YES
Chack tor boao TCM connacto.a. ll nacoraary, aubrlhula a known-good TCM lnd mclract.
14-40
Selt-diagnosl. I 04 | Indlcator llght blnk! four tm.,
Possiblo Caus ' Disconnoctod vhicl spood snsor{VSS)congctor . Short or opn in VSS wir6 ' FauhyVSS
R.l.J to S.ctlon 23 tor v.Hcle speed s.nlor (VSSI l.{.
. Mak. ru16 lft!,lrckr, end lrloty stends are plac.d properly (!oo sactlon 11, . Sot tho parklng blaks r.cul.ly lnd block lhc rcer whccb. . Jeck up tho troni ol the clr .nd ruppoit whh srtcty .t!rdr.
Disconnect the 26P and 22 connoctorg trom th6 TCM. C o n n e c tt h s T 6 s t H a r n e s s "4" and "D" connectors to th6 wire harnessonv, not to tho TCM {1+35).
ooooooooooo
ooooooooooo
Turn th6 ignhionswitch ON.
Botate the f.ont wh61 snd check for voltagbotweonthe Dg and A2ryA26 terminats. Block th6 other whe6l so it dos not tum,
Doesth vohageO-12 V spp6arshrnteV?
Chock for lhort or oDon ln ORI{ wh! bglwaln th. Dg tcrmlnll .nd th. VSS. It wl.a lr OK, check rh. VSS (rc. lecllon 23).
Chack to. bosa TCM conrEclor3. lf nceaaary,aubatftuto a known-good TCM tnd .echock.
(cont'd)
1441
Troubleshooting Electrical
(cont'd) Troubleshooting Flowchart
s.fil|lno.lt I D4 | Indcliot |!t'n b&*! tlv!-m.t. Possiblo CauE6 ' Sho.t in A/T g6sr position switch wir6 ' Faulty A/T gsr positioh switch
Turn th6 ignhionswhch ON.
Obsrvetho A/T 906r position indbator, 6nd saloct oach posF tion sopr6aat6ly.
NOTE:
Codg 5 is causod wh6n th TCM rsc6iv6s two gpar position inputs at tho 3ametim6,
Do ony irdicalors tail to lightwhn shiftdthrough sll positionsT
So. A/T g.r po.hlon Indlior l.Epactlon (raa aactlon 23).
Turn tho ignitionswhch OFF.
Connoct the Tost Hamoss btwoon th6 TCM and connoctors {'l+3$.
Turn the ignhionswhch ON.
Bsnery vohaoo? r@l a21 A25 o o ooooooooOo O I O:66irO ooo ooooooo o O:fto:lG6{ticie,Ol ooooooooooooo I oogsgooc,l'g ottgoo I oooooooo ooo 426
Mo.surc tho vohago botwoen tho A21 and A2gA28 termi nals.
ls thre battory voltag?
Chock to. .ho.l ln GRI{/RED wl.. b.tween tho A2l to.irjnrl |nd th. A/T o.!r po.hlon lwhch or A/T gelr po.ltlon Indhlto.. It wlr. l! OK, chack fof bolo TCM connoctorr. ll nacallary. aubtthula a known.goodTCM and rochock.
.-@r A19 A25 Msssure th6 vohag btwoen tho A19 ard A2tA26 tormina|s.
Esttrv voftaoo?
YES
To paga1+43
Chock loJ .hort ln LT GRN wlr. belw..n tho A19 tormlnll rnd th. A/T gelr po.ltlon Indlcltor or . lhort In GRN/IVHT o. GRI{ wlrer b.tw..n th. A/T glr po.ltio.r Indlcltor lnd tho A/T golt pothlon awhch. lf wlia b OK. c$acl tor loora TCM c$nactot!. lf nacoatlry, .ubrtltut. t known-good TCM .nd r.chock.
14-42
Frcm. page 1442
r-@-r
Moasurothe vohsge betwosn the Af7 and A2gA tetminals. A26
Battery vohag6?
ls thore battery vohag?
Chock fo. lhon In GRN/8LKwire betwoon th. Al7 t.rmln.l rnd tho A/T g.ar polition luyitch. lf wiro is OK, chock fo. loolo TCM connoctor!.It noco$ary, 3ubstllutc a known-goodTCM and.ochock.
Masurthe vohage between the A15 and A2tA26 termin6ls.
A26
ls ther6 battory vohago?
Check tor.hort in GRN/BIUwlro botwoon ths A'15 torminal rnd tho A/T gear position switch or A/T g6ai po.hlon indlcator.lf wira ls OK, chock for looso TCM connesto''. It necersa.y, lubatliuto a knowngood TCM and rochock.
Moasurethe vohago btwogn trho A13 and 429A26 t6rminals.
426
ls th6r battery vohage?
Chock tor short in GRN/YEL wire betwoon tho A13 t.rmlnal and the A/T goor posltlon swltch or A/T g.ar porition indlc.tor. lf wl.o b OK, check lo. loor6 TCM connociors, It n6cas3!rv, subatitute a knowngood TCM and recheck.
Moasurethe voltage botwen th6 A11 and A2tA26 termina|s. a26
Check for short in LT GRN/W}|T wiro botw.on the A11 torminrl and the A/T opar polition lwitch or A/T go.i po.hion indicator. lf wi.e i! OK, chack for loose TCM connoctora. lf nocorsa.y. rubrtltuto a known-goodICM and rachock. Ched( tor bo36 TCM connactor!. It necolsa.y, substilute a known-good TCM and rochock.
lcont'd)
1443
Flowchart (cont'd) Troubleshooting
Solf-dlrgno.lr I D4 I Indlcrtor Ight bll.I(. !h tma. PossiblC.uso . Disconnctod A/T gpa. posF tion sw?tchconnector ' Op6n in A/T g6ar position switch wirs ' Faulty A/T 066r position switch
Connoct tho Tgst Hamess btweon th TCM and conn6ctors {1+35}.
Mesurstho vohage btwoen th6 A21 6nd A29A26 terminab.
o o oooo o oo o o o o t:ltoooojs9$:*:occD.gol ooo oo o oo ooo o oo oo o oo o o oo o l,(to.ooogrri6:{lifxl{lotllt:lo oo oooo o oo o
R.pdr opn In GR /RED wlr. batwaan th. A21 tarmlnal lnd th. Al g.!r po.ltlon rwhch.
Mssuroth6 vohag btwo6n the A19 and A2tA26 te.minals.
Rcprlr opln In LT GB wl.. b.two.n th. A19 tormlnC and th. A/T g.!r po.lllon hdlclto..
To psg 1+45
14-44
From p.g6 1/+-44
Voh6g.? Measur6ths vohago botwaon tho A17 dld A2dA26 r6rmF nab.
ooooooooOooo oooooooooooo
R.p!h op.n ln GRN/8L|( wiro b.tw.cn th A17 t.rmln l .nd tho A/T g6a. polhlon .wltch,
Volt.go?
Mo!8uro vohag tho botweon th6 415 ard A2gA26 tsrminab.
Ropll op.n In GRT BLU wlro betw..n thr Al5 t.rmlnll ..rd th. A/Y 96r. l|orhlon !wltch. Vollrg.?
Moasuro the vohago t atweon th A13 sd A2dA28 t6.tr* n6b.
R.pllr op.n In GRT YEL wl.. b.tw.en tno 413 t.rmlnll rnd lh. A/T gar polhlon twltch.
Voh!96?
Meaguretho vohago bgtwoon th6 A11 and A2ryA28 terminab.
R.pllr op.n In LT GRN/WHT wlra b.tw..n tho All t.rmln.l .nd tho A/T gclr poohlon lwhch.
Chact lo. loo.. YCM codr.ctora. lt nacaaaary. lr$atltuta t known-good TCM .nd rochodr.
{cont'dl
1445
Caus Possibl . Disconngctod shilt control vafu6A connector solonoid ' Short or opon in shift control valve A wire solsnoft, ' Fauhy thift control solnoid
ths 26P connsctor Disconnoct trom th6 TCM.
12-24 A? {rslK-l 6\ _ ___r_5_ BLU/YEL BLK/RED
Moasureth6 vohag btwson tho A5 {BLU/YEL} ANd A25 GLK/REo) or A26 (BRII/BLK) t6rminals. Roplir ahon to powai loulca ln BLU/YELwh. botw.en tho A5 tordml ard thc lhlft control loLnold valvc A. Turn tho ignitionswhch OFF,
NOTE:
View from terminals'Nls.
M6aure the resistanco btws6n th AS (BLU/YEL)snd or A25 (BLK/RED) A26 (BRiU BLK)t6rminals. Chock fo. loo.. TCM codr.ctor!. lf naceaaary, rubltlistc ! known-gpod lolonold vllvo lrtambly or TCM rnd iechack.
ls tho resistanc612-24 Q ?
Disconnctth6 3P connoctor trom the shift control solonoid valvs assombv.
Chgck for continuity bstwon th A5 (BLU/YEL}8Nd A25 (BLK/RED) A26 (BR|I/BLK) or t6rminals. Ropllr rhort to g.ound in BLU /YEL wlro botwen tho A5 totrnlnll and th6 lhllt corttol aolenold vllvo A. Measurth resistanc6of tho solgnoid at the 3P connsctor {1+63). Ch.ck tor opon In BLU/YEL wlre botwoon the A5 tormlnal .nd tho rhlfl comrol lolenold valva A.
fs the rsistsnce12-24 Q7
Roolace lho !hlft control sobnoid valvo a!!mblY.
14-46
Self-diagnoli3 | D4 Indlcator light btnkr oight tlm.s,
PossibhCause . Disconnctod shitt control valv6 g connoctor solenoid ' Short or opsn in shift control solnoid valvo B wire ' Fauhy shift control solonoid vslv B
Disconnectth 26P connctor trom the TCM.
Measurethe vohag btween th6 43 (GRN/YEL) snd A25 (BLK/RED) A26 (BRN/BLK) or lermanals. Ropllr rhort to powar tource In GRIIUYEI wlro botw..r th. A3 termln.l and rhlfl coDtrol lolenold vrlvo B. Turn the ignitionswitch OFF.
NOTE:
View from trminalsid6.
Measure th resistance be^ tween the 43 (GRN/YEL) and A25 (BLK/BEO) A26 (BRll/ or BLK)terminals. Chack for bolo TCM conn.cto.r. It noco$ary. lubrtltuto a known-good roLnold valvo !rrembly or TCM ond rachack.
ls th resistsnc612-24 O ?
Disconnsct the 3P connoctor lrom the shift control solonoid vave assembv.
Chsck tor continuity bstwen the 43 (GRi.i/YEL)and 425 (BLK/RED) 426 {BRN/BLK) or t6rmrnals. Rcpalr rhort to g.ound In GRN /YEL wlr. b.twe.n lhe A3 termlnal and the lhift control lolonold valvo B, Measureth6 resistanceof the solenoid th6 3P connctor at (1+63). Chock to. oD.n ln GFTUYEL wl.g botwoon tho A3 tormlnal and the lhlfl conlrol lolonold vllvo B.
ls the rosistance12-24 O ?
Replaca the 3hilt control lolonold valvo a$amblv.
(cont'd)
14-47
S.ltdl.g|lorl! | Da I lrdlcltor lghtbtr*.nln.-il-m... Cause Possibl ' Loose or falhy connoction btweon th TCM and car har_ ness. ' Disconnct6d count6rshatt gpoedsonsoa connoctoa ' Shon or opn in tho count6t_ shaft spedsenaorwire ' Fauhy countorshaft spd sonsot
ls tho coumsGhaft sposd proporv? snsorinstalled
Disconnsct th 2P connoctor Irom tho countrshaft spood sensorconnector,
Moasureth6 rosistancoof th6 countsrshaftsPeeds6nsor.
lsthe rsistance 400- 6@ o ? (at7OoF. 2OoC)

Cootl Disconnecttho 22P connoctor from th TCM. Connoct the "O" connoctoa Tost Hsrn6ss to th wir6 harnossonlY, not to tho TcM {14-3$. lty?
Check for cottinuitY betwoon body ground8nd D17 torminsl and D15 terminalindividuslly. R.o.l. rhort In BLU/GRN or BLU/YEL wlr. b.tw..n D17 lnd Dl5 tcrmlnaL and lh. coumorrhaft apead tdrtor. Roconnct th6 countershoft sp6edsensorconnector.
To pdss1+/{)
14-48
From pag 14-/18
400 -600 0?
l\teaaurc thg roaisttnco botw6n Dl7 E ld Dl5torminah.
b th6 a6!iat6nc6
4@-8(D O? 2OoC) lar 7OoF,
Rapllr boaa tarmlnrl or opan In BLU/GR o. BLU/YELwlr. b.tw...r D17 did D16 farrtnala |r|d tha coumarlhnft apaad lanror.
Chad( for loa. TC co.rrcior. lf r|.c...Jy, rubathul. . lnown-good TCM lnd rachad(.
1449
Solt-diagnoslsI D4 | indicatoi lghl blinks tont-ime.. Possibl Cause ' Disconnacted engine coolant t6mperature (ECT) sensor connector ' Short or op6n in th ECT sensorwire ' FauhyECTsensor
Chock whethor the Malfunc_ tion Indicator Lamp (MlL) blinkslse6 section 11).
Booah lho PGM-FI Syttem l!.o 3oction 111.
Turn the ignitionswhh OFF
Disconnect the 26P and W connectors lrom the TCM. C o n n e c tt h e T e s t H a r n e s s "A" and "O" connoctors lo th wire harnessonly, not to the TCM(14-35).
A?5
Turn tho ignitionswitch ON.
ooooooooooo oooooooo
Measurethe vohage betwoen the 018 ard A2tA26 termina|s. Ropair opon or rhort in LT GRN/BLKwir. botween the O 18 t.rmin6l and tho ECM,
ls the vohag64.75-5.25V?
C o n n 6 c tt h e T 6 s t H a r n e s s ..A,. and ,,D,, connectols to tho TCM.
Start th engino and warm it temperup to normaloprating ature (the radiator fan comes on).
Measurethe voha96 betwoen the D5snd A2ryA26 terminals 'lV? Ropoil opon or short in YEL/ the D5 tor_ BLU wiro botvvsen mlnrl and th6 ECT!on3or.
ls the vohagelssthan
check for loolo TCM connoc_ tor!. ll noce!.s.Y, subatitut6 a lnown-good TCM snd aactEck.
14-50
PorrlbL Caula . Disconn6cted ignition coil connocror . Short o. opon in ionhioncoil Oiaconngct the 26P connector from tho TCM. . F6uhyignhioncoil
Turn ths ignitionswhch ON.
Moasurotho vohago botwoon tho A9 IBLU and A25 (BLK/ RED) or A26 {BRN/BLK) torminab. Viw trom lrminal6id6.
Raprl? opon or .hort ln BLU wh. b.tw.on tho A9te.mlnal lnd tho lgnhloncoll. Chod. fof l@q. YCM conlracto.a. lf naca$lry, tubttltqt. a known.good TCM lnd aachad(.
14-51
s.||d.enodt I D4 | Indlcato. leht bld.. to|rtTi'tlmrt.
PorrlbL cluto
Shortor openin FAS{OBiY wi. RED) Troubl ECM in

n.o!L th. PGM.FI SYltem (r.. !.ctlon 111.
r Make sure llfts, iacks and satety stands 416 placed propsrly, and hoisl blackots aro attachad to the corl6c-t position on tho ongino (seosection 1). . Whlle testing, bo caroful of the lotatlng flont wheels.
15 ths Maltunction hdicator L.mp (MlL)on ?
Start th ongin and wtrm it up to normal operrlino temp6ratuao{tho rsdiator fan comesonl.
Approx.5 v?
swhch OFF. Turn tho ignitfttn
ooooooooooo
oooooooQooo
Connoct th6 Tolt Harnoss botwon th6 TCM tr|d coonector3 (1+351.
Turn the hnition swhch ON a.d wait Ior at l6aat two ggcotxt5.
l\reaaure voh.go tgtweon the the 016 {+) rnd A2gA26(-l torminab.
Ch.d( to. l@a TcM conrrcto.r, ll nacortxy, !t bttitul. ! known-good TCM and rcch.ck. Turn th6 ignitionswitch OFF.
Dkconnoct ths ToEt Haangss from tho TCM. L66ve conn6ct6d lo car n6anoa8.
switch ON. Turn th6 i{tnit'ron
To prg61+lB
14-52
From pag14-52
Msasurgth6 vohago botwoon the D16(+) and A2gA26(-) torminab.
Ch.ck tor bola TCM corr nacto[. lt ]raca$ary, rubtdtut. ! known-good TCM ard rachack. Disconnoctthe 26P connector from th ECM.
Check for continuity btwsn the D18 and A25lA26 torminalsot th Test Harn6ss.
R.o.h .hort ln OR /RED Tcltl {FAS} wh. b.tw..n lnd ECM.
Ch6ck for continuity on tho ORÎ/REO wire botween the D 18 t.min8l on ths TCM snd tho AlStorminalontho ECM.
Ch.d( tor loot! TCtt oo.r nactora. It nacattary. tubttltuto r known-gogd TCM and rcchack. R.p!|. lhoit In OR /REO (FASI wlr. b.tw..n TCM ..d ECM,
(cont'd)
14-53
Po.rlblo C!u!. . Disconnectodmainshaft 9pe6dsonsorconnector . Shon or op6n in mainahaft wilo spdSonsor . F6uhymainshaftsp66d 0nsoa A cod 15 on th TCM doesn't th/vay6msan th6re'e an sl6ctricsl problm in ths main8h.ft or countorahatt sp6d sonsor circlh; code 15 may 8bo indicato 6 problmin th transmbsion. mochanical
NOTE:
Ars th mainshstt and count6rshaft sPsed senaors properly? installd
Disconnectthe 2P connector trom th6 mainshaft spood s6nsor.
Masur6th resistanceof the mainshrft spoodsengor.
4OOls th rssistanc 2OoCl 600 O 7 (6t7OoF,
Disconnectth 22P conn6ctor trom th6 TCM. C o n n 6 c tt h e T o s t H a r n o s s "0" connctor to ths wire harnoss only, not to thg TCM
(1+35).
ooooooooooooo ooooooooooooo
Ch6ck th continuity botwoen D19 and D12 torminalsand body ground. Ropllr lhort In O8N/8LU or WHT/BLU w1..3 b.tw..n D 19 and Dl2 t.lmlnab lnd lhc rmlmhlfl apaed tanaoa. Roconnsct the 2P connoctor apeodsonaor' to th rnsinshdft
To psg 1+55
14-54
From p6ge1+54
D' l I
Measure th resistance between D19 and O12 trminals.
ooooooooooooo ooooooooooooo
ooooooooooo ooooo9ooooo
400-600 0? ls th resistance 4OO600 Q ? lat 70oF.2OoCl Chgck tor corninuity between D19 terminal and the mainshaf sp6edsensor. t
R.palr op.n in ORN/BLUwi.e batwaan D19 t..min!l and tha malnlhatt spcad r.n!or. Ch6ck fo. continuity btw66n O12 terminal and th6 mainshaf spg6dsensor. t
Rep.ir opon In WHT/BLU wlro botwaan D12 tormlnal and tho malnahlft rDoodlanror. Run El.clricsl Troublcrhooting to. codc 9. Ch.ck tor looro TCM cfinecto.. It necsrrlry. rubatltuta ! known-good TCM lnd rochock,
Ch.ck tor loor. TCM cor! nacto6. It nacalatry, aubrtltute t known-good TCM and rachack.
(cont'dl
14-55
Flowchart {cont'd) Troubleshooting
I or I tndicator llght do.t not 6-m. oo with the lgnition ON. lh thouH c!m. on 3vYttch lor gbout 2 aocond!.)
Does tne @
indicator lhhl
Ch.ck lo. bot. TCM connac_ tola, lf nacoraary, aubllltut. r known-good TCM lnd Echrck,
Turn the ignitionswitch OFF
the 26P connector Disconngct {rom the TCM. connect th6 Tst Harn6ss "A" connector to tho wire harnsss only, not to the TCM (1+35).
Cor ollty?
Check for continuity btweon rhe A25 lorminal and bodY ground and 426 and body ground. R.Drl, opon BLK/REDo. BR / BLK wirc. b.tw.!n A25 ot A 20 t.rrnln.lt .nd GI 01 .
vatecr [P oattc,v A23A25
Measurethe vohage betwon th A23 or A24 and A25 or A 26 trmlnals. R.prlr opon o. lhon In BLK/ YEL wlr. botwoon tho A23 andloJ A24 taamlnala and undo?-hoodf uaa/r.ltY box.
ls thers batterYvohag? YES Turn the ignitionswitch OFF. To psge 1+57
14-56
From page1+56
C o n n 6 c tt h e T 6 s t H a r n e s s "A" connsctor to the TCM.
Turn the ignition switch ON. Be sure th6t voltago is availabl6 tor 2 seconds b6tween the Ag terminal and A2gA26 trminal.
oooooooooooo oooQoooooooo A8 Lo-.._----J

Voh!ge?
A25
Chack lor opan or ahort In GRN/OR wlro betwe.n tho AB tormlnsl ond tha gaugo a!!omblv. Turn ths ignitionswhch OFF.
Oisconngct the Tst Hsrness "A" connector from the TCM.
Check ior cominuhy between th6 A8 trminal and rhe GRI/ ORN wiro at the gauge assemDry.
Ropairop.n In GRwOnN wh. betwon the A8 tormlnll .nd tho gaugllrombly.
Chod( for loo6o TCM connoctor!. Ch.ck tho A/T gear po!ftlon awftdr. lf noco3aary, aubstltut. I known-good TCM and rechock.
(cont'd)
14-57
I D4 I Indlc.tor llght It on ;i--adY {not bllnllng} whon.vd th. lgnltlon twttch b oN.
Turn tho ignitionswitch OFF.
oisconhoctths 26P connoctor trom the TCM. C o n n o c tt h o T 6 s t H a r n e s s "A" coonectoa to the wiro harngssonv, not to the TCM. (1+35).
Iurn the ignitiooswitch ON.
Measuroth voltago betwoen th6 A8 torminal and bodY ground.
C o n n 6 c tt h o T o s t H a r n 6 s s "A" connectorto the TCM.
Moasureth vohag6 b6tw69n the GR[{/ORN wir6 at th6 gaug6 assembt and to bodY gaouno.
A8
Volt.gc?
RaDllr rhort to powot toutco oo G8N/ORNwlr. brtweon A 8 tarml[l and lEugp a!!em_ blv.
14-58
l.Ep.ctlon ot rh. A/C tlgnll.
Symptom . Lockrp chnch doos not havo duty opo.dtion(ONe OFFI. . Lock-up chjtch dos not eng6g6.
Tu.n tho bbwer switch ON.
Pu3htho A,/Cswitch ON.
8c. Alr Condhlonlng Inrp.ctlon (... r.cilon 22).
NOTE:
Disconnoctth6 26P connector from th6 TCM.
trom torminalsid.
Measuroths vohag botweon the A22 IRED/BLU)6nd A25 IBLK/RED)or A26 {BRwBLKI tsrminals. {A/C comDaealror OFF)
RED/BLU Eanaryvoltage?
Rcpah open lo RED/BLU wlr. b.tw..n th. A22 t.rmln.l and A/C compr.$or clutch rcLy. 'A/C.ler|llbOK. ' CH( lo. loor. TCM corF .racto.a, It nacaaatay, ar5. .inul. a Lnown-good TCM and rachack. ' lnlD.ct th. .lr cor|dtlonftt (!.. r.ctlon 22,.
(cont'd)
14-59
Svmptom Shift hv6r camot bo mov6d irom E position with tho brako pd6ld6prsssed. Ch6ck that the brak lights come on with the brake Pdal dopressod.
Disconnect the 26P and 22P connectorsfrom the TCM. C o n n e c tt h e T o s t H a r n e s s "A" and "O" connoctors to th6 wil6 harnssonly, not to the TCM (1+35).
Moasuroth6 vohagg betwoon th6 02 and A2tA26 termin3k with the br6ko Podal depresssd.
ooooooooooo
oooooooooo
ris
t_----{}-
D2
Baitery voh.g.?
Rrplh op.n In GRN/WHT wlrc b.lw..n lh. D2 t rmlnd and b]ak. lwhci.
' Br.ko rrvhch tlgnal OK. . Chod( for loot TCM connacto.r. lf nocoltary, tub_ rtltuto a known-good TCM and rcchack. . lnrDoct the brgka twhch circuh {!.a aociion 23}.
14-60
Mainshaft/Gountershaf t SpeedSensors
Replacement
1. Removthe 6 mm bolt f.om th transmissionhousing and remove the mainshaft and countershaft soesd sensors.
6 x 1 . 0m m 12 N.m {1.2 ks-m , g b-tt}
COUNTERSHAFT SPEED SENSOB
o-R[{GS Rplsc6.
6x1.Omm 12 N.m (1.2 ks-m , I lb-ft)
MAINSHAFTSPEED SE SOR
Replacthe O-ringswith a new one before reassemblingthe mainshaftand countershaftspeedsensors.
14-61
ValveA/B Lock-upControlsolenoid
Test
NOTE: vaves A and B must be removed/ Lock-up control solenoid as reDlaced an assembly. 1. 2. Disconnect the connector trom the lock-up control vave A/8. solenoid Measure the resistsnce between the No, 1 terminal (solenoldvalve. A) of the lock-up control solenoid valve connector and body ground, and between the valve B) and body ground. No. 2 terminsl (solenoid 2,
Replacement
1. Remove the mounting bolts and lock-up control valve assembly. solenoid NOTE: Be sure to rmove or replsce the lock-up control vakes A and B 8s an assembly. solenoid Check the tock-up control solenoidvalv oil passages for dust ot din, 8nd replscs 8s sn sssembv, if necessarv. CONTROL LOCK-UP VALVE SOLENOID ASSEMBLY
6r1.0mm 12 N.m {1.2 kem , 9 lb-ft)
STANDARD: 12- 24Q
CONTROL LOCK-UP VALVE SOLENOID ASSEMBLY
Cloanth mountingaurface andoil passag68.
FILTER/GASKET Roplac6.
the ReDlace lock-uDcontrol solanoidvatue assemblyil the resistanceis out of specification. lf the resistanceis within the standard, connect the No. 1 terminal of the lock-up control solenoid valve connector to the batterv positive terminsl' A clicking sound shouldbe he8rd. Connect th No. 2 terminsl to the battery positive terminsl. A clicking sound should be heard. Replacethe lock-up control solenoidvave assemblyif no clickingsound is heard'
Clean the mounting surface and oil psssgesof the klck-up control solenoidvslve assembly,8nd install I new tilter/gasket. Check the connector for rust, dirt or oil, and raconnect it securely.
14-62
Valve A/B Shift ControlSolenoid

Replacement
NOTE: Shift control solenoidvalves A and B must be removd/ reolacedas an assemblv. 1. 2. Disconnect the connector from the shiJt control solenoid vave A/8. Masurethe resistance between the No. 1 terminal (solenoidvalve A) of the shitt control solenoidvalve connactor and body ground, snd between the No. 2 terminal(solenoid valve B) and body ground. 2. 1. Removethe mounting bohs and shift control solenoid vafueassamblv. NOTE: Be sure to remove or replacethe shift control solenoid valvesA and B as an assembly. Check the shift control solenoidvatue oil passages for dust or dirt, and replaceas an assembly, necesssry. if
6x1.Omm 12 N.m11.2kg"m, 9 lb-ft)
STANDARD: 12- 24Q
Cl6anthe mountingsurfac6 and oilpassgBs. FILTER/GASKET sHtFT COI{fROL R6placs.
SOLENOID VALVE ASSEMBLY
3.
Clean the mounting su ace and oil passagesof the shift control solenoidvalve assembly, and installa new fiher/gasket, Chsck the connector for rust, dirt or oil, and reconnect it securely.
4. Replacethe shfft control solenoid valve assembtyif th rsistanceis out of soecification. lf the resistsnce is within the standard, connsct the No. 1 terminal of the shift control solenoid valve connector to the battery positive terminsl. A clicking sound shouldbe heard.Connect the No, 2 terminalto the battery poshive terminsl. A clicking sound should be he8rd. Replace the shiJt control solenoid valve assemblyif no clickingsound is hesrd,
14-63
Chart Symptom-to-Component
HydraulicSystem
SYMPTOM
Emine runs, but.car oasnot move m anYgaar. "8" and "2" but not in "Dg" "D+" or "1" Car movos in , , oosition. "Ds" "D1" "1" "R" but not in "2" Car moves n , , , , Dosition. "'1" but not in "R" "Ds" "Dt" "2' Car moves in . , , , Dosition. ''Dosition. C8r moves in "N Excessiveidlevi )rauon. liosin 8 oaars. "1" No enqinebrakinqin Dosition. os in 1st oe8r, rs in 2nd qear. rs in 3rd gear, lios in 4t n oear SliDsin reversegsar. Flsres on uos Flares 2-3 uDs t . on Flares 3- uos on stays in 1st gear. No upshift; transmission No downs ift to lst qeat h Late upshift. Erraticshittins. Harshshi t {uDand down s tnHar Checktheso items on ths CAUSEList PROBABLE Check these items on th8 NOTESList
a,8,44,4a 9, 30,49 ,22, 34,34,39,&

.4
c,M,o
C,L
K, , . R , S
t 12Har t(3 Harshkick-dowr h kick-down shi 8t closedtl Harshdowns ngto "1" Dosition. s Har h shift when manuallv on Axle s) slipsout of transmission turns. Axle sl stuck in transmission. "R" position. ns noisewhn shifting into Ratc "R posrtion. Loud ooooinono sewhen takins off in "R" to "P" positionor noisewh8n shifting from Ratcheting from "R" to "N" oosition. in Noisefrom transmission all selectorlver positions, on Noise{rom transmission v when wheeF are rollrnq. Gesr whine, rom relsted (Ditchchanseswith shi tanges wnn spee( 16 Goarwhine.sDeed "D4" w to 4th qesr in Dosition, Transmission nor s lock-upsmool .ock-uoclutch does not .ock-uD clutc r does not oDerateDroDel has Transmission multitudeof problemsshifting. At disassmbly,large particlss ot metsl are found on maqnet.
i.H
38,39,40, 45
.4i ,41 7
L,O
43
L,O
14-64
PROBABLE CAUSE 2.
4. Shift cablebroken/out of adiustment Throttls cabletoo short. Throttls cabletoo lono. Wronq tvoe ATF. e rDmtoo low/hish. il oumDworn or bindino. ressurerequlatorstuck, st clutch defective. nd clutch defective, 3rd clutch defective. clutch defective. st-holdclutch d6fectivs. Mainshatt,countsrshatt,and scondarvshatt idlsrq6arsworrvdsmaosd. Modulatorvalve stuck. e vafueB stuc TF strainercloqoed. oroue converter defective. oroue convgrter check valvs stuck,
- 2 shift vefue stuck-
5.
7.
e
2i
shift valve stuck. shift valve stuck. orvo control vSlvestuck. ftch oressurecontrol (CPC) valve stuck. 2nd oritice controlvalve stuck. Ori{icecontrol valve stuck,
3-2 kickdown velve stuck.
3i 35.
2A
37. 38. 39.

4 4 4i 4 47.
t.
3rd kick-down valve stuck. 4th exhaustvalve stuck. st accumulator dafectivs. nd accumulator defective. 3rd accumulatordefective. 4th accumuletor defective, st-holdaccumulator detective. ervo vave stuck. ock-uo timinq valve stuck. ock-uo shit'tvalve stuck ock-uo control valvs stuck. Shift tork bent. qearsworn/damaoed qsars}. Reverae {3 versesebctot worn. (2qesrs). rd q6arsworn/damaqed (2 inaloearsworn/damaqed osars). DitferentialDinion shaft worn. esdoiDe O-rinqbroken, r searsworn/damased(2ssars). eat clarance incorgct. Clutch clssranceincorrect. ne-way (soraq) clutch dsJective. worn. ealinqrinqs/quide Axl-inboard ioint clip missino.
14-65
Ghart Symptom-to-Gomponent
HydraulicSystem (cont'dl
The followingsymptoms can be caused by improperrpairor assembly. )ar creeosin N Dosition. "D3" or "D4" position. )ar dos not move in ransmission locks uD in "R" position. (cgssivedraqin transmission, ve vibration,rom r Noisewith wheels movinoor
n aeal DoDsout.
thssitemson th6 Check PROBABLE CAUSE DUE To IMPROPER REPAIR List
hsms on th6 NOTESList
ariousshiftins problems. HarshuDshifts.
PROBABLE DUE IMPROPER TO REPAIR CAUSE
14-66
NOTES A.
R
D,
procedure, Seeflushinq Daqe 1+142snd 143. Sst idle rpm in gear to specitiedidle speed.lf stillno good, adjust rnotor mounta as outlinsd in enginesection ol service manuel. lf th l8roeclutch oiston O-rinois broken,insoactthe Distonqroovefor rouqh machininq. It the cfutch psck is seizedor is exceasivelyworn, inspect the othr clutchgstor wear, and chsck th6 orifice controlvefuesand throttle valves for free movemnt. lf throttle valve B is stuck. insoectthe clutchesfor wear. lf the I - 2 shift v8lve is stuck closed,th6 transmission will not upshift. lf stuck open, the transmission has no
lst oaer.
K.
th 2nd orifice controlvalve is stuck, insDectthe 2nd and 3rd clutch oscks tor wear. th oaificecontrol valve is stuck. insDecttho 3rd 8nd 4th clutch Dscksfor wear. the clutch oressurecontrolvalve is stuck closed.th trsnsmissionwill not shift out of lst qe8r. lmpropor alignmentor main vav body snd torqus convrtr ho$ing may causo oil pump seizure.The
svmbtoms er6 mostlv en rom-rdletgd tickino noise or d hioh-Ditchod sdueek-
M.
N.
o.
R.
s.
r.
U.
tf the ATF strainer is clogedwith particlesol steelor aluminum,inspoct the oil pump 8nd diff6rentialpinion sheft- lf both 616OK snd no caus6lor the conteminetionis {ound. roolecethe tordua convertor. lf th lst clutch feedpipe guide in the right sida cover i8 scorod by the secondaryshaft, inspct tho ball be8ring xc6ssiv6mov6m6ntin tho transmission lor housing,lf OK, roplacoth6 right sid6cov6r as it is dsntad. Th O-rinoundrtho ouideis Drobablv wo.n. the Replaco mainshaftiJ the bushingfor th 4th feedpipeis looseor dsmagd. lf th6 4th {eedpipeis dsmsgedor out of round, roplacsit. Bsplsceth countershaftif the bushingfor the 1st-hoHfgedpipeis loossor dsmsged. lf th 1si-hoHfeedpipeis damaged out of round,replach. or Rsplace the secondaryshaft it the bushingfor the 1st feodpipeis looseor damgod. lf the 1st f66doiDe damaodd out of round.rsDlacsh. is or A worn or damagad spragclutch is mostly a result oJ shitting the transmissionin "D3" or "D4" posrtionwhile the wheels rotato in aoverse. such as rockinothe caain snow. nsDectthe frame tor collisiondamase. Inspectlor damage wear: or 1. Reverseselectorgearteeth chamfers, teeth chamfersof countershatt4th snd revsrsegar, 2. Engsgement 3. Shift fork for scuff marks in center. 4. Differentialpinionshatt lor wear under piniongears. 5. Bottomof 1st-hold clutchfor swirlmsrks. Replace items 1, 2, 3 and 4 it worn or damaged. transmissionmskes clicking,grindingor whirring noise,also lf replacemsinshaft4th gear and reverseidlergear andcountershsft 4th gear in additionto 1, 2, 3 or 4, lf differential pinion shaft is worn, overhaul differentialssembly,and replsceATF strain6r,and thoroughly flush torque convartsr, cooler and lines. cleantransmission, lf bottom oJ 1st-holdclutch is swirled and transmissionmakes gear noise, replaceth countershaft and tinal driven oeer86 very careful not to damagethe torque converter housingwhen replaclngth main bsll besring.You may also damagethe oil pump when you torque down the main valve body. This will resuh in oil pump seizureif not detected.[Jseorooertools. Installthe main s6alflush with the torque converter housing.lf you push it into the torqus converter housing until it bottoms out. h willblock the oil return Dassaoe resuftin damaoe. and Harsh downshifts when coasting to a stop with zero throttle may be cauaed by a bent-in throttlo valve retainer/camstooDer.Throttle cablesdiustmentmav clearthis Droblm. th check vave may have been pushed Check if servo vatue stopper cap is installed.lf it was not installod, out bv hvdraulicoressurecausinoa leak (internal) atfectinq sllforward qears. Throttle cable adjustmentis essentialfor proper operation of the transmission.Not only does it sffect the but shift points if misadjusted, alsothe shift qualityand lock-upclutch operation. A cable adjustedtoo long will resuh in th.ottle pressureb6ingtoo low for th6 amount of enginetorque input into the trsnsmissionand m8y causeclutch slippage. cablesdjustedtoo short will resuttin too highthrottle A oressurewhich mav causeharshshitts, erratic shitts andtorque conveter hunting,
14-67
RoadTest
NOTE: Warm up the enginsto normsloporatingtemperature(the radiatortsn comes on). position while 1. AppV parking brake 8nd block th wheels. Start the engine, thon mov the selector lever to @] shouldnot stall. it th depressing brak6 pedal.Dopressthe accelaratorpedaland release suddenly.Engine test in I D3 l poshion 2. Repeetsame tol 3. ShiJtthe selectorlev-er Dn-lpositionand check that the shiJ'tpoints occur at approximatsspeedsshown. Also check slippage. and clut-ch for abnormalnoise NOTE: Throttle positionsnsorvoltagBtepresentsth throttls opening. - 1. -2. Connectthe Test Harnessbetween the ECMand connector (seesection 11l' Set the digital multimstr to check voltage betwen Dl1 (+) terminal and D22 {-) trminal for the throttle posiiionaenaor.
CAUTION: . Al SRS oloctrlcal wldng harnot3as aro covolad whh yelow outor Inrulatlon. . Bololo dsconnecllng tho SRSwlro herna$, Installtho short connoctor{ll on tho !lrb.g(!}. . Replac6tho or|tlle sffocted SRS hlrnoss ass.mblY if h has an opon chcuh or damrgod wlring.
SRS MAI'{ HARI{ESS
MULTIMETER DIGITAL KS_AHM_32
14-68
F22Al Engln.:l Da I Polhlor 1st+2nd Throttlo polhlon lorEor voltago: 2ndJ3rd Lock"up Cinchof'l
o.83V
mph km/h mph km/h mph km/h
13- 15
26-24
42-45 37 -4'l 60-66
36-40
58- 64 57-63
l4-17
Coaatlngdown-hll from a stop
21-24
17- 2'l
23-27
6 1- 6 7
Throttlcporhlonlomor vohago: 2.'t8V Accobratlon from a stop

Fu[throttlo AcceLrltlon from a stop Dowruhltt Throftlo porhlon sg]lor voltego:
27-34 E-34 47 -55

Lock-up Clutch oFF
92-101 88- 94 142-'151

3rdJ2nd 18-22l4tHld) E-35{4thrhdl
98- 108
8t -86
60-65 97- 105

4thJ3rd
130-138
2nd-+ l st 6- 10
o.83V Corstlng braklng ! stop or to
mph
13- 16 2't-26 53- 59 &5-95 77-82 124-132 76-42 123-132
km/h
mph km/h mph
10-16
Throttb po3ltlon lsmor Yoftago: 2.18V When car is sbwed by increr3od grldo, wlnd, oic. Fd-throttlo When car lr tbwed grada,wlnd, etc. by Increased
52-
al
2'l -26 34- 42
km/h
u-92
{cont'd)
14-69
RoadTest
(cont'd)
H23Al Engine: Da I Position I 'Upshift lst-2nd mph km/h mph km/h mph km/h 2nd--r3rd 3rd -,4th Lock-up Clutch 0N 14-'17
Throttleposition sonsolvohago: o.83V from a stop Coasting down-hlll Thlottls position sensor vohago: 2.18V from I stop Accaloration
Full-throttle Accelerationtrom a stop .Downshift
13-15
26-A
42*45
36-40
58- 64
23-27
58- 64
1A-22 29-35 E-34

47-55 Lock-uD oFF Clutch
36-40 58- 64 57-62 92- 100

4th-J3rd
54-60
87 -97
93- 103
&l-88
134-142 3rdJ2nd 18- 22(4thJzd) 29-35{4th+hd}
s-85
l?9-137 2nd+lst
Thlottleposition sensolvoltago: 0.83V

Coasling 01 blaking to a stop
mph km/h mph km/h mph km/h
13- 16
6- 10 10-16
21-26
48-5/. 77-47
Throttle position 3onsorvohage: 2.18V wh6n car is slowed by incleased grado,wind. otc. Full-throttlo When car is slowed by Incroased grade,wind, etc. 4.
73-& 117-lE
73-79
117 127
51-56 82- 90
24-A 39- 47
Accelersteto about 35 mph(57km/h) so the transmisionis in 4th, then shift lE+-Jpositionto f Z-l position.The car should immediately boginslowingdown from enginebraking, GAUTION:
the transmission.
you over to at DonotshifrtromIoi lor lE-l position E-lor F-l posltlon sposds 63 mph(1ookm/h]; meydamaso in and clutch slippage the following positions. Check lor abnormalnoise
5.
L! ] {lst Gear)Position -1. Accelerate or trom a stop t lullthrottle.Checkthat theris no abnormalnoise clutchslippago. - 2. Upshiftsshouldnot occur with the selectorin this position. [7 (2ndcear) Position - 1. Acceleratefrom I stop at tull throttle. Checkthat there is no abnormal noiseor clutch slippage. - 2. Upshiftsand downshifts shouldnot occur with the selectorin this position, T-:-1,tl |lr|eversel rostuon A.ccelerste from 8 stop at fullthrottle, and check to. abnormslnoiseand clutch slipp8ge. 6. Test in I P I lParkino) Position Release brake;the car should the Parkcar on slope(approx.16o),sppv the parking brake,and shift intoI P I position. not move.
14-70
StallSpeed
Test
CAUTION: . To provont tlansmissiondamago,do not t6st stall spoodfor mors than 1Olocond! at r tlma, . Do not shlft tho lovel whlle lalsing tha enginespeed. . 86 suro lo romovo the prossuregaugobefolo testlng stal spood. 1. 2, 3. 4. parkingbrakeand block the front wheels. Engge Connecttachometer.and sta.t the engine. Makesurethe A/C switchis OFF. After the enginehas warmed up to normaloperatingtempersture (the rad;8tortan comeson), shift into @ Ooshion.
and for and sped, 5. Fully depress brakepedal accelerator 6 to 8 seconds, noteengins the for thenrepeat test inloil, [Tl , ana[_] oositions. the 6. Allow2 minutes coolins, NOTE: . St8llspeed restsshould used diasfEtiplqrpossonly. be lor . Stall in speed should the same L91l , L?l , L1l andL!_l positions. be
Stall SoeedRPM: F22Al Engin Spoclficatlon: Sarvice Limit: H23Al Engino Spcification: Service Limit:
2,500rpm 23&-2,6fu
rpm
2,7@rpm 2,60O-2,90O rpm
TROUBLE
PROBAELE CAUSE
Low fluidleveloroil pumpoutput Clogged ATF strsiner Pressurergulstolvafuestuck clossd Slipping clutch Slippage 4th clutch ol Slippage 2nd clutch of Slippage 1st clutch or lst gesr one-wayclutch of Engine output low Torque converter one-way clutch slipping
starlrpm i" F;] ,E .E -o E hish posruons
Stallrom hiohin @ nosition
Stall rom hiehin@ and@ oositions Stall rpmhish E position in
stallrpm i" [D;l .E low

positions
,f
a.a@
14-71
FluidLevel
Checking/Changing
Chocklng NOTE: Chsck ths fluid lvsl with th6 6ngin6 at normal opsrstingtemperaturs (th rsdistorf8n comes on). 1. 2. 3. Psrk the car on lv6lground,Turn oft th 6ngin6. Remov6 ths dipstick {yellow loop) from th transmission, and wipe it with a cls8ncloth. 2 Insertths diDstickinto th trsnsmission, DIPSTICK LOOPI {YELLOW Roinstsllths drain plug with a nsw saling wsshr; to thon rsfill ths tranamisaion the uDDermark on th dipstick. Automatlc Tranlmllllon FhrldCapachy: at chsngins 2.4 t (2.5 US qt , 2.1 lmp qt) at ovsrhaul 6.0 e (6.3 US $ , 5.3 lmp qt) NOTE: lf 8 coolr flushar is to be usad, sa6 paee 14-142 and 143. ChEnglng 1. Bring the trsnsmission up to normal oprating tampsrature lths radistorf8n coms on) by drivingthe car. P6rk ths car on l6vel ground,turn the 6ngin6olf, andthn romovothe drain plug.
Romoveths dipstick and ch6ck ths fluid bvel. lt shouH be bstw66n th6 uDDer and lowgr marks. DRAI'{PLT'G 18r 1.5rnm 50 N.m(5O ks-m , 36 lb-tt)
DIPSTICK
I A
Ell-
UPPER LOWER
lf the lvel is below the lower mark, add lluid into tho tub to bringh to the upper mark. Use HondsPremium Formula Automstic Transmission Fluid or an equivalentDEXROIIall Automstic TrsnsmissionFluid (ATF)only. hsert th dipstick bsck into th6 transmission.
14-72
I
. Whlle t$tlng, bs careful of ths rotallng tront whoob, . Mak6 suro tfts, lackr. End safoiy stands aro phccd proparly(3oosoctlon 1l. CAUTION: . Botora toltlng, bo surc tho tra]lmirlion fluld lr flled to tho plopol loval. . Wsrm up tha onglnebtoro toltlng. 1. 2. 3. Raise car.{seesection1). the Warm up the engine, thon stop ths sngine End connect a tachometer. Connect the oil pressuregaugeto esch insp6ction hole. TOROUE: 18 N.m (1.8 kg-m, 13 lb-ft)
4.
Stsrt the engins, and msasurs ths rospoctivs Drssuro follows: as ' LinePr6ssuro . Throttl B Prossur . Clutch Pr6ssur6 ' Clutch Low/High Prassurs Instsll a new waahsr and the sesling boh in th6 inspectionhols, andtighton to th6 sp6cifi6dtorqus. TOROUE: 18 N.m (1.8 kgm , 13 lb-ft)
NOTE: Do not rsuse old aluminumwashers.
CAUTION: Connect tho oll prssuragaugo 3ecuroly;be rure noi to allow dust and other folelgn partlcl$ to ent.l th lmpoctlon hol.
A/T OILPRESSURE GAUGE SET 07406- 0020003
A/T OILPRESSURE HOSE 07406- 0020201
A/f LOW PRESSURE GAUGE
07408-OO7o(xXr
(cont'd)
14-73
Testing Pressure
(cont'd)
. Llno Prcrluro Maalurcmcnt - 1. -2. - 3. Set the psrkingbrake 8nd block both rear wheels securely. RunthE 6ngineat 2,000 rpm. Shift ths s6l6ct l6v6r to N or E position .
NOTE: prossures boindicEted measurements made solctor positions in othrthanLryl orLll position, Highsr msy it ar
-4, M8sursline pressur.
PRESSURE LINE I SPECTION HOLE F22A1 Engin PRESSURE Line
SELECTOR POSITtON
FLUID PRESSURE
SYMPTOM No (or low) line pressure
PROEABLE CAUSE
Standard Scrvlcc Llmh Torqu6conv6rt6r, oil pump, prossurs regulator, torque converter check valve
E*E
&O- 85O kP8 750 kPa(7.5 ks/cm,, (8.O-8.5 ks/cm' , 107 psi) 1 1 4 - 1 2 1p s i )
H23A1 Englno
PRESSURE
Ltne
SELECTOR POST|oN
FLUIDPRESSURE
SYMPTOM
No (or low) line pressu,e
PROBAELE CAUSE
Stand!rd
Scrvlco Llmh
Eo'E
Torqueconverter, oil pump, pressure regulator, torqug convertr check vatve
85O-9OOkPa &O kPa(8.Oks/cm,, (8.5-9.O ks/cm, , '114psi) 1 2 1 - 1 2 8p s i )
14-74
. Thlotllo I ProssulMoasurement - 1. Set the parkingbrakesecurelyand block the wheels. -2, -3. Runthe ongine8t 1,00Orpm. Disconnectthe throttle control cable lrom the throttle control lev6r and set the throttle control lver in full throttle position. THROTTLE PRESSURC B INSPECTIOI{ HOLE
THROTTLE COiTTROL CABLE
THROTTLE COiITROL LEVER F22Al Englno
PRESSURE
Throttle B
SELECTOR POStTtot{
FLUIDPRESSURE
SYMPTOM Prssure too hish
PROBABLE CAUSE
Standard SorvlceLlmlt Throttls VElveB 0 kP8 (O kgy'cm', 0.0 psi) throttle lver tullyclosod kPa &0-850 18.0-8.5 ke/cnt' , 114-121 psi) throttl lever fullyopensd 75O kPa (7.5 kg/cm, , 1O7 psi) throttle lever fullyopeneo
No or low pressure
H23A1 Engine PRESSURE Throttle B SELECTOR POSITtON FLUIDPRESSURE
SYMPTOM
Pressure too high
CAUSE PROBABLE
Standard SorvlcoLimh Throttl Vslve B 0 kP8 (0 ks/cm' , O.O psi) throttle lever fulvclosd 85O- 9OO k P8 (8.5-9.0 kdcnP . 121- 128 psi) throttle leve. fullyopen6d SO kPa {8.0 ksr'crn,. 114 psi) throttle lever fullyopened {cont'dl
No or low pressure
14-75.
Testing Pressure
(cont'dl
. Clutch PressuloMeaaurmant
@
Whila t$ting, bo ca.fulof tho totatlng front wheals. -'1. -2. -3. -4, -5. brskeandblockboth rearwheelssecurely. Set the parking Raisethe front of the car and support h whh salety stands. Allow the Jront wheelsto rotate freely, Runthe engineat 2,0OO rpm. Measure eachclutchpressure.
PRESSURE lST CLUTCH INSPECTION HOLE
PRESSURE 2NDCLUTCH II{SPECTION HOLE
lST-HOLD CLUTCHPRESSURE INSPECTION HOLE
PRESSURE 4TH CLUTCH II{SPECTK)]T HOLE
PFESSUBE 3RDCLUTCH INSPECTIOI{ HOLE
CENNEB BEAM
14-76
F22Al Englno
SELECTOR PRESSURE POSITtON

1st Clutch 1st-hold Clutch 2nd Clutch 2nd Clutch
SYMPTOM No or low lst pressure No or low lsthold pressure No or low 2nd pressure No or low 2nd pressure No or low 3rd pressure llo or low 4th pressur
PROBABLE CAUSE
Standard lst Clutch 1st-holdClutch 2nd Clutch 2nd Clutch SO-85O kPa {8.0-8.5 kgy'cm', 114-121 psi)
FLUID PRESSUBE
Servic6 Limit 75O kPa (7.5 ks/cm, . 1O7 psil
E",F;]
tr
tr;-] L1l
3rd Clutch
3rd Clutch
4th Clutch
4th Clutch
5OOkPa (5.0 kg/cm, , 71 psi) (Throttlelsvr fully closedl 85O kPa (8.5 kg/cm, , 121 psi) {Throttlelever more than 3/16 oDened) 53O kPa {5.3 kg,icm,, 75 psi) (Throttlelever fully closd) 85O kPa (8.5 ks/cm, , '121psi) (Throttlelever more than 3/16 ooen6d)
gJO-a5O kP8 lE.O-8.5 kg/cm, , 114-121 psi)
tr
H23Al Englne SELECTOR PRESSURE POSITrON lst Clutch 1st-hold Clutch 2nd Clutch 2nd Clutch
Servo Vslve or 4th Clutch
450 kPa (4.5 kg/cm, , 64 psi) (Throttlelver fully closedl 75O kPa (7.5 ks/cm' . 107 psil (Throttlelsver more than 3/16 oDenedl 4$ kPa 14.8 kg/cm, , 68 psi) (Throttle levor fully closed) 75O kPa {7.5 kg/cm, , 107 psil (Throttle lever more thsn 3/16 oDnedl 75O kP8 (7.5 kg,/cm', 107 psi)
SYMPTOM
No or low 1st pressure No or low lsthold pressure No or low 2nd prsssure No or low Zrd pressure No or low 3rd prssure No or low 4th pressure
PROBABLE CAUSE
Standrrd 1st Clutch 1st-holdCluich 2nd Clutch 2nd Clutch
FLUID PBESSURE
Sorvico Limlt
E-[5.']
tr
tr;-l
85O 9OO k Pa (8.5-9.0 ks/cmz , 1 2 1 - 1 2 8p s i )
&O kPa{8.0 ks/cm' , l14 psi)
IA
r=---l l u 4I
3rd Clutch
3rd Clutch
4th Clutch
4th Clutch
SrvoValve or 4th Clutch
50O kPa (5.O kslcm, , 71 psil (Throttle lever fully closed) 90O kPa (9.0 kg/cm' . 128 psil (Throttle lover more than 3/16 oDencdl 53O kPa (5.3 ks/cm, , 75 psi) (Throttlelever fully closed) 9OO kPa (9.O kg/cm, , 128 psi) (Th.ottle lever more than 3/16 ooened) 8S-9OO kPa (8.5-9.0 ks/cm' , 121-128 psi)
45O kP8 (4.5 ks,/cm' , 64 psi) (Throttlelever tully closed) 800 kPa (8.0 kgy'cm,, 114 psi) {Throttlo lever more than 3/16 ooened) 4m kPa (4.8 ks,/cm' , 68 psi) (Throttle lever fully closed) 80O kPa (8.0 kg/cm, , 114 psi) (Throttlelever more than 3/16 ooened) DO kPa (8O ks/cm' , 1'14 psi)
14-77
Pressure Testing
(cont'd)
. Low/Hlgh ProssuroTost -1, -2. -3. -4. Set the psrkingbrake and block the rear wheels securety. Raisethe car and support with satety stands. pressure Attach the gaugeset to the approp.iate inspectionholes. Remove the throttle control cable end of the throttle control lever, NOTE: Do not loosen the locknuts; simply unhook the throttle control cableend. THROTTLE TROL CO CABLE LOCKNUT -8. With the enginidling,lift the throttle control l6vr up approximately 1/2 of its possible travel and increasethe engine.pm until pressureis indicated on the appropriate gaug. Record th8 highest pressurereading obtained.
THROTTLE CONTROL LEVER THROTTLE COIVTNOL LEVER -9. -5. Warm up the engine to normal operating temperature(the radiatorfan comeson). Repe8tsteps -7. and -8. tor each clutch pressure beinginspectd.
E
-7.
with the engineidling,move the slector leverto

position.
Slowly move the throttle linkageto increasesngin rpm until pressure is indicated on the appropriate gauge. Then releasethe throttle linksge,sllowingthe engineto return to an idle. and record the pressure reading.
THROTTLE LINKAGE
14-78
CE TERBEA]II
Englno
PRESSURE
2nd Clutch 3rd Clutch
SELECTOR POSITtON
FLUID PRESSURE SYMPTOM

No or low 2nd pressure No or low 3rd pressure
DD'IEADI E 'TA I ICE
Standard
SorYiceLlmlt 45O kPa {4.5 ks/cm, , 64 psil lever fullycbsed) {Throftle 75O kPa (7.5 kg/cm, , 107 psi) (Throttlelever more than 3/16 opend) 4& kP8 {4.8 ks/cm, , 68 psi) lever fulv closed} {Throttle 75O kPa (7.5 ks/cm, , 107 psil (Throttle lever more than 3/16 opened)
L9!
2nd Clutch 3rd Clutch
5OO- 85O kPa lc.u-5,9 Kg/cm' , 71-121 psi) vsries with throttle lever opning
4th Clutch
No or low 4th pressure
4th Clutch
53O-850 kPa (5.3-8.5 ksy'cm, , 75-121 psi) varies with throttle lever opening
Engino PRESSURE 2nd Clutch 3rd Clutch SELECTOR POSITtON FLUIDPRESSURE SYMPTOM No or low 2nd pressure No or low 3rd pressure
PROBABLE CAUSE
StEndard Sorvlce Llmit 45O kPa (4.5 ks/cm, , 64 psil lever fullycbsed) {Throttle &O kPa (8.O kg/cm, , 114 psi) (Thfottle lever more than 3/16 opened) 48O kPa {4.8 kg/cm, , 68 psil lever fulv cbsd) {Throftle 8OO kPa (8.O kg/cm2, 114 psi) (Throttle lever more than 3/16 opened) 2nd Clutch 3rd Clutch 50O- 9OO kPa (5.0-9.O ksy'cm, , 71- 128 ps') varieswith throttle leveropening
4th Clutch
No or low 4th pressure
4th Clutch
53O- 90O kPa (5.3-9.O ksy'cm' , 75-128 psi) varieswith throttle lever opening
14-79
Transmission
Removal
t.
Disconnectthe battery negative (-) 8nd positive {+) cablesfrom the battery. Remov the battery set pl8te, then remove the battery.
. Make Eu16ltfts. iacks and safoty stands aro placed properv, 8nd hoist brackots ato attachod to the corroct positlon on th6 6n9lne(360soctlon 1). . Apply psrklng brak6 and Hock roar wheols, so car will not roll otf stands and ta[ on you while worklng und6r h. CAUTION: Uso fnder covols to avold damagingpaintodsurfacs. CAUTION: . A[ SRS olsctrical wi]ing halnossas are covetd whh yellow outor insulation. . Bofore dlsconncting the SRS wlro harnoss, install tho short connoclor (3)on the slrbag ls). . Reolacotho entlre affocted SRS ham$s assemHy if it has an open circuit or damagedwirlng. NOTE: The radio mav have I codd theft protection circuit. Be sure to get the customer'scode numberbefole. - Disconnecting battery. the - Removing No.43 (10 Alfuse. the fuse/relayboxl {ln the under-hood - Removing radio, the AJter service, reconnect power to the r8dio and turn it on. "CODE" is displsyed, enter the When th word customer's Sdigh code to restore radiooperation.
5.
Remove the drsin plug, and drain the automatic the transmissionlluid (ATFl. Reinstall drsin plugwith a washer. new sealing TOROUE: 50 N'm (5.O kem , 36 lb-ft)
DRAINPLUG 18x 1.5 rrm 50 N.m (5.0 ks-m , 36 b-ft)
4.
Removethe resonator,intaks air duct and air clesnet housing. Disconnect the connectot from the intak conttol vacuum tank, then removs the intake control vacuum tank 8ndtank bracket. NOTE: Do not remove the vacuum tube from the intsko tank. controlvacuum
HOUSIM! AIRCLEAI{ER
VACUUMTANK I]YfAKECOi{TROL
14-80
6.
Disconnect the glound cabsl from the transmission and body. Removethe bEttery basewhh th groundcable.
1 3 . Removethe starter rnotor cables. 1 4 . Disconnectthe countershattspeedsensorconnector.

COUNTERSHAFT SPEED SENSOR CONNECTOR
6.
Removsthe battery bassstay.

GROUND CABLE
BATTERY BASE STAY

q
STARTSER MOTOR 15. Disconnect the vehicle speed sensor connecter. Remove the rear stiffener, then remove the vehicle speedsensor/powersteeringspaedsensor. NOTE: Do not disconnectthe power steeringpressurehoses from the vehicls speed sensor/powr steering speed s9nsor, POWER STECRING VEHICLE SPEED PRESSURE HOSES SENSOR REAR EI{GINE MOUI{T
Disconnectthe lock-upcontrol solenoid valve and shift control solenoid valve connectors. controllever.
1 0 . Disconnectthe throttle control cablefrom the throttle 1 1 . Disconnectthe mainshaftspeedsensorconnector. 12. Removeths ATF cooler hosesat the joint pipes.
Turn the ends of the ATF cooler hoses uo to Drevent ATF from flowing out, then plugthe ioint pipes. NOTE: Check for any signsof leakage tha hose joints. at
MAI]TSHAFT SPEED SE SOR COI{NECTOR
SOLENOID VALVE coNf{EcToRs
TRANSMISSK)N
GROUD CABLE
POU'ER STEERIT{G SENSOR \SPEED
REARSTIFFENER
O-RING Replac6.
(cont'dl
14-81
Transmission
Removal(cont'd)
housingmountingbohs. 16. Removethe transmission mount. 1& Removsthe transmission TRAl{SMlsSOt{MOUI{T
HOUSING TRANSMISSION BOLTS MOUI{TING
17. Loosenthe Jront enginemount brscket bolts.

FROiIT E]{GII{E MOUNTT BRACKETBOLTS
19. Rsmovethe splsshshield.
SHIELD SPLASH
FRONTENGINE MOUiTT
14-82
20. Rmovethe center beam8nd r6ar beamstifJener.
B.
Pry the drivshaftsout ot ths differentisl. drivshafts(s6ssction 16).
24. Pullon the inboardjoint and remove the right and left
Tie plasticbagsov6r the drivsh8ftenos. NOTE: Coat 8ll precisionfinished 9urf8c6s with clean ongine oilor groass.
DRIVESHAFT D E
21. Romovsths cottr pins and castls nuts, thsn sep8r8t6

the ballioints from the low6r arm (seesection 18), dampertork and lower arm.
26. Removethe right dsmpsr pinch boh, then separatetho damoerfork and dsmoor, 27. Remove the self-locking bolts and self-locking nut, then romoveths right radiusrod. SELF.LOCKIIIG NUT ReDhco.
22 Remove the damper tork bohs. then separste tha
r
SELF.LOCKING UT Roploco.
DAMPER PII{CH EOLT R6plac.
DAMPER FORK
P6*ii53., cAsrLENur
rY
sELF-L(rcKhIG BOLT
R6place,
RADIUSROD
(cont'd)
14-83
Transmission
(cont'd) Removal
n.
E.
Rmovo ths torque convorter covr and shift csbb covgt. R6moveths lock bott sscuringthe control lver, then rsmovo the shift cablswith the controllsvsr. CAUTION: Tlks care nol to b.nd tha lhlft cable whllo removlng h. 31. Plsce 8 jack undr the transmission, and raise th transmissionjust enough to take weight oft of the mount. 32. Romovethe intake manitoHbracket. 33, Removethe trsnsmissionhousingmountingbolts 8nd rear anginemountingbolts, 34. Pull the transmissionaway trom the ngine until it clesrs the 14 mm dowel pins, then lower it on the jack. transmission
HOUSING TRANSMISSION MOUiTTI'{G EOLTS
SHIFT CABLE INTAKE TIAI{IFOLD ERACKET
TOROT,E COI{VERTER COVER
30. Rsmovoths eight drive plate bolts one at a tims whils

rotatingth cr8nkshEftpulby. TRANSMISSION JACK
DN|VE PLATC BOLT 6x1.Omm
PLATE DRIVE
14-84
lllustratedIndex
Right Side Cov
14-86
SIDECOVER PROTECTOR SPEED SENSOR Replace,
SIDECOVER
Replace. TH CLUTCH FEED PIPE SIDECOVERGASKETReDlsce. Replace. PIPEGUIDE RING ST CLUTCHFEEDPIPE Replace. PIPE GUIDE RING Replace. SPEED SENSOR lST.HOLDCLUTCH FEED PIPE PIN
@O-RlMisReDtsce. P|PE @FEED GUTDE OSNAPR|NG @CouITERSHAFT LocKNUT,24 x 1.2s mm (Flange nutlReplsce.
SPRING WASHERReDlace. ARKINGGEAR NEEDLE BEARING IDLERGEAR EEARING
SHAFTLOCKNUT, x 1.25 mm 24 @SECONDARY nut) Rplace. {Flange SPRING WASHER Reptace. @CONICAL SHAFT IDLERGEAR CISECONDARY Replace. @LOCKWASHER LEVER @THROTTLECONTROL @THROTTLECONTROLLEVERSPRING HANGER @'TRANSMISSION @ATF LEVELGAUGE @DRAINPLUG @SEALINGWASHERReplace. E)PARKINGBRAKEPAWL BRAKEPAWL SPRING @)PARKING @PARKINGBRAKEPAWL SHAFT @PARKINGBRAKEPAWL STOPPER @LOCK BOLT @LOCK WASHERReplace. BRAKE LEVER @PARKING OPARKINGBRAKESPRING g) PARKII{GBRAKESTOPPER HOUSTNG 6)TRANSMTSSTON HOUSING GASKETReDtace. 6)TRANSMISSION @)DOWEL P[rl 6)ATF COOLEFPIPES WASHERSReplace. @ SEALING 6)JOTNTBOLT @SEALINGWASHERSReplace. STEERING @VEHIGLESPEEDSENSOR/POWER SPEED SENSOR Replace. @ O-Rll,lG IDLERGEARSHAFT HOLDER G)REVERSE BEARING @ NEEDLE
BOLT @tJorNT
(Flange nut)Replace. NOTE:Left-handthreads WASHERReptace. OCONICALSPRTNG IDLERGEAR @)MAIN!|HAFT
NEEDLE BEARIMi WASHER LOCKNUT, x 1.25 mm 24
TOROUE SPECIFICATIONS
Ref No. A B E H TorqueValue 1 2 N . m( 1 . 2 k g - m , I l b - t t ) 14 N.m (1.4 ks-m, 10 lb-ft) 18 N'm (1.8 ks-m, 13 lb-ft) 55 N.m (5.5 ks-m ,4O lb-ftl 29 N.m (2.9 kg-m,21 lb-ft) 50 N.m (5.0 kg-m,36 lb-ftl 23O N.m (23.0 ks-m, 166 lb-ft) 170 N.m (17.0 kgrm, 123 lb-ft) 230 N'm (23.0 ksFm,166 lb-ft) 1 7 0 N . m( 1 7 . 0k s - m , 1 2 3 l b - f t ) 23O N.m (23.0 ks-m , 166 lb-ft) 170 N.m (17.0 kg-m, 123 tb-ft) 8 N'm (0.8 ks-m , 5.8 lbjtl Bolt Size 6x1.Omm 6x1.Omm I x 1.25 m m 1 0x 1 . 2 5 m m 12x1.25 m m 1 8x 1 . 5m m z+x t.zcmm 24 x 1.25mm z4 x t.zc mm 5x0.8mm Remarks
Joint Boft DrainPlug MainshartLocknut Left-handthreads SecondarySh8tt Locknut Countershaft Locknut
14-87
lllustratedIndex
Housing Transmission
@ B @ @
@ @
o
{}
o
(t
14-88
WASHER OTHRUST NEEDLE OTHRUST BEARING OSEcoNDARY SHAFT 2NDGEAR BEARINGS @NEEDLE NEEDLE @THRUST BEARING WASHER @SPLINED Stective osrt @1ST/2ND CLUTcH ASSEMBLY Reptace. @o-RlNGs (9)SECONDARY SHAFT @THRUST NEEDLE BEARING BEARING ONEEDLE @SECoNDARY SHAFT lsr GEAR @DtsrANcEcoLLAR.s.o mm @corrERs, 29 mm
RETAINER RING RINGS, mm 32
Replace.
NEEDLE EEARING
4TH/REVERSE GEAR BEARII{GS I{EEDLE BEARING GEARCOLLAR TH CLUTCHASSEMBLY GEARCOLLAR
THRUST ]TEEDLE BEARIITIG BEARING

3RD GEAR
NEEDLE 8EARI]{G Rephce.

RINGS,35mm RING,29 mm BEARING
BOLT
WASHER Replace. FORK 2ND GEAR REVERSE GEAR BEARING
SELECTOR HUB SELECTOR

4TH GEAR BEARING RING
RII{G IDLER GEAR SHAFf HOLDER BEARING

SEAL Reolace. HOUSING SEAL Reolace. OIL SHIM SelectiveDart OUTERRACE HOUSING GASKETReplsce. HOUSII{GMAINSHAFTEEARII{G HOUSIMI SECOI{DARY SHAFT
32 mm TERS, mm 29 ANCECOLLAR
3RD GEAR NEEDLE BEARING @oNE-WAY CLUTCH 1ST GEAR }COUMIERSHAFT BEARING )NEEDLE @THRUSTWASHER lST GEARCOLLAR @COUNTERSHAFT @tlsT-HoLD cLuTcH ASSEMBLY TOROUESPECIFICATIONS Ret No. TorqueValu 1 2 N . m( 1 . 2k g - m , 9 l b - f t ) 14 N.m (1.4 kg-m, 10 lb-ftl
EEARI'{G HOUS|NG COUI\TTERSHAFT BEARTNG @)TRANSM|SS|OI{ IDLER GEAR @NEVERSE ASSEMBLY GDIFFERET\ITIAL OUTER RACE G)EEARIIIIG COI{VERTER HOUSING SEALReDtace. OIL @)TOROUE COI{VERTER HOUStitc @TOROUE
Boh Size
Rsmsrks
6x1.Omm 6x l.Omm
14-89
lllustratedIndex
Housing TorqueConverter
\l
@.-.
il
I U
I
lL? a
@@ '
&P
14-90
OATF STRATNER @MAGNET PIPE @OILFEED P|PE @otl FEED covER @4THACGUMULAToR @o-Rlltc Reohce. OLOCKwAsHERReotace. BASE @sERvoDETENT BoDY @sERvo SEPARAToR @SERVO PLATE @cHEcKBALL vALvE BoDY @SECoI{DARY PIN @DOWEL @SECoNDARY SEPARAToR PLATE @AccuMULAToR BoDy covER @lsT AccuMUrAToR cHoKE @cHEcKBALL @1sT/2 D ACGUMULAToR BoDY vALvE BoDY @THROTTLE pt-arE SEPARAToR @THRoTTLE PrN @oowEtCOTTROL SHAFT !THROTTLE Replace. @ERING Replace. @FILTER VALVEBODY @REGULATOR Replace. @O-RllJG SHAFT @STATOR SHAFT @STOPPEB COiTVERTER CHECK VALVE @TOROUE CONVERTER CHECK VALVESPRING @TOROUE
FEED PIPE
BALL TERReplace. PIN
FEED PIPE VALVEBODY

PUMPDRIVENGEARSHAFT PUMP DRIVEGEAR PUMP DRIVENGEAR SHAFT SPRIiIG ARM ARM SHAFT PIN SEPARATOR PLATE
NEEDLE BEARIM! GUIDE PLATE

SHAFT BALL EEARING
GUIDE PLATE SEAL COiITROL SOLEI{OID FILTER/GASKET Replace. COiITROL SOLEI{OID VALVEA$SEMBLY -UPCONTROL SOLENOID VALVEASSEMBLY -UPCOTIITROL SOLENOID FILTER/GASKET
Replacs. CONVERTER HOUStt{c @TOROUE 6)II'AINSHAFTBALL BEARING @OlLSEAL Replace. HOLDER
1 2 N . m ( 1 . 2k g . m , I l b - f t ) 18 N.m (1.8 ksFm 13 ltsft) ,
6x1.0mm 8 x 1.25mm
14-91
RightSide Cover
Removal
NOTE: . Clean all parts thoroughly in solvent or carburetor cleanersnd dry with complssedair. . Blow out allpasssges. . When removing the transmission right side cover, replacethe following: , Rightsidecover gasket . Lock washers . Transmission housinggasket . O-rings . Eachshatt locknut and conicalspringw8sher . Sealing wsshers L Removethe elevnbolts scuringthe right sido covet, then removethe right sidecover. NOTE: h is not necessarv to remove ths right side covsl protector. Slipthe specialtoolonto th mainshsft. HOLDER MAII{SHAFT or 07GAB-PF5010O 07GAB-PF50lOl
LOCKNUT
cott|cAl sPRlltG
WASHER R6phc.
RIGHTSIDECOVER GCAN PARKIT{G GEAR IDLER COUNTERAHAFT
GEAR IDLER REVERSE SHAFTHOLDR
PAWL ERAKE
W-
n
\
RIGHTSIDE
LEVER "o rNGBBAKE
V-TRA]{SM|SS0i{HOlrSlNo BOLTS TRANSMISSO HOUANG
GASKET COVER Rplace.

TRANSMISSION HANGER ATF LEVELGAUGE
E x 1 . 0m m BOLT
GEAR IDLER REVERSE
HOUSII{G TRA SMISSIO|{ GASKET

R6Dlsco.
ATF COOLER PIPES
JOINTBOL
}IOUSII{G CO TOROUE VERTER

WASHERS SEALII{G Rophc6.
14-92
J.
Engage parkingbrake pawl with the parkinggear. the Cut the lock tabs of each shaft locknut usinga chisel as shown. Then remove the locknuts and conical springwashersfrom esch shaft, NOTE: . Mainshaftlocknut has left-handthreads. . Cleanthe old locknuts; they are used to installthe press fit idler gearson the mianshaftand secondary shaft andthe parkinggearon the countershaft. . Always wear safety glasses, CAUTION: Keep all of ths chiselod particlos out ot tho tranamission.
12. Removethe reverseidlergear shaft holder. NOTE; The steel ball does not pop out becsuseit is stsked in the shaft. 13. Move the reverse idler gear to disengage trom the it countershaftand mainshsftreversegarsas shown. NOTE: The transmissionhousingwill not separate from the torque converter housing if the reverse idlsr gesr is not removed. REVERSE IDLER GEAR Moveinthisdirsction.
4.
MAINSHAFT
LOCKTAB
Rsmove the special tool from the mainshaft after removingthe locknuts.
o.
,! o_ -:.-.:{>, a
\!r' l
Remove the parkinggear using a puller f.om the countershaft as shown. Then remove the idler gesrs usinga pullerfrom the mainshaftand secondaryshaft.
i
COUNTERSHAFT
14. Align the spring pin of the control shstt with the transmission housing groove by turning the control shaft. 15. Install the speci8l tool on the transmission housing, then removethe housing shown. as
HOUSING PULLER
Remove the countershaft idler gear, needle besring. thrust needle bearing. and thrust washer from the countershaft. 8. Removethe parkingbrake pawl, spring,shaft. and stopperfrom the housing. throttle control shaft. GROOVE
9 . Removethe throttlecontrolleverand springfrom the 1 0 . Removethe ATF coolerpipe mounting boh from the
transmission hanger. 1 1 .Removethe transmission housingmountingbotts.
SPRING PIl{ CONTROL SHAFT
14-93
Housing Transmission
Removal
HOUSI G TRANSMISSION Removal 14-92
2ND GEAR COUNTTERSHAFT GEAR REVERSE COUiITERSHAFT
I{EEDLE BEARII{G
TRANSMISSO
HOUSlttc GASKET Replace.
HUB REVERSE SELECTOR

SHIFTFORK
SELECTOR BEVERSE
MAII{SHAFT SUB.ASSEMBLY
COUITTERSHAFT 4TH GEAR THRUSTWAS}GB BEARIiIG THRUST I{EEDLE COUTYTERSHAFT SUB.ASSEMBLY

SHAFT SECONDARY 2'{D GEAR
BEANI GS NEEDLE ]{EEDLE BEARIiIG THRUST SPLII{ED WASHER SECOI{DARY SHAFT SUB-ASSEMBLY
DIFFEREICTI,AL ASSEMBIY
HOUSING TOROUE COIWERTER
14-94
NOTE: . Cl8n 8ll parts thoroughly in solvent or carburetor cleansrand dry wilh comDressed air. . Blow out all passsges. . Whsn rmoving the transmissionhousing, roplace the following: . Trsnsmission housinggaskst . Lock w8sh6r 1. 2, 3. Removethe trsnsmissionhousing(seepage14-94. Rsmove the reverse idler gar from the transmission housing. Removs ths countrahaft 2nd go8r, reverse gear, socondaryshaft 2nd gear, thrust washr, and thrust nsdl besring togsther from the countershaft and secondaryshaft. Remove the lock bott socuring the shift fork, then romovs ths fork with tho ravrse slector from the countershaft. Rmove tho n66dle besrings,thrust nesdle besring, 8nd splinedwasher from the socondaryshaft. Romovethe secondsryshaft sub-Ess8mbly, Removethe msinshaftsub-assmbly. Removethe countershaftsub-assembv. Removethe differentialass6mbv.
4.
5. 6. 7. 8. 9.
14-95
Body Torque ConverterHousing/Valve

Removal
THROTTLE COI.ITROL SHAFT.
O.RING Roplace,
fi nllltn \s ll llUlfllle t il ril,H|Jil _

1 II s 1!1 ' U I
^3a
o r FEED F
P'PE \
f,
a
ATF STRAINER
;HROTTLE VALVE BODY
E-R.NG fl Replace.
. \ -
ll u
S1
-
>[nN * /
rHRorrLGsEpARAroR
PLATE
4TH ACCUMULATOR COVER
\
STOPPER SHAFT
ff
REGUtAroBvAtvE
O-RING Rephce. STATORSHAFT
LOCK WASHER Replac6. DETENT SEBVO BASE
I
BODY SERVO SEBVO SEPARATOR PLATE
CHECKBALLS
TOROUE CONVERTER CHECK VALVE CHECK VALVE

SPRING OIL FEEDPIPE
OETENT ARMSHAFT ARM DETENT
colvrRoL
SHAFT
VALVE SECONDARY BODY DOWEL PIN

MAIN VALVE BODY
SECONDABY SEPARATOR
OILPUMPDRIVEN GEAR SHAFT OILPUMPDRIVEN GEAR OILPUMP DRIVE GEAR ACCUMUI.ATOR BODY COVER IST/2NDACCMULATOR BODY
MAIN SEPARATOR PLATE DOWELPIN
HOUSING TOROUECONVERTER
14-96
NOTE: . Clsn all parts thoroughly in sotuent or carburtor air. cle8nrand dry with compressed . Blow out all p8ss8g8, . Whsn removingthe vslve body, replscethe following; . O-rings . Lock w88h6rs 1. 2. 3. 4. Removsthe two bohs securingthe servo detent base, thn rsmovs ths aervo detent bass. Removsthe two bohs sgcuringth6 ATF strsiner,then removs th ATF strainsr. Remove the oil fe6d pipes from the srvo body and mainvalve body. Rmovethe three bofts securingthe 4th accumulator covsr, thsn removethe 4th accumulator covr. NOTE; Ths 4th accumulator covsr is spring loaded, to prsvsnt strippingthe threads in the srvo body, press down on tha accumulstorcover while unscrewingthe bohs in a crisscrossDsttern. 5. 6. 7. R6movethe seven bohs securingth8 servo body, then removs the sarvo body snd s6parstor plats. Removethe secondsryvalve body and soparstorpl8te. Rsmove the seven bohs securing th throttle valve body, then remove the throttle valve body and soparatorplata. Rsmove the boh securing the regulator vslve body, then removethe rsgulatorvElvebody.
9 . Romovethe ststor shsft snd stopper shaft. 1 0 . Romovthe dstsnt spring from ths dstsnt arm, thsn
remove the control shaft trom the toroue converter housing. 1 1 .Rsmovthe detent arm snd detent srm shalt from the m8inv8fus body.
12. Removoth four bohs securingtho main valve body,

th6n rmoveth mainvalve body.
1 3 . Remove the six bofts securing the lst/2nd accumulstor body, thn rsmovs the 1st/2ndaccumulator body. 1 4 . Remove the oil pump drivon 968r shatt, then remove the oil pump gears. 1 5 . Rgmov th6 main seDarator Dlat6 with three dow6l Dins.
8.
14-97
Valve Body
Repair
NOTE: This repair is only necessary if one or more of the valves in a valve body do not slide smoothly in their bores.You may use this ptocedule to free the vaves in the valve bodies. Soak a shet of $600 abrasive paper in ATF for about 30 minutes, Carefully tap the vatve body so the sticking vslve droDsout of its bore. CAUTION: h may bo necossaryto us a 3mal3crewd vor to plY tho valve fioo. Be carsful not io scratch the bot whh ths sclowdrlvor. InsDectthe vave tor any scutf marks. Use the ATFsoaked #60O paperto polishotf any burrs that are on the valve, then wash the vatue in solvent 8nd dry it 8ir. with compressed Rotl up hlf a sheet of ATF-soaked f60O paper and insert it in the valve bore ot the stickingvalve. Twist ths paper slightly,so that it unrollsand fits the the boretightly,then polish boreby twistingthe paper as you push it tn and out. CAUTION: Th6 valve My is aluminum and doosn't roquito much polshing to remove any bulls. VALVE Removthe #600 paper.Thoroughlywash the entire air. vavs body in solvent,then dry with compressed
6. Cost the vslv whh ATF, then drop it into its bor8. h
shouH droD to thg bottom of the bore under its own weight. ll not, ropeat step 4, then retest.
ffi
t
VALVE BODY
7. Romovs tho vslve 8nd thoroughv clean it 8nd the
valve body wilh solvent. DrY 8ll parts with comDroasedair, then reassemble using ATF 8s a lubricant.
snl [ssYi
vV/fJ
,.llJ'"-Q)
14-98
Valve
Assembly
NOTE: Cost all psns with ATF before assembly. . lnstallthovalvs, valve springandcap in the vavo body, and securwith ths rollsr. Sst the springin the valv6 and installth6m in tha valvs body. Push th spring in with 8 scrowdrivor, th6n instsllthe springssat.
VALVEBODY
ROLLER
14-9!)
Valve Caps
Description
Caps with one projocted tip and one flat end are installedwith the flat end towsrd the inside ot the valve body. Caps with a projectod tip on ach end are instslled with th6 smsller tip toward th8 inside ot the valve body. The smslltip is I springguide. Caos with hollow ends ar6 installedwith the hollow awav trom the insideof the valve body. CaDswith notched ends are instslledwith the notch toward the insideot the valve body, Caps with flat gnds and a hole through the center are installsdwith the smallerhole towsrd the insideof the vave body.
TOWARD OUTSIDE VALVEBODY OF
TOWARD OUTSIDE VALVEBODY OF
EEEA
TOWARD II{SIDE VALVESODY OF TOWARO SIT'E VALVEBODY I OF Caps with one projected tip snd hollow end sre instslledwith the tip toward tho inside oJ the valve body. Th6 tip is I springguide.
TOWARD OUTSIDE VALVEEODY OF
TOWARD INSIDE VALVE BODY OF
14-100
Oi l Pu mp
lnspection
1. Install the oil pump gears 8nd oil pump driven gear shsft in the mainvslve bodv. Measurethe side clearsnceof the oil pumDdrive and driven gars. OilPump Ga.lE Side (Radial) Cloalance: Standard(New)l Oil Pump Ddva goal 0.210-0.265 mm (0.0083-0.0104 inl Oll Pump Drlvan g6al 0.035-0.063 mm (O.OO14-O.0O25 in)
OILPUMP ORIVE GEAR Inspect tethlor wearor damage. 3. Remove the oil pump driven gesr shaft, Measurethe thrust clearanceof the oil pump driven gear-to-valv body. OllPump Drlvo/DrivonG6sr Thrust (Axiall Clearance: Standard(Now): 0.03-0.05 mm (0.001-0.002 in) Selvico Limit: 0.07 mm (O.0O3in)
STRAIGHTEDGE
MAIN VALVE BODY
14-101
MainValve Body
Disassembly/lnspection/Reassembly
NOTE: . Clean8ll parts thoroughlyin solvent or carburetorcleaner,and dry with compressd8ir. Blow out all psssages. . Replace valve body as an assemblyif any parts are worn or damaged' . Check allvavs tor free movement.lf any fail to slidefreely, seeVafueBody Repairon page1+98. CAUTION: Do not use a magnotto tomovo tho ctrock balb; it may magnotizotho bak.
MODULATOR VAIVE
CPCVALVE
3-2 K|CK-DOWN FILTER VALVE SEAT

R6phc6. lnstsll in this diroction-
OIL FEEDPIPE
\n U
SHIFT CHECK BALLS 3pcs.
DETENT ARM
VALVE 1_2 SHIFT
VALVECAP
R u
VALVE 2_3 SHIFT ROLLER
MAIN VALVE BODY Inspectlor scoring or domag. MANUAL VALVE
14-102
FILTER Rephce.
E E
CHECKBALLS
MAIN VALVE BODY (SctionalView)
DETEN|T ARMSHAFT
SPRING SPECIFICATIONS Standard(New) No. Spring Wire Di8. Lock-up control valve spring Lock-up shift valve spring Coolerrelist valve spring Modulatorvalve spring CPCvatuespring vatuespring 3-2 kick-down 1-2 shitt valvspring 2-3 shift valve spring
Unit:mm (in)
o.D.
6.60(0.260) 7.60(0.299) 8.40(0.331) 9.40{0.370) 9.40(0.370) 7.10{O.2m) 8.60(0.339) 7.60(0.299)
Free Length
No. ot Coils 14.1 32.O 't7.o 10.5 10.5 20.6 16.9 26.8
@ @
o o @ o
@
o.70(0.028) o.90 {0.035) (0.043) 1.10 1.40(O.O55) 1.40(0.055) 1.20(O.O47t 1.00(0.039) o.90(0.035)
(1.496) 38.00 73.70 .2.9021 (1.8431 46.80 (1.299) 33.OO 33.00 {1.299) 46.90{1.846) (1.626) 41.30 57.@t2.2441
14-103
Valve Body Secondary

NOTE: . Clesnall parts thoroughlyin solvnt or carburetorcleansr,and dry with compressod8ir. Blow out all passages. . Check allvalvesfor lree movsment.lf sny fail to slidefreely, seeVave Body Rep8iron page1+98. . Coat all parts with ATF befor assembling. . Replace vave body as 8n assemblyif any pans 8re worn or damaged. the CAUTION: Do not uso a mrgnoi to romova th chock balls;h may magnatizotho bak'
3_4 SHIFTVALVE
,n4u %
0 l
BALLS CHECK 7 pcs.
SECONOARY
VALVE BODY Inspect scoring for or damag6.
-p^
'cqtcrco/
COI{TROL 21{DOR|F|CE VALVE
/
SLEEVE @
/"%
14-104
L
CHECKBALLS
CHECK SALLS
n LJ
r 1 n n - l-_\)v, V U l-l
r.,f7
CHECKBALLS
SECO DARYVALVEBODY (SoctionslVisw)
SPRITIIG SPECIFICATIONS Stsndard(llew) No, Springs Wir Dia. 4th sxhsust valve spring 3-4 shift vatuespring 3rd kickdown vslve spring Sarvo controlvalva spring Orifice control vslve spring 2nd orifice controlvalve spring
Unh: (in) mm
o.D.
7.10(0.2&) 7.@ (0.299) 7.60{0.299) 8.10(0.319) 6.60(0.260) 6.@ (0.260)
Free Lngth
No, of Coils
O
@ @
@ @
0.90(o.o35t 0.90(o.o35) (0.043) 1.10 1.@(0.039) 0.s to.031) 0.60(0.024)
60.e (2.394) 57.@ l.2.244l. 48.30(1.902) 52.60l2.O71l 52.&12,06,7l 5A30 (2.295)
4.9 26.8 4.3 22.4 33.O 15.8
14-105
Valve Body Regulator

NOTE: . Cleanatlparts thoroughlyin solvent or carburetorcleaner,and dry with comprsssadair. Blow out all p8ssages. . Replace valve body 8s an assemblyif any parts are worn or dsmaged. . Ch6ck 8llvalvesfor tree movement.lf 8ny tailto slidefreely, see Valve Body Repairon page1+98. 1. Holdthe regulatorspringcap in plscewhile removingthe stopper boh. Oncethe stopper bolt is removed,releasethe spring c8p slowty. CAUTION: Th rogulatorspllng cap can pop oui whon tho lock boh is romovod. 2. R8assembly the reversordgr of disassembly. is NOTE: . co8t 8ll parts with ATF. . AliSnthe hole in the rogulatorspringcap with the hole in th valve body; thsn pressthe spring c8p into the valve body and tightn the stoppor boh.
REGULATOR SPRING CAP
BOLT STOPPER 6x1.0mm 12 N.m(1.2ks-m,9 lb-ft) VALVE REGULATOB
FILTER Rophce. LOCX.UP TIMING VALVE E BOOY

Inapgctfor w6ar. scratchos or scorng.
TOROUE CONVERYER CHECK VALVE
ROLLER SPRING SPECIFICATIOTSS Standard(New) No. Springs Wire Di8. Regulator valve springA Regulator valve springB Stator reactionspring Lock-uptlming vaVe spring Torque converter check valve spring F22A1 engine H23A1 engine Unit:mm (in)
o.D.
FreeLength
No. of Coils 16.5 16.5 12.7 1.92 't4.7
O
t
i
3 ra
1.O (0.O71) 14.70(O.579) 86.50(3.406) 1.80(0.071) 14.70 (0.579) 88.60{3.488) r.s (0.071) 9.60 (0.378) rr4.oo(1.732) (1 4.50(0.177) 35.40(1.394) 30.30 .193) (2.012) o.s {o.o31) 6.60 (0.260) 51.10 (0.043) 8.40(0.331) 36.rto(1.433) 1.10
't2.o
14-106
Throttle Valve Body

Disassembly/lnspection/Rassembly
NOTE: . Cleanall parts thoroughlyin solvent or carburetorcleaner,anddry with comprossd Blow out all passagas. air. . Check allvalvesfor free movement,It any failto slidefreely, see Valve Body Repairon page14-98. . Coatallpartswith ATF beloreassembling. . Replace valve body as an assemblyif any parts are worn or damaged. the AOLT 5r0.8 8 N m(0.8 s m , 5 . 8 l b - f i ) k
\ \ \
THROTTLE SHORT VAIVE B
THROTTLE LOI{GVALVE
THROTTLE CAM STOPPER
THROTTLE ADJUSTING BOLT CAUTION: Do not loosen or remove. RELIEF VALVE
THROTTLE VALVEBOOY InsDect wear, lor scratches scoring. or
SPRING SEAT
SPRING SPECIFICATIONS Unit:mm (in) Stsndard{New) No. Springs Wire Dia. ThrottlevalveB spring Throttle vaVe I adjusting spring Relietvalve spring
o.o.
FreeLength
No. of Coils 10.5 11.2 't2.4 8.O '15.1
o
@
1.40{O.O55) 1.40{O.O55) (O.Oss) 1./tO 0.& (0.o311 (O.O39) 1.OO
8.so(0.335) 41.50(1.634) 8.50(0.335) 41.50(1.6341 ( 8.50(0.335) 4 1 . 6 0 1 . 6 3 8 ) ( 6.20tO.2Ml 3 0 . 0 0 1 . 1 8 1 ) (1.539) 8.40(O.331) 39.10
14-107
Servo Body
NOTE: . iiel"n attp"rts t6oroughlyin sofuentor carburetorcl6aner,anddty whh compt6ssdEir.Blow out all passag.s. . n"ptt"" itt" ""*o body as an assemblyil anYparts are worn or damsgd' . Replace ATF strainet if its inlet openingis clogged. . Cost all Dartswith ATF before assembly. TORCOVER
MAG[{ET Clean.
(<
\j ATF STRAINER Cleanor roplac.
4TH ACCUMULATOR PISTON
BASE DETET{T SERVO
PIPE OILFEED
BODY SERVO
Inspoctlor woar scratchg8or scoing. O.RING Replace,
VALVE SHAFT/SERVO SHIFT FONK for Inspoct sco ngor dama|o. 3RD ACCUMULATOR PISTON
SPECIFICATIONS SPRING Stsndard(New) No. Springs sPring 4th accumulator spring 1st-holdaccumulator spring 3rd accumulator Wire Di8.
Unit: mm (in)
o.D.
FreeLengrth
No. of Coils
o t\
(3.547) 2.90(O.114) 22.@ (0.866) 90.10 (0.157) 25.@ (0.984) 64.702.5/.71 4.OO (4.114) 2.60 (O.102) 17.50(0.69) 104.50
10.9 7.3 18.O
14-108
1st/2nd AccumulatorBody
NOTE: . Cleanall parts thoroughlyin solvont or carburto.claaner,and dry with comprsssadair, Blow out all passsges. . Cost sll psns with ATF bfore sssembly. CAUTIO : Do not usa r mrgnot to temoya the cfiack bal!; h may megnotlzo tho bals. ACCUMULATOR EODY COVER
CHECK BALL
PrsTot{
lST ACCUMULATOR
2I{DACCUMULATOR PISTON
sPRtt{G SPEC|F|CAT|O S
Unit:mm (in) No. Standard(Nsw) Springs Wire Di8.
o.D.
FreeLength
No. ol Coils 18.6 11 . 1
lst accumulatorsprim zrd accumulatorspring
1.e (o.o71) 16.30 to.64a 115.40 (4.543) 3.30 to.130) 22.@ (0.866) 84.90 (3.343)
14-109
Mainshaft
NOTE: . Lubricate reassembly. allpartswith ATF during .Instellthethrustneedlebearingswithunrollededgeofbearingretainerfacingwasher. . Inspectthrust needle and needlebearingsforgalling and roughmovement. . Before instslling O-rings,wrap the shaft splineswith tape to prevent damage the O-rings. to the
NUT} LOCKNUT{FLANGE Replace. NOTE: Lotr-handthr6ads 23O N m (23O ks-m , 166 lb-ft} +O ) 170 N.m (17.0 ks-m.123 lb-ft) WASHER CONICALSPRING R6place. IOLER GEAR TRANSMISSION HOUSING BEARING
RING SNAP COLLAR BEARING THRUST NEEDLE 4TH/REVERSE GEAR
NEEDLE BEARINGS
O-RINGS Replaco.
EEARIiIG THRUSTNEEDLE 4THE GEARCOLI.AR
3RO/4TH CLUTCH ASSEMBLY

MAINSHAFT Chck splinesfor excessive w6ar or oamage, Check beadngsurtacetor scorang, scratchesor
3RD GEARCOLLAR
?I{RUST EEDLE BEARING NEEDLE BEARING
3RDGEAR BEARING THBUSTNEEDLE
SEALING RINGS. mm 35 RING,29 mm NEEDLE BEARING SET RING,23 mm
14-110
Countershaft
NOTE: . Lubricateallparts with ATF duringreassembly. .Installthethrustneedlebearingswithunrollededgeofbearingretainerfacingwasher, . Inspectthrust needle and needlebesringstor galling and rough movement. . Before installing O-rings, the wrap the shaft splineswith tape to prevent damage the O-rings. to
2ND GEAR LOCKNUT(FLA'IIGE NUTI Replace. 230 N.m (23.0 ks"m , 166 lFft) --r O -) 1 7 0 N . m( 1 7 O k s - m , 1 2 3h - t t l NEEOLE BEARING CONICALSPRING WASHER RsDhca.
REVERSE SELECTOR
REVERSE SELECTOR
4TH GEAR
PARKII{G GEAB THRUST NEEDLE BEARII{G IDLER GEAR
NEEDLE BEARING COLLAR. mm 32 COTTERS, mm 29 DISTANCE COLLAR

3RO GEAR
EEDLE BEARING THRUST EEDLE BEARhIG THRUST WASHER TRAl{SMtSStot{ HOUSII{G BEARING
ONE-WAYCLUTCH
1STGEAR
COUI'ITERSHAFT Ch6ck splinsfor excessive war or damage. Check baring surtacetor scoring.scratchesor
1ST GEARCOLLAR
lST-HOLD CLUTCH ASSEMgLY
14-111
Countershaft
Removal
1. Using a press, press out the countershEft while supponingth lst-hold clutch. NOTE: Place an attachment betwoen the press 8nd countershaftto prevent dsmagsto the shalt.
14-112
lnstallation
NOTE: Lubricateall parts with ATF duringEssembv. 1, Instslltwo new O-ringson the countershaft, NOTE; Before installingthe O-ring6,wrap ths shaft splines with tape to prsvent dsmagsto the O-rings. 2. Assemblsthe 1st-holdclutch assembly,lst gearcollar, thrust washer, needl bearing, lst gaar, one-way clutch, thrust needlebearingand 3rd gear. NOTE: . Also align the shaft splines with those of th lsthoH clutch when pressing the countershaft into the 3rd gear. . Use 8n attachment between the shaft and a press to provant damage the countershatt. to . Stop pressingthe countershaJtwhen the 1st-hold clutch contacts the finaldrive gear. 4. Align the shaft splins with thoso of 3rd gaar, then pressthe countershaftinto 3rd gearwith a press.
3RDGEAR
PRESS
THRUST '{EEDLE BEARIl{G
O]TE-WAY CLUTCH lnstall thisdirection. in
1ST-HOLD CLUTCH
lST GEAR
I{EEDLE BEARING
THRUSTWASHER
lST GEANCOLLAR
1ST-HOLD CLUYCH ASAEMBLY
3.
Installth8 above assemblv the countershaft. on
14-113
One-wayClutch
Disassembly/lnspection/Reassombly
1. Separatecountorshstt 3rd gar from countershaft 1st gear by turning3rd garin the directionshown, 3. Inspectthe parts as follows:
COU]YTERSHAFT 3RDGEAR
Inspsct3rd gear for wear oascoring-
COUNTEBSHAFT IST GEAR
ffi.-
Inspoct the thaust noodls bearing tor damage or faulty movmgm.
Inspectth ono-way clutch for damagoor fauhy movement.
Remove the one-way clutch by prying h up with the end of a screwdriver,
Inspect lst gear tor war or scoring.
ONE.WAY CLUTCH
holdcountershatt After the Dartsare sssembled, 1st gesr and turn countershatt 3rd gear in directionshown to be sure it turns Ireelv. 3RD COUI{TERSHAFT GEAR
1ST COUT{TERSHAFT GEAR
14-114
Secondary Shaft
NOTE: . Lubricstesll parts with ATF duringreassembly, o lnstalltho thrust needlebesringswith unrollededgeof bearingretaineffacingwasher. . Inspctthrust needle and needlebesringstor galling 8nd rough movement. . BsJoreinstalling O-rings, the wrap the shatt splineswith t8pe to pravent damage ths O-rings. to
LOCKNUT{FLANGE NUT}
Roplsc6.
23ON.m(23,0kg-m, 166 |tsft) -JO-) 170 N.m(17.0 ks-m.123lb-ft) CONICAL SPRING WASHER Replsco. GEAR IDLER TRAI{SM|SS|OI{ HOUST G BEARII{G THRUST WASIGN THRUST NEEDLE BEARING 2NDGEAR
SECONDARY SHAFT Check splinsfor oxcossive w6ar or d6magE. Chgck bearing surfacofor scoring,scrotchesor excosstvowoat.
NEEDLE BEARI]IIGS
THRUST NEEDLE BEABII{G SPLIT{ED WASHER prt Sol6ctiv
THRUSTNEEDLE BEARII{G I{EEDLE BEARIMi
1STGEAR
DISTANCE COLLAR. mm 5 COTTERS, mm 29 COTTER RETAINER SNAP RING SEALING RINGS, mm 32
14-115
SecondaryShaft
Inspection
. CbarancaMaasurement NOTE: Lubricstall parts with ATF duringsssemblv. 1. Rmove the secondsry shaft bearing trom the housing(seepsgo 1+129). transmission 2. Assomble the s6condsry shEft sssembly without O-rings.Instsllth6 idler gear usinga press,then to.qu the 36cond8rythaft locknut to 30 N.m (3.0 ksFm, 22 lb-tt) NOTE: Do not instsllthe O-ringsduringinspection. 4.
while moving2nd Messure gearsaxialclearance 2nd gear, in) 0.07-0.15 mm(0.003-O.0O6 STANDARD: NOTE: and in Takemeasurements at loastthlee plscos, use clearance. as the average the actusl
LOCKITUT
5. Attach the disl indicatorto 2nd gearas shown. DAL INOICATOR
It the clearanceis out of tolerance,removethe splinsd the washer and measure thickness. WASHER SPLINED No. Pari l{umbol fhbknols in) 4.05 mm 1O.159
3.
90406- PX4- 700 90407-PX4-7@ 90408- PX4- 700

4 5
o
in) 4.10 mm(0.161 in) 4.15 mm(0.163 in) 4.20 mm(0.165

4.25 mm (0.167 in) 4.30 mm {0.169 in) in) 4.35 mm 10.171 4.2!Omm {0.173 inl 4.45 mm {0.175in)
90rto9- PX4- 700

90410-PX4-7@
90411-PX4-7m 90412-?X4-70o
90413-PX4-700
90414-PX4-700
2ND GEAR
6.
the splinedwashsr, make sur that the After r8plscing is clearance within tolgrance.
14-116
Clutch
lllustrated Index
3RD/4TH CLUTCHASSEMBLY
SI{AP RII{G
CLUTCH EI{DPLATE
ct uTcH Drscs
Stshdardthickness: 1.94 mm {0.076 inl
CLUTCH PLATES Standard thicknoss: 2.30 mm(0.091in)
nEruRNsPuu'rc---'--@
SNAP RII{G
srRrnc aeurnea.-(C) s APRTNG--o

SPRI]TG RETAINER
RETURN SPRII{G
PISTON
CLUTCHDISCS Standard thickn6ss: 'l .94 mm (0.076 inl
O.RINGS Rsplacs.
CLUTCH DRUM
(cont'd)
14-117
Clutch
H23A1 Ensino ASSEMBLY: 1ST/2NDCLUTCH
CLUTCHENDPLATE
SPRING RETAINER
SPRING RETAINER
CLUTCHENDPLATE
SNAP RING 2ND CLUTCHDRUM
DRUM lST CLUTCH
14-118
L
1ST/2ND CLUTCH ASSEMBLY: F22A1Enstn
O-RINGS Replace.
----.....-__----l/ PrsroN Xtt
qfluansrnrNcre
SPRTNG -=...._<> RErarr{ER
SNAPRtNG--___..v-)
CLUTCH PLATES Standard thicknoss: 2.60 mm(0.102in)
Y)
&
smr nnc--..-...-
-l-,,
sPRrRETATNEB----__.._<> G
RETURN SPRING DISCSPRING
2ND CLUTCH DBUM
1ST CLUTCHDBUM
{cont'd}
14-119
Clutch
1ST-HOLDCLUTCHASSEMBLY
E CLUTCH O PLATE
PLATES CLUTCH thicknsss: Standard 2.00 mm(0.079inl
R|NG sr{AP -----------....
13
RETATNER SPRTNG ------..-..-<>

RETURN
DISCSPBING
PISTON
O-RllrlcS B6placs.
CLUTCHDRUM
14-120
Disassembly
1. Remove the snap ring, then remove the clutch end plate,clutch discs and plates. NOTE: For a clutches Installthe specialtoolsas shown. NOTE: For lst-hold clutch
SNAP RING
CLUTCHSPBING COMPRESSOR ATTACHMENT oTLAE-PX40100
SCBEWDRIVER
CLUTCHSPRING COMPRESSOR ATTACHMEI{T 07HAE-P150100
Remove discspring. the NOTE: For 1st-holdnd 2nd clutches NOTE: For 1st,2nd,3rdand4th clutches.
DISCSPRING
CLUTCHSPRING COMPRESSOR ATTACHMEiIT OTLAE-PX/[O1OO
CLUTCHSPNNG COMPRESSOR ATTACHMEIYT 07HAE-P150100
CLUTCHSPRING COMPRESSOR AOLT ASSEMBLY 07GAE-PG40200 {cont'dl
14-121
Clutch
(cont'd) Disassembly
CAUTION: It olthor ond of tho comproraor attachmont i! 3ot ovel an aroa ol the sprlng rotalner which ls unsuppo od bY the rsturn sprlng.the rotalnor may be d8magod. Removethe snap ring.Then remove the spscialtools, 8nd retainer retrunspring. spring
Do not s6t hore.
NOTE: SteDs4 thru 6 are for allclutches. the Comprss returnspring.
the clutchdrum and apply8ir Wrap a shop rag around pressureto the oil passage removethe piston.Plsco to a tingertip on the other nd while appving air pres6ure.
14-122
Reassembly
NOTE: . Clean sll parts thoroughly in solvnt ot carburetor cleangr,and dry with compressed arr. . Blow out all psssages, . Lubricateall parts with ATF beJoreassembv. 1. Inspectthe piston for a loosecheck vslve, if the check valve is loose,replaceth p;ston. CHECK VALVE 4. Installthe piston in the clutch drum. Apply pressure and rotate to ensureproper seating. NOTE: . Forallclutches . Lubricate the piston O-ring with ATF before installing. CAUfION: Do not dnch O-ringby instaling the ],iston whh force.
PISTON
PISTON
Be sure that the disc springis securelystaked. NOTE: For 1st, 3rd and 4th clutches Installnew O-ringson the piston.
O-RINGS CLUTCHDRUM
Installthe return springand springretainerand position the snapringon the retainer. NOTE: For allclutches
(cont'd)
14-123
Clutch
(cont'd) Reassembly
6. as specialtools shown. Installthe clutch NOTE: For 1st-hold CAUTION: lf otthor end of lho comprslsol attachmcnt b 8ct ovor an lroa of the sp ng lelalnor whlcft k unrupportod by tha toturn sprlng.tha rctalnel may b dam!god.
CLUTCHSPRIiIG COMPRESSOR ATTACHMEiTT 07LAE- PX40100
CLUTCHSPRI G COMPRESSOR ATTACHMENT oTHAE- Pl601 00 Do not set h6ro. CLUTCHSPRING COMPRESSOR BOLTASSEMBLY 07GAE-PG402q)
NOT: Steps 7 thru I 8re for allclutches. 7. the ComDresa retuln sPring.
NOTE: For 1st, 2nd, 3rd and 4th clutches
SPRING CLUTCH COMPRESSOR ATTACHMEITT 07LAE PX40lOO
CLUTCHSPRI G COMPRESSOR ATTACHMET{T oTHAE-P150100
SPRING CLUTCH COMPRESSOR SOLTASSEMALY OTGAE PG4O2OO
14-124
8.
Installthe snap ring.
NOTE: Steps11 thru 15 aretor allclutchos. 11. Soak the ctutch discs thoroughv in ATF tor I minimum ot 30 minutes. 12. Starting with I clutch plats, ahernately instsll ths clutch platesand discs,Installthe clutch end platewith flat sidetoward the disc. NOTE: Before installingthe platss snd discs, mske sure the insideof the clutch drum is free of dirt or other forsign mattot.
CLUTCHENDPLATE
CLUTCH
Dtsc
9 . Remove special the tools. 1 0 . Installthe disc spring.
NOTE: . For 1st-holdand 2nd clutches . Installthe disc springin the directionsnown. 13. Installth snspring. Dtsc SPRI{G
SCREWDBIVEB
(cont'dl
14-125
Clutch
(cont'd) Reassembly
14. Measurethe clearancebetween th clutch snd plate 8ndtop discwith a dislindicator. Zero the dial indicstor with the clutch end plste lowered and lift it up to the snap ring. The distancs that the clutch end plate moves is the cleatance botween th clutch end plate8nd top disc. NOTE: Measureat three locations. Clutcfi End Plato-to-TopDisc Glearance: Clutch 1st 2nd 3rd 4th 1st-Hold Seryico Llmh
1E
It the clearanceis not within th service limits,select a new clutch nd platefrom the followingtable' NOTE: It the thickest clutch nd plst is installsd but the clearanceis still over the st8ndatd,roplacethe clutch discs 8nd clutch plstes. CLUTCHENDPLATE Phte t{o. 1 3 4 5
o
Part Number
Thlckncrs mm (lnl
0.65-0.85 mm(0.o26-O'033in) 0.65-0.85 mm(0.026-0.033 in) 0.40-0.60 mm(0.016-0.024 in) 0.40-0.60 mm(0.016-0.024 in) in) O.&-1.0O mm(0.031-0.039
I 9
22551-PX4-@3 2,562-PX4-m3 22553-PX4-OO3 22554-PX4-0o3 22555-PX4-@3 22556-PX4-@3 22557-PX4-@3 22558-PX4-003 22569-PX4-003
(0.o&') 2.10 2.n lo.oaTl

2.30(0.091) 2.40 to.og4l 2.50(0.098) 2.60(0.102 2.70(0.106) 2.& (0.110) 2.90(0.114)
TOPDISC
ENDPLATE CLUTCH
14-126
TorqueConverterHousingBearings
Mainshaft Bearing/Oil Replacement Seal
1. Driv out th mainshaftbearingand oil seal, usingthe sDecisltools shown, as 3. Installthe nw oils6alflush with the housing,usingthe as sDscialtools shown.
DRIVER 07749-OOTOOOO
DRIVER 07749-001o(xro
ATTACHMEIYT 07947- 6340500
ATTACHMEI\IT. 72x75mm 07740-(x)lo6{x, TOROUE COI{VERTER HOUSIT{G
Orive in the new mainshaftbsaringuntil it bottoms in the housing, usingthe specialtoolsas shown.
DRIVER 07749-OOl(xXX'
ATTACHMENT, 62x68mm
07746-(xrlos(x,
14-127
TorqueGonverterHousingBearings
CountershaftBearingReplacement
1. Remove the countershaft bearing using the special toolas shown.
Replacement Secondary ShaftBearing

1. Remove the secondary shaJt bearingby heating the torque converter housing to 212oF {10O"C) with a heat gun, then tap the housinguntil the bearinglalls our. CAUTION: Do not hoat tho case in excsss of 212oF (1OOoCl.
Comrnarclaly AvoiLbL 3/8 ln, r 16 throad./ln.

![de hammai
ADJUSTAELE BEARII{G PULLER, 25-4O mm 07736-AO1000A
COUTttTERSHAFT NEEDLE BEARII{G
/-\.=\-\ \, _-,/-_--_\,
Installthe oil guideplate. Drive th6 new bearing into th housing, using the specialtoolsas shown.
2. Installthe oil guideplate,

5.
Drive the new bea.ing into the housing, using the as specialtools shown.
DRIVER 07749-(x)lOqro
DRIVER 07749-OO10000
ATTACHMEifT, 62x88mm 07746-0010500
BEARING
BEARING
0 -0.03 l0 0.01inl
O-0.03 mm (0-0.01 In)

HOUS[{G
HOUSING
OII GUIDEPLATE
OIL GUIDEPLATE
14-128
Housing Bearings Transmission

1. To rrnovsths mainshait,countershsft and secondary shaft bearingslrom the tranamissionhousing,expand each snap ring with snap ring plisrs, thon push th bearing out. NOTE: to Do not remove th snap rings unlessit's necesaary clanthe groovesin the housing. insert Expsndach snap ring with snap ring pliers,ins the :he new baringpart-way into it. then releasethe pliors. I until the Push the bearingdown into the transmissionu ringsnapsin placaaroundit, NOTE: inside Inst8llwith groove side o{ the housingfacing ins the transmission housing.
lnstali
I
Remov
After installing bosringverify the following: th6 . The snap ring ls se8tedin the bearingand hol housing groovas. . Th6 snap ring operatesproperly. . Ths ring6nd gap is correct.
P: 0-7mm (O-o.28 in) SNAP RING
14-129
Transmission
Reassembly
NOTE: . Coat all parts with ATF. . Replace partsbelow: the .O-rings . Lock washers . Gaskets . Locknuts washers andconicalspring . Sealing washer . Torque mm Bohs: the 6 x 1.O k 1 2 N . m( ' 1 . 2 s m , 9 l b - f t )
6xl,Omm 2 Bohs
THROTTLE
CONTROL SHAFT
F;flilf":-.
STOPPER
Iw
Tluffir
e:'1
1 Boh VALVE REGULATOR BODY
O-Rlf{G Replace. 7 STATORSHAFT DETEI{T ARM S}IAFT DETENf ARiI
ATF STRAINER
4TH ACCUMULATOR COVER

8x1.Omm 2 Bohs LOCKWASHR Reolace.
SERVO DETET{T BASE SERVO SODY SEPABATOR SERVO PLATE CHECK BALLS VALVE SECOI{DARY BODY
COIWERTER TOROUE CHECK VALVE

CHECKVALVE SPRING
OIL FEEDPIPE
cot{TRoL
SHAFT
6x 1.0 1 Boh 8 x 1.25mm '18N m (1.8ks-m '13lb-ftl MAINVALVEBODY

OIL PUMPDRIVEN GEARSHAFT GEAR OIL PUMP DRIVEN
SEPAFATOR SECONDARY PLATE
V
GEAR OILPUMP DRIVE
PLATE MAIN SEPARATOR
6 x l.O inm 6 Eohs
ACCUMULATOR BODY COVER lST/2ND ACCUMULATOB EODY
DOWELPIN
CO HOUSIT{G TOROUE VERTER
14-130
Installthe main sepa.ator plate with three dowel pins on the torque converter housing.Then install the oil pumpgearsandoil pumpdrivengearshaft. NOTE: Installthe oil pump driven gear with its grooved and chamteredsidefacingdown,
OIL PUMP DRIVEN GEARSHAFT
8. Installtho scondarysaparator plate with two dowol

pins on the mainvalve body. Installth control shali in the housingwith the control together. shaft and msnualvafue
1 0 . Installthe dtent arm and alm shatt in the main valve

body, then hook the detent springto tho detent arm.
\ orl PUMP
DRIVEGEAR
rr-'rr \
SERVO SEPARATOR PLATE
11 ll
\U
II
II
GRoovE
SECO DARYVALVEBOOY OII PUMP DRIVEN CHAMFER GEAB
Groovednd chamfer6d aidefacs separatorplats.
COIVTBOL SHAFT
Installthe main vafue bodv whh tour bohs. Maks sure the oil pump drive gear rotates smoothly in the normal operating direction and oil pump driven gsar shaft movss smoothly in the axial and normal operating directions. lf the oil pump drive gear and oil pump driven gear shatt do not move treely, loosenthe main valve body bohs, realignthe oil pump driven gear shatt, and th8n retightento the specifiedtorque. CAUTION: Failuro to align tho oll pump drlvan goEr shaft correctly wlll rosuh In a seizadoll pump drlva getl 01 oil pump driven gear shalt.
DETEI{T SPRING
MANUAL VALVE 1 1 . Installthe secondaryvslve body, servo separatorplate and servo body with seven bohs.
't2. Installth6 oil fosd pipe in tho servo body, then install
the 4th 8ccumulator cover whh three bohs.
OIL PUMPORIVEN GEARSHAFT
12
Installth6ATF strainerwith two bohs.
:/ )
OIL PUMP DRIVEGEAR OIL PUMP DRIVENGEAR
14. Installthe servo dotont base with two bohs and new lock w8shers.
1 5 . Inst8llthe lst/2nd sccumulstorbody with six bohs. 1 6 . Installtwo oil ts6d pipes in the main valv body and
th pipe in the servo body,
4. 5.
Installthe stator shaft and stoDDer shaft. Install the two dowel pins, torque converter check vafue and torque converter check valve spring in the mainvalve body. Installthe.egulator valve body with the bolt on the mainvalve body.
7.
Installthe two dowel pins and separator plate on the regulator vatue body, then install the throttle vave bodv with seven bohs.
(conr'd)
14-131
Transmission
(cont'd) Reassembly
17. Install the differential assembly, countershaft subassembly, mainshatt sub-sssembly, and secondary in shaft sub-assemblv the torque converter housing.
MAINSHAFT SUB-ASSEMBLY
20. Turn the shitt tofk shaft so the largechamferedhole is facingthe fork bott hole.Thn installthe shift fork and the lock boh with a new lock washer, and torque Bendthe lock tab againstthe boh head
COUNTERSHAFT SUB-ASSEMBLY SH|T FORKBOLTHOLE
SHAFT SCCONDARY SUB.ASSEMBLY
LOCKWASHER Rplac6.
BOLT LOCK 6x1.Omm 14 N.m{1.4 kg-m, 10 rb-ft) FOBK SHAFT SHIFT HOLE BOLT hole Large chsmtred facssthisway.
TOROUE COi|vERTER HOUSING 1 8 . Installthe splined washer, thrust needle besring 8nd needlebearings the secondaryshaft. on
2 1 . lnstsll the secondary shaft 2nd gear, thrust needle

boaring and thrust washer on the socondary shalt. Installthe countershaft reverse gear and 2nd gear on the countershaftas shown.
1 9 . lnstall the needle bearings. countershaft 4th gear,

reverse selector hub, and reverse selector with the shift fork on the countershaft. NEEDLE BEARING REVERSE SELECTOR REVERSE
lnsta in this direction.
THRUST WASHER SHIFT FORI( THRUST NEEDLE BEARIMi
COU TERSHAFT GEAR 21{D
COUUTERSHAFT REVEBSE GEAR SECONDARY SHAFT 2NDGEAR
EEDLE BEARINGS
COUNTERSHAFT
THRUST NEEDLE BEARING
COUNTERSHAFT 4TH GEAR
SECONDARY SHAFT
NEEDLE BEARIiIG COUNTERSHAFT
SECOI|I'ARY SHAFT
14-132
22. Slipthe rverseidlsr gearinto the transmissonhousing s snown.
m. hstall the trsnsmissionhousingbolts and t.ansmission hanger,then torque the bolts to 55 N.m (5.5 kg-m, rlo lb-ft) in two or more steps in the pattern shown.
v|>=l
,Adlafu
R@P
23. Align the spring pin of the control shaft with the transmission housing g.oove by turning the control shaft. 24. Install thr6 dowel pins and a new gasket on thg torqus converter housing, 25. Plscs ths transmission housing on the torque convertr housing. CONTROL SHAFT the reverse idler gear to the countershaft and 27. Engage mainshattreverse gesrs, then installthe reverse idler gesr shaft holderon the transmission housing,
6x1.0mm 12 N.m (1.2 ks-m , I lb-ft)
1 0r 1 2 5 m m 55 N'm (5.5 kg-m , 40 b-ftt
DOWEL PI
h E
28. Install the parking brske lever on the control shaft, then torque the lock bolt loosely with a naw lock wasner. NOTE: Do not tighten the lock boh to the specifiedtorque and bendthe lock t8b in this steD.
DOWEL PIN
14-133
Transmission
(cont'dl Reassembly
the 29. Sliothe sDecialtoolonto mainshaft.
MAINSHAFTHOLDER OTGAB-PF50100ol 07GAB-PF50101
35. Placea 24 mm socket on the parkinggeEr,and instslla 10 x 1.25 mm boh in the count8rshaft. Then engage the parking brake pawl with the parking gesr by movingup the parkingbrake pawl. CAUTlOltl: Kap anof tho particlosout of tho transmissionwhon insialllng a bolt. 36. Tightenthe boh and lightlyseat the parkinggear. NOTE: Do not drive the parkinggearon whh a hammer. 37. Removethe boh and socket. 38. Use the old locknut to tighten the press fit parking gearto the specifledtorque, then loosenit. TOROUE:230 N'm {23.Oks-m,166 lb-ft)
30. Installthe mainshaftidlergear.

21
Installthe old locknut on the mainshaftto seat the idler gear. NOTE: . The mainshaftlocknut has left-handthresds, . Do not drive the idlergearon with a hammer. TOROUE:230 N m (23.Oks-m, 166 lb-ft)
mm SOCKET.24
PARI(ING GEAR
32. Installthe secondaryshaft idlergear on the secondsry

shaft.
10 x 1.25 mm BOLT PARKING BRAKE
33. Installthe thrust washr, thrust needlebearing,needle

bearing,countershatt idler gear and parking gear on the countershatt. PAWL
34. Installthe old locknut on the secondaryshaft. Tighten
the old locknut to seat the secondaryshaft idler ge81 the while holding countershsJtidlergear. NOTE: Do not drive the idlergearon with a hammer. TOROUE: 30 Nm(23.0 ks-m,166 lb-tt) 2
39. Remove th old locknuts, th8n install new conical springwashers8nd new locknutson each shstt' CAUTION: Insts[ th conical spfng washora In tho di]octlon shown,
MAINSHAFTLOCKNUT Left-h8ndthrads
PARKII{GGEAR
COUMTERSHAFT LOCK'{UT
Stmp siJs
CONICALSPRING WASHERS hstall in this diroction.
SHAFT SECONDARY IOLER GEAR
14-134
40, Tightenthe locknutsto spcifiedtorque. TOROUE: Mainrhaft Countorshaft Secondaryshaft 170 N'm {17.Okg-m, 123 lb-Jt) 170 N.m (17.0 ks-m , 123 lb-ftl 't70 N.m (17.0 ks-m, 123 lb-ft)
42. St rhe psrking brake lever in tne lT-l position, thon
the verity that the parkingbrake pswl ei-gages parking 9ear.
4i,. lf th pswl doss not engagefully, check the psrking brake pawl stopper clearanceas describedon page 1+136. 44. Tightenthe lock boh, and bendthe lock tab againstthe bolt head. PARKIMiBRAKE ROLLER LEVER
NOTE: threads locknut lelt-hand has Themainshsft
TOROUE WRENCH
SECONDARY SHAFT IOLER GEAR
PARKINGBRAKE PAWLSHAFT
PAWL
45. lnstallthe right sidecover.

41. Stake each locknut into its shsJt using a 3,5 mm puncn.
TOROUE: 12 N'm {1.2 kg-m, 9 lb-ftl
0.7-1.2 mln 10.o3-0.05Inl
washers. 46. InstalltheATF cooler pipeswith new sealing TOROUE:29 N'm (2.9 ks-m , 21 lb-ft) 47. Installthe ATF levelOauge.
14-135
RightSideCover
FeedPipeInstallation
Installthe feed pipes in the right side cover with new the lugs with the grooves in the right O-,ings,aligning side over. Installthe snap rings,
ParkingBrakeStopper
Inspection/Adjustment
1. 2. brakeleverin thel P lposition. Set the parking Measurethe distancebetween the psrkingblake pawl shaJtand the parkingbr8ke lever roller pin as shown. STANDARD:64.5-65.5 mm {2.54-2 58 in)
PARKINGBRAKE PIN LEVERROLLER LOCK BOLT 6xl.0mm 14 N.m (1.4 kg-m , 10 tb-ft)
PARKINGGEAR
Distanc6
BRAKE PARKING STOPPER

PARKING BRAKELEVER
NGHTSIDE COVER
Fififtflllf*
PARKTNGBRAKE
ff the measuremant is out oJ tolerance, select and parking brakestopperfrom the install sppropriate the tablebelow.
, '.l r - - f f i - T , , . --Tr
I r lr \ , l\ ,l , / |
\ \t-l /
PARKINGBRAKESTOPPER
,/r>
BRAKE STOPPER PARKING

Mark
I
Part Numbor
Ll
Lz
-PA9-OO3 11.0Omm 24537

(0.433 in)
11.00mm (o.433in)
10.65 mm (0.419 in)
24538-PAg-m3
1O.8Omm (0.425 in)
24539-PAg-OO3 10.60mm
(0.417 in)
10.30mm (0.400in)
brakestoppor,make sure the After replacing parking the distanceis within tolerance.
14-13 6
TorqueConverter
Disassembly
ErlOm.r| 75 N.m{7.5kem , 54 b-ftl
DRIVE PLATE lnsDct crackg. for
TOROUE VERTER CO GEAR ASSEMBLY/RI'{G
1 2x 1 . 0m m 75 N.m(7.5kgtsm54 b-ft) , Torquo crisscrogs in Dattgrn.
14-137
Transmission
lnstallation
1 . Flush ths ATF cooler as describedon psges 14-142 and 143. 5. Installthtransmission housingmountingbolts.
2. lnstall the stsrter motor on the torque converter

housing, inst8llthetwo 14 x 20 mm dowel pinsin and the torque converter housing, ATARTER MOTOR
45 N.m 14.5 kg-m ,
33 tuft)
DOWEL '14x 20 PIN mm
HOUSIG TRAI{SMISSION MOUiITING BOLTS 12 r '1.25 mm 65 N.m(6.5 kgtsm lb-ft) ,47 PIN DOWEL 14r20mm TOROUE CONVERTER ASSEMBLY
Roplaca.
o.
Place the transmission on I jack, and raise to th engine8ssmblylevel. 4. Attach the transmissionon the engine,then installthe transmission housing mounting bolts, raar engine mountingbohs and intake maniJold bracket botts.
INTAKEMANIFOLD ERACKETBOLTS I x 1.25 mm 2. N.rn 12,2 kg-m , 16 tb-ft)
Tighten the front engine mount bracket bolts to sp6cifiedtorque.
FROT{T EI{GII{E MOUNf BRACKETBOLTS 10 x 1.25 mm 39 N.m (3.9 ksFm, 28 lb-ft)
I1{TAKE MANIFOLD
BRACKET
TRANSMlsSION HOUSING MOUNTING BOLTS 12 r 1.25 mm (6.5 kg-m , 65 N.m 47 tb-ft}
FNOI{T E GINE MOUNTBRACKET
FROI{TE'{GINE MOUl{f
TRAfISMISSK)N JACK
MOUNfiNG REARENGINE BOLTS 12 x 1.25 mm Rplac. 55 N.m (5.5 ks-m ,40 lb-ft)
14-138
Installthe transmissionmount. Tighten the bott then tighten the nuts to specifiedtorque, and retightenthe boh to specified torque. NUTS 1O 1.25mm x 39 N'm(3.9kem,28 b-ft)
10. lnstafi the control lsvsr with the shift cable on the control shaft, CAUTION: Tak6 cara not to bondtho shlft cEHo. 11. lnstallthe lock boh with a new lock washer,then bend ths lock tab. 12. Instsll the toroue converter cover and shift cable covar.
cot{TRoL LEVER
SHIFT CABEL
LOCK WASHER R6plsc.
CONTROL SHAFT
SHIFTCABLE COVER
1 2 r 1 , 2 5m m 65 N.m {6.5 kgim , 47 h-ft)
LOCI( BOLT 6x1.Omm 14 N'm (1.4ks-m, 10 b-ft)
TOROUE COI{VERTER COVER
8 x 1.25 mm 18 N.m (1.8 kg-m , 13 lb-ftl
0 x 1.0 nvn 12 N.m (1.2 kg-m,9 lb-ft)
8. o
jack. Removethe transmission
13. Install rightradius anddamper the rod fork.

Attach the torque converter to the drive plats with eight bolts, snd torque to 12 N.m (1.2kg-m, 9lb-ft). Rotate the crankshsJt 8s necessary to tighten th 'll2 botts to of the specifiedtorque, then linaltorque, in I crisscrossDattern. After tightening the last bolt, check thst the crankshaft rotstes freslv.
6x1.Omm 75 N'm (7.5 kgtsm 54 h-ft) .
NOTE: Checkfor dotsrioration damage the radiusrod or of rubber bushings.

SELF.LOCKING NUT 12x1.25 m m
DAMPEBPINCHBOLT 1Ox 1.25 ftm Roplace. 55 N.m {5.5 kg-m ,40 b-ft}
R6place.
44 N.m(4.4kem,32 b-tr)
RUBBER BUS}IINGS RADIUS ROD

l2 x 1.25 mm 105 N.m (10.5 kgFm.76 lb-ft) Roplaco. {cont'dl
14-139
Transmission
1 4 . Instsllnew set ringson th end of th drivsshsfts' 1 5 . Installthe right snd left driveshafts. NOTE: Turn the right 8nd lelt steeringknucklesfully outward, and axisllv into th difterential until you f8sl th set th ring engage sidegear.
to.
19, Installthe vehicle speed sensor/powersteeringspeed ssnsor and roar stiffoner. Conngcl the vehiclo spe6d
connecror. sensor
BOLT SPECIAL 6x1.Omm 12 N'm(1.2kgFm.9b-ft)
lnstallths damDerfork to the lower arm. Thsn instsll the bslljoint to the lower arm. Usethe castls nuts whh new cotter olns.
POWER STEERIl{G SPEED SE\lsqR 10x 1.25mm 21 N'm (2.'lks-m, 15 tb-ft) O-RING R6pbc6.
REARSTIFFENER
1Or1,25 m m 39 N.m(3.9 ks-m, 28 lb-ft)

NUT SELF-LOCKING 12 r 1.25 mm 65 N.m {6.5 kem , 47 b-ft} R6phco.
n.
CASTLE IUT l2 x 1.25mm 65 N.m16.5ks-m, 47 h-ft) COTTER PI Replaca.
Connoctth ATF cooler hosesto the ioint pip6s. solsnoid vslve connectors, 8nd the throttle control cabls.
21. Connect the lock-up control solenoid, shift control
22. Connectths msinshaftsp66dsenaorconnector.

17. Installth rear beamstiffner 8nd center be8m. SOLEM)ID VALVE col{t{EcToRS
CEI{TER BEAM 1 0x 1 . 2 5 m m 39 N.m{3.9 ks-m. 28 b-ft) 18. hstat the solashshield. 10 x 1.25mm 60 N.m{6.0 krm , 43 tb-ft)
Installthe ground cablein step 26.
,t
14-140
B . Connectthe countershaitsoeedsensorconnector. 24. Connectth starter motor cables.

NOTE: When installingthe starter cable, mak sur6 that the crimped side ot the ring terminal is facing out (see section 23). COUI{TERSHAFT SPEED SEITISOR CONNECTOR
27. Install the intske control vacuum tank and intake control vacuum tank brscket, then connect the connecror. 28. lnstallthe air cleanerhousingand intake air duct. with ATF (see page14-74. 29. Refillthetransmission 30. Connect the battery positive (+) and negative (-) cablesto the battery. Set the parkingbrake,and shitt the 31. Start the engine. trsnsmissionthrough all gears three times. Check tor proper shift cablesdjustment. 32. Check 8nd adjust the front wheel alignment (see section 18).
33, Let the enginereach operatingtemperatur!_lthe ralie-tor coms with the transmission I N I or f8n on) in thenturn it off andch6cktluidl8vel. I P I position,
34. Roadtest as describedon pages1+68 thru 14-7O. 35, R8setths radiostations. 36. Loosenthe tront enginemount bracket botts after the road test, and retightenthem to specitiedtorque.
CABLS
25. lnstallthe bsttery bsseand basestay. 26. Connect the ground cable to the body and the
transmission. GROUND CABLE
FRONTENGINE MOUNTERACKET BOLTS 1Ox 1.25 mm
39 N.m(3.9 ks-m, 28 lb-ft)
FROl{f ENGINE MOUiff BATTERYBASESTAY
14-141
I
Transmission
CoolerFlushing
7. To prcvent iniury to faco and eyes, always woar salety glasses 01 a laco shleld when using tho lransmlssion tlusher, NOTE: the This procedureshouldbe performedbefore reinstalling transmission. 1. Checktool andhosesfor wear or cracksbeforeusing. It wear or cracks are found, replacethe hoses betore using. Usingthe measuring cup, fillthe tank with 21 ounces (approximately full)of biodegradable fluid tlushing 23 (J35S44-20). Do not substitute with any other tluid. procedureon the tluid container. Followthe handling the Securethe flusherfiller cap and pressurize tank a w i t h c o m p r e s s i r t o b e t w e e n5 6 0 - 8 4 5 k p a { 5 . 6 8.45ks/cm,,80- 120 psi). NOTE: The air line should be equippedwith a water trap to I ensure drYair system. 4. 5. 6. Hsngthe tool underthe vehicle. Attach the dischsrgehose of the tank to the return lineot the transmission cooler usinga clamp, Connect the drain hose to the inlet line of the transmission cooler usinga clamp. IMPORTANT: Securelyclampthe oppositeend of the drain hose to a bucketor floordrain, With ths water and air valves oft, attach the watr (Hot water it svailsbl8.) 8nd air suDDlies the Jlusher, to
OFF
2.
3.
Turn on the flusher water vave so water will flow the for through oilcooler 10 seconds NOTE: lf wster doos not flow through the oil cooler it is completoly plugged.cannot be flushed, and must be reolaced.
9. Depressthe trigger to mix the flushing fluid into thg

water flow. Usethe wire clip to holdthe triggerdown.
1 0 . While flushing with the wat6r and flushing fluid {or 2

every 1S minutes, turn the sir valveon for 5 seconds 20 secondsto create a surgingaction. AIR PRESSURE; MAX 845 kp8 (8.45kg/cm', 120 psi) the trigqer,then 11. Turn the water vave off. Release reversethe hosesto the cooler so you can tlush in the oppositedirection.Repeatsteps I through 1O. 12, Releasethe trigger and allow wster only to rinss the coolr with water tor one minule 13. Turn the water vslve ofl 8ndturn off the water supply. 14. Turnthe air vslveon to dry the systemout with airJor two Jull minutes or until no moisture is visible leaving the drainhose. CAUTION: Rosldual moisturo In the oil coolor or plpo3 can damagethe tiansmlssion. 15. Removethe flusherfrom the coolerline.Attach the drainhose to a oil container, 16. Install the transmission and leave the drain hose attachedto the coolor line.
COOLER TRANSMISSION FLUSHER J38405-A
14-142
L
1 7 . Make sure the transmission inl P lposition. is Then tillthe trsnsmissionwith ATF and run the engine for 30 secondsor until approximately0.95 0 (1.0 US qt.,O.8lmpqt.l is discharged.
TOOL MAINTENANCE 1. Emotyandrinseatter eachuse.Fillthecan with watsr and pressurizethe can, Flush the discharge lino to ensurethat the unit is clean. lf dischargeliquiddoes not foam. the orifice may be blocked. To clean,disconnectthe plumbing trom the tank at the large coupling nut. Remove the inline tiher from the dischargeside and cleanif necessary. The Jluidorifice is locatedbehindthe fiher. Cleanit with the pick stored in the bottom of the tank handleor blow it cleanwith air. Securelyreassemble all
DArtS.
1 8 . Remove the drain hose and reconnect the cooler

return hose to the transmission.
tcl
2. 3. 4. 5.
Refillthe transmission with ATF to the orooer level (seep89e 1+74.
FILLER CAP
14-143
shift cable
1. . Make suro llfts, lacks and satty stands aro dacod plopelly, and hobt brackots ars attachod to the corroct positlon on the englne{se6sectlon 1). . Apply parklng brake and block roar whoob, so car wlll not lol olf stands and fal on you whllo working undorh. CAUTION: . A SRS olectllcal wiring harnorsos aro coverod whh ydbw oui61 imulaiion. . Boforo dlsconnectingthe SRS who harness, Instal tho short connctor(s)on the aiftag(sl. . Roelacetho 6nthe aftctod SRS harn63sa$cmbly lf h has an opon circuh or damagdwiring. Z. Removethe front console{seesection 2O}' Stritt to I tttl position, then remove the lock pin from the cabte-adiuster. Removethe bohs securingthe bracket.
3.
LOCK PI 6 x 'l.Omm 10 N.m (1.0 kg.m , 7 luft)
BRACKET ADJUSTER
4.
Removethe shitt cablecover. Remove the lock boh securingthe control lever, removethe control lever with the shift cable'
SRSMAIN HARI{ES8
COt{TROL LEVER
6x1.Omm 1 2 N . m( 1 kem , I lb-lt)
SHIFTCABLE
sHtFT CABLE COVER

8 x 1.25 mm 18 N.m (1.8 ks-m, 13 b-ft)
BOLT LOCK 6x1,0mm '10lb-ftl 14 N'm 11.4kem ,
14-144
6.
Removeth exhaust pipeB and heat shiell. SELF.LOCKING NUT 34 N'm(3.4 kem . 25 b-ft)
R6pl8c.
8.
Removethe cotter pin and lock pin, then separatetho control lver from the shift cable.
SHIFTCABLE SELF.LOCKING NUT 56 N.m (5.5 k$m ,40 b-ft) HEAT SHIELD
PIN COTTER Rspbca. PIPE B EXHAUST GASKET R6phc. 9. lnstallth8 shift cablin the reverseorder of removal, 10. Check the cable adiustment after instsllingthe shift cable (seepage1+146).
7,
Romovethe cablsguideand grommet.
Exl.Omm 12 N.m (1.2 ksFm,I b-ft)
14-145
Shift Cable
Adjustment
CAUTION: . All SRS oloctlical wirlng harno3sos alo covorod whh ydbw ouier insulation. . Befolo disconneclingtho SRS who harn6ss, lnllall tho short connoctor (s) on tho ai6ag (s). . Replscsthe sr iro 8fiect6d SRs halno$ Esrembly lf h has an open circuit or damagdwiring. 4. Check that the hole in the adiusteris pertectv sligned with the holein the shift cable.
AIT'USTER
Cabh Too Shon
Cabl Too Long
Exact Alignmnt
Stan the engine.Shift to reverseto see il the reverse on gear engages. not, reJerto Troubleshooting page lf 1+64 thru 67. With the engine off, remove the tront console (sae section 20). Snit to I tt l position, then remove ths lock pin from the cable-adjuster,
NOTE: There are two holesin the end of the shift cable.They 9Ooapart to allow cable adiustmentsin are Dositionad 1/4turn increments. loosenthe locknut on the shift lf not pertectly alignod, cable,and sdiust as required.
6. Tightenthe locknut.
Installtho lock pin on the adiuster.lf you tesl the lock pin bindingas you reinstall it, the cable is still out of adjustmentand must be readiusted. Move the shift lever to eachgearand verify that the A/T gear position indicator follows the A/T gear positionswitch.
l'.
Start the engineand check the shift lever in allgears.lf any gear does not work properV, reler to troubleshootingon page14-64 thtu 67, gar indicatot panel,8nd verify that the shift lock lever is released.
1 0 . Insertthe ignitionky into the key cylinderon the A/T
SHIFTCABLE
LOCK NUT 7 N'm lO.7kg-m 5.1 tb-it)
AOI'STEN
14-146
E.
GearshiftSelector
CAUTIOI{: . A[ SRS olectrlcal wlrlng hamossos alo cove]ad with yellolYouter inlulation. . Baloro dlsconnectlng tho SRS who harn6ss, Instsll the short connector (s) on the alrbsg (sl. . Raplacotho entilo affectsd SRS harnoss assombly lf it h!3 an opon circuit or damagedrylrlng.
SELECT LEVER KNOB
SRS MAIN HARI{EAS
,,J:::$
3 N.m(0.3 ks-m, 2.2 b-ft) AppV non-hardening thre8d locksoalsnt.
A/T GEAR POSITION INDICATOR PANEL
-Gl
ICONE GREASE
COVER LEVER
10 N.m ('1.0kgFm, 7 h-ft)
MOUNT BRACKET SELECTOR
14-147
Panel Indicator A/T GearPosition

Adiustment
CAUTIO : r Al sRS clectrlcd wl ng h!m.rsc! ar. covoled wlth yalow outcr lmuhlon. . Bcforo dtconncctlng th. SRS wlr. harn33s, lmtal tha rhort comoctor bl on tha ahbrg lsl. . Replrct th..ntlrc eff.ct.d SRS harn.3. assombly lf h ha! an opan drcuh or damagpdwlrlng. 1 . With the transmissionin I N I position, chsck that the alignswith ths N mark on index msrk on the indicst-or gosr plgtion indicator panel when th the A/T t.ansmissionis in Lll position. lf not sligned,rsmovs the front conaole (sso section
2ol.
3. Remove the A/T gear position indicstor pansl
mountingscrews, and adiustby movingth8 pansl' NOTE: Whenever the A/T g8r position indicstor panel is removed,.sinstallths psnelas d6scribedabovo. POSITIOI{ A/T OEAR PAI{EL II{IXCATOR
14-148,
ThrottleControlCable
Inspection
NOTE: Before inspecting the throttle control cable, make sure that: . Throttle cablefree Dlayis correct {seesection 11), . ldlespeed correct(seesection11). is . You warm up the engineto normal operating temperature{theradiator comeson), tan 1. Verify that the throttle control lever is synchronizsd with the th.ottle linkagewhile depressino and releasing the acceleratoroedal. 2. ff the throttle control lever is not synchronizedwhh the throttle linkage. ad.iust throttle controlcable. the 3. Check that there is plsy in the throttle control levsr while depressingth accGlerator pedal to the fulF throttle oosition.
THROTTLE LINKAGE
Remove the cable end oJ the throttle control cablo trom tho throttls controllavsr. 5.
THROTTLE CABLE
Check that the throttle control lsv6r moves smoothly.
THROTTLE CONTROL LEVER
THROTTLE COI\ITROL LEVER
1 4 -14 9
Throttle ControlCable
Adiustment
NOTE: the Beforeadjusting throttle controlcable,make sure that: . Throttle cablefree play is correct (seesection 11). . ldlespeedis correct(sesection11). . You warm up the engine to normal operatingtemperfan ature(theradiator comeson l, 1. Verify thst the throttle linksge is in the fully-closed oosition. 4. Tightenthe locknuts.
LEVER THROTTLE CONTROL
LINKAGE THROTTLE
5.
A{ter tightening the locknuts, inspect the synchronization8ndthrottle control lever movemsnt.
Loosenthe locknut on the throttle control cableat the throttle control lever. Removethe free play in the throttle control cablewith the locknut, whil6 pushingthe throttle control lavt to the tullv-closed Doshionas shown.
NOTE: To tailor the shift/lock-up characteristicsto 8 particular customer's driving expct8tions, you can adiust the throttle control cablup to 2mm {0.078inl shorter thsn tho "synchronized" point.
LEVEB THROTTLE COI{TROL Pushin this direction.
t-
14-150
Differential
Manual Transmission ............................ 15-t Automatic Transmission ....................... 15-10
(ManualTransmissionl Differential
Special Tools.......... ...........15-2 Differential lllustrated Index................................. 15-3 Backlash Inspection ...... 15-4 FinalDriven GearReplacement ........ 15-4 Tapered RollerBearing Replacement ....................................... 15-5 Oil SealRemoval ........... 15-5 Bearing OuterRace Replacement ....................................... 15-6 Tapered RollerBearing Preload Adjustment .................... 15-7 OilSeallnstallation ....... 15-9
SpecialTools
Re{.No.
Tool Numblr 07GAD07HAJ 07JAD07JAD07LAD07746 07746 07746 07749 PG40'100 PK40201 PH80101 PH80400 PW50601 0010400 0010500 0010600 0010000 Driver Attachment Tool Inspection Preload Driver Attachment Pilot.28 x 30 mm 40 Attachment, x 50 mm l.D. Attachment,52 x 55 mm Attachment.62 x 68 mm 72 Attachment, x 75 mm Driver 15-9 15-7 15-9 15-5 15-6 '|5-6 15-6 I 15-6,
o @ o
@ @
@ @
@
,6
15-2
lllustratedlndex
NOTE:lf the ' mark partswere replaced, taperedrollerbearingpreloadmust be adjusted (seepage15-9). the
OIL SEAL Removal,page 15-5 Installation,p8ge 15-9
.BEARIT{GOUTERRACE page 15-6 Replacsment, Inspecttor wear and damage, .TAPERED ROLLER BEARING page 15-5 Replacement, Inspgctfor wear and damag. 'TAPERED ROL1IR BEARING page 15-5 Replacement, Inspoctfor wear and damagg. TBEABINGOUTEB RACE page 15-6 Replgcement, Inspectfor wear and dam6ge.
.THRUST Sel6ct,Adjustment,page 15-7 10 x 1.25lnm kg-m,7a lb-ftl 103 N.m 110,3 Left-handthreads.
DRIVENGEAR page 15-4 Replacement Inspectfor wear and damage.
(@o..._
ITHRUSTSHIM CAFBIER Inspectfor cracks.
r;-
page 15,5 Remov1, lnstallation, pag15-9
15-3
BacklashInspection
1. assemblyon V-blocksand inst8ll Placedifferential both driveshafts. of the Measure backlash both piniongears. mm Standard {Newl: 0.05- O.'15 10.002 0.006in)
FinalDrivenGearRePlacement
1, Remove the bolts in a crisscrosspattern in several steps,and removethe final drivengearfrom the ditcarrier. ferential NOTE: The final driven gar bolts have left-hand threads,
2.
Chamferon inside diametor of final driven goar facoscarraer' DIAL INDICATOR PINIONGEARS
10 mm EOLT 103 N.m (10.3kg-m, 74lb-ft|
Installthe final driven gear by tighteningthe bolts in a crisscrossDatternin severalsteps.
lf the backlashis not within the standard,replace carrier. the differential
15-4
Tapered RollerBearing
Replacement
NOTE: . T h e t a p e r e dr o l l e r b e a r i n ga n d b e a r i n go u t e r r a c e shouldbe replaced a set. as . Inspect and adjustthe taperedroller bearingpreload wheneverthe taperedrollerbearingis replaced. . Check taperedrollerbearings wear and rough the for rotation.lf taperedrollerbearings are OK, removalis not necessary. 1. Remove the taperedroller bearingsusinga bearing puller.
BEARING PULLER
Oil SealRemoval
1. 2.
Remove differential the assembly. Remove oil sealfrom the transmission the housing.
OIL SEAL Replace.
3.
Remove oil sealfromthe clutchhousinq. the
Installnew taperedroller bearings usingthe special tool as shown. N O T E ;D r i v et h e t a p e r e dr o l l e r b e a r i n g s n u n t i l o they bottomagainst differential the carrier.
CLUTCH HOUSING
ATTACHMENT, 40 x 50 mm l.D. 07LAD - PWSool
otl sEAt_
Replace.
15-5
OuterRaceRePlacement Bearing
NOTE: . T h e b e a r i n go u t e r r a c e a n d t a p e r e dr o l l e r b e a r i n g as shouldbe replaced a set. . Inspectand adlustthe taperedroller bearingpreload the whenever taperedrollerbearingis replaced. 1. housing the Remove oil sealsfrom the transmission (see age'15) h a n dc l u t c h o u s i n g P 5 Drivethe bearingouter raceand thrust shim out of o h t h e t r a n s m i s s i o n o u s i n g , r r e m o v et h e b e a r i n g outer race and thrust shim from the transmission h h o u s i n gb y h e a t i n gt h e t r a n s m i s s i o n o u s i n gt o ( ) a b o u t2 1 2 " F 1 0 0 ' Cw i t h a h e a tg u n . CAUTION: Do not reus the thrust shim if the outer racGwas driven out. h N O T E : D o n o t h e a t t h e t r a n s m i s s i o n o u s i n gi n of excess 212'F(100'C).
TRANSMISSION HOUSING: ORIVER 07749- OOl(Xno
3.
After installingthe thrust shim. install 8n bearing outer race in the transmissionhousing and clutch tools as shown. housingusingthe special NOTE: . Installthebearingouter racesquarely. . Check that there is no clearancebetween the bearing outer race,thrust shim, and transmission housin9.
2.
TRANSMISSION HOUSING: DRIVER 077a9 (xn(xx)o
ATTACHMENT, fi:l x 68 mm 077i16- (x)los(x)
ATTACHMENT, 52x55mm 07715- (X)10400 THRUSTSHIM
THNUSTSHIM
CLUTCH HOUSING:
BEARING OUTEFRACE
:'----J)-4
ATTACHMENT. 72xt5mm 07746 - 0011}600
DRIVER - 00tqx)0
EEARING
OUTER THRUST Install the oil seal{seepage15-9).
4.
THRUST SHIM
RACE OUTER
15-6
RollerBearing Preload Adjustment Tapered

NOTE: lf any of the items listed below were replaced, the taperedrollerbearingpreloadmust be adjusted. . o . o . 1. Trsnsmission housing Clutchhousing Differentialcarrier Tapered rollerbearingand bearingouter race Thrustshim After installingthe thrust shim, installthe bea bearing outer race in the transmissionhousing (see t re page 15-6). NOTE: . Install the bearingouter racesquarely. . C h e c kt h a t t h e r e i s n o c l e a r a n c e e t w e e nthe b between transmis bearingouter race,thrust shim and transmission nousrng.
4.
R e m o v et h e b e a r i n go u t e r r a c e a n d t h r u s t s h i m from the transmission housing(seepage 15-6). NOTE:Installthe thrust shim onlv on the transmission housingside. CAUTION: Do not reusothe thru3t shim it the boaring outer rrco wls drivcn out, NOTE:Let the transmission cool to the room temperature if the bearing outer race was removed by heatingthe transmission housing befo.e adjusting the taperedfoller bearingpreload.
W i t h t h e m a i n s h a f ta n d c o u n t e r s h a f tr e mo v e d , o' i n s t a l lt h e d i f f e r e n t i a a s s e m b l y , n d t o r q ue t h e l a e housing, clutchhousingand transmission TOROUE: x 1.25mm:45 N.m 10 ('1.5kg-m, 33 lb-ft| 8 x 1.25mm: 28 N.m (2.8 kg-m, 20 lb-ft1 N O T E : l t i s n o t n e c e s s a r y o u s e s e a lI in g a g e n t t ng ( betlveen housings. the
5. 2. F i r s tt r y t h e s a m e s i z et h r u s t s h i m t h a t w a s r e moved. 6. CAUTION: Use only ono thrust rhim.
Rotatethe differential assemblyin both direct directions to seatthe taperedrollerbearings. Measurethe startingtorque of the differentialasrent|al semblywith the special tool and a torquewrenc wrench. 1.4 STANDARD: - 2.6 N.m 114 26 kg-cm,12 - 23 lb-inl
THRUSTSHIM
I
C
HOUSING TRANSMISSION
NOTE: . M e a s u r e h e t a p e r e dr o l l e r b e a r i n gp r e l o a o I roa A t normSlroom temperature. a M e a s u r e h e t a p e r e dr o l l e r b e a r i n gp r e l o a oi n t both directions.
WRENCH
TOOL INSPECTION PRELOAD 07HAJ- PK40201
{ c o n td I
15-7
Differential {ManualTransmission)
Tapered Roller BearingPreloadAdiustment {cont'dl
7. ll the tapered roller bearing preload is not within selectthe thrust shim which will give the standard, the correcttaperedroller bearingpreloadfrom the followingtable. NOTE: Changingtho thrust shim to the next size o t w i l l i n c r e a s e r d e c r e a s e a p e r e dr o l l e r b e a r i n g preloadabout3 - 4 kg-cm(2.60 3.47lb-in). THRUSTSHIM Part Numbr 41381 PXs- 000 B 41382-PX5-000 41383-PX5-000 Thickneee in) 1.90mm (0.075 i 1 . 9 3 m ( 0 . 0 7 6n ) m in) 1.96mm {0.077 '1.99 mm (0.078 in) inl 2.02mm (0.079 in) 2.05mm (0.081 in) 2.08mm (0.082 i 2 . 1 1m m ( 0 . 0 8 3n ) i 2 . 1 4m m ( 0 . 0 8 4n ) i 2 . 1 7m m { 0 . 0 8 5n } in) 2.20mm (0.087 in) 2.23mm (0.088 in) 2.26mm (0.089 in) 2.29mm {0.090 in) 2.32mm (0.091 in) 2.35mm (0.092 in) 2.38mm (0.094 i 2 . 4 1m m ( 0 . 0 9 5n ) in) 2.44mm (0.096 in) 2.47mm (0.097 10 TOROUE: x 1.25mm: 45 N'm {,[.5kg-m, 33 lb-ftl 8 x 1.25mm: 28 N'm (2.8kg-m, 20 lb-ft| assemblvin both directions 1 1 . Rotatethe differential seatthe taperedrollerbearings. to thrustshim: the 9. How to select correct - 1 ) C o m p a r et h e t a p e r e d r o l l e r b e a r i n gp r e l o a d you get with the thrust shim that was removed, preloadof l4 - 26 kg cm ('12 with the specified - 23lb-in). -2) lf your measured taperedrollerbearingpreload subtractyours irom the is lessthan specified. specified. , l f y o u r s i s m o r e t h a n s p e c l f i e ds u b t r a c t h e from your measuremenl. specitied with a 2.17mm thrustshim: For example 26 kg-cm(23 lb-in) @ specified you measure 6 kg-cm(5 lb-in) 2 0 k g - c m 1 8 l b - i nl)e s s { @ you measure 34 kg-cm(30 lb'in) - specified 26 kq-cm(23 lb-in) 8 kg-cm(7 lb-in)more -3) Eachshim size up or down from standard makesabout 3 - 4 kg-cm (2.60- 3.47 lb-in) in difference taperedrollerbearingpreload. . taperedroller In exampleA, your measured p r e l o a dw a s 2 0 k g - c m l e s s t h a n bearing s t a n d a r ds o y o u n e e d a t h r u s t s h i m f i v e sizesthickerthan standard(try the 2.32mm thrustshim,and recheck) . In exampleB, yours was 8 kg-cm more than s standard, o you needa thrust shim two s i z e st h i n n e r( t r y t h e 2 . 1 1m m t h r u s ts h i m , and recheck).
c
E
F
41384-PXs-000
41385-PX5-000
41386-PXs-000 41387-PXs-000 41388-PXs-000

41389-PX5-000
J K L M
N
41390-PXs-000
4 1 3 9 1P X 5 - 0 0 0
41392-PXs-000 41393-PXs-000
41394-PX5-000 41395-PXs-000
o
P
41396-PXs-000
41397-PX5-000
o
R T 8.
41398-PXs-000
41399-PX5-000 4' 1400-PX5-000
'10.After adjustingthe tapered roller bearingpreload,

and installthe transmisthe assemble transmission sion housing(seepage'13-3'l).
Recheck taperedrollerbearingprload. the
15-8
Oil Seallnstallation
lnstallthe new oil seal flush with the transmission tools as shown. housingusingthe special 2. Installthenew oil sealinto the clutchhousingusing as the sogcialtools shown,
TRANSMISSloN HOUSING
CLUTCH HOUSING
DRIVER 077it9 001qxto

OIL SEAL Replace. OR]VERATTACHMENT otGAD - FG('lrX) PILOT,2E x 30 mm 07JAD - PHE0/00 OIL SEAL Roplace.
DRIVER 077a9 001o{xlo

DRIVERATT 07JAD- PHgtl01
PILOT, x 30 mm 28 07JAD - PH8o4{r0
15-9
(AutomaticTransmissionl Differential
15-12 Tools.......... ........... Special (Automatic Differential Transmission) .. 15-13 lllustrated lndex .......... Backlash Inspection ...... 15-14 ......................... 15-1 4 Bearing Replacement .................... 15-15 Inspection/Disassembly Reassembly .................... 15-16 15-17 Oil SealRemoval ........,.. TaperRollerBearing Preload .................... 15-18 Adjustment Bearing ..... OuterRaceReplacement 15-20 ....... 15-20 Oil SealInstallation
SpecialTools
R{.No.
Tool Number 07GAD07GAD07HAJ 07HAD 07JAD07JAD07LAD0774907947or SD40101 SD40100 PK40201 SF10r 00 PH80101 PH80400 PW50601 0010000 SD90200
Do3cription DriverAttachment Tool Preload Inspection Driver Attachment Driver Attachment P i l o t , 2 8 3 0m m x Attachment,40 x 50 mm Oriver DriverAttachment
oty
1 ,l 1 I 1 I 1 1
Poge Refercncc
o
@
15-20
1E_14
o @ o @ o
15-19 15-20 15-20 15- 4 1 15-19,20 15-20
@ @ > a @
IT @
@
I
t9
I
@
@
cro)
o
15-12
(AutomaticTransmission) Differential
lllustratedIndex
THRUSTSHIM page15-18 Selection,
OUTERRACE
eg 9"
FII{ALORIVEN GEAR page 15-15 Disa6s6mbly, psge 15-15 Inspgctaon, Insp6ctfor exc6ssive
10 mm BOLT kg-m,7a lb-ft1 103 N.m 110.3 Left-handthreads
ROLLEB BEARING TAPER lnspect f6ultymovement. for
lnstall in this direction. DIFFERENNALCARBIER lnsoocttor cracks. THRUSTWASHEB
PINIONWASHER
TAPER ROLI..ER
PIN SPRING PINIONGEAR page15-14 inspection, Backlash
BEARIiIG OUTERRACE
PINIONSHAFT Inspgct{or wear or damage.
15-13
Inspection Backlash
' t . P l a c et h e d i f f e r e n t i a a s s e m b l yo n V - b l o c k s l installboth axles. Checkbacklash both side gears. of StandardlNowl: 0.05- 0.15mm 10.002 0.006in.l
BearingReplacement
NOTE:Checkthe bearings wear and rough rotation. for lf the bearings OK, removalis not necessary. are Removethe taper r o l l e rb e a r i n g s s i n ga b e a r i n g u puIer. BEARING PULI.IR
DIALINDICATOR SIDEGEARS
BEARING TAPER ROLLER Installthe new taper roller bearings. usingthe specialtool and a pressas shown, 3. lf out of tolerance, disassemble differential the and from the table below. selectnew pinionwashers NOTE: . Drivethe bearings until they bottom. on . Usethe special tool: . large end for torque converterhousing side bearing. housingside bearsmall end for transmission Ing.
ATTACHMENT, ,(t x 50 mm 07LAD- PW5o601
PINIONWASHEB Part Numbcr 4135-PGI -000 1 41352 PG1 000 41353 PG1 000 * PG1 000 41354 41355 PG1 000 41356-PGl-000 41357 PG1 000 41358 PG1 000 Thickness 0.70mm (0.028n ) 0.75mm (0.029n ) 0.80mm (0.031n ) 0.85mm (0.032n ) 0.90mm (0.035n ) 0.95mm (0.036n ) 1.00mm (0.039n ) 1.05mm (0.041n )
NOTE: . The bearingand outer race should be replaced as a set. . lnspectand adjustthe bearingpreloadwhenever a bearingis replaced. . Drivein the bearings securely that there is no so clearance betweenthe bearingsand differential carner.
15-14
Inspection/Disassembly
Removethe final driven gear and inspectteeth for wear or oamage. NOTE: The final driven gear bolts have left-hand threads, 3, Remove the pinion shaft, pinion gears, washers, and side gears. thrustwashers,
FINAL DRIVENGEAR PINIONGEARS
SIDEGEAR CARRIER DIFFERENTIAL
Driveout the springpin with a pin punch.
Wash the pans thoroughlyin solventand dry them with compressed air. Inspoctall pans for wear or any that are defective. damageand replace
5.0 mm PIN PUiICH
15-15
Reassembly
'1. Installthe side gears, with thrustwashersin tho differential carrier. NOTE: Coat all gears with molybdenum disulfide greaseon all sides. Rotatethe gears until the shaft holes in the pinion gearsIine up with the shaft holesin carrier. Insertthe pinionshaftand alignthe spring pin holes in one end with the matchinghole in the carrier.
Alignthe holes.
THRUSTWASHER
5.
Drivein the springpin with a pin punch.
Set the pinion gears in the place exactlyopposite each other in mesh with side gears,then install a pinion washer behind each one. Wsshersmust be of equalthickness. NOTE: Selectthe correct Dinion washer from the tableon page15-14.
Checkbacklash both piniongearsagain. of Standard {New}: 0.05- 0.15 mm {0.lxt2- 0.006in} It still out of tolerance, replacboth thrustwashers. lf still out of tolerance. replace the side and pinion gears,and recheck backlash. lf still out of tolerance, replace carrierassemthe ory.
15-16
Oil SealRemoval
7. Installthe final drivn gear.Torquethe boltsto 103 N.m (10.3kg-m,74 lb-ftl. NOTE:The final driven gear bolts have left-hand th.eads. ass6mbly. 1 . Remove differential th Remove oil sealfromthe transmission the housing.
FINAL DRIVENGEAR
Chamf6ron innsr side ot final driven gear fac6s cSrner.
10 mft EOLT 103 N,m 110.3 kg.rn, 74 lb-ftl Lett-h8ndthreads
OIL SEAL
TRANS| tsstotrl
HOUSI G
Remove th oil seal from the toroue convrter housing.
CONVERTER TOROUE HOUSING
OIL SEAL Replace.
15-17
Differential {AutomaticTransmissionl
Adjustment TaperRollerBearingPreload
NOTE: lf the transmissionhousing, torque converter housing,differential carrier,taper roller bearing.outer the bearingpreload raceor thrust shim were replaced, must be adjusted. 1. R e m o v et h e b e a r i n go u t e r r a c e a n d t h r u s t s h i m housingby heatingthe housfrom the transmission with a heatgun. ing to about212"F(100'C) CAUTION; . Do not h6at tha houling in oxcass ol 212'F {100"c1. . Roplacothc tapsr rollor bearing when tho outer race is to bs rgplacad. . Do not uso a ghim on the torqug convsrt9r hou3ing sid6. h N O T E :L e t t h e t r a n s m i s s i o n o u s i n gc o o l t o t h e r o o m t e m p e r a t u r eb e f o r e a d j u s t i n gt h e b e a r i n g preroao. Selectthe thrust shim from the table below so that is in). theirtotal thickness 2.60mm (0.102 CAUTION: Do not use mor than two shims to adiust tho bearing prelosd.
BEARING OUTER RACE
HEATGUN
THRUSTSHIM No. Part Numb6r 41441 PK4- 000 41442-PK4-000 41443-PK4-000 41444-PK4-000 41445-PK4-000 41446-PK4-000 41447-PK4-000 41448-PK4-000 41449-PK4-000 J K L M
N
Thickncss 2.20mm (0.087 in) in) 2.25mm (0.089 2.30mm (0.091 in) 2.35mm (0.093 in) i 2 . 4 0m m ( 0 . 0 9 4n ) in) 2.45mm (0.096 in) 2.50mm (0.098 i 2 . 5 5m m ( 0 . 1 0 0n ) i 2 . 6 0m m ( 0 . 1 0 2n ) i 2 . 6 5m m ( 0 . 1 0 1n l i 2 . 7 0m m ( 0 . 1 0 6n ) 2 . 7 5m m ( 0 . 1 0 8n ) i i 2 . 8 0m m ( 0 . 1 1 0n ) 2 . 8 5 m { 0 . 1 1 2n ) m i 2 . 9 0m m ( 0 . 1 1 4n l i 2 . 9 5m m ( 0 . 1 1 6n ) i n 3 . 0 0m m ( 0 . 1 ' 1i8 ) 3 . 0 5m m ( 0 . 1 2 0n ) i
* Standard shim
B D
E F G
n
41450-PK4-000 4 1 4 5 1P K 4 - 0 0 0 41452-PK4-000 41453-PK4-000 41454-PK4-000 41455-PK4-000 41456-PK4-000 41457-PK4-000
41458-PK4-000
15-18
3.
After instaliing thrustshim, installthe outer race the in the transmission housing,usingthe special tools as snown. CAUTION: . Install the outsr .ace squaraly in tho trsnsmi!. sion housing. . Check that thero is no cloaranco bciwocn th, outsr race,shim and t ansmissionhousing. . Install tho gasket whon chocking pr6lo6d.
6,
M e a s u r et h e s t a r t i n g t o r q u e o f t h e d i f f e r e n t i a l with the special assembly tool and a to.que wrench. STANDARD: Now bosrings:
2.8 -,[.0 N'm 128- ,l|) kg-cm, 2,1- 35 lb-inl Rculod bslrings: 2.5 - 3.7 N.m (25 - 37 kg-cm, 22 - 32 lb-in)
07?49 qlrqtoo
,'l
TOOL PRELOADINSPECTION 07HAJ - PKIO201
NOTE: ! Measu.e starting the torque normal at roomtemp6.ature bothdirections. in

lf out of spec,selecttwo thrust shimswhich will give the correct preload,and repeatsteps 1 - 6. Changingone of the shims to the next sizewill increase decrease or staningtorque about3 - 4 kg-cm(2.60 3.,17 lb-ln). T o i n c r e a s e h e s t a r t i n gt o r q u e , i n c r e a s e h e t t t h i c k n e s so f s h i m s . T o d e c r e a s e h e s t a r t i n g t torque,decrease thickness shims. the of
With the mainshaft,countershaftand secondarv shaft removed,installthe differential assemblyand torquethe transmission housing. TOROUE: N.m 15.5 55 kg-m. /r0 lb-ft| Rotatethe differentialassemblyin both directions to seatthe bearings.
15-19
(AutomaticTransmission) Differential
OuterRaceReplacement Bearing
Remove the bearingouter racefrom the torqueconv e r t r h o u s i n g b y h e a t i n gt h e h o u s i n gt o a b o u t 212"F(100"C) with a heatgun. CAUTION: Do not hcat the hou3ing in excassof 212"F(100"c). NOTE: . Replace the bearingwith a new one whenever the outer raceis to be replaced. . Do not use shims on the torque converterhousing side. . Adjust preloadafter replacing the bearingouter raceand bearing.
TAPERROLLER HEATGUN
Oil SealInstallation
1. h I n s t a l lt h e o i l s e a l i n t h e t r a n s m i s s i o n o u s i n g , u s i n gt h e s p c i a tl o o l s a s s h o w n .
DRTVER 07749 00ltXXtO
OIL SEAL
2.
housing, Drivethe oil seal into the torqueconverter usingthe special tools as shown.
I n s t a l lt h e n e w b e a r i n go u t e r r a c ef l u s h w i t h t h e housingusingthe specialtools.
07749 - 001(xXlO
ATTACHMENT DRIVER or 07GAD- SO|O101 o]GAD - SD.O100
15-20
Driveshafts
S p e c i aT o o l s . . . . . . . . l Driveshafts Removal Disassembly Disassembly/lnspection Reassembly Installation IntermediateShaft Replacement............. .. Disassembly Disassembly/lnspection Reassembly
16-2 16-3 16-5 16-6 16-7 16-9 16-11 16-12 16-13 16-14
SpecialTools
Rel. No.
Tool Numbel
o
6\ /?\
@
rA
\of
oTGAD-PH70201 oTGAF-SD40700 oTMAC-SLOO100 o7746-OO10200 07746-O010400 07746-OO30400 o7749-OO'OOOO l
Oil Seal Driver Base Hub Dis/Assembly BallJoint Remover,32 mm Attachment,37 x 40 mm Attachment,52 x 55 mm Attachment,35 mm LD. Driver
16 - 1 4 1 6 - 1 2 ,1 4
I o-J
16-1 2 16-14 16-14 1 6 - 1 2 ,1 4
re
l---:z-----.1
,;A
@
tll
@
ct_@
o
16-2
Driveshafts
Removal
INSPECTION Drivoshaft Boot Check the boots on the driveshaftfor cracks,damage, leakinggreaseor loose boot bands. It any damageis found. replacethe boot. Spline Looseness Turn the driveshaftby hand and make sure the spline and joint are not excessively loose. It damageis found, replacethe inboardjoint. Twisted or Crscksd Make sure the driveshaftis not twisted or cracked. Replace necessary. if l. Raisethe car and placesatety standsin the proper locations(seesection 1). Removethe tront wheels. Dralnthe transmission or fluid. oil 4. Raise the lockingtab on the spindlenut and remove rt,
OAMPEB
5. Remove the damper tork nut, bolt and damper pinch bolt. 6. Removethe damperfork.
OAMPERPINCH BOLT (SELF.LOCKING BOLT) 10 r 1.25mm
NUTI ISELF.LOCKING 1 2 x 1 . 2 5m m Replace.
DAMPERFORK BOLT
7, Remove the cotter pin from the lower arm balljoint castle nut and removethe nut. 8. Installa 14 mm hex nut on the ball joint, Be sure that the 14 mm hex nut is flush with the ball joint pin end. or the threadedsectionot the balljoint pin might be damagedby the ball joint remover.
FRONT WHEEL
9. Use the ball ioint remover, 32 mm as shown on page 18-13 to separatethe ball joint and lower arm. 1O, Positionthe specialtool between the knuckleand lower arm as shown, then separdte the lower arm. CAUTION: B careful not to damag the ball ioinr boot.
CASTLEXUT
SPINOLE NUT 24 r 1.5 mm Replace. 14 mm HX NUT
Replace.
(cont'd)
16-3
Driveshafts
Removal(cont'd)
11. Pry the driveshaftassemblywith a screwdriveras shown to force the set ring at the driveshaftend past the groove, Shaft: with lntermediate Removethe left driveshaftfrom the bearingsuppon by tapping the inboardjoint of the driveshaJt with a Dlastichammer. CAUTION: a Do not oull on the driveshaft. as the CV joint may come apan. a Use care whsn prying out the assembly and pull it stlaight to avoid damaging the diffelsntial oil sal.
12. Pullthe inboard ioint and removethe driveshaftand case as an assembly. CV joint Jromthe ditferential
13, Pulltheknuckleoutward and removethe driveshaft outboard ioint from the front wheel hub using a olastichammer.
KNUCKLE
OUTBOARDJOINT INBOARDJOINT
16 -4
Disassembly
CAUTION: Do not try to disassmble the outboard joint. 1. To rmovethe boot band, pry up the lockingtabs with a screwdriverand raisethe end of the band. CAUTION: Tak care not to damage the boots. NOTE: Carelullv clamp the driveshaft in a vise with solf jaws. Removethe inboardjoint and rollers. Removethe circlip.then removethe spiderusinga commercially available bearingremover. NOTE: Before disassembly, mark the spider and driveshaft they can be reinstalled their original so in positions.
BEARINGREMOVER
STOPPER RING
INBOAROJOII{T
16-5
Driveshafts
Disassembly/lnsPection
NOTE: duting reassembly. to a Mark the rollersand rollergroovesduringdisassembly ensureproperpositioning in reinstalled their originalposilions. mark the spiderand driveshaftso they can be a Beforedisassembly, a The inboardjoint must be removedto .eplacethe boots. a lf the boot band is the welded type, cut off as shown. CAUTION: Take care not to damag tho boots.
DRIVESHAFT
INAOARDJOINT Checksplinestor wear or damage. Check insideborelor wear. Inspectfor cracks, SET R|NG __571 Replace. LEFT INBOARD JOINT lYvith int6rmodlato Checksplineslor wear or damage. Check insidebore for wear. Inspect for cracks.
SPIOEB
ROLLER STOPPER RING
BOOT INBOARD lor Inspect cracking, splittingand wear.
CIRCLIP DYI{AMIC OAMPERBAND (A/T mod.b, loft ddvosh.ft onlYl Replace.
BOOTBAND Replace. AOOTBAND Replace.
------.,
OUTBOAROJOINT Inspect Ior faulty movement and wear. Inspect ball bearings whilo rotaiang Do not try to disassemble
BOOT BANO Replace. OUTBOARD EOOT Inspect cracking, for splittingandwear.
OUTAOARORING Checkfor damage. DRIVESHAFT
16 -6
Reassembly
Cleanthe driveshattsbeforereassemblv. Wrap the splineswith vinyl tape to preventdamage to the boots and dynamicdamper(A/T models,ltt driveshaftonly). Installthe outboardboot, dynamicdamperand inboard boot to the driveshaft, then removethe vinyl
IADE.
6.
Pack the outboard joint with the joint grase cluded in the new driveshaftset. crease Ouantity. 130-140 9 (4.6-4.9 ozl
BOOT OUTBOARO
VIf{YL TAPE
DYNAMICDAMPER lA/T modob, loft ddvGhaft onlvl
INBOARD BOOT Installthe stopperring into the driveshaftgroove, Rotatethe stopperring in its grooveto be sure it is fully seated. 4. Installthe spider on the driveshaftby aligningthe marks on the spiderand end of the driveshaft. groove.Rotatethe Fit the circlipinto the driveshaft circlip in its grooveto be sure it is fully seated,
CIRCLIP
to Fit the rollers the spiderwith their high shoulders facing outward. CAUTION: a Rainstalltho rollor3 in their o ginal posilions on the sDidel. a To prsvnt it from talling off, hold tho drlveshatt assembly so th spidor and lollor point up.
b """@
SPIDER
STOPPER RING
1S7
Driveshafts
Reassemblylcont'd)
8. Packthe inboard ioint with the ioint greaseincluded in the new driveshaftset. GroasoOuantity: 130-140 g (4.6-4.9 oz) A/T modls, Laft ddveshaft 120- 130 g 14.2-4.6 ozl 9. Fit the inboardioint onto the driveshaft. CAUTION: To provant it from falling oft, hold tho drivoshaft assomblYso tho inboard joint points up.
INBOARDJOINT OnlY: ManualTransmission Align the holder direction of the rollers toward the slot of inboard joint as
1 1 .lnstall new boot bands on the boot and bend both sets ot locking tabs portionsto reduce 1 2 . Lightlytap on the doubled-over their height.
HOLOER
1 0 .Adjust the length of the driveshafts to the tigure below. then adjust the boots to halfway between and Iull extension. full compression
NOTE: The ends oJ boots seat in the grooveof the driveshaftand joint. i R i g h r :5 0 7 . 9 - 5 1 2 . 9 m m ( 2 O . O O - 2 0 . 1 9n ) Left: . A/T modelg 8 6 2 . 9 - 8 6 7 . 9 m m ( 3 3 . 9 7- 3 4 . 1 7 i n l
13. Positionthe dynamicdamperas shown below. a Install a new dynamic damper band and bend down both sets of lockingtabs. a Lightly tap on the doubled-over portion of the band to reduceits height.
DYNAMIC OAMPEB
a 175 r 2 mm 16.9 O.l In)
M/T models 52O.9- 525.9 mm (2O.50-20.7O inl
DAMPERBAND
16 -8
lnstallation
joint in the knuckle,then loose1 . Installtheoutboard ly installthe spindlenut. Apply 1 .O- 1 .5 g (O.O4-O.O5 oz) of specified grease to the whole spline surface of the intermediateshatt, NOTE: Atter applyinggrease,remove the grease from the splinegroovesat intervalsof 2-3 splines and Jromthe set ring grooveso air can bleedfrom the inboardjoint.
J.
Installthe new set ring onto the driveshaftor intermediateshaft groove. CAUTION: Always use a new set dng whon6va? th6 drivoshatt is being installod.
NOTE: Atter applying grease, rcmove the )ve grease from the spline grooves at int( tntervats g groove, ot 2-3 splines and trom the set ring g
4.
Installthe inboardend of the driveshaft into the ditferentialor intermediate shaft.
NEWSETRIIIG INTERMEDIATE SHAFT
SETRINGGROOVE
INBOARD JOINT
SET RING RIGHT Make sure the right driveshaft locks in the dit{erential side gesr groove, and the CV ioint sub-axle bottoms in the ditterential. LEFTDRIVESHAFT Insert the le{t driveshaft CV joint sub-axle anto (cont dI the intermediate shaft until the intermediate shaft set ring locks in the groove in the lelt driveshaft.
16-9
Driveshafts
5. and Installthe damperfork overthe driveshaJt onto arm. Install the damper in the damper the lower tork so the aligningtab is alignedwith the slot in the damperfork. Looselyinstallthe damperpinch bolt, and the new damoerfork nut and bolt. NOTE: The bolts and nut shouldbe tightenedwith the vehicle'sweight on the damPer.
DAMPERPINCH BOLT BOLTI {SELF-LOCKING 10 x 1.25mm 44 N'm 14.4 kg-m, 32 lb-ft)
8. Tightenthe new spindlenut 9, lnstsll the wheels with the wheel lug nuts. NOTE: Before installing the wheel, clean the mating surtaceof the brakedisc and insideof the wheel.
6.
FRONTWHEEL
WHEELLUG NUT 1 2 x 1 . 5m m 1 1 ON ' m (11 kg-m, 80 tb-ft)
kg-m,47lb-ft| 65 N.m 16.5 knuckle on the lower arm, then tighten l. t",i"tbtrf,+r" the castlenut and installnew cotter pln. CAUTION: a 8e calotul not to damago tho ballioint boot. a Torque the castle nut to the lowol torque specitication, thon tightsn it only far snough to align tho slot with ths pin hol. Do not 8li9n tho nut by loosening.
FORK DAMPER NUTI TSELF-LOCKING 1 2 x 1. 2 5 m m
NUT SPINDLE 24 x 1.5 mm 25o N.m 125kg'm, 'l8l lb-ft} use NOTE:Aftertightening, a dritl nut to stakespindle shoulder the against d veshatt.
1 0 .Tightenthe damperpinch bolt and the new damper

tork nut with the vehicle'sweight on the damper. 1 1 .ReJillthe transmissionwith recommendedoil or tluid.
1 2 .Check the tront wheel alignment and adjust if

necassary(seepage 18-4).
COTTERPIN On reassembly, bendthe cotter pin
CASTLENUT 14 x 2.0 mm 5 0 - 6 0 N ' m ( 5 0 - 6 . 0 k9_m' 36-43 tb-ftI
16-10
Intermediate Shaft
Replacement
1 . Drainthe transmission or fluid. oil 2. Remove the left driveshstt assembly (see page 16-4). Removethe flange bolt and hex bolts. 5. Installin the reverseorder of removal. FLANGE BOLT 39 N.m 13.9 kg-m, 2a |b-fr) \
I
HEX BOLTS
\ t
,a\,
HEXBOLTS 39 N.m 13,9 kg-m, 28 tb-ftl
Removethe intermediate shaft assemblyfrom the differential. CAUTION: To prevent damage to th diftersntial oil s81,hold ths intormediate shaft horizontal until it is clear ot tho diffsrontial.
rrrrnme6lhrrsxlrr
16-11
lntermediateShaft
Disassembly
NOTE: Be carefulnot to damagethe metal ringson the shaft during disassembly intermediate 1. 2. Removethe set ring. shaft outer seal from the Removethe intermediate bearingsupport. Removethe externalcirclip. 5. Removethe internalcirclip.
3.
EXTERNALCIRCLIP
{) \J l
SEAL OUTER Replace. 4.
SET RII{G Rplace.
6.
Press the intermediate shaft bearing out oJ the bearingsuppon usingthe specialtoolsand a press.
Press the intermediate shatt out to the shaft bearing using the specialtools and a press. NOTE: Positionthe specialtools so they do not damagethe metal ring on the shafr.
Pres!
I
SHAFT BEARING INTERMEOIATE HUB DIS/ ASSEMBLYBASE 07GAF-SD40700
16-12
Disassembly/lnspection
INTERMEDIATE SHAFT RING Checkfor damageor distonion. INTERMEDIATE SHAFT Checkfor damage.
BEARINGSUPPORTRING Check tor damage or distortion.
HEXBOLTS
FLANGEBOLT
INTERITAL CIRCLIP
BEARINGSUPPORT Checktor damage.
INTERMEDIA SHAFT ATE ! EEARING Replace.
@,, @ I
EXTERNAL CIRCLIP
d^
OUTER SEAL Repl.ce.
0\
SET RING Replace.
16-13
IntermediateShaft
Reassembly
NOTE: Be carefulnot to damagethe metal ringson the shalt during reassembly intermediate 1. shaft bearinginto the bearPressthe intermediate ing supportusing the specialtools and a press
Pre3s DRIVER o7749-OO10000
Seat the external circlip in the groove of the in termediateshaft. CAUTION: Installthe circlip with the taperedend tacing out, 5 , Pressthe outer seal into the bearingsupportusing the specialtools and a Press. CAUTION: Do not damage the lip on outer seal duringinstallation. NOTE: Press the seal flush with the bearing support.
I
ATTACHMENT 52x55mm 07746-OO10400
Packthe interiorand lip of the outer seal. 2 . O - 3 . 5 g ( O . 0 70 . 1 2 o z l
HUB DIS/
oTGAF-SD40700 2. Seatthe internalcirclipin the grooveof the bearing supPort. shaft into the shaft bearing Pressthe intermediate tool and a Press. using the special
Pr6ss
3.
F-t F4
n +*:-+
F
| .,-.t
m
6, shaft Installthe new set ring in the intermediate groove.
ATTACIlMENT, 35 mm l.O.
46-0030400
HUB DIS/ 07GAF-SD40700
16-14
Steering
. . . . . . . . . . . . . . . . .7 - 2 1 SpecialToofs General lnformation I . 4 W S S e r v i c en f o r m a t i o n . . . . . . . . . . . . . . . . . , . . ,7 - 3 1. Component Location I n d e xl 2 W S i 4 W S ) . . . . . . .1 7 - 5 Component Location . . . . . . . . . . . . .1 7 - 6 . I n d e x( 4 w s l System Descliption FluidFlow Diagram 1 7- 7 1 7- 8 Steering Pump . F l u i d e s e r v o i r / F i l t.e... . , , . .- . . . . .- . . . . . . . .... . ' t 7- 9 R . , 1 7- 1 0 4-way Valve F u l l - l o cU n l o a d eS y s t e m . . . . . . . . . . . . . . . . . . .1 . - 1 2 k r .7 PowerSteering SpeedSensor 1 7- 1 2 ElectronicallvControlled P o w e rA s s i s t e d W S . . . . . . . . . . . . . . . . . . . . . . 1.7 - 15 4 . . Troubleshooting (Power Steering System) T . . G e n e r a l r o u b l e s h o o t i n.g. . . . . . . . . . . . . . . . . . - 1.7- 2 5 ..,.. 17-24 Noissand Vibration Ffuid eaks L . . . . . . . . . . . . . . .1 7 - 2 9 . Troubleshooting l4WS) L . . ... C o m p o n e n to c a t i o n. . . . . . . . . . . . . . . . . . . . . . 1.7 - 3.0 C o n n e c t oL o c a t i o n s , . . , . . , . . , . , . . . . . . . . . . . . .17-31 r . ... Cilcuit Diagram 17-32 4WS CONTROL UNIT Terminal 17-34 Arrangement Diagnostic TroubleCode(DTCI 17-36 Precautions 17-37 S y m p t o m - t o - S y s t sC h a r t. . . , . . . , . . . . . . . . . . .1 . - 3 8 m .7 r .. 4 W S I n d i c a t oL i g h tC i r c u i t. . . . . . . . . . . . . . . . . . .17-42 TroubleCodes {DTCS): Diagnostic 17-45 1 0 , 1 2 ,r 6 DiagnosticTlouble Codes (DTCsl: 1 1 , 1 3 ,1 7 17-50 DiagnosticTiouble Codes (DTCsl: 2 0 , 2 2 , 2 4 , 2 8 . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7 . . .5 . . -5 . Diagnostic Trouble Codes (DTCsl: 2 1, 2 3 . 2 5 , 2 9 17-59 TroubleCodes (DTCsl: Diagnostic 17-63 30,34 ............... Tlouble Codes (DTCSl: Diagnostic 17-64 3 1 .3 5 . . . . . . . . . . . . . . . Diagnostic Troubls Codes (DTCs): 32,36 ............... 17-66 TroubleCode(DTCI:33 .......... 1 7 - 6 8 Diagnostic TroubleCode(DTC):50 .......... 1 7- 7 0 Diagnostic D i a g n o s t iT r o u b l e o d e{ D T C } 5 1 . . . . . . . . . .1 7- 7 1 c C : TroubleCodes {DTCS}: Diagnostic 1 7- 7 1 6 0 , 6 1, 6 2 , 6 3 Maintenance P u m pB e l tA d i u s t m e n t. . . . . . . . . . . . . . . . ........ . . .17 - 74 On-Car Checks A . . R a c kG u i d e d i u s t m e n t. . . . . . . . . . . . . . . . . . . . . . 1.7- 75 FluidReplacement ,..,.. 17-77 P u m p r e s s u r eh e c k. . . . . , . . . . . . . . . , . . , , . . , .7 - 74 P C 1 ,... P . S t e s r i n g h e e f o t a t i o n a l l a y. . - . . . . . . - . . - . 1.7 - 7 9 W S Power Assist Chsck w i t h C a rP a r k e d . . . . . .1 7 - 7 9 A s s i s tC h e c ka t R o a dS D e e d. . . . . . . . . . , . . . . . . 1.7 - 8 O . Power Steering Speed Sensor Replacement . . . . . . . . . .1 7 - 8 0 Steering Wheel 1 R e m o v a, l. . . . . . . . . , . . ..,.... 7-81 1. D i s a s s e m b l y / R e a s s e m . .l.y , . . . . . . . . . . . . . . . .7 - 8 3 .b . Installation 2 W S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 . . - 8.4 . . . . 7 .. . 4 W S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17.-.8 .6 . . . .. . . SteeringColumn R e m o v a.l. . . . . . . . . . . . ....... 7-89 1 . . . . . . . . . . . . . . . . .7 - 9 2 1 fnsoection Installation . . . . . . . . . . . . . . .1 7 - 9 3 . SteeringPump 17-96 Beolacement P u l l e R e p l a c e m e . . t. . . . . . . . . . . . . . . . . . . . . . .1 7.-.9 . y n .. .6 Flow Control Valve Insoection 17 -97 and Rsplacement 17-99 Disassemblv lllustrated Index 17-102 17 - 1 0 3 Ass6mblv Steering Gearbox l n d e x. . . . . . . . . . . . . . . . . ....... 7-105 1 . . . . . . . . . .1 7 - 1 0 6 V a l v eB o d yU n i r . . . . . . .1 7 - 1 1 4 Gearbox emoval R n . . . . . . . . . .1 7- 1 1 7 l l f u s t r a t sfd d e x O v e r h a u.l. . . . . . . . . . . ....... 7-118 1 . . . . . . . . . . . . . . .1 7- 1 3 4 . fnstallation Rear Steering Actuator (4WS) f f f u s t r a t efd d e x n . . . . . . . . . .1 7 - 1 3 7 1 R e m o v a. l. . . . . . . , . . . . ......, 7-138 Disassembly . . . . . . . . . . . . .1 7 - ' l 4 O . . . . . . . . . . . . . . . .1 . . - 1 4 1 .7 Asssmbfv fnstallation . . . . . . . . . . . . . . .1 7- 1 4 4 . 4WS Control Unit . R e m o v aa n dl n s t a l l a t i o n. . . . . . . . . . . . . . . . . . . . ' l7 - 14 5 l Tie-rod End Boot . . . . . . . . . . . . .1 7 - 1 4 5 . Replacement 4WS System Inspection 1. E l e c t r o n iN e u t r aC h e c k . - . . - - . . . . . - . . - . . - . . - .7.- 1 4 6 c l 4WS System Adiustment 4 W S S y s t e m d j u s t m e n t . . . . . . . , . . . . . , , . . , . . .7'-l 15 1 A . . Sub SteeringAngle Sensor ........... 7-153 1 Adjustment
S p e ci a l To ols
Ref. No.
Tool Numbel OTGAF SD40TOO oTJGG-OO10100 OTLAG_SM401OA OTLAG SM402OA OTLAG SM403OA o7t\4AA-SLOo20A oTMAC-SLOO200 'IA 1 OTNAK SR3O OTNAK_SR3012A oTNAB-SSOO100 OTNAJ_SSOO2OA 07406-OO10101 o7406-OO10001 o7406-oo10300 07406-OO10400 o7725-OO30000 o7746-0010200 07746 0010300 07749-OO l OOOO o7947-6340500 o7974-6920500
DoscriDtion Base Hub Dis/Assembly Belt TensionGauge PistonSeal Ring Guide PistonSeal RingSizingTool CylinderEnd Seal Slider LocknutWrench, 43 mm BallJoint Remover,28 mm P/S Joint Adapter {Pump) P/S Joint Adapter(Hose) Rack Holdr RearSteeringCenterLock Pin BypassTube Joint (lncluded ith 07406-001OO01 l w P/S Pressure Gauge Pressure ControlValve Gauge Pressure Holder Universal Attachment,37 x 40 mm Attachment,42 x 47 mm Driver DriverAttachment Hub AssemblyGuideAttachment
Oty 1 'I 1 1 1 I I 1 1 I 1 I 1 1 1 1 1 1 I 1 1
Page Relerence 17 - 1 0 8 17-74 1 7- 1 2 5 1 7- 1 2 5 1 7- 1 2 6 17 15,76, 132 1 7- ' t1 4 , 1 3 4 17-74 1778 1 7- 1 4 0 , 1 4 2 17-4,144, 150, 15 6 . 1 5 7 17-80 17-78 1 7- 7 I 1 7- 7 4 '17-96 17-103 1 7- 1 2 0 , 1 2 3 1 7- ' t2 3 17-103 17,145
o (;\
aa) @
Lcf
o
,G)
@ @
@ @ @-1 @-2 @
(t
@ @ @ @
o
/g)
\Z'cfp
@
/t-\
i=
@@
7-2
GeneralInformation
4WS ServiceInformation
power assisted controlled 4WS (4-wheelsteeringsystemi, note the foliowOn modelsequippedwith the electronically befo.e service. ing specialprecautions a After performing and the following operations, check and adiustthe 4WS systemto be sure that it is electronically mechanically neutral(all 4 wheels in properalignment). in
Operation Rack guide adjustment Steeringwheel removal/installation Steeringwheel replacement Steeringcolumn removal/installation or Front steeringgarboxremoval/installation dissssemblv Rearactuatorremoval/installation Ffont/rear sub steeringangle sensor removal/installation Front msin steeringangle sensor removal/installation Rearmain steeringanglesensor removal/installation
Check for mechanical neutral
Checkfor electronic neutral
Relerence page 1 77 6 1 7 - 8 ' ,l 8 6 17-86 17 89, 93 17 - 11 8 , 13 1 17 137

1 7 - 1 1 71 3 7 ,
o o
o
o
o
o
o
o o o o
o
o
o
1-t -92 17 137
Perform the following in a Th6 4WS Systemmust be ( l ) mechanically (2) electronically neutralfor Woperoperation. and first, then performthe followingelectronicneutral neutralcheck on the system and adjustas necessary mechanical (4WS system adiustmeni:see page 17-151 ) check and adjust as necessary. (l) Mechanically neutrsl: Be surethat the front and rearwheelsalignpfoperlywith the steeringwheel in the straightdrivingposition(i.e.dif four wheel alignmentequipmentreadingbetweenthe right and left wheels is within 0.5 ferencein computerized mm/O.02 inl. neutral: {2) Elctronic wheelin the straightdrivingposition. in are Be surethat the tollowingsensors electronically neutralwith the steering neutralpositionis indicatedby blinkingor lightingof the 4WS indicatorlight. Electronic Front Main SteeringAngle Sensor Front Sub SteeringAngle Sensor Rear Main SteeringAngle Sensor RearSub SteeringAngle Sensor
4ws tNDtcaToR LtcHT I . ,.. I at{rt4-
( c o n t ' d)
7-3
Generallnformation
4WS Service lnformation (cont'd)
o It the spokesngleof steeringwheel is not atthe designated anglewhiledrivingstraight,checkwhetherit was caused of simply by an improperlyinstalledsteeringwheel or by the misalignment the lront and rear wheels. Check the wheels for properalignmentbefore adjustingthe steeringwheel spoke angle. check Installtherearsteeringlock pin in the rearactuatorand. with the steeringwheelin the straightdrivingposition, readingbetweenthe in four wheelalignment equipment the wheelsfor properalignment(i,e.difference computerized right and left wheels is within 0.5 mm/0.02 in). Checkthe sensorsfor electronicneutralto be sure that the rearwheels are in correctsteeringanglewhile driving. and the a Do not contaminate front and rea. sub steeringanglesensors, front and rearmain steeringanglesensors, the rear steeringactuatormotor terminalswith mud, oil, and grease. " a Thephrase"the steeringwheel in the straightdrivingposition meansthat the front wheels are in the straightdriving positionwith the steeringwheel spokesat a horizontal angle. a lf the power to the 4WS controlunit was shut down for the followingoperations, start the engineand turn the steering wheel tully right and left before checkingand adjustingthe 4WS system. - Battery removal/installation - 4WS control unit removal/installation - No,43 fuse CLOCKRADIOremoval(in the under-hood fuse/relay box) CAUTION; a The roar whoel steoring angle is not controlled when the engine is OFF. When the engine is staned, the rear whaels aro ste6r6d to an angle in accordancewith the front whoelangle. We recommendthat the steering system b6 sorviced wilh the steering whoel set in th6 straight driving position, a Do not st8n the engino with the lock pin sot in the rear acluator. The rear actuator might be damaged whsn the rear whools aro steorod. Bo surs to removs ths lock Din after service.
CAPBOLT 22 N.rn 12.2kg-m.16 tb-ftt
SEALINGWASHER Replace.
17-4
ComponentLocation
Index (2WS/4WS)
NOTE: lf an intact driver's airbag assemblyhas been removedfrom a scrappedcar or has been found defectiveor damagedduringtransit, storageor service,it shouldbe deployed{seesection23}.
WHEEL STEERING Removal l2WS/4WS).page 17'81 page Disassembly/Reassembly, 17-83 Installation {2WS}, page 17-84 Installation {4wS}, page 17-86 STEERING COLUMN page 17-89 Removal, p6ge 17-92 Inspection, page'l7-93 Installation, FRONTMAIN STEERING ANGLE SENSOR{4WSI Adiustment,page 17-15'l IGNITIONSWITCH Steering Lock Replacomentand Swirch Test, see ElectricalSection STEENI G GEARBOX pago 17-75 RackGuideAdiustment(2WS/4WS), pge 17-114 Removal, Index,page 17-1 17 page 17-118 Ovrhaul,
SPEEDSENSOR POWERSTEERING Rgplscement,pag 17-8O
VALVEBODYUNIT
page 17-106 Ovsrhaul, FROI{T SUB STEERING ANGLE SENSORI4WS) Adiustment, p a g e1 7 - 1 5 3 FLUIORESERVOIR FluidReplacement, page 17 77
ENO TIE.ROD BallJoinr Eoot Replacement, p g a e1 7 - 1 4 5
STEERING PUMP page 17 74 Pump Belt Adjustmenr, page 17-77 FluidRepfacement, PumpPressure Check,page 17-78 page 17-96 Pump Replacement, page 17-97 and Replacement, ControlValve Inspection page 17-99 Disassembly, page 17-103 Reassembly,
17-5
GomponentLocation
Index (4WSl
4WS COTTROL UI{IT page | 7-145 Removal/lnstallation, 4WS SYSTEM I SPECTION.nd ADJUSTMET{T page 17-15'l Inspction,
RACK EI{O page 17-138 Removal, page 17-144 Installation,
ANGLE SENSOR REARSUB STEERING Adjustmenl,page 17 155 page 17 138 Romoval, page 17-141 Installation,
ANGLE SENSOR REARMAIN STEERING R e m o v a lp a g e1 7 1 4 1 , fnstaf lation,page 17'1 42 TIE-RODEND Boot Replacement, p a g e1 7 | 4 5
ACTUATOR REARSTEERING Index,page 17-137 lllustrated page 17-138 ActuatorRemoval, Actuator Dissssembly, Page 17-140
17-6
SystemDescription
FluidFlow Diagram
the The reservoirsuppliespower steeringtluid to the pump; the pump pressurizes fluid and deliversit through a high pressure hose to the valve body unit on the gearbox. The 4-way valve {in the valve body unit) controlsthe directionof the turn by shiftingfluid to the left or right side of the piston on the rack {in the power cylinder). the stroke of the 4 way The gain control valve jn the valve body unit controlsthe amount ot the assistby regulating which is regulated the pressure by control ot valve.The operation the gain controlvalveis atlectedby the fluid pressure, valve, sensororifice and power steeringspeed sensor. Constant pressureis generatedby the pressurecontrol valve. This pressureis used as a referencepressuretor the this pressure the power steeringspeedsensorthroughthe sensororilice, to response the car speed.By introducing to is pressure downstreamol the orificeis changedaccording the speedof car. This pressure then used to operate to the of the gain control valve.Two orificesare pfovidedaroundthe circumference the gain controlvalve.Theseorificesprovide th steplessreductionof the pressuretrom the pump accordingto the changesin the car speed.The reduced in the pressu.eis then sent to the reactionchambers.Theretore the assistvariesby regulating lluid pressure the valve body unit accordingto the speedot car. throughthe cooler. lrom the power cylinderflows back throughthe 4-way valveand out to the reservoir FIuidretrrrning
VALVE EODY UNIT
tr---------ORIFICE SENSOR
------l
PRESSURE CONTROL VALVE
RESERVOIR
GAIN CONTROLVATVE REACTIONPLUNGER
a-say y4s-ys{
GEARBOX I I
CYLINDER FLOW CONTROLVALVE lhas s built-in reliel valvel
WHEEL STEERING
7-7
System Description
Construction
reliefvalve)and is drivenby a V-beltfrom a The pump is a vane-typeincorporating tlow controlvalve(with an integrated lor operations every rotationof the crank pulley.The pump features1Ovanes.Eachvane performstwo intake/discharge pulse becomesextremelysmall duringdischarge. th rotor. This meansthat the hydraulicfluid pressure
FLOW CONTROLVALVE
DRIVESHAFT
Operation
pressure applied to is pullevrotatesthe rotor throughthe drjve shaft. As the rotor rotates,the hydraulic The belt-driven of beingpushedonto the innercircumference the cam rlng' the vane chamberof the rotor and the vaneswill rotatewhile so the rollers of The inner circumterence the cam ring has an extendedportionwith respectto the centerof the shaft, volumeof the the directionas the carrierrotates.As a resultof this rollermovement, internal move downward in the axial vane chamberwill change,resultingin fluid intake and discharge
FLUIDMOVEMENT FLUIDDISCHARGE
START OF FLUID INTAKE INLET POBT
FLUID INTAKE
The vanes are pushed onto the inner circumferenceof the cam ring.
The volume of the chamber increases so t h a t tluid is suckedin.
The sucked-in fluid moves toward the discharge port,
As the vanes return to the their original position on the inner side, the volume of the vane ch6mber decreases so the fluid is discharged from the discharge pon.
17-8
Fluid Reservoir/Filter
Flow Control
Fluidtrom the pump runs through a meteringorificeto diJference the valve body unit. This createsa pressure between the pump and valve body unit sides of the orifice.When pressurein the pump side is higherthan the force ot the spring holdingthe flow control valve closed, it pushesthe valve down (openl, and excess fluid returnsto the Dumoinlet. The combinedetiect ot and the flow controlvalve provides the metsringoriJice constantflow of Jluidto the valvebody unit. a relatively reservoir and filter is attachedto the tender A one-piece apron on the left side of the enginecompartment.The should be replacedif the fluid and the filter/reservoir or system is openedfor repairs, if the fluid gets water or dirt in it. CAUTION: Use only Honda Powsr sleering Fluid-V,The use ot othel fluid such as A.T.F., or othor manufacturor's power stsering fluid. will cause damago to the system.
METERING ORIFICE
<To Valve bodv Unit
Prossure Relief
As prssureon the valve body unit side builds up, it pushes the relief valve ball (inside the tlow control valve)up againstits spring,and excessfluid returnsto underthe flow control the pump inlet. As the pressure valve drops,the reliefvalve ball is closedby its spring, and the flow control valve is forced down again.allowing excesslluid from the pump side to returnto the invalve cylinder keeps let. This tlow control valve-relief pump output pressure between TOOO-8OOO kPa ( 7 O - 8 0 k g i c m ' .9 9 5 - 1 , 13 8 p s i ) .
VALVE OPEN RELIEF From Valve body Unit
Steering SpeedSensor
<r
To Steering Pump
RELIEF VALVE EALL
1 7- 9
System Description
4-Way Valve
by Mountedon ihe lower sideof the gearboxis a 4-way valvethat is movedhorizontally a pin on the pinionholderto shift to tluid pressure the right or left side of the power cylinderwhen the steeringwheel is turned. one on each side. reactionchambers, It has thrust pins at both ends, and two inter-connected plungersthat rise againstright and lelt thrust pins. Eachreactionchambercontainsa pair of spring-loaded are The valve body fluid passages controlledby the 4-way valve. by is in Fluidpressure the reactionchambers reduced the gaincontrolvalvein orderto changethe amountof the assistin with the changein the car's speed accordance
VALVE BODY UNIT SENSORORIFICE
RESERVOIR
GAIN CONTROLVALVE
4-WAYVALVE +
l r >
matl ontrtce
i ----------JJ-l-
L________
FLOW CONTROLVALVE lha! I built-ln toliot valvo)
POWERCYLINDER
+WAY VALVE
17-10
(for left or in unit, the methodusedto directa singlesourceot fluid pressure eitherof two directions In the power steering "message" oJ directionto the tluid in the 4-way valve a right turns) involvesthe piniongear transferring which are in turn mountedin a pinionholdercylinderthat The pinionis mountedslightlyoff-centerin a pairot bearings, At rotates,centeredin its own outer bearings. the bottom ol the PinionHolderis a pin, which fits in a slot in the 4-way valve. it it As the pinionis turned (to turn lett or right),because is off-center. alsomovesslightlyalongthe rack.This movement to to is transferred the holder.The pin in the holderthen movesthe 4-way valve,to directfluid pressure eithersideof the in th power cylinder. rack The bsck edgesot the pinionholder(facingaway lrom the rack)hit the stopscast into both sidesof the gearhousingto The tront edgeof the pinionholdercuts off assistat full lock as avoidpushingthe 4-way valvetoo far in eitherdirsction, described the next page. on
POWERCYLINDERS
NEEDLE ROLLER BEARIG

BALL BEARING Plt{
RACK STEERING
+WAY VALV
HOLOEB
4.WAYVALVE
RACK
1 7- 1 1
System Description
Full-lockUnloaderSystem
The 4-way valveshifts the directionof fluid flow when the steeringwheel is turned right or left. However,when the wheel is turned to the right or left lock at parking speed, the edge of the pinion holder ridesup on the end of the rack, movingthe pin in the opposite directionwhich pulls the 4-way valve back to nsutral. This keeps pump pressure from building up (which could cause idl speedto drop), and improvessteering leel by increasing resistance left and right lock. at
Power SteeringSpeedSensor
The power steering speed sensor is a trochoid-rotor, hydraulicpump combinedwith a reliefvalveand a onegear shatt way valve. lt is driven by the speedometer which in turn is driven by a helical gear on the differential.
INNERROTOR OUTERROTOR
ONE-WAY VALVE
Controlin "assist" position
SPEEDOMETER GEAR The power steeringspeed sensorturns only when the car is moving.controllingthe gain control valve. The constant pressureis generatedby the pressure conlrol valve. This pressureis used as a relerencepressurefor the response to the car's speed. Bv introducing this pressureto the power steeringspeed sensor through the sensor oritice, the pressuredownstream of the to orifice is changedaccording the speedof the car.
PRESSURE CONTROLVALVE To power steeringspeedsensor
4-way valve moves back to "neutral" position
Pressure response in to vehiclespeed FEEO SIDEORIFICE
17-12
With the engine running at idle in a parked car, fluid flow through the sensor rotors is blockedbecausethe rotors are not turning.Theretorethe gain control valve movesto the left. On the gain controlvalve.the oritice is resistance high on pump side, while it is low on the in reservoir side, with the resultthat pressure the reaction chambe,is loweredand steeringassist is high.
When the car is moving at high speed, the sensor turther and the gain control valve reducesthe pressure moves furthsr to the right. The orifice pressure the on pump side is low and the pressure the reservoir on side in is high,the fluid pressure the reactionchamberis also high giving the steeringwheel less assist.
Hydraulic prossurein response to the car's speed(Lowl
FEEDSIOEORIFICE RESERVOIR SIDE OiIFICE
Hydraulic pressurein response thg car's to speed{High}
RETURl{ RETURN GAr{ CO|{TRO|VALVE

Pressurein reaction chamber(Low)
As th car is driven.the rotorsstart turningand the fluid returns to the reservoir, reducing the fluid pressure at the the gaincontrolvalve.Theretore, gain controlvalve on bsginsto move to the right. The orifice resistance balanced, sidesis appropriately the pump and reservoir with the result that the reaction chamber is in the is mediumrangeand the steeringresistance moderate.
in Hvdraulic Pressure reaponse (Mdium) ro the car'ssDeed SIDE RESERVOIR ORIFICE FEED
REACTIONCHAMBER
(cont'd)
17-13
System Description
PowerSteeringSpeedSensor(cont'd)
Speed Valve(ln PowerSteering One-way Sonsorl
Wh6n the car is moving at high speed, negative pressure develops at the sensor inlet because the power steeringspeedsensoris pumpingfasterthan the for To fluid can be supplied. compensate this, the outlet and inlet ports are connectedinternsllyby a passage containinga one-way valve that lets output tluid recir pressure. culate to the inlt pon to equalize Driving at Hlgh Speed:
ReliefValve (ln PowerSteeringSpeedSensorl

When the car is moving in reverse,the power steering speed sensor also turns backward and pumps tluid in in the oppositedirection.To avoid buildingup pressure steeringefthe reactionchambersthat would increase ton while driving in reverse,the inlet and outlet-ports containing are connectedby a secondinternalpassage a relief valve that allows the tluid to recarculate.
Driving in Reve.se:
ONE.WAYVALVE
ROTORS
VALVE RELIEF
17-1 4
Electronically ControlledPower Assasted 4WS

Outline
The electronically controlledpower assisted4WS (4-wheelsteeringsystem)consistsof the hydraulicpower steering systemthat steersthe front wheels,the rearactuatorthat steersthe rearwheels,the 4WS controlunit, and the sensors gearboxandthe rearactuatorare connected The front steering that detectthe car's speedand othersteeringconditions, The rearsteeringangleis controlled electrically, allowingthe rearwheelsto be set at any desigrated by a wire harness. steeringangle.
ANGLE SENSOR FRONTMAIN STEENING
VEHICLE SPEED
17-15
System Description
ElectronicallyControlledPower Assisted 4WS (cont'd)
System Operation
The 4WS control unit receivesinput from the VehicleSpeedSensor(VSS),front main steeringanglesensor,and the turningangle,steering speed the f.ont sub steeringanglesensor.The 4WS controlunit calculates vehiclespeed,steering the best angleto steer the rear wheels. and steeringdijectionto determine
(System opration flow)
VSS ggrves the soeedmeter as well.
Front main st66dng angle sgnsol
Front gub stooring angl sonaol
Calculation of the car's apggd
C.lculation ot steoring rotation speed
Calculation ot stooring angle lor toar whgels
4WS Control unit
17-16
The rear wheels are turned by a motor built into the rearsteeringactuator.The motor is activedby the power circuit in the 4WS controlunit. The actualsteeringangleof the rearwheelsis detectedby the rearmainsteering anglesensor,and the rearsub steeringanglesensor.The 4WS controlunit adjusts the angleaccording the difference to betweenthe sensed steeringangle of the rear wheels and the targetedsteeringangleof the rear wheels.
FRONTMAIN STEERING ANGLESENSOR SENSOR REARSUB STEERING ANGLESENSOR
ACTUATOR REARSTEERING FRONTSUB STEENING ANGLE SENSOR 4WS CONTROLUNIT REARMAIN ANGLE STEERING SENSOR
(cont'd )
1 7- 1 7
System Description
Electronically ControlledPower Assisted 4WS {cont'd)
System Operation
Featuresol rear wheol steering: controlledpower assisted4WS sets the rear wheels at the best steeringanglelor the car's speed, The electronicsllv steeringrotationspeed,steeringwheel angle,etc. a Car speed direction the front wheels of When the car is travelingat low speed,the 4WS systemturns the rearwheelsin the reverse to in proportion the rotationangleof the steeringwheei. When the car is travelinga higherspeed,the system increases the steeringangle of the rear wheels in the same directionas the front wheels. to of the Changing steeringangleperformance the rearwheelsin relation the car's speedgivesthe car improvedhandling characteristics. a Steeringspeed 18 mph (3O km/h) or above The rear wheel steeringanglevarieswith how rapidlythe steeringwheel is rotated.See graph
lSto6ring angl/sped portoamanco cuwol
Slow st6.ing
Rapid stooring
0. 5 200 0 -0. 5
300
400
100
17-18
Component Function & Operation

Roa?actuator: The rearactuatoris mountedat the rearoI the car to steerthe rearwheels.The motor, built into the actuator,is madeup of a stato. with a permanentmagnet. a rotor. and brushesthat pass electricjtyto the commutators.The motor is mountedon the sameaxis as the steering shaft screw, makingthe rearactuatorcompactand light in weight. The rearactuato. also containsthe rear main steeringanglesensorand the rear sub steeringanglesensor. The 4WS control unit drivesthe electricmotor with DC current.lt switchesthe currentpolarityto changethe motor's direction.Two strong return springs,one at each end ot the actuator,providea centeringaction.They returnthe rear positionwhenevercurrent is cut to the motor. wheelsto the straight-ahead
REARSUB STEERING ANGLESENSOR
ACTUATOR HOUSING
STATOR REARMAIN STERING ANGLESENSOB
RETURN SPRING
STEERII{G SHAFT SCREW
COMMUTATOR BRUSHES ROTOR
RECIRCULATING BALL SCREW <RETURN SPRINGOPERATION >

Mov6s to lft:
Moves to right:
The return spring compresses when the steeringshaft screw moves to right or left. When the motor is OFF, the stesring shaft screw is held in the straight ahead (neutral) positionby the force oJ the return spring. {cont'd)
17-19
Maintenance
Transmission Oil
NOTE:Check oil with the engineOFF, the and the car on levelground. 1. Removethe oil tiller plug, then checkthe level and conditionof the oil.
Back-up Light Switch

Replacement
NOTE:Check switchseesection23. the 1. Disconnect the back-uplight switch wire connecrors. Remove back-up the light switch,
2.
WASHEN
Replace.
Proper Level.
OILFILI.IR PLUG 45 N.m(4.5kg-m,33lb-ftl 2. The oil levelmust be up to the fill hote.lf it is below the hole, add oil until it runs out. then reinstall the o i l f i l l e rp l u g . l f t h e t r a n s m i s s i o n i l i s d i r t y , r e m o v et h e d r a i n o p l u ga n dd r a i nt h e o i l . R e i n s t a ltlh e d r a i n p l u g w i t h a n e w w a s h e r ,a n d refillthe transmission to the properlevel. oil NOTE:The drain plug washershouldbe replaced at everyoil change. 5. Reinstall oil filler plug with a new washer. the Oil Capacity 1.9/ 12.0 qt, 1.7lmp qtl ar oil chango. US 2.0 / {2.1 US qt, 1.8 lmp qtl at overhaul. Useonly SAE 10 W - 30 or 10 W - 40,SF or SG grade.
3.
4.
3.
Installthenew washerand back-up light switch,
OIL FILLER PLUG '15N.m (4.5kg-m. 33 lb-ft) WASHER Feplace.
13-3
System Description
Electronically GontrolledPower Assisted 4WS (cont'd)
Component Function & OPeration
Front main stso.ing anglg sensor: The front main steeringanglesensoris mountedin the stee,ing column. lt senssthe directionand angle of steering wheel {otation and converts it to electrical signalsthat are sent to the 4WS control unit.
CIRCUIT
MR ELEMENT
HALL IC
Roal main stedng angle 9en9o1: The rear main steeringanglesensoris mountedon the rear actuator. lt sensesthe directionand angle of the rear wheels and sendssignalsto the 4WS control unit. as The 4WS controlunit usesthis information feedback to determineif the actual rear wheel positionmatches the desiredDosition.
HALL IC
MR ELEMENT
17-20
Front tub stoering angl snsor: The front sub steeringangle sensoris mountedon the front stgering gearbox. lts purpose is to detect the posi tion of the front wheels and convert this inJormationto an slectrical signal for the 4WS control unit. The front sub steering angle sensor uses a springloadedplungerthat ridesin a slopedgroovein the rack. As ths rack turns the tront wheels,the plungerridesup the slope and is pushed into the differential transformer The plunge.'spositionis used to determine assembly. how tar the rack is turned.
ANGLE SENSOR FROI{T SUB STEERING
RACK STEERING
Rgar sub gtoodng anglg aensor: Th6 r6a. sub steeringangle sensor is mounted on the rear actuator spring cover. lts detects the position oI the rear wheels as a feedbacksignalfor the 4wS contrcl unit. lt ogerates in exactlv the same wav as the front sub steering angle sensor.
11-21
System Descripton
ElectronicallyControlled Power Assisted 4WS {cont'd)
Componont Function & Operation (cont'dl
a Average moving curent control movThe 4WS controlunit monitorsthe averagemovingcurrentol the motor to protectthe system.Whenthe average ing currentexceedsa given value,the 4WS control unii lowers the currentto changesteeringangleof the rear wheels graduslly(approximately degrees/3osecondsl.When the averagemoving currentto the motor is below the given 6 minutes). 6 steeringangle slowly {approximately degrees/2 value,the rear wheels returnto the designated a Over-voltage control An increasein battery voltage (due to a voltageregulatorfailure,for example)could causeexcessiveactuationof the motor and grraticcontrolof the rarwheels.To preventthis, the 4WS controlunjt monitorsthe voltage.lI it exceedsa voltageto the givenvalue,the 4WS controlunit slowly returnsthe rearwheelsto the straightaheadpositionby reducing motor and turns the 4WS indicatorlight ON.
17-2 2
Fail-sat Function: When the 4WS controlunit sensesa tailurein the system,it switchesto fail-safe mode. In this mode, it powersthe tailsafe and damper relays.The fail-salerelay cuts power to the rear steeringmotor, while the damper relay slows the motor's returnto neutral.As a result,the rearwheelsreturnslowly to the straightaheadpositionand then remainthere. The car then drives like conventional 2WS. When the 4WS control unit switchesto fail-safe mode, it storesa Diagnostic TroubleCode(DTC)and turns on the 4WS indicatorlight to notify the driver of a problem.This code can be read by connecting the servicecheck connectorter minals with a iumoerwire under the dash. The code is read as blinksof the 4WS indicatorliqht.
4WS INDICATORLIGHT
;=;
..
=' -:-
Flr,\-n-'Puf
="1
:a.
JUMPER WIRE
Damper Control: relay.Without sometype mode,it cuts power to the motor by poweringthe fail-safe When the system goesinto fail-safe position too rapidly,adversely atlecting of damping,the returnsspringswould turn the rearwheelsto the straight-ahead the car's handling. motor is To counteractthis, the 4WS control unit also powersthe damperrelay.The armatureo{ the now deactivated by The voltagegenerated this spun by the movementof the steeringshaft. This causesthe motor to act as a generator. action is appliedback to the motor throughthe damperrelay.This causesthe motor to resistthe force ot the returnsprings. allowingthe rear wheels to go back to the straightaheadpositionslowly.
1 7- 2 3
System Descripton
PowerAssisted4WS (cont'dl Controlled Electronically
Componont Function & Operation (cont'dl
a Elctronic neutral Position alignment ln other For the 4WS system to work correctly,it must be in elctronicalignmentas well as mechanical words,thesYstem,s'rontandrealsensorsmustSigna|thatthewhee|sarepointedstraightaheadwhenthewhee|sare "electronicstraightahead" by connecting the service pointedstraightahead.The techniciancan test tor mgchsnically terminalswith a iumper wire and turning the front and rear wheels' ch6ck connector
17-24
(PowerSteeringSystem) Troubleshooting
GeneralTroubleshooting
Check the following betoreyou begin: a a a a a a Has the suspension been modifiedin a way that would affect steering? Are tire sizesand air Dressure correct? ls the steeringwheel originalequipmentor equivalent? ls the power steeringpump belt properlyadjusted? ls steeringfluid reservoir filledto properlevel? ls the engineidle speedcorrect and steady?
HardSteering
Littleor no assistin both directions with car parked.
Assislin one direction only, littleor no assistin the olher.
Check for bubbles in power steering fluid.
l{ there are no bubbles, check i{ assist improveswhen engine speed is increasedlC| 3,O00 rpm.
It there are bubbles, check the reservoir inpul side hoses and pump front seallor air leaks. Repairas necessary.
Remove the valve body unrt and check the pinion pin for free movement. lf OK, check lhe 4 way valve for free movement (see page 1/,107|. Repair as necessary.
checkthe pump lf assistimproves, flow control volve lor internal leak' ing, and clean or replace as (seepage 17-98). lf the necgssary valve is OK, replacethe steering
lI assist does nol improve,check tluid pressure, using power steering pressure gauge with shut off valve closed(seepage 17-78).
Fluid pressurebelow 7,000 kPa (7O kglcm2, 995 psi).
Fluid pressure7,00O 8.O00 kPa l 7 o - 8 0 k s l c n ' . 9 9 5 - 1 .1 3 8 p s i ) .
Checkthe pump flow controlvalve Ior internal leaking,and clean or replace 6s necessary {see page 17-98). lf the valve is OK, replace the pumP.
The pump is OK. Measurethe force requiredto turn the wheel with the speed sensor hose plugged and the car parked (see page 17 79).
Steering effort above30 N (3.0 kg, con' 6.6 lbs)- Check the pressure trol valve for stickingor a clogged orifice; clean or replacethe valve (seepage 17'107). lf as necessary the pressurecontrol valve is OK, checkthe pinionpin for free move_ ment. lf seizedor bindingoverhaul the steeringgearbox,
Steering effon below 30 N (3.o kg, speed 6.6 lbs).The power steering internallyi replace sensoris leaking the power steeringspeed snsor ( s e ep a g e1 7 B 0 ) .
(cont'd
17-25
GeneralTroubleshooting(cont'd)
Beltslipping the pulley. on Replace Adiustthe belttension. (seepage the belt,iJ necessary 17-141.
Checkgaincontrolvalve;clean or replace gaincontrol the valve or valvebodyunit.
ldle speed low or erratic.
lI the engine stallswhen wheel is turnedwhilecar is stopped or movingat low speed, adjustidle speed(seefuel section).
rough ataering.
Air in reservoirtank, o. low powersteering lluid level.
Check power steeringfuid level, lf levelis excessivelylow. check for leaks in the system. Add tluid to the soecitiedlevel.
It fluid levelis OK, check O-rings and sealson both ends ot the pump inlet hose, and the oil pump housingmatingsurfaces tor suctionleaks.ReDlace Darts as necessarv.
Adjustthe rackguide(seepage 1 7 75 r ' .
lf the rack guide adjustmentis OK, check the pinion bearings for wear or damage. Replace them as necessary.
7-26
Pump belt slipping on pulley (pump stops momenlarily). Shock or vibrationwhen wheel turned to tull lock.
(seepage Adiustthe belttension 17-74)or replace belt.
pressure Set the powersteering gauge.Closethe shut-offvalve fully and measurethe pump (seepage17 781. p.essure
The pump pressure should be 7,000 8,000 kPa (70 80 k g / c m ,9 9 5 - 1 , 1 3 8p s i )w i t h , needle fluctuation of t 5OO k P a ( t 5 k g / c m , ,a 7 0 p s i )o r l e s s .l l t h e n e e d l e l u c t u a t i o n f exceeds :t 5O0 kPa (t 5 kg/cm' ,:t 70 psii checkthe f l o w c o n t r o v a l v e ,o f t h e J l o w l controlvalve is OK, replace the pump.
Assist (excessively light steering)at high speed:
Measure force required turn to wheel with bypass tube joint installed, and car parked on dry paved surface (see page 17-80).
lf below, check gain con trol/pressure control valves and valve body unit and replace parts as necessary.
Adjust the belt tension (see page 17 74l' or replacebelt.
Steering kicks back during wide turns.
Sticking gain control valve or valve body unit.
Replace the gain control valve or valve body unit.
Rackguideadjustedtoo loose.
Adjust the rack guide (see page 17 751.
Wheel will not return shoothlv.
Readjust front wheel align, the ment or replace parts as necessary.
1 7- 2 7
Noiseand Vibration
NOTE:PumDnoise in first 2-3 minutesafter starting in cold weather (-2o'c, -4oF or colder)is normal
when wheel is turned of Hummingdue to pulsation fluid is normal,particularly wilh car stopped. lf equipped with autolnalic the transmission, hum couldbe torque converter or pump noise,
High p.ssure lrame. line touching lhe
Confirm by temporafily removrng pump bert.
R e p o s i l r o nl h e f i n e .
Pinion shaft seal nol lubricatod Horn contact nol lubricaled, or

Grease the conlacl, or bend rl to reduce tne pres3ure.
"clunk" maY bo e notmal amount of linkageclearance' To NOTE: A sangte this lyp ol clunk, turn th wl|el back and lorth with lhe engineOFi distinguish Tighten or replace pulley ll sh6lt is loose, raplacelh pump.
Check and tighlen, or teplace gans
Loosc pump pully.

Rattle or chr(e.ing Loos6 sleerinO shtfl conn6ctor, ti6_ rod, or ball pant.
Columnshaft wobbling.
the Replace columnassemblY.
Lines or hoses from the valve bodY unit louching each other. Noise from valve body unil.
Pump gea. norse
NOT: Pump noise up to 2-3 mrnutes afler starting in cold weather (-2OoC, -4oF or colde.) Compere pump norse at ope.atrng lemperalure to another car
loud, lf pump noise is abnormally check the pump ball bearingand any parts.(seepage 17-102).
Check llurd level l l l o w , f r l l r e s e r v o r rl o p r o p e r l e v e l . and check for leaks Trghten or replace as necessatY
Gratrngdorselrofi pump
Check lo. crushed suclron hose o. a loose hose clamp allowrng ar Inio Trghten of replace as necessary
17-28
Fluid Leaks
NOTE: When tluid leaks lrom one side of the rack the balance tube transfers the fluid to the other side, giving the appearance that both sides are leaking. To troubleshoot, remove both boots, clean the rack and locate the leak.
Bemove the 4 way valve and inspect the 11 mm O-ring and rhe port housing bore for pits, burrs or s c r a t c h e s( s e e p a g e 1 7 1 0 7 ) . Repair as necessary.
Resealgearbox and inspect the rack sealingsurfacebetweenthe steeringrack piston and the righl
e n d { s e ep a q e 1 7 1 1 7 ) .
lf no abnormalrty is found, replace the O ring, reseal the gearbox and Inspect the steeflng rack seaiing surface lor burrs or scratches be tween the steenng rack gear teelh and the piston. Inspect the seal re tainer bore in the gearbox housing for proper chamfer and sharp e d g e s ( s e ep a g e 1 / 1 1 7 1 .
Trghten attachrng bolls or replace valve body or port housrng. Sreeflng gearbo'(
Leaking l.om erlher side of valve
Replace all valve body unit seals and O-rings.
Replacethe valve body.
Replace the front seal.
Pump housrng leaks et ither end
Replace housing O rngs. ll lhe housrng st|ll leaks, replace the pump
Leaking from around cap,
R e s e r v o i ro v e r l i l l e d Pullolt the hose and drarnto proper
Air leak in s4r,.
lhrgh pressure)
LO\/vpfessure hoses
Lealrng because ol damage, delefioralron, or rmproper as.
Replacor repar as necessary
Tighten connector. lf still leaking. the prpeor vaive bodv unrt.
Leaking at gearbox connection {at O ring jojnt).
1 7- 2 9
Troubleshooting(4WS)
ComponentLocation
NOTE: The radio may have a coded theft protectioncircuit. Be sure to get the customer'scode number betore - Disconnecting battery. the - Removing the No. 43 CLOCK.RADIO (1O Al fuse. - Removingthe radio. After service,reconnectDowerto the radioand turn it on. When the word "CODE" is displayed,enter the customer's 5-digit code to restoreradio operation.
CLOCK,RADIO(10 AI FUSE UNDER'HOOD BOX FUSE/RELAY
ANGLE REABMAIN STEERING SENSOR
ABS CONTROLUNIT
REARSUB STEERING ANGLESENSOR FRONT MAIN STEERING ANGLE SENSOR
REARACTUATOB UNDER,DASH BOX FUSE/RELAY VEHICLESPEEOSENSOR
{vss)
ANGLE FRONTSUB STEERING SENSOR I2P} CHECK CONNECTOR SERVICE Behindthe cenler console
No. 22 4WS tto Al FUSE
17 -3 0
Connector Locations
UNIT CONNECTOR ABS CONTROL TERMINAL UNIT POWER 4WS CONTROL G 503 \ 4WS CONTROLUN|T CONNECTOR {4p)
4WS CONTROL UNIT CONNECTOR {18P) SPEED SENSOB VEHICLE CONNECTOR I3P)
CONTROL UNIT CONNECIOR I12PI
SERVICE CHECKCONNECTOR {2P} Behind the conler console.
1 7- 3 1
(4WS) Troubleshooting
CircuitDiagram
UNOR.HOOD FUSENELAY BOX
wffi--------*-No. FUSE 23
FUSE LABELNAME
ECU F/C MIRNOR
METER
1WS
UNDER-OASH 80X FUSEiRELAY
LIGHT SYSTEM CI'IARGING
IGNITION SWITCH l|G1l
VEHICI.E SPEEDSENSOR
GRNETD
41., ,ro* \ ll^ ,/ LEVEL

STEERING REAR STEERING FRONTSUB SUB ANGLE SENSOR ANGLE SENSOR
*1- swrcr
A -= G301
-+YELtsLU V'/HTALUBLK+YEUBI( B[K/r{HI------OGRY
ANGTE SENSOR SITIRING FRONTMAIN
WHTELU-.+GRYmt
---.BLK GRY/BLK
*l
SENSOR AMNGLE MAIN SIIERING REAR
cIr
GO2 G101
17-32
SERVICE CHECK CONNECTOR IGNITION SW]TCH l|G2) ABS CONNOL UNII

IGRt{nED
l--':*ln'"-Io'j
J91,v116g
(lL PARKTNG ,
rr\
anlxeY'
IWSCONTROL UNIT POWER TERMINAT
I8PCONNECTOR 1 4 7
U
12P CONNECTOR 1 9 20
21 27 28
23
10
't2
1 4 1 5 16 1 7 1 8
IWS CONTIOL CONNECTOR UNIT
interiorside
17-33
Arrangement UNITTerminal 4WS CONTROL
(AI 18P CONNECTOB (B) 12P CONNECTOR (C) 4P CONNECTOR TERMINAL POWER ID}
2 10
192 0 24 2 5
22 2 3
13 14 1 5 16 17 18
26 1 , /
2 8
View from controlunit terminalside
concon_ necror necror No.
Check W i r ec o l o r name Termanal Measurement condition

While the wheel is being rotated slowly Engine ON
Normal voltage 5V-OV Batteryvoltage. O V 5 V-O Battery voltage O V O V 5V-OV O V

Battery voltage
Measuremt termimals 1- 2 4 2-24 3-24 4-24
G R Y / R E D R e a rr i g h tp u l s e
2 3
WHT/BLU GRY/WHT BLK/YEL
Charge Rear left pulse

lgnition 2
EngineOFF While the wheel is being rotated slowly IG SW ON IG SW OFF, ACC, START IG SW ON While actuatormotor is runningslowly
Light ON
5
6 1
RED WHT/GRN PNK GRN
Rearmain steering angle sensorground Rearmain steerang angle sensorA phase

Warning 1
5 -ground 6-24
Lisht OFF While steeringwheel is being rotated slowlY Short Open While steeringwheel is being rotated slowlY While actuatormotor is runningslowly ON
OFF
I
I
Front main steering angle sensorA phase
5V-OV
8-24
OV 5V(AT:1lV)
10
1 1
1')
B R N / W H T Service check signal
10-24
BLU
BLU/GRN
Front main steerlng angle sensorZ phase Rearmain steerrng angle sensorB phase
5V-0V 5VOV
O V Battery voltage
12,24
13
14
I D
G R N / R E D Parking brake
1 4- 2 4 15,24 16-ground 1 7- 2 4
YEL/RED
BLK
Front main steerlng angle sensorB phase Ground2 Rearsub steering anble sensorcenter
While steeringwheel is being rotated slowlY IG SW ON Analogtester DC range At all times
5 V-0
O V approx. 2 . 5V Battery voltage
17 18
GRY/YEL
WHT/YEL I Back up Power source
18- 24
s w i t c h ,A C C :accessory{'l position)
17 -34
18P CONNECTOR IAI 1
12P CONNECTOR IB} 7
CONNECTOR {c)
3 t0
6
1 4 l 5
t9 20
24 25 26
21 2 2 2 829
12 1 3
16 17 18
ffi Eqql
Ch e c k Normal voltage
View from control unit terminalside
interior side
connector
connector No.
Wire color
Terminalname
Measurement condition While front wheel is being rotated slowly While actuator motor asrunningslowly Analog tester AC range Analog tester AC range
Light ON Light OFF
Measuremt rermtmats
'19 20 21
ORN GRN
Vehiclespeed sensor Rearmain steering angle sensorZ phase Front sub steering angle sensor left Front sub steering angle sensorright Warning 2 Ground 1 lgnition 1 Front sub steering angle sensorcenter
5 V*O 5 V.,O
Left CenterrRight
19-24 20 24
YEL/BLK YEL/BLU
s.ovT2svb.o v
Left O V Battery voltage O V
Baltery voltage Right
21 26
2 . OV 2 . 5 V 3 . 0 v
22 26
23
24
23
B
PNK BLK
24
gtound
24 25
IG SW ON IGSW ON I G S W O F F ,A C C
Analog tester DC range
YEL/RED
YEL/GRN
O V
approx. 2.5 V
25 24
)6 ?4
27 2S 29 GRY/BLK
GRY Rearsub steering angle sensorleft Rearsub steering angle sensorright Analog tester AC range Analog tester AC range
Left Cen! Right
2 . OV 2 . 5 V
Left
3 . 0v
Right
2A 17 29 17
3 . 0v 2 . 5V 2 . OV
31 32 YEL
34 BLU Damper Damper Motor power source power (motorl ground Motor terminal
Start the engine
Resistance range Disconnect4P connector. Start the engine At all times IG SW ON
Continuity Momentarily open, no conI|nutry Battery voltage
33- 34
control untt Iermtnal ground ground ground
WHT
FI
A B C
BRN RED
O V O V Battery voltage
BLK
Motor terminal
D -- ground
The normalvoltage is the value when the system is working properly.
17-35
Diagnostic Trouble Code(DTC)agnOSIlC I rOUOle UOOe tu I l-f
To display the DiagnosticTrouble Code (DTC)
( 1 ) Pullout the servicecheck connector(2P) locatedbehindthe centerconsoleand connectthe two terminalsof the connectorwith a iumper wire.
(3 DATA LINK CONNECTOR P)
NOTE:
Do not attach the jumper wire.
,-->,/
' _ \
JUMPR
SERVICE CHECK coNNECIOR (2Pt
(2) Turn the ignitionswitch ON. but do not start the engrne.
( 3 ) Watch as the 4WS indicatorlight blinksto displaythe code

{4) Recordthe codes. NOTE: a Be sure to recordthe code. lf you do any oI the following, the code will be erased. - Disconnect the battery terminals - RemoveNo. 43 CLOCKRADIO (10 A) fuse from the under-hood fuse/relaybox - Disconnect the 4WS control unit connector. IndicatorLamp (MlL) will stay on a It the engineis started with the serviceconnectorjumped, the N,lalfunction pattern DTCindication Main - sub
V.fv6 chock t+ #12, o.g 0.4 t--0.8 #22 o.g o.4 --,
--+' l'.""i11,n"i""
signsl 3.0
sub *
5'u" --"
Main
12
F-#22=,
t<-#
0.8 0.4 0.8 0.4 light can displaymultiplecoma light displays code by a seriesof long and short blinks.This indicator The 4WS indicator ponent problemsby blinkingseparatecodes,one after another.The numberof long blinksequalsthe lirst d;git of the code. the numberof short blinksequalsthe seconddigit. When there are multiplecodes,there is a two secondpause betweenthe codes. in units (CPUS) the 4WS control unit System problemscan be detectedby both the main and sub centralprocessing Each CPU can memorizeup to 1O codes. lf both CPUshave stored codes, the 4WS indicatorlight will: a Blink quickly once as an indicatorlignt check, (this happensonly when the ignitionswitch is first turned on). a Pausetor three seconds. a DisDlav the codes stored in the main CPU. a Pausefor 1.6 seconds. a Blink rapidlytor three secondsto indicatethe switch betweenthe main and sub CPU. a Pausefor 1.6 seconds. a Displaythe codes stored in the sub CPU. a Pausefor three seconds,then repeatthe cycle. This cycle will continueuntil the ignitionis turned OFF. NOTE: a Be su.e to check both CPUsfor at least 10 codes betoreturning OFF the ignitionswitch a lf the main and sub CPUSdisplaythe same codes,those codes need only be checkedonce.
7-36
Precautions
DiagnosticTrouble Code (DTC):
even if it was a temporarycondition.To The DTC is memo.izedwhen the 4WS control unit detects an abnormality, light cameon, and try to duplicate when the 4WS indicator troubleshoot, the customerin detailaboutthe conditions ask duringthe test drive.lt the 4WS indicatorlight does not come on duringthe test drive,do not continue those conditions procedures assumethat the symptom is occuning. the to troubleshoot; system is OK at this time, The troubleshooting Check for loose connections poor contacts at the connectorsby wigglingthe harness.etc. or
in on lightcomeson when the 4WS controlunit detectsa problem the system.Depending the problem, The 4WS indicator by the 4WS indicatorlight may be canceled turningthe ignitionswitch ofl, or it might requireremovingthe CLOCK,RAfuse/relaybox. It a problemis detectedin the main steeringangle sensorsystem, DIO (10 A) tuse in the under-hood you must removethe CLOCK,RADIO{1O A) fuse to cancelthe 4WS indicatorlight. lI a problemis detectedin any other part of the system, turningthe ignitionswitch off will canceithe 4WS indicatorlight. of NOTE: It the 4WS light comes on because a temporaryproblemin the main steeringanglesensorsystem, it cannot be canceledby simply removingthe causeof the problemand cyclingthe ignitionswitch; the CLOCK,RADIO (10 A) fuse must be removed. The 4WS indicatorlight does not come on when the DTC is 71 , 72, ot 73. However.the 4WS indicatorlight will flash these codes when the servicecheck connectoris iumoed.
TemporaryDriving conditions:
it harshor abnormal conditions, 4WS controlunit interprets as a problem the underextremely Whenthe vehicleis operated the DTC. and memorizes
DTC
Operation The ignitionis turned from OFF to ON while driving. on with the driver and three passengers The car is driven aggressively board. or the steeringwheel is turned with a rear wheel blocked by the curb, etc.
The engine is started while quick-charging the battery.
4WS IndicarorLight ON
70
71
74
Drivingthe car with the parkingbrake ON.
ON 5 minutes after detection
Fail-safe control:
When the fail-safe conditions are met, the 4WS control unit stops the 4WS control and returns the rear wheels to the straight driving position slowly.
17-37
Troubleshooting(4WSl
Symptom-to-SystemChart
FAIL SAFE(F/S)ITEM
l5
F
AFFECTED
l F
z a
-LE o t
z 3;
F14
It
z
F X
c 4
t--
= .rr nr T
zz. A H > ;
riz
t z ; o
Z
z
f
tr9
o:l z ,,,
F
& z
F
I > o
(r o
F f
-'z ) a
o z o
c F C) c0
o
E F
t
F IE F E
z i
36
O O
z -
6 =
;E
7 +23
18 25 2
z = i z i z tr< t <
> 6 Eul [ <
a=
t-z crii'i
= z
z
(J
t-
2 o
ACTION
<(r
nfr
o l(l. < D < i aa E t1) t a
2=,
< 3 #A 5
2e R+
z
lr F
(, =
NO code
o o
Go to trouble shoo!ng
Go to trouDte snoorng
No code
1 74 2
10
FRONT
22
Go to
o
snoorng Go to
1 14 5
1t
REAR
17
a)
snoorng
Go to trouole snooflng Go to trouble snooflng Replace
1750
FRONT
o
11
1 74 5
REAR
o v,
14 FRONT
2a
c)
1750
(, z
(9
o
Replace
z tr
F
REAR
o
trolunrt
at) l
16
FRONT
22 26 21
Go to
o o
o
shootrng Go to trouble snoorng
1t 45
17
REAR
17
,-l
17 50
2a
18
Repiace 4WScon
17-38
(F/S)ITEM FAIL-SAFE
(9
4 (E
lDz F q
z ) i z
tr<
rroLrble- 17 59
Go to
1 7- 3 9
Chart (cont'dl Symptom-to-System
FAIL-SAFE {F/S)ITEM
(9
F
AFFECTED
l E F F p tD F^
z i l o -.lE o l E Z
F
o =
t;i
(9 2
= ;o
z i O ltr . TL
t z
I l
t z ) o
F
E F l F
o
F E
l5
z,,, <5
o(J
2za x
;fr
@ z Ful Z:! i z
-'z
z.z t z ) <1, < = = 6 <
; o t z
o - z
E"'
E
z o
co
z o
O
o < E
tr< aa<E
s:
<tr
*E
^ 3 < ;5 P $ E
la iE
E d) (9
z 2 o
ACTION
z
cc
E
33
REAR R/L
3
'l
Go to trouble- 1 7 - 6 8 snoorng
34
FRONT
19
o o o o o
o o o o
Go to
17-63
REAR L
I
3
I
17-64
REAR R
17-66
shooting
37
REARL
Replace 4WS con-
VEHICLE SPEED
o o o o o
Replace 4WS con trol unrt
40
CONTROL UNIT CONTBOL UNIT
41
42 43
44
L z :) o F z o o =
CONTROL UNIT
UNIT
o
UNIT
45
UNI-T
4WS CONTROL UNIT
o o
C +
46
o o
Go to
1770 1 7- 7 1
z o 5 t 6
C + D _
17-40
Go to trouble' shooting
11-11
1 77 1
1 7- 4 1
Troubleshooting (4WSl
4WS IndicatorLight Circuit
4WS CONTROL UNIT 18P/12PCONNECTORS The 4WS indicarorlight does noi como on whon ignition switch is first turned ON.
Connect
View from terminal side.

Turn the ignition switch ON and pull the parking brake.
Does the brake indicator light
f c h e c k t h e N o . 1 3 M E T E Ru s e 1 1 0A ) i n t h e u n d e rd a s hf u s e k e '
ls the luse OK? No. Connect 4WScontrolunit the and No. 23 ter7 terminal(PNK) minal(PNK) wire to body ground.
Reolaceth fuso and rocheck.
ReDairopen in the YEL wire b tuso 110 twn rhe No. 13 METER Al .nd the 4WS indicator light.
Does the 4WS indicator light
Reolacerhe 4WS control unft.
The 4WS indicator light does not go oft alier stariing ngineand no DTC is shown.
Start the engine and check the charging system light.
Does the light go off?
Turn the rgnrlronswitch OFF.
RADIO Checkthe No. 43 CLOCK, fuse (10 A) in the under_hood
ls the fuse OK?
Reolace the fuse and recheck,
{ T op a g e1 7 4 3 )
17-42
lFrom page 17-42)
Checkthe No. 22 4WS luse (10 A) in the undeFdashluse/rel8y box.
ls the fuse OK?
Replacoth. lulc 6nd rochock.
checktheNo.I R/c MlRRoRluse (15 Alin theunder-d8sh fuse/retayDox.
Roolacotha fula and rochock.
Disconnect 4WS controlunit thg 'l8P connector and 12P connector.
Repalrihort in tho Pf{K wlrc! b6tw6en tho 4WS cont.ol unit and tho indicrtor light.
Connect lhe 4WS contiol unit 18P connoctor and 12P con' nector,
UNIT 18P CONNECTOR 4WS CONTROL
8aft6ry Voltsgo? Measure voltage between the 4WS controlunitNo. 18 terminal (WHTrYL)and body ground. Ropalrop.n in WHT|'EL wlro botwcon tho 4WS control unit .nd undor-hood fuaa/rolay bor.
ls there bsttery vollage?
{To page 17-44}
4WS IndicatorLight Circuit (cont'd)
(Frompage 17-43) 4WS CONTROLUNIT CONNECTOR 12? Measure voltage between the 4WS control unit terminals:No. '|8 (WHTryEL) and No. 16 (BLK), and botwenNo. 18 (WHT,ryEL) and No. 24 (BLK). Ropairtho poor ground lcso'l) o. oDon in BLK wir6 bolwesn tho 4WS control unit and body ground. Turn the ignitionswitch ON.
View lrom terminalside
Measure voltag between the 4WS controlunit No. 25 terminal (YEL/RED) body ground, and wlr6 Reprir op6n in tho YEL/REO btw6n the 4WS conlrol unh and undr-d6ahfuse/rolav box. 18P Measure voltage betwen the 4WS control unit No. 4 terminal and body ground, {BLK/YEL) Ropairopen in tho 8LK/YELwir6 botwoon tho 4WS control unit and tho under-dashtusoholay box.
ls there battery voltageT
4WS CONTROL UNIT CONNECTOR 12P
V ) Bsttory
Measure voltage between the 4WS controlunit No. 2 terminal and body ground. {WHT/BLU) Ropairopnin th6 WHT/BLUwir6 btwoon tho 4wS conttol unit and tho undor-dashfuso/rolav box. Roplacoth6 4WS control unit.
Diagnostic Trouble 10, 12, 16 Codes(DTCs):

-Thc 4WS indicoro. light has boan roDortodon. -With sorvico ch6ck conn6ctor irmpod codos 10. 12, 16 610indlc.tcd.
Disconnectthe front sub steering anglesensorconnector,
Measurresistancebetween the No. 1 terminal {BLK)and No. 2 ot terminal{WHT/BLU} the sensor side connector.
l s t h e r e8 . 4 - 1 2 . 2 O ?
Measureresistancebgtween the and No. 2 terminal {WHT/BLU) No. 3 terminal(BLKMHTI ot rhe senaor side connector.
ls rhere8.4- 12.2O?
ANGLESENSOR FNONTSUB STEERING SENSONAIDE CONNECTOR
Checkfor continuity between the sensor side connsctor No. I te.minal (8LK)and body ground.
Continyity? 8.4-12.2 A? View from terminalside.
(To page '17-46)
1 7- 4 5
(4WSl Troubleshooting
DiagnosticTroubleCodes {DTCs): 10, 12,16 {cont'd)
lFrom page 17-45)
Measurethe voltsge betweenthe 4WS control unit side of the ssnsor connector No. 1 torminal (YEL/BLK)and body ground.
ANGLESENSOR FRONTSUB STEERING UNIT SIDECONNECTOR 4WS CONTROL
i+_I-} /J\ z.svr Y

View from terminalside. Disconnect 4WS controlunit the 12P connector. SIDECONNECTOR UNIT 12P SENSOR 4WS CONTROL
2.5 ls there approximatly V?
Checktor continuity between the 4WS controlunitNo.21 terminal and body ground. {YEL/8LK) Viw from terminalside. R.o.li short in the YEL/BLKwire botwoontho 4WS controlunil and tho front sub steering angle sonsor.
Connect the 4WS control unit 12P connector. UNIT 12P CONNECTOR 4WS CONTROL Measurevoltagbetween the No. 21 terminal{YEL/BLKI the 4WS ol control unit and body ground.
2.5 ls there approximarely V?
R6plac6 the 4WS conlrol unit.
lfo page 17-471
Ropairop6n in tho YEL/BLKwiro botwoon tho 4WS control unit and th tront sub stooring anglo 30nsot.
17 -46
(Frompage 17-46)
Measurethe voltage belween the 4WS control unit side of the sensor connector No. 2 terminal and body ground. IYEL/GRN)
ANGLESENSOR FRONTSUB STEERING UNIT SIOECONNECTOR 4WS CONTROL
rlTf-\ w
(V) 1 25 v?
Y
View from terminalside. Disconnectthe 4WS control unit 12P connector. SIDECONNECTOR 4WS COI{TROL UNIT 12P SENSOR
1.25 V? ls there app.oximately
Checktor continuity between lhe 4WS controlunit No. 26 terminal and body ground. {YEL/GRN)
Continuity? View trom terminalside.
Ropairshort in the YEL/GRNwire botw66n the 4WS control unit and tho sub steeJingangle sensor.
Connect the 4WS control unit 12P connector. UNIT 12P CONNECTOR 4WS CONTROL
Measur6 voltage betwoen the 4WS controlunitNo. 26 terminal and bodv ground. {YEL/GRN) View from terminalside.
1.25 V? ls there approximatoly
Rool6c6the 4ws control unit.
{To page 17-481
R6pai opon in tho YEL/GRN wire borwoon tho 4ws contol unit and tho front rub staering anglo aonaot.
17 -47
DiagnosticTroubleCodes (DTCs):10, 12, 16 (cont'd)
lFrcnr,page 17'471 ANGLESENSOR FRONT SUB STEERING 4WS CONTROLUNIT SIDE CONNECTOR
Messurethe voltage betweenthe 4WS control unit side ol the sensor connector No, 3 terminsl(YEL/BLU) body ground. and
( v )2 . 5 V l
:r
View from terminalside.
2.5 ls lhere approximately V?
Disconnectthe 4WS control !nit 12P connector, SIDECONNECTOR UNIT 12P SENSOR 4WS CONTROL
Checkfor continuity between the 4WS controlunit No. 22lerminal (YEL/8LU) and body ground. View from terminalside. Ropai.shorl in the YEL/BLUwiro b,6two6nth6 4WS contiol unh 6nd 3ub stooring 6n9lo sonsor.
Connect the 4WS control unit 12P connector. 4WS CONTROLUNIT 12P CONNECTOR
Measure voltage between the 4WS controlunitNo. 22 terminal (YEL/BLU) and body ground.
View trom terminalside. ls there approximately 2.5 V? Raolac6tho 4wS control unit.
(To page 17 49) Rop6iropon in tho YEL/BLUwiro botrYoontho 4WS control unh ald the front sub 3t66ring angl6 sonsor.
17 -48
(Frompage 17-48) 4WS CONTROL UNIT 12P CONNECTOR
Conneclthe front sub steeringangle sensorconnector. List6d Voltage? View from terminalsideFRONTSUB STEERING ANGLESENSOR TERMINALVOLTAGE IREFEBENCE}
STEERING WHEEL P0stTt0N

Whileturningthe steering wheel, measure voltagebetweenNo. 22 (YEL/BL|) and No. 26 (YEL/GRN) terminalsol the 4WS control unit usingAC rangeof analogtester.
LEFT approx 2 . OV
CENTER approx 2 . 5V
RIGHT approx
Voltage
3 . 0v
Analog tester AC range
Does voltage change as shown in the table?
Check the neutral point of the front sub steeringanglesensor. { s e ep a g e1 7 1 4 6 ) .
ls the neutralpoint OK?
Adtust the noul.al point ot tho troni 3!b steering sensor.
ReDlacoth6 4WS control unit
17-49
Troubleshooting(4WS}
Diagnostic Trouble C o d e s( D T C s ) :1 1 , 1 3 , 1 7
-Th6 4WS indicator light has boon toDorled on. -With sorvic6 chock connoctor 'l7 are iniumpod cod6s 1l, 13, dicatod.
ANGLESENSOR REARSUB STEERING SIDECONNECTOR SENSOR l|l 12.3Lua\ lr /^\ Ir,/ \"/ \ ..r/ Continuitv?
/z\ -r_
Disconnectthe rear sub steerang anglesensorconnector.
ur\u \"/
/-\rFP
a . 4 - 1 2 . 2A ? +
Measure resistancebetween the No. 1 terminal {BLKMHT), and oI the No. 2 terminal{WHT/BLU} connector' th sensorsade
l s r h e r e8 . 4 - 1 2 . 2 0 7
Measure rosistancebetween the and No. 2 terminal (BLK,ryVHT), th6 No. 3 terminal (BLK)of the sensor sadeconnector,
l s t h e r e8 . 4
1 2 . 20 ?
Chock for continuity between the sensorside connectorNo. 3 ter minal (BLK)and ground.
llo page r /-5l l
17-50
lFrom page 17-5Ol REAR SUB STEERING ANGLE SENSOR 4WS CONTROL UNIT SIDECONNECTON
r-Ffi-r
Measurethe voltage bGtweenthe 4WS control unit side of the sensor connector No, 1 terminat (GRYI and body ground.
(V) z.svz Y
ls there approximately 2.5 V?
Disconnect 4WS conlrolunit the 12P connector. 4WS CONTROL UNIT 12P SENSOR SIDECONNECTOR
fl-ll
Check for continuity between the 4WS controlunit No. 29 terminal (GRY)and body ground.
wrl
I
YES
rarfT l
continuiry
RoDairshort in the GRY wiro between the 4WS control unit and the rearsub steeringanglesonsor.
Connect the 4WS control unit 12P connector. 4WS CONTROL UNIT 12P CONNECTOR
Measure voltage between the 4WS controlunit No.29terminal (GRYIand body ground. View from terminalsrde,
ls there approximately V? 2.5
fio page 17-52l, R6pairopon in tho GRY wir6 b6twoon the 4WS control unit and tho roar sub stooring anglo aonsor.
17 - 5 1
T D i a g n o s t i c r o u b l eG o d e s( D T C s ) :1 1 , 1 3 ' 1 7 ( c o n t ' d l
( F r o m a g e1 7 - 5 1 ) p ANGLESENSOR REARSUB STEERING UNIT SIDECONNECTOR 4WS CONTROL
Meas!re the voltage betweenthe 4wS control unit side of the sensor connector No, 2 terminal wire and body ground. {GRY|YL)
1.25V?
View lrom terminalside.
'1.25V? ls there approximately
Disconnectthe 4WS control unit 18P connector. SIDECONNECTOB UNIT 18P SENSOB 4WS CONTROL
Check for continuitv between lhe 4WS controiunit No. 17 terminal and bodv ground. {GRY/YEL)
Reoahshort in the GRY/YELwire betwoontho 4WS conttol unit and anglesensor. the rearsub stGring
Connect the 4WS control unit 18P connector. UNIT 18P CONNECTOR 4WS CONTROL
Measure voltage between the 4WS controlunitNo. lTterminal (GRY/YEL) body ground. and View from terminalside. '1.25V? ls there approximatelv Roolaceth6 4WS control unit.
(To page 17-53)
Ropairopen in the GRYI/EL tYire b6lwo6n tho 4WS control unit and tho roar sub steoring englo sonsor.
17-52
(Frompage 17-52)
REARSU8 STEERING ANGLESENSOR 4WS CONTROL UNIT SIDECONNECTOR (3.1 I !
Masurethe voltage betwoen the 4WS control !nit sido of the sensor connector No. 3 terminal (GRY/BLK) and body ground.
(V) z.svz Y
View trom terminalside
Disconnect 4WS controlunit the 12P connector, SIDECONNECTOR UNIT 12P SENSOR 4WS CONTROL
Checklor continuity between the 4WS controlunir No. 28 terminal and body ground. {GRY/BLK)
Repai. shon in the GRY/8LK wiro hw6n the 4WS controlunitsnd tho rotr sub storinganglosonsor.
Connect the 4WS control unit 12P connector,
4WS CONTROL UNIT ,I2P CONNECTOR Measure voltage between the 4WS controlunit No. 28 terminal and body ground. {GRY/BLK)
View from terminalside. ls there approximatelv V? 2.5 Reolace4WS control unit.
{To page 17-54)
Ropairop.n in tho GRY/BLKwire between $ 4WS control unit and th roaasub Stseaingangle sensor.
17-53
Troubleshooting(4WSt
Diagnostic Trouble C o d e s( D T C s ) :1 1 , 1 3 , 1 7 { c o n t ' d )
(Frompage 17-531 UNIT'I8Pi12P 4WS CONTROL CONNECTOR Connectthe rear sub steeringangle sensor connector-
TERMINAL VOLTAGE ANGLESENSOR REARSUB STEERING (REFEREI{CE)
While turning the steering whool voltagebetweenNo. and measure and 17 lGRY,ryELl No. 29 (GRY) terminalsof the 4WS controlunit using AC range ot an analog tester.
WHEEL STEERING P0stTt0N Voltage
LEFT
approx
CENTER approx 2.5V
RIGHT approx 2 . OV
3 . 0v
Analog tester AC
Doos voltage change as shown in the table?
Checkthe neutralpoint ot the rear sub steering angle sensor (sse page 17-1461.
ls the neutral point OK?
Aqu3t dre iratural point of tt| tolr aub ltoailng aanlor.
Replacotha 4WS control unit
17 -54
DiagnosticTroubleCodes (DTCsl: 20, 22, 24,28

-Th6 4WS indicator light has bggn reDortodon. With service chock conngctot iumpod codes 20. 22, 24. 28 are indicated. Disconnect front main steerthe Ing anglesensorconnector, Turn the ignitionswilch ON. Measure voltage between the 4WS controlunit sideconnector No. 1 terminal {BLK/YEL} and body ground. Ropair op6n in th6 harnoss wiro betwoen tho No. 22 4WS tuso and tho tront main stoering angle sonsor. Measurethe voltage between the 4WS controlunit sideof the senNo. 4 terminal(LT sor connector GRN)and body ground.
ANGLESENSOR FRONTMAIN STEEBING 4WS CONTROL UNIT SIDECONNECTOR
BsnoryVoltago?
ANGLESENSOR FRONTMAIN STEEBING 4WS CONTROLUNIT SIDE CONNECTOR
fT-fFlt -X( V.)c.svr
:r
View from ierminalside.
UNIT 18P 4WS CONTROL SENSON SIDECONNECTOR Disconnectthe 4WS controll unit 18P connector.
ls there approximately V7 4.5
Checkfor continuity between the 4WS control unit No. 8 terminal (GRN)and body ground.
Rooairshort in tho GRN wiro betwoon tho 4WS control unit and th6 main stedng angle aonsor. Connect the 4WS control unit 18P connector.
4WS CONTROL UNIT 18P CONNECTOR
Measure voltage between the 4WS controlunit No. 8 terminal (GRN)and body ground. View from terminalside. ls there approximately V? 4.5 Roolaceth6 4WS cont.ol unit.
( T op a g e1 7 - 5 6 )
Ropah open in the GRN wiro betweon the 4WS control unit and the front main sloo.ing anglo
17-55
DiagnosticTroubleCodes (DTCs):20, 22, 24, 28 (cont'd)
{Frompage 17-55) ANGLESENSOR FRONTMAIN STEERING 4WS CONTROLUNIT SIDE CONNECTOR
Measurgthevoltage between the 4WS control unit side of the senaor connoctorNo.3 terminal(BLU) and body ground. View from terminalside.
4.5 ls there approximately V?
Disconnectthe 4WS control unit 18P connector.
UNIT 1AP 4WS CONTROL SIDECONNECTOR SENSOR
Check tor continuity between the 4WS controlunit No. 3 terminal {BLU}and body ground. View lrom terminalside. R.Dair short in tha BLU wire b6twoon tho 4WS cont.ol unit and the main stooring angl aonsor.
Conn6cl the 4WS control unit 18P connector.
Moasure voltage between the 4WS controlunitNo. 12 terminal (BLU)and body ground. View from terminalside.
4.5 V? ls there pproximatoly
Roplsce the 4WS control unit.
(To psge 17-57) Repair opon in tho BLU wiro betwoon th6 4WS control unit 6nd th6 front main stoodng anglo 30n3('t.
17-56
{Frompage 17-56}
ANGLESENSOR FRONTMAIN STEERING 4WS CONTROL UNIT SIDECONNECTOR
Megsureth voltago between the 4WS control unit side of the sensor connectol No. 2 trminal (YEL/REDI and bodyground. wire View from terminalside.
ls th6re approximat6ly 4.5 V?
Disconnect 4WS controlunit the 18P connector.
4WS CONTROL UNIT 18P SIDECONNECTOR SENSOR
Checkfor continuity between the 4WS controlunit No. 15 terminal and {YEL/RED) body ground. View from terminalside,
Ropairshon in tho YEL/RED wire botweon lhe 4WS control unit and tho main stering sngle snsor. Connect the 4WS control unit 18P connector. UNIT 18P CONNECTOR 4WS CONTROL Measure voltage between the 4WS controlunit No. 15 terminal and {YEL/BEO) body ground.
View from terminalside. ls there approximately 4.5 V? Reolacethe 4WS control unit.
lTo page 17-58)
Ropairopon in th6 YEL/REDwire botwo6n tho 4WS control unit and th6 front main sto6.ing angle aon30r.
1 7- 5 7
Diagnostic Trouble Codes IDTCs):20, 22, 24, 2A (cont'd)
(Frompage 17-57) ANGLESENSOR FRONTMAIN STEBING 4WS CONTROLUNIT SIDE CONNECTOR
Check for voltage between the and No.2 terminalIYEL/RED) the No. 5 terminalIELK)of the 4WS control unit side connectorof the anglesensor. front main steering Rcpair tho poor ground lG 4Ol, 402, 4041or oDenin rhe BLKwiro botwon th6 front main atooring anglo 3onsor and body ground.
[T'T-TT;I
l ^
\:/
4.5 V?
View from terminalside
4.5 ls there approximately V?
Reconnect front main steering th anglesensor5P connector,
While turning the steeringwheel, check for the signalsbetweenthe following 4WS control unit termi' nals and the body ground with an analogvoltmoteron the DC range. A-phase: Betwsentho No. 8 terminal(GRN) and body ground: should pulse O-4.5 V rspidly {every2o) B-phas6: Between th No. 15 terminal (YEL/RED)and body ground: (ev pulse0e4.5 V rapidly should ry 2o) Z-ph8se: Bgtween the No. 12 terminal IBLU) and body ground: should pulse0*4.5 V onceper steoring wheel revolution
0-4 . 5 v ? ( V ) ( V )
(V
Are the signalsavailable between the respctive terminal and the body ground?
Checkthe Z-phaseneutralposi' t i o n ( s e ep a g e1 7 - 1 4 6 ) .
ls the Z'phasein the straight drivingposition? YES
adjust the front main stooringanglo sonsor noutral poaition {soo pago 17-15) Srraight l revolustion A-phase o B-phase Z-phase
4.5 0 4.5
Podorm lor troublgshooting OTCa . 1 0 . ' 1 21 6 . pag6'17451. {3e6
---------------- Time
L-
17 -58
DiagnosticTroubleCodes (DTCs):21 , 23, 25,29
-Th6 4WS indicalor light hss b6on rooorlod on, -V\fth sorvica check connecto. .iumpodcod6s 21 , 23. 25, 29 ato indicatod.
REARMAIN STEERING ANGLESENSOR 4WS CONTROL UNIT SIDECONNECTOR
\\.)t t..
w \:/
I
tlt
JJ
Battery voltaqo?
Disconnectthe rear main steering angresensorconnector.
Turn the ignitionswitch ON. REARMAIN STEERING ANGLESENSOR 4WS CONTBOL UNIT SIDECONNECTOR Measure voltage between the 4WS conlrol unit side connector No. 1 terminal (RED)and body grouno. Ropair open in thg hahoss wire bolweon tho No.22 4WS fuse and the reaamain gtoering tngla sensot.
ls there battery voltage? YES Measurethe voltage between the 4WS control unit side No.3 termi nal {WHT/GRN} and body ground.
View from terminalside 4WS CONTROL UNIT 18P SENSOR SIDECONNECTOR
Disconnecl the 4WS control unit 18P connector.
YES
Checktor continuity belwoen the 4WS controlunit No. 6 terminal (WHI/GRN)and body ground. View from terminalside
ls there continuity? NO Connect the 4WS control unit 18P connector.
Repair short in the WHT/GRNwire betwecn tho 4WS controlunit and the main steering angle sensor, 4WS CONTROL UNIT 18P CONNECTOR
Measure voltage between the 4WS controlunit No. 6 terminal {WHT/GRN} and body ground.
ReDlacothe 4WS control unir.
lTo page I7-60)

I
Repairopon in th6 WHT/GRN wi.o botwoon the 4WS contol unit and the aoaa main stooring angle sensot.
17-59
DiagnosticTroubleCodes (DTCs):21, 23, 25, 29 lcont'd)
{Frompag6 17-59) ANGLE SENSOR REAR MAIN STEERING 4WS CONTROLUNIT SIDE CONNECTOR Measurthe voltage betwen the 4WS controlunit side No 4lerminal (ORN) wire and body 9rouno.
View from lerminalside 4.5 V? ls ther pproximately Disconnectth 4wS control unit 12P conneclor. 4WS CONTROLUNIT 12P SIDECONNECTOR SENSOR
l--T--fl nr lEf-l
Checklor continuity between the 4WS controlunit No. 20 terminal {ORN)snd body ground.
ffiwx)
(p Continuitv?
View trom terminalside RoDairshon in ths ORN wiro botweon tho 4WS control unit 6nd tho .oar main stoering anglo 80n8('t.
Connoct the 4WS control unit 12P connector. 1 CONTROL,UNIT2P CONNECTOR
Measure voltage belwoen the 4WS controlunitNo. 20terminal {ORN)snd body ground
r'.l-H-tD ff
(V) +.svr
:r
4.5 V? ls there approximately
Roplacotho 4WS conttol unit
{ T o p a g 61 7 - 6 1 )
Ropairopon In tho OBN wi.c bo_ twoon tho 4WS conttol unit and the roar main 3loaring angle 30nlot.
1 7 -6 0
{Frompage 17 601
REARMAIN STEERING ANGLESENSOR 4WS CONTROL UNIT SIDECONNECTOR .-rnfla / F vl5,l,/t )
Measurethe voltage betweon the 4WS control unit side No. 6 ter m i n a l ( B L U / G R N )a n d b o d y gtouno,
( V ) a . sv r Y
Disconnect 4WS controlunit the 18P connector.
4WS CONTROL UNIT 18P SENSOR SIDECONNECTOR
Checktor continuity between the 4WS controlunit No 13 terminal and body ground. {BLU/GRN)
View from terminal side
YES
ReDai.short in the BLU/GRN wire betweenthe 4WS controlunit and the rear main stgoring angle sensor.
Connect the 4WS control unit l8P connector.
4WS CONTROL UNIT 1AP CONNECTOR
Measure voltage between the 4WS controlunit No. 13 terminal (BLU/GRN) and body ground.
Raolace the 4WS control unit.
{To page 17-62)
R6pai.op.n in the BLU/GRNwire botween tho 4WS control unit and tho ioaa main Stoaring anglg sensor.
1 7- 6 1
21' 23, 25, 29 lcont'dl Trouble Codes(DTCs): Diagnostic
(Frompage 17-611 ANGLE SENSOR REAR MAIN STEERING UNIT SIDECONNECTOR 4WS CONTROL
Masure voltsge betwson the and the No,6 terminsl {BLU/GRNI No. I terminal (RED)of the 4WS contrcl unit aide connector ot the reat main steedng angle sensor. R.p.l opcn In th. RED wir. botwocn tho 4WS cont?ol unit and tha ra.] maln ltooting anglo Itn!o1, View from terminalside
4.5 ls there pproximately V?
Rsconngctthe rear main ateering sngle sonsot 8P connector.
While turning th steering whe|, check for the signalsbetwenthe following 4WS conttol unit termin6ls and the body ground with an analogvoltmeteron the DC range. A-phase: Eetween the No. 6 terminal (WHT/GRN)ahd body ground: shouldpulseO-4.5 V rapidlylevery 2o) B-phase: Between thc No. 13 terminal (BLU/GRN) and body ground: shouldpulseO-4.5 V rapidly(ov' ery 2ol Z-phaae: Betwesn the No. 20 terminal IORN) and body ground: should pulsoO4.5 V once per ste6ring wheel revolution
UNIT 18P/12P 4WS CONTROL CONNECTOR

I
O-4
. 5v ? ( V
ri+ffi M
(v)
Y
l2oHl
Are the signals availablebetween lhe resDectiveterminal and the body ground?
Check the Z-phase neutral Position {seo page 17-'146).
ls the Z-phase in the straighi driving position?
Porform trouble.hooting of the DTCs 11, 13, 17. (.o6 psgo t7-501
A-phase B-phase Z-pha86
4.5
4.5 0 4.5 0
---------------- Time
17-62
DiagnosticTroubleCodes (DTCsl: 30, 34

vehicle speed sensor (VSS) NOTE: DTC 34 may have been memorized 4WS control unit after the using ALB checker. on It so, disconnectNo. 43 CLOCK,RADIO(10 A) fuse in under-hood tuse/relavbox to reset the 4WS control unit.
-Tho 4WS indicator light has boon roDortedon. -With aervice check connector iumpod codos 30 and 34 are indicated.
Disconnectlhe 43 fuse{'l0 A) No. in the undeFhoodfuse/relaybox.
Tesl drive the car.
Do codes 30 and 34 appear?
Sy3tom is OK at trrb tims. Inlpoct tho vohicle spoed sonso. tominal connecrots.
Does the speedometer operate properly?
(Go to pago 23-1181
Disconnect 4WS controlunit the 12P connector,
4WS CONTROL UI{IT 12P SENSOR SIOECONNECTOR
Measurevoltage betweenthe No. l9 terminal(ORN) sensorside of connector ot 4WS control unit and body ground.
ls there more than 5 V?
Rool6c6 the 4WS control unit lwhon tho symplom rocurrod.)
Repaii opon or short in the ORN wh to body ground betwoen the vehiclospeedsensorand rhe 4WS contol unil.
17-63
(DTCs): 35 (cont'd) 31, DiagnosticTroubleCodes
-Tho 4WS indicator light ha6 boon ropott6d on. -With asivico chock connoctol jumpod codos 31 and 35 oro indicatod.
View trom terminalside Does the ABS indicator light stay ON? Go to pago 19-54 Problem in ABS rystom
Stop the engine.Then turn the ignition switch back ON.
With the loft rear wheel raisedoll ground, slowly rotate the wheel while checking {or voltage be tween the 4WS control unit No. 3 terminal{GRYMHT) and body ground. Record lhc DTC rnd clear the 4WS contiol unit. Tost drive th6 car, if th6 DTC doo3 not roaPpear, chock tho to.minal connoctions ol th 4WS co.rtrol unii 18P connc'l4P tor and tho A8s contiol unit connoctor.
Does the voltage alternate from zero to approximately 5 V?
(Topage1 7 - 6 5 )
7-64
l F r o mp a g e1 7 - 6 4 )
4WS CONTROL UNIT 18P SENSOR SIDECONNECTOR
Disconnectthe 4WS control unit connectorand the ABS control unil connector, View from terminalside Checklor continuity betweenthe 4WS control unit No. 3 terminal (GRY/WHT) and body ground. Repeir shon in tho GBY,^/HT wire bctwoon tho 4WS control unh and tho ABS control unit.
4WS CONTROL UNIT lAP CONNECTOR
Measurevoltagebetween the No. 3 terminalof the 4WS control unit connectorand body ground.
View from terminal sade
ls there approximately V? 5
Rophco tho 4WS control unit. ABS CONTROL UNIT 14P SENSOR SIDECONNECTOR
Measure voltage betweon the No. 3 terminal (GRY/WHT) of sensor side connector oI ABS control unit 14P connector and body ground.
Rsp.ir opsn in tho GRY/WHTrYiro botwoon tha 4WS control unh snd th ABS control unit. R6olacothe ABS control unit.
(4WSI Troubleshooting
32, 36 TroubleCodes(DTCs): Diagnostic
-Th. 4WS indlcator light h$ baan ropo.tgd on. -Yvlth lowica chack connoctor iumpod code. 32 and 36 sro indiclt.d.
4WS COI{TROLUNIT IAP CONNECTOR
View trom terminalside YES co to p!9.'19-54 ftoblem in ABS .y.t.m
Stop the engine.Then turn the ignition switch back ON.
With the right rear whol .aised off the ground. slowly rotate the wheel while checking for voltag betweenth 4WS contrclunit No. 1 terminal IGRY/RED)and bodv grouno. Rocord tha DTC .nd cl..t th. 4l rS control unll. l.al driv. tho c.r, it tha DTC dodc not ro.ppaat, afFck tra tarmind connacdonr ot d|. 4WS cont ol unit 18P cofir.c_ toi and th. ABS control unit l4P connoqtoi.
Does the voltage alte.nate trom zero to approximstely 5 V?
NO
{To page 17-67}
17-6 6
(Frompage 17-66)
4WS CONTROLUNIT
'I8P SENSORSIDE CONNECTOR
Disconnectthe 4WS control unit connector and the ABS control unit connoctor, Viw from terminalside Check tor continuity between the 4WS control unit No. 1 terminal and {GRY/REO} body ground. wi?o Rap.i. .hon In th. GRY/RED bltwa.n th.4WS conltol onh and th. ABS conlrol unit.
4WS CONTFOLUNIT 18P CONNECTOR Turn the ignitionswitch ON.
Moasurevoltagebetweenthe No. 1 terminal (GRY/REDlotth 4wS conlrol unit conneclor and body ground.
ls there approximately 5 V?
Rcplscr lh. 4WS control unii

SIOECONNECTOR UNIT 14P SENSOR ABS CONTROL
Measurevoltagbetween the No. 1 terminsl IGRY/RED)of sensor sideconnectorof ABS controlunit and body ground. 14Pconnector Rcplli opcn in th! GBY/REDwite b.twran th.4WS coiltol unh lnd th. ABS control unit. Roplacalhc ABS conttol unit.
17-67
Trouble Code(DTCI:33 Diagnostic
NOTE: Problem code 33 is memorized when the front wheelsare turned at a speedot 30 km/h for 2 minuteswith the brake must be off to test this code.) lront wheels raisedoff the ground and the rear wheels blocked.(Parking
-The 4WS indicator light has boon roDortodon. -Whh sorvic6 chack connoctor iumpod codo 33 ir indicsted.
4WS CONTROL UNIT 18P CONNECTOR

3
0-5 V?
Does the ABS light stay ON?
View from terminalside Perfo.m troubleshooting ol tho ABS system (pag6 '19-541
Stop the engino.Then turn the ignition switch back ON.
Rotate the rear left wheel slowly and check for voltage btween the 4WS unit control No. 1 terminal IGRY/RED) body ground, and and betweenthe No. 3 terminal (GRYA HT) and body ground. Record tho DTC and clear th6 4WS control unit. T6st driv th car, if th6 DTC doos not rsappoar, chock tho torminal3 connoctions ot tho 4WS control unit 18P connector and tho ABS control unlt 14P connoctor.
Doesthe voltage from both rear wheel sensorsalternatefrom 5 zero to approximately V?
(To page 17-69)
17-68
(Frompage 17-68) 4WS CONTROL UNIT Disconnoctthe 4WS control unit connector and the ABS control untl connectol, 'I8P SENSOR SIDECONNECTOR
Chockfor continuity between the 4WS control unit No. 1 terminsl (GRY/RED) body ground. and wire Ropai.shorl in tho GRY/RED botwoen 4WS control unit and the ABS control unit.
SIDECONNECTOR UNIT 18P SENSOR 4WS CONTROL Check for continuity between the 4WS controlunit No. 3 terminal and body ground. {GRY/WHT) Ropairlhon in th6 GRY/WHT wiro between tho 4WS control unit snd tho ABS control unit.
4WS CONTROL UNIT 18P CONNECTOF
Measure voltage between the 4WS control unit No. 1 terminal (GRY/RED) body ground. and View from terminalside 5 ls there approximately V? Roplac6ths 4WS control unit.
YES
{To page 17'70)
17-69
(4WSl Troubleshooting
Code{DTC}:50 Trouble Diagnostic Trouble Code(DTCI:33 (cont'dl-Diagnostic
{Frompage 17-691 UNIT 18P CONNECTOR 4WS CONTROL
Measure voltage between thg 4WS control unit No. 3 terminal IGRYMHTI and body ground. View from terminalside ls there approximately 5 V? Beolaco tho 4WS control unit. UNIT 14P CONNECTOR ABS CONTROL Measure vollage between the ot No. 7 terminal{GRY/RED} the 14Pconnectorof the ABS control unit and body ground.
9;;;
wiro. Ropair opn in th6 GBY/RED UNIT ABS CONTROL
TERMINAL
View from terminalside ls there approximstely 5 V? 'I4P CONNECTOR
Measure voltage between the No. 8 tgrminalof the 14Pconn6ctor of the ABS control unit and body Oround. View from interiorside ls there approxinately 5 V?
Baplaco the ABS control unit.
REARACTUATOR MOTOR TERMINAL
Diogno.tic Trouble Cod6 (DTCI: 50
-The 4WS indicato. light hes boon rcooned on. -with aoavico Ghock connectol iumped codo 50 is indicolod.
Start the engine. Turn the stoeF ing wheel and check the rear stering motor lor function, Cloa. tho 4WS control unit and rotort, if tho DTC roccouB, then .6placo tho contlol unit.
TERMINAL UNIT POWER 4WS CONTROL
Does it operate properly?
8LK MOT _
l
Roplacotho r6aaactuator motot. R E DM O T + BRN GND
I
l
WHT+B
17-70
(DTCsl: 61, 62, 63 (DTCI: 60, Trouble Codes 51-Diagnostic Trouble Code Diagnostic
Diagnostic Trouble Codo {DTC}: 51
-Tho 4WS indicstor light ha8 boon rgportod on. -Wlth s6rvico chock connoctoi iump6d codo 51 is indicatod.
Start the engine. Turn the steer ing wheel and check the rear steeringmotor for function. Th6 DTC 51 blinkt whon lhg roar whoals cannot bo atoerod bgcause th6y aia blockad wfth tho cuab, otc. ll tho DTc 51 blink! aftor rhr rg3t drivo, tho control unit i. taultY. 4WS CONTROLUNIT POWERTERMINAL
Does it operate properly?
Rolacoth6 roar actuatoamolor.
Diagnostic Troubl Codes {DTCS):60, 61, 62, 63

-Th6 4WS indicator light h.s boen roportod on. -With sorvico chock connoctor iumpod codos 60, 61,62, 63 aro indicatad.
B.tt.ry Voltago? Batt.ry Voltage?
check the No.38 4ws fuse (60 AI in the under-hood fuse/re-
Battory Volrage? View from interiorside
Roplaco th turo lnd rccheck
Measure voltage between the A rarminal(WHTI of the 4WS con body trol unit powerterminaland grouno. Ropairopon in th6 WHT wi.a botwo.n thq undo,-hood fute/tol.y box and tho 4WS control unlt. Measure voltage between the B terminallBRN)of the 4WS control unit power torminal and body grouno. Rop.lr tho poor gtound lG5O2l or opon in ths ERltl wiro balw.dr lh6 4WS cont.ol unlt and bodY ground lG5O2l. Startthe engineand immediately (withinapproximately seconds 2 after starting the engine) check for voltage between the C termi nal {RED) the 4WS controlunit of powrterminal and bodyground.
Roplsco th6 4WS control unit.
7-7
60, 61, 62, 63 (cont'd) DiagnosticTroubleCodes(DTCs):
l F r o mp a g 1 7 - 7 1 ) TERMINAL UNIT POWER 4WS CONTROL
Stop the engineand turn the ig_ nition switch ON.
Measure voltage between the D terminal (BLK)ot rhe 4WS control unit power terminal and body groundimmediately after {wilhin 2 approximately seconds)starting the engrne.
Roplacolh 4WS control unit
Measure voltage between the C terminal(BED)of the rear actu ator motor and body ground after{withinapproximmediately imately 2 seconds)startingthe engine. Repair opsn in the RED wi.o betwoen tho 4WS control unit and tho roar actuator motor.
Measurevoltagebetweenthe D rerminal{BLK}of the rearactua tor motor and body ground alter {withinapprox' immediately imately 2 seconds)startingthe engine. Ropair opon in the BLK wir6 between tho 4WS control unit and the rcar actuator motor.
Measure voltage between the of No. 33 terminal{YEL} the rear actuatormotor and body ground immediatelyafter lwithin approximalely 2 secondslstartingthe engine.
ACTUATORMOTORTERMINAL
D U P + N O .3 3 I Y E T I
(To page 17 73)
Battery Voltag6?
17-72
lftonl. page 17-721
Raolacotho rsar actuato. motor.
ACTUTOR MOTOR TERMINAL
Measure voltage between the No. 34terminal(8LU)of the rear actustor motor and body ground immodiatelyafter (within approximately 2 secondsl slarting the engrn9.
Roplacotho roar actuator motor.
Meaaure voltsge between the (YEL) controlunitNo. 33 terminal and body ground immediatelvafter (within spproximately 2 seconds) starting the engine. Ropair op.n in tho YEL wir6 botwo6n the 4WS cont.ol unit and tho roar actuator motot. 4WS CONTROLUNIT 4P CONNECTOR 'rT\
Measure voltage between the control unit No. 34 terminal (8LU) and body ground immediatelyatter (within approximstely 2 seconds) starting the ngine. Repaii opon in the BLU wir6 b6twoon th6 4ws control unil and the ioai actuator motoi.
( v ) ( vBattory Voltago? )
Y:T
ffi
ls there baftery voltage?
Roplacs lhc 4wS control unit.
Maintenance
Pump Belt Adjustment
NOTE: When using a new belt, first adiustthe deflection or tensionto the valuesfor the new belt.then read just the deflectionor tensionto the valuesfor the used belt after runningenginefor tive mjnutes. 1 . A p p l ya l o r c eo f 1 0 ON ( 1 Ok g , 2 2 l b s )a n d m e a s u r e the deflectionbetween the power steeringpump and the crankshaftPulleys. Doflection: U s 6 db e l t : 1 3 . 5 - 1 6 . 5 m m { 0 . 5 3 - 0 . 6 5 i n l New belt: 9.5-11.5 mm (0.37-0.45 in) NOTE: lf there are cracks or any damageevident on the belt, replaceit with a new one. PULLEY POWER STEERING 2, Loosen the power steering pump mounting bolt, nuts and adjustingbolt locknut. Turn the adjustingbolt to get the properbelt ten sion, then retightenthe adiustingbolt locknut and mountingbolts. Start the engineand turn the steeringwheel lrom times,then stop the engineand several lock-to-lock recheckthe deflectionof the belt
3.
4.
POWER STEERING BOLT MOUNTING kg-m,16lb-ftl 22 N.m 12.2
AOJUSTING BOLT LOCKNUT .5 15 N.m 11 kg-m, 1 1 lb-tt)
Measurewith Belt TensionGaugel Attach the belt tension gauge to the belt and measurethe tension of the belt. T6nsion: U s db o l t : 3 5 0 - 5 O O N ( 3 5 - 7 0 k g , 7 7 - 1 1 Ol b s l Now belt: 7oo-9oo N {70-90 kg, 154-198 lbs} NOTE: lf there are cracks or any damageevident on the belt, replaceit wilh a new one. lor instructions the tenFollow the manufacturer's srongauge. PULLEY STEERING POWER
ADJUSTING STEERING POWER NUTS MOUNTING 2 2 N ' m ( 2 . 2k s ' m , 1 6 l b - t t )
CRANKSHAFTPULLEY
17-74
On-CarChecks
RackGuideAdjustment
CAUTIONTwhen servicing,be careful not to damage the power steering fluid linss with the special tool.
SCREW RACK GUIOE
NOTE: Adjust the rack guide at the center ol the rack stroke. 2WS: '1. Removethe gearboxshield. 2. Loosen the rack guide screw locknut with the specialtool. Tighten,loosenand retightenthe rack guide screw two times to 4 N.m (O.4kg-m, 2.9 lb-ft) then back * it oft 20 3". T i g h t e nt h e l o c k n u tt o a b o u t 2 5 N . m ( 2 . 5 k g - m , 18 lb-ft) while holdingthe guide screw. Checkfor tight or loosesteeringthrough the complete turning travel. s a R e c h e c k t e e r i n g s s i s t( s e ep a g e1 7 7 9 ) .
3.
4.
5.
6.
1 7- 7 5
Checks On-Car
Rack Guide Adjustment {cont'd)
4WS: '1. Removethe gearboxshield. 2. Cut wire tie trom the cover, then removethe cover from the front sub steeringangle sensor, CAUTION: Cut the wire tie with carefullv,so as not to damago the harness. 4. Loosen the rack guide screw locknut with the specialtool. the rack guidescrew 5. Tlghten.loosenand retighten two times to 4 N.m (O.4kg-m, 2,9 ib-ft) then back * it olf 20 !'. 6. Tighten the locknut to about 25 N.m (2.5 kg-m, 18 lb-ft) while holdingthe rack guide screw. 7. Check for tight or loosesteeringthrough the complete turningtravel. 8. Rechecksteeringassist (seepage l7-79i.
WIREHARNESS SENSOR
cot{t{EcToR
COVER
zo.3'
ANGLE SENSOR FRONT SUBSTEERING
3. Remove the sub steeringanglesensorwire harness from the clamDand disconnectthe connector. RACKGUIDESCREW LOCKNUT
43 WRENCH, mm LOCKNUT 07MAA-S10020A RACKGUIDESCRW
9. Reconnectthe connector and secure the sensor wire harnesswith the clamp and installthe cover. NOTE: a Be sure the sensor wire harness dois not interfere with the stabilizer and other moving parts. a Be certain that the sensor wire harnessis not twisted before connectingit. angle sen1O. Set the cover on the tront sub steerang sor. Securethe cover with the new wire tie. NOTE: After rack guide adjustment,perform the electrical check on the 4WS system (see page 17-146).
17-76
Checks On-Car
Fluid Replacement
Fluid Level Inspection
Check the power steeringfluid level with the engine cold and the car parkedon levelground.Make surethe levellines and LOWER fluid levelis betweenthe UPPER lf on the reservoir. the level is near or below the lower level line, check the system for leaks.lf the system is not leking.and fluid levelis low, add fluid to the upper level line.
FluidReplacement
1. Raisethe reservoirand disconnectthe hose that goes to the oil cooler. Connecta hose of suitablediameterto the disconnected hose that goes to the oil coolerand put the hose end in a suitablecontainer. Startthe engine,let it run at idle,andturn the steering wheel from lock-to-lockseveraltimes When tluid stops running out ol the hose, shut off the engine. Discardthe fluid.
2.
3.
RESERVOIR
4.
the return hose to the reservotr. Reconnect to Fill the reservoir the upoer levelline. NOTE: Take care not to spill the fluid on the body and parts. Wipe oll the spilledat once, CAUTION: Uso only Honda Power Stsering Fluid-V. Using other fluids such as ATF or othor manufactuer's pow6r steering fluid will damagethe systm. System Capacity: 1 . 7 l i t e r( 1 . 8 0 U S q t , 1 . 5 o l m p q t l 8 t c h a n g o RosorvoirCapacity: O.5 liter 10.53 US qt, 0.44 lmp qt) Start the engine and run it at idle, then turn the severaltimes bleedair to steeringfrom lock-to-lock from the system.
7.
the fluid leveland add some if necessary. Recheck beyondthe upCAUTION: Do not fill the reservoir oer lovgl line.
1 7- 7 7
Checks On-Gar
Pump PressureCheck
Check the fluid Dressureas follows to determine whether the trouble is in the pump or gearbox. NOTE: First check the power steeringtluid level and pump belt tension. CAUTION: Dlsconnct tho high plossule hosa carofully, so as not to spill tho power steering tluid on thg trame and other parts. 1. Disconnectthe outlet hose from the pump outlet Jifting, and install the pump joint adaptor on the pump outlet. 9. 2. Connectthe hoseioint adaptorto the power steergauge,then connectthe outlet hoseto ing pressure the adaotor. Install the power steering pressuregauge to the pump joint adaptoras shown. O p e nt h e s h u t o f f v a l v ef u l l y . control valve fully. 5 . Open the pressure 6 . Start the engineand let it idle. '1. Turn the steeringwheel from lock-to-lockseveral times to warm the fluid to operatingtemperature. Close the shut oft valve, then close the pressure control valve gradually until the pressuregauge needleis stable.Readthe pressLrre. l m m e d i a t e lo p e nt h e s h u t o l f v a l v ef u l l y . y CAUTION: Do not keep the shut-oft valve closed mol than 5 secondsor the pump could be damaged by over-heating. l l t h e p u m p i s i n g o o dc o n d i t i o nt,h e g a u g es h o u l d k r e a d a t l e a s t7 , O 0 O - 8 , O O 0 P a ( 7 0 8 0 k g / c m ' , m 9 9 5 1 , 1 3 8 p s i ) .A l o w r e a d i n g e a n sp u m p o u t put is too low for full assist. Repairor replacethe pump.
8.
3.
P/S JOII{T ADAPTOR{PUMPI oTNAK-SR30l1A
P/S JOINT AOAPTORIHOSE) 07NAK-SR3012A
VALVE
VALVE SHUT-OFF
17-78
SteeringWheel RotationalPlay
1 . Placethe lront wheels in the straight ahead position and measurethe distancethe steeringwheel can be turned without movingthe front wheels. the servicelimit.checkall steer2 . lf the play exceeds ing components.
Power Assist Check with Car Parked

'1. Check the power steering fluid level and pump beil Iensron.
2,
Start the engine.allow it to idle, and turn steering severaltimes to warm up wheel from lock-to-lock the Jluid. Attach a spring scaleto the steeringwheel. With the engineidling and the car on a clean.dry floor, pull the scale as shown and read it as soon as the tires begin to turn.
3.
0- 10 mm (O-0.4 inl
SPRING SCALE The scaleshouldread no more than 30 N (3.O kg, 6.6 lbs). lf it readsmore or less,go on step 5. Stop the engine. Disconnectthe hose from the power steeringspeedsensorand plugthe hoseand the sensorfitting as shown.
POWERSTEERING SPEED SENSOR
o.
Start the engineand let it idle. a I t t h e r e a d i n gs n o w 3 0 N ( 3 . 0 k g , 6 . 6 l b s ) o r i less. replacethe power steeringspeed s e n s or , see page 1 7-8O. a lf the readingis still more than 30 N a 6 . 6 l b s ) ,c h e c kt h e g e a r b o x n d p u m p
17-79
Checks On-Car
Assist Check at Road Speed
'1.
P o w e r S t e e r i n gS p e e d S e n s o r Replacement
1. 2. Removethe rear mountingbracketstay. Disconnectthe sensor wire connector trom the power steenngspeeo sensor.
Check the power steering fluid level lsee page 17-771and pump belt tension (see page 17 74).
2 . Sta.t the engine,let it warm up to normaloperating

temperature(the cooling fan comes on), and turn the steering wheel lock-to lock a few times to warm up the fluid. Stop the engine.To simulatespeedsabove 50 mph (80 km/h), disconnectthe hoses from the power steering speed sensor and connect them to the bypasstube joint. PIugthe end of the bypasstube joint. TUBE JOINT BYPASS 07406-0010101
(lncluded with
3 . Remove the sensor mounting bolt and pull the

power steeringspeed sensorlrom the diflerential nousrng. 4. the sensorhosesand plug the tittings. Disconnect
07406-0010001)
MOUNTING BOLT SENSOR 6 x 1 . Om m 19 N.m (1.9 kg-m, 14 lb-ft) NEARMOUNTING HOSES
POWERSTEERING SPEED SENSOR
BRACKET STAY
Plugs.
4.
Attach the springscaleto the steeringwheel.With the engineidling and the car on a clean,dry floor, pull the scale as shown and read it as soon as the tires beginto turn.
10 x 1.25mm 21 N.m ( 2 . 1k s - m ,1 5 l b - f t I 'l 10 r .25 mm N.m 39
O-RING Replace.
(3 9 kg-m' 28 lb-ftl
Alter installing new power steeringspeedsensor, a turn the steeringwheellock to lock with the engine idlingto bleed air lrom the system. (see and add fluid if necessary 6 . Checkthe reservoir p a g e1 7- 7 7 1 . lf the scalereadsa normal50 N (5.o kg, 1 1 lbs), or more the assistproblemat high speedsis being caused by reduced power steering speed sensoroutput. Replace the power steeringspeed sensor. r l l f t h e s c a l e e a d s e s st h a n 5 0 N ( 5 , Ok g , I 1 l b s ) , the power steeringspeed sensoris OK and the problemis in the sensorleed line, the pump, or lhe valve body unit. Seeif the feed line is pinchedor bent then check pump(seepage 17-25). Troubleshooting See General
17-80
SteeringWheel
- Removal
with sRs:
store a removed driver's airbag !@ assemblywith the pad surlace up, i{ lhe airbaqis impropelly stored face down, accidentaldeployment could propel tho unit with enough lorc to cause sedous injury. CAUTION: a Eefore removing the steering wheel, align the front wheels straight ahead. a Do not installused SRS parts Jrom anolhercar. use only new SRS parts. When repairing, a Caretully inspecl the airbag assmbly belore installing. Do not install an airbagassemblythat shows signs of being dropped or imp.oparly handled,such as dents, cracks or deformation. a Always keep the shon connector(s) the airon bag(s)when the harnessis disconnected. a Do not disassemble tamper with the airbag or assembly. NOTE: The radio may have a coded theft protectioncircuit. Be sure to get the customer's code number betore - Disconnecting battery. the - R e m o v i n gh e N o . 4 3 ( 1 OA ) t u s e l i n t h e u n d e r t hood fuse/relaybox). - Removing the radao. After service, reconnect power to the radio and "CODE" is displayed, turn it on. Whenthe word enter the customer's s-digit code to restoreradio ooeration.
a
Disconnectthe negative and positive cable from the battery. Removethe accesspanel from the steeringwheel lower cover, then remove the short connector (RED). Disconnectthe connectorbetweenthe airbagand c a b l er e e l . 4. Connect the short connector (RED)to the airbag side ot the connector.
ACCESS PANEL
Removethe covers. Remove the two TORXo T3O bit bolts, then removethe driver's airbagassembly.
AIREAGASSEMBL DRIVER'S
1..-\
&
I\T
TORXO
Replace.
SRSMAIN HARNESS
(cont a
17-81
SteeringWheel
Removal(cont'd)
7. Disconnect the connectors from the horn and switches connector' cruisecontrol set/resume Without SRS: - Removethe emblemand steeringwheel nut' NOTE: Be carefulnot to damagethe emblemand steering wheel. - Remove the steering wheel by rocking it slightly from side-toside as you pull steadily with both hands. WHEEL STEERING EMBLEM NUT Replace.
t-
CRUISECONTROL SWITCHES SET/RSUME
bo
I I
WHEEI. STEERING
- Removethe steeringwheel nut - Remove the steering wheel by rocking it slightly Irom side-to-sideas you pull steadily with both hands,
17-82
store a rsmoved driver's airbag assombly @ with the pad su.face up. ll the airbsg is improperly stored faco down. accidental deploymont could propol th unit with 6nough forc6 to cause serious inlury. NOTE: lf an intact driver's airbag assemblyhas been removedfrom a scrapoedcar or has beenfound defective or damaged during transit, storage or service, it shouldbe deploved(seesection 23). <With SRS:> WHEEL NUT STEERING 5ON'm (5.Oks-m, 36 lb-ft) CAUTION: a Carelullyinspectths driver'sairbagass6mbly betore Do installing. not installthe driver'sairbagassembly that shows signs ol being dropped o. impropo.ly handled,such as dents, cracks or deformation. a Always keep the short connector{s} the airbag(s} on when the halnessis dioconnected. o Do not disassemble temper, with the d.ivsr's airor bag assembly.
\ roRx@ BoLr \
@ -Rg p^
WHEEL STEERING
ii#I'i" b
\*.R=
$q>
I
DRIVER'SAIRBAG ACCESSPANEL
<Without SRS:>
Qlt
EMBLEM
I I
7 -83
SteeringWheel
lnstallation
2WS/With SRS: CAUTION: a Bfore installing the stearing wheel, align the front wheels straight ahead. a Be suro to install the ha.ness wires so that they are not pinched or interfering with other ca. pans. a Do not replace the original steering wheel with any othor dsign, since it will make it impossible to properly install the airbag. lOnly use gsnuine HONDA replacement pans) a Aftel ieassembly, contirm that the wheels are still straight ahead and that steering wheel spoke angle is co ect. lf minor spokeangle adiustmnt is necessary, do so only by adiustment of tho ti rods, not by lemoving and lspositioning the stesring wheel. conlirm that ths driver's airbag l@ assembly is socutely attached to lhe steering whe6l; othorwise, sgvgie personal iniury could result during airbag dgploYment 1. Before installing the steering wheel, center the cable reel, Do this by first rotatingthe cablereelclockwiseuntil it stops. Then rotate it counterclockwise(approximately two turns) until: - The yellow gear tooth lines up with the alignment mark on the cover. - The arrow mark on the cable reel label points straight uP. 2. Installthe steeringwheel and tighten the steerang wheel nut. NOTE: Be sure the steeringwheel shaft engages the pins of the cable reel.
CABLEREEL PIN
WHEEI STEERING NUT 50 N.m l5.O kg-m, 36 lb-ft)
WHEEL lnsert the cruise control set/resume swltches connector to the steering wheel clips. Connect the horn connector.
MARK ALIGNMENT
17-84
5,
Install the driver's airbag assembly with new TOBXo bolts.

DRIVER'S AIRBAGASSEMBLY
9. Connect the battery positive terminal and then connectthe negativeterminal. '10. After installingthe driver's airbagassembly,con firm propersystem operation: a Turn the ignition to ll position:the instrument p a n e l S R S i n d i c a t o r i g h t s h o u l dc o m e o n f o r l about six secondsand then go off. a Confirmoperationof horn buttons. a Confirm operationof cruise control set/resume S\/!r'rrcns. a Turn the steeringwheel counterclockwise and m a k e s u r e t h e y e l l o w g e a r t o o t h s t i l l I i n e su p with the alignmentmark.
TORX@ BOLT lO N.m {'l.O kg-m, 7 lb-ft|
TORX@ BOLT
10 N.m 11.0kg-m, 7 lb-ftl
6.
from the airthe short connector(RED) Disconnect bag connector. Connect the airbag connector and cable reel connector. Attach the short connector {BED) to the access panel, and installthe accesspanelon the steering lower cover.
7,
8.
YELLOWGEAR TOOTH CAELE REEL CONNECTOR
SHORTCONNECTOR
17-85
SteeringWheel
2ws/without SRS: 1. Installthe steeringwheel and tighten the steering wheel nut. NOTE: Align the slots on the steeringwheel and sleeve. tabs on the turn signalcancelling 2. Installthe emblem. WHEEL STEERING
SIGNAL
4WS/With SRS: CAUTION: a The tront main steeringangle sensor with the neutrallock mechanismis mounted on the column shall ot the car. When the steeringwheelis removed,the rotationpart oJ the sensoris locked at the electricallyneutral position,and it is unlockdwhen the steelingwheel is inserted to position. the specifiedinstallation angle a lf the spokeangleis not at the designated while driving straight, check the front and rear beforeadjusting the wheelsfor properalignment spokg angle. Pertorm the electronic n6utral check ot the 4WS systemto be surethat the rearwheelsare at the correct steedng angle while driving {see page 17-146). a B6fore installingthe steering wheel. align the f.ont whsels straight ahead. a B su.e to installthe harnesswiles so that they aie not pinched or interfering with other car oarts. a Do not replacethe originalsteeringwheel with any other design,sinceit will make it impossible to properlyinstallthe airbag.lOnly use genuine parts) HONDA replacement confirm that the airbag assemblyis !@ attachedto the steedngwheel;otherwise, securely sevorepersonalinjury could tesult during later airbag dsployment. 1. the steeringwheel, centerthe ca Beforeinstalling ble reel. Do this by first rotating the cable reel clockwise until it stops. w Then rotate it counterclock ise (approximatelv two turns) until: - The yellow gear tooth lines up with the align ment mark on the cover. The arrow mark on the cable reel label points strarghtuP.
ARROWMARK
WHEEL STEERING
EM BLEM
STEERING WHEEL NUT 50 N.m {5.Oks-m, 36 lb-ft|
ii.
fr. l
CABLEREEL
MARK ALIGNMENT
17-86
2 . Temporarilyinstall the steering wheel aligning it

with the column shaft serration. Turn the steeringwheel fully to the right and left and set the steering wheel in the center of the rangewhere the front wheels move (i.e.centerthe steeringrack). NOTE: a Be sure that the tront wheels are in the straight aheaddrivingposition. a Be sure the steering wheel shaft engagesthe Dinsof the cable reel.
6.
Reinstall the steering wheel in the straight ahead d r i v i n g p o s i t i o n ,b e i n g c a r e f u ln o t t o m a k e i t o f f t o either side from the position set in step 3. NOTE: a A l i g n t h e h o l e i n t h e s l e e r i n gw h e e l w i t h t h e p i n of the cable reel. a Align the steering wheel with the sefiations which makes the spoke angle closest to horizontal.
\,'
CABLEREEL
/^\
tE#
i rj
7. lf the spoke angle is not horizontal, adjust the steer ing wheel slightly right or left, without pushing in the steering wheel too deep.
\rD,,
4. Removethe steeringwheel. Check whether the yellow paint mark of the tront main steering angle sensor rotor is facing down (i.e. in neutral lock position where the rotor does not turn). NOTE: lf the paint mark is not facingdown, adjust as tollows. 1) Temporarilyinstallthe steeringwheel with the spokesat a horizontal angle. 2) Turn the steeringwheel until the mark is facing down. 3) Returnthe steeringwheel spokesto the horizontal angle set in the step 1, being carefulnot to push in the steeringwheel. Remove the steering
wneet. 8. FRONTSTEERING ANGLE
ffi
WHEELNUT STEERING 50 N'm {5.0 kg-m, 36
With the spoke angle set at the horizontal, then push the steering wheel in fully. Tighten the steer ing wheel nut while pushing the steering wheel NOTE: Do not turn the steering wheel when pushing the steering wheel. Check the four front and rearwheelsfor alignment and perform the electronic neutral check on the 4 W S s y s t e m ( s e e p a g e 17 1 4 6 ) .
ICOn: -
sEilsoR
17-87
SteeringWheel
lnstallation{cont'd)
switches con9. Insertthe cruisecontrol set/resume nector to the steeringwheel clips. Connectthe horn connector' r th 1 1 . D i s c o n n e c t e s h o r tc o n n e c t o( R E D f)r o m t h e a i r bag connecror. '12. Connect the airbag connector and cable reel connector.
SWITCHES SET/RESUME
13. Attach the short connector (RED)on the access panel,and installthe accesspanel on the steering lower cover.
IREDI
10. Install the driver's airbag assembly with new TORX@bolts.
14. Connectthe batterypositiveterminalandthen con nect the negativeterminal, con 15. After installingthe driver's airbag assemblY, sYstemoPeration: lirm ProPer a Turn the ignition to ll positionl the instrument panel SRS indicator light should come on for about six secondsand then go off. a Confirm operationof horn buttons. a Contirm operationot cruise control set/resume switches. and a Turn the steeringwheel counterclockwise make sure the yellow gear tooth still lines up with the alignmentmark.
AIREAGASSEMBLY ORIVER'S
BOLT
10 N.m {1.O kg-m 7 rb-ft1
TORXO EOLT 10 N.m 11.0kg-m, 7 lb-ftl
17-88
SteeringColumn
Removal
Wirh 4WS: CAUTION: Th6 front main steering angle sonso. with the neutral lock machanism is mounted on the column shaft ol the car. When the steering wheelis removed, the rotation part ol the ssnsof is locked at tho olectrically nautral position, and it is unlockd whgn the stooring whoel is inserted to th spociliod installation position. 1 . Removethe driver's airbagassemblyand steering w h e e l( s e ep a g e 1 7 - 8 1 ) . Remove the steeringjoint bolt and toothed lock washer (from the enginecompartment).
TOOTHEDLOCK WASHER
with sRs:
CAUTION: a All SRS glsctrical wiring hamossas are coversd with yellow outer insulation. a Before disconnocting thg SRS wire harness install th6 $hort connector(s) on the airbag(s)(s6e page 23-290|. a Rplace tho entire affected SRS harnass assembly it has an open circuit or damagsd wiring. NOTE: The radio may have a coded theft protectioncircuit. Be sure to get the customer'scode number betore - Disconnecting battery. the - Removing the No. 43 (1O A) fuse lin the underhood Juse/relay box). Removing the radio. After service, reconnect power to the radio and "CODE" is disolayed, turn it on. When the word enter the customer's s-digit code to restoreradio oDeratlon.
Remove the dashboard lower cover and driver's knee bolster.
KNEEBOLSTER DRIVER'S
SRSMAIN HARNESS
OASH BOARD LOWER COVER
(cont'd)
17-89
Column Steering
(cont'd) Removal
4. Removethe upper and lower column covers. 6. Removethe cable reel assembly(SRSonly).
ASSEMBLY CABLEREEL
Removethe cable reel harnesslrom the underside oJ the column bracket by removingthe clip (SRS onlv).
7.
sleeve,combinathe turn signalcanceling Remove and front main steeringangle tion switch assembly sensor(4wS only) by removingthe circlip NOTE: After removingthe combinationswitch assembly, place it on the floor gently so that it does the not hinderyou in service.Do not disconnect cables from the combinationswitch assembly.
CIRCLIP
@!
\
TURNSIGNAL CANCELING SLEEVE CLIP SRS WIRE HARNESS FRONTMAIN STEERING ANGLESENSOR (4WS Only)
17-90
8.
Removethe air duct.
1O. Disconnect the ignitionswitch wtre connecror. 1 1 . Remove the steeringcolumnassembly removing by the attachingnuts. bolts and column holder.
AIR OUCT
COI-UMNHOLDER
9.
Removethe steeringjoint cover.
STEERING JOINT COVER
1 7- 9 1
SteeringGolumn
Inspection
and steeringshaft for propermovementand damage steeringioint bearings NOTE: Checkthe tilt mechanism, as an assemblyif damagedor faulty. CAUTION: Do not apply an impact load to the column shaft in the axial direction Front Main Stooring Angle Sensor (4WS): Checkwhether the Yellowpaint mark of the front main steering angle sensor rotor is facing down {i.e in neutral lock position where the rotor does not turn). that the front main steeringanglesensor This indicates in is electronically neutral. CAUTION: It th tront main steering angle sensor is unlocked onca, turn it to tho locking position and lock sgcu16ly.
COLUMN STEERING FRONTMAIN STEERING ANGLESENSOR I4WS ONLY}
Replace
PAINTMARK YELLOW
RETAINING COLLAR Checkfor damage.
@
FRONTMAIN STEERING ANGLE SENSOR
rN-\
qt
t4ws oNLY)
FLANGENUT I x 1 . 2 5m m 't6 t{.m ('1.6kg-m, 12lb-ft)
tr
,,,\ colur'rr ttot-DER
FLANGEBOLT 39 N.m (3.9 kg-m, 28 lb-fil
,{g
(2.2 kg-m, 16 lb-tl)
for a Check the tilt mechanism propermovement and damage. - Attach a springscaleto the knob of the tilt lever. to the preloadrequired move the lever. Measure Prsload:7O-9O N U-9 kg, 15-20 lbs)
SPRINGSCALE TILT LOCKBOLT
-6.1
STOPPER
- lJ the preload measured is not within the removethe 6 mm bolt and stopspecification. per. Then adjust the preload by tightening or the tilt lockboltat the lever pulledup. loosening - Reinstall the stopper and 6 mm bolt, then recheckthe preloadagain. CAUTION: Do not loosen the tilt lover when setthg dp ltoppor and when iightening the bolt.
6 mm EOLT 1 0 N . m { 1 . 0 k g - m ,7 l b - f t l
17-92
lnstallation
NOTE: a Be sure the pinion shaft and the steeringshaft are aligned;the joint should sllp on freely. lf not, repositionthe steering rack to correct the misalignment. a Coat the interiorof the steeringjoint grommet with grease. 1. Guidethe steeringshaft through the enginecompartmentbulkhead. Align the bolt hole in the steering joint with the slot in the steeringshaft, and insert the shaft into the steeringjoint.
STEERING JOINT BOLI Bolt rnust line up with lhe tlat on shaft22 N.m SHAFT (2.2 kg-m, 16 lb-fi) STEERING JoINT COVER 5. CLIP
4.
Installthe steeringjoint cover with the clampsand cliP.
Install the front main steering angle sensor (4WS o n l y ) , c o m b i n a t i o ns w i t c h a s s e m b l ya n d t u r n s i g n a l c a n c e l i n gs l e e v e w i t h a c i r c l i p . NOTE: a Be sure the wires are not caught or pinched by any parts when connecting the combination switch and the cable reel. a A l i g n t h e s l o t s I n t h e t u r n s i g n a lc a n c e l i n gs l e e v e w i t h t h e t a b s o n t h e f r o n t m a i n s t e e r ; n ga n g l e
SREERIITG JOINT joint onto the steering Slip the upperend of the steering shafi (lineup the bolt hole with the groovearoundthe shaft) and inslallthe steering ioint bolt.
Installthesteeringcolumnassembly with the nuts, bolts and column holder. Connectthe ignitionswitch connector.
sensor,
TURNSIGNALCANCELING MAIN STEERING SLEEVE
FRONT
COMBINATION SWITCH
16 N.m 11.6kg-m, 12 lb-ft) HOLDER
39 N.m 13.9kg-m,28 lb-ftl

FRONTMAIN STEERING ANGLESENSOR l4WS Onlyl tconl c
17-93
SteeringGolumn
6. (SBSonlv). Installthe cable reel assemblY NOTE: Align the slot in the cancelingsleevewith the projectionon the cable reel (2wS only). 2WS:
PROJECTION UPPER COLUMNCOVER
8.
Installthe upper and lower column covers
ANGLE SENSOR FROI{T MAII{ STEERING
9.
Installthe air duct.
Connect the cable reel harness and SRS wire harness,then attach the cable reel harnesson the ot underside the column bracket with the clip.
AIR DUCT
SRS WIRE HARNESS
17-94
1O. Install the driver's knee bolster and dashboard tower cover.
DRIVER'S BOLSTER
6 mm BOLT WASHER 1 ON . m (1.O kg-m, 7 lb-ltl DASH BOAND LOWERCOVER
1 1 . I n s t a l l t h e s t e e r i n gw h e e l a n d d r i v e r ' s a i r b a g ( a s s e m b l y s e ep a g e 1 7 8 4 o r 8 6 ) .
17-95
SteeringPump
Replacement
the NOTE: Beforedisconnecting hosesfrom the pump, place a suitablecontainerunder the car. 1. 2. Orainthe tluid from the system (seepage 17-77). Removethe belt by looseningthe power steering mountingbolt, nut and adjustingbolt Disconnectthe inlet and outlet hoses from the pump and plug them. NOTE: Take care not to spill the fluid on the body and parts. Wipe oft the spilledat once 4. Removethe power steeringmountingbolt and nut, then removethe pumP. ADJUSTING HOLDER UNIVERSAL 07725-O030000
PulleyReplacement
Hold the steeringpump in a vise with soft jaws, and hold the pulleYwith the specialtool, and remove the p u l l e yn u t a n d P u l l e Y t n N O T E : P u l l e y u t h a s l e l t - h a n dh r e a d s .
3.
o9llEr eolr
BOLT
't 't N.m
11.1kg-m, 8 lb-ft) PUMP ASSEMBLY
O.RING Replace. NUT PULLEY thread Left-hand STEERING NUTS MOUNTING 22 N.m 12.2kg-m, 16 lb-ftl INLET HOSE
HOSECLAMP
the pulleyin the reverseorder ol removal Reinstall NOTE: Installthe pulleyas shown
BELT POWERSTEERING PULLEY POWR
NUT PULLEY
65 N'm (6.5 kg-m,47 lb-ft)
BOLT MOUNTING 22 N.m

(2.2 ks-m. 16 lb'ft)
NOTE: Do not turn the steeringwheel while the pump removeo. 5. 6. 7. Looselyinstalla new pump on the bracket. Connectthe inlet and outlet hosesto the pump. lnstalland adiust the belt (seepage 17-741. CAUTION: a Mak sure that the powel steering belt is securoly on the groove of tho pulleys a Do not get powor stering fluid or groase in the powsr steeiing belt or pulley {aces. Clan ofl any fluid or gloase bsforo installation. 8. level with new fluid to the UPPER Fill rhe reservoir fine on the reservoir {see page 17 -771
Check that the pump turns smoothly by turning the pulley.
17-9 6
Flow Control Valve Inspectionand Replacement

Removethe controlvalve cap by removingthe two tlange bolts. Removethe flow controlvalve,springand O-rings. 4. Slip the flow control valve back in the pump and check that it moves in and out smoothly.
FLOWCONTROL VALVE
SPRING
FLOWCONTROL VALVE
@-'@h,
,q/@
"o"r*o,- uo.u. "o,
lf OK. go on to step 5; if not. replacethe flow control vatve: a The original valvewas selected a precise in the for {it pump housingbore, so make sure the new one has the same identification mark.
IDENTIFICATION
Check lor wear, burrs, and other damageto the edges of the groovesin the flow control valve,
Mark
Part Name FLOW CONTROL VALVE A
S i z em m ( i n ) 17.991 17.996 (o.7083-O.7085) 17.996-18.OO1 (o.7085-O.7087)
FLOW CONTROL VALVE B
lconl dI
17-97
SteeringPump
(cont'd) Flow Control Valve Inspectionand Replacement
Attach a hose to the end of the flow control valve as shown. the bottom end of the {low controlvalvein a 7. ClamD vise with sott jaws. 8. Unscrewthe seal in the top end of the tlow control valve, and removeanv shims,the reliefcheck ball, relief valve and relief valve spring. BALL RELIEF CHECK
VALVE RELIEF
'%
| "*,",.,
11.3kg-m, 9 lb-ft)
FLOW CONTROLVALVE Clamp this end in

a visg with sott jaws.
SPPING
9. Clean all the parts in solvent, dry them olf then and retest the flow control valve. reassemble relief pressureis adjustedat NOTE: lf necessary. the factory by adding shims under the check ball seat. It you found shims in your valve, be sureyou as reinstall many as You took out. 'lO. lnstallthetlow controlvalve in the reverseorderof removal. NOTE: a Coat the tlow control valve with power steering fluid, then installit and sPring. a When replacing the flow control valve, be sur flow controlvalvehasthe same the replacement identificalionletter as the originalflow control VALVE
Submergethe llow control valve in a containetof power steering fluid or solvent. and blow in the hose. lf air bubblesleak through the relief valve. or reDlace repairit as Jollows.
AIR PRESSURE No mor6 than 20 kPa {0.2 kg/cm2, 0.3 plll
a-fuh,
J contnoL vlle
clp
**@'.
FLANGEBOLT 11N.m (l .1 kg-m, a lb-ft|
22.1 x 1.9 mm O-RING
5.8 x 1.9 mm O'RING
17-9 8
Disassembly
CAUTION: The pump components are made ot aluminum. Be careful not to damago thm wh6n sorvicing. 1. 2. 3. 4. Removethe pump from car (seepage 17-96). Removethe pulley (seepage 17-96). Removethe flow control valve (see page 17-971. Removethe inlet joint and 13 x 1 .9 mm O-ring.
HOUSING PUMP CAM RING
6 . Remove the pump cam ring from the

housing.
INLETJOINT
1 3 x ' 1 . 9m m O-RING Replace.
5.
Remove the pump cover and O-ring.
7.
Removethe pump rotor and pump vanes.
PUMP VANES
68.5 x 1 O-BING Replace.
"d
f..!
PUMP COVER
(cont'dt
7-99
SteeringPump
Disassembly(cont'd)
8 . Removethe two rollersfrom the side plate. 9 . Removethe side plate and preloadspring.
ROLLER x 26.8 mm CIRCLIP SIOE PLATE
11. Remove the circlip. then remove the drive shaft from the pump housingusing a plastic hammer. 12. Removethe pump seal spacerand oil seal.
-:. U,s-' ' - . . ., -OAtVe e) / sHAFf
ff t-\v1t
Il
\:/
\a__-/
A1/sP^cER
PUMPHOUSING
U -.ryv:jjAr
orr sFA OIL SEAL Replace.
1O. Removethe O-ringsfrom the side plate.
1 3 .Inspectthe bearingby rotatingthe outer raceslowis ly. lf any play or roughness felt, it must be replaced. Performstep 14 and 1 5
1 6 . 8x 1 . 9 m m O-RING Replace. Sx1.9mm O.RING Replace.
SIOE PLATE
BEARING
17-100
14. Remove the bearing using the special tool and pressas shown. Pross
HUB OIS/ASSEMBLY BASE OTGAF-SDi+O7OO
15. Installthe new bearingusingthe pressand special tool as shown.
+
Blacksealside.
Red seal side.
Plo!!
HUB DIS/ASSEMBLYBASE oTGAF-SD40700 NOTE:Hold the innerrace with the tool securely.
17-101
SteeringPump
lllustlated Index
CAUTION: Pump components aro made ot aluminum, Be careful not to damago lhem when servicing' NOTE: parts thoroughly. a Cleanall of the disassembled a Replaceall O-ringsand seals.Do not dip new O-ringsand sealsin solvent; coat O-ringswith power steeringfluid and make sure they stay in placeduring reassembly. before installation, a lf any part denotedwith an asterisk(*) is worn or damaged,replacethe completepump.
NEEDLE ROLLER EEARING FLANGEBOLT
20 N.m (2.0kg-m,14
PUMP COVER Check for damage to face. sealing ROLLER 4.5 x 49.8 rnm
iPUMP CAM RIf{G Check lor damage and wear, 'PUMP VANES (10 platBl Checkfor damage
88.5x 1.9 mm O.RING Rplace.
.PUMP HOUSING Chock {or damage to salingfaces.
-6.l
16.8x 1.9 mm O.RING Replace.
1 3x 1 . 9 o-Rtt{G Rgplace.
OIL SEA Replace. PUMP SEAL SPACER ORIVE SHAFT Checkfor damage and wear.
--(cL
FLANGEBOLT 11 N.m (1.1 kg-m, 8 lb-ft} JOINT IT{LET FLOW CONTROLVALVE Check lor pressure leak. 22.1 x 1.9 mm O-Rl 6 -'>Q
PULLEY for Check distortion

and cracks.
*{@
B1.2'""'-"
CONTROLVALVE CAP
BEARING Checklor
excessive ptay.
f^@'
PULLEYNUT 65 .m 16.5 ks-m, 47 lb-ft)
FLANGEAOLT 11 N.m (1.1 kg-m, 8 lb-lt)
17-102
Assembly
'I . Coat the lip of the new oil sealwith steeringgrease P { H o n d a / N0 8 7 3 3 - B o 7 o E ) . Install the new oil seal in the pump housing by
hand. o.
Installthe preloadspringin the pump housing.
2.
7 . Set the 4.5 x 49.8 mm rollerin the 4.5 mm hole in the pump housing. 8 . Set the side plateover the rollerand installit on the pump housrng,
o Set the 5 x 26.8 mm rollerin the 5 mm hole in the
Installthe pump seal spacer,then installthe drive shaft in the pump housingusingthe specialtools. Installthe circlipwith its taperedside facing out.
side plate. 5 x 26.8 mm ROLLER
CIRCLIP
)
ATTACHMENT DRIVER 07947 -6340500
ATTACHMENT, 37 x 40 mm 07746*0010200
ruI\
9=-o*,ve
Y
\v
sHAFr
4.5 x 49.8 mm ROLLER
senl FI purrrp SPAGER Jl
PRELOAD SPRING
HOUST G
4.5 mm HOLE
10. Assemblethe pump rotor to the drive shaft with the "O" mark on the.otor facing upward. 5 . Coat the side plate grooves with power steering fluid, then positionthe 16.8 x 1 .9 mm and 54 x 1.9 mm O-ringson the side plate.
16.8x 1.9 mm O-RING
1 1 . Set the 1O vanes in each groove in the rotor. NOTE: Be sure that the round end of the vanes is in contact with the slidingsurfaceol the cam ring.
/E
,,O" MARK 54 x 1.9 mm O.BING Round 6nd
PUMP ROTOR
4 o
{cont d
VANE
17-103
SteeringPump
Assembly{cont'dl
1 2 .Set the pump cam ring over the two rollerswith the
" : " m a r ko n t h e c a m r i n g u p w a r d . 1 3 . Apply clean power steeringfluid to the vanes and pump cam flng.
PUMPCAM RING
'17 o . S e t t h e 1 3 x 1 . 9 m m O - r i n g n t h e i n l e tj o i n t ,ano installthe inlet joint on the pump housing,
INLETJOINT
FLANGEBOLT 11 N'm (1.1 kg-m, 8 lb-ftl
18. Installthe flow control valve (seepage 17-98). 1 4 . I n s t a l lt h e 6 8 . 5 x 1 . 9 m m O - r i n go n t h e p u m p cover. 1 5 .Align the rollerset holesin the pump cover with the rollers. Align the projectionon the pump housingand the projection the pump cover,then tightenthe tour on bolts. FLANGE BOLT 20 N.m
(2.O kg-m, 14 lb-ft)
19. Installthe pulley (see page 17-96) and check that the pump turns smoothly by turning the pulley.
68.5 x 1 . 9 m m O-RING
ROLLEBS
17-104
SteeringGearbox
Index
CAUTION: Betore diEassambling the gsarbor, wash it oll with solvent and a brush.
--=.-
ss t.13.9 kg-m, 28 lb-ft)
VALVEBODYUNIT page17'106 Overhaul,
GEARBOXSHIELD
lr.O tg-m, 7 lb-ftl RIGHTMOUNTING BRACKET AIR

CLAMP TIE.ROD LOCKNUY 45 N.m (4.5 kg-m, 33 lb-ftl TIE.RODEND \ RACKEND BOOTBAND 65 N.m 16,5kg-m,47 lb-ft) neptace. \
8o,or \s \ =K\ \)
MdNNry:
\
TUBE CI-AMP TRANSFER HOSE TRANSFERHOSE CLAMP
9-I
I
50-60 N.m (5.0-6.0 kg-m, 36-43 tb-ft)
Ss'..t
/-
-ArR HOSE BAND RUBBER
AIR HOSE BAND
COTTER-PIN Replace.
17- 105
SteeringGearbox
Valve Body Unit
Romoval
1. 2. Drsin the power steeringfluid (seepage 17-77). 6. Removethe gearboxshield. Remove the O-rings and port orifices trom the gearbox. the two I mm flangebolts and removethe Remove valve body unit from the gearbox.
9.8 x 1.9 mm O.RING Replace.

PORT ORIFICE 45.5 x 2 mm O.RING Replace.
GEARBOXSHIELD
Usingsolventand a brush.wash any oil and dirt off the valve body unit, its lines, and that end of the gearbox.Blow dry them with compressed air. UsingJlarenut wrenches,disconnect the four lines Jrom the valve body unit. A: To oil cooler: 17 mm wrench 8: To power stqring spsed sensor: 12 mm wrench C: To reservoir:12 mm wrench D: From pump: 14 mm wronch
8 mm FLANGEEOLT
UNIT
17-106
Valve Body Unit

Disassembly
1. Removethe three 6 mm flange bolts, then remove the valve body cap trom the valve body. Removethe cap seal trom the valve body cap. VALVEBODY VALVE CONTROL PRESSURE for or Check scoring and scratches, rough opgration. 4. control valve: Checkthe Dressure Inspectits surfacefor scoringor scratchss. Slip it back into the valvebody. and makesure it slides smoothly without drag and without slde play.
2.
6 mm FLANGEBOLT
NOTE: lf the valve body is damaged,replacethe controlvalve. valvebody unit (valvebody, pressure gain control valve,4-way valve)as an assembly. the pressure controlvalveand valvespflng Remove from the valve body. 5 . Remove the gain control valve and valve spring irom the valve bodv.
VALVE BODY
VALVE BODY
\(C
\, .la
4*
VALVESPRING
VALVE SPRING (conl ct
17-107
SteeringGearbox
Valve Body Unit (cont'd)
6. Checkthe gain control valve: a Inspectits surJace scoringor scratches. Jor a Slip it back into the valve body and make sure it slides smoothly without drag and without side pray. VALVE GAIN CONTROL for Check scoring, scratches, rough or
operation.
9. Remove the rollers from the 4-wav valve bv pushingthe valve out one side of the valve body, and then the other. NOTE: When removing the rollers, hold the plungerswith your linge.s to keep them ffom popprng our.
PLUNGERS
NOTE: lf the valve body is damaged,replacethe valvebody unit (valvebody, pressure controlvalve, gain control valve, 4-way valve) as an assembly. the valve body and port housing. Separate
1O. Remove the plungers, return springs and 4-way valve from the valve body. 11. Removethe 11 mm O-ringt.om the 4-way valve. 12. Check the plungers.
Removethe port seal and dowel pins trom the port housing.
a Inspecttheir surfacefor scoringor scratches. a Slip each plungerinto the valve body, and make sure it slides smoothly, without drag or side play. lf any plungeris damaged.replaceit. VALVEBOOY
PLUNGERS Check for scoring or scratches, and rough sliding. PLUNGERS Check lor scoring or scratches, and rough sliding.
DOWEL PIN
17-108
'13.
Checkthe 4-way valve. Inspectits surfacefor scoringor scratches. Slip it into the valve body, and make sure slidessmoothly.without drag or side play,
4.WAY VALVE Checkfor scoring, scratches, or rough operation,
NOTE: lf the valve body is damsged,replacethe valvebody unit (valvebody, pressure controlvalve, gain control valve,4-way valve)as an assembly. 1 4 . Using a 3 mm (1/64") drill bit, removethe sensor oriJiceand 3.4 m O-ring,
gh
PORTHOUSING
17-109
SteeringGearbox
Valve Body Unit
Assembly
lllustratd lndx parts shown below. 1, Throughlycleanthe disassembled 2. 3, Coat the plungers,pressurecontrol valve, gain control valve and 4-way valve surfaceswith power steeringfluid. Beassemble pans in the reverseorder of disassembly. the CAUTION: a Replacothe O-rings and ssals with nw onos, a Do not dip tho O-dngs and saals in solvent. a Apply tb power stedng fluid in the eal groovos to keep tho leals in pl8cs, (Pa.t NumbrO8733-BO?OE| . -6f : STEERING GREASE
PORT HOUSING
1l mm O-RING
45.5 x 2 mm O.RING Replace.
PRESSURE
DOWEL PII{S
cof{TRoL VALVE
uo.u."r*nol trN
VALVE EODY PLUNGERS 6 mm FLANGEBOLT I N.m lO.9 kg-m, 7 lb-ft)
S*"MS^"..'.
.\/lil ' "/)H -^d qq \ + w r vv t v e \\
1 \ sENsoR
SPRINGS ROLLER 3.4 m]n O-RING R6place.
oo,n "onrro. vALvE

oRtFtcE
NOTE: lf the valve body is damaged,replacethe valve body unit (valvebody. pressure controlvalve,gain control valve, 4-way valve)as an assembly.
17-1 1 0
4.
Coat the surface of the 4-way valve with power steeringfluid, and installinto the valve body.
7. Coat the pressurecontrol valve and gain conttol valvewith power steeringfluid, and installtheminto the valve body, 8. Installthe valve springs.
5 . Coat the surfaceo{ the plungers with power steering tluid, and install the plungers,return springs and rollerson the valve body.
VALVEBODY
1 1 mm SPRINGS
r0
VALVE SPRINGS
PRESSURE CONTROLVALVE
PLUNGERS
E
6. fluid, and inCoatthe port sealwith power steering stall it the grooveof the port housing.Then install the valve body and port housing.
9. Coatthe cap sealwith power steeringfluid, and install it in the groove ot the valve body cap. 1O. Installthe valve body cap on the valve body with 6 mm flange bolts. CAUTION: Maka sure the mating surface ot th6 valve body and cap are flush at the uppor sid6.
VALVE BODY PORT HOUSING 6 mm FLAIIGE BOLT 9 N.m (0.9 kg-m, 7 lb-ft)
VALVEBODYCAP
rol
{cont 6
17-111
SteeringGearbox
Valve Body Unit (cont'd)
'I 1. Make sure the 4-way valve moves smoothly,and returnsto neutrSlDosition.
lnstallation
1. Coatthe 9,8 x 1.9 mm O-ringswith power steering fluid, and installthem togetherwith the orifices. Installthevalvebody unit on the gear housingwith the two 8 mm bolts. CAUTION; a When installing, be caleful not to hil th pinion holderpin. a Mak sure the O-rings are in place and not
pinchad, PINIONHOLDERPIN
2.
-6l
9.8 x 1.9 mm O-RINGS
E
PORTORIFICES 45.5 x 2 mm O.RING
ks-m' 16 lb-lil 22 N'm 12.2 Connectthe four linesto the valve body unit, using flare nut wrenches. A: To oil coolor: 17 mm wrench 29 N.m {2.9 kg-m, 21 lb-ftl B: To power stering spoed aensor: 12 mm wrench 13 N.m (1.3 kg-m, 9 lb-lt) 12 mm wrench C: To rgsorvoir: 13N.m (1.3 kg-m, 9 lb-ft) 14 mm wrench D: From pump: 38 N.m (3.8 kg-m, 28 lb-tt)
BODYUI{IT
17-1 1 2
Fillthe reservoir with power steering fluid and bleed air from the system by turning the steeringwheel from lock to lock severaltimes with the engine warm lsee page 17-771. Make sure there are no fluid leaks,then installthe gearboxshield.
o.
Recheck the fluid level in the reservorr.
GEARBOXSHIELO
1 ON . m (1.0 kg-m, 7 lb-ftl
17-113
SteeringGearbox
GearboxRemoval
NOTE: Beforeremovingthe steeringgearbox,alignthe front wheels straightahead. 1. on Drainthe power steeringfluid as described page 17-77. Raisethe front o{ car and supporton safety stands in the properlocations(see sectjon 1). Removethe front wheels. Remove the cotter pin lrom the castel nut and removethe nut. Installa 12 mm hex nut on the ball joint. Be sure that the 12 mm hex nut is tlush with the ball joint pin end, or the threadedsectionof the ballioint pin might be damagedby the ball joint remover. NOTE: Removethe ball joint using the Ball Joint Remover.Referto page 18-13 tor how to use the ball joint remover. the Separate tie-rodballjoint and knuckleusingthe s p e c i atl o o l . CAUTION: Avoid damagingthe ballioint boot.
EXHAUST PIPEA
7 . Removethe selfJockingnuts that connectthe exhaust pipe A to the three way catalyticconverter, and the exhaustoiDeA to the exhaustmanitold. 8. Disconnectthe heated oxygen sensor connector (H23A1 and H22A1 engine)and remove the exhaust pipe A, CAUTION: Replac tho oxhaust gaskot and salflocking nuts when you loinstall ths pipe.
2.
3. 4.
only. Automatic transmission a Removethe shift cable holder and disconnect ihe shift cablefrom the shift control shaft.
SHIFT CONTROLSHAFT
12 mm HEX NUT
SHIFTCABLEHOLDER
17-114
1 0 .Removethe center beam.

NOTE: Replacethe self-lockingbolts if you easilythread them in.
1 2 .Usingsolventand a brush,wash any oil and dirt ofl the valve body unit, its lines, and the end ot the gea.box. Blow dry them with compressed air. CAUTION: Aftel disconnecting the hoses and pipes,plug or sealthe hosesand pipeswith a piece of tape o. equivalent to paevent foreign material lrom entering the valve body unit.
1 3 .Usingtlare nut wrenches,disconnect four lines the

trom the valve body unit. A: To oil cooler: 17 mm wrench B: To power stssring speed sensor: 12 mm wrench C: To reservoir:12 mm wrench D; From pump: 14 mm wrench
11. Removethe gearboxshield.
4WS: 14. Cur the wire tie from the cover, then removethe cover from the front sub steeringanglesensor, CAUTION: Use care when cutting the wire tie so as not to cut into the wire harness, 15. Removethe sensor wire harnessfrom the clamp and disconnectthe connector.
CONNECTOR COVER
GEARBOXSHIELD
WIRETIE Replace. FRONTSUB STEERING

ANGLESENSOR
17-115
SteeringGearbox
gearDox llemoval lcont q, Gearbo Removallcont'd)
16. Lock the steeringshaft with ignition key to keep the steeringshaft position. 17. Removethe steeringjoint bolt, and move the joint toward the column.
STEERING JOINT
1 9 . Removethe left-tie rod end, then slidethe rack all the way to the right.
20. Pull the steering gearbox assembly all the way

down to clear the Dinionshaft lrom the bulkhead. to 21 . Move the steeringgearboxassembly the right so the left rack end clearsthe rear beamHold the steeringgearboxassemblyand slide the rack all the way to the left. Placethe left rack end below the rear beam. Move the steeringgearboxassembly the left and to tilt the left side down to removeit from the car.
LOCK WASHER TOOTHED 18. Remove the left mounting bracket first, then removethe right mountingbrackets.
RAq In6ta innoa
STEERING GEARBOXASSEMBLY
o{
R.!
35.
CAUTION: Bo calsful not to bond or damage the four power aleedng lines when lomoving the gearbox aasemblv.
z<
AIR HOSE CLAMP
17-1 1 6
lllustratedIndex
a a a a
parts. Thoroughlyclean all disassembled Always replaceo-rings and seals. parts with damagedslidingsurtaces. Replace grease, fluid or steering makesurethey stay Do not dip sealsand O-ringsin solvent;coat O-ringswith power steering in positionduring reassembly, and use the appropriate specialtools to installlhem where necessary. : STEERING GREASE {P/N08733 BoToEl -!56{
FRONTSUB STEERING ANGLESENSOR
l4wsl
Adjustment page 17-132 RACKGUIDESCREW (2WSl SEAL RETAI'{ER BUSHINGSTOPPER CYLINDERCAP ..@] SPRING RACK cutDE AALL BEARING -: -GEAR
RETAIT{ING WASHER Beplsce. 9.8 x 1.9 mm _-.,t o-RTNGS--J
HoLDER AE5<-- PrNtoN \-+-pr roNHoLDER
ffi
HousrNG
""'!kr ser. ersron

35.5 x 2.4 mm BING Feplace
PORTORIFICES
#.'=....-#
&--(nlr-
ffi"k
BALL BEARTNG
SAf{P R|NG
)d'ffi"o
CYLINDER ;rd$;t
R'. iJillitt.l"l3T-0"-"," i:11T,""*,

SNAP RING Inspect lor damage to inner surface CYLIIIIDER ,sPRlNG
-";tJilhre$m''L,NDER
--=.:=\/V\\-\ -5ffiq
O-RING Replace.
fiI.;!,?,T \
I::X'"T:U:'*""
/'e'-
CYLINDERBOLT 22 N.m 12.2 kg-m, 16 lb-trl
17-117
SteeringGearbox
Overhaul
1. Remove the two 8 mm flangebolts and removethe valve body unit trom the gearbox. Remove the O-rings and port orifices from the gearbox.
8 m m FLANGEBOLT
4WS: 5. Loosen the locknut and remove the rack guide screw/front sub steeringangle sensorassembly. 6. Removethe spring and rack guide from the gear housing.
2.
45.5 x 2 mm O-RING Replace.
9.8 x 1.9 mm O-RINGS Replace.
RACK GUIDE
Loosen the locknut and remove the rSck guide 5Crew. Removethe spring and rack guide trom the gear housing.
7,
Removethe rack guide screw, O-ringand locknut from the front sub steeringangle sensor.
LOCKNUT
RACKGUIDE
17-118
8 . Csretully clamp the gearbox in I vise with soft

jaws.
1 1 .Hold th steeringrack with I wrench and unscrew the rack end with a wrench.
9 . Removethe tie-rod end.

RACK END LOCK WASHER
TIE.RODLOCKNUT
,^@ @-=-47'
1- r_------_1,
\
TIE.ROD END
1 0 . Bemovethe boot bands and tube clamps. Pull the

dust sealsaway from the ends of the gearbox.
1 2 . Removethe dust cover. 1 3 .Removethe gear housingcap from the gear housing by removingthe four 6 mm flange bolts. 1 4 . Remove the steering pinion seal from the gear housingcap.
DUST COVER
STEERING PINIONSEAL Replace. GEAR HOUSINGCAP 46 r 1.5mm O.RING Replace.
TUBE CLAMP
(cont'd)
17-119
SteeringGearbox
Overhaul(cont'd)
15. Pushthe right end ot the rack back into the cYlinder housing so the smooth surtace that rides agsinst the seal won't be damaged. a Removethe ball bearingusing a commercially bearingpuller. available
Install the ball bearing on the pinion using a p.ess and the specialtools.
to.
Checkthe ball bearingot the pinionfor play; if it is good, go on step 17, play,replace lf the bearingis noisyor hasexcessive the bearing. a Removethe snap ring.
BALL BEARING
17-120
a Installthe snap.ing on the pinion.
19. Remove the cylinder end seal from the cylindel housing. NOTE: Useyour tingersor a woodenstick to avoid damagingthe housing.
PINION
I I
CYLINDER SEAL CYLTNDER END HOUStt{G 17. Removethe four cylinderbolts from the end of the cylinder housing, then slide the housing off the tacK. 18. Remove the O-ring. back-up ring, steering rack bushingA and cylinderspring.
@
END
cylindercap and sealretainer, the cylinder, 20. Remove steeringrack from the gear housing.
CYI-INDER
GEARHOUSING
17-121
Gearbox Steering
Overhaul(cont'd)
the retainer washerJromthe gearhousing. 21. Remove a Remove the pinionholdertrom the gearhousing. a Check the needle roller bearingsin the pinion holderand gear housingfor damage;if oK, pack the needlerollerbearingwith grease.lf the bearings are damaged.replacethem as a set.
PINIONHOLDER
I t
!
GEAR I{OUSING
22, Check the pinion holder for tree movement, excessiveplay and rough movement;if it is good 90 on steD 23. lf it is damaged, if dirt has gone past the sealinto or the grease,replacethe bearing. a Removethe circlipfrom the pinion holder.
a Checkthe ball bearingfor damage;it it is good. go on step 23. a Remove the pinion ball bearingfrom the gear housing.
BALL BEARING PINION HOLOER
17-122
a Drivethe new ball bearinginto the gear housing using the specialtools.
a Reinstall the circlip with its taperedside facing ouI. NOTE: Circlip ends must be alignedwith the flat area.
ORIVER 07749-OO10000 47 mm CIRCLIP
a Installthe pinion holderin the gear housing.
PINIONHOLDER
23, Remove the cylindercap and sealretainerfrom the steeringrack.
CYLINDERCAP/ SEAL RETAINER NEEDLE ROI-LER BEARINGS
STEERING RACK GEARHOUSING
{cont d,
17-123
SteeringGearbox
Overhaul(cont'd)
24. Removethe O-ringand snap ring ftom the seal retainer.then removethe cylindercap from the seal retalner. 25. Removethe O-ringstrom the cylindercap.
29.7x 1.9 mm O.RING Replace.
pry 28. Carefully the piston sealting and O-ringoff the olsron,
43.3 x 1,5 mm O.RINGS Replace.
SEAL RETAINER
(\s CI
SNAP RING
I I
CAP CYLINOER
PtSTON SEALRI[{G RPlace.
Remove the bushing stopper ring lrom the seal retainer.
NOTE: Befo.e reassemblingany parts, inspect on them as described page 17-'l17 and mak sure worn or damagedparts they are clean. Replace
2 7 . Removethe cylinderend seal and rack bushingB.
BUSHINGSTOPPER
SEAL RETAINER
RACK BUSHINGB
SEAL
17-124
29. Install a new O-ring on the piston with Its narrow

dge facing out.
32. Coat the piston seal ring and insideof the special tool with power steeringfluid. 33. Carefullyslidethe tool onto the rack and ove. the pistonsealring, then rotatethe tool as you move it up and down to seat the piston seal ring.
30. Coat the pistonseal ring guide with power steering fluid. then slide it onto the rack, big end fifst. 31. Positionthe new piston seal ring on the special tool, slideit down onto the big end of the tool, then pull it otf into the piston groove on top of the Oring.
34. Coat new O-ringswith powe. steeringfluid and install them on the cylindercaD.
43.3 x 1.5 mm O-RINGS STEERING RACK
(cont'dr
17-125
SteeringGearbox
Overhaul(cont'd)
35. Slidethe cvlindercap onto the seal retainer. 36. Installthe snap ring on the seal retainerand coat new O-ringwith power steeringfluid and installit on the seal reta,ner.
S[{AP RII{G 29.7 x 1,9 mm O-R|NG
the slidingsurfacesot the new cylinderend 38. Grase sealand the specialtool.then placethe sealon the specialtool with its grooved side facing opposite the slider.
\.-6 ^@"\ * \ !
BACK.UPRING Make sure the back-up ring is seated in the cylinde.end seal.
@'f
\ SEALRETAINER
cYtlt{DERcAP
ENO SEAL CYLINOER lnstall end soal with its grooved side facing opPosite seal slider.
END CYLINDER SEALSLIDER 07LAG-SM/tO30A 37. Greasethe sliding surface of the rack bushingB. and installthe bushingon the steeringrack.
39, lnstallthe specialtool and cylinderend seal.
-Gl
RACK BUSHING
17-126
40. Separatethe cylinder end seal from the special

tool, then removethe specialtool from the fack.
4 2 . Push the rack bushing B toward the seal retainer by

hand until the cylinderend seal is seatedin the retainer.Fit the bushingstopperring in the grooveot the sealretainersecurely. Then grease the steerinq racK.
CYLINDEREND SEAL SLIDER 07LAG-SM4030A AUSHINGSTOPPER RING SEAL RETAINER
RACK SUSHINGB
RAC( BUSHINGB
41. Fit the seal retaineron the steeringrack.
43. Installthe retainerwasher on the gea. housing.
SEAL RETAIT{ER GEAR HOUSING
{cont'dl
17-127
Gearbox Steering
Overhaul(cont'd)
44, Placsthe gea. housingon the work bench and inand steeringrack into the gear sert the sealretainer housing. 45. Coat the insidesurfaceof the cylinderwith powet fluid, slideit overthe rack and into the gear steering housing;press it into the housinguntill il seats' 48. Coat the insidesurfaceof the cylinderwith power end seal with steeringfluid and installthe cYlinder its groovedside Jacingout.
GROOVES
STEERING RACK CYLINDEREND SEAL SEAL RETAIITER
CYLINDER ENO SEAL
then installtheO49. Coatthe new O-ringwith grease. ring into the gear housing. ring and back-up 50. Carefullypositionthe cylinderon the gear housing and looselyinstallwith four cylinderbolts. CAUTION: Bo cartul not to damagetho 6nd sel in the cylinder housing.
HOUSING
46. Installthe cylinderspringover the rack, then coat

the rack bushingA with greaseand installit on the sp.ing. 4 7 . Wrap the end of the steeringrack with vinyl tape. Coat the tape with grease.
CYLINDERHOUSING
-6q
A_e2 RACK BUSHTNG
,6Q
CYLINDERSPRING
RACK STEERING
--F\
d
Vinyl tape
A) -.9
59 x 2.4 mm O.RING
-6ll
-Gl
17-128
51. Removethe vinyl tape from the steeringrack. 52. Tightenthe four cylinderbolts. NOTE: Beforetighteningthe bolts, make sure the mating surfaces the cylinderand gearhousingfit of properly by pushing them together; hold them togetherwhile tighteningthe bolts.
55. Greasethe sealinglip ot the steeringpinion seal. and installit on the gear housingcap. 56. Wrap the spline area of the steering pinion with vinyl tape and greasethe surfaceoi the tape. 57. Greasethe new O-ring and install it in the gear housing. 58. Slidethe gear housingcap over the steeringpinion, being carefulnot to damagesealinglip or dislodge the springof the steeringpinionseal. 59. Removethe vinyl tape.
6mm FLANGEBOLT 1'l N'ln {1.1 kg-m, 8 lb-ft} DUST
CYLINDER HOUSING
/
:ERINGPINION
CYLINDENBOLT 22 N.m 12.2kg-m, 16 lb-Ill
-6i
HOUSING CAP
Make sure the O-ring is in placeand not pinched. HOUSING
-61
Vinyl tape
'
46 x 1.5 mm O-RING
53. Insert the steeringrack into the cylinderhousing, being caretul not to damage the steering rack slidingsurface. 54. Installthe pinion in the pinionholder. Install the circlip securely in the pinion holder groove. NOTE: Installthe circlip with its taperedside facIng our.
6 0 . Screw each rack end into the steeringrack while holdingthe lock washer so its tabs are in the slots in the steeringrack. Hold the steeringrack with a wrench and tighten t h e r a c ke n d t o 6 5 N . m ( 6 . 5 k g - m , 4 7 l b - f t ) .
RACK ENO
PINION HOLDER
STEERING RACK
{conl d
17-129
SteeringGearbox
Overhaul{cont'd)
62. After tighteningthe rack end, stske the four sections of lock washer with a dritt, of 6 3 . Apply greaseto the circumlerence the rack end.
6 4 . Coat the tie-rodgrooveand insideoJ the boot with

siliconegrease.
DRIFT AVAILABLE COMMERCIALLY

(Roll Pln Ddft, SnsPOn No. PPfi8l
SILICONEGREASE Cost the sliding surface ot the rack end.
-6,1
RACK END
GROOVE NOTE: This drift has a tlat, to prevent punctunng the metal washer.
6 5 . lnstall the boots on the rack end with the tube

qamps. NOTE: Checkthat the boot joint piece(i.e.air hose ioint) is not clogged with grease.
LOCK WASHER
Wood block
1.0- 1.3mm (0.04-O.05 inl Check the lock wssher diameter aftr staking.
I' I
TUBE CLAMP
17-130
66. Installthe right and lft tie-rod6nds.
70. Adiust the rack guide at the center of the rack stroke. 71. Tighten the rack guide screw until it compresses the spring and seats againstthe rack guide, then loosenrt.
TIE-ROOLOCKNUT Final to.que: 45 N.m {4.5 kg-m, 33 lb-ft|
72. Retighten to 4 N.m (O.4kg-m, 2.9 lb-ft), back it it off about 20 + 5; then installthe locknuton the rack guide screw. 73. Tightenthe locknut with the specialtool to about 25 N.m (2.5 kg-m, 18 lb-ft) while holdingthe rack guide screw. RACK GUIDE SCREW mm WRENCH,43 LOCKNUT oTMAA-SLOO20A
NE.RODEND
6 7 . Greasea new O-ringand instsll it in ths groovs in the rack guide sctew.
6 8 . Coat the rack guide slidingsurfacewith grease,. 6 9 . Installthe rack guide, spring and rack guide screw
on the gear housing.
GEAR HOUSII{G
4WS: 74. Installthe locknut on the front sub steeringangle sensor. 75. Greasea new O-ringand installit in the groove in the front sub steeringanglesensor.Installthe rack guide screw.
SPRING
RACK GUIDESCREW
GUIDE LOCKNUT
t*F
Loosolyinslall. (cont d
SteeringGearbox
Overhaul{cont'd}
76. Coat the rack guide slidingsurfacewith grease. 77. Installthe rack guide, spring, O-ringand the .ack guide screw/frontsub steeringanglesensoron the gear housing. Then adjust the rack guide at the center of the rack stroke. 81 . Coat the 9.8 x 1 .9 mm O-ringswith power steering Jluid.and installthem togetherwith the orifices. 82. Coat the 45.5 x 2 mm O-ringand pinionholderpin with grease,then installit in the valve body unit. 83. Installthe valve body unit on the gear housingwith the two 8 mm bolts. CAUTION: a Whon installing. b carolul not to hit the pinion holderpin. a Make sute the O-rings ale in place and not pinched.
LOCKNUT
RACK GUIOE O.RING
SCREW RACKGUIDE ANGLE SUBSTEERING FRONT SENSOR
-6,1
8 mm BOLT 22 N.m '16 (2.2 kg-m, lb-ftl
78. Tighten the rack guide screw until it compresses the spring and seats againstthe rack guide. then loosenit. it 79. Retighten to 4 N.m (O.4kg-m, 3lb-ft). back it otf + about 20 3' and install the locknut on the rack guide screw with the specialtool. 80, Tightenthe locknut to with the specialtool about 25 N.m (2.5 kg-m, 18 lb-tt) while holdingthe guide screw.
Ee?H",.
45,5 x 2 mm O.RING 9.8 x 1.9 mm O.RINGS
17-132
NOTE: Install the boot band with the rack in the straight ahead position (i.e. right and left tie-rodsare equal in length). 84. lnstallthe boot bandso that the lockingtabs of the band (stakepointsl are in the rangeshown below. (Locking tabs shouldtace up and slightlyforward.) 85. Installnew boot bandson the boot and bend both sets of lockingtabs. ponions to reduce 86. Lightlytap on the doubled-over their height. CAUTION: a Stako the band locking tabs firmly. a When staking. be cartul not to damag the boot.
8 7 . lnstallthe air hose cliDas shown.

8 8 . lnstallthe bandcushionand air hoss band;Dosition the band as shown then tighten it. Installthe air hose, slidethe rack right and left to be 8 9 . After assembling, cenain that the boots are not deformedor twisted. NOTE: After installation, perform the electrical check on the 4wS system (seepage 17-146).
AIR HOSECLIP (Viewedlrom the right side) Clamp AIR HOSE CLIP
AIR HOSE BAf{O (Viewed lrom the right side) 6mm
atRHosE
NOTE: Connect with the protector side toward
th6 gearbox,
AIN HOSE BAND

45i5o
TUBE
JOINT
Front +
LOCKINGTA&S The locking tabs (stake points) should be in this range. Bandwinding direction.
OFFSET SHAFT LINE CENTER LEFT BOOTBAND (Viewed from the lelt side)
10a50
RIGHT BOOT BAND (Viewed from the right side)
17-133
SteeringGearbox
lnstallation
Slidethe rack all the way to the right. Pass the right side of the steering gearbox assemblyabove and through the right side of the rear Deam, Hold the steeringgearboxassembly8nd slide the rack all the way to the right. 4. Raise the left sideot the steeringgearboxassembly above and th.ough the left side ot the rear beam. 7 . Positionthe steeringrack centerof its strokes. Make sure that the cable reel of the driver'sairbag system is centeredas follows: a Turn the steering wheel left approx. l50 degrees,to check the cable reel position with indicator. a lf the cable reel is centered,the yellow gear tooth lines up with the aljgnmentmark on the cover. a Return the steering wheel right approx. 150 degreesto position the steering wheel to the straightaheadposition.
Looselyinstallthe left and right mountingbrackets with the six mountingbolts, Tighten the mounting bolts on the left mounting bracket ti.st, then tighten the mounting bolts on the right mountingbrackets.
\ <L6tt
\
LEFTMOU NNG BRACKET
GEAR
YELLOW Slip the lower of the steeringjoint onto the pinion shaft (line up the bolt hole with the groovearound joint bolt. the shaftl and looselyinstallthe steering NOTE: a Connectthe steeringshatt and pinionwhen the cable reel and steeringrack are centered. a Be sure that the steeringjoint bolt is securelyin the groove in the pinionshatt.
9.
39 N.m
(3.9 kg-m, 28 lb-ftl <Bight Sido:> 44 N.m {4.4 kg-m, 32 lb-ft|
BOLTHOLE
JOINT BOLT STEERING 22 N.m 12.2 kg-m, 16lb-ft) JOINT STEERING
MOUNTIT{G
BRACKET
FGHT MOUNTING TNACKET AIR HO CLAMP NOTE: The arrow on the brscket points toward the front. 39 l{.m 13.9 ks-m, 28 lb-ft)
17-134
1 0 .Connectthe four linesto the valvebody unit, using

flare nut wrenches. A: To oil cooler: 17 mm wrench 29 N.m (2.9 kg-m, 21 lb-ftl B: To powgr stoedng speod sen3of: 12 mm wranch 13 N.m {1.3 kg-m, 9 lb-ft} 12 mm wrench C: To rsseryoir: 1 3 N . m ( 1 . 3 k g - m ,9 l b - t t ) pump: 14 mm wronch D: From 38 N.m {3.8 kg-m, 28 lb-ft)
Fill the reservoir with power steering fluid and bleod air from the system by tufning the stesring whesl from lock to lock several times with the engine warm (see page 17-77l.. 1 4 . Make sure there afe no tluid leaks,then installthe gearboxshield, Recheck the fluid level in the reservoir.
1 1 .Reconnectthe connector and secure the sensor wire harnesswith the clamp and installthe cover. NOTE: a -Be sure the sensor wire harnessdoes not inor terferewith the stabilizer other moving parts. a Be certain that the sensor wire harnessis not twisted betore connectingit. Set the cover on the front sub steeringangle senand cover with sor. Securethe sensorwire harness a new wire tie.
CONNECTOR SENSORWIRE GEARBOXSHIELD 15. Install the center beam. {1.0 kg-m, 7 lb-ft}
60 N'm
TIE WIRE
CI-AMP
SUB STEERING
60 N'm {6.0 kg-]n,4.:lb-ft1
NOTE: After rack guide adjustment,perlorm the electrical check on the 4WS system (see page 17-146],.
{cont d
17-135
SteeringGearbox
lnstallation(cont'd)
model only. 16. Automatictransmission a Connectthe shift cable end to the shift control shaft. and installthe cable holder. 18. Reconnect the tie-rod ends to the steering tortightenthe castlenut to the specified knuckles. que, and instailnew cotter pins. CAUTION: Torque the castle nut to the lower tolqu sp6citication, th6n tighton it onlY tar nough to atign the slot wilh the pin hol6. Do not align the nut by loosening.
SHIFT CABLE
CASTLENUT 50-60 N.m (5.0-6.O kg-m. 36-/13lb-ft)
CABLE
tl.4 kg-ln, 10 lb-ftl
1 8N ' m k 1 11.8 g-m, 3lb'ft|
17. Installthe exhaustpipe A with a new gasket.then tighten the new self-lockingnuts. Connect the heated oxygen sensor connector (H23A1 and H22A1engine).
COTTER PIN On reassembly,bond the cottgr pin as shown.
'19.
Adiust the front toe (seesection 18). NOTE: lf the steeringwheel and rack are notalignat the ed centered,reDosition serrations lower end of the steeringjoint.
20. Fillthe system: a Fill the reservoirwith new Honda Power Steeri n g F l u i d - V s e ep a g e 1 7 - 7 7 ) . { perform the following chcks 21. After installation, a Stan the engineand let it run at idle, then turn the steering wheel trom lock-to-lock several times to bleed air from the system (see page 1 7- 7 7 t . a Check the fluid again, and add more if necessary. a Check the gearboxfor leaks. a Check the tront toe (seesection 181. a Check the steeringwheel spoke angle. a Checkthe 4WS system {4WS only).
55 N.m 15.5kg-m,40 lb-ftl
EXHAUST PIPEA
7 -136
RearSteeringActuator
lllustrated Index
CAUTION: a Do not strlks tho rack end and shaft scrow. a Us the spocial tool when removing the rear stee ng actuator. Tho special tool should remain installed excopt whon tha aciuator ia inspected tor tunction, stc. a Do not try to disasEamble tho rear stoering actuator. lf the actuator is taulty, roplace it a3 an assembly. a Whon disassemblingand sorvicing. do not let dust, din. and forign matelials snter tho rgar atsring actuator. a Whn eithor th roar sub stoering anglo sonsor or th6 roar main st6o.ing angle sensor are removsd, pertorm Inspgction and adiustmont ot the raar sub stee ng angle sensor aftr installing ths rear steering actuator. a Lock th shatt scrow using th6 r6ar steoring lock pin special tool betole removal/installstion and dlsassembly/rassembly tho real steering actuator assembly. of
5O-60 N.m 15.0-6.0 kg-n, 36-43 lb-ft)
\ t
LOCKNUT 45 .m 14.5kg-m,33 lb-lrl
RACK 55 N.m (5.5 kg-m, 40 lb-ftl
BOOTBAI{D Replace.
d% w
Replace. REARSUB ANLGE SENSOR 5 Adjustmenl. page 1 7 - 1 5 LOCKNUT 25 N'm (2.5 kg-m, 18 lb-ft)
TORX@ BOLT '10t{.m (1.O kg-m, 7 tb-ft| O.RING Replace. NOTE: Do not let dust, dirt, and {oreign materials enter the actuator.
REAB STEERING ACTUATOR
SHAFT SCREW
17-137
Removal
1. Raisethe rear of car and supporton safety stands in the properlocations(seesection 1). NOTE: When the engineis OFF,the shaft screw of the rearsteeringactuatoris held in the neutralposition (straightaheaddriving position)by the return springtension. CAUTION: Do not start the ngin with the real stering lock pin set in lhe roal stoering actuator. lf the stering whsal is tumed with the engina running, the rear 6teringactuator will oporate, damaging th rear stoering actuator. 5. Removethe rear steeringactuatorcover.
2 . Remove the cotter pin from the castel nut and removethe nut. Installa 12 mm hex nut on the ball joint. Be sure that the 12 mm hex nut is tlush with the ball joint pin end. or the threadedsectionot the balljoint pin might be damagedby the ball joint remover. NOTE: Removethe ball joint using the Ball Joint Remover.Referto page 18-13 for how to use the ball joint .emover. the Separate tie-rodballjoint and knuckleusingthe specialtool. CAUTION: Avoid damaging th6 ball ioint boot. 12 mm HEXNUT
3.P CONNECTOR
REAR STEERING ACTUATOR COVER 6. Disconnectthe ground cable connectorsand terminalsfrom the rear steeringactuator.
TERMINALNUTS
NOTE: Do not contaminatethe terminal bolt and nut with grease.Cleanthem if necessary.
17-138
7.
Removethe rearsteeringactuatorby removingthe four mountingbolts and bracket.
ACTUATOR REARSTEERING
MOUNTINGERACKET MOUNNNG AOLTS
17-13!l
Disassembly
1. Removethe tie-rod ends, 3. Using a soft hammer,drive in th spcialtool between the actuator housing and stopper washer with the flat side of the specialtool toward the housing. the tie-rod lock washer. Straighten
4. TIE.ROD END
RACKHOLDER O7NA8-SSOo1OO
LOCK WASHER Reolace.
Removethe boot bands and tube clamDs.Pullthe boots awav trom the ends ot the rack end.
5.
Hold the shaft screw end with the spscialtool and unscrewthe rack end with a wrench,
RACKEND
TUBE CLAMP
6.
Removethe specialtool.
17-140
Assembly
the rearsub steetinganglesensorfrom the 7 . Remove actuatorhousing. 1 . Installthe locknut on the rear sub steeringangle sensor,then greasea new O-ringand installit. Screw the rear sub steeringangle sensorinto the actuator housingfully by hand, back it off about 1/2 turn, and looselytighten the locknut.
REARSUB STEERING ANGLE SENSOR
REARSUBSTEERIITG AI{GLE SENSOR

Screw in the resr sub stgering angle sonsor until se6ted, thgn back it oft about 1/2 turn.
LOCKNUT
ACTUATOR HOUSING LOCKl{UT
8.
Removethe rear main steeringangle sensorfrom the actuatorhousing.

ACTUATOR HOUSII{G REARMAIN STEERING
NOTE: Adiust the rear sub steeringangle sensor (seepage 1 7-155) after instslling the rear steering actuatoron the car.
CAUTION: Aftor disassembly, attach a pioco of tape or equivalent materialon each port andioint ot tho r6ar stooring actuator to protoct it trom dust. dirt, and foraign matoriala.
{coltl c
17-117
Assembly(cont'd)
3. Greasea new O-ringand installit in the .ear main steering angl sensor, then install the rear main steeringangle sensor.
REARMAIN STEERING ANGLE SENSOR TORXO EOLT 1O lt'm {1.Oks-m, 7 lb-ttl
5 . Using a soft hammer, drive the special tool between the housing and stopper washer with the tlat side of the specialtool toward the housing.
o.
Tightonthe rack end securely,then bend the lock washer back against the tlat on the flange as snown.
ACTUATOR HOUSING
-611
o-Rrr{G
DOWEL PINS
55 N.m 15.5kg-m,rto lb-ftl CAUTION: a Tako exfiomo car6 not to apply axisl impact and fotational tolc on the shaft screw. a St th projoction ot the lock washer in the groove in the lack securely. After tightoning the rack ond, bend th6 tabs of ths washer sgainst the tlats securly. 7 . Removethe specialtool,
Screw each rack end into the shaft screw while holdingthe lock washerso lts tabs are in the slots the shaft screw end. NOTE: Install the stopDer washer with the chamferedside tacing out.
8 . Apply greaseto the circumference the rack end of

STOPPER WASHER o
housing. Coat the rack end groove and insideot the boot with siliconegrease.
:GREASE Coar the sliding surtace of the rack end. BOOT TUBE CLAMP
17-142
1O. lnstallnew boot bands, - Installthe boot band so that th lockingtabs oJ the band (stake points) are in the range shown below. {Tabsshouldface up and slightlyforward.)
LOCKING TABS RIGHT SOOT BAI{D Front lr
11. Installthe right and left tie-rod ends on the right and lsft rack ends.
LEFTBOOT
Th locking tsbs (stake points) should bs in this range. The locking tsbs (stske points) should be in this ran9e. -
Install new boot bands on the boot and bend both sets of locking tabs.
- Lightly tap on the doubled-overponions reducetheir height, CAUTION: a Siako tho band locking tabs firmly. a Whan staking, bo careful not to damago the boot.
LOCKINGTAB{i
17-14:l
lnstallation
Installthe rear steeringactuator with four mounting bolts and bracket. NOTE: Installthe bolts looselyfirst, then tighten them.
MOUNTINGCUSHION ACTUATOR REARSTEERING
NOTE: Do not contaminatethe terminal bolt 8nd nut with grease.Cleanthem iJ necessary. Connect the ground cable, connectots and ler' minalsto the rear steeringactuator. NOTE: Be surethe wires are not caughto. pinched by any parts.
,-9
I I
44 N.m (4.4 kg-m, 32 lb-ft)
MOUNTINGSRACKET The arrow on the bracketpoint up.
39 N.m (3.9 kg-m,28 lb-ft|
2.
Reconnectthe tie-rod ends to the rear steering tor tightenthe castlenut to the specified knuckles, que, and installnew cotter Pins. CAUTION: Torquethe castls nut to the lower tolque specitication, then tighten it only tar enough to align the slot with the pin hole. Do not align the nut by loosening. 4.
CASTLENUT 50-60 N'm l5.O-6.0 kg-m, 36-43 lb-ft}
Adjustthe rearsub steeringanglesensor(seepage 17-1 51. 5 NOTE: a Be sure that the tront sub steeringanglesensor and front main steering angle sensor are in neutral8nd the steeringwheel is in the sttaight aheaddrivingposition, a Bs sur that the rear steeringlock pin {special tool) is set in the rear actuator. lnstalltheterminalcover and rearsteerlngactuator cover,
COTTERPIN bend On reassembly, lhe cotter pin as shown,
END TIE-ROD
17-144;
4WS ControlUnit
Removaland Installation
1 . Removethe rear seat back {seesection 20}. , Disconnect terminalwires and connectors the f.om the 4WS control unit. Removethe 4WS control unit.
Tie-rod End Boot

Replacement
Removethe boot.
2 . Packthe interiorof the boot and lip with grease.

Wipe the greaseoff the slidingsurfaceof the ball pin, then pack the lower area with lresh grease. CAUTION: a Koep groase otl the boot installation sction and th6 tapersd section of the ball pin. a Do not sllow dust, din, or othar foreign matrials to onter the boot.
UNIT 4WS CONTROL
-\P
BOOT INSTALLATTON SECTION and BALL PIN TAPERED SECTION
BLK wire. 7 N.m lO.7 kg-m, 5 lb-lt)
4.
Installthe new balljolnt boot usingthe specialtool as shown below. NOTE: After driving the boot onto the ball joint, apply sealantbetweenthe tie-rod end and boot.
REDwire.
BRNwire.
END TIE.ROD
4.
Installin the reverseorderof removal. NOTE: Turn the ignitionswitch ON and check the 4WS indicatorlight operation. CAUTION: After installing the boot, check the ball pin tapered section fol grease contamination and wipe it if necossary.
17-145
4WS System Inspection

ElectronicNeutral Gheck
Preparation
NOTE: a lf the power of the 4WS control unit was shut down tor the following operations,start the engine and turn the steering wheel lully right and left. - Batteryremoval/installation - 4WS control unit removal/installation - N o . 4 3 f u s e C L O C KR A D I Or e m o v a l{ i n t h e fuse/relaybox) under-hood a Before performingthe electronicneutralcheck on the 4WS system check the following items. Be surethat the steeringwheelspokeangleis anglewhile drivingstraight at the designated aneao. - Be sure that the rear wheels are not steered to the right or left, but in the straight ahead drivingposition, Jack up the car and placethe tour wheelsslowly in the ceriterof the lurning radiusgaugeturn tables. tape or equivalent approxPlacea pieceof masking imately 3OOmm {12.O in) long on the top edge of the steering wheel. Place a mark on the tape at each of the following measurements: a Center (highestpoint of the steeringwheel). a 9 mm {O.4 in) right and lell oI center (Forfront main steeringanglesensor). a 18 mm {O.7in) right and left of center(Fortront sub steeringangle sensoradjustment). a 55 mm (2.2 in) right and left of center(Forfront sub steeringangle sensorinspection). 4. are NOTE: The sDecifications the measurements of on the outer circumference the steeringwheel.
a18 mm l!0.7 inl Florn
MARK CENTER MARK CENTER
a9 mm 110.4inl From
and place a Fashion pieceof stift wire (coathanger) Position the wire so the it on top of the dashboard. indicatingtip is closeto the marks on the steering wheel and tape the wire down securely. Set the steeringwheel in the straightaheaddriving positionand set the wire at the centermark on the steeringwheel.
17-146
5.
Take out the service check connector (BLU 2P) trom behind the center console.Connect the terminals with a piece ot jumper wire. NOTE: a The 4WS indicator light will not indicate that sensorsare in the neutralpositionwhen displaying stored problemcodes. a Check and verify any problemcodes displayed beforecheckingthe neutralposition.
Front sonsors insoection: 7. Checkthe front main steeringanglesensorwith the ignitionswitch on (engineoff), - From the straight ahead driving position, turn the steering wheel to the left, then turn the steering wheel slowly to the right beyond the straight aheaddriving position.Do not turn the steeringwheel inversely. - Turn the steeringwheel to the left, then turn to the right beyondthe straightaheaddrivingposition. Repeatthis operation severaltimes until vou tind the position where the 4WS indicator light starts to come on steady.
4WS INDICATOR LIGHT
' ,r9 mm (t0.4 in/:!3of F.omCENTER MARK -: --=- rll
-Br\ '11
!
JUMPER WIRE SERVICE CHECK

CONNECTON IBLU 2P}
!1i
o-
Pullup the parkingbrakeleverfully and turn the ignition switch on (engineoff) to turn the parking brske indicatorlight on. This sets the front sensors in the insoectionmode.
The 4WS indicatorlight should start to come on within the rangeof i9 mm (1O,4 in/a3") from the center mark on the steeringwheel. NOTE; a The 4WS indicator light might look as if it is blinkingat a point nearthe ends of the specilied range. a To determine that the 4WS indicatorlight is oo and not blinking,be surethat the 4WS indicator light stays on for more than 2 seconds. - Adjust the 4WS system if the indicatorlight startsto come on at a ooint outsidethe marked range on the steering wheel (see page 17-151l.
(cont'd)
17-147

ElectronicNeutral Check (cont'd)
8. Checkthe front sub steeringanglesensorwith the ignitionswitch on {engineoff), - From the slraight ahead driving position. turn the steeringwheelto the right,then turn it slowly to the left beyond the straight aheaddriving position. Do not turn the steering wheel inversely. - Turn the steeringwheelto the right,then turn to the left beyondthe straightaheaddriving position. Repeatthis operationseveraltimes until you find the centerpoint of the rangewhere the of 4WS indicatorlight blinks(at the intervals O.2 seconds). Rsal sgnsols insDection: the 9. Release parkingbrakeleverfully to turn off the parkingbrakeindicatorlight. This sets the rearsenmode. sors in the insDection
4WS INDICATORLIGHT
'I
O. Turn the ignitionswitch off.
1 1 .Removethe cap bolt and sealingwasher from the rear steeringactuator.and screw the specialtool into the rear steeringactuatoras far as it will go. NOTE: Do not start the engine with the special tool set in the rear steeringactuator.
The centerpoint shouldbe within the rangeof t55 mm l!2.2 ini11 6,50 ) from the centermark on the the front sub steersteeringwheel. After adjusting ing anglesensor,however,the centerpoint should b e w i t h i n t h e r a n g eo f 1 1 8 m m ( 1 0 . 7 i n / 1 5 . 5 " ) from the center mark. - It the center point is outsidethe markedrange wheel. adjustthe front sub steeron the steering ing anglesensor(see page 17-153).
17-148
'12.
Set the steeringwheel in the straightaheaddriving positionto preventthe rearwheelsfrom steeringif the engineis started in error.
14. Set the steeringwheel in the straightahesddriving positionto preventthe rearwheelsfrom steeringit the engineis startedin error. 15. Turn the ignitionswitch on (engineoff) and check the rear main steeringanglesensor. - Pushthe rearleft wheel fully to the left by hand, then push it slowly to the right. - The 4WS indicatorlight should turn ON when the rear wheel is pushedto the right.
13. Turn the ignition switch on (engineoff) to check the rear sub steeringanglesensor. - Push the rea. left wheel fully to the .ight by hand, then push it slowlv to the lett. - The 4WS indicatorlight shouldblink at intervals of O.2 secondswhen the rearwheel is oushedto the lett.
4WS If{DICATORLIGHT
' ra,.!?. " """""ffi--1_.-1) 1
4WS INDICATOR
uear
REARLEFTWHEEL
TURNTO LEFT
TURN TO RIGHT
Froni
Front
NOTE: The 4WS indicatorlight blinks in a narrow range.Take care not to overlookit - lf the 4WS indicatorlight does not blink, adjust the rear sub steering angle sensor (see page 1 7 - l5 5 ) .
NOTE: a The 4WS indicator light turns on in a narrow range.Take care not to overlookit. o The 4WS indicator light might look as it it is blinking at a point near the ends oI the range where the light is on. a To determine that the 4WS indicatorljght is nor blinking. be sure that the 4WS indicator lighr stays on tor more than 2 seconds. a lf the 4WS indicator light does not turn on, removethe rear main steeringanglesensorand check it for damage.
17-149

ElectronicNeutral Check {cont'd)
16. Turn the ignitionswitch oJt. 17. Removethe specialtool from the lear steeringactuator, and installthe cap bolt and the new sealang washer on the rear steering actuator'
REAR STEERII{G ACTUATOR 18. Removethe jumper wire from th ssrvice check connectorterminals{BLU 2P). 19. Returnthe connectorbehindthe center console. the removedparts. 20. Reinstall
17-150
4WS System Adjustment

Adjust the 4WS system usingthe followingprocedure, NOTE; a lf the Dower ot the 4WS control unit was shut down for the Jollowing operations,start the engine and turn the steeringwheel tully right and left. - Battery removal/installation - 4WS control unit removal/installation - N o . 4 3 f u s e C L O C KR A D I Or e m o v s l{ i n t h e fuse/relavbox) under-hood 1, Jack up the car and placethe wheelin the centerof the turning radiusgaugeturn tables. a Check whether the yellow paint mark ot the tront main stseringangle sensorrotor is facing down (i.e. in neutral lock position where the that the front rotor does not turnl. This indicates in main steering angle sensor is electronically neutral. NOTE: lf the paint mark is not facing down, adjust as instructedin step 5, (1) through (3) on page 't7 -87 .
FRONTMAIN STEERING
RADIUS GAUGE TURNING TURNTABLE in Set the steeringwheelso that it is positioned the rangewhere the steeringwheelturns centerof the fully to the right and left. (This centers the tront steeringrack.l lf the steering wheel spoke angle is not at the anglewith the steeringwheel set in the designated positionexplainedin step 2. adjustthe tront main steeringanglesensorand spoke angleas follows. a Set the steeringwheelin the straightaheaddriving position,then removeit.
WHEEL STEERING
a Installthe steeringwheel, aligningit with the serrationwhich makes the spoke angle closest to horizontal. - lf the spokeangleis not horizontal, adjustthe steering wheel slightly right or left. being careful not to push in on the steeringwheel. NUT WHEEL STEERING 5ON.m
{5.0 ks-m, 36 lb-ft)
a With the spoke angle set at horizontal,then push the steeringwheel in fully. Tighten the steefing wheel nut while pushing the steeringwheel in. NOTE: a Do not removethe steeringwheel until adjustment is completed. a Do not turn the steeringwheel when pushing the steeringwheel.
tcont c
17-151

4WS System Adjustment (cont'd)
4. Be sure that the rear wheels are not steeredto the right or left, but in the straight ahead driving Dosition, Checkthe sub and main steeringanglesensorsusing the table shown below (seepage 17-146). NOTE: a Turn the ignition switch on (engine off ) to check. a The 4WS indicatorlight does not indicatethe electronicneutralpositionwhen it is indicating problemcodes. a Check the sensors by turning the specified wheel in the specifieddirection shown in the if are table below, The sensors adiustedproperly the 4wS indicatorlight turns on in the specilied range on the steeringwheel, or if the center ot light blinksis the rangewhere the 4WS indicator rangeon the steeringwheel. within the specified
Sensor type Frontmain steering angre sensor Front sub steering angle sensor Rearsub steering angle sensor Check Parkingbrake lever *2 Release l Pull
Take out the service check connector (BLU 2P) trom behind the center console.Connectthe terminalswith a pieceof jumper wire.
Turn front wheelsto right
.2 0N
Turn front wheels to left '4 Turn rear wheelsto lefl
*3 Blinks
'3 Blinks
Flearmain *4 Turn rear steering *2 Blinks wheelsto angle ngnt sensor *'1:Be sure that the parking brake indicatorlight operates properly. '2: The 4WS indicator light might look as if it is blinkingat a point near the ends oI the range where the light is ON. *3: The 4WS indicator lighl blinks in the intervalsof O.2 the main seconds.When the indicatorlight is indicating ot condition steering anglesensor {lightON),indication the is condilion blinking canceled. by sub steering anglesensor *4: Turn the rear wheel slowly by hand with the specialtool (rear steering center lock pin) sel in the rear steering actuator,
17-152
Sub Steering Angle Sensor Adjustment

7 . lf the sensors are not sdiusted properly. adjust eacn sensof. a It the front main steeringanglesensoris not adiusted properly, start with the step 2. a Front sub stee,ing angle sensor adiustment: see psge17-153. a Rear sub steerlng angle sensor: see page 17-155. NOTE: The rsar main steeringanglesensorcannot be adjustsd.lf the rear main steeringangle sensor is sbnormal,removeit and check it tor damage.
Front Sub SteeringAngle Sensor

NOTE: Before adjusting the sub steering angle sensor. check that the front main steeringangle senso. is adjustedproperly(see page 17-146). 1. Jack up the ca. and raise all four wheels off the ground.Placethe salety stands in the properlocations to supportthe car (seesection 1). 2. Set the steeringwheel in the straightaheaddriving oosttton. Take out the service check connector (BLU 2P) from behind the center console.Connect the terminals with a piece of iumper wrre. NOTE: . The 4WS indicatorlight will not indicate that the sensors are in the electronic neutral oosition when displaying stored Diagnostic Trouble C o d e s( D T C ) . a Check and verify problem codes displayed betorecheckingthe electronicneutralposition.
3.
4.
Set the parking brake lever and turn the ignition switch on {engineofl). Be sure that the parking brakeindicatorlight turns on, Turn the ignitionswitch oJf.
17-1!i :l

Sub SteeringAngle Sensol Adjustment (cont'd)
6. Cut the wi.e tie from the cover, then remove the cover Jromthe front sub steeringanglesensor. CAUTION: Uso car6 whon cutting lhe wire tie so as not to cut into the wiro harnsss. 7, Removethe sensor wire harnessfrom the clamp the connector. and disconnect 9, Turn the ignitionswitch on {engineoff). 10. Set the steeringwheel in the straightaheaddriving position.Set the front main steeringangle sensor electronicallyin neutral (4WS indicator light is blinking) this time. NOTE: Hold the steeringwheel in this positionunis til adjustment completed,lJ the steeringwheel is moved in effor. repeat the adjustment procedure starting with step 10.
CONI{ECTOR
COVER
WIRETIE
R6place.
/w
" \ '
11. Turn the front sub steering angle sensor slowly clockwise. and check the range Jrom where the light startsto blinkto where it stops. 4WS indicator 12. Loosenthe front sub steeringanglesensor.Repeat the step 11 severaltimes to set the sub steering anglesensorin the centerof the rangefrom where the 4WS indicatorlight starts to blink to where it srops. ] CENTER
LIGHT STABTS TO BLINK LIGHT OFF
Loosenthe locknut. Tighten the locknut fully by hand, back it off about 3/4 turns and connectthe connector.
LOCKf{UT
FRONTSUB STEERING ANGLE SEIISOR
TURNINGDIRECTIOI{
NOTE: a Turn the front sub steering angle sensor clockwiseto makethe 4wS indicatorlight blink. a lf the sub steeringangle sensorwire is twisted excessively, turn the ignitionswitch ott, disconnect the connector,and straightenthe wire.
17-154
13. Tighten the locknut while holding the front sub steefingangle sensorwith a wrencn. NOTE: Take carenot to turn the tront sub steerino angle sensor.
LOCKNUT 25 N'm 12.5 kg-m, 18 tb-ftl FRONTSUB STEERING ANGLE SENSOR
RearSub SteeringAngle Sensor

1. Jack up the car and raise all four wheels off the ground.Placethe safety slands in the properlocations to supportthe car (see section 1). 2. Take out the service check connector (BLU 2Pl from behind the center console.Connect the terminalswith a pieceof jumper wire. NOTE: a The 4WS indicatorlight will not indicate that the sensor is in electronic neutral oosition, when displaying stored Diagnostic Trouble Codes (DTC). a Check and verify problem codes displaved beforecheckingthe electrically neutralposition.
SENSOR WIREHARNESS
'I 4. Disconnect front sub steeringanglesensorconthe nector to straightenthe sensorwire harness. Reconnect the connecior. NOTE: Do not contaminate the front sub steering angle sensor connector terminals with mud, oil, and grease. '15. Check that each sensoris electronicallv neutral in { s e ep a g e 1 7 - 1 4 6 ) . NOTE: Be sure that the centerof the rangewhere the 4WS indicatortighr btinks (indicating that the front sub steeringangle sensoris electronicalty in n e u t r a l l ,s i n t h e r a n g e : t 1 8 m m ( a 0 . 7 i n / r s . 5 0 ) i from the center mark on the steeringwheel.
i18 mm lao.7 in) Frorn CENTERMARK
JUMPERWIRE
'
'
///{\ . .
t(rir'
3 . Release parkingbrakeleverfully and turn the igthe

nition switch on (engine otf). Be surethat the parking brake indicatorlight goes olt. 4. Turn the ignitionswitch off.
PARKINGBLAKE LEVER
16, Reconnect connectorand securethe sub steerthe ing angle sensorwire harnesswith the clamp and installthe cover. NOTE: a Be sure the sensor wire harnessdoes not interferewith the stabilizer other movingparts. or a Be certain that the wire is not twisted before connectingit. 17. Securethe cover with a new wire tie. (cont'd)
17-155

Sub SteeringAngle SensorAdjustment lcont'dl
Removethe fear steeringactuatorcover
o.
Remove the cap bolt and sealing washer from the rear steeringactuator.Sc.ew the specialtool in as far as it will go.
WASHER SEALIT{G
9. Set the steering wheel in the strsight ahead driving position to prevent the rear wheels trom steering if the engineis startedin error. 1O. Turn the ignitionswitch on (engineotf). 11. Push the rear left wheel tully to the left by hand, then push it slowly to the right to turn the 4WS indicatorlight on (i.e..ear main stee.inganglesensor in is electronicallv neutral). REARLEFTWHEEL
TURNTO
STEERING
LOCKPIN CENTER REAi STEERING 07NAJ-SSOO20A 7. Remove the rear sub steering angle sensor wire from the clamp and disconnectthe connector' Loosen the locknut. Tighten the locknut tully by 'l12 turn and connect hand, then bsck it oft about the connector' LOCKNUT
Frcnt
8.
NOTE: a The 4WS indicator light turns on in a natrow range.Do not ovetlookit. a Work with ca.e so as not to move the real wheels from this neuttal position.
17-156
12. Turn the ignitionswitch on {engineoff}. 13. Turn the .ear sub steering angle sensor slowly counterclockwise, checkthe rangelrom where and the 4WS indicstorlight starts to blink. to where it srops. 14. Tightenthe rear sub steeringangle sensora little. Repeatthe step l3 severaltimes to set the sub steering angle sensor in the center of the range from where the 4WS indicatorlight starts to blink, to where it stops. I CEIITER LrcHToFF I
LIGHT STARTS TO BLII{K TURI{ING DIRECTION
16. Disconnect the rear sub steeringanglesensorconnecto. to straighten the wire. Reconnect the connector. NOTE: Do not contaminatethe rear sub steering angle sensor connector terminals with mud, oil, ano grease. 17. Checkthat each sensoris electronicin neutral(see p a g e1 7 - 1 4 6 ) . 18. Turn the igntion switch olf. Removethe special tool from the rear steeringactuator,and installthe cap bolt and the new sealingwasher on the reat steeringactuator. 19, Installthe rear steeringactuatorcover. CAPBOLT 22 N.m {2.2 kg-m,16 lb-ft)
SEALINGWASHER
NOTE: a Turn the rear sub steering angle sensor counterclockwise make the 4WS indicator to light blink. a lf the rear sub steering angle sensor wire is twistd excessively, turn the ignitionswitch off, disconnectthe connector, and straightenthe 15. Tighten the locknut while holding the rear sub steeringangle sensorwith a wrench. NOTE: Take care not to turn the rearsub steering angle sensor.
REARSUB STEERING ANGLESEI{SOR
REARSTEERING ACTUATOR REARSTEERING CENTERLOCK PIN 07NAJ-SSOO20A
Suspension
......... 18-2 SpecialTools ComponentLocation .... 18-3 l n d e x. . . . . . . . . . . . . Alignment Wheel S e r v i c e1 n f o r m a t i o n , , , . . . . . . . . . . .1. .- 4 .8 ,, Camber . . . . . . . . . . . . .1 8 - 5 . .... 18-5 C a s t o r. . . . . . . . . . . . Front Toe Inspection/ Adjustment ..... 18-6 RearToe Inspection/ Adjustment ..... 18-7 Turning Angle Inspection/ ..... 18-8 Adjustment Wheel Measurements E . . B e a r i n g n d P l a y. . . . . . . . . . . . . . . . . . . .1 .8 - 9 R u n o u t. . . . . . . . . . . .... 18-9 Front Suspension ................ 8-10 Torque Specifications 1 Knuckle/Hub I . . l l l u s t r a t e dn d e x. . . . . . . . . . . . . . . . . . 1.8 - 11 . . . . . . . . .1 8 - 1 2 Removal Hub Unit and Wheel Bearing Replacement ... 18-15 ...... 18-17 lnstallation Arms Suspension Removal/lnspection ................18-19 ...... 18-20 lnstallation ....... 18-21 Ball Joint Boot Replacement Lowerarm Bushing Replacement 18-21 .... Front Damper Removaf .............18-22 Disassembly/lnspection .............. 1A-22 ........ 18-24 Reassembly ......... 18-25 lnstallation Rear Suspension ..... 18-26 Torque Specifications ........... Knuckle/Hub ........ 1A-27 llfustratedIndex ............. ......... 18-28 Removal ...... 18-31 lnstallation Suspension Arms Removal/lnspection ................18-33 Installation ...... 18-34 BallJoint BootReplacement ......... 18-35 LowerArm Bushing Replacement 18-35 .... Rear Damper Removal .......... 18'36 .... 18-37 Disassembly ....... 18-37 Inspection ..... 18-39 Reassembly ...... 18-40 lnstallation . . D a m p e rD i s p o s a.l. . . . . . . . . . . . . . . . . . .1 .8 - 4 1
SpecialTools
Rcf. No.
Tool Number
Desc ption Base Hub Dis/Assmbly Tool Hub Dis/Assembly Hub Assembly Guide Attachment Ball Joint Boot CliDGuide Driver Attachment Ball Joint Remover,32 mm Ball Joint Remover,28 mm BushingDriver Attachment, 62 x 68 mm Driver support Base BallJoint Boot Clio Guide
O'ty
Pag. Refcrcnce
@ @ @ @ @ @ @ @
oTGAF-SD40700 oTGAF-SEOo100 oTGAF-SEOO200 -SD40700 07GAG oTHAD-SG00100 07MAC-5100100 oTMAC-S100200 oTNAD-SS00100 10500 07746-OO 07749-0010000 07965-SD90100 07974-SA50800
2 r 1 1
r
r
r
1A-'t5 1 8 - 1 51 6 ,1 7 , 18-17 L , | 1 8 - 2 13 5
1 1
I ra-ro
I rg-rs
| 18-14,30 | 1 8 - 2 1 .3 5
14, I ra-ra, so,36
r
1 1
e re , Jr 8 - - r ,s 7 1 16 1
I 1 8 - 2 1 ,3 5
I
{--ru
:,.--l
H | l
@
tr
I (J
@
v
/
F1
\
@@
/-] l , r a l
---G-1
N W
@
@
@
@o
n
hJ
@
H l_,
@
8-2
Component Location
lndex
The tront and real dampe.s contain nitrogon gas and oil undor presauro,The prsssuro must be raliovd @ betore disposal to provent oxplosion and possiblo iniury whon scrapping. Wheel Alignment,page 18-4 Front Suspension:
FRONTDAMPER . Removal, page 18-22 . Disassembly/lnspection, page 18 22 . Reassembly,page 18-24 . Installstion, page 18-25 . Disposal, page 'l8-41 FROI{T UPPERARM . Removal/lnspection, page 'l8-19 . Installation, page 18-2O
STABIUZER BAR . Removal/lnspection, 18-19 page . Installation, 18-20 page

FBOI{T KNUCKLE/HUB . Removal, page 18-12 . Bearing Replacement, Page 18-15 . lnstallation, page 18-17
FRONTLOWERARM . Removal/lnspection, page 18-19 . Installation, page 18-20
t l /
ROD RADIUS ,/ . Removal/lnspection. 18-19 p6ge . Installation, 18-20 page
Roar Suspension:
BEAR UPPERARM . Removal/lnspection,page 18-33 . Installation. page 18-34
REAR OAMPER . Removal, page 18-36 . Disassembly, page 18-37 . Inspection, pago 18-37 . Reassembly, page 18-39 . Installation, page 18-40 . Oisposal, page 18-41
REAR KNUCKLE/HUB . Removal, page18-28 . Installation, 18-31 pago
REAR LOWEA ARM . Removal/lnspection, Page 18-33 . Installation, page 18-34
TRAILINGARM . Removal/lnspection,page '18-33 . Installation, page 18-34
1&3
Wheel Alignment
Service Information
NOTE: For proper inspection/adjustment of the wheel alignment, check and adiust the following before checking the alignment. a a a a Check that the suspension is not modified. Check the tire size and tire pressure Check the runout oJ the wheels and tires. balljoints. (Holda wheel with Checkthe suspension your hands and move it up and down and right and left to check for wobbling.)
wheel alignment adjustment procedure

Each of the wheel alignment elements relates to the other, Theretore, the total adjustment of the lront/rea. whenevereitherone of leis wheel alignment required ments (i.e.camber.caster.toe, snd/orturningangle)is adiusted.
Adiust cambet
Adiust caster
Adiust toe
Adiust turning angle
Radjust camber
Read,ustcaster
Roadiusttoe
Readjustturning angle
18 -4
Camber
lnsp6ction
four NOTE: Use commerciallyavailablecomputerized wheel alignmentequipmentto measurewheel alignment (i.e. caster, camber,toe, and/orturning anolel. Follow the equipment manufacturer's instructions. 1. Check the tire pressure. 2. 3. Turn the Jront wheels to the straight ahead position. Check the camber angle. Cambel angle, Front: 0oO0' t 10 10 (2WSl Roar: -Oo45't
Caster
Inspection
NOTE: Use commerciallyavsilablecomputerized ;ommercially four wheel alignmentequipmentto measurewheel alignment ent equipmer (i.e. caster, camber,toe, and/orturning angle).Follow ramber, instructions. rt manufact! the equipment manufacturer's 1. Turn the front wheels to the straight aheadposition. te Check the caster angle. ngl: 20, Caster angl: 2o4O' 1 1" ll adjustment is required, nent r recordthe casterreading, o 4 then go to step 4, lf adjustment is not required, regnmentequipment. move alignment( :aster an NOTE: Caster angle can be adjusted by increasing/decreasingthe numberol the sdjustingshims. lasingth Remove and install the radius rod each time the inst rgle a( caster angle is adjusted. 4. Raisethe front end of the car and placesafety stands en( in the proper locations(see section 1). oper locr Removethe selfiocking nut on the end of the radius the selfi( rod. Remove the radiusrod attachingbolts at the lower radiu n remov{ arm, then removethe radiusrod (page 18-19). Adiust the caster angle by increasing/decreasing the e adjusting shims. I shims. - One adjusting djustingshim changesthe casterangle by 40' and the caster anglecan be adjustedby I o20' d cas maxtmum. - One adjusting s h i m i s 3 . 2 m m ( O . 1 i n l i n 3 thickness.
-oo45' r 30' (4ws)
4.
Front: lf out of specitication.check for damagedsuspensroncomponents. Rear (2wsl: lJ out oJ specification, chck for components. damagedsuspension (4WSl: - lf adiustment is requared, to step go - i no adjustmentis required,remove alignmentequipment. 5.
Rear Camber Adjustment (4WSl

5, Hold the adiustingbolt and loosenthe self-locking nut. Adjust the rear camber by turning the adjusting bolt until camberis co.rect. nut and tighten while Installthe new self-locking holdingthe adjustingbolt.
b.
o.
7.
ADJUSTING SHIM
NUT SELF.LOCKIIIG 12 x 1.25mm Rgplace. 65 N.m 16.5 kg-m, 47 tb-ft}
SELF.LOCKING NUT ! 55 N'm {5.5 kg-m, Replac.
BADIUS ROO
ADJUSThIG BOLT
NOTE: a Do not use more than two adjustingshims. ul a After the adjustment. tighten the self-lockingnur re to the speci{ied torque. sD
18
Wheel Alignment
Front Toe Inspection/Adiustment
four NOTE: Use commerciallyavailablecomputerized to wheelalignment equipment measure wheelalignment {i.e. caster,camber,toe. 8nd/or turning angle),Follow the equipmentmanufacturer'sinstructions. 1. Check the tire pressure. 6. 2. 2WS: Set the tront wheels to the straight ahead posation. 4WS: Set the front main steering angle sensor in the neutral position and jump the service check connector to turn the 4WS indicator ON (see page 1 7 - 15 6 ) . and duringinspection this condition NOTE:Maintain adjustment.
4WS INDICATOR
Loosenthe tie-rod locknutsand turn both tie-rods in the same directionuntil the lront wheels are in straightaheadposition. Turn both tie-rodsequallyuntil the toe is correct. tighten the tie-rod locknuts. After adjusting, NOTE: Repositionthe tie-rod boot if it is twisted or displaced.
TIE-RODLOCKNUT 14 r 1.5 mm 45 lrl'm {4.5 kg-m, 33 lb-ft)
TIE.ROD
Check the lront toe. Front toe: 0 t 2.O mm lO a O'O8in) - lt adjustment is required, go on to step 5. , - lf no adjustment is required. remove alignment equipment.
8-6
RearToe Inspection/Adjustment
NOTE: Use commercially available computerized tour wheel alignmentequipmentto measurewhe6l alignment (i.e. caster,camber,toe, and/or turning angle).Follow instructions. the equipmentmanufacturr's 1. 4WS only: Checkthe rear main steeringanglesensor is in the neutralpositionand jump the service checkconnectorto turn the 4WS indicatorON (see psge17-156). NOTE:Maintainthis conditionduring inspection.
4WS INDICATOR
4.
2WS: a Hold the sdjusting bolt on the rear lower arm B and loosen the self-locking nut. a Adjust the rear toe by turning the adjusting bolt until toe is correct. nut a Install the nw self-locking andtighten while holdingthe adjustingbolt.
4WS: a Loosenthe tie-rod locknuts and turn both tie-rods in the samedirectionuntil the rearwheelsare in the straight ahead position. NOTE: Make sure the 4WS indicatoris ON parkingbrake. Release Check the rear toe. NOTE: with the a Measureditferencein toe measurements wheels pointed st.aight ahead. o lf the parkingbrakeis engaged,you may get an incorrectreading. Reartoeln: 2.O ! 2.O mm (O.08r O.OBin) - lf adjustment is required, go to step 4, - lf no adjustmentis required,removealignment equrpmenr. a Turn both tie-rods equally until the toe is cortect. a After adjusting.tighten the tie-rod locknuts. the NOTE:Rsposition tie-rodboot it it is twisted or disDlaced,
45 N.m (4.5 kg-m, 33 lb-ft|
TIE.ROD
1*7
Wheel Alignment
TurningAngle Inspection/Adjustment
NOTE: Use commercially available computerized four wheel alignmentequipmentto masurewheel alignment (i.e. caster,camber,toa, and/orturning angle).Follow the equipmentmanufacturer'sinstructions. 1, Jack up the tront of the car. Set the turningradius gaugesbeneaththe front wheels. then lower the car. 2, 2WSt Jack up the rearof the car. Placeboardsthat are the same thicknessas the turningradius gaugesunderthe rearwheels,then lower the car. 4WS: Jack up the rear of the car. Set the turning radiusgaugesbeneaththe reat wheels,then lower the car. the NOTE:Foraccuratereadings. car must be level. 3. Turn the wheel right and left while applying the brake. Measure the tutning angle oJ both front wheels, and both rear wheels (4WS models). 4. are It the measurements not within the specifications, adiust as required by turning the tie-rods. NOTE:After adiusting, recheck the front wheel toe the and readiustif necessary.Reposition tie-rod boot it twisted or displscad. TIE-ROD LOCKNUT 1 4 x 1 . 5m m 45 N.m (4.5 kg-m,33lb-ft) llE-ROD
Front turning angl: lnwa.d whsol: 36o20' ! 2o Outward whaol: 29o4O' (roloronca) Raar tuming anglo (4WSlr lnward wheel: 6000' 1 10 Outward whcsl: 6020' (.otoronce)
18-8
Wheel Measurements
Bearing End Play
1. Raisethe car and support it with safety stands in the proper locations(seesection 1,. the lug nuts. Removethe wheels, then reinstall Attach the dial gauge as shown. end play by movingthe disc in the bearing Masure and out.
Runout
1. Raisethe car and support it with safety stands in the proper locations(see section I l. Check tor bnt or deformedwheels. Attach the dial gauge as shown. Measurethe wheel runout by tuming the wheel.
2. 3. 4.
2. 3. 4.
Front and Raar Wheel Axial Runout: Standard: 0- 1 .O mm (O-O.O4 in) St6ol l|haol: AluminumWhool: O-O.7 mm {0-0.03 in} 2.O mm {0.O8 inl Se.vlce Limitr
front wheol End Play: Standard:0-O.O5 mm {O-O.002 inl
Rear Who6l End PlsY: Standard:0-0.05 mm (0-0.002 in)
Front and Rear Wheel Radial Runout: St.ndard; 0-1.0 mm (O-O'O4 inl Stoel Whool: Aluminum Wh.ol: O-O'7 mm (O-O.O3 inl 1.5 mm (0.06 inl Scrvico Limlt:
is lf the bearingend play measurement more than replacethe wheel bearing. the standard,
lf the wheel runout is more than the servicelimn reolacethe wheel.
1&9
Front Suspension
TorqueSpecifications
CAiJ-fN, a Reiface the slf-lockingnuts after rsmoval. nut a Beplacotho solt-lockingbolts it you can aasily thlaad a non-soll-locking past th6ir nylon locking lnsotts. {lt shoub requir 1 N'm (0.1 kg-m. O.7 lb'ft) ot torqus to tuln thc nut on tho bolt}' a The vehtg|es-hould on th groundbeloreany bolts or nuta connoctedto rubbermountsor bushingaro tighten6d. b thon tighton lt only far onoughto aligntho slot with tho dn a Torqueihe castlenut to th low6r torquespocification. holo. Do not align the nut by loosening.
the bloretightening nut at the balljoint. Wipe off the grease NOTE:
INSERT
NUT SELF.LOCKIT{G 1 0 x 1 . 2 5m m 30 N'm (3.0 kg-m,22 lb-ftl Replace.

SELF-LOCKII{G 1{UT 12 r 1.25 ]nm 65 ltl.m 16,5kg-m, 47 tb-ttl Replace.
NUT 1 0 x 1 . 2 5m m 39 N'm 13.9kg-n. 28 lb-tt) NUT CASTLE lO r 1.25mm 4O-48 N'm l4.O-4.8 kg-tn,29-35 lb-ft}
SELF.LOCKII{G NUT 1 0 x 1 . 2 5m m 30 t{.m {3.0 ks-m, 22 lb-ftl

Reolace.
DAMPER NNC'.IEOLT (SELF.LOCKII{G EOLTI 1 0 x 1 . 2 5m m 44 N.m 14.4kg-m,32 lb-ft} SELF.LOCKII{G BOLT 1 2 x 1 . 2 5m m NUT CASTLE 12 , 1,25rnft 50-6{, ]t.m 15.O-6.0 kg-m, 36-43 tb-frl
55 N'm (5.5 kg-m, 40 tb-ftl
SELF-LOCKING t{UT 1 2 r 1 . 2 5m m 55 N.m(5.5kg-m, 40 tb-ft) Replace.
t{ur sPtt{Dt"E
24 x 1.5 mm 25ON'm (25 kg-m, r81 tb-ft| Raplacs. NOTE: Aftsr tightoning, I drift to uso nut stakgths apindlG ahouldsr ag6rnst tho spindle. t{UY DAMPB FORK NUTI {SELF.LOCKII{G 1 2 r 1 . 2 5m m 65 'm (6.5 kg-m,47 lb-ft) Beolace.
NUT CASTLC
BOLT SELF.LOCKI]TG 1 2 x 1 . 2 5m m 105 N.m(10,5 kg-m, 76 lb-ft
NUT SELF-LOCKING '1.25 mm 12 x 55 N'm 15.5kg-m,40 lb-ttl

Replace.
CALIPER BRACKET MOUNTING BOLT 1 2 x 1 . 2 5m m 11ON.m(11 ks-m,80 lb-ft|
14 r 2.o mm 50-60 I{'m{5.0-6.0 ks-m, 36-43 tb-ftt
18-10
Knuckle/Hub
lllustrated lnd6x
NOTE: wheel weights may corrode8nd damsge a Use only genuineHondawheel weights for aluminumwheels.Non-genuine the aluminumwheels. a Before installing the brake disc, cleen the mating surfacas of the front hub and inside ot tbe brake disc. the wheel, clean the mating surfacesof the brake disc and insideof the wheel. a Beforeinstalling
K1{UCKIE Checkfor dam8ge.
PROTECTOR KNUCKLE Ch6cktor damage.

BOLT-WASHER 6 x 1 . Om m 10 N.m (1.Okg-m, 7 lb-ft)
K UCKLE RING Checkfor damag,
COTTER PIl{ Roplace.

WHEEL AEARING Replace. psge 18-15 Replacament, CIRCLIP SPLASH GUARD Check tor bending or damage.
BALLJUNT EOOT Checkfor doteiorstion or damago. CIRCLIP----"""i)
:3J.'ff*.--.......
SCREW 10 'm (1.0 kg-ft, 7lb-fil
HUB FROI{T or Chckfor d6mag6 cracKs.
BRAKEDISC Chsck for w6ar or rust. Inspoction, soction 19
LUG UT
1 2 x 1 . 5m m 1 10 N.m 111 kg-rn, 80 b-trl
I lnm EnAKEDISC SCREW RETAII{ING 10 'm (1.0 ks-m,7 lb-ft|
atl
1&t I
Front Suspension
Knuckle/Hub(cont'd)
Removal
Loosenthe wheel nuts slightly. Raisethe Jrontof car and supporton safety stands in properlocations{seesection 1). Removethe wheel lug nuts and front wheel. 4. Raisethe lockingtab on the spindlenut. then remove the nut. 7. 8. Removethe 6 mm brake disc retainingscrews. Screwtwo 8 x 1 .25 mm bolts into the disc to push it away from the hub. NOTE:Turn each bolt two turns at a time to prevent cockingthe disc excessively. 9 . Removethe b.ake disc from the knuckle.
x 1.25 mm BOLTS
DISC 6 mm SRAKE SCREWS RETAINING
1 0 .Removethe wheel sensorwire bracket,then remove

the wheel sensorfrom the knuckle. Removethe brake hose mounting bolts. NOTE:Do not disconnectthe wheel sensor wire.
6 . Removethe caliperbracket mounting bolts and hang

the csliperassemblyto one side. CAUTION: To provont accidantal damago to the calipr assomblyor brako hos. us a short piece ol wire to hang lhe calipel sgombly from lhe undrcariago.
CAIIPR ARAO(ET MOUNTING BOLTS 12 r 1.25mm
18-12
the balljoints NOTE:Use ballioint remover,to separate or from the suspension steeringarm. CAUTION: B calotul not to damEgothe ball ioint boot' 1 1. Cleanany dirt or greaseotf the ball joint. on to 12. Apply grease the specialtool the areasshown. ot This will esse installation the tool and prevent damageto the pressurebolt threads.
Apply greasehere.
1 6 .Once the tool is in place,turn the sdiustingbolt as

necessaryto make the jaws parallel.Then handtighten the pressurebolt and recheckthe iaws to make sure they are still parallel.
PRESSURE BOLT
BoLT ADJUSTING 13. Removethe cotter pin Jromthe steering arm and remove the nut. 14. lnstalla 12 mm hex nut on the balljoint. Besurethat the hex nut is flush with the balljointpin end to prevent damageto the threadedend of the ball joint. 15. Use the ball ioint removeras shown. Insert the jaws carefully,making sure you do not damagethe ball joint boot. Adjust the iaw spacing by turning the pressurebolt. NOTE:It necessary,apply penetratingtype lub.icant to loosenthe ball joint.
;i
1 7 . With a w.ench, tighten the pressurebolt until the ball joint shaft pops loose from the steeringarm. w6ar eye protsction. The ball ioint l!@ can brsak loose suddenly and scatto. dirt or othgl debris in your oyos. the 1 8 . Remove tool. then removethe nut lrom the end of the ballioint and pullthe balljoint out ol the steerjng/suspension arm. Inspectthe ball ioint boot and replaceit if damaged.
)
12 mm HEX
{cont c
1&13
Front Suspension
(cont'dl Knuckle/Hub
19. Rmove the cotter pin and lowef arm balljoint nut. 20. Install 14 mm hex nut on the balljoint.Be surethat a the hex nut is flush with the ballioint pin end, or the thresded section of the ball joint pin might be damagedby the ball joint remover. 21. Use the balljoint .emoveras shown on page 18-13 to separatethe ball ioint and lower armNOTE:lf necess8ry,apply penetrtingtype lubricant to loosenthe ball ioint. 22. Remove the knuckle protector, 23. Removethe cotter pin and the upper balljoint nut. 24. Installa 1O mm hex nut on the ball joint. Be sure that the hex nut is tlush with the ballioint pin end, or the threadedsectionot the balljoint pin might be damagedby the ball joint.emover. 25. Use the balljoint removeras shown on page 18-13 the ball joint and knuckle. to separate NOTE:lJ necessary,apply penetrstingtype lubricant to loosenthe ball joint.
BA1I JOIITT
oTMAC-StOO200
1.. \
r',
10 mm HEx NUT
BAI.I JOINT REMOVER, mm 32 07MAC-SLOOTO0
CASTLE 10 x 1.25 ]nln
COTTER PII{ Rplace,
26. Pulltheknuckleoutwa,d and removethe driveshaft

joint Jromthe knuckleusinga plastichamoutboard mer. then removethe knuckle.
KNUCKLE
18-14
Hub Unit and Wheel BearingReplacement

the NOTE:Replace bearingwith a new one after removal. 27. Separatethe hub from the knuckleusing the special tools and a press.
29. Remove the circlip and tho splash guErd from tho knuckle.
cAuT|O:
a Take cars not to distort th6 splash guard, a Hold onlo the hub to k6ep it trom talling whon pressod clear.
30. Pressthe wheel bearingout ofthe knuckls using tn special tools and a Press. HUBDIS/ASSEMBLY TOOL oTGAF-SE00tOO 28. Removethe knucklering trom the knuckle. ORIVEB 07749-OOIOOOO
KNUCTLE
ho!t
ATTACHME'{T. 82 x 88 mtt
07744-(xr1oBm
@
BASE HUBDIS/ASSEMBLY 07GAF-SD/()7OO
(cont'dl
18-15
Front Suspension
Knuckle/Hub {cont'dl
31. Pressthe wheelbearinginnerracef rom the hub using the specialtools and a commercially available bea.ingseparalor. NOTE: Wash the knuckle and hub thoroughly in high tlash-point solvent bfore reassembly. 32. Pressa new wheel besringinto the hub using the specialtools shown and a press, HU8 DIS/ASSEMELY TOOL 07GAF-SEOOIOO
BEARII{G SEPARATOR INNERBACE
praaa
DRNE'
ATTACHMET{T oTHAD-SGOO100
WHEEL BEARII{G
BASE SUPPORT 07965-SD90100 33. Install the circlip securly in th knuckle groove. 34. Install the splash guard and tighten the screws.
18-16
3 5 . Installthehub on the knuckleusingthe specialtools

shown and a Dress. CAUTION:Tak car6 not lo diston tho splarh guard. HUBASSEMBLY GUIDEATTACHMENT 07cAF-SEOO200
lnstallation
CAUTIOIII: a B csrotul not to damage ths ball irint boot. a Torquo tho castlo nut to th lowor torquo specitication, thon tlghton it only lar enough lo align the slot with tho pin holo, Do not allgn the nut bY loo8cning37. Installthe knuckleon the driveshaft. 38. Installtheknuckleon the lower arm and the tie-rod, then tightsn the castle nuts and install new cotter Dtns.
COTTER PII{ On reassembly, bond the cofte. pin
BASE
36, lnstallthe knucklering on the knuckle.
I{UT CASTLE 1 2 t 1 . 2 5m m 50-60 N'm {5.o-6.o ks-m, 36 - 43 tb-frl CASTLENUT 14 x 2.0 mm 50-60 N'm (5.0-6.0 kg-m,36-43 lb-ft| 39. Installthe knuckleon the upper arm, then tighten the castle nut and install a new cotter pln. 40. lnstall the knuckle protector with the 6 mm bolt.
RING KNUCKLE
@
K UCI(LE PNOTECTON
COTTENPIN On reassembly. bgnd the cotter pin
10 N.m (1.Okg-m' 7lb'frl CASTLENUT 10 x 1.25mm
(cont'd)
rlo-rt8 N'm (4.0-4.8 kgn, 29-35 lb-ft)
18-17
Front Suspension
Knuckle/Hub (cont'd)
41. Installthe wheel sensorwith the sensormounting bolts. NOTE:8e careful when installingthe sensorsto avoid lwisting wires. 44. Install the brake caliper with the calipel bracket mounting bolts. 45. Install the brakehose with the brakehosemounting bolts. BRAKE HOSE BOLTS MOUNTING lo N'm (t.o kg-m,7 lb-ft1
42. lnstall the sensorwire with the two bolts.

10 N.m (1.O SENSORMOUNTING BOLTS 22 N.Jn 12.2 ks-m, 16 lb-ft)
7 tb-fr)
'l '10N.m (11 kg-m.80 lb-ftl 46. Tightenthe new spindlenut.

WHEEL SENSOR
NOT:Betoreinstalling wheel,cleanthe mating the surlace of the brake disc and inside ot the wheel. 47. Installthe wheel with the wheel lug nuts.
43. lnstallthe brakedisc with the 6 mm brakedisc retaining screws.
WHEEL LUG NUT 12 x 1.5 mm t10.in {11 kg-m. 80 lb-fr}
6 mm BRAKE DISC RETAII{II{G SCREWS 10 N.mll.0 kg-m,7 tb-fr)
24 x 1.5 mm 250 'm {25 kg-m, 181 lb'ftl NOTE: After tightening, use a drift to stake sDindlenut shoulder againstthe spindle.
44. Check the front wheel alignment and adjust if necessary (see page 18-41.
8 -18
Arms Suspension
Removal/lnspection GAUTION: nuts aftor removal. a Roplace salt-locking tho nut bolts it you can oasilythiead a non-selt-locking past thoir nylon lockingins6n8. a Rplaco salf-locking the (lt shouldrquire1 N'm (0.1 kg-m, O.7 lb-ft) of to.qus to turn lho nut on th bolt). the a Bo carfulnot to damage ballioint boots.
SELF.LOCKING NUT 12 x 1.25mm Replace. ARM ASSEMBLY UPPER Checkfor bendingor damage. NOTE:Do not disassemble.
BALLJOINTBOOT Checklor detorioration or damage.

BOLT SELF-LOCKING 12 x '1.25 rn''rjf
STABIUZER BAR Checkfor bending or damage.

RADIUS ROD WASHERS NUT SELF-LOCKING 12 x 1.25mm Replace. STABILIZERLINK RUBBER BUSHING Check Ior delerioration or damage. LOWERARM Checktor damage. OAMPERPINCH BOLT BOLT) ISELF.LOCKING t0 x 1.25mm NUT SELF.LOCKING 12 x 1.25mm Replace. DAMPERFORK NUT NUTI {SELF-LOCKING 12 x 1.25 rnm Replace.
RADIUS ROD
DAMPERFORK CheckIor damage. NUT SELF-LOCKING 8 x '1.25mm Replace. ADJUSTING SHIM
NOTE:Adjustthe casterangleby increasing/decreasing the adjustingshims (seepage 18-4).

'aqa a
1&19
Front Suspension
Arms {cont'd) Suspension
Installation
CAUTION: Th6 vehicle should bs on th glound bstoro any bolts or nuts connctd to rubbol mounts or bushing are tightened. NOTE: a Wipe off the greasebefore tighteningthe nut at the ball joint. a The right and left dampertorks 8re not symmetrical. The left damperfork is markedwith "SL" while the right damper "SR". Do not inte.change tork is markedwith them. a The right and left upper arms are not symmetrical, The left upper arm is markedwith "SL" while the right arm is "SR". Do not interchange markedwith them. a AJter installing the suspension arm. check the wheel alignmentand adjust it necessary. a When installing the radius rod washers,the "FR" mark faces the front of the car.
SELF"LOCKING NUT '12 x 1.25 mm 65 N'm (6.5 kg-m, 47 lb-ft)
UPPER ARM ASSEMBLY SELF.LOCKING BOLT 1 2 x 1 . 2 5m m 55 N.m (5.5 kg-m, /rc lb-fr)
SELF-LOCI(ING NUT 12 x 1.25mm 55 N.m (5.5 ks-m,40 tb-ft) STABILIZEBBAR BOLT I x 1.25mm 22 N.m 12.2 kg-m, l6 lb-ftl SELF-LOCKIG NUT 12 x 1.25 fi.n 55 .m (5.5 kg-m, tlo lb-ft) RUBAER RUBBER AUSHING .@]
stLrcoNE
GREASE
stLtcoNE
GREASE
BOLT SELF-TOCKING 12 x 1.25mm 105 N'm {10.5kg'm, 76 rb-ftl
DAMPER PINCH BOLT BOLTI ISELF.LOCKING 10 x 1.25mm tt4 N.m (4.4 kg-m, 32 lb-ftl DAMPER FORKNUT (SELF-LOCKING NUT) 12 x 1.25mm 65 N.m {6.5 ks-m, 47 lb-ft} DAMPERFORK SELF-LOCKING NUT 8 x 1.25mm 18 N'm {1.8 kg-m, 13lb-ftl Align the marKs.
FRONT:GD,
CAUTIOII: Do not interchange the radius lod rubbor bushings.
1a-20
Ball Joint Boot Replacement

'1.
Lower Arm BushingReplacement

Adjust the bushingdriverso that it matchesthe outside dimension the lower arm bushing, of Press lowerarm the bushingusing the specialtool and a press. NOTE:When installing the lower arm bushing,press it so that its leadingedges are llush with the lower arm.
Removethe set ring and the boot. CAUTION: Do not contaminate the boot installation section with gf6as6. Pack the interiorof the boot and lip with grease.
BALL PIN TAPEREDSECTION
SOCKETBOL
'l
BOOT INSTALLATIONSECTION
BOOT INSTALLATION SECTION
Wipe the greaseoff the slidingsurfaceof the ball pin and pack with fresh grease. CAUTION: a Koep gloase oll the boot installation sction and tho tapored soction of tho ball pin. a Do not allow dust. dirt, or othor toreign mata.ials to enter tho boot. 4. Installtheboot in the grooveot the boot installation section securely,then bleed air. Installthe upperand lower balljointboot clipsusing the specialtools as follows: tool with the adLower balljoint: Adjust the special iusting bolt until the end ol the tool alignswith the grooveon the boot. Slidethe set ring over the tool and into position. Upper ball joint: Hold the tool over the ball joint, then slidethe clip over the tool and into position.
BALL JOINT BOOT CLIP GUIDE ADJUSTING BOLT Adjust the depth by turning the bolt. ARM BUSHING
<+
UPPER BALL JOINTBOOT: o7974-SA50aOO LOWER BALL JOINTBOOT: OTGAG-SO/rO7O0 40 mm CIRCLIP CAUTION: Afler installing tho boot, chock the ball gin tapeld sction tol greas contaminalion and wipo it if necossary,
6ET RING
1&21
Front Damper
Removal
1 . Removethe brake hose mounting bolts from the oamper.
Disassembly/lnsPection
Disassembly
1. compressthe damperspring with the spring compressoraccordingto the manufacturer'sinstructions, nut. then removethe self-locking CAUTION: Do not compress th spling more than necessary to remove tho nut.
2 . Removethe damper pinch bolt.

Removethe damperfork nut, bolt and removethe damperfork. BRAKE HOSE MOUI{TING BOLT (8x 16
PINCH BOLT OAMPER BOLT) ISELF-LOCKING
NUT SELF-LOCKING 1 0 x 1 . 2 5m m Replace.
BRAKE HOSE MOUNTING BOLT (8 x 20 mml
STRUT SPRING COMPRESSOR: Cornmordally Avallablo BRANICKO T/N MST-sAOA o. oouivalont
FORK DAMPER
2.
the Removethe springcompressorthen disassemble damperas shown on the next page.
Inspection
DAMPERFORK NUT NUTI {SELF-LOCKING Replac6. DAMPEn
1. 2. 3.
Reassemble parts. except the spring. all Push on the damperassemblvu" "hi-n. Check for smooth operationthrough a full stroke. both compression and extension. NOTE:The dampershould move smoothly. lf it does not (no compression no extension),the gas is leakor ing. and the damper should be replaced.
4.
Removethe damperby removingthe three nuts. NUTS

1 0 x 1 . 2 5m m
4.
noisesor bindingdurCheckfor oil leaks,abnormal ing these tests. NOTE:See page 18-41 for damperdisposal.
8-22
Inspection
SELF.L(rcKING ]{UT 1 0 x 1 . 2 5m m 30 N'm (3.0 kg-m,22 lb-ft| ReDlacs.
DAMPER MOUNTING WASHER Checkfor wgakness. DAMPER MOUNTII{G RUBEEB DAMPER MOUNTING COLLAR
\ , /
@z
a@\,/
*{
DAMPER MOUNTI'{G
Rueeei (92'
BUMP STOP PLATE BUMP STOP Check tor weakness o, ,/ ,/
damage.
_\
-.-..t.@@
vH
SPRINGMOUNTING BUBBER Check for damag.
\J
DUSTCOVERPLATE
-----@
l l Y
l l
OUSTCOVER Checkfor bending damage. or
OAMPERUNIT . Check tor leaks and faulty operation. . Check tor rust.
1a-23
Front Damper
Reassembly
Installthe damper unit on a spring compressor. instructions. NOTE:Follow the manufacturer's in orderof disassemAssemble damDer reverse the bly except the dampermounting washer and selflocking nut. NOTE: Align the bottom of the dsmperspringwith the spring lower seat as shown, Positionthe dampermountingbase on the damper unit as shown.
SELF.LOCKING NUT 10 x 1.25mm 30 N.m 13.0 kg-m, 22lb-l1l
4.
the damperspringwith the spring comCompress Dressor. CAUTlOltl: Do nol comptess tho spring more than necosaary to install lhe nut. inInstallthedampermountingwasher.then loosely stall the new seltlocking nut.
6.
Hold the damper shatt and tighten the new selflockingnut.
<LEFT:>
STUDBOLT
STRUT SPRII{GCOMPRESSOR: CommorciollyAvail.blo T/N MST-sAOA BRANICKO
SPRINGLOWERSEAT
18-24
Installation
1 . Loosely install ths damper on thg trame with the sligningtab tacing inside.
2 . Installthe damperfork over the driveshaftand onto

the lower arm. Installthedamperin the damperfork so the aligningtab is alignedwith the slot in the dampertork.
a
NUT 1 0 x 1 . 2 5m m 39 N.m 13.9kg-n, 28 lb-ftl
Hand-tighten the bolts and nuts. Raise the knucklewith a tloor jack until the car just litls otJ the salety stand. NOTE:The bolts and nuts shouldbe tightenedwith the vehicle'sweight on the damper.
4.
5 . Tightenthe damperpinch bolt.

Secure the dampertork bolt with I new selflocking nut. to Securethe damperassembly the frame with the flange nuts. 8. lnstall the brske hose mounting bolts.
BRAKE HOSE MOUNTII{G EOLT {8 x 16 rml 22 N.m 12.2kg-m. 16 lb-ft)
BRAKE HOSE MOUNTING BOLT (8 x 20 mm) 22 N.m 16 tb-frt 12.2
DAMPER BOLT (SELF-LOCKING BOLT) 10 x 1.25mm 44 N.m (4,4 kg-m, 32 rb-ftt
DAMPER FOBK AOLT DAMPERFORK NUT NUT} {SELF-LOCKING 12 x 1.25mm 65 N'm (6.5 kg-m, 47 lb-ft)
18-25
RearSuspension
Torque Specifications
CAUTIOIT: a R.C.cr tho 3olt-locking nuts aftor removal. a RaDLc. tho rett-locklng bohs It you can easily throad a non-salf-locking nut past thair nylon locklng in3.rls. {h.houH r.quko 1 N'm (0.'l kg-m, 0.7 lb-ft) of torque to tuln tho nut on tho bolt}' a lta vhlcla should bo on th6 ground botore any bolts or nuts connoctedto rubbor mounls or bushings 8re tightenod, a Torquc th! casdo nut to tha lower torquo epoqlllcatlon, then tight6n lt only far enough to align tho llot wfth the dn hole. Do not allgn thc nut by loosoning. NOTE:Wipe off th greasebetore tighteningthe nut at the ball joint.
SEIF.LOCKINGNUT 10 r 1.25mm 30 N.m l3.O kg-m, 22 lb-frl Rgolace.
NUT 1 0 x 1 . 2 5m m 39 N'm {3.9 ks-m. 28 lb-ft)
SELF.LOCKING NUT 12 x 1.25mm OE .m 16.5 kg-m, 47 lb-ft| Roploce. CASTLEttIUT 1 0 x 1 . 2 5m m 40-48 N.m {4.0-4.8 29-35 tb-ft|
kg-m,
BOLT 8 x 1,25 lnm 22 N.m {2.2 kg-m. 16 tb-ft)
l '
l NUT sELF-LocKtt{c
45 N.m (4.5 ks-m, 33 lb-ft) Replace. /
10 x 1.25mm
]{UT SELF.LOCKII{G 1 2 x 1 . 2 6m m 65 t{.m (5.5 kg-m,40 lb-ftl Rgoloce.
CASTLENUT 12 x 1.25mm 50-60 tl.m 15.0-6.0 ks-rn, 36-43 tb-ftl
fIUT SPI]TDLE 22 x 1.5 fim 185 N.m {18.5 kgn, 134 lb-tt} Replac6. NOTE: After tightoning, use I drift to stske the spindlo nut shouldor against the spindle. CASTLE NUT 14 x 2.0 mm 50-60 N.m {5.0-6.0 ke-m, 36-43 tb-ft| BOLT SELF.LOCKING 12 x 1.25 mrn CALIPERBRACKETMOUNTII{G BOLT 65 N.m 16.5 kg-m, 47 lb-ftl 12 x '1.25lrxn 39 N'm (3.9 ks-m, 28 lb-ftl
18-26
Knuckle/Hub
lllustrated lndex NOTE:
a Use only genuineHondawheel weightsfor aluminumwheels. Non-genuine wheel weights may corrode8nd dsmsge the aluminumwheels. a Beforeinstalling the brake disc, cleanthe mating surfacesot the rear hub and insideof the brakedisc. a Beforeinstalling the wheel, cleanthe mating surtacesof the brake disc and insideof the wheel.
BOLT SELF-LOCKING 10 x 1.25mm 44 N.m 14.4 kg-m, 32 lb-tll
COTTERPIN Replace.
\--q,
PROTECTOR KNUCKLE Ch6ckfor damago. BOLT 6 x 1 . 0m m

10 N.m ll.O kg-m, 7 lb-frl
b
REAR SPINDLEASSEMBLY Check for damage.
SPLASHGUARD Checkfor bending or damago. 10 N'm l1.O kg-m, 7 lb-ft)
sREARWHEEL HUB UNIT Check for cracking or damags.
\ COTTERPIN Replace.
WASHER SPINDI..E
tan^l
BRAKE OISC Check for wear or rust. Inspection, section 19 6 mm BRAKEDISC RETAININGSCREWS 10 N.m (1.0 kg-m, 7lb-ft|
ae
WHEELLUG NUT 12 x 1,5 mm 110 N'm 111 kg-m,80 lb-frl (cont'dl
18-27
RearSuspension
(cont'dl Knuckle/Hub
Removal
1. Loosenthe wheel nuts slightly. 2. Raisethe rearof car and support it with safety stands in properlocations(seesectjon 1). Bemovethe wheel lug nuts and rear wheel.
8 . Removethe 6 mm brake disc retainingscrews 9 . Screw two 8 x 1.25 mm bolts into the disc to push
it away from the hub. NOTE:Turn each bolt two turns at time to prevent cocking the disc excessively.
3. 4. 5.
1 0 .Removethe brake disc.

Pull the parking brake lever up. Removethe hub cap, then raisethe lockingtab on the spindlenut, then removethe nut. HUBCAP Replace.
NOTE| Take care not to damagethe hub
I x 1.25 mm BOLTS
BRAKEOISC
6 mm ERAKE 5 MM EBAKE DISC SCREWS S RETAINIT{G
1 1. Remove the hub unit from the knuckle,
o.
Removethe brake hose mounting bolts. boltsand hang Remove caliper the bracketmounting the caliperassemblyto one side. CAUTION: To prevent accidental damage to the caliper assemblyor brake hoss, use a shon pisce ot wir to hang th calipr as$mbly lrom th6 und6.cardag6. BRAKE HOUSE MOUNTING BOLT
7.
TRAILINGARM
CALIPER ASSEMBLY CAUPERARACKETMOUNTING BOLT
18-28
12. Removethe splssh guard from the knuckle.
1 5. Removethe rear spindleassemblyfrom the knuckle.

SELF-LOCKING NUT 10 x 1.25mm Replace.
ASSEMBLY 13. Removethe parkingbrakecabletrom the knuckle. 14. Removethe wheel sensorwire bracket.then remove the wheel sensorfrom the knuckle. NOTE:Do not disconnectthe wheel sensorwire. WHEEL SENSOR
1 6 .Hold the ball pin of the stabilizertink with a hex

wfench and loosenthe self-locking nut. Removethe selflocking nut, then disconnectthe slabilizerlink from the stabilizer bar.
PARKINGBRAKE CABLE
1 2 r 1 . 2 5m m Replace.
{cont'd)
18-29
l'-
Rear Suspension
Knuckle/Hub {cont'd)
18. Remove the cotter pin from the tie-rod end (4WS) or lower arm B (2WS) 8nd removethe castle nut. 19. lnstalla 12 mm hex nut on the ballioint. Besurethat the hex nut is flush with the balljointpin end. or the threaded section of the bsll joint pin might be damagedby the ball joint remover. 20. Usethe balljoint removeras shown on page | 8-13 to separate the ball ioint and knuckle. NOTE:lf necessary,apply penetratingtype lubricant to loosenthe ball joint.
COTTERPIN Replace.
24. Removethe knuckleProtector. 25. Removethe cotter pin and the upperbsll joint nut.
26. lnstall a 1O mm hex nut on the ball joint. Be sure that the hex nut is flush with the bsll ioint Dinend, or the threadedsectionot the balljoint pin might be damagedby the ball joint removar. 27. Usethe balljoint remove.as shown on page 18-13 the balljoint and knuckle,then remove to separate the knuckle. NOTE:lf necessary,apply penetratingtype lubricant to loosenthe ball joint, BALLJ()|NT 28 REMOVER. mm oTMAC-SLOO200
BALL JOINT REMOVER,28 mm oTMAC-SLOO200
the cotter pin and lower arm balljoint nut. 21 . Remove a 22. Install 14 mm hex nut on the balljoint.Be sutethat the hex nut is flush with the balljoint pin end, or the threaded section of the ball joint pin might be damagedby the ball joint remover. 23. Usethe balljoint removeras shown on page 18-13 the ball joint and lower arm. to separate NOTE:lf necessary,apply penetratingtype lubricant to loosenthe ball joint.
Rplace.
K UCKLEPROTECTOR
,a,-,",
mm HEX NUT
NUT CASTI.E 14 x 2.0 mm EALLJOINT 32 REmOVER, mm
-slooro0 oTmac
18-30
lnstallation
28. Connectthe lowe. arm, lower arm B (2WSl or tierod end (4WS) 8nd upper arm with the knuckle, then tighten the castle nuts, 29. Installthe naw cotter oins. 30. Installthe knuckleDrotectorwith the bolt. 31. Connect the knuckle and the stabilizerbar, then tighten the new selflocking nut. NUT CASTLE 1 0 x 1 . 2 5m m 40-/t8 N.m 14.0-4.8 kg-ir, 29 - 35 tb-tr)
33. Installthe whel sensor, wheel sensor wire bracket and parkingbrake cable on the knuckle. NOTE:Be careful when installingthe sensorto avoid twisting the wire.
22 .m {2.2 kg-m, 16lb-ftl
COTTER PIT{ On roa$ombly, bondth cottr pin
I{UT SELF.LOCKING 1 2 x 1 . 2 5m m
55
22 N.m 12.2kg-m, 16 lb-ft)
.m 15.5 ks-m,40 lb-ttl
CASTLEITUT 14 x 2.0 mm 50-60 N.m(5.0-6.0 kg-m, 36-43 tb-ft|

COTTERPIN CASTLE NUT 1 2 x 1 . 2 5m m
34. Installthe splashguard with the bolts.
50-60 .m (5.0_6.0 kg.h, 36_43 tb-ttt 32. Installthe rearspindleassemblyon the knuckle,then tighten the new self-locking nuts. SEI.F.LOq(NG IIUTS lO r 1.25mm 45 N.m (4.5 kg{n, 33 lb-ftl
10 N.m(1.0 kg{, 7 |tsft}
18-31
RearSuspension
Knuckle/Hub (cont'dl
35. Install the hub unit and spindle washer on the knuckle. with the caliperbracket 37. Installthe caliperassembly mounting bolts. 38. Installthebfakehosewith the brakohosemounting bolts, BOLT HOSE MOUI{TING BRAI(E 16 tb-ft| 22 N.m 12.2
ASSEMBLY CALIPER
BOLTS MOUNTII{G 39 N'm 13.9kg-m,2a lb-ft)

SPi DLE WASHER
39. Installthe new spindlenut, then tighten the nut' 40. Installthe new hub cap.
ito.
lnstallthe brakedisc with the 6 mm brakedisc retaining screws.
41. Installthe rear wheel with the wheel lug nuts. the instslling wheel,cleanthe mating NOTE:BeJore surfaceof the brakedisc and insideo{ the wheel.
REANWHEEL
SPI DLE ]{UT 22 x 1.5 mm 185 N,m (18.5 kg-m. 134 lb-ft| NOTE: After tightening, uss a drift to stake the spindle nut shouldgr against
the spindl6.
LUGNUT WHEEL 1 1 0N . m (l I kg-rn,80 lb-ft}
6 mm BRAKE DISC RETAII{INGSCNEWS 10 N.m (l.o kg-m, 7 lb-ft|
and adjustif neces42. Checktherearwheelalignment sary (seepage 18-4).
18-32
SuspensionArms
Removal/lnspection
GAUTION: a Rplacetho selllocking nuts afte.;emoval. a Roplacethe self-locking bolts it you can oasily thread a non-solt-locking nut past thoir nylon locking insons, (lt should roquire 1 N.m (O.1 kg-m, O.7 lb-ft) of torque to turn the nul on tho bolt). a B caroful not to damage the balljoint boots.
NUT SELF.LOCKING 12 x 1.25mm Replace.
UPPER ARM ASSEMBLY Check bending damage. lor or NOTE: not disassemble. Do
SELF-LOCKING NUT 10 x 'l.25 mm Replace. l2wS only) SELF.LOCKING NUT 12 x 1.25mm Roplace. {4wS only)
bo
SELF.LOCKING BOLT 14 x 1.5 mm (2wS only)
SELF-LOCKIf{G 12 x 1.25mm Replace.
STAAILEER BUSHII{G Check lor deterioration or damag6. LOWERARM B Check tor bnding or damage. (2WS only)
,aar-ao"*,no "oa\
""\;\^.J
RUBBER BUSHING Checktor deterioration or damage.

BOLT SELF-LOCKING 12 x 1.25mm
TRAILINGARM BUSHING Check for deterioration or damage.
{cont'd)
18-33
Rear Suspension
SuspensionArms (cont'dl
Installation
CAUTION: Tho vohiclo ehould be on the ground bofor any bolts or nuts connectod to rubb3r mounls or bu3hlng arc tlghtcnod. NOTE; a Wipe ofJ the grease before tightening the nut at the ball joint. by a The right lower arm B is identiJied white paint. "L" while the right 8rm is markod a The right and left upper arms are not symmetrical. The left upper arm is marked with "R". Do not interchange them. with a After installing the suspension arm, check the wheel alignment and adiust if necesssry.
NUT SELF.LOCKING 12 x 1.25mm 65 N.|n (6.5 ks-m, 47 lb-ft1
-\
_rrat
ARM ASSEMBLY UPPER
T{UT SELF.LOCKING 10 x 1.25mm 55 N.m 15.5 kg-m, 4{' tb'ft| (2WS onlyl
NUT SELF-LOCKIT{G 12 x 1.25mm 65 N.m (6.5 kg-m, 47 lb-ft| (4wS only)
BOLT
10 x 1.25 rn.n 44 .m {4.4 kg-rn, 32 lb-ftl
BOLT SELF-LOCKING 14 x 1.5 mm
85 N'.n 18.5ks-m, 61 lb-ft) (2WSonlyl BOLT 8 r 1.25mm 22 N.m 12.2kg-m, 16 lb-ft|

I
22 N.m 12.2kg-m, 16 tb-ft}
NUT SELF-LOCKING 12 x 1.25 tnm 55 N'm {5.5 kg-m. /to lb-ft)
ARM B LOWER
onlyl
LOWER ARM
BOLT SELF-LOCKING 12 x 1.25mm 65 i.in 16.5 kg-m, 47 lb-ft} ARM TRAILIT{G
BOLT SELF-LOCKI]TG 1 2 | 1 . 2 5m m 65 N.m 16.5kg-m,47 lb-ftl
18-34
Ball Joint Boot Replacement

Removethe set ring and the boot. CAUTION: Do not contaminate ths boot installation soctlon with giease. Pack the interiorof the boot and lip with grease.
BALL PIN TAPEREDSECTION
Lower Arm Bushing Replacement

Adjust lhe bushing driver so that it matches the outside dimensionof the lower arm bushing.Pressthe lower arm bushingusing the specialtool and a press. NOTE:When instsllingthe lower arm bushing,press it so that its leadingedges are tlush with the lower arm.
BOOT INSTALLATIOI{SECTION
Pr9!a
BUSHITIG DRIVER o7t{AD-SSq)lOO
BOOTINSTALLATIOT{ SECTION 3. Wipe the greaseotf the slidingsurfaceof the ball pin and pack with tresh grease.
a Keep g.oas off the boot inatallationssction and ths tapered soction of tho ball pin. a Oo not allow dust, dirt, or other foroign mat6dals to ontJ the boot. 4. Installthe boot in the grooveof the boot installation section securely.then bleed air. Install the upperand lower balljointboot clipsusing the sDecial tools as Jollows: Lower balljoint:Adjust the specialtool with the adjusting bolt until the end of the tool alignswith the grooveon the boot. Slidethe set ring over the tool and into position. Upper ball ,oint: Hold the tool over the ball joint. then slidethe clip over the tool and into position.
BALL JOINT BOOT CLIP GUIDE AOJUSTII{G BOLT Adjust the depth bV turning the bolt.
5.
BALL UPPER JOINTBOOT: 07974-SA50800 BALL LOWER JOINTBOOT: 07GAG-SD/rO700 40 mm CIRCLIP CAUTION: Attor installing the boot, chck tho ball pin tapered soction tor greaso contaminatlon and wipe it it nscossary.
SET RING
18-3s
Rear Damper
Removal
1 . Jack up the rear of car and support on satety stands in properlocationslsee section 1). Remove the rear wheel.
t
9 . Remove the damper mounting bolt. 1 0 . Lower th8 raar suspnsionand remov the dampgr
assemblv.
Removethe trunk side trim. Removethe two nuts, NUTS 10 x 1.25rfn
4.
Removethe knuckleprotector. 6. 7. Remove the cotter pin and the upper ball ioint nut. lnstalla 1O mm hex nut on the ball ioint. Be sure that the hex nut is flush with the ball joint Dinend, or the threadedsectionof the ballioint pin might be damaged by the ball joint remover.
8 . Usethe balljoint .emoveras shown on page 18-13

to separatethe ball joint 8nd knuckle. NOTE:lf necessary,apply psnetratingtype lubricant 1o loosenthe ball joint.
MOU TINGBOLY (SELF.LOCKIl{G BOLT) 1 2x t . 2 6 m m
10 mm HX
UT
BALL JOINT BEMOVER,28 mm oTMAC-SLOO200
PROTECTOR KNUCKLE l{UT CASTLE 1 0 x 1 . 2 5m m
PIIT COTTEB Replaco.
BOLT 6x t.Omm
18 -3 6 'b'--
Disassembly
1 . Compress th damper spring with the spring compressoraccordingto the manufacturer'sinstructions, CAUTIO : Do not compr.rs th6 sprlDg mora than noceaaaryto ramovo tho sclt-locking nut.
Inspection
Reassembleall parts, except the spring. Push on the damper assemblyas shown.
J.
Check for smooth operation through a full stroke. both comoression and extension. NOTE:The damper should move smoothly. lf it does not (no compression no extensionl,the gas is leakor in9, and the dampershould be replaced.
Remove the selflocking nut trom the damper assmbly,
STRUT SPRINGCOMPfiESSOR: Commo.d.lly Av.illbl. BRANICKOT/t{ MST.5g)A or oquivrlant
3.
Remove the spring compressor and disassembly the damper as shown on the next page.
4.
noisesor bindingdurCheckfor oil leaks.abnormal ing these tests. NOTE:See page 18-41 for damperdisposal.
(cont'dl
18-37
RearDamper
Inspection (cont'd)
NUT SELF-LOCKING 10 x 1.25mm Reolace. 30 N.m (3.0 kg-m, 22 lb-ft|
DAMPER MOUTTTTNG ^r' WASHER -_ --.f.:, g Ch6cktor

woakness. \Y
./
DAMPER MOUT{TING RUBBER DAMPER MOUI'IN G BASE DAMPCRSPRII{G Check for weakened compresspnor oamage.
iUBBER
DAMPER MOUl{TrirG
F
ll l*----.-
t---^6
\r'
ooio" "ornr,ro
--
PLATE BUMPSTOP
w
,ffi,
t ',/
SPf,INGMOUNTING RUBBER Check lor damago or cracKs.
*r'
DUSTCOVERPLATE
DUSTCOVER Chocklor bending or damage.
DUSTCOVER AOOT Ch6ckfor detorioration or damage.
DAMPER UITIT . Check tor leaks and faulty operation. . Check tor rust.
18-3 8
Reassembly
1 . Install th dampel unit on 8 spring compressor. NOTE: Follow the manutacturer's instructions. AssemHe the damper in revsrse order of disassembly except the damper mounting washr and sel{locking nut. NOTE:Align the bottom ot the damperspringwith th6 spring lower seat as shown,
a
w
4. Compress the damper spring with the spring compressor. GAUTION: Do not compross ihe spring more than necesaary to Install tho nut. Installthe dampermounting washer, then loosely install the new selflocking nut.
6 . Hold the dampershaft and tighten the self-locking

nut.
Position the damper mounting base on the dsmpr unit as shown. SELF-LOCKII{G lrluT 1 0 x 1 , 2 5m m 30 tl.m l3.Oks-m, 22 ltFftl OAMPM WELDED UT WASHER
<LEFT:>
<RIGHT: >
STRUT SPRII{G COMPRESSOR: Commrrd.lly Avdllbl. BRAt{lCKo T/1{MST-580A
SPfiING LOWERSEAT
18-39
Rear Damper
Installation I
1 . Lower the rear suspension and set the damperas, semblv. 4. Connectthe upper arm and knuckle,then tighten the castle nut. Installthe knuckleprotectorwith the bolt.
2 . Connectthe damperassemblyand the lowe. arm,

then looselyinstallthe dampermounting bolt. NOTE:The damp. mountingbolt should be tightened with the damDerunder vehicleload.
5.
KNUCKLE PROTECTOR
COTTERPIN On reassembly, bend the cotter pin
..:-.'l"t'
DAMPER MOUNTING BOLT (SEI"F-LOCKING BOt TI 1 2 r 1 . 2 5m m
- { 4
I
CASTLE NUT 1 2 x 1 . 2 5m m 40-48 N'm {4.O-4.8 kg-m, 29 - 35 rb-frl COTTERPIN l0 . m { 1 . Ok g - m , 7 l b - f t l
WELDED NUT Tightenthe two nuts.
Raisethe rearsuspension with a tloor jack until the weight ot the car is on the dampe,. 7 . Tightenthe dampermounting bolt
NUTS l O x 1 . 2 5m m 39 N'm (3.9 kg-m,2a lb-trl
DAMPEB MOU]IINNG AOLT {SELF.LOCKING
BOr-Tl
12 x 1.25mm 65 N.m 16.5 kg-m, 47 tb-ftl
8.
Checkthe rearwheelalignment and adjustif necessary (seepage 18-4).
18-40
Damper Disposal
a Ths dampors contain nitrogn gas and oil under p(3sur6. Tha prossur6must b6 roliovod boforo disposal to provent explosion and possible hiuly whon scrapping. a Always wear oye protsction to avoid getting motal shavings in your eyes whon the gas dampel prssuro is rolieved. Placethe damperon a levelsur{acewith its rod extende d a n d d r i l la h o l eo t 2 . 0 - 3 . 0 m m { 0 . O 8 - 0 . 1 2 i n l d i ameter in the body to release the gas.
( Front Damper:>
Drill here.
( Rear Damper:>
Drill here.
18-41
Brakes
Conventional Brakes...... 19-1 A n t i - L o c k r a k e y s t e m( A B S I . . . . . . . . . . . 9 - 3 1 B S 1
ConventionalBrakes
.......... 19-2 Toofs Speciaf l l l u s t r a t eId d e x . . . . . . . . . . . . . . . . . . . . . , . .19.-. 3 n .. PedalHeight ......... 19-4 Adjustment ParkingBrake ......... 19-5 Adjustment Flont Brakes T o r q u e / l n s p e c t i . . n. . , . . . . . . . . . . . . .1. . - 6 o. .9 Front Brake Pads ..............19-7 Inspection/Replacement Front Caliper ....... 19-9 Disassembly . . . . . . . .1 9 - 1 0 Reassembly Front BrakeDisc n .9 R u n o u I n s p e c t i o . . . . . . . . . . . . . . . . , , . 1. . - 11 t Thicknessand Parallelism ....... 19-11 Inspection . . . . . . . . . . . . . . 1.9 - 1 2 . Bleeding Master Cylinderand Brake Booster ................... 9-13 1 Removal/lnstallation Master Cylinder .........19-14 . Inspection Brake Boostel .....19-15 Tests............ Adjustment..... 19-15 Pushrod Clearance RearDisc Brakes T o r q u e / l n s p e c t i . . n. . . . . . . . . . . . . . . . 1 9 - 1 7 o. RearBrake Pads ..............19-18 Inspection/Replacement RearBrake Disc 1.R u n o u It n s p e c t i o n , . . , , . . . . . . , , . . . . , ,9 . .2 0 Thicknessand Parallelism Inspection ....... 19-20 RearCaliper ....... 19-21 Disassembly Reassembly ........ 19-24 BrakeHoses/Pipes fnspection ...,,,,,.. 19-27 .............19-28 Brake HoseReplacement ParkingBrake Disassembly Reassembly ...... 19-29 and
SpecialTools
Rol. No.
Tool Number
oTHAE-SGOO100 oTJAG-SD40100 o7914-SA50000 o7916-6390001
BrakeSpringCompressor Pushrod Adjustmenl Gauge Snap RingPliers LocknutWrench
19-22, 19-25 19-l5 19-22, 19-25 19-21, 19-26
an
19-2
lllustratedlndex
FRONTBRAKES Torque/lnspection,page 19-6 Front Brsk Pads. page 19-7 Front Csliper, pag6 19-9 FrontSrakeDisc,page 19-11
PARKINGBFAKE Adjustmont, pago | 9-5 Diaa$embly 6nd Reassombly, p6go 19-29
REARDISC BRAKES Torqu6/lnspsction,p8g 19- l7 R6arBrak6P8ds,psgs 19-18 R6ar Brak Disc, page 19-20 R6ar Calipr, page 'l9-2'l
ERAKE PEDAL psg l9-4 Adjustmont,

MASTER CYLIT{DER AND BRAKEBOOSTER psge 19-13 Rgmoval/lnstallation, page 19-14 MastsrCylinder, BrakgBooster19-15
BRAKEHOSES/PIPES pag 19-27 Inspoclion, Brake Hoso Replacmnt.p6g 'l 9-24
19-3
PedalHeight
Adjustment
'I . Disconnect brakeswitch connector,loosenthe the brakeswitch locknutand back off the brakeswitch until it is no longertouchingthe brake pedal. 4. Screw in the brake switch until its plungeris fully depressed(threadedend touching the pad on the pedal arm). Then back otf the switch 1/4 turn to make O.3 mm {0.O1 in} of clearance between the threadedend and pad. Tightenthe locknut tirmly. Connectthe brake switch connector. CAUTION: Ch6ck that the brak lights go oft whon ths psdsl is lleased.
2 . Measurethe pedalheight from the left side center

of the Dedalsurface. BRAKE
swtrcH
PAD
A: Podal Freo Play 1-5 mm (1/16- 13/64in) B: Standard Pdal Height (with floor mat removed) MT: 165 mm (6.5 inl minimum AT: 186 mm (7.3 in) minimum
BrEke Podal Froe Play Inspection: Stop the engine and inspect the play by pushingthe pedalby hand. BrakePdalFreePlay: 1-5 mm {1/16-13/64 inl CAUTION: It tho pedal freo play is insufficient, it may ro3ult in brak drag.
3 . Loosenthe pushrodlocknutand screw the pushrod

in or out with pliersuntil the standardpedalheight After adjustment. tighten from the floor is reached. the locknut firmlv,
PUSHROD LOCKNUT l5 N.m 11.5kg-m, 11lb-fll tor cai. without ABS 19 .m {1.9 kg-m, 14 lb-ftl for cars with ABS
19-4
bsnmrr
ParkingBrake
Adjustment
NOTE: After rear brake caliper servicing,loosen the parking brake adiusting nut, start the engine and depressthe brake pedal severaltimes to set the selfadjustingbrake beforeadjustingthe parkingbrake. Bbck the flont wheots beforo iacking up @ the loar of the car1. 2. Raisethe rear wheels off the ground. Make sure the lever of the rear brake calipercontacts the pin ot the brake caliper.
E
Tighten the adjusting nut until the rear wheels drag slightly when turned.
o.
Relase parkingb,ake lever and check that the the rar wheels do not drag whn turned. Readjustit nScessarv. With the equalizer properly adjusted, the rear brakes should be tully applied when the parking brake lever is pulledup 6 to 1O clicks.
3 . Pull rhe parkingbrake lever up one notch.

Removethe tront consoleand centerconsole(see p a g e2 O - 5 1 ) .
19-5
Front Brakes
Torque/lnspectaon
a Nevgl us an air hos6 or dry brush to clan braks assamblies. a Use an OsHA-spproved vacuum cl6aner, to avoid breathing brake dust, a Contaminated brake discs or pads reduce stopping ability. CAUTION: a Do not spill brake tluid on tho car; it may damagethe paint; it brakefluid does contact tho paint, wash it ott immediately with water. a To prevont spills, cover the hose loints with rags or shop towels. a Cl8n all pans in brake lluid and air dry; blow out all passageswith comprossdail. a Btore reassembling.chcck that all parts ar free of dust and othr toreign particlas. a Replaceparts with new ones whcnvel specitisd to do so. a Make sure no dirt or othor lorign mattr is allowed to contaminato th6 brako fluid. a Do not mir different brands of braks fluid as thy may not b6 compatible. a Do not reuse the drained tluid. Us6 onlv clean DOT 3 or 4 brake fluid. NOTE: a Coat piston, piston seal, and caliperbore with clean brakefluid. a Reolace rubberoarts with new ones wheneverdisassembled. all -ffi: rubbergrease. Brakecyrindergrease(P/N:08733-Bo2oE) or equivalent
OUTERPAD SHIM Check tor wear or oamage. Apply Molykoteo N477ptt{ B to pad side of shim. Checkfor bendingor damage.
..6|t,
siliconegrease.
WEAR INDICATOR INNERPAD SHIM B lnstallinnerpad with Checklor wear or atswear indicatorupward. oamage. Apply Molykoteo M77 to shim A sade shim. ol
1 2 x 1 . 2 5m 1 1 0 N . l n ( 1 1 . 0k g - m , 80 lb-ftl
\ / L ,r. t \ I { ( /?
-41
Ptt{BooT
\"--'--\ t t ^
\ ( i
INNERPAD SHIM A / CheckIor wear or damage. Apply Molykoreo M77 to both sidesof shim. 10 x 'l.O mm 50 N'm {5.0 kg-m, 36 tb-ftl
q{
4,/
BUSHING
t I
Replace.
-6l
-6,l
BRAKEPADS
rinins check thicknes. P t o . /
yN
< 'iN.-_
Check for bending or
damase.
u afl
BLEEDSCBEW I N.m (0.9 kg-m, 6.5lb-fr)
_G1
RETAIl{ER Check for
damage.
na ffi,.--Eih Nv Yl(o,6 -N/ffiL

PrsroNSEAL
CALIPER BODY CheckIor scoring on cylinderwall-
I \V--\.-_
I
PISTONBOOT Replace.
."o,,nn 8'n"i"?nfo,
on srlrface.
19-6
Front BrakePads
Inspection/Replacement
4. a Nevar us an air hoss or dry brush to clan blake assemblies. a Use an OsHA-approved vacuum cleanet, to avoid broathing brako dust. 1. Loosenthe front wheel lug nuts slightly,then raise the car and supporton safety stands, Removethe front wheels. Remove the caliperbolt and pivot the caliperup out of the way. Removethe pad shims, pad retainers and pads. Using vernier calipers,measurethe thickness of each brakepad lining. Brako Pad Thickness: Standard: F22A1 and H23Al sngine: 12.5 mm (O.49in) H22A1 engin: 1 1.O mm {0.43 in) Servic Limit: 1.6 mm {0.06 inl
2.
CALIPERSOLT
CALIPER BODY 3. lf the brake pad thicknessis lessthan servicelimit at step 5, replacethe front pads as a set.
NOTE: Measurement doesnot includepad backing plate thickness. 6. Cleanthe caliperthoroughly;removeany rust, and check for groovesor cracks. Installthe pad retainers.
Front BrakePads
(cont'd) Inspection/Replacement
8 . Apply Molykote@ M77 compound to the pad
shims and the back of the pads. Wipe off excess. 9 . lnstallthe brake pads and pad shims correctly. then installthe 1 1 .P ivotthe caliperdown into position, caliperbolt (flangebolt). NOTE: Make sure the pin is clean before installagrease the inside to tion, then applya cleansilicone ot the boot and the Din.
@ a Wh6n
reusing th pads, always leinstall tho brake pads in their original positions to pravent loss ot braking efticiency. a Contaminated brake discs or pads reduce stopping sbility, Kep greas oll the discs and p8ds.
NOTE: Installthe pad with the wear indicatoron the inside.
CALIPER 50 N.m
{5.Okg-m, 36 rb-ft| PISTON
INNERPAD SHIM A Apply Molykote@ M77 to borh sidesof shim.
INNERPAD SHIM B Apply Molykote@ M77 to inner INNERBRAKEPAD sade shim. of
t ' \
E i
V
OUTER BRAKE PADS
t l
Apply Molykoteo M77 to inner side of shim.
12. Depress brakepedalseveraltimes make sure the to the brakeswork. then road-test.
indicator)
1O. Pushin the pistonso that the caliperwilltit overthe pads. Keepthe boot in positionto preventdamaging the boot when pivotingthe caliperdown.
NOTE: Engagementof the brake may requi.e a greater pedal stroke immediatelyafter the brake pads have been replacedas a set. Severalapplications of the brake Dedalwill restore the normal oedal stroke.
19-8
FrontCaliper
Disassembly
a N6vor uso an air hose or dry brush to clean brake assmbli9s. a Use an OSHA-approved vacuum clganr to avoid broathing brake dust. CAUTION: a Do not spill brak fluid on the ca1;it may d8magthe paint; il brake fluid dos contact the paint, wash it ofl immediatoly with wat6r. a To plevent spills, cover the hose ioints with rags or shop towels. a Clean all parts in brak6 tluid and air dry; blow out all passages with comprossed air. 1. Removethe banjo bolt and disconnectthe brake hose from the calioer. Removethe caliperbolts, then removethe caliper. lf necessary,apply compressed to the caliper air fluid inlet to get the piston out. Placea shop rag or wooden block as shown to cushion the oiston when it is exoelled. Use low pressure in short spurts. air Removethe piston from the caliDer.
a Do not placo your fingsrs in front of th piston. a Do not use high air pressuls; use an OSHAapprovsd 30 PSI nozzle.
2.
4.
Removethe piston boot and piston seat. CAUTION: Take care not to damago the cylindel bore,
SEALING WASHERS Replace.
CALIPERBOLT
19-9
Front Caliper
Reassembly
CAUTIOt{l a Do not spill brako fluid on the ca.; it may damagethe paint; if brake fluid do6s contact th paint, wash it off immediately with water. a Bofore reassgmbling,chock that all parts are troe ot dust and othol toreign pa.ticles. a Raplacepans with new ones whgn6vo. spocitied to do so. a Make suls no di.t or othor loroign mattor is allowod to contaminate the brak tluid. a Do not mix different brands ot brake tluid as they may not be compatible, a Do not reus tho draindfluid. Use onlv cloan DOT 3 or 4 brakefluid. 1. Cleanthe piston and caliperbore with braketluid and inspectfor wear or damage. Coal a new piston sealwith siliconegreaseand install it in the cylindergroove. Apply brakecylindergrease(P/N:08733-BO2OE) or equivalentrubbergreaseto the sealinglips and insideof a new piston boot, and installthe boot in the cylindergroove. 6. 4. Lubricate calipercylinderand pistonwith brake the fluid, then installthe piston in the cylinderwith the dishedend facing in,
2.
5.
3.
Install the brake pad retainersand brake pads in their originalpositions(seepage 19-8). Always rinstall the brake pads in @ their o.iginal positions to prevent loss ol braking ofliciancy. Installthecaliperon the caliperbracketand tighten the caliperbolts.
7 . Connect the brake hose to the calipe. with new sealingwashersand tighten the banio bolt.
BANJO BOLT 35 t{.m {3.5 kg-m,
25 tb-ftt
,:^" #-i!!r9ul
RUBBER GREASE
PISTONSEAL
-611
SILICONE GREASE
SEALING WASHERS
CALIPER BOLT 50 .m (5.0 kg-m, 36 tb_trl 8. Fill the brake reservoir up and bleed the brake s y s t e m{ s e ep a g e1 9 1 2 ) .
19-10
Front BrakeDisc
Runout lnspection
Loosenthe front wheel lug nuts slightly,then raise the car and supporton safety stands. Removethe front wheels. 2. 3. Removethe brake pads (seepage 19-7). Inspectthe disc surfacefor cracks,and rust. Clean the disc thoroughlyand removeall rust. Use lug nuts and suitableplainwashefsto holdthe disc secu.elyagainstthe hub, then mount a dial indicatoras shown and measure runoutat IO mm the (O.4 inl from the outer edge oJ the disc, Brak6 Disc Runout: Scrvlc. Limlt: O.10 mm (0.004 in) 5. lf the disc is beyond the servicelimit, refinishthe rotor with an on-car brake lathe. The Kwik-Lathe producedby Kwik-WayManufacturing Co. and the "Front Brake Disc Lathe" offered by Snap-onTools Co. are appfovedfor this operation. MEx. Refinishing Limit: 21.0 mm (0.83 in)
Thicknessand Parallelism Inspection

Loosenthe front wheel lug nuts slightly,then raise the car and support on safety stands. Removethe front wheels.
2 . Removethe brake pads (see page 19-7).

Using a micrometer, measure disc thickness at eight points, approximately 45o apartand 1O mm (O.4 in) in trom the outer edge of the disc.
4.
Brako disc thickness: Standard:23.O mm {0.91 inl BrakoDisc Parallelism: O.O15mm (0.00OO mar. in) NOTE; This is the maximum allowabledifference between any thicknessmeasurements.
4.
lf the disc is beyondthe servicelimit for parallelism, refinishthe rgtor with an on-car brake lathe. The producedby Kwik-Way Manufacturing Kwik-Larhe Co. and the "Front BrakeDisc Lathe" offered by Snap-onTools Co. are approvedfor this operation. Max. Rfinishing Limit: 21.O mm (0.83 in)
NOTE: A new disc should be retinished if its runout is greaterthat O.l O mm {O.OO4 in}.
19-11
Bleeding
cAUTtOt{: o Uso only clsan DOT 3 or 4 brake fluid, a Mako suro no dirt 01 othl toreign mattor i5 allowod to contaminate ths brake tluid. a Do not mix diflorent brands of brako fluid as they may not be compatible. a Do not spill brake fluid on tho car; lt may damags the paint; it brake tluid does contact the paint, wash it ofl immadiately with wator. NOTE: The reservoiron the master cvlinder must be full at the stan ot bleedingprocedure,and checked after bleeding each brakecaliper.Add fluid as required. Use only clean DOT 3 or 4 brakefluid. BLEEDING SEOUENCE: FRONT:
REAR:
O Fronr Right O Roar Rlght
BI-EED SCREW
a Front Loft
a R..r L.fi
1 . Have someone slowly pump the brake pedal severaltimes, then apply steady pressure. Loosenthe brake bleed screw to allow air to escape from the system. Then tighten the bleed screw securelv. 3. Repeatthe procedurefor each wheel in the sequence shown above, until air bubblesno longer appearin the fluid, by Check brake performance road testing.
4.
19-12
Master Cylinderand BrakeBooster

CAUTION: a Be calelul not to bend or damago tho brake pips whsn removing tho mast6r cylindor and boostef. a Do not spill brako fluid on the cai; it may damagthe paint; if brake fluid dos contact th paint. wash it oft immediately with watr. o To prevsnt spllls, cover the hose ioinis wiih rags or shop tow6ls. a Before lesssembling, check that all parts als tree ol dust and othr toreign particlos. a Mako sur6 no din or oth6r foroign matter is allowod to contaminat th brake tluid. a Do not mir dift6r6nt brands ot brak tluid as they may not bo compatibls. a Do not raus th6 draind fluid. Us only closn DOT 3 oi 4 brake fluid. a Whon connecting the b18kpipes, msko suro that thor6 is no intoderenco botwoan tho brake pipos and othor parts. a Do not disassmbletho mastor cylindor or boost6r, Roplacothm as complots assomblies. Drainthe brakefluid from the mastercylinder. Disconnect the brakefluid level switch connectors. Disconnect the brake pipesJromthe mastercylinder. Removethe mastef cylindermountingnuts and the mastercylinder. Disconnect the vacuum hose from the boosterand removethe vacuum hose bracket. Remove the thfottle/cruise controlcableb.acket,then.emovethe throttlecableg.ommetfrom the enginecompartment bulkhead, 7 . Removethe intake air temperature sensorfrom the intakemanifold. PUSHBOD LOCKNUT 8 . Loosenthe pushrodlocknut. and removethe cotter pin and joint pin. 15 N.m ll.5 kg-m,11 lb-ftltor carswithout ABS q 19 N.m 11,9kg-m, 14lb-ftl tor cars with ABS Removethe boostermountingnuts and clevis, COTTER.PIN 1 0 . Removethe brak booster(seenext page). BRAKEBOOSTER 1. 2. 3. 4. 5. 6.
8 x 1.25mm 13 N.m 11.3kg-m, 9 lb-ft| Do not disassemble.
JOII{T PIN
-6l
To rightrcar blako
DUALPROPORTIONING VALVE Oonot disassemble. x 1,25
To left-.e6r b.ako
l5 N.m ( 1 . 5 k g - m ,1 1 l b - f t )
--19 N.m {1.9 kg-m, 14lb-ft)
l O r 1 . Om m 19 N.m {1.9 kg-m, t4 lb-ftl
,/
To .ight-tront brako
11. Installthe brake boosterand mastercvlinderin the reverseorder oI removal. (seepage 19-15). NOTE: Beforeinstalling the mastercylinder,check and adjustthe pushrodclearance 12. After installation, check and adjustthe brakepedal height (seepage 19-4). 1 3. Fill and bleedthe brake system {see page 19-12). (cont'd)
19-13
Master Cvlinder and Brake Booster

(cont'dl Removal/lnstallation
Boorter Replacement
1. Pull th8 brak6 booster torward. then turn it to th6 right until the oporating rod is clear of the bulkhead as shown below. Move the ope.sting rod beyond the left dampe. bas6 by turningthe brake booster. EFAKE BOOSTER ROD OPERATII{G
Master Cylinder
Inspection
CAUTION: a Do not splll brak6 tluid on the car; it may damagc the palnt; il brak fluid doos contact th paint, wash lt ofl immediately with vvater. a Bforo roassambling,check thst all parts ar treo ot dust and other fo?olgn particles, a Do not try to disasssmblo th6 maEtar cylindef assembly, Beplaco tho ma3tr cylindor assombly with a now part it necessary. a Make sura no dirt or othof toloign matter is allowed to contaminate tho blako tluld.
2.
Frcnt / LEFTDAMPER BASE
Continue to turn the brak8 booster until the ope.ating rod points forward, Rmove the brake booster from the engin compartmont with the front cylinder shell sid8 of the boosteruDw8rd. b18k
FRONTCYLII{DERSHELL
SILICONEGREASE
CYLINDER Checkfor loaksor damags.
ROD OPERATING
19-14
BrakeBooster
Tests
Functlonal Test 1, With the enginestopped.depressthe brake pedal severaltimes, then depress the pedalhardand hold that pressure 15 seconds.lf the pedalsinks,the fo. master cylinder, brake line or a brake caliper is taulty. 2. Start the engine with the pedal depressed. the lf pedal sinks slightly,the vacuum booster is working. lf the pedalheightdoes not va,y, the boosteror check valve is faulty.
PushrodClearanceAdjustment
NOTE: Master cylinder pushrod-to-pistonclearance must be checkedand adjustments made, if necessary. bfore installingmastercylinder. 1. Set the specialtool on the master cylinderbody; push in the center shaft until the top ot it contacts pistonby turningthe with the end of the secondary sdjustingnut. PUSHBOD ADJUSTMENT GAUGE -SD40100 0TJAG
Lesk T6st 1. Deprsssthe b,ake pedal with the enginerunning, then stop the engine.It the pedal height does not vary while depressed 30 seconds,the vacuum for booster is OK, lf the pedal rises, the booster is taulty. CAUTION: Do not try to disa$ombl th boosto.. Replacthe boostor assembly with a new ono. 2. With the enginestopped,depressthe brake pedal several times using normal prssure.When the pedal is first depressed, should be low. On conit pedalheight shouldgradualsecutiveapplications, ly rise. lf the pedal positiondoes not va,y, check the boostercheck valve.
ADJUS?ING NUT
MASTER CYLINOER SECONDARY PISTON CENTERSHAFT
Without disturbingthe center shaft's position,install the specialtool upsidedown on the booster. Install the master cylinder nuts and tighten to the specified torque. 4. Connectthe booster in-linewith a vacuum gauge 0-760 mm HS (O-30 in Hg) to the booster's engine vacuum supply, and maintain a engine speed that will deliver 500 mm Hg (2O in Hg) vacuum.
Check Valve Tost 1. Disconnect the brake boostervacuum hose at the booster. 2. Stsrt the engine and let it idle. There should be vacuum available.lf no vacuum is available.the check valve is not working correctly. Replace the check valve and retest.
5 . With a feeler gauge. measurethe clearancebetween the gauge body and the adjusting nut as snown. Cloaranc6: C81swithout ABS: O-0.4 mm {O-0.O2 in} Car8 with ABS: O-O.2 mm (O-O.01 inl
VACUUM GAUGE 0-760 mm Hg lO-3O in Hgl (Commercially Available)
CHECK VALVE
15 N.m 11.5kg-rn, 1 1 tb-ft}
]{UT ADJUSTING
(cont'd)
19-1 5
BrakeBooster
PushrodClearanceAdjustment (cont'd)
NOTE: lf the clearancebetween the gauge body and adjustingnut is 0.4 mm (0.02 in) [cars with ABS: 0.2 clearanceis 0 mm (0.01 inll, the pushrod-to-piston betweenthe gauge body mm. However,the clearance and adjusting nut is O mm, the pushrod-to-piston inl is clearance O.4 mm (O.O2 lcars with ABS: O.2 mm (O.O1 it in)l or MOBE.Therefore, must be adjustedand rechecked. 6. is lf the clearance incorrect: - Cars without ABS: loosenthe star locknut and by adjustthe clearance turningthe adjusterin or out while holdingthe pushrod. torque Tightenthe star locknut to the specified tool. and removethe sPecial NOTE: vacuum a Adjustthe clearance while the specified is appliedto the booster, a Hold the cleviswhile adjusting, O-O.4 mm (0-0.02 inl STARLOCKNUT 22 N.m kg-m,l6lb-ft| 12.2 7 . Adjust the pushrodlength as shown ii the booster is removed.
1 1 6r 0 . 5 m m (4.6 t 0.02 in)
PUSHROD
LOCKNUT 15 N.m (1.5 kg-m, 11 tb-ftt
8.
o
lnstallthe mastercylinder(seepage 19-13). After installation,perform the following inspections and adjustil necessary. a Brakepedal height {seepage 19-4} . Brakepedalfree play (seepage 19-4)
- Cars with ABS: removethe specialtool and adjust the clearance turning the adjusterin or by out while holdingthe output rod. O - O . 2m m 1 0 - 0 . 0 1i n l
19-16
RearDisc Brakes
Torque/lnspection
a Ngver use an air hose or dry brush to clean btake assemblies. a Use an OSHA-approved vacuum cleaner,to avoid breathingbrakedust. a Contaminated brake discs or pads reduce stopping ability. CAUTION: a Do not spill blake tluid on the car; it may damagethe paint; il brske fluid does contact the paint, wash it oft immediatoly with watsr. a To prevent spills, cover the hose ioints with rags or shop towels, a Clean all parts in brako fluid and air dry; blow out all passagewith comprssdair. a Batore reassembling,check that all parts ar6 free of dust and other toreign panicles. a Replacs parts with new ones whenevei sDeciliedto do so, a Make sure no dirt o? other loreign mattet is allowgd to contaminate the blake fluid, a Do not mix different brands of brake fluid as they may not be compatiblo. a Do not reuse the drained lluid. Use onlv clean DOT 3 or 4 brake fluid. NOTE: a Coat piston, piston seal, and caliperbore with cleanbrakefluid. a Replace rubberparts with new ones wheneverdiassembled. all -{Z-aiiif-{ : Brakecylindergrease(P/N:08733-Bo2oE) or equivalent rubbergrease.
BRAKEPADS CheckliningthickINNERPAD SHIM Checktor wear. Apply Molykoreo M77 ro pad side of shim.
.-6f
, Silicone grease.
'10x 1.25 mrn 39 N.m (3.9 kg-m, 28 lb-ftl
RETAINER OUTERPAD SHIM Checkfor weakness Checkfor wear. or oamage, Apply Molykoteo M77 to pad side of shim.
CALIPER BRACKET CheckIor cracks.
PARKING NUT 10x1.25mm 28 N.m (2.8 kg-m. 20 tb-frl SPRING CAM BOOT Replace. PAD SPRING cr,."t r". *.* or
damage, \
-.'j@Ell
PINBOOTS
Replace.
I I
f
PlsroN SLEEVE Checkfor wear

or damaoe.
D S^
O-RING'Reolace. CALIPERBODY Checkfor scoring on cylinderwall. 8 mm FLANGEBOLT 23 N.m (2.3 kg-m, 17lb-ftl c:_9!!a!$l
',.'' 1
'''ry9
.,,cuP ./
Replace. A-^ ._=i!!l!iil
KX( lniir-
I I
check ror wearor d"maqe.
PISTONASSEMBLY Checktor scoringon the surface,
=^"
BEARTNGA Check for damage ADJUSTING Replace. B SPRING SPBING tor Check Checkfor damage.
'y"P"M
cfRcLrP /
(nl,--/
/r,"ron
"oo,
Replace.
4..
19-17
RearBrakePads
Inspection/Replacement
@ uae an alr hose 01 dry blush to cloan brake a iloyor

assamblies. a Us6 an OsHA-approvod vacuum cloanor, to avoid breathing brake dust. 1. Block the front wheels, loosenthe rear wheel luq. nuts slightly, support the rear of car on satety stands.then removethe rear wheels. Release the parkingbrake. Removethe calioershield.
lf liningthicknessis lessthan servicelimit at step 5, .eplace the rear pads as a set.
2,
CALIPER SHIELD Remove the two caliper mounting bolts and the calipertrom the bracket. CAUTION: a Thoroughly cloan ths outsido ot tho calipsr to prevont dust and dirt ttom ontodng insid6. a Support the calipel with a pleco ot wilo 5o that it does not hang trom tho brako hose.
CALIPERMOUNTING 4.
Removethe pad shims, pads and pad retainers. Using vernier calipers,measurethe thickness of each brakepad lining, B.ako Pad Thicknass: 9.O mm (O.35 in) Standard: ServicoLimii: 1.6 mm (0.06 inl
doesnot includepad backing NOTE: Measurement Dlatethickness.
19-18
o.
Cle6nthe caliperthoroughly;removeany rust, and check lor groovesor cracks. Make surethat the pad retainers installed the are in correct Dositions.
9. Rotatethe caliperpistonclockwiseinto placein the cylinder, then alignthe cutout in the pistonwith the tab on the inner pad by turningthe piston back. CAUTION: Lubricats the boot with silicone groaso to avoid twisting the piston boot. lf piston boot is twisted, back it out so it sits proporly, 1O. Installthe caliperon the caliperbracketand tighten the calipermountingbolts.
7.
BRACKET
8.
Install the brake pads and pad shims on caliDer bracket.
a Whon rousing tho pads, always reinstall the blake pads in their original poaitions to prevent loss ot braking sfficioncy. a Contaminated brako discs or pads reduco stopping abillty. Kop greaseoft tho disca and pads. NOTE: a Apply Molykote@ M77 to the pad side of the shims. Wipe excessgreaseoff the shims. a Install the inne. pad with its war indicator facing upwa.d.
MOUNTING CALIPER BOLTS 23 .m (2.3 kg-m, t 7 lb-ft1
PISTONBOOT
11. Installthe calipershield.
=^" #.!!!4t!x
12. Depress brakepedalseveral the times to make sure the b.akeswork, then road-tesr. NOTE; Engagementof the brake may require a grater pedal stroke immediatelyatter the brake pads have been replacedas a set. Seve.alapplications ot the brake pedal will restore the normal pedal stroke.
REARBRAKEPADS
19-19
RearBrakeDisc
Runout Inspection
Loosenthe rear wheel lug nuts slightly,then raise the car and supporton safety stands. Removethe rear wheels.
Thicknessand Parallelism Inspection

1. Loosenthe rear wheel lug nuts slightly,then raise the car and supporton safety stands. Removethe rear wheels. Removethe brake pads (seepage 19-18). Using a micrometeJ.measure disc thickness at 45o apart 8nd 1O mm eight points, approximately (0.4 in) in from the outer edge of the disc.
2 . Removethe brake pads (see page 19-181.

InsDectthe disc surlace tor grooves,cracks, and rust, Cleanthe disc thoroughlyand removeall rust. 4. Use lug nuts and suitableplainwashersto hold the disc securelyagainstthe hub. then mount a dial inthe dicatoras shown and measure runoutat 1Omm (O.4 inl from the outer edge of the disc. Brake Disc Runout: Selvics Limit: 0.1O mm (0.O04in) lf the disc is beyondthe servicelimit, refinishthe rotor, Limit: 8.O mm lO'32 in) Max. Rslinishing
Blake Disc Thickness: Standard:1O.Omm (O.39in) inl O.O15mm (O.O006 max. BrakeDisc Parallelism: NOTE: This is the maximum allowablediJference between any thicknessmeasurements. 4. It the disc is bevondthe servicelimit tor parallelism, .efinishthe totor. Max. Refinishing Limit: LO mm {0.32 in)
NUT WHEEL N 11O 'm tl1 kg-m'80 lb-ft| NOTE: A new disc should be refinished if its runout is greatetthan O.1Omm (O OO4in).
19-20
RearCaliper
Disassembly
a Never use an air hose or dly brush to clean brake assemblies. a Use an OsHA-apprgved vacuum clganer to avoid bleathingbrake dust. CAUTION: a Do not spill brake fluid on the car; it may damago th paint; it brake fluid does contact the paint, wash it off immediately with water. a To prevent spills, cover the hose ioints with rags or shoo towels. a Clean all parts in brake tluid and air dry; blow out all passages with complessed air. 1. 2. R e m o v e h e c a l i p e s h i e l d( s e ep a g e1 9 - 1 8 ) . t r R e m o v e h e l o c k p i n a n d c l e v i sp i n . t Removethe cable clip and disconnectthe parking brake cable trom the arm.
LOCK PIN
ren
5 . Removethe pad springfrom the caliperbody. 6. Remove the piston by rotating the piston counterclockwise with the specialtool and remove the Distonboot. CAUTION: Avoid damaging the piston.
PISTONBOOT
WRENCH LOCKNUT 07916-6390001
7.
Removethe piston seal. CAUTION: Take cars not to damage th6 cylinde. bole.
3. 4.
Removethe banjo bolt and two sealingwashers. Removethe two calipermountingbolts and caliper body from the bracket.
MOUNTING EOLT CALIPER
Replace.
SEALING WASHERS Replace.
(cont'd)
19-21
RearCaliper
Disassembly(cont'd)
8. Install the specialtool between the calipet body and spflng cover. CAUTION: Be careful not to damag th inside of tho calipor cylinder du ng calipGrdisa$mbly. the locknutsas shown, then turn the shaft 9. Position until the plate just contactsthe caliperbody, NOTE: Do not compress the spring under the spring cover. 1 1. Lower the locknutslully and tighten the locknuts securely. NOTE: Keepthe locknutsin this positionuntil you reinstall the citcliD.
LOCKNUTS PLATE
BRAKE SPRING COMPRESSOR oTHAE-SGOOIOO
12. Removethe circlipwith snap ring pliers.

SNAP RING PLIERS
07914-SAs(Xxro
1O. Turn the shaft clockwise 1/4-112 turn to compressthe adiustingspring B in the caliperbody. CAUTION: To plsvnt damags to ths innr compononts, do not turn thg shaft more than 1/2 tutn.
19-22
13. Hold the plate with your fingersand turn the shatt counterclockwise. Remove the sDecialtool from the caliper.
1 6 . Remove the sleevepiston,and removethe pin from the cam.
SLEEVE PISTON 17. Removethe return spring. 18. Removethe parkingleverand cam as an assembly from the caliperbody. 1 4 . Removethe adjustingbolt. Remove the spring cover, adjusting spring B, spacer,bearingA and cup trom the adjustingbolt. CAUTION: Do not loosn the parking nut with tho cam installod in tho calipar body. It the lever and shaft must b6 sopa.ated, hold the levsr in a viso and looson tho parking nut. 19. Removethe cam boot.
RETURN SPRIlTG PARKINGLEVER/ CAM ASSEMBLY PARKI G NUT
19-23
RearCaliper
Reassembly
CAUTION: a Do not spillbrakotluidonthe car; it may damagothe paint; if blake fluid does contact the paint, wash it oft immsdiatoly with water. a Botore reassembling,check thst all pa.ts aro floa ol dust and othr forsign panicles. a Roplaceparts with new ones whenve. spcifisd to do ao. a Make sure no din or other forign matter is allowed to contaminato the brak tluid. a Oo not mix different brands of brske fluid as thoy may not be compatibl. a Do not reuse th drained tluid, Uso only cloan DOT 3 or 4 brakefluid. 'I . Pack all cavitiesof the needle bearingwith commerciallyavailable assemblylube. Coat the new cam boot with commercially available assemblylube and installit in the caliper
DOOy.
Z^" #jlqqil
: Commarcially.vailabl ..'embtv tube
RETURN
2.
3.
Apply commercially available assemblylube to the pin contactingarea of the cam and installthe cam and lever assemblyinto the caliperbody. Installthe return spring. CAUTION: a When the cam and leve? wa.e separatgd, bo sure to assemblothsm betoro installing the cam in th caliper body. Install tho lvsr and 3p ng washer, apply locking agnt to ths threads, and tighten the parking nut whib holding lhe lovor with a viso. a Avoid damaging the cam boot since it must be installed botore the cam. a When installing the cam, do not allow the cam boot liDs to tu]n outsid in.
4.
lnstsllthe pin in the cam. Installa new O-ringon the sleevepiston. lnstallthe sleeveDistonso the holein the bottom of the piston is alignedwith the pin in the cam, and two pins on the pistonare alignedwith the holesin the caliDer.
HOLES
nSTOf{ SLEEV
19-24
8. Cost a new cup with brake cylindergrease (P/N: 08733-BO2OE) or equivalentrubber grease,and A instaltit with its groovefacingthe bearing sideof the adiusting bolt. 9. Fit the bearingA, spacer, adjustingspring B and springcover on the adjustingbolt. and installthem in the calipercylinder.
11. Check that the tlared end of the spring cover is below the circlipgroove. 12. Installthe circlip in the groove, then remove the specialtool. NOTE: Check that the circlip is seated in the groove properly.
SI{AP RING PLIERS
SPRING COVER
@-S";X""'Y"
@+SPACER +__EEARINGA
/15
\=z
l<ro'lusrnc
{=="r"
r:4i!!l!!,il
=^^
'lo. Installthe specialtool on the springcover and tu.n

the shaft until the locknut contactsthe olate.
13. Coat a new pistonseal with siliconegreaseand install it in the caliper. 14. Apply brakecylindergrease(P/N:08733-BO2OE) or equivalentrubber greaseto the sealinglips and inside of a new piston boot, and install it in the calioer.
PISTONSEAL
-Gr
PISTONBOOT
.4-$q!!n RUBBER GREASE (cont,d)
tzt=-1"=-- "
19-25
RearCaliper
(cont'd) Reassembly
15. Coat the outsideof the Distonwith brakefluid and install it on the adjusting bolt while rotating it clockwisewith the sDecial tool CAUTION: Avoid damaging the piston and piston boot. 19. Installthe caliperon the caliperbracketand tighten the calipermountingbolts. 20. Connect the brake hose to the caliper with new sealingwashersand tighten the banjo bolt.
BAI{JO BOLT 35 N.m 13.5kg-m. 25 rb-ft|
CALIPER MOUNTING BOLTS 23 .m (2.3 kg-m, l7 lb-ft) CALIPERBRACKET
EXTENSION 8AR Commercially available
CALIPER
16. Installthe pad spring on the caliper.
21. Insen the parkingbrakecablethroughthe arm and connect the parkingbrake cable to the lever with the clevis pin and lock pin. Installthe cable clip securely.
LOCK PIN
PAD SPRING
PARKINGBRAKE
CABLECLIP
17. Installthe brake pad retainers and brake pads. 18. Align the cutout in the pistonwith the tab on the tnn e r p a d { s e ep a g e 1 9 - 1 9 ) .
22. Fill the brake reservoir up and bleed the brake s y s t e m( s e ep a g e1 9 - 1 2 ) . 23, Operatethe brakepedalseveraltimes, then adiust the parkingbrake (seepage 19-51.
19-26
BrakeHoses/Pipes
Inspection
1. 2. 3. or Inspectthe brake hosesfor damage,leaks,interference twisting. Also check ior bent brakelines. Chckthe brakelines tor damage,tipping, rustingor leakage. and retightenif necessary. Check fo. leaksat hose and line joints or connections. CAUTION: Roplacotho brako hose clip whonever the blake hos6 is servicod.
BBAKE LINE.TO.ARAKE HOSE 15 N.m {1.5 lg-m, 1l lFftl
BRAKE LII{E.TO.BBAKE HOSE 15 N.m 11.5 kg-m,11 lb-ftl

LINE MASTER CYLIT{DER-TO.BRAKE 19 .m {1.9 ks-m. 14 lb-ft)
SCREW BLEED 9 N.m (0.9kg-m,6.5lb-ftl BRAKE HOSE.TO.CALIPER BOLTI IBANJO 35 .m {3.5 kg-m.25 lb-ft|
BLEEDSCREW 9 N.m lO.9 kg-m,6.5 lb-ftl BRAKEHOSE.TO.CALIPER IBANJO BOLT) 35 N.m {3.5 kg-m,25 lb-ft}
19-27
BrakeHoses/Pipes
Brake Hose Replacement
cAuTro :
a Bofo.. reassembling,chck that all parts are free ol dust and othel toraign particles. Roplaceparts with new ones whenevl spocitiod to do so. a Uss only clan DOT 3 oi DOT 4 braks fluid. a Mako suro no dirt or otho. toroign mattar is allowod to contaminate th blake tluid. a Do not mix diffrnt brands of brako fluid 8s thoy may not be compatibl. a Do not spill brake fluid on the car; it may damagethe paint; it brake tluid doos contact the paint, wash it oft immediately with wator. 1. Replacethe brake hose if the hose is twisted, crackedor if it leaks. Disconnect the brakehose from the brakeoioe using a 1O mm flare nut wrench.
BRAKE P'PE BANJO BOLT 1 0 x 1 . Om m 35 N.m 13,5kg-m, 25 lb-tt) HOSE MOUNTINGBOLT 10 N.m (1.0kg-m, 7 tb-ftl BNAKEHOSE CLIP Roplace. BRAK HOSE MOUNTING SOLT (8 x 16 mml 22 N.m 12.2 kg-m, 16 tb-frl
2.
BRAKEHOSE MOUNTING BOLT 1 8x 2 0 m m ) l
22 N.m 12.2 16 lb-fr)
6.
Installa new brakehose with the brakehoseclamo bolts.
7 . Connectthe brakehoseto the caliperwith the banjo bolt and new sealingwashers. 8. Installa new brake hose clip on the brakehose.
9 . Connectthe b.ake hose to the brakepipe.
Removeand discardthe brake hose clip from the brake hose. 4. Removethe banjo bolt and disconnectthe brake hose from the caliper. Removethe brakehose clamp bolts and the brake hose.
BRAKEHOSECLIP
1 0 .After installingthe brake hose, bleed the brake

system (see page 19-121,check the hose and line joints for leaks.and tighten if necessary.
19-28
ParkingBrake
Disassembly Reassembly and
CAUTION: Tho parking brak cables must not be bont or distorted. This will load to stift operation and prematurr cablo tailure,
PARKINGBRAKECABLES Check for laulty movomont.
" / / /
CLEVISPIN
ds \ \ \
LOCK PIN Replace.
EOUALIZER
(Sliding surface)
Disconnectthe pa,king brake cable from the lever on the caliperby removingthe lock pin and clevispin, and removethe cable from the arm by removingthe clip.
cLEVtSnN
19-29
Anti-lockBrakeSystem(ABSI
.......... 19-32 Tools Special n .. l l l u s t l a t oId d e x . . . . . . . . . . . . . . . . . . . . . . . .19.-. 3 3 (ABSI Anti-lock Brake System Featules/Construction/ ........ 19-34 Operation ....... 19-46 CircuitDiagram Locations ............ 19-5O Wiring/Connoctol ALB Checker ...... 19-51 Test Function Wheel Sensor Signal ... 19-53 Gonfirmation Troubleshooting Anti-lock Brake System (ABSI .. 19-54 IndicatorLight Chart .......... 19-56 Symptom-to-System ......... 19-57 Flowcharts Hydraulic System Connections........ 19-80 Index Hydraulic Relieving Accumulator/ ... 19-81 LinePressure Modulator Unit .... ............... 19-8.2 Removal/lnstallation ....... 19-83 lndex/Torque Solenoids ............19-84 LeakTost Pump Switch Replacement...... 19-84 Pressure Accumulator ..............19-85 Disposal . . . . . . . . . . . . . . .1 .9 - 8 6 . Bleeding Electronic Components ABS ControlUnit Replacemont..... 19-87 ... 19-87 RelayInspection Puleers/WheelSensors ...........19-88 Inspection ..........19-89 Replacement WheelSensor
Sp e ci a l To ols
Ref. No.
Tool Numbel OTHAA-SGOO101r o oTHAA SG00r O0 O T H A J - S G O OO A o r l OTHAJ_SGOOlOB oTHAJ-SGOO200
Description Bleeder T-wrench ALB Checker ALB Checker(Canada)
Oty
Page Reference 19 - 5 7 . 1 9 - 6 4 , 't9-81.19-86

1q_ql 1q_A?
o
,a\
r 9-86
ffi?n
-Ti-l E
tr{ +
ll
II
U o
tl u
i.?,,
I
19-32
"
lllustratedIndex
The accumlator contains high-pressure nitrogon gas, do not puncture, expose to tlame or altempt to @ the accumlator or it may explode; severe personal injury may.osuh. disassernble
MODULATOR UNIT page 19-80 Hydraulic Connection, page 19-82 Removal/lnstallalion, page 19-83 Index/Torque, page 19-85 Accumulator, HYDRAULICSYSTEM Accumulator/Line Relieving page | 9-81 Pressure, page 19-86 Bleeding,
REARWHEEL SENSOR page 19-88 Inspection, page 19-89 Replacement,
BRAKEHOSES/PIPES fnspection, page 19-27 BrakeHose Replacement, page 19-28
ABS CONTROLUNIT page 19-87 Replacement,
PARKINGBBAKE Adjustment,page 19-5 Disassembly and page 19-29 Roassembly,
FRONTERAKES page 19-6 Torque/lnspection, Front BrakePads,page 19-7 page 19-9 Front Caliper, 1 Fronl BrakeDisc,page 19_1
REARDISC page 19-17 Torque/lnspection, RearBrakePads,page 19-18 RearBrakeDisc, page 19-20 page 19-2't RearCaliper, WHEELSENSOR page 19-88 Inspeclion, paqe 19-89 Replacement,
MASTERCYLINDERAND BRAKEBOOSTER page 19_8O Conneclion, Hydraulic page 19 14 MasterCylinder, page 19 15 BrakeBooster,
19-33
Anti-lockBrakeSystem (ABSI
Features/Construction/Operation
In a conventional brakesystem, iJ the brakepedalis depressed very hard,the wheelscan lock beforethe vehiclecomes to a stop. In such a case,the stabilityof the vehicleis reducedif the rearwheelsare locked,and maneuverability the of vehicleis reducedif the front wheels are locked,creatingan ext.emelyunstablecondition. The Anti-lock BrakeSystem (ABS)modulates the pressure the braketluid appliedto each front caliperor both rear of calipers therebypreventing lockingof the wheels,whenever the the wheelsare likelyto be lockeddue to hardbfaking.lt then restoresnormalhydraulicpressure when there is no longerany possibility wheel locking. of
F6atures
a a a a Increased brakingstabilitycan be achievedregardless changingd.ivingconditions. of The maneuverability the vehicleis improvedas the system preventsthe front wheels from locking. ot When the anti-lockb.ake system goes into action, a kickbackis felt on the brakepedal. The system is equippedwith a self-diagnosis function.When an abnormality detected.the ABS indicatorlight is comeson. The locationoi the system'stroublecan be diagnosed from the frequency the systemindicator of light blinks. This sYstemhas individual controlot the lront wheels and commoncontrol ("Select Low") lor the rear wheels. "Select Low" means that the rear wheel that would lock first (the one with the lowest resistance lock-uo) to determines anti-lockbrake system activationtor both rear wheels. The system has a fail-safefunction that allows normal braking if there's a problemwith the anti-lockbrake svstem.
Construction
In additionto the conventional b.aking system, the anti-lockbrake system consistsof: gear pulsersattachedto the rotating part of individual wheels; wheel sensors,which generatepulsesignalscorresponding the revolutionof the to gear pulsers; ABS controlunit, which controlsthe workingof the anti-lock brakesystemby performing calculations based on the signalsfrom the individualwheel sensorsand the individualswitches; modulatorunit, which adjuststhe hydtaulicpressure applied each caliperon the basisot the signalsreceived to from the ABS controlunit; an accumulator, in which high-pressure brake lluid is stored, a pressureswitch, which detects the pressurein the accumulatorand transmits signalsto the ABS control unit; a power unit, which suppliesthe high-pressure working fluid to the accumulatorby meansof a pump; a motor relayIor drivingthe power unit; {ail-saie relays.which cut off the solenoid valve ground circuit when the fail-safedevice is at work; and, an ABS indicatorlight. ABSCONTROL
MASTER CYLINDER WHEEL SENSOR
PULSER SENSOR
19-34
Master Cylinder
1. Construction A tandemmastercylinderis usedto improveth safety of the brakingsystem.In addition,centervalvesara usodso as to match the anti-lockbrakesvstem oDeration. sectionsby two smallholes.lt hastwo to tank which is connected the cylinder The mastercylinderhas one reservoir works pistons:primaryand secondary, which are crisscross connectedwith the cslipersso that the fluid pressure on separately each system (front right wheel & rear left wheel, and front left wheel & resr right wheell. at movementof the primarypistonis provided the sideof the mastercylindetbody. A rd A stop bolt for controlling tank. switch for detectingthe braketluid volume is also providedin the cap of the reservoi, 2. Ooeration pistonis pushed throughthe brakeboosterand the contervalveB the When the brakepedalis depressed, secondary is on side.At the sametime, the p,imarypistonis push6dby is closedso that fluid pressure generated the secondary both on th is and the centervalveA is closedso that brakingfluid pressure generated the sscondaryfluid pressure primaryand secondarysides. the primaryand secondarypistonsare returnedto the originalpositionby the When the brake pedal is released, and piston spring. brakefluid pressure
VALVEB CENTER
(cont'dl
19-35
(cont'd) Features/Construction/Operation
3. Responses when fluid is leaking (1) In case of leakingtrom the primarysysteml Sincethe fluid pressure the primaryside does not rise,the primarypiston is pushedby the fluid pressure on of piston and the tensionof the pistonspringuntil the end hits on the cylinder.The brakingis perthe secondary formed bv the fluid oressure the secondarv on side.
FRONT-LEFT
t 2 l In case of leakingfrom the secondarysystem:

The secondarypiston does not producefluid pressure, keeps moving ahead,hits on the end surlace of the primarypistonso that the primarypiston is pushedunderthe sameconditionas an ordinaryrod. Theretore, the brakingis conductedby the fluid pressure the primaryside. on
1 9 -3 6
Wheel Sensor
of magnet type that detectsthe rotatingspeedof a wheel.lt is comprised a permanent The wheel sensoris a contactless and coil. When the gear pulsersattached to the rotating parts of each wheel (front wheel: outboard toint of the generaling driveshaft,rear: hub bearingunit) turn, the magneticllux aroundthe coil in the wheel sensoralternates. are to voltageswith frequencyin proportion wheel rotatingspeed.Thesepulses sentto the ABS controlunit and the ABS control unit identifiesthe wheel speeds.
PERMANENT MAGNET
/ JJ"-'-c-- ou*ur , f t
GEAR PULSER at HIGHSPEED "-', VOLTAGE at LOW SPEED
\lrrral
ABS ControlUnit
brakesystem,and of The ABS controlunit consistsof a main functionsection,which controlsthe operation the anti-lock "self-diagnosis" subfunction,which controlsthe pump motor and '1. Main Function on The main lunction sectionof the ABS controlunit performscalculations the basisof the signalslrom each wheel sensor and controlsthe operationof the anti-lockbrake system by putting into action the solenoidvalves in the modulatorunit for each front brakeand lor the two rear brakes. 2. Sub-tunction "selt-diagnosis" necessary signals, to sectiongivesdrivingsignals the pump motor and alsogives The sub-function for backingup the anti-lockbrakesystem.
ABS CONTROL UNIT WHEEL SENSORS MAIN FUNCTION
soLEf{orD
VALVES
SWITCH PRESSURE PUMPMOTOR PARKINGBRAKE
swtrcH
SUB-FUNCTION . FAIL-SAFE . PUMPMOTORCONTROL . SELF-DIAGNOSIS MAIN FUNCTION
SUB.FUNCTION . FAIL-SAFE . PUMP MOTOR CONTROL . SELF.DIAGNOSIS
19-37
Anti-lock BrakeSystem (ABS)

(cont'dl Features/Construction/Operation
1. Sell-diagnosticFunction ol the brakingpressure when a wheel is about to lock, .egardless the Sincethe anti-lockbrakesystem modulates driver's intention,the system operationand the braking power will be impairediJ thsre is a malfunctionin th function,p.ovidedin the at system. To preventthis possibility, speedsabove 6 mph (1O km/h). the selt-diagnosis is sub-tunctionof the ABS control unit. monitorsthe main system functions.When an abnormality detected,tho systemitself;when the ignitionswitch ABS indicatorlight goes on. Thereis alsoa check modeof the self-diagnosis sfter the enginestarts,to signify is tirst turned on, the ABS indicatorlight comeson and stays on for a Jew seconds system is functional. that the self-diagnosis Function Fail-safe are by the operations suspended is When abnormality detectedin the controlsystem by the self-diagnosis, solenoid valvesto inhibitanti-lock the relays)which disconnect groundlinesof all the solenoid turningoft the relaysItail-sate one, msintaining the brakingsystemfunctionsjust as an ordinary Underthese conditions, brakesvstem operations, brakingfunction. When the ABS indicatorlight is turned on, it meansthe tail-safeis Junctioning. the necessary
2.
ModulatorUnit
in Modulatorsfor each wheel and solenoidvalvesare integrated the modulatorunit. mainvertically improved for construction and are positioned for The modulators front and rearbrakesare ot independent ControlValve)in ordelto preThe modulators rearbrakesare providedwith a PCVfunction(Proportioning for tainability. vent the rear wheel from locking when the anti-lock brake system is malfunctioning or the anti-lock brake system is not actrvated. The solenoidvalve featuresquick response(5 ms or less). The inlet and outlet valves are integrated in the solenoid valve unit. There are three solenoid valves provided, on fol each front wheel, and one for the rear wheels.
SoLENOtO
To Pump Aas6mbly F.om M..t r Cylnd.r Pl.tor
M..l.r CyLd.t Prlrnary Plrto|r
From Pump Ar36mbly
To Lcft-f.ont Brakc Cdllpol To Rlght-rea. B]rk. Callpr
19 -3 8
Accumulator
in high-pressure brakefluid fed from the pump incorporated the is type which accumulates The accumulator a pneumatic power unit. When the anti-lockbrakesystem operates, brake the accumulator and the power unit supplyhigh-pressure Jluidto the modulatorvalve via the inlet side ot the solenoidvalve.
ACCUMULATOR
ALADDER
PressureSwitch
(pressure and is turnedoff lrom the pump)in the accumulator accumulation The pressure switch monito,sthe pressure switch is turnedoft, the switchingsignalis level.Whenthe pressure becomeslower than a prescribed when the pressure the signal,the ABS controlunit activatesthe pump motor relayto operate sent to the ABS control unit. Upon receiving value,the ABS indicatorlight comes on. doesn't reachthe prescribed the motor. lf the pressure ODeration switch deformsoutwards.When the tube in the pressure in rises,the Bourdon When the pressure the accumulator is amount,the micro-switch activatedby the force of free end of the Bourdontube movesmore than the prescribed due to anti-lockbrake in decreases the spring attachedto the sensinglever. When the pressure the accumulator above, and the microoperations. the Bourdontube moves in the directionopposileto the one described system this signal, the ABS controlunit activatesthe motor relayto operate turned off. Upon receiving switch is eventually the motor.
SENSINGLEVER
(cont'd
19-39
Anti-lockBrakeSystem (ABS)
Power Unit
The power unit consistsof a motor, filter, guide, piston rod and cylinderbody. Sincea guide is positioned oftset to the centerof the motor shalt, the rotationof the motor and cylinderbody provides reciprocating the motionto the piston,od, The brakefluid is thus pressurized and fed to the relief valve. accumulator and modulator, in As the pressure the accumulator exceeds the prescribed level,the pressure switch is turnedon. Approx.O.5 sconds after receiving the ON-signal. ABS control unit stops the motor relayoperation. this state, the pressure the acthe In in cumulatorreaches23000 kPa (23Okg/cm' , 327O psi). period,the lf the pressure doesn't reachthe prescribed valueafter the motor has operatedcontinuously a specitied tor ABS control unit stoDsthe motor and activatesthe ABS indicatorliqht.
ACCUMULATOR
PRESSUBE
swlTcH
To Modulator
Roliot V.lvo
valv6 Rod cylindor Eody lRotationl Pisron Rod (ReciptocaringMotionl
Anti-lock BrakeSystem (ABSI IndicatorLight

This warningsystemturns on the ABS indicator light when one or moreof the belowdescribed is abnormalities detected. This is onlv a oartiallist. a When the operating time of the motor in the power unil exceedsthe specitiedperiod. a When vehiclerunningtime exceeds30 secondswithout releasing parkingbrakelever. the a When one of the rear wheels is lockedduring running, a When absenceot speedsignalsfrom any of the tour wheel sensorsis detected. a When the activationtime of all solenoidsexceedsa given time or an open or short circuit is detectedin the solenoidsystem. a When solenoid output is not detectedin the simulated anti-lock brakesystemoperation carried out duringrunning at speedsof 6 mph (1O km/h) or more. To checkthe ABS indicator light bulb.the light is activatedwhen the ignitionswitch is turnedon. lt is turnedoff after the engrneis startedif there is no abnormality the system, in
19-40
Operation
1. OrdinaryBrakingFunction pressure In ordinsrybrakeoperations, cut-off valvein the modulator open,transmitting hydraulic the is the from the maste. cylinderto the brake calipers chamberA and chamberB. via to open.lt is alsoconnected the ChamberC is connected the reservoir throughthe outlet valve,which is normally to pressure hydraulicpressure source (pump,accumulator, switch, etc.)via the inlet valve.which is normallyclosed. ChamberD servesas an air chamber.Underthese conditions, the pressures chambers and D are maintained ol C at pfessure,permittingregularbrakingoperations. about atmospheric
O CHAMBER RESENVOIR
SLIOE PISTON CUT.OFF B CHAMBER
VALVE
CHAMBERA CALIPER
ACCUMULATOR C CHAMBER
19-41
Anti-lockBrakeSystem (ABS)
of largeand a possibility wheel lockingoccu,s, the ABS It brake inputs (torceexened on brake pedal)are excessively control unit operatesthe solenoidvalve, closing the outlet valve and openjngthe inlet valve. As a result, the high pressure di.ectedinto chamberC, the piston is pushedupward,causingthe slidepistonto move upward and the cutis the to off valveto close.As the cut-oft valvecloses,the tlow from the mastercylinder the calipetis interrupted, volume in and the fluid pressure the caliperdeclines, ol chamberB. which is connectedto the caliper,increases. the in When both of the valves,inletand outlet, are closed(whenonly the outletvalveis activated) pressure the caliperis maintained constant. valve is in to of When the possibility wheel lockingceases,it is necessary restorethe pressure the caliper.The solenoid thereforeturned off (outletvalve: open, inlet valve: closed).
Process
CaliperPressure
Outlet Valve Electric Power Hydraulic Circuit Close Close Open
InletValve Electric Power ON OFF OFF Hydraulic Circuit Open Close Close
declining Caliperpressure constant Caliperoressure increasing Caliperpressure
ON ON OFF
MASTER RESERVOIR CHAMBER D
CHAMBER8
CHAMBER A
CALIPER
ACCUMULATOR
CHAMBERC
19-42
2.
SlidePistonFunction loseadhesion, antilock brakesystemmay functhe When the car is used on roughroadswhere the tires sometimes causinga very largevolumeof brakefluid to flow into chamberC. When this occurs,the piston is tion excessively, in resultingin an abnormalloss of pressure chamberB. In orderto overcomethis problem.the moved excessively, in slidepiston is kept in properpositionby springforce to preventthe pressure chamberB from becomingnegative.
CHAMBERC
(cont'dl
19-43
(cont'dl Features/Gonstruction/Operation
3. Kickback and the pistonmovesupward.the volumeof chamberB increases, When the anti-lockbrakesystem is functioning. A andthe brake pressure the caliperside is reduced. the sametime. the volumeof chamber is reduced At on the fluid the Whenthe braketluid is pushedbackto the mastercylinder, drivercanfeel to fluid is returned the mastercylinder. the brakepedalis kickedback. the functioningof the anti-lockbrakesystem because ControlValve) Function PCV {Proportioning This proof fo. ln the modulator the rearwheels.the diameters the pistonandthe slidepistonare distinctlydifterent. ControlValve) function to preventthe rear wheelsfrom lockingduringan emergency vides a PCV (Proportioning stop. P t { 1 ) B e f o r eh e T u r n i n g o i n t : 1)When the fluid pressurelrom the master cylinderis below the turning point. the cut off valve is always pusheddownward by the force of the slidepiston and its spring, there is a gap betweenthe cut-off valve shoulderand the sleeve.ChamberA and Underthese conditjons, from the mastercylinderflows into the chamberB are theretoreconnectedthrough the gap. The pressure rear calipersthrough chamberA and chamberB.
4.
MASTER
CHAMBERC
19-4tr;
trom the mastercylindefreaches turningpoint,the force on the slidepistonoverthe 2) When the fluid pressure comes the torce ot the spring,causingthe slidepislon to travel upward. The cut-ofI valve,previously beingin contactwith the bottom of the slidepiston,then movesupwardandthe (the fluid pressure this point is calledthe at cut-otl valveshoulderhits the sleeve,blockingthe fluid passages turning point).
E3 6E
Hi
CHAMBERC
(2) After the turning point: in from the mastercylinderincreases, pressure chamberA becomeshigher,causinga the As the lluid pressure the force to push down the largediamelerportionot the piston. Consequently, slide piston comesdown. the cut-off valve is pusheddownward by the bottom of the slide piston, allowingchambersA and B to connect the As in momentarily. this occurs, pressure chamberB increases, slide piston is pushedupward, the cut-off above, valve goes up. and the connectionbetweenchamberA and chamberB is blockedagain.As described in the pressure the in when the pressure the mastercylinderis abovethe lurning point,the slidepistonreduces amount by repeating ihis process. rear caliperto the prescribed
1945
(2WSl CircuitDiagram
FUS No. FUSE TAEELNAME ECU 't3 MElrR
BATTERY
UNOR.HOOD FUSENEIAY 8OX
Rrc MIRROR
sumL-f
UNDEfiOASH FUSENELAY 8OX
A
GL*,,,n,.uf
CHASGING UGHT SYSIEM
tG (50 s:w Al
88ATE SYSIEM UGHT
sTotHoRN A) lr5
A \ I .-.1U'88AIG $,$fCH
I I
INDICATOR UGI{T A8S
YE$c+
A8S i,lOT0R Al 150 YEUGRT{-ar-
A8S 05 A} Ur{rI
WHTETU REOAVHT
sLuau(*l
PUMP l r u I ABS MOTON
GRN
BU(
+
G|03
8U(
-o-=
Gr0l Gt02 GOl
19-46
ECM
,\o ,rrtrr lSERVICE CHECK CONNECTOR ,A ttl-t,-l{,F_YEL+sLK-a
IGR{NEO GRMED
ERAKE FI.UID EVrI
PREssuRE
srvrrin
t9 WASN 2 5 WARti r
swtTcH
3i3;
Gl01 ABS INSPECTION
WHIELj(
s0[rNolDs
FRONT.R
3 fl-ot T RLW{+l 11 R.tN 6 ROW
18P CO[{NECTOR
12P CONNECTOR
30 29 28
21 7
l1
o
5
't0 ,/
8
1
21 2 0 1 9 1 8 1 7 1 6 1 5 1 4 1 3
ABS CONTROLUNIT COIINECTOR View t.om terminal side.
CASE View trom terminalside. GSOUND
ABS CONTROLUNIT CONNECTOR
1947
Circuit Diagram(4WS)
FUSE No. FUSE NAIVE LABET SAMRY UNDER.HOOD FUSENEIAY BOX 13
9 MFTEfi
R/C MIFROR
UNDEROASH FUSENEIAY BOX
rG {50 sw a)
STOP {15A} HORN
wHr-{ EvnED_fABS MOTOR A} {50
>_
JJm
A8S UNIT{?.54)
WHI,ATU I 8TD/WHT
r-
sLu,sLX_reL
A8S PUMP MOTOR

GRN BtK
SLK
BEAR FAII--SAFE RELAY
+
19-48
J-=
G101 G102 GOI
G103
A8S CONTROT
' TC|V (SCS) . ECM ISCS) glgl,rrgf-l ECM
x,a
IGRMEO GRMTD
s8vtcE cHEcK CONNECTOR Â nL*t,i[9-YEL+8LK-a
swtTcH
18WARN 2
BRAK FTUID LEVEL
Tt::$E swrlcH
.*
b*,
Gt0l
ABS INSPECIION
-J
s0tEN0tDs IRONT-R
R L W ( +1 7 ) 8RP 7 RLP 8
2OPCONNECTOR
34 33
30
28
2 6 15 CASE ABS CONTROLUNIT CONNECTOR GROUND View from terminalside.
25 24 2322 212 0 19 1 8 17
ABS CONTROLUNIT CONNECTOR View from terminalside.
19-49
Locations Wiring/Connector
ABS 82 II5 A}
UNDER.HOOD BOX FUSE/RELAY
ABS UNIT (7.5 A} FUSE
FUSE
STOP/HORN {'l 5 A} FUSE
ABS MOTOR RELAY ABS 81 (20 A} FUSE
EATTERY {1(x' A} FUSE

ABS MOTOR (50 A) FUSE
rG sw {50 Al FUSE UNIT U1{IT MODULATOR
ABS COI{TROL
iTGHT.BEAB WHEEL SEI{SOR
LEFT-REAR WHEEL SENSOR
RIGHT.FRONT WHEELSENSOR
RIGHT.FRONT WHEELSENSOR
FAIL.SAFE RELAYS
WHEEL SENSOR CONNECTOR
LEFT-FROl{T WHEELSENSOR
19-50
F.
ALB Checker
FunctionTest
NOTE: a The ALB checker is designed to confirm proper operation of the anri-lockbrake system (ABS) by simulatingeach system function and operatingcondition. Before using the checker, contirm that the anti-lockbrakesystem (ABS)indicatorlight is not indicating some other problemwith the system. The light shouldgo on when the ignitionis first turnedon and then go off and stay off one second after the engineis started. a The checkershouldbe used through modes 1-5 to confirm properoperation the system in anv one of of the following situations: - After replacing any ABS component. - After replacingor bleedingthe system fluid {0 mode not necessaavl. - After any body or suspensionrepair that may have affectedthe sensorsor their wiring. a The procedure modes 1-5 are on this page and {or 19-52, mode "O" {wheel sensorsignal)is on page 19 - 5 3 . Disconnoct the ALB checker belore driv@ ing the car, A collision can rosult tlom a roduction, or completo loss, of braking ability csusing aevo.o personal injury or doath. 4W ALB CHECKER 1. With the ignitionswitch off , disconnect ABS inthe spectionconnector(6P) from the connectorcover located on the cross-member under the passenger's seat and connect the ABS inspection connector(6P) to the ALB checker. NOTE; Placethe vehicleon level ground with the wheels blocked,out the transmission neutraltor in manualtransmission models,and in @ positionfor automatictransmission models. Stan the engineand release the parkingbrake,
5.
Operatethe ALB checkeras follows: ( l ) T u r n t h e M o d e S e l e c t o s w i t c ht o " 1 " . r (2)Pushthe Start Test switch: - The test in progresslight shouldcome ON. - In one or two more seconds, all four monitor lights should come on (lf not the checker is faultv). - The ABS indicatorlight shouldnot come ON. NOTE: When the test in progressindicatorlight is ON, don't turn the Mode Selectorswitch.
Monlror Lights
Taal ln prog.art
I
) o
Porval Ol{
Start Tcat
Modo Slscro.
4.
Turn the Mode SelectorSwitch ro "2"
A
oTHAJ-SGOO108
checkers. See poge 19-32 for othe. applicable
{cont'd)
19-51
ALB Checker
FunctionTest (cont'd)
Depress the brake pedal firmly and push the Start Test switch. The ABS indicatorlight shouldnot go on while the Test in P.ogress light is ON. There should be kickbackon the brakePedal. NOTE: The operation sequence simulated by Modes 2. 3, 4 and 5: Inspection points: '1. The ABS indicatotlight comes ON. a Check the DiagnosticTrouble Code and go to se8 page 19-55. the troubleshooting, 2. The.e is no or liftle kickbackin modes 2 through 5 and the ABS indicatorlight does not come ON' line a Air in the high Pressu.e a Restricted high Pressureline. a Faultvmodulatorunat.
Aboul 30 racond3
6.
"3", "4" and Turn the Mode Selectorswitch to "5" . Perform step 5 for each oJ the test mode positions.
Mode 1 : S8ndsthe simulateddrivingsignalO mph (O km/h) * 1 1 3 m p h ( 1 8 0 k m / h l - 0 m p h { Ok m / h )o f e a c h wheel to the ABS control unit. Thereshouldbe NO kickback. Mode 2: Sendsthe drivingsignalot each wheel, then sends the lock signal of the left .ear wheel to the ABS control unit. There should be kickback. Mode 3: Sndsthe drivingsignalof each wheel, then sends the lock signal of the right rear wheel to the ABS control unit. There should be kickback. Mode 4: Sendsthe drivingsignalof each wheel, then sends the lock signal of the left front wheel to the ABS control unit. There shouldbe kickback. Mode 5: Sendsthe drivingsignaloJ each wheel. then sends the lock signalot the right ftont wheel to the ABS control unit. There shouldbe kickback. Mode 6: Not used on this model.
WheelSensorSignalConfirmation
"O") to contirm NOTE: Use the ALB checker (mode properwheel sensoroperation. 1. Disconnect the ABS inspection connector {6P) from the connector cover located on the crossmember under the passenger'sseat and connect the ABS insDectionconnector (6P) to the ALB checker.
4W ALB CHECKER Monitor Lig}lt3
Toat In Prog6ss
Powot ON
Start Te3t
Modo Scbctot
5 . With the transmission neutral.rota each wheel in rotate briskly (one revolutionper secondl by hand, and ndl conJirm that its respectivemonitor light on the ritor checkerblinks as the wheel rotates. NOTE: a Rotatinga wheel too slowly will p ill produceonly a weak blink of its monitor light thl may be difthat Jicultto see. a In bright sunlight.the monitor ligl may be diflight Jicultto see. Performtests in a st r shadedarea. a In some instances, may not be p( it e possible spin to get the tront wheelsfast enoughtoI ge a monitorindication.It necessary, stan the en{ engineand slowly accelerate and decele.ate the front wheels. he The monitor lights should blink, indicating a ink, good wheel sensorsignal. lf any monitor light fails to blin check the blink, susPected sensor, its air gap and its wiring/connectors.
-SGOo10B 07HAJ checkers. Seepage19 32 for otherapplicable
Raisethe car so that all lour wheels are ott the ground and supporton safety stands. Turn the ignitionswitch ON. "O". Turn the Mode Selectorswitch to
19-53
Troubleshooting
Anti-lock BrakeSystem (ABS) IndicatorLight
Tomporary Driving Conditions: 1. The ABS indicatorlight comeson and the ABS control unit memorizesthe diagnostictrouble code (DTC)under certainconditions. NOTE: The DTCSare explainedon page 19-56. cora The tire(s)adhesion lost due to excesslve is neringspeed. DTC: 5, 5-4, 5-8. o The vehiclelosestraction when startingftom a stuck condition on a muddy, snowY, or sandy road. DTC: 4-1 . 4-2, 4-4, 4-4. a When the patkingbrakeis appliedfor mofe than 30 secondswhile the vehicleis being driven. D T C :2 - 1 . a The vehicle is driven on an extremely rough road. The ABS js OK. it the ABS indicatorlight goes off atter the engineis testarted. ABS Indicatol Light Circuir: CAUTION: Us6 only the digital multimetr to chsck th. syst6m.
1 . The ABS indicato.light does not go on when the ig-
nition switch is turned on. Check the following items. lf they are OK, check the ABS control unit connectors.lf not loose or substitutea known-goodABS condisconnected, trol unit and recheck: . Blown ABS indicatorlight bulb. a Open circuit in YEL wire between the No. 13 fuse/relay METER('lO A) fuse in the under-dash box and gaugeassembly. a Open circuit in BLU/REDwire between the gauge assemblyand ABS cont.ol unit, a Poot ground connection between the ABS control unit and the body. light remainsON after the engine The ABS indicator light does not is started.howeverthe ABS indicator blink any DTC. Check the following items: a Looseor poor connectionof the wire harnessat the ABS control unit. . Faulty ABS 82 (15 Al Juse in the under-hood fuse/relaybox. a Open circuit in WHT wire betweenthe ABS 82 (15 A) fuse in the undet-hood box and fuse/telay ABS control unit. wire betweenthe No. 9 a ODencircuitin BLK/YEL R/C MIRROR (15 A) fuse in the under-dash fuse/relaybox and ABS control unit. a Short circuit in BLU/REDwire between gauge assemblyand ABS control unil a ODen circuit in WHT/BLU wire between alternator and ABS control unit. lf the Droblemis not found, substitute a knowngood ABS control unit and techeck whether the ABS indicatorlight remainsON.
ABS INDICATORLIGHT
lf you receivea customer'sreportthat the ABS indicator light sometimes comes on, check the system using the ALB checkerto contirm whether there is any trouble in the system. S e e p a g e1 9 - 5 1 . The ABS indicatorlight will come on and the ABS control unit will memorizea DTC when there is insulficient battery voltageto the ABS control unit. An examplewould be when the batteryis so weak that the car must be iump-started Aftet the battery is sufficiently recharged,the ABS indicator light will work normallyafter the engineis stoppedand restarted. However, after rechargingthe battety, the DTC must be cleared from the ABS control unit's the memory by disconnecting ABS 82 {15 A) luse fuse/relaybox ior at least three in the under-hood seconds.
1 9 -5 4
Oiagnostic Troubl Cod {DTCI: 1. Disconnect the servicecheck connectorfrom the connectorcover locatedbehindthe tront of the centerconsole. Connectthe two terminalsof the servicecheck connectorwith a jumper wire. 2. Turn the ignitionswitch on. but do not start the engine. 3, Recordthe blinkingfrequencyof the ABS indicatorlight. The blinkingfrequencyindicatesthe diagnostictroublecode (DTC). CAUTION: Bforo starting the engine, disconnact the lumper wire from tho sorvico ch6ck connoctor, o. els the MalfunctionIndicatorLamp (MlL) will stay on with tho engine.unning.
DTC indication oatto.n
A8S Indicator -, light on ABS lndicator light oft
Tum the lgnition switch on -.
DTC.4-2 MainCode:4 Sub-Codo:2
DTC: 1 Main Cod6: 1 Sub-Cods: none
Dfc| 7 -2 Mlin Code:7 Sub-Cod!:2
Conngct tho iumpor wi.e
1 Second Socond pauso p6u30 1 Socond
5 Socond pau30
5 Sacond pauro
Socond paulo
NOTE: a The ABS control unit can indicatethree DTCS(one,two or three problems). a lf the ABS indicatorlight does not light, see Troubleshooting ABS IndicatorLight Circuitpage 19-54. of light again. a lf you miscountthe blinkingtrequsncy,turn the ignitionswitch off then on to cyclethe ABS indicator fuse/relaybox for at least a After the repairis completed.disconnsctthe ABS 82 {15 A) fuse in the under-hood three secondsto erasethe ABS control unit's memory.Then turn the ignitionkey on agsin and recheck. a The memoryis erasedit the connectoris disconnected from the ABS controlunit or the ABS controlunit is removed from the bodv. a AJter recording referto the Symptom-to-System Chart. the DTC (if applicable),
SERVICE CHECX CONNECTOR I2PI
(3PI DATA LINK CONNECTOR NOTE: Do not attach the jumperwire.
ABS INDICATORLIGHT
19-55
Troubleshooting
Symptom-to-SystemChart
DIAGNOSTIC AFFECTED CODE PROBLEMATIC TROUELE (DTC) COMPONENT/ SYSTEM FRONT FRONT REAR REAR MAIN SUB. RIGHT LEFT RIGHT LEFT CODE CODE
ABS pump motor over-tun
PAGE
OTHER COMPONENT
PAGE
Solenoid
1 9 - 5 7 ABS pump motor

switch Pressure 19-59 ABS motor relay ABS unit tuse ABS motor fuse 19-87
{3}
.tt!
ABS pump motot circuit problem High pressure leakage
\7
1 9 - 6 2 Solenoid{s) 19-63 19-64 Jluid level I I Brake 19-64 I switch, I light sYstem I I Brake 19-88
Wheel sensor installation
19-84
it)
Pressure switch Accumulator I | gas teakage

Parkingbrake switch-related problem
{t} '.'-
x,.
tu
{3}
/*\
{i}
o o o o
J.;\
Pulser(sl
o o
o
o
19-65
Wheel sensor
tqt
\:l
Wheel sensorls)
rD
o o o o o o
o
o
19-67
\9r
r:\
o
{1}
o o
o
19-69
Modulator Rear brake drag 19-87 (Function Test) ABS 81 fuse Front Jail-saferelaY Rear tail-safe relay
relay Fail-sale
{u
v..
rt
!)
Solenoid related problem
19-75
19-78
19-56
Flowcharts
Diagnostic Trouble Code (DTC) 1: ABS Pump Motol Over-run (2O seconds) CAUTION: Uso only tho digitsl multimetor to chock tho systom' Pro-lat st6p: a Check tor tluid leaksfrom the tunctionalparts and teplacethe faulty pans it there is a leak' Functional pans: a Modulatorunit a ABS Pump assembly a High pressure hose/pipe
With onglno running, ABS indicotor llght ls Oil. \ tith Bewicchsck connocto. iumpod lsoe pago 19-55), DTC 1 b lndlcat6d. View lrom underhood lusekelav box terminal side.
FmnffiffirflFTr;l IUffilluffillE:l
Bleed high pressure fluid from the maintenance bleeder with the EleederT-wrench {see p6go 19-81).
Connect the No. 29 and 30 terminals using a jumpe. wire lor about eighl seconds. Pump runr with a conatant 3oft touno: Blo.d sl. trom anil-lock b.ako lyttam uling the procoduto on p6go 19-86 and chock the pump round again.
UNDER-HOOD BOX FUSE/BELAY
Doesthe ABS pump motor run loud, with an increasingly raspy sound?
Check the accumulator fluid quantity by bleeding the high pressureline with the BleederT' BOX CIRCUITDIAGRAM FUSE/RELAY UNOER.HOOD
ls there40-70 cc?
(To page 19-59)
uMlTl 70 cc (UPPER 40 cc {LOWERLlMlTl
(To page 19-58)
T-WRENCH BLEEOER oTHAA-SGOO101
{cont ct
19-57
Troubleshooting
Flowcharts (cont'dl
(Frompage 19-57) {Frompage 19.571
Connectthe No. 29 and No. 30 terminals usinga jumperwire for about 1O seconds.
Check if there is any changein the fluid level in the reservoir tank. ls there anV change? Faulty ABS pump motor {Rell6t velve i3 dofective and ooenl. Replace tha ABS pump a$emblv.
F.uhy.olonoid (loak.g6l. R6plac6lho modulator unit.
Connect the No. 29 and No. 30 terminals usinga iumperwire for about 1O seconds.
Disconnect the pressure switch 2P connector and checkthe continuity betweenthe No. 1 (YEL) and No. 2 {YEL)terminals.
Continuity? View from terminalside.
TIE v.r|.ch b OK at thb timo.
19-5 8
TroubleCode (DTCI l-2: ABS Pump Motor CircuitProblem Diagnostic CAUTION: Use only the digital multimeterto check the system. NOTE: l{ a malfunctionis detected,this code appearsand the fail-safelunction is activated.The ABS indicatorlight the the comesON after restarting engineuntil the DTC is erased{by disconnecting ABS 82 (15 A) fuse in the under hood fuse/relaybox for three seconds). Pre-test stgps: a Check ABS MOTOR \5O A) iuse in the under-hood luselle\aY box box. a Check ABS UNIT {7.5 A) fuse in the under hood {use/relay fuse/relaybox connectors. a Check for loose under-hood
Wirh engine running, ABS indicator light is ON. - With sruicecheck connector iumped lsee Pago 19'551, DTC 1-2 is indicated.
Checkthe ABS pumPmotor relaY (seepage 'l9-87).
Does it work Proporly?
Connectthe No. 29 and No. 30 terminals using a iumPer wlre.
box View from underhood luse/relay terminalside.
Doesthe ABS oumpmotor run?
( T op a g e1 9 - 6 1 )
ffilffilffil _ ll l _?9lgl91l-l l___q1_1_
Removerhe ABS UNIT (7.5 A) Iuse in the underhoodfuse/relaY box.
(To page 19-60)
JUMPERWIRE
BOX CIRCUITDIAGRAM FUSE/RELAY UNDER.HOOD
19-59
Troubleshooting
Flowcharts (cont'd
19-59t
Check tor voltage belween lhe underhood fuse/relavbox ABS UNIT fuse No. 31 terminal and body groLrnd. Repairopen in WHT/BLK wire between the ABS UNIT (7.5 Al luse in ihe undr-hoodluse/rlaYbox and ABS contaolunit.
ls there battery vollage?
the fuse in the under' Reinstall box. hood fuse/relay
Disconnect the 2P connector lrom the ABS pump molor-
Check for voltage between the ABS pump molor relay No. 30 terminaland body ground.
UNDER-HOOD Batteryvoltago? FUSE/RELAY AOX

ls therebatteryvoltage?
Check for voltage between the No. 32 termjnal and body ground.
ls therebatteryvoltage?
Rpair opon in BI-K/YELwire betwsen the No. S R/C MIRROR (15 Al fuso in the undeFdash fusa/relav box and ABS PumP motor alav.
l2WSl 18P CONNECTOR 2 5 2 4 23 30 29 2a 27 t!J 14 13 22 21 20 1 9 1 8 1 7 1 6
'l8P the {4wS: 2OP) Disconnecl connectorfrom the ABS control unit.
B.ttery
uon"n", )r,-,r.o Qf IPMR} I
View from ABS controlunit terminalside Check {or voltage between the ABS control unit connectorNo ter 18 {4WS: No. 21 ) (YEL/RED) minal and body ground. wire be' Ropairopsn in YEL/REO tween iho ABS pump motor relay and ABS control unit. Battery vorr"e"z $)
l4WSl 20P CONNECTOR
34
24
32 3 1
lul
30
2A 21 't5
2 1 20 1 9 1 8 1'1
YES
\tu"o
t'"t'
View from ABS conlrolunit terminalside

trcl rrir dd recheck
19-60
lFrompag619 59)
Cheek tor vollago bgtwoon the No.29 terminal and body ground.
CONNECTOR HARt{ESS-SIDE BLK (GROUNDI Disconnect the 2P connector Irom the ABS pump motor. WHT/BLU IMOTOR RELAYI
Check for voltagg btween the No, 1 (WHT/BLUItrminal and body ground.
ls thro battry voltage?
Rogah opn in WHT/BLU wiro bctwaan th6 ABS pump motor rohy and ABS pump molor. COI{NECTOR HARNESS-SIDE
Ch6ck for voltage betwen the 'l (WHT/BLU) terminal and No. No. 2l8LKl tsrminal.
BLK {GROUNDI
WHT/ALU IMOTOB
86ftery Voh.g?
View from terminalside. Rpairopen in BLK wlro botwoon tho AgS pump moto. and g.ound or pool ground 1c403).
ls there battery voltago?
Fauhy ABS pump motor. Roplac tho ABS pump a.tom' blv.
191
Troubleshooting
Flowcharts (cont'd)
Diagnosric Troubl Code (DTC) 1-3: High Pr6$ur Leakag6 CAUTIOI{: Uso only th digital multimetor to check tho syEtam. Pre-test steps: a Check reservoir fluid level. and if necessa.y, to the MAX level line. fill a Check for tluid leaksfrom the lunctionalparts and replacethe faulty parts if there is a leak. Functional parts: a Modulatorunit a ABS Pump assembly a High pressurehose/pipe
Whh 6ngino running, ABS indicator light is ON. With soryice chock conngctor jumpod (s6o pag6 19-55), DTC 'l-3 is indicatod,
View trom undeFhood fuse/relay box terminalside.
il-fnntrT-ll ll-Tl-f-Tlll
IUffil[Iml|[[_trl
I l'.ll
Bleed high pressure lluid lrom the maintenance bleeder with T-wrenchlsee p6ge the Bleeder 19-81).
Connectthe No. 29 and No. 30 terminals using a iumper wire lor about 10 seconds.
Disconnect the 2P connector from the pressureswitch.
AAS PUMP AAg UiIIT I7.5AI
Alter 30 minutes, check for continuiry belween the No.1 {YEL) terminalson the and No.2 {YELI switch side of connector.
BOX CIRCUITDIAGRAM FUSE/RELAY UI{OER-HOOD SWITCH SIDE CONNECTOR
The v.hicL l. OK rt thb tlmo.
Continulty? Frrty .oLnoid (leakago). Ragaac. tha modulator unit.
19-62
J ! ' . r t i t . d .
Dlagnostic Trouble Code (DTC) 1-4: PressurSwitch Circuit CAUTION: Uso only tho digit8l multim6tor to chock tho systom.
Wlth.nglno iunnlng, ABS indlcator llghi 18ON. - With solvico check connoctor iumped (3e p.go 19-551, DTC t-4 k indicatod.
8led high pressure fluid trom the maintenance bleeder with the Bleeder T-wrench {soe page 19-81). CONNECTOR SWITCH.SIOE Oisconnect the 2P connector from the pressureswilch.
Chock ths continuiiy ol prssur switch b6twe6n the No.l (YEL) terminals. and No.2 (YEL)
Continuity?
View trom terminalside.
CONNECTOR HARNESS.SIO
Check for continuity between the No. 1 (YEL) terminal and body ground on lh harness sade connsclor.
Ropairlhort In YEL wl.o ttotwoen tho ABS control unit and P]taur6 lwitch.
Chock for looao ABS control unii connactor!. lf noc6ara.y, lubatituto a known-good ABS control unlt and r6chock.
(conl d,
19-63
Troubleshooting
Flowcharts (cont'd)
Diagnostic Troublo Codo {DTC) 1-8: Accumulator Gas Leakage Chock tho tollowing itoms: a The relief plug is loose. a The reliet plug O-ringis out ol place. a Bleedthe high pressure T-wrench.Operate line with the Bleeder the ABS pump motor for 10 secondsand bleedthe pressure with the Bleeder T-wrench.lf no tluid or more than 70 cc of lluid come out, replace the ABS high line again pump assembly.
BLEEDER T.WRENCH 07HAA-SGOOIO'l or 07t{AA-SG00100 RESERVOIR
ABS PUMP ASSEMELY
Diagnostic Trouble Code {DTC) 2-1: Parking Brake Stvitch Related Problom lf causes. they are OK, checkthe ABS controlunit the lf the parkingbrakehasbeenreleased. followingitemsare possible substitutea known-goodABS control unit and recheck. connectorsfor good connection.lf not looseor disconnected, fuse/relaybox for three DTC 2-1, removethe ABS 82 {15 A) fuse in the under-hood NOTE: Beforetroubleshooting secondsto clearthe ABS control unit's memory,then test drive the car. is lf the ABS indicatorlight stays otf, the probability that the car was drivenwith the parkingbrakeapplied. a a a a a a The parkingbrake is appliedfor more than 30 secondswhile driving. The brakefluid level in the mastercylinderis too low. wire is shortedbetweenthe brakesystem light and parkingbrakeswitch. GRN/RED wire is shoned betweenthe brake system light and brakefluid levelswitch. GRN/RED The brakesystem light is blown GRNiRED wire has an open betweenthe brakesystem light and the ABS control unit.
'
Diagnostic Troublo Code {DTC} 4-1 to 4-8: Wh6el Sensor CAUTION: Us only th6 digital multimeter to chck ths systsm. The ABS indicator light may functionis activated. NOTE: lf a malfunctionis detected,this code sppears and the fail-safe the come ON after restarting the engineuntil the DTC is erased(by disconnecting ABS 82 (15 A) fuse in the under-hood fuse/relavbox for three seconds).
With ongine running, ABS indicator light is oN. With servico chgck conneclor ju.npod (s66 pag. l9-551, DTCa 4-1, 4-2, 4-4 andlol 4-8 a.e indicaled.
FL BRN: O
18PCONNECTOR {2WSl FR GRN: O GRN/BLU: @ FL

FR GRN/BLK: @
Disconnect the 18P 14WS:20P) connectorfrom the ABS control unil.
cRy: RL O BLU/YEL:RR O
GRN/YEL: @ RR LT/BLU: BL @
Vi6w from ABS control unit terminal side. 20P CONNECTOR l4WSl
Check the rcsistance of each sensor between the positive and negatave: . GRN/BLK: Front Right Positive GRN: Front Right Negative . GRN/BLU:Front LeIt Positive BRN:Front Left Negative . GFN/YEL: RearRightPositive RearRight Negative BLU/YEL: . LT ELIJ: Rear Left Positive GRY: Rear LeIt Negative
BRN:FL O
GRN:FR O GRN/BLU: O FL
34 33 32 3 1
Lq
21
30
2A 27
24 23
19 1 8 17 1 6 1 5 GRN/YEL: LT/BLU: RL O
GBY: RL O BLU/YEL:RR O
View lrom ABS control unit terminal side
ls there Front: 70O-11OO O, Rear r 10OO 1600 o? Rpsir short in Senaor wire ol Roplacotho whool ren3or. CONNECTOR SENSOR-SIOE Check for loose ABS conttol unit connoctors. Chock thai th6 son3o. is installod p.operly. ll nocoslary. substitulo g knowngood ABS control unit and rschck. ls there '1000, Front:7O0- 1 Rear: 1OO0- 1600 0? FRONT REAR
5--/
Disconnoct the 2P connector of the wheel sensor.
(l zTI' |)
\+# @
r-t tl
_/r-l\//---\\
I|Ell
rFSb
.LOr
1000-1600 0? 700- l too o? Viewfromterminal side.
(To page 19-66)
19-65
Troubleshooting
Flowchart {cont'd)
(Frompage19-65) 'l8P (4WS: 2OP) Roconnect th connector to the ABS control unit. HARNESS.SIDE CONNECTOR FRONTLEFT FRONTRIGHT
Check each wire for continuity belween the whoel sensor terminalsand body harness-side ground.
ffi"U""'os4ffiffin's
@ +
Rapalr opan lo wlr! hrmaaa.
o +
o
@ +
l\-/l
I6
Contlnuity? REARLEFT REARRIGHT cRY: /=\ _LT8LU: BLU/YEL:_ GRN/YEL:
o-tFlfl-gf @ -t-
-tF'tl_-
lHgf o
I
Chock tor looao whool 3onaot connoctoE. It nocolltry, tubatiiuto a known-good ABlt control unit and rochock.
Positivs: k0 a 15% is OK. 3.3 Nggrtivo:Lessthon 1 O i6 OK.
0 I
0L
0 I
Contlnulty? Visw from terminal side.
19-6 6
""hi r r! $Hl L,lllft&trrt,
Dbgnctic Troublo Code (DTC) 5 to 5-8: Wheol Snsor(s) CAUTlOttl: Use only th digltal multimotor to chock tho syEtm. light may The ABS indicator functionis activated. and the iail-safe NOTE: lt I malfunctionis detected,this code appears the the engineuntilthe DTC is erased{by disconnecting ABS B2 (15 A} fuse in the under-hood ON sfter restarting come box tor three seconds.) (2WS) 18PCONNECTOR
Wlth onglnc running, ABS in' dc or llght l! ON. Wlih lowlco chock connoctor iump.d {roe paga t9-55), DTC. 5, 54 or 5-8 l! indlcrtod.
30
2a 27
21 20 1 9
t!!J
'18
26 25 24
1 1 16 1 5 1 4
LTBLU:RLE :RLO \ RR BLU/YEL: O the Disconnect 18P(4ws: 2OP) lrom the ABS control connoctor un|t.
Viw {rom ABS control unit t6rminal sido'
20P CONNECTOR {4WSl 34 32
uJl
21 20
30
1 8 't7 1 6
26
Chock th .esistance ot each sonsor between th positive and n6gativo: . GRN/YEL:Rsar Right Positive SLU/YEL: Rssr Right Negarive . LT BLU: Rear Left Positive GRY: Rear Left Ngative
25 24 23
GRY: R L O \
BLU/YEL: O RR
LYELU:RL@ RR GRN/YEL: O
tsrminalside. Vigw from ABScontrolLrnit
ls thero 1OO0- 1600 07 Rcprlr rhort In lonlor wiro ot Rapbco tha whaol lonaor.
Disconngct lhe wire trom wheel sensor.
hamgss
Rconnect the l8P (4WS: 2OP) connsctor to the ABS control unit.
Connoct the ALB checker to tho ABS insDeclionconnector. Chock Ior resistance botween ths sensor terminals. Chck for ABS lunction in mode 2 and 3. Dos it work prop.ly? SENSOR.SIOE CONNECTOR REAB
Check to, rctr bt.k6 dr.g. ll OK, sub.ftut6 a known-good ABS control unlt and .ochgck.
ls there 1OO0- 1600 O?
YES (To pag 19-681
1000- 16000? side. (conl.d) Viewfromterminal
19-67
Troubleshooting
Flowcharts {cont'd)
Reconnecr the 18P l4WS: 2OP) connoclor to th ABS control unit.
HARNESS.SIDE CONNECTOR REARLEFT REARRIGHT GRY:\ /=\ lT BLU: BLU/YEL:^ GRN/YEL:
Check each wire for continuity between the wheel sensor harness-sidetorminals and body ground.
e_HE{_e l:l
9 +
9 +
o_r$Lo l,*,I
9 +
0 +
Contlnulty? Rrpdr op.r| lo whr h.rnaar, Vi6w trom torminal sido.
Chock lor looig whool lenaoi conn6ctorE.It nocoraary, aubatitut6 a known-good ABS control unlt and rochock.
Positivs: 3.3 k0 a 15% is OK. Nogative: Less th6n 1 O is OK.
1 9 -6 8
Diagnostic Trouble Code (DTCI 6-1 : Front Fail-SafeRelay Cilcuit CAUTION: Use only the digital multimtel to check tho systom. Ple-test steDs: fuse/relaybox. a Check ABS B1 (2O A) tuse in the under-hood a Check for loose under-hood fuse/relavbox connectors.
With engine running, ABS indicator light is ON. With so.vic6 chock connector iumped lsee pags'19-551. DTC 6-1 is indicated. FAIL.SAFERELAYS
Removethe lronl faifsale relay from under the gauge assembly.
Wire colors oI the laifsate relay conneclor FTONT: BRN/BLK, BLK/YEL, YEL/GRN, BLK Rear: BLU/8LK,BLK/YEL, YEL/GRN, 8LK
Check relay function lsee page 19-87).
Doesrt work properly?
R6plac. thc tront f.ll-..f.
r.hy.
Check for voltage between the fail-saferelay connector No. 1 (BLK/YEL)termanal and body ground, Repiropen In 8LK/YEL wlre between the No. 9 R/C MIRROR {15 A} fuso In the unde.-da.h tuao/rolay box and lront tald-ato reley.
HARNESS-SIDE CONNECTOR
ls there batte.y voltage?
Disconnectthe 10P connector from the solenoids. B.ttoryVoltago? Check for continuity between the fail safe relayconnectorNo. terminal and bodv 2 (BRN/BLK) ground. Continuity?
View trom terminalside.
{ T op a g e1 9 7 0 ) {cont'd)
19-69
Troubleshooting
Flowcharts (cont'd)
(Frompage19-691 R.pai. rhon In BRN/BLK wlro botwoon thg aolenold and lront tlilal. rolry.
Check each wire {or continuity between the solenoid terminals and body ground Front Right No.4 {BRN/BLK): Front LeIt No. 6 (BRN/BLU): View from trminal sid6. F.uhy lol.nold llhortl. RapLca tha modulator unh. (2WS) 12P CONNECTOR REO/8LU RED/BLK tFL-r ) tFR-rN)
YEUBLK IFR.OUTI
YEUBLU
{Ft-our}
Continuity? Viw trom ABS control unit terminal sid6. (4WSl 14P CONNECTOR RED/BLU RED/BLK (FUINI {FR.IN)
Disconnct the connectors lrom the ABS control unit.
Check each wire for conlinuitY between the ABS control unit connectot and body ground. Front Rightlnlet RED/BLK: YEUBLK:Front RightOutlet RED/BLU:Front LeIt Inlel YEL/BLU:Fronl Left Outlet F.p.h lhon In wi . b.twgln tho roLoold lnd A&S cont.ol unh: RED/BLK:Froot Right InLl YEUELK: Front Rlglrt Outht RED/8LU: Front L.ft Inlot YEUBLU: Froot L.ft Outlct { T op a g e1 9 - 7 1 )
YEUBIT( (FR.OUTI
YEL/BLU (FL.OUT)
Contlnulty? Viw from ABS control unit terminal side.
. ",r-,.:,i .:dt til{ril
(Frompage19-7O)
'l8P CONNECTOR (2WS) 30 29 2A 27
llJ
26 25 24 14
21 20 1 9 1 8 1 1
c o n t i n u i t v r( C l ) ' Y E U G R N
Check tor continuity between the No. 17 (4WS: No. 19) (YEL/GRNIterminal and body ground.
View {rom ABS control unit terminal side.
20P CONNECTOR t4WSl
34 33
25 24
31
30 2a 27 21 20 't9 1 8 1 7 1 6 1 5
tlJ
Rcoair rhon in YEUGRN wire bctwaon tho ABS control unit rnd tront l.ll-.afo rol6y,
r'3*:::,, I
View from ABS controlunit terminalside. 'l8P CONNECTOR l2WSl
Reinstallthe tront lail-sale rolay.
30 E 2a 27 tlJt 26 25 2 1 14 13 22 2 1 20 1 9 1 8 1 7 1 6
Turn th ignition switch ON. Batteiy Check lor voltafe btween the ABS control unit connector No. 17 l4WS: No. 19) {YEL/GBN)terminaland body ground.
"o,,un"r (V)',tt"t{f*n
View from ABS controlunit terminalside.
20P CONNECTOR {4WSt
34 25
uJl
30
2A 27
15
21 20 1 9 1 8 11
,""ili*' (V
ls there batlery voltage? Roplir op.o in YEUGR wi o bot$,6on tha front lall-aalo rolay and ABS control unlt. 8att6.y Voltago? View from ABS controlunit terminalside.
Chock to. looso ABS cont.ol unit connoctor3. ll n6c63sary, substituto a known-good ABS control unit snd .ochock.
19-71
Troubleshooting
Flowcharts (cont'd)
Diagnostic Troublo Codo (DTC) 6-4: Re81Fail-SafoRolay Cilcuit CAUTION: Use only digital multimetar to chock tho system.
FAIL.SAFERELAYS Whh engine running, ABS indicator light ie ON. - With sorvice chock connoctol iumpod lsee pago 19-55). DTC 6-4 is indlcated.
Remove the rear lailsafe relay from underthe gaugeassembly. Check relay function (see Page 19,87). Does ir work proprly?
Wire colors of the tsil-s9te relay connector BLK BLK/YEL, YELiGRN, Front:BRN/BLK, YEL/GRN, BLK Rear: 8LU/BLK,BLK/YEL,
Rplacethc r6at fall_3aferolaY.
CONNECTOR HARI{ESS.SIDE Turn th6 ignition switch ON.
Check for voltage between the fail-saferelay connector No. 1 (BLK/YEL) terminal and body ground. R.plir opon In BLK/YEL wlro botwon th. No. 9 B/C MIRRoR (15 Al fute In th! und.i-dalh lu$/roby bor and ttont f.ll-lafo lollY. Turn tho ignition switch OFF. BlttoryVoh.go? Cootinuity?
Vi6w from trmin6l side. Disconnectthe lOP connector from the solenoids.
Check Ior continuity between the fail-safe rclay connector No. 2 {BLU/BLK)terminal and boclv ground.
Ropai. 3hon in BLU/BLK wlro b.twoon tho iolonold and torr failaalo rglav. NO ( T op a g e1 9 7 3 )
19-72
:i
(Frompage19-72)
CONNECTOR SOLENOID-SIDE
Chcck to. continuity bslwoon th solenoidNo. 5 IERN/WHT) terminal snd body ground.
Faulty lolondd {rhortl. Roolacctha modulalor unit.
Disconnect the connectors from the ABS control unit.
Check each wire tor continuity betwegn the ABS control unit connector and body ground, RED/WHT: Rearlnlet YEUWHT; Rear Outlet
RED/WHT IR.IN)
View from ABS controlunit terminalside. 14P CONNECTOR l4WSl RED/WHT {R.INI
12
8 7 6.
[]t
413
1 l 10 9 1
YEL/WHT I
Continuity?
View from ABS controlunit terminalside. Repairrhort in wlre b.twoon tho aolanoidond ABS control unit: RED/WHT:Rear Inlot YEI/WHT: Roar Outlot
lTo page19-74)
(cont'dl
19-73
Troubleshooting
Flowcharts (cont'd)
(Frompage19-73) laP CONNECTOR l2WS)
[Jl 26 25 24 23 30 29 2A 15 14 22 21 20 1 9 1 8 1 1
Check for continuity between rhe No. l7 (4WS: No. 191 (YEL/GRN)terminal and bodv ground.
Continuity?
tFsR)
View lrom ABS control unit terminal side.
20P CONNECTOR t4WS) 34 33 24 3l
tllj
30
28
26
22
20 1 9 1 8 1 7 '16 1 5
Fop.lr lhort In YEL/GRN wito btwon tho ABS contlol unit and '.ar lail3ata rclay.
,'.:1;"' e
Continuity? =L.
View from ABS control unit terminal side. Reinstallthe rear laifsate relay. {2WS} 18P CONNECTOR Turn the ignitionswilch ON. 25 2 1 30 29 2A 27 uJ 't9 1 8 't7 1 6 1 5 1 1 21 20 22
Check for vollage between the ABS control unat connector No. ter17 (4wS: No. 19) (YEL/GRN) minal and body ground.
(V) vorr"e"z
;:;;
View from ABS control unit terminal side
20P CONNECTOR l4WS) 34 33 25 24 3l
tlJl
30
2A 27 26
2'l 20 1 9 1 8 1 7 1 6 1 5
YEL/GHN t \l tFsRt \-rganeryVoltage?E

ls there battory vollage? Repair op6n in YEL/GRN wito b6twcan thc toar fail-3at6 rel6Y and ABS cont.ol unil. View from ABS controlunit terminalside.
chck lor looso ABS cont.ol unlt connoctors, It necesaary, subrtituts a known-good ABS con_ trol wrh snd rocheck.
19-74
, .d.'{Fi.FFn-.r-,,q.iiillilnryl&_
Diagnostic Trouble Code {DTC) 7-1 and 7-21 Front Solonoid RolatedProblom CAUTION: Uso only tha digital mullimeter lo chsck tho systom. Pr6-test steps: . Check ABS B1 (20 A) fuse in the under-hood tuse/relay box. luse/relaybox connectors. a Check for loose under-hood
wlth ongino running, ABS inlcator light is ON. - Wlth sorvico ch6ck connocto. ,umpd lloo pa96 t9-551, DTCa 7-1 6nd/or 7-2 ir indic.tod,
RED/BLU{FLIN)
CONNECTOR SOLENOID-SIDE RED/BLK(FR-INI
oisconnect the lOP connoctor from the solenoids.
Check for resistance between terminal: the solenoid ) N o . 1 ( R E D / B L Ka n d N o . 4 FrontRight Inlet {ARN/BLK): N o . 3 { R E D / B L Ua n d N o . 6 ) (aRN/BLU): Front LeIt Inlet
1-3 0?
ls there 1 -3 0?
Check lor resistance between the solenoid terminals: ) N o . 8 ( Y E L / B L Ka n d N o . 4 (8RN/BLK):Fronr Right Outlel No. 1O (YEL/BLU)and No. 6 IBRN/BLU):Front Left Outlet
'l ls there -3 O?
t-30? Viewfromterminal side.
{Topage19-761
(cont dI
19-75
Troubleshooting
Flowcharts (cont'dl
(From page 19-75) (2WSI HARNESS-SIOE CONNECTOR
Disconnect the 12P (4WSr 14Pl connector from the ABS control unit,
RED/BLU IFL,IN)
YEL/BLK (FR-OUTI
Check each wire lor continuity belween lhe ABS cont.ol unit and front solenoid. RED/BLK:Front Righr Inlet YEL/BLK:Front Right Outlet RED/BLU:Front Lelt Inlet YEL/BLU:Front Left Ourlet
YEL/BLU IFL,OUTI
Continuiiy?
RED/ALUIFI--IN)
tFR-OUtl
View lrom ABS controlunit terminalside. HARNESS-SrOE CONr{ECTOR t4WS} REO/SLK {FR-INI View lrom lermanalside. REOiBLU IFL{NI
YEUALK (FR-OUTI Contlnuhy?

RED/8IU (FL.II{}
YEL/BLU (FL,OUT)
Rapdr opan h vri a batwaan tha |oldrold ..d ABS coitrol unh: REDrSL|(: Froit Rlght lnbt YEUBLK: F oni Rlght OutLt REO/8LU: Front L.ft InLt YEUBLU: F or L.ft OutLt
YEL/8LK IFR-OUTI View from ABS conirolunil terminalside.
12P CONNECTOR t2WS) REO/8LU {FL-IN) REDiBLK {FR{NI

8
Check each wire tor continuity between the ABS control unit and body ground. RED/BLK:Front Right Inlet YEL/BLK:Fronl Right Ourlet RED/BLU:Fronl LeIt Inler YEL/BLU:Front Lelr Ourlet
11 1
llJ
10 I 3 2
1n
YEL/BLK IFR-OUTI
;l:tt$
Continuity?
.o) (o.
(To page19-77)
View lrom ABS controlunit terminalside.
1 9 -7 6
" -ffit4!{r"{?flFqrr+*'
"'frf,!ffiru..
(Frompage19-76)
14P COI{NECTOR {4WS) RED/BLU(FL-IiI} RED/BLKIFR.INI
12 tlJ 1 1 1 0 I ) I 7 6 5 4 3. 2
Conrlnulrv? / |
YEL/BLK IFR-OUTI
6 c)| ['.:-6'r'Y' oXo

View from ABS controlunit terminalside. View from controlunit terminalside. Ropalrrhort In wlre baiwaen th lolonold and ABS contrcl unlt: RED/BLK:Fronl Rlght Inlot YEL/BLK:F.oot Rlght Outht RED/BLU:Front Lolt lnlor YEUBLU: F ont L6ft Outl.t Wiro colors of the tail-saIe rlav connecror FTONT: BRN/BLK,BLK/YEL,YEL/GRN,BLK Rear: BLU/8LK. 8LK/YEL, YEL/cRN, BLK FAIL.SAFERELAYS
Remove the lront foil-sate ilav from under the gauge assembly.
Check for relay function (se pago 19-87).
Ooes it work propedy?
R.placc thc fronl tall-..fo .elay. HARNESS-SIDE CONNECTOR
Chck for continuity betwoen th fail-sato rglsy connectoi No. 4 terminal and body ground.
Roprli opcn In BLK wire betwen tho fall-aafo l6lay and g.ound or poo. ground lG4O1, G4O2, G/rO4l. View from terminalside. Check BRN/BLK wirs for conand tinuity bgtwoonthe aolonoid3 front failsate relay. =
CONNECTOR HARNESS.SIDE
Rcpair opon In BRN/BLKwl.o b.twean tho rolanolda and f.ont lall{ol. relay,
BRN/BLK
Chack tor looae ABS control unh connactota. lf nocolaaty. .ublthuto . known-good ABS contrcl unh ond rechock. View Irom terminalside.
19-77
Troubleshooting
(cont'd) Flowcharts
Dllgnostic Troublo Code (DTCI 7-4: Roar Solenoid Problem CAUTION: Uso only tha digltal multimolol to chck the systm'
YVhh.nglno runnlng, ABS Indcator fight ir ON. - Whh raNico chqck conneclol jurnp.d (te6 pag 19-551, DTC 74 l. indlc.lod.
REDAAIHT
tR-rNl
BRN/WHT YEL/WHT {R-OUT}
Oisconnect the lOP connector from the solenoids.
1-3 0?
View from tsrminal 9ido.
Check for registance between the solenoid terminals: I N o . 2 ( R E D / W H Ta n d N o . 5 (BRN/WHI: RearInlet I N o . I ( Y E L f l V H Ta n d N o . 5 (BRN/WHT):Rear Outlst
I2WSI COI{NECTOR HARNESS.SIOE
tgrminal 3ide. ls thete 1 -3 O? Co lnuhy?
YEL/WHT (R-OUTI (R.IIU RED/WHT
the 12P (4WS: 14P) Disconnect connector trom ABS control unit.
Check each wt {or continuity botween the ABS control unit and r6ar solenoid: RED/WHT: Rear Inl6t YEL/WHT: Rear Outlet
View Irom ABS control unit terminal gide CONNECTOB I4WSI HARNESS-SIDE
Raprlr opan In wlra botwaan tho rolonold .nd ABS cont.ol unlt: REO/WHT:R.at Inl.t YEL/WHT: Redr Outlot Condnuity?
(R.INI REDAATHT
YEL/WHT{R-OUTI
(To page19-79) View from ABS control unit terminal side'
1 9 -7 8
{Frompage19-781
(2WSl 12PCONNECTOR RED/WHT {R.INI
14P CONNECTOR t4WSl REON/HT IR-INI
Check each wi.e tor continuity between the ABS control unit and body ground: RED/WHT: RoarInl6t YEUWHT: Roar Outlet
IR-OUTI
View trom ABS control unit terminal side. Roolir lhort ln wlre btwocn iho lolgnold and ABS cont.ol unlt: REO/WHT:Roar Inlot YEL/WHT: R6or Outlct Remove the rear lail-safe relav Irom under the gauge sssembly. Wire colors ot tho fail-safe relay connector F.ONI: BRN/BLK. BLK/YEL, YEL/GRN, BLK Rear: BLU/8LK,BLK/YEL, YEL/GRN, 8LK
View from ABS controlunit terminalside. FAIL-SAFEBELAYS
Check for rglay lunction {se page 19-87).
Does it work properly?
RapLco tho rorr tril-lafo
roaly. HARNESS.SIDE CONNECTOB
Check for continuity betweon the tail-safe rclav connector No. 4 (BLK) terminal and bodY grouno. Raprlr opon in BLK wl.o botw66n tho hll-refe rcl.y and ground o. poo. ground lc4o1, G402,
G/ro4l.
Check BLU/BLK wire tor continuity betwsen th solenoidand rar tail-safe rlay.
CONNECTOR HARNESS.SIDE
Ropalrop6n In BLU/BLKwi.o b.twaen lhe 3oLnold rnd roar faillrtc rohy.
BLU/BLK
Chock for loote ABS cont.ol unlt connecioaa. lf nccoraary, aubBtitute a known-good ABS cont.ol unh and rochock.
Continuity?
19-79
HydraulicSystem
Index/HydraulicConnections
CAUTIOI{: Do not spill brsks tluid on tho car; it may damage the paint; if brake fluid does contact the paint, wash it oft im.nadillcly tYith water.
TANK RESERVOIR Brake Fluid Draining, page19-81
' 1 0x 1 . 0 m m 1 9 N . m 1 1 . 9k g - m , 't 4 tb-ft)
To right-l.onl brako
To lolt-tiont
to agnr+eat,// 7' br.ke ,/

To loft-roar brake
MODULATORUNIT page 19'82 Removal/lnstallation, page 19-83 Index/Torque,
10 x 1.0 mm 1 9 N . m ( 1 . 9k g - m , 14 tb-ft}
19-80
RelievingAccumulator/LinePressure
@ 1. 2. 3. Use the BloederT-wrench before disassemblingthe parts shaded in th illustration, Ooen the hood. Rmovethe red cap from the bleederon the modulatorbody. Installthe specialtool on the maintenance bleeder and turn it out slowly 90" to collecthigh-pressure fluid into the reservoir. Turn the specialtool out one completeturn to drainthe brakefluid thoroughly. Retighton the maintenance bleederand discardthe fluid. Reinstsll the red cao.
4. 5.
ReservoirBrake Fluid Draining

1. Drainingbrakefluid from modulatortank: The brake fluid may be sucked out through the top of the modulatortank with a syringe.lt may also be drained through the pump joint after disconnecting pump hose. the Drainingbrakefluid from mastercylinder: Loosenthe bleed screw and pump the brake pedalto drainthe brakefluid from the mastercylinder.
2.
a High-p.ossul tluid u,ill squirt out if th6 shadod hoso and pip are removod. a To drain high-prossursbrake tluid. follow the procodure on this page.
19-81
ModulatorUnit
CAUTION: a Ba carsful not to bond 01 damage tho brako pipos when romoving tho modulator unit' a Do not spill brake lluid on th car; it may damagthe paint; if brak fluid dos contact the paint, w88h it ofl immodiately rYilh tYatel, a To pravont spills, covol tho hose ioints with lags or shop towels' a Bofore reassembling,ch6ck that all pans are free of duEt and othr fo?sign particlss' a Do not mix diffarsnt brands ot brako tluid as thoy may not b compatibl' a Do not reus6 the dtaind fluid. Uso only clean DOT 3 01 4 brake fluid' a Whan connocting tho brak pipos, mako sula that thelo is no intorflonce betwaon th braka pipos and othor panE' 1. Drainthe brakeJluidIrom the mastercylinder. hose is to be disconnected, fluid (seepage 19-81) when the high pressure the high pressure 2. Relieve 3, 4. Removethe intake air duct switch connectors' the solenoid,pump motor and pressure Disconnect the six brakepipesJromthe modulatorunit. 5. Disconnect 6.Loosenthetwo|owermount|ngbo|ts,andremovetheuppermountingbo|tsndthemodu|atorunitlromtheframe. 7. 8. lnstallthe modulatorunit in the reverseorder ot removal. After installation, till and bleed the hydraulic system.
MOUI{TII{G BOLT UPPER 8 x 1.25 mm 22 N.m 12.2kg-m, 16 lb-tt)
SOLENOIDCOI{NECTOR
MODULATORUNIT
PRESSURE swlTcH
CONNECTOR
LOWERMOU'{TING BOLTS I x 1.25mm 22 N.m 12.2 kg-m, 16 lb-ft) Loosn.
10 x 1.0 mm 19 N.m 11,9 kg-m, 14 tb-ft)
1 2 x 1 . Om m '19 N.m ll.9 kg-m, 14 tb-ft)
19-A2
slrrr{EriE.a..
Index/Torque
Before removing tho modulatol-to-pump high-pressurelino, bo sur to reliove ths tluid ptossure trom th. @ maintenanc bloeder{se page 19-81). CAUTION: a Do not spill brake tluid on th6 car; it may damagetho paint; it brake fluid does contact the paint, wash it oft immodiatoly with watel. a To prvent spills, cover the hose ioints with rags or shop towols' a Befora roaassmbling.chock that all parts are freo ol dust and othor foreign particlos. a Do not mix diffsront brands of brato fluid as thoy may not b compatible. a Do not rous the drainod tluid. Use only cl6an DOT 3 or 4 brako fluid. a Do not dissssembltho modulator unit, Replacotho modulator unit as an asssmbly if it is defectiv. a Do not disassomblsthe pump (oxcept plsssuro switchl,
6 r 1.0mm 1O N'm (1.O kg-m. 7 lb-ft| MODULATORASSEMBLY Do not disassemble.
CONNECTOR BRACKET SEALINGWASHERS Replace.
SOLENOIDS Leak Test,page19-84
BANJO BOLT 35 N.m {3.5 kg-m. 25 tb-ft)
I x 1.25rnm 1 5 N . ml l . 5 k g - m , lt tb-frl
PUMPEBACKET
6x1.Omm 1 0 N . m 1 1 . 0k g - m , 7 tb-tt)
MODULA ARACKET
6 r 1 . Om m 1O N.m {1.O kg-m, 7 tb-ft)
ACCUMULATOR psgo 19-85 Disposal,
HOSE CLAMP
EANJO BOLT 35 N.m 13.5 kg-m, rb-ft)
Str.O^,'/
1 0 N . m 1 1 . 0k g - m , 7 tb-til
SEALINGWASHERS Replace.
PRESSURE SWITCH PUMP ASSEMELY

Do not disassemble.
19-83
Solenoids
LeakTest
the brake fluid NOTE: lf a solnoidleaks excessively, level in the modulator reservoirtank will rise when operatingthe ABS pump motor. The modulatorreservoir may also overtlow. 1. Disconnctthe pump motor and ptessureswitch connectors. Connsct an ohmmeter between the YEL and YEL switch connector. terminalsof the pressur Attach the positive(+) leadoJ a fully charged12 V battery to the RED/WHTterminal ot the motor connector and negative(-) lead to the GRN trminal, and install a switch between negative lead 8nd GRNterminalas shown. Turn the switch on to allow sutficient grssure to and checkfor conbuild uo within the accumulator tinuity. lf ths ohmmete.shows continuity(pressure switch turned on), run the motor for 1O seconds mors, then turn the switch off
Pump
Pressure Switch Replacement
Removal
'1. 2. Securethe pump assemblyin a vise. Rmovethe banjo bolt, then removethe pressure switch from the pump housing
2.
BANJOBOLT 35 N.m 13.5kg-m,25 lb-ft)
3.
o@
/@
/1
4.
lnstallation
lnstall the pressure switch with the banjo bolt and sealingwashers,then tighten the bolt.
Replsce hissesor squeaks. a CheckiJ the solenoid the modulatorif the solenoidhissesor squeaks. a Check the pressure switch for continuity within 30 minutes,lt is normalif there is continuity' ll there is no continuitv, a solenoid is taulty or line high-pressure leaks.
19-84
Accumulator
Disposal
The accumulatol containa high prssur @ nltrogen gas. Do not puncturo. oxpose lo the flamo, or attomot to disassomblotho accumulatol or it may xplode and avar6 porsonal injury may lsult. 1. Securethe pump assemblyin a vise and remove the accumulator by turning it counterclockwise wrench. with a 19 mm oDen-end ACCUMULATOR
reL
in Securethe accumulator a vise so that the reliet plug points straightup. Slowly turn the plug 3-112 turns and then wait to three minutestor all pressure escape. 4. Remove the plug completely and dispose ot the accumulator.
19-8s
Bleeding
CAUTION: a Do not spill brake fluid on the car; it may damagetho paint; it brako fluid does contact the paint, wash it off immdiataly with water. a Make sure no dirt or other loreign mattsr is allowed to contaminato tho brake fluid. a Do not mix dilferent brands of brake fluid as they may not be compatible. a Do not rous ths drained tluid. Use only clean DOT 3 or 4 blake fluid. 1. Placethe vehicleon level ground with the wheels in blocked.Put the transmission neutralior manual transmission models, and in @ position for models. Release the parkautomatictransmission ing brake. Disconnect the ABS inspection connector (6P) underthe passenger's seat irom the cross-member connector(6P) to and connectthe ABS inspection the ALB checker.
CONNECTOR 4.
Start the engine and allow it to idle for a iew minutes,then stop it. Check the fluid level in the and refillto the MAX levelline modulatorreservoir if necessarv. fluid from the maintenance Bleed high-pressure bleederwith the specialtool. T.WRENCH BLEEDER oTHAA-SG00101
2,
o.
Start the engine and allow it to idle lor a few minutes,then stop it. Check the fluid level in the and refillto the MAX levelline modulatorreservoir if necessary, Turn the Mode Selectorswitch of the checkerto 2.
Seepage19-32lor other applicablo chockers.
the 8 . While dpressing brake pedal fitmly, push the Start Test switch to operatethe modulator.There should be kickback on the brake pedal. lf not. fepest steps 5 to 8. NOTE: Continueto depressthe brakepedalfirmly when operatingthe checker' 9. Turn the Mode Selectorto 3, 4. and 5 Performstep 8 for each oJthe test mode positions.
3.
Fill the modulator reservoirto the MAX level ltne cap. and installthe reservoir
MAX LEVELLINE
to 1O. Refillthe modulatorreservoir the MAX levelline snd installthe reselvoircaP. Disconnect the ALB checker botors driv@ ing tho car. A collision can result tlom a teduction ol complt6 loss ol braking ability, causing sevsrs prsonal iniury or death.
19 -8 6
ElectronicComponents
ABS Control Unit Replacement
1 . Removethe right quartertrim panel. 2 . Disconnect ABS control unit connectors. the
J.
Relay Inspection
1. Removethe fail-saferelaysand motor relay (locat i o n : p a g e1 9 - 5 0 1 . 2. Check for continuity betweenthe terminalsC and D. Thereshouldbe continuity. 3. Check for continuitybetweenthe terminalsA and B. There should be continuity when the battery is connected betweenthe terminalsC and D. There should be no continuity when the baftery is disconnected, <Fail-sate Relay:>
Removethe ABS control unit attachingbolts, then removethe ABS control unit.
ABS CONTROLUNIT
lnstallthe ABS control unit in the reverseorder of rmovar.
<Motor Rlay:>
19-87
Pulsers/Wheel Sensors
Inspection
Front
teeth and 1. Checkthe pulserfor chippedor damaged replaceif necessary. 2. Measure the air gsp betweenthe sensorand pulser all the way aroundwhile rotatingthe driveshaftby hand. Standard:o.4- 1 .0 mm (0.02-0.04 in) NOTE: lf the gap oxceeds1.Omm (0.04 in) 8t any point, the probabilityis a distortedknuckle,which should be replaced. 4.
Rear
assemblY. 1 . Removethe rear caliDer
2 . Removethe rear brakedisc.

teeth Checkthe rearpulserfor chippedor damaged and replaceif necessary. the air gap betweenthe sensorand pulser Measure all the way around while rotatingthe hub bearing unit by hand. Standard:O.4- 1.O mm {O.O2-O.O4in} in) NOTE: It the gsp exceeds1 .O mm (O.O4 at any point, the probabilityis a distortedknuckle.which should be reolaced.
SENSOR WHEEL FRONT
REARWHEELSENSOR
19-88
Wheel SensorReplacement
Front NOTE: a Be carefulwhen installing the sensorsto avoid twistingthe wires.
a After sensorreplacement, contirm properoperation ( s e ep a g e 1 9 - 5 3 1 .
6 r 1 . Om m 10 N.m (1.0 kg-m, 7 tb-ftI
ft I
e
fr
6r1.Omm '10N.m ll.0 kg-m, 7 tb-fr)
8 x 1 . 2 5m m 22 N.m 12.2 kg-m, 't6 tb-frl
Rear NOTE: a Be carefulwhen installing the sensorsto avoid twistingthe wires. proper operation a After sensor replacement, confirm ( s e e a g e1 9 - 5 3 ) . p
6 r 1.0mm lO N.m (1.0 kg-m, 7 tb-ft)
\ * )
l\h
"Y
8 r 1.25 mm ,/ 22 N.m 12.2 kg-m, 16 lb-ft)
6 x 1.0 mm 1 0 . r n ( 1 . Okg-m, 7 lb-trl
19-89
Body
Bumpers
Sill Roof Molding/Side Panel
Reolacement .......2G68 ...............,.,,....,. 2G58 FrontReolacement ...............,,.,,..,,,. 2G60 FrontDisassembly 2G61 .............,............ Rear Replacement ....20-62 ....................... RearDisassembly Reolacement .......2G 48 .......2G5O
Seats
*Carpet
.....2G38 FrontRemoval 2G38 ..,.,.,.................. FrontReplacement ..., FrontSeatCoverReplacement 2G4O 2G41 Rear Reo|acement,......................... 20-43 ......................... FrontReplacement ..................,,.,,... 2045 Rear Reolacement ............2G46 lnsoection .... ChifdSeatAnchor Plate............. fu47
*Consoles
Replacement
Seat Belts
*Dashboard
......... Removal/lnstallation 2O-5'l ComDonent .......2G55 Replacement
Doors
rame Sub-f
.......20-71
Sunroof fuz 1ndex .................................................
DoorPanel/Plastic 2Gg CoverReolacement,............... ........ 2G5 Replacement OuterHandle ..................... 20-6 LatchRep|acement Replacement 2G7 ... Glass/Regulator ...... Replacement 2Gg OuterMolding ..... Weatherstrips Replacement 2G9 .2G1 .................,........ 0 Adjustment Glass ....................... 2Gl 1 Adjustment Position ......................... *12 Adiustment Striker
*FrameRepair n-72 Chart............... FuelLid

Ooenerand FuelLid 2C167 ..................... Latch Reolacement ........... 2G66 OpenerCableReplacement
...2$ 28 lndex.................. ..............................Tn Troubfeshootin9 HeightAdiustment ...2G29 Panel Sliding 2G3O Closing Adjustment...... RearEdge Panel SunroofLinerand Sliding ...2G30 ReDlacement ............ 2G31 SunroofRepair/lnstallation Motor, DrainTube,and Frame ... fu32 ReDlacement Lifter and Panel Stay/Slider. Replacement ............ 2G33 GuideRails DragCheck Opening (MotorRemovedl ........................ 20-34 ForceCheck Closing (MotorInstalledl 2G35 .......................... .....,,.,,,,,. 2G64 Repf acement/Adjustment 2G67 Replacement ...................... Opener .......2G65 Trunk Lid LatchReolacement ........... 2G66 OpenerCableReplacement Weatherstrip/License Opening 2G69 ............. PlateTrim Replacement Replacement ...........2G7O Trunk Spoiler
TrunkLid
Headliners
Replacement
.......2G36
Hood
.............. 2G63 Replacement/Adjustment .... Openerand Latch Replacement 2G63 ......2G69 Replacement Hood Edge Protector Reofacement ,...,,. n'37
Trims lnterior
Window/ Windshield/Rear Ouarter Glass

fndex......,............ Windshield Removal lnstallation RearWindow Removal lnstaffation OuarterGlass Removal fnstallation ...20-14 ........... 2G15 2G16 ........ ...........2O-2O ........ 2G21 ...........2G25 .'.....2G25
Mirrors
..2G12 Power DoorMirrorReplacement ............ 2G13 Replacement MirrorHolder ....., MirrorReolacement 2G13 Rearview lnstaflation ...........2G7O
RearEmblem
Doors
lndex
CENTER SASHGUIDE so Rphcofirom, pags2O7 RBOTTATOR R.pboe.v|6m, p.g 2OB ss
GLASS Roplacofirorlt, s6g pr6 2G7 Adjustnrsnt, soo pago 20l0
OUTER ]IIOLDING 2G9 Replacemont, psB so6
GLAsSRUN CHAiT{EL
CHAI{]{EL CEI{TER R6placomat, pagp2Og sse
r(D
a (U
POWEA WNDOWMOTOR LocK cYLr DR------&

Rophcemont, sso p6gE2G5
-$
H/\I{DLE OUTER Rsplaceinent, Ee6p.!B 2Gs
ARMREATPOCKET
TXX)R Adjustm,n, 2G11 s6epa

^ d P
CJfs t ba
DETEiIT ROD
*^r.r3:
Adjuatmont, s'6psfle n-12c
ftto
HIiIGE
@RJ o \
PLASTIC COVER
I]U{ER HA DLE
POWER DOOR MIRROR SwlTCH
I I{ER HA DLE TRIM PA EL
FOWER DOOR LOCKSWTTCH POWER WNDOW swtTcH SPEAKER COVER
I'OOR PAI{EL Rplacmnt, s66 psc|e2G3
20-2
._-
CoverReplacement DoorPanel/Plastic
Pry the cap, thon rmovethe scrow. Removsth6 clips 8nd disconnoctth connectors,thon trim oan8l. remov6tha innerhandle NOTE: . Remove ths hook by slidingthe innsr hsndle trim panel bsckward whil6 pulling the handle, then ramoveths innerhandletrim panel. . Tak6 care not to scrachthe innerhsndlotrim psnel' N ENHA DLE TRIMPA EL HOOK >: Clp bcttlon
NOTE; to with aslittleb6nding possibl 8s the Romove doorpansl it. or svoidcroasing breaking In) . 95 mm(3.74 | -1 l - - '\
12 hm
CLIP REiIOVER sltAPO *a177
''-L---tu io-;;7;1
---frhl {o.oa I l____l

45 mm
Il{l{ERHANDLE
r * n l
, F
irr.-F5.
{1.77In}
Rsmove the screws and clips bee clip tetnover) attachingthg door pansl, h Rsmovethe door panslby pulling upward. Disconnoctthe oowsr door mitror awitch conn6ctor.
SCREW > : Clp bc.tloru l9l POWER DOOR LOCKSW]TCH CONiECTOR POWER Wtl{DOW slvrTcH coi[{EcToR PAI{EL DOOR Pry the c8p and ramovo the acrew, then rsmovo tha armrst Docket.
SCREW Pry tho cap.
1".,, F l*"Yl
\__ F{
Pry th6 cap.
SCREW
SCREW POWEF TXX'F MIRROF SWITCH
Pushher.
COT{NECTOR (cont'd)
Doors
(cont'd) GoverReplacement DoorPanel/Plastic
4. Remove th grommats, bracket and door lock unit, thsn carefuly removethe plasticcover. Apply sdhesivoalongthe edge where necessaryto maintain8 continuousaealand DrsvsntwEtsr l6aks.
GROMMETS GROMMETS
BRACKET
DOOR LOCK UMT
lnstallth6 door Daneland olastic covr in th revarae ordel ol removal. NOTE: . Maka sure the door harnsssssand connoctors are lastenedcorrsctly on the door.
(D: tlarno$ ctp locltloo!
. Before tighteningth6 door psnel mounting screwa, are mako sur6 tho door harnesaes not pinchod,
.flEl-..
Replacement OuterHandle
NOTE: Raisth glassfully. 1. R6movs; o Door panel(seepage2G3) . Plasticcover (ses page2G4) P66loff ths accesshol soal.
rod tho Prv the lock cvlinder out, then remove out6r handle, NOTE: the rod, Takecarenot to bend lockcvlindr
3 . Removs ths mounting bohs and clip, then pull the

outr handlsout. CAUTION: Uro protac{lve tapo lround tho outll prevrnt damage. handlo to
NOTE: bohs 8nd clip insideth door. Do not drop th rnounting OUTER HA]IDLE
PROTECTME TAPE MOUI{TING BOLTS 6r1.Omm 5 N.m(0.5kem . 3.6 b-ft) OUTER HAI{DLE 6. Pu[ out the ret8inerclip,then removethe lock cylinde].
LOCK CYLINDER ROD
4.
Pry the outer hsndlerod out ot its ioint usingI flat tip screwdriver. CAUTIOI{: Whon prylng whh a llat tip lcrawd vsr, wrap h whh protctlvo tapo to pravont damlge, L(rcKCYLII{DER NOTE: . To eas6 rosssembly,note the location @ of the it. outer handlerod on the joint before disconnecting . Tske ca.e not to damage joint. the 7. Installation the reverseof the removalprocedure. is
Doors
Latch Rephcement
NOTE: R8iseths glassfu[y. 1. Removs: r Door panel(seepage2G3) . Plasticcovor (seepage2G4) . Center sssh (8page2G7) . Outr handls{seepage2G5) Disconnoctthe inner handlerod and lock rod from the inner handleand lock crank. Rsmovethe scrsws, then removethe innerhandleand lock crank, NOTE: Tak6 care not to bendthe rods. FASTEI{ER Disconnectthe connector and harness clip from the door, Removethe mountingscrews, then remove the latch throughthe hole in the door. NOTE; Take care not to bendthe lods.
OUTERHAM'LE ROD
2.
iloul{Tllrlc SCREWS 6r 1.O m m

5 N.m (0.5 kg-m ,
3,8 b-frl
HARNESS CLIP
4. lnstallation the reverse the removal is of Drocedur. NOTE: Make sure the rods and connectorare fastend correctly.
20-6
Replacement Glass/Regulator
Rmove: . Door psnel(soepage2G3) . Plasticcover (sse page2G4) Lowr th glassf ully. Peeloff the sssh guidecovsr and remove the gcrewa, then .emove the centr sashguidfrom the door. CEI'IIER SASHGUIDE 5. I Csrefullypullthe 9l8ssout throughthe window slot. NOTE: the Take csre not to drop tho glassinsideI door, PIf{ GUIDE
\ \ LI
GLASS
MOU]\ITI[{G BOLTS GLASS 6r1.0mm 6 N'm10.6ks-m, 4.3 b-ftl . Check th guide pin for damag, and replaco it necssary. NOTE: show th6 original Sclib E line aroundth guide pin to s location, PIN GUIDE
SASH GUIDE COVER NOTE: Whon inataling, appv tho doublo-faced adh$ivo tapo to the sashguid6covor.
4,
Caretulv movs the glasauntil you can 8oe th thss mountingbolts,then looanthe glasamountingbohs. Slidtho guidto the rear.then ramovtho glaaa.
R..r.ldo: From aHa:
GUIDEPI
l___@.)l +
GUII'EPIN MOU TI[{GBOLT c[ 6rl.0mm 3 N'm(0.3 ks.m, 2.2 lb-ft)
SEAL
{cont'd}
20-7
Doors
(cont'd) Glass/Regulator Replacement
P66lth glassrun channolout of the front chsnnel. Rmove the mounting bolts, then remove the front channol8nd center chsnnel. NOTE: After instslling,mak sur6 th ghss run chsnnolis not twisted. FROl{I CHANNEL BEGULATOB MOU]TTING BOI-TS 8r1,Omm 8 N.m(0.8ks<n, 5.8 b-ftI
Loosenthe bohs.
BOLLER
OLASSRUN 8x1.0mm I N.m {O.8kg-m , 5.8 lb-ft)

q
MOUNTINGBOLTS Sxl.Omm I N.m (0.8 ko-m . 5.8 lb-ft)
Greaseall th6 slidingsurtaces oJ th6 regulatorwhere snown. location by scribingI line across th6 sctor gear and rgulator. Install using th6 motor mounting bohs. Move th regulatorto tho originsl position by conecting I 12 V battsry to tho power window motor {seos6ction 23).
SECTON GEAR
1 0 . Before removingthe powar window motor, mark tho

MOU TII{G BOLTS 6r1.Omm I N.m (0.9 ks-m ,6.5 lb-ft)
NOTE: To install. the glass channel the front andcsnter fit run into
channls shown. as CEl{TER CHA NEL
GLASS RUI{ CHANNEL
FROI{T CHANNEL
NOTE:
Apply tho adhssivo th6 to shadowodar6s.
Removothe two mountingbolts, two rollrguidebolts and loosn the two mounting bolts. Disconnect the conector. Remove th regulator through the center holein the door. NOTE: Scrib a line around the roller guide boh to show the originsladjustment, ROLLER GUIDE BOLT
POWER wlI{DOW MOTOR l l . lnstEllEtion thg rovorss of ths removalorocsdurs. is
12. Roll the glass up and down to so6 il it moves frsev

without binding. Also make sur that there is no clearance between the glass 8nd glass run channol when the glass is closed. Adjust the position of th6 glassas necesssry(seepage2Ol0). Attach the door hsrness to th6 door correctly (see psgs 2G4). 1 4 . When reinstallingthe plastic covr, apply adhesive 8long the edge wh6r6 noccssary to msintain a continuousssal and prevsnt watsr lgaks{seepag2G 4t.
20-8
{'!ficarfr-
Replacsmont OuterMolding
Remove; . Door pansl(s66pass 2O3l . Plasticcover (ss page2G4) . Door mirror (seepagea,Aj-.lA . Glass(se6pase2G7) > : Clp locrilon.
Replacement Weatherstrips
> : Clp bc.rlon
WEAY}ERSTRIP
cLtP16l
WEATHERSTRIP
NOTE: the Takecarenot to twist or scratch outsrmoHing.
rnside f
MOLDIG OUTER pry up st Staning tho reEr, the outormoHing .rd the tho detach clps.thon.6movo out6rmolding. CI.ASsRUl{CHA EL
is lnstsllation the reversaof ths removalprocodure. NOTE: . ll nsces,sary, rsplscs any dsmagod clips. . When instslling,slign ths r88r dgs of tho outsr moldingwith the resr edgoof the door, WEATHERSTRIPS NOTE: . Before instElling w68th6rstrip, sppv cle8r s68l8ntto th6 ths @ arasof th door as shown. e lf necessary,replac6any damagd clips. S!.hm: Comcdlnc # 85OO
20-9
Doors
GlassAdjustment
NOTE: . Placsthe vshiclo on I tirm, lval surtsco when sdiusting tha dass. . Check th6 weathorstrip 8nd glEss run channel for dsnrsgaor doteriorstion8nd rpl8ceil nsccoasary. 1. R6movsth6 door p8nl8ndps6loff the plasticcovsr (sa6pagss2G3,4). 2. 3. Conn6ct th powor window switch connoctor to the conngctor. door harna9a Loosenth rollor guide bolts and sdju$ the glassso h with ths glassrun chann6l. is p8rall6l NOTE: Mak6 sure the guid6pin i9 in ths centst sashguide. Maks surs tho glassgoss up anddown smoothv.
6. lf ncsssaly, sdjust the front channgl and c6ntor

channel,
FROIIITCHAiTIEL
CXAiT{EL CE]|TER
GUE'EPIl{ 7.
Rsisath giasstully snd check for g6ps.

OLASS RUl{ CHAi'IEL
WEAT}fRSTN|P
S"\
AOLTS ROLLER GUDE Loos6n,
gbssoporstion, & Chock NOTE: Chockthst tho ghss contactsthe ghss run channel evsnlv.
R8issth glassas far up 8s possiblaEndhold it sgainst th gbss run chann|, Thon tbhten the rollerguid6bolts.
20-10
'F1rfrtryl-.
Position Adjustment
9. Check watorl6aks. lor NOTE: water. Donot usshighprossure
NOTE: Place the vehicle on I tirm, level surface when adiustine the doors. the Aft6r instslling door, check tor a flush fh with the body, thgn check for equalgapsbstween the front and rear, and top 8nd bottom door edgssand the body, Adjust 8t Th door and body edgesshouldalso b p8rall8l, the hings8s shown. GAUTION: Plec6a shop towol on tho ieck to prevent damagoto lho door whcn the mountig bohs are bosend for adiuttmem. MOUI{TING BOLTS DOON I x 1.25mm 30 N'm(3.0 lg-m , 22 lb-ft) the Looson door moumingbohs slkthtv to movotho door lN or OUT until it's tlush you with tho body.tf nocoasry, caninstall to a shim bhindoo hingE m6k6the doo. PARALLEL tho body, whh odgss
y"i-6,
1 0 . Routg the door harnossssand connectors and faston

them to ths door (ss6 pag82G4). 1 1 . Attsch ths plastic cover, rhen install the door p8n6l (soepEgss2G3.4),
HINGE Low6r the gla8s.
HINGE MOUNTII'IG BOLTS 8 x 1.25mm 30 N.ml3.Oks-m. 22 lb-ft) Loos6n th hing mounting bohs, 6nd move tho door BACKWARD FORWARD. or to UP or DOWNos n6cossary eqraliz6 gaps. th
SHOP TOWEL Tho door and body 6dg6sshouHb6 pralle..
NOTE: for Chsck waterleaks.
20-',1
Doors
Striker Adjustment
Make su.e the door latchessecurelywithout slsmming. lf it needs adjustment: 1. 2. Drawa linearoudthe strikertor reference. Loosenthe mountingscrews and move the striker lN or OUT to make the latch fit tighter or looser. Move the striker UP or DOWN to align it with the latch opening,Then lightlytighten the mountingscrews and recheck.
STRIKER
Mirrors
PowerDoorMirrorReplacement
1 . Pry out the covr panol with I flat tip scrswdrivor, then removethe covGrpanel. Disconnectthe connector.
2. Rernovethe mounting scrows while holdingtho door

mirror.
DOORMIRROR
MOUrrnG SCReWS I x I.25mm 1 8 N.m {1.8 kg-m . 1 3 b-ft)

2
COVER PAI{EL
Installation the reversof ths removalprocedure. is Checkfor water leaks. NOTE: Do not use high pressurwat6r.
4.
NOTE: . Holdthe outer handleout and push the door against the body to be sure the striker allowsa tlush Jit. . Do not tap the striker with a metal hammer to adiustthe position. lf the door lstches properly, tighten the mounting screwsandrecheck. NOTE: the Rplace strikor it it is cracked.
20-12
Mirror HolderRoplacement
1, Pry the mirror hoher from the bottom until you can seethe actuator,thn detachth hooks usinga flat tip screwdrivras shown. NOTE: Tak6 care not to scratchth mirror housing.
ADIfSIVE TAPE
Rearview MirrorReplacement
1. 2. Carstullyremoveths cover with a flat tip screwdrivr. Loosen the lock boh, then slide the mirror stay from th lug.
REARVIEW MIRROR
ffirSr
COVER ACTUATOR Disconnectthe hooks and connector,then removth mirror hoHer from the actuator.
MIRROR STAY
FJ
Removethe lock boft, thn rmove th toothed lock washsr 8nd hoH springfrom the mirror stay.
ACTUATOR LOCK BOLT

Loft-h6nd th16ads
TOOTHED LOCKWASHEN HOLD SPRING
-ld
.:I;) ,"i
MIRRORHOLI'ER
HOOK PLATE
MIRROR STAY
3.
is Installation the reverseof ths rsmovalprocedure.
4.
lnstallation the revarseof the .ernovalDrocedure. is
20-13
Glass RearWindow, O,uarter Windshield,

lndex
( ):Ouanthyof part usd.
ffndd{dd:
(1) FASTE]TER CENTER (Clip-typ) FASTENER I2I UPPER (Clip-typ)

CLIP{2} CORNEB
cLrP {6)
(8I RETANER
WINDSHIELD s66 2G'15 Removsl, p8g 2G16 s66 Instolltion, pago
DAMS RUBBER
(2} FASTEiIER UPPER (solf-adhosive.typo)
FASTEER(1} CENTER
(Solf-adh68iv6-tYP6)
GLASS BRACKET12}
--=-Tr"-;;
MOLDIMi
R.ar Wlndow:
RUBBER DAMS REAR WINDOW Romovsl, pag62O2O roo so Instslldtion, pag62G21
Ouortor GLrr:
\*r
I
OUARTERGLASS soe p8g2G25 Romovsl, soe Installation, pagE2G25
q.
SV-p\
\
\
{2) GLASSBRACKET GLAss'
DAM nuesen
\
LOWERMOLDtitG
MOLDII{G HOLOER(7)
20-14
Windshield
Removal
CAUTION: . Woar glov63to remove and Instal the windlhiald. . Use aeat covols to avoid damagingany surfaces. 1. To removethe windshield, first removethe: r Rearviewmirror (seepsge2G13) . Sunvlsors(seepage2G36) . Front pillartrim (seepage2G37) . Front wipers snd air scoop {seesection 23) Detach the clips from the retainers,then remove the side sectionof the windshieldmoldingas shown. NOTE: clips. lf necessary,replsce8ny dsmaged 3, Peeloff the upper section ol the windshieHrnolding. NOTE: Wh6n the upper section of the windshield molding removalis difficutt, cut oll the windshieldmolding. 4. (seepsgG Pulldown the front ot the front headlinr 2G36). CAUTION: Take caro not to bond the h6adln6r oxcosrivev. 5. 6, 2. Remove the other retainers and Jastnersfrom the body. Apply p.otctiva tape alongthe edgoof the dashboard and body as shown. Usingan awl, mske a holethroughthe rubberdam and sdhesive from inside the car. Push the oiano wire throught the hole and wrap each end aroundI pieceof wood. PROTECTIVE TAPE
WINDSHIELD MOLDING
WINDSHIELD MOLDING
\)v/
@Y
CORNER CLIP
l\..n'
TAPE PROTECTIVE 7. With helpe. on the outside, pull the piano wire back and forth in a sawing motion and careJully through cut the adhesive around the entire windshield, then carefullyremovethe windshield. CAUTION: HoH tho plano wlre as closo to tho wlndshioH as possiblo to pr6vent damago to tho body 8nd dashboard.
PI,ANO WIRE
/Zh ;Erl (
/ / '
RETAINER GLASSBRACKET
WINOSHIELD
NOTE: It necessary, remove screw,thenreplace ghss the the bracket.
20-15
Windshield
lnstallation
1. Scrape the old sdhssiv smooth with a knile, to I thicknsss of sbout 2 mm (0.O8 in) on tho bonding surlaca aroundthe entir windshieHoponingtlangs. NOTE; . Do not scrape down to the p8intsd surface of the body; damsged psint will interfere with prop8r bonding. . Remove the rubber dsm and fsstners from the bodv. o Mask of{ surrounding surfacesbstore p8inting. 2. Clean tho body bonding surfscs with a sponge in damDened slcohol. NOTE: After cleaning,keep oil, greaseor water from gatting on the sulfaca. 3. ]f ths old windshieH is to be reinstslled,use I putty knife to scraDs off all trscss of oH 8dhesiv8, thon clean the wlndshisldsurfac with slcohol wh6re new sdhesiveis to be appliad. NOTE: Mak sure the bondingsutfecs ia kept 1166ot watsr, oilandgre8se. CAUTION: Avoid stilng tho wlrdshl.H on h3 edlps; tmd.filpE may hsr dovobp Into clrckt. NOTE: Cleanthe shadowed8reE. 5.
WI DSHIELD 9mm 10.35Inl
4.
Glue the rubber dams to the inside faca of th windshieldas shown, to contain the sdhssiv durim installation, NOTE; Be careful not to touch th windshieldwhsro adhssivg willbe aeplied.
65 mm 326.5 mm 12.56In) {12.a5In}
RUEBER DAMS
95 mm(3.74hl
WIiDSHIELD
Glu6the csntor and uppr fastsnrs to the insidetaco ol tho windshislJas shown, 326.5mm 66 mm (2.56Inl h2.85 Inl I,,PPR FASTEiER (2)
95 mm 13.74lnl
CE TER FASTET{ER
WhIDSHELD
WINDSHIELD
FASTEI{ERS
WINDSHIELD
20-16
to retainers and fasteners the brackets, 6, Inst8ll glEss the bodyasshown, NOTE: sclews. the bracket mounting Donottighten glass
FASTENER
With 8 sponge, apply a light coat of glass primer around the edge of the windshield as shown, then lightlywipe it off with gauzeor cheesecloth. NOTE: . Do not apply body primer to the windshield,and do not get body and glassprimerspongesmixed up. . Nevertouch the primedsurfaceswith your hands.lf vou do, the adhesive may not bond to the windshield properly, causing a leak atter the windshieldis installed. . Keepwster, dust. and abrasivematerislsaway from the primedsurface.
/////f : Agply slast$lmd h6ro. CENTER FASTEI{ER I mm 10.35in)
l ;-\
I
FASTE ER UPPER
CENITER FASTENER {1}
L\_r=
lfiftm?
\_.:
326.5mm 11285Inl
RUBEER DAM FASTENER UPPER
WINDSHIELD
RETAII{ER {8I (2} GLASS BBACKET

WINDSHIELD
7.
Set the windshieldupright on the glassbrackets,then center it in the windshieH opening. Mske slignment marks across the windshieldand body with I grease at Dncil the four points shown.
11 mm 10.43Inl MARKS ALIGNMENT
9.
With a sponge,apply a light coat of body p.imer to tho origin8l adhesive remaining around the windshield openingflsnge. Th windshieldshould be installed10 minutes after you applythe body primer, NOTE: . Do not appv glass primer to the body. and be andbody primersponges. carefulnotto mix up glss . Nevertouch the primedsurfaceswlth your hands. . Mask off the dashboard before paintingthe flange.
'//Z I Apd,t bod,t Nlmor horo.
WII{DSHIELD
inl 30 mm ('1.18
WINDSHIELD GLASS BRACKETS
NOTE:
Adjust th6 glsss brackts until 'l th6ro is 6 sap ol 1 mm (0.4 in) botwesn ths uppgr sdge ot the edgs of windshieh snd the lading th rool, th6n tightn the mountingsct6ws.
(conl d\
20-17
Windshield
1 0 . Thoroughv mix the adhssiveand hardenartogether on
a glassor rnetalplatewhh a putty knife. NOTE: . Clesn 8 glass or metal plate with a sponge and slcoholbefore mixing. . Folow the instructionsthat come with the adhesive. 1 1 . Before filling a carttidge,cut the nd ot the nozzlas shown. end cut nozzle
10 mm (0.39ln}
13. Uso suction cup8 to hold tho windshiold over tho marks madin stsp opening,alignh with the slignrnont 7 and sst it down on the sdhssive.LightlYpush on th windshiHuntil h8 edg6is fullv seatedon the sdhosiv6 sllths wav around. NOTE: is . Do not closs or opgntho doors until adhesivo dry. . Mako surothe fastonela are fastensd correctlY. WII{DSHELD ALIG MEiT il|ARK8
7 mm10.27In)
12. Pack adhssiveinto the cartridg without air pockots

to ensure continuous delivery' Put the csnridge in a calking gun and run a bead of adhesivo around the edgeof the windshieldas shown.
NOTE: AppW the sdhesivewithin 30 minutes alter sppving the glassplimer.
tho clips on tho windshioldmolding. 14. Install
Inl 2 mm (o.Og
-Tr
t
Make s slghtly thickor bo.d at 6ach cornr d uppr.
Fffi,I\:AD}IESNE
l
8mm 10.31in) lmm Emm (o.31 lnl (0.04
'l
CET{TER FASTEIIER
RUBBER OAM WI DSHELD
At +cslvE
WII{DSHIELD
20-18
Scrape or wips ths 6xc63s 8dh68iveoff whh a putty knife or tow6l, NOTE: To r6mov6 adhssivs from I Daintedsurface or the windshieH, wipo with 8 solt shop towel damp6nd whh alcohol.
1 7 . Let ths adh6siv6dry for 8t l68st one hour, than sprsy watr over the windshisH and ch6ck for laks,Mark loakingErsassnd l6t th6 windshielddry, then sesl with saalant. NOTE: . Lot th car stand for at last four hours aftsr windshisH install6iton,ll th6 c81 h8s to bs ussd within th first four hours,it muat b6 drivn slowly. . K66p ths windshiH dry for th6 first hour sttol installstion. . check rhst the snds ol tho windshieldmoHing are sat underths air scoop. 8ll 1 8 . Reassembls r6mov6dp8rts. NOTE: lnstallth6 r6srvi6w mirror after the adh6siv6has dri6d throughly.
1 6 . Installth6 windshioHmoHing.
NOTE: . Wh6n instslling, make surs th6ra aro no twists in the molding. . Install th windshield molding by starting Et th6 upper corn9r. . Gluethe upper soction with the Edh83iv8.
> : Clp, r.l!h.r
bcltlonr
WIl{DSHIELD e WINDS]iELD MOLDIT{G MOLDIT{G
R ETAIT{ER {4}
# 4
\k
<'.fr
I (31 cLrP
20-19
RearWindow
Removal
cAuTto :
. War llovaa !o lamovo rnd ln3td thc loal wlndow. . Do not drmrgc tho dctrortcr grld lnos. 1. To rorbvo the rsar window, first romove: . Trunk lid (seepage2G64) o Rearshelf (seepage2G37) . Resr pillartrim panel{seepags2G37) Disconnoct ths dofrosler l8ads, and rmove thil holdars. NOTE: Avoid scrstching the r8r window whh ths cutter blade. 3. Remove the moldinghoHers, thon rorrove the lowel molding. 4. Peeloff th6 roar window molding. NOTE: o When th6 rosr window moldingremovslis difficuh, whh 8 knife. cut the 168rwindow mold:ng . lf ngcossary,remov6the screw, th6n replacetho glas.s brsckets'
REARwlMrcW
WINDOW REAR MOLDIIIG
2.
l^ 1"7'*
(W
"-\\
I ,L
CAUTIO : Td(. cr?c not io b.nd thc h3l
ADHESIVE
th6 r6ar hosdlinerls6o p8g2G36). Ronrovo ml .rcosllvclY'
Apply protectiv8 tap6 to slom the odgeof ths bodYas shown. Usim En awl, mak a holethrough the rubbr d8m and adh6siv6from insidothe car. Push pisno wira thlough tha hole Endwrsp each and s;ound a pi6coof wood.
Moldng hoHot rcmovel: 1) Removeor loo8snthe screw. a Plscothe screw in tho screw grommst agEinldo not screw it in) and Drsssit down. Pull the screw with th8 molding hoHer o|'n of tns bodY.
'
Affi***S\ts,ro.or*
\r HoLDER
V*
R{ ,s
HAM)WNE
3)
10 ,,.,
riigEb--
lnstallation
With a helpl on ths outside, pullthe piano wire back 8nd torth in a sawing motion Endcarefullycut through the adhesive sroundthe ontire rear window. CAUTION: Hold the pl8no who ar dolo to tho rlar wlndow ss posslbb to provc damagoto tha body. PIANO WIRE REAR WINDOW Scrape the oH adhesiv smooth whh s knil6, to ! thickness of about 2 mm (0.08 in) on the bondim surfsc aroundthe ntir rear window oponingfhnga. NOTE: . Do not scrape down to the painted sur{ace of tho body; dsmased paint will intsriers whh proper bonding. . Remove the rubbsr dam and fastenars from the body. . Mask otf surrounding surfaces before applying orimer. Clean the body bonding surfacs with a aponge damponed alcohol. in NOTE: After clesning.keep oil, greaseor wat6r from gEtting on th6 surface. It the old rear window is to bs rsinstallsd,use I putty knile to scrape oft all tracs of oH adhesive,thn clgan the resr window aurtaca with alcohol whsre new adhesivis to be appli6d. NOTE: Make sure the bondingsurface is kept fre of wst6r, oil andgrssse. CAUTION: Avold sottlng the resr wlndow on h3 edgas; smal chip may h davalopinio cracks. 8. Carefullvremovoths rsar window. NOTE: Cleanthe shsdowedarss.
REAR DOW WI
(cont'd)
20-21
RearWindow
4. Gbo rha rubber dams to the inside lsce of ths roar window as ahown, to contain th adhssive during instalrtion. NOTE: Bs careful not to touch the roar window whra sdh6sivewill b6 sDolid.
glass to and brackts fastenrs the body8s 6. Installth snown, NOTE: 8crews. brscketmounting the Donot tighten glsss
REAB WINDOW
Glu6th side and uppar tastenersto the insid6fsce oJ r6ar window as shown.
GLA88BRACKETS {2} FAETENER BUBBER DAM 7. Set the rear window upright on the ghss brsckots, than centr it in the opening.Make alignrnontmarks acroaathe roar window 8nd body with E greasepncil at the tour ooints shown.
ALIGNMEIfTMARKS
MARKS ALIGNMENT (2} UPPER FASTEI{ER
DAM RUBBER
10 lnm (039 Inl
. - I
Nft
I
FASTENER {4)
(2} SIDEFASTENER
REAR WII{DOW
NOTE: to Adiustths brsckts centerthe rsar windowin the screws. th then opening, tighten mounting
20-22
8.
With a spongo, apply a light coat ot glass primer around the edge of the rear window as shown, then lightlywipe it off with gauzeor cheesecloth. NOTE: . Do not apply body primer to the rear window, and do not get body andglassprimerspongesmixed up. . Nevertouch the primedsurfaceswith your hands.lf you do, the adhesive may not bond to the r6ar wlndow properly, causing a leak after the rear window is instslled. . Keep w8ter, dust, and abrasivematerialsaway trom the primedsurface. '////z t apply snrt wl^", hcr..
1 0 . Thoroughlymix the 8dhesiveand hardenertogother on

a glass or mtal plate with a putty knife. Follow th8 instructionsthst came with the adhesive. NOTE: CleanI glassor metal plste with s spongeand alcohol before mixing. 1 1 . Before filling I cartridge,cut the end of the nozzleas snown,
Cut nozzle end as snown. mm {0.39 In)
9 mm(0.35inl
I f-l
LJ
Ndffi-/ IDAM RUBEER
I |
GLAss ,/
In) 7 mm(O,27
12. Pack adhesiveinto the csrtridge without 8i. pockets

to ansure continuous delivery. Put the canridge in a calking gun and run a bead of adhesive around the edgeof the rear window as shown. NOTE: Apply the sdhesive within 30 minutes after applying ths glassprimr.
9 . With a sponoe,apply a light coat oJ body primer to the

original adhesive remalningaround the rear window openingflange.The rear window shouldbe installed1O minutessfter you appV the body primer. NOTE: . Do not apply glass primer to the body, snd be carefulnot to mix up glassand body primersponges. . Nevertouch the primedsurtaceswith you. hands.
/////t ; Appiv body pdmor horo. 20 mm {0.79 in}
2 mm10.08 in)
bead at each :ADHESIVE upp9r, ano Mak I slightly thicksr corner
.'f.ffi,T\
8mm (0.31 In)
UPPER FASTEI{ER
8mm 1031 In)
tG mm 10.63lnl
7.4 mm{o.29in} ADHESIVE
RUAEEB DAM
(cont'd\
20-23
RearWindow
13. Us suction cups to hold the reat window over the it oponing,align with the alignmentmarks madein step Lighttypush on the 7 and st it down on the adhesiv. raar window until its edges are fully sested on the allthewaV around. sdhosive NOTE: I Do not closeor open the doots until adhesiveis dry. correctly' . Mske sure the fastenersare Jastened
MARKS ALIGNMENT
16, Installthe moldingholderon the lowr molding.
REAR
wtt{oow
CUPS otf 1 4 . Scrapeor wipe excess adhesive with a puttY knile or tow|. NOTE: from I paintedsurfsce or the rear To removeadhesive window, use a sott shop toweldampsnedwith alcohol'
ta.
1 7 . lnstsll the lower moHing, then tighten the mounting screws,
lnstsllthe rear window molding. NOTE: make sure thsre are no twists in the . When installing, rear window molding. . First instaltthe upper section, thn install the each side. . Gluethe upper sectionwith the adhesive' WII{DOW REAR MOLDNI{G
l1
18. Let th adhosivedry for at lesst one hour, then sprsy wate. ovst the tear window 8nd check for leaks Mrk l8king areas and let the rear window dry, than seal with s68l8nt. NOTE: Let the csr stsnd for 8t least fout houts after lar ;indow installation ff the cat has to be used whhin the first four hours,it must be driven slowv 8ll 19. Rssssomble removedParts.
20-24
OuarterGlass
Removal
CAUTION: . Woar 9bv63 to lomovo and In3ial th gbar. . U3osoat covors to lvold damaglngany aurlecor. NOTE: Replace qu8rterglasswith new one when removingit. the 1. To rrnovethe quartergl8ss,first removeth6: . Rearpillartrim panllsoe pago2G37) . Ousrter t.im (s6epage2G37) . Ousrter trim panellsee pag2G37) 2.
lnstallation
l. Scrape the old adhosive smooth with a knife, to s thicknoss ot about 2 mm (O.O8in) on the bonding aurfacearoundthe entire quarterglassopeningflango. NOTE: . Do not scrape down to the painted surface of th body; damagod paint will interfero whh proper bonding. . Msk ofJ surrounding surtacas before applying onmar. Clean ths body bonding surtace with a sponge dampsnedin alcohol. NOTE: After cleantng, keep oil, greaseor water from gatting on the surface, 3. Clean the new quarter glass surface with slcohol where adhesiveis to be applied. Make sure the bondingsurtace is kept free of watr, oilandgrease.
from inside UseI knite to cut thloughth Edhssive thoc8r,allthe wayaround. NOTE: grass body, Takcarenotto damage quarte, the and
OUARTERGLASAMOLDI G
CLIP
it /
Clan tho shadowd sr6s all the way around.
3.
Removethe qus.ter glass.
20-25
OuarterGlass
', with E spong3, sppv a light coat of glass prirnr to the insilo tEco ot tho qusrtsr glass 8s shown, then lightly wipe it off with gauzeor chaesecbth' NOTE: . Do mt sppv body prinrel to ths quarter ghss, and do not gpt body 8nd glass primer sponga mixed up. . l{ovr touch ths primodsurtacoswith your hsnds.ll you do, the adhesivsmay not bond to the quErter glssproperly,causinga leak sfter ths quartsr glas is instsllod. . Kegp w8ter, dust, and sbrasivomsteriab away from the Drimedsurfaco. r'///////, : Af,y fit stmr hen. 5. With a sponge,apply 8 light coat oI bodv primerto the o.iginal adhesive remainingaround the quarter 91888 openingfl8nge.Ths quarter glassshouldbe installed10 minutesafter you spply the bodYprimr. NOTE: . Oo not apply glass primer to the body, and be careful not to mix up glsss8nd body primersponges. . Nevertouch the primedsurfaceswith your hands' '/f ; Applybody prlmethte'
38 mm {1.49In}
11 |fxn lo4:l hl
GTASA OUARTEB 6.
38 mm (1.49In)
Throughv mix the adhesiveand hardenertogether on a gbss or metal plste with I puttY knife. NOTE: o Clean a glass or metsl plate with a sponge and alcoholbefore mixing. . Folbw the instructionsthat came with the adhesive.
7.
Befor6 tiling a cartridge,cut the end ot the nozzle8s shown.

cut nozzb end 63 gttown.
10 lnm (0.39Inl
7 mm {0.27 In}
20-26
8.
Pack adhesiveinto the cartridge without air pockets to ensure continuous delivery. Put th cartridge in a calking gun and run a bead of adhssive around the edgs of the quarterglassas shown. NOTE: Apply the adhesivewhhin 30 minutes after applying the glassprimer,
9.
Use suction cups to hold the quarter glsss over tt| opening,alignit with the clip setting points and st it down on the adheisive,Lightly push on the quaner glassuntil its edgesare fully seatedon the adhesivea[ the way around. NOTE: Do not oDen or close the doors until the adhosivois drv.
CLIP
2 mm (0,08Inl
-Tr
13 mm {O.51Inl
n:ADHEsrvE
8mm {0.31 Inl
Msk a slghtv thicker boadat 6ach coln6r.
-zH ) f _
6 mm (O23 In)
i i ,L= * r - _ _*_
SUCTK)N CUPS
CLIP
1 0 . Scrspe or wipe the excess adhesiveoff wlth a putty

knifeor towel, NOTE: Use a soft shoD towel damDenedwith alcohol to remove adhesive from a painted surlace or quaner gEss.
OUARTERGLASSMOLDI G
1 1 . After the adhesive is dry, spray water over the quarter glassand check for leaks. Mark leakingareas and let the quaner glassdry, then sealwith sealant. NOTE: Let the car stand for at least four hours after ouarter glassinstallation. the car has to be used within the It first four hours,it must be driven slowly. parts. removed all 12. Reinstall remaining
20-27
Sunroof
lndex
PANEL SUNROOF Adiustmont, s6e paE2G29 Rsplacmofi,seepagpan31
SEAL SUI'IROOF REARSEAL HOLDER
FRONTSEAL HOLDER
SIDE SEALTOLDER
LINER SUNROOF s6e Roplacemont. pag20.30
CABLE ASSEMBLY OUTER sse Rsplscomnt. pag2G33

MOTOR Repl6coment, se p6g6 2G32
PANEL BBACKET
",,,or --#
ggygtr-4
llniRt
.^*--,^,e ] ttottt*
b'=-n*o""r,
REARDRAIN CHAI{NEL
on",.o"
,*ER--& Y^*J"\
DRAIN FROTT CHANNEL
FAONT STOPPER
FRAMESEAL
REARDRAII{TUBE
FRAiIE Roplacamont, soe psB2G32
20-24
dtrr..-.
Troubleshooting
Symptom Water leaks
ProbablaCauso 1 . Clogged draintube. rooJpanel. Gapbetweensunroofsealand J . Defectiveor improperlyinstalled sunroof seal. 4 . GaDbetwan frame sealandroof Danel, betwaen sunroof sealand roof Danel, 1. Excessive cleSrance 1, Loosemotor. 2. Worn gearor besring. 3. Outer cabledeformed,
1 . Clutch out of adjustment.
Wind noise Motor noise
Sunroof Danal does not move, but motor turns
a lnnercableloos. 4. Outer cablenot attached properly.
Foreignmatter stuck btwoen guiderailand slider,
Sunroof Danel dos not move and motor does not turn lsunroof panel can be moved with sunroot wrench)
1. 2. 3. 4. 5.
Blowntuse. Fauhyswitch. Battery run down, Dtective motor, Fsulty relay.
Sunroof PanelHeight Adjustment

Boot panel should be even with the sunroof seal to within 1.9 t 0.5 mm (0.o7 + 0.02 in) 8ll the w8y around.lf not, tih the sunloot panelfully,and: 1.9t o.5mm {0.07t O.02Inl
pA ROOF EL
SUNROOF SEAL
SHIMS PANELBRACKET
1.
Removeths sunroof liner (seepage2G3O). Loosen the sunroof panel mounting nuts and instsll shims between sunroof panel and panel bracket as shown. 1.O mm (O.O4in) Shlm thlcknos!: Adlustmont: max. 2.0 mm (0.O8in) Repeaton oppositesids if necessary.
20-29
Sunroof
RearEdgeClosingAdjustment
ODen the sunroof Danslabout a foot, then closeit to check where rear edgbeginsto rise. lf it risestoo soon and sats too tightty agEinstthe roof panel.or too late and does not sest tithtv enough,adjust it. 1. 2. Remove the sunroof liner, then remove the sunroof panel. Chock that the position ot the litter is the same on eachside. NOTE: It the position difters from sids to side, remove tha motor (seepage2G32),then adjustthe positionof the lifter on each side. 3. Loosenthe mountingscrews. Align the panelbracket to the same positionon each side.
SunroofLinerandSunroofPanelReplacement
l.
Remove front of the root trim. the Align the locstion @ position ot tho fram6 to the mountingscrew.
sut{RooF
LINER
MOUI{TING SCREW
l.
Removsthe mountingscrews 8nd clips. then slideths sunroot linerslightlytorward. NOTE: Take care not to scratchtho sunroof liner.
> | CIp bcltlott! AU ROOF LINER
lnstall the sunrool panel. ClosBthe sunroot panol, then check the alignment between the rool panel and sunroot panel. NOTE: Adjust the sunrool panel right 8nd lft bY using the oanelbracket mountingholes With the sunroof panel closed fully, check for water leaks. NOTE: water. Do not use high Pressura Slidethe sunroof linerbackward,thn romovoit'
SU ROOFPAI{EL
4.
LINER SUNROOF
20-30
Sunroof SealRepair
brackats on nuts 5. Rsmove mounting fromthe panel the panel lifting by up. the bothsides, thenrernove sunroof NOTE: the Donot damage roof panel.
ff a sunroof sealis leaking, if it is to be replaced,proceod or as follows: 1. 2. 3. SUNROOF PANEL Removethe sunroof liner (seepage2G30). Removethe sunroof panel. peelthesealoff the Carefully Remove the sealholder, sunroof panel. SUNROOF SEAL
> : Scrow,nut locttlon!
r ' 9
c
t, 6
c,A
I N'm (0.9 ksFm,6.5 h-tt)
SU R(X)F SEAL
Fillwirh adhesive. o.
is lnstallation the reverseof the removalprocedure. NOTE; . Before installing sunroof liner,close the sunrool the panel fully, then check fo. closing slignment, lf necessary,adjust the sunroot panel alignment{see page2G3Ol. o When instlling the sunroof linar, make sure the sunroot liner is fastned correctly with the clips and holder. Check tor water leaks. NOTE: Do not us highpressurwater, 6. 7. 8. 4.
PANEL SUNROOF Cleanthe sunroof sealattachingsurfaceswith a clean in cloth dampened alcohol. NOTE: keep oil, greaseor wster from getting After cleaning, on the surface. 5. Fill the sunroot seal groove with adhesive.Coat the sunroof seal attching surfaces of the sunrool panel with the sam adhesive. Fit the sunroot seal onto the sunrool panel evenly all the way around. Wlpe off excess sdhesive with a clean cloth dampened with alcohol. Allow the sdhesiveto cure tor st leastfour hours atter sunroot seal installation 8nd before operating the sunroof panel. Checkfor water leaks. NOTE: Do not use highpressurewater.
9.
20-31
Sunroof
Motor, DrainTube, and Flame Replacement
cAuTto :
Be c'rfirl 1. 2. ]pl to damagoth soats or oth6l intorlor trim.
(seepage2G36). Rornovethe headliner the ceilinglight wire harness' Disconnectthe motor connector;removathe clips securing NOTE: When removingthe motor, removethe two mountingbohs andthree nuts.
3. 4. 5.
page2G31). the Remove sunroolpanel(see Disconnectthe draintubes. Removethe 10 mountingbolts and rear hooks,then removethe frame from the car' NOTE: when removingthe lrame. You mav requireassistance DRAhI TUBE To instsl,sid6ths drsintubs ovorth st trsrnsnozzl loast10 mm (0.4in). DRAI TUBE
GUIDEPIiI
T()OK (2} REAR
FRAMCSEAL
I x 1.On||n 10 N'm (1o kgFm. 7 b-ft) lf you n6ed to remov6 a drain tubo, tie a string to th6 ond ot it so h can bs roinstalld. REARDRAINTUBE
NOTE:
FRAME
\g
/-:\
MOTOR M6ko su.o th lft6.s 6re pal.l6l when instarng th6 motor.
@
DRAIN TUBE FRONT
To install,insrt ths Jrama'sfear hooks into th body hols,then installparts in the reverseorder of removal. NOTE: of . Install tube clips with the 6ndsfacingto the sideto esse instsllstion the headliner. rhe . Cleanthe surfaceol frame. . Checkthe frame seal. . Check tor wster leaks.
20-32
Panel Stay/Slider Lifter and Guide v.etrv errvr RailsReplacement

r
1. 2.
Rsmovothe frame (seepage2G32). Removethe front drainchannel,

o.
Removsthe motor (page2G32). Remove the mounting screws @, then remove the guide rail. Remove the mounting screw @, then removthe outer cableassemblv. NOTE: Tske care not to bendthe cableDiDos.
6r1,Omm 10 N.m(t.Oks-m lb-ft) ,7
GROMMET NOTE;
MOUiITING SCREW To install,fill the groove in 6ach grommotwhh seahnt, CABLE PIPE PANEL STAY
FROI{T DRAIN CHANNEL
OUTER CABLE ASSEMSLY
GUIDE RAII. Slide the p8n6l stay backwsrd, than remove it from the guiderail. 8. Remove the liftr Jrom the inner cable end, then separats the panel stsy, lifter, slide stoppet link 8nd slider. NOTE: To install,apply muhi-purposegreaseto the lifter and slidestopper link.
Romovethe rear drainchannel. Romovethe resr railholder.
6x1.Omm 10 N.m (1.0 kg-m , 7 b-ft)
SLIDESTOPPER LINK {co.rt d
Sunroof
Panel Stay/Slider, Lifter and Guide (cont'd) RailsReplacement
9. Tu,n the hook ol the snchor rod with I flat tip screwdriver, then remove the anchor rod and anchor springfrom the guidersilby slidingit backward. NOTE: greaseto the hook. To install,apply muhi-purpose
OpeningDrag Gheck (Motor Removed)

Betor inEtallingthe motor, measure stfon required to open sunroof panelusinga springscaleas shown
cAuflo :
wh.n rFlng a cp ng scals. proiect the loadingodgo ot tho sunroof panelwhh a lhop towol. lf load is over 1O kg (22 lbs), check side clearanceand sunroot panelhoightadiustment{spage2G29).
ANCIIORSPRING
ltooK
At{cHoRROD
procedure. ot is 10. Installation tha revetse the rmoval NOTE: to . Beforeinstalling guiderail,appv the calking the guide mountfacesof the frame. rail
SHOP TOWEL
GUIDERAIL
FRAME
. Damaged parts shouldbe replaced' . Apply greaseto the slidingportion. . Belore installingthe motor, adiust the litter to the samepositionon each side.
20-34
GlosingForceCheck (Motor Installedl

1. After installingall removed parts, hav a helper hold the switch to close the sunroof panel while you measure force required to stop it. Attsch a spring scaleas shown. Readthe torce as soon as the sunroof panel stops moving, then immedistely releasa the switch and springscale. CAUTION: When udng a spring scale. protest th badng adgo of tha 3unroof panelwhh a 3hoptowel. ClosingForce: 20-30 ks {/t4-66 lbs)
SPRING SCALE
SHOPTOWEL
install I new bck lf force is not within sDociJication, washer,sdjust the tension by turningthe motor clutch adjusting nut, and bend th lock washer agsinst the motor clutch adjustingnut.
WASHER
t ocK
20-35
Headliners
Replacement
> : Clp b.rtlo.!
wwzz
'
-w(:
'_-
) - )
lr.#IlE
/
t6l
*_)
-lN-
@)
CAUTION: When prying whh a flat tip scrowdrlvor, wrap it whh protcctlve tapo to pravent damago. NOTE: . Removthe front se8ts (seepage2G38). . Tako care not to bendor scratch the flont and rear hoadliners. o Keep water away Jromths front 8nd rsar headlinets. . Be caretul not to dsmagethe dsshbosrdand other interiortrim' JOtitT TRIM OROOF OFRONT IEADLII{ER HEADLII'IER @REAR
)HOLDER
t
Looaoh th6 bohs.
O}iGH-MOUT{T BRAKE LIGHT
@suNvtsoR
(DCEILIIIG LIGHT Dbconnoct tho connoctol.
OLE S
OHIGH.MOUiII LIG+IT BRAKE COVER
REARPILLAR TRIM PA EL
NOTE: sids dool opening' from the passenger's Removethe headliner l|stallationis the reverseol the removslprocdure. NOTE: . V,lt\en \nsta\\ng the lront and tsar head\nsrs, be csrstu\ r\ot to lo\d or bsnd R' A\so, be cqrelu\ not to scrstch ths bodY' are . Chckthat boih sidesof the tront and rearheadliners sscurelyattschadto the body and rear pillartrlm panol' . Whon installing root trim, installthejoint towards the rear. the . It nocessary, replaceany damaged clips.
20-36
lnteriorTrims
Replacement
> : Clp bcltlon.
I B
in Disassemble numberdsquence.
-r-)rv_trj
OREARPILLAR TRIMPAI{EL Firstromov roar the (s6s 2G36). headlinor psg6 TRIM @DOOR
#l M\ryi
t N t |
" 1 "
H I
_:)_
ffii
- )
CAUTION: Whan prylng whh a tlrt tlp 3crcwdrlvel, wrap h with protoctivo tapo to prevont damago.
l, (#"" @'
ldB.t
NOTE: the or Takecarenot to bnd scratch trimsandpanels.

C)qUARTER TRIii
\\--""-T
@REARSHELF Fhst rsmov th spoakors (s6sction23) and 166lsoat upprtrim panellse psf|eMA.
OSEATLOCKCOVER (soepa62G42
u
SILL OOOOR MOLDING
:z
@RIGHI TRUNKSIDE
OTRUNKTRIM
TRUNKFRO]'IT @RIGHT PANEL First rgmovthe r6ar s6at {soepags2G41).
OiIGTITKICKPA EL
LID oSPARETIRE
C)REARTRIM PANEL
procedure. of is lnstallation the revelse the removal NOTE: clips. replace damaged 8ny lf nocessary,
PANEL REARUPPER
20-37
Seats
Front Removal
NOTE: TSkecare not to scrStchthe sest covers and body. 1. 2. Removethe mountingbolts covers. Remove the mounting bohs and disconnect the connector.then removethe tront seat.
Front Replacement
NOTE: Take care not to scratch the seal covers and bodv. 1. 2. Removethe front s6at, then take it out from the doot oPening. Remove the screws and knobs, then removo the reclinecover,
RECLII{E COVER
FRONTSEAT
@scREw
MOUiTTNGAOLTS 1Ox 1.25 mm ito N.m l4.O ks:m . 29 tb-tt) Disconnct th6 aeat hgAtorconnoctor (canada SR 4WS/ I
r(
3.
@<
\oulmonv
xroa
KNOB ORECLII'E Removeth screws, then removethe center coval.
sR-v).
a.
\,
Disconnect ths connector (drivor'sonly).
a iV*
i,OUI{TI G BOLT COVER
MOUI{TING BOLTS 10x 1.25mm /O N'ml4.OkgFm b-ft) ,29 3. Instalhtionis the reverseof tho rsmoval procedure.
Rmovethe lower clips and Jastenerslrom the asatback, then Joldthe sest cover back.
> : Clp locltlont
SEA-AACK
Foldthe s6at-b8ckcover 8nd pad back until you can see the seat-backmountingbolts. NOTE: the pad. Tsks care not to damage Rmove the seat-back and s68t cushion mounting bolts and pivot nut, thon remove the soat-backEnd seat cushionfrom the innrand outsr ssat tracks.
> | Cllp locltlom
PlvorNur Pvor wAsHER
b4;;w^sHER il
BUSH
SEAT-BACK
,/'wqP
O: Clp loo.tloB
UNIT SEATHEATER
PIVOTI{UT I x 1.25mm 2 N'mlz2 ks-m, 16 b-ft)
REAR SEAT
To 86at bolt buckh.
accEas
CABLE
SEAT cusHtof{
lo rast-back.
BOLTS MOUNTIiIG SEATCUSHK)]T 10 x 1.25mm 43 N.m(4.3 kg-m,31 b-ft)
To so6t-back. Diaconnoct th6 r6ar

366t aCCgSll
SEAT CUSHION
RECLIiE AII'USTER
cabb.
SR HoatedSoat {C6nada: 4wS/SR-V) BOLTS SEAT.BACK MOUNIT|NG 1Ox l,26 mm 43 N.m (4.3 kem .31 b-ft)
INNERAEAT TBACK
BOLTS MOUI{TING SEATCUSHION 1O 1.25mm x 43 N.m{4.3 kg-m.31 b-ft}
JOINT ROD NOTE:

Take c6re not to b6ndth rod.
SCATTRACK OUTER
7.
is lnstallstion the rsverse of the romovalprocodule. NOTE: 8 . To prevent wrinkles when installing seat-backcover, makg aurs tho materialis stlgtched evsnly ovel ths frame bsfore sllthe clips. securing . Apply gteaseto the movingsurfaces.
20-39
Seats
FrontSeatCoverReplacomnt
CAUTION: Wora gbv! to lomov and iNtal the sgat-backand seat cushion covols. NOTE: Take cars not to tear the ssamsor damsgethe seat-backand ssat cushioncovers. Soat-backcover romoval: 1. Removethe sat-b8ckfrom the innerand out6r seat trscks. 2. 3. Removethe rea. seat accsstrim and lumbarsupport knob (6xcept S modsl:Driver's). Removthe ssat-backcovsr by releasing allth insidesprings, SEAT-BACK COVER
I;f.:fo:Sffi*.
or. crp'rmovlr:
il#ss\\K;,i-l
\\
"OU
^n- I
'w,
Seal curhlon covar ramovsl: 1. Removeth6 s6at cushionfrom ths inn6r andouter s6at tracks, 2. 3. Removsall clipsfrom undsrths ssat cushion,thsn loossnthe ssat cushioncovar, Pullback th6 6dgoof the seat cushioncov6r allthe way around,th6n rsloasoth6 pad clips and insidssprings. SEAT
custto
COVER
FRAME SEAT CUStflOil COVER Clp Inrtllrtlon: RING UPK)LSTERY PLIERS Commgrciatry sv.ilablo. EW CLIP
hstsllstion is the reverseof the removalorocedure, NOTE: . To prevent wrinkles, mak sure ths matrialis stretched 6venv over the lrsme b6tor securingallthe clips and insidesprings. . ll necsssary,replaceany damaged insidesprings. . RoDlace cliDs. the
WIRE. s lCovor kl6l
PAD
(P.dsidsl WIRE
20-40
..
RearReplacement
in Disassomble numboredssquencs.
t2l G)HOOK
SEAT-8ACK OLEFT
@10x 1.25mm /tO N.m14.0ksFm 29 b-ft| ,
) (_
6l ----v
Push the roat cushion. Pull th knob. th6n dirconnoct th6 hook. PulluDsnd fomovo tho 3aat cu3hion.
CARPET
SEATCUAH|oN )N|GHT
OLEFTSEATCUSHION
2041
Seats
(cont'd) RearReplacement
Dbsssofi$b in numboredsequsnce.
Rrlr aeat btch/Lock cylndor rgmoval: SEAT LOCK COVER REAR AHELF
SEATLOCK COVER
OG r 1.0mm ks.m,7 b-ft) 10 Nm 11.0

6x1.0mm 10 N'm (1.0 kgFm 7 b-ftl NGHT PNOT BRACKET
Pry h6re.
LOCK CYLI]'IDER tho R6movo rear shotf{seepag62G32.
sEAT. ORIGHT BACK
LEfT PIVOT BRACKET
t ocK RoD NOTE:

Tak car not to bsndtho bck rod.
6x1.Omm 10 N'm (1O ksm ,7 tr-ft)
Hq)KS
I t 1.0 rnm 10 N'm (1O kg|.m. 7 b-ft)
PIVOTBRACKET RIGHT trim Removo ouanor ths pansl(so. psa2G37).
LEFT PIVOTBRACKET tho R6movo soatcorltea pd(sepsgo92.
hstEllationis the revsrs6of the rmovalprocodur. NOTE: . Bolore sttsching the sest-back and sgat cuahion, ,n8ke surathere ar no twists in th6 seat bh. . Whon instsllinsthe ssat cushion, poshion the seat behs correctly.
> : Clp bcltlonr A l TN\\\\\\\$ B I l ]
N i
+ i
\)
_-__)
20-42
Seat Belts
Front Replacement
CAUTIOITI: Chock tho 5o!t bohs for damago and roplaco thom ll necossary. B carelul not to dsmago thom durlng removd and inslalation. 1. Remove: o Front seat (seepage2G38) o Rearseat (seepage2G41) . Door trim (seep8g2G37) o Rearshelf (seepage2G37) . Rishttrunk front panellsee page2G371 . ouarter trim panel(seepag2G37)
2. Removethe sest boh quideand centor cover.

Remov th all three anchor bohs, retractor bolt and ret.actor mounting bolt, then remove the segt belt 8nd seat belt buckle. NOTE: Whn removingth anchorbohs and retlactor boh, use a 17 mm socket or box-andwrench.
TUPPER ANCHORBOLT 7/16-20 UNF 33 N.m (3.3 kg-m , 24 b-ftl
SEATBELT GUIDE SEATBELT GUIDE MOU Tllrlc BOITS 6xl.0mm
10 N.m (1.0 kem. 7 b-ft)
SEAT BELT
RETRACTOR BOLT 6x1.Omm
10 N m (1.0 ksm .7 lb-ft)
RETRACTOR
REiRACTORBOLT 7/16-20 UNF 33 N.m (3.3 ks-m . 24 b-ft)
SEATBELT EUCKLE COVER CEI{TER (seepag620-38)
LOWERAI{CHORBOLT 7/16-20 UNF 33 N'm (3.3 ks-m , 24 lb-.ft)
ANCTIORCAP
LOCK TOOTHED WASHER

the Disconnct connoctor ldriv6r'sonlyl.
\\\
ICE TEB ANCHORBOLT 7/16-20 Uf{F 33 N m (3.3 ksFm.24 b-ft)
(cont'd)
2043
Seat Belts
(cont'd) FrontReplacement
Aarchoabolt coft.lructlon :
LOCK WASHER BEARING
WAVEWASHEF LOCK WASIER AITICHOR \ LOWER BOLT \ */ \
J'Jil
WASHER TOOTHED LOCK WASHER 4. 5. is lnstallation the revorsof the removalproceduro'
EEARNG
PLAII{ WASHERS
TOOTIIED LOCK WASHER
on tunctions as described pago2G46. ChBckthat the retractor lockingmechanism
NOTE: . Make sure you assemble washers8nd collsls on the uppr and low6l dnchorbolta aa ahown. the . Before attschingthe quartertrim pan6l,maks sure thra are no twists or kinks in the ssEtb6lts. . On reassembly, rpl8cethe upper anchorboh and center anchorbolt {') and u86liquidthr68d lock'
20-44
RearReplacement
CAUTION: Chsck tho roat bolts tol damago and roplaco them ll necesrary. 8o careful nol to damage tham du ng lemoval and in3talation, 1. Remove: . Front s6st (seepage2G381 . Rearseat (8epagp2G41) . sest center pad (s,e page*42!. r Rearshetf (seepage2G37) . Center console(seepsg82G51) . Door trim (Esepsse 2G37) . Righttrunk front panel(seepage2G37) . Ouarter trim panellsee pags 2G37) (ses psge2G361 . Hsdliner . Rarpillartrim panel{see page2G37} Detschth seat belt guids.
J.
Remov th6 all thrss anchor bohs, retractor bolt and retractor mounting bolt, thsn remove the sat belt snd se8t beh buckle. NOTE: When removingthe snchor bohs and retractor boft, us a 17 mm socket or box-endwrench. TUPPER AI{CHOR BOLT 7/16-20 U]{F 33 N.m(3.3 kg-m, 24 b-ft)
-)I,lbl 'lll
.U\
IW
It6\
BELT n ,-,.' SEAT curDE f;l,?-
BOLT RETRACTOR 7/16-20 UNF 33 N.m(3.3 kem .24 h-ftl

MOUNTING RETRACTOR BOLT Exl.Omm 10 N'm (1O kg-m, 7 b-tt)
AI{CHOB BOLT LOWER 7/ta-20 UNF 33 N.m(3.3 ks-m. 24 lb-fr)
TcENTER Ar{cHoR Botr ---------9.
\
Anchor bolt conrtructlon:
3l'i-?:Tn-.ro,"n, "*r"b BUCKLE

4. functionaas Checkthat the retrsctor lockingmschanism describsdon psge 2G46. is lnstsllation the rverseof the removalprocedul. NOTE; . Belore attachingthg rear pillartrim paneland .ear seat, make sure thsre are no twists in the seat bett. . On raassembly,replacethe upper and centr anchor bofts (') snd use liquidthroad lock.
UPPER ANCHOR
.CE TERA CHOR BOLT
2045
Seat Behs
Inspection
RciEcto? hapoctlon tho 1. Btor6 installing retractor, check thst ths ssat bh can be pulledout fr66ly. 2. Mko sur that ths ssat beh does not lock when th retractor is l6andalowly up to 15" flom the mountod oosilion.Th seat beh shouldlock when ths ratractor is leaned ovr 4.0o. GAUTlOlt: Do not attempt io dls$romble tho lotraclor.
r: Mountld Poitloti
On-tho-CarSost Beh Inlpoction 1. Check thst the s6st belt is not twisted or caught on anything. the 2. After installing anchors.check for Jree movement on the anchor bohs. lf necessary,remove the anchor bohs and check thst the washers and other Dartsare not damsgador improperlyinst8lled. Check the sest behs for damage or discoloration. Cl68nwith a shop towel if necessary CAUTION: Uso only 3oap and wator to clean. NOTE: Dirt build-upin ths metal loops of the upper anchors can causetha seat behs to retract slowly. WiDs the inside of the loops with 8 cl8n cloth in dampond isopropvlalcohol. Check that the seat belt does not lock when pulledout to slowv. The 88t beh is designed lock only during a suddenstop or impact. Make sur that the seat belt will tetract sutomaticslly wh6n rlgasad. 6.
t,
I
Forwlrd hrld.
ReDlscsthe seat beh with 8 new one if there is any abnormality.
RETBACTOR
Forw!.d h.ld.
Replaceth s6at belt with 8 now ons if thers is anY abnormality,
20-46
ChildSeat Anchor Plate

Attachment points are provided for a rear seat mounted childrestraintsystem which usesa top tethe., The attachment points are located on the rear sholf, iust behindthe rear sest-b8ck. When usinga childsest with a top tether, use a razor blade or sharp knife to carefully cut 8 1 inch diamster circle at tho location ot the attachment points and installthe child seat ancho. Dlatesecurelv,
15Omm {5.9Inl
POItYfS ATTACHMET{T
8 x 1.25 mm 22 N.m 12.2ks-m , 16 lb-ft}
CHILDSEAT PLATE ANCHOR
TOOTHED WASHER
NOTE: . Do not remove the toothed washor from the child seat anchor plate, Use the child sest anchor plste with the toothd wssher attachedto it. . When installing child seat on the rear seat, follow the a instructionsof the manutacturorof the childseat, . Additionslsnchor Dlates avsilable. are
r So not \3q i\q t*{\d sst\ a\{i\sr $Er\c ls\ N\ tl\\6\ purpos6;it ls dosignadexchsivolY for Instanatbn ol a child so8t. . Mako eurs tha lear soat-back ie locksd fhmlY whon Insta$ng a chlld seat.
2047
Carpet
Replacement
are SRSwire harnesses routod neat the carpet. CAUTION: . Al SRS cloctlical whing halnosses ale covorad whh yolow outer iNubtlon. . Bofor! disconnocting the SRS wiro halnos3, Inltal thc short connoctol(s)on tho airbag(s). . Reg|lco the entiro affocted SRS hrrnoss alscmblY if ll has an opon chcuft or damagedwitlng. NOTE: The radio may hsve a coded thft protection circuh. Bo sureto get the customer'scode numberbefore - Disconnecting battery. the -Removing the l,lo.43 (1OA) fuse (inthe under-hood fuse/relaybox). - Removing radio. the Atter service, reconnect power to the radio and turn it "CODE" is displayed, enter the on. When the word customer's Sdigit code to restore radiooperation. 1. ' Remove: . Front se8ts (seepage2G381 . Consols(seepage2G50) . Centerpanel{see page2G51} . Dashboard lower cover, knee bolster (seepago2GtB) . Glovs box (seepsge2GS) . Rearseat {seepage2G41) . Seat center pad (seepage&2) o . . . . opener cover (seepsge 2G67) Front seat beh lower anchor(seepage2G43) Door sill moldingand door trim (seepage2G37) Kick panel(spsse 2G37) RMt trunk front panaland quartrtrim panel (seepage2G37) . Footrest
2. Pry out the clips and removethe retainorfrom the door silltlange.
Detachthe fsstnar in the driver's side carpet,thsn pull back ths carpot at ths bottom of heatr.
4 . Removethe carpst by slidingh rsrward.

NOTE: wrinkle or twist th carpet, Take care not to damage,
20-44
>:Cllpbcationr
Fq)TREST
FASTEI{ERS
TRIM OUARTER PAI{EL psgp 2G37) {se6
DOORSILL MOLDING (s6e page 2G37)
SEAT HARI{ESSES
SEAT HARI{ESS
DOORSILLMOLDING (s6epage2G37)
DOOR A|LL MOLDII{G
5,
is Installation the reverseoJ the removalprocedure. NOTE: . Take care not to damage, wrinkle or twist the carDet. . Make sure the seat harnesses routed correctlY. are
DOOR SILL FLAI{GE
2049
Consoles
Replacement
near tront console. the are wire hsrnesss routed SRS CAUTlo : . Al SRSlrctrbal whlng harnessos covotadwfth are yclow outorlmuhion.
8.fo.o dsconnoctlng the SRS who halno3s, Install th. 3hort connoctorb) on the alrbag(sl. Rcpbc. tho entir affoctod SRS harness assomHy lf h hrs an opon chcuh 01damagodwl ng.
il""ll!'S
sF
SRS UNIT
CAUTIO : . To plevenl damageto tho 3hlfl bvot knob ard shlft Indicatort m rlng, wrap thom whh a shop towol' . When prying whh a th tip sclowdllver, wlaP h whh plotostlvo tape to prevent dEmago. NOTE: . Take ca.e not to scrgtchthe front and center consolesand dashboard. . Slidethe front sest fully to the rear.
> r Clp locltlon! SHFT II{DICATOR TRIM RING Auiomlllc trantmllllor modal: SHIFT II{DICATOR TRIM RII{G
FROiIT COI{SOLE r
Manual t]antr alloo mod.l:
SHIFT LEVER KI{OB

FROi'T CONSOLE
hstElation is the reverseof the removalplocedure.
20-50
.L
Dashboard
Removal/lnstallation Component
SRS wire hsrnesses8r routed near the dashboardand steeringcolumn. CAUTION: o AI SRS oloctrlcal tyhlng harnossea!rc covord whh yolow outor insulatlon. . Botole dkconnectlng th SRS wlro hamesr, Inrtafi tho rhort connoctor(s)on the alrbag(sl, . Roplscotho ontlre alfeaed SRS harnols astombly lf h has an opon drcuh or damlged whlng. . Aftor Inrtalrtlon ol ths gauge a$ombly. iochock the oFrEtlon of tho SRSIndcator lght.
NOTE: . The radiomay h8v a codedthett protectioncircuit. Be sure to gat ths customer'scode numbarbofore - Disconnecting battery. the - Rsmovingthe No. 43 (10 A) tuso {inths under-hood fuse/rhy box). - Romoving radio. the "CODE" is displaysd, entr tha customsr'a Sdigit After service,reconnect power to the radioand turn it on, Whn th6 word code to restora radiooDeration. . Tak care not to scratchthe dsshboard and rslsted p8rts. . Do not drop the screws insidethe dashbosrd. cAUTrOil: Whon prylng whh a flat tlp screwdrlvel, wlap h wlth protoctiv6 tape to pravolrt damlgo, ATEREO RADK)/ CASSETTE
Looaenths bolts.
Disconnoct the conn6ctols.
scREws
PANEL CENTER Removoth front coneole (see palp 2G5O).
(cont'd)
20-51
ClutchOverhaul
Removethe centernut while holdingthe armature plate. 3. Remove snap ring B with a snap ring pliers. the NOTE: . Oncethe snap rjng B is removed,replaceit with a new one. a Be caretulnot to damagethe compressorbody and rotor pulleyduring removal/installation.
HOLDER A,/CCLUTCH Commorcirlly av6ihble Robin.ir: P/N 10204 Kent-Moore:P/N J3?872
CENTER NUT 18N.m11.8 kg-m, 13lb-ft1
A
\/ :
ROTOR PULLEY
@)
the Remove armatureplateby pullingit up by hand. lf you can not remove it by hand, attach the flywheel pullerto the armatureplate,screwthe bolt in plate. the centerand removethe armature the rotor pulleyfrom the shaftwith a puller Remove tool. and the special NOTE:Putthe clawsofthe pulleron the backofthe r o t o r p u l l e y ,n o t o n t h e b e l t a r e a ;o t h e r w i s et h e rotor pulleycan be damaged.
PULLER FLYWHEEL 07935-8050003
SEAL DRIVER 07945-4150200
(cont'd)
22-37
Compressor
(cont'dl ClutchOverhaul
5. Remove snap ring A with a snap ring pliers. the Releasethe field coil connector from the connector holder,and disconnect connectorand field coil the groundterminal. Remove field coil from the comDresso.. the NOTE: . Oncethe snap ring A is removed.replaceit with a new one. . When installing the field coil. align the boss on the tield coil with the hole in the comDressor. 7. lnstall in the reverseorder of removal, and: . Clsan the rotor pulley and compressorsliding surfacaswith non-Detroleum solvent. . Installth6 snap rings with the chamferedside facing out and make sure the snap rings are in the groov complgtoly. . After installing,mak sure that the rotor pulley turns smoothly. . Routeand clamp the wirs properlyor they can be damag6d by the rotor pulley.
6.
Position rotor pulleysquarely the overthe field coil. Pressthe rotor pulley onto the compressorboss with the soecial tool. lf the rotor pulley does not presson straight, remove it and checkthe rotor pulleyand compressor bossfor burrsor damage, CAUTION: Maximum press load: il00 kg (882lbsl
SHAFTRING _ REMOVER OTJAC SH2O3OO
Vv
22-38
ThermalProtestorReplacement
1 . Remove th6 bolt,tield coil terminal,and retsiner, Removethe thermal protector. Remove the rssidueof siliconsssalantfrom the top of thermal orotector.
Removal
NOTE: Make sure the suction and dischargeports are pluggedwith caps. 1. reliefvalve, Removethe three bolts,heat insulator. and O-ring. NOTE:Be sure to use the right O-ringsfor R-l34a to avoid leakage. CAUTION: Be caretul not to spill comprGssor oil, lnd mlb gura there is no foreign matter in the 3y3t.|n. HEAT II{SULATOfi
!2 N.m {1.2ks-m,I lb-ftl
RELIEF VALVE New p.rt (R-134.1 10 N.m (1.0kg-m, 7 tb-ftl O.RING NGwp.rt (R-134.) Replace.
to Apply siliconesea18nt the top of the thermalprotector.
lnstrllation
1'
Cleanoff the reliefvalvematingsurface, Replace O-ringwith new one at the reliefvalve,and a p p l y a t h i n c o a t o f r e f r i g e r a n to i l ( S P - 1 0 : P / N 3-0031beforeinstalling it. 38899-Pl NOTE: . Oo not return the oil to the containeronce dispensedand nevermix with other refrigerant oils to avoidcontamination. . lmmediatelyafter using the oil, replacethe cap a o n t h e c o n t a i n e r n d s e a li t t o a v o i dm o i s t u r e absorption. . Do not spill the refrigerant on the car; it may oil oil damagethe paint; if the refrigerant contacts th paint,wash it off immediately, Tightenthe reliefvalve.
SILICOI{ESEALAN'
4,
orderof removal. lnstallin the reverse
Checkthe relief valve for leaksand cap the relief valvewith the valveseal.
Belt Adjustment
1.
Apply a torce of 100 N (10 kg, 22 lbs) and measure rhe deflection betweenthe alternator and crankshaft DUIeY. Comp.6so. Beh Moction: in) U.cd Eolt: 10.0- 12.0mm 10.39 0.,17 N.w Bh: 4.5 - 7.0 mm (0.18- 0.28 in) P/S Pump Belt Usod Bolt: 13.5- 16.5mm (0.53- 0.65 in) in) Now Bslt: 9.5 - 11.5mm (0.37- 0.,15 NOTE: . lf there are cracksor any damageevidenton the belt,replace with a new one. it . "Used belt" means a belt which has been used for five minutesor more. . "New belt" means a belt which has been used for lessthan five minutes.
Measure with BeltTensionGauge: Attachthe belt tensiongaugeto the belt and measurethe tensionof the belt. CompresgorBglt Tension: Used Bsh: 450 - 600 N {i[5 - 60 kg,99 - 132 lbs] New Belt: 950 - 1t5O N {95 - 115 kg, 2Og- 254 lbs) P/S Blt Used Beh: 350 - 500 N {35 - 50 kg, 77 - 110 lbs} Nsw Eolt: 700 - 900 N (70 - 90 kg, t5'l - 198 lbs) NOTE: . lf there are cracksor any damageevidenton the belt,replace with a new one. it a Seethe instructions the tensiongauge. for
BELTTENSION GAUGE 07JGG- (x)l010A AOLT THBOUGH il5 N.m {i1.5 kg-m, 33 lb-ft)
BOLT THROUGH 45 N.m 1,1.5 kg-m, 33 lb-ft)
\
ADJUSTMENT LOCKNUT 22 N.m {2.2kg-m, 16lb-ft| CRANKSHAFT PULI-EY
2.
A/C COMPRESSOR
Loosen through bolt and alternator the n"t. Turn the adjusting bolt to obtainthe properbelttens i o n , t h e n r e t i g h t e nt h e a d j u s t m e n tl o c k n u ta n d through bolt. Recheck deflection the belt. the of
3.
Condenser
Replacement
1. 2. Recoverthe refrigerant(see page 22-251. pressureswitch 2P connector, the Ay'C Disconnect line A. then removethe receiver Iinefrom the condenser. the Disconnect discharge CAUTION:Cap the opon fittings immediatcly to keop moi3ture 8nd dirt out ot tho sy3l6m.
LINE DISCHARGE Now prrt (R-134.1
o.
Removethe two mounting bolts, then lift out the as condenser shown. CAUTION:Do not damage tho radiator and condenserfins when removing the condenser.
3.
O.RING Now pa.t {R-13,lal R6place. CONOENSEB
MOUNT
RECEIVER LINE A O.RING N.w p.rt lR-134r1
CONDENSER MOUNT CUSHION
SWITCH A/C PRESSURE 2 P CONNECTOR
6x1.0mm
kg'm,7lb-ft| 10N'm{1.0 hose bracket Removethe two bolts and Ay'C Removethe four bolts and radiator upper mount brackets. 6x1.0mm kg-m,7 lb-ft) 10N.m11.0
6x1.0mm UPPEF 10 N.m 11.0kg-m, 7 lb-ft) RADIATOR MOUNT BRACKET 'l.O mm 6 r 10 N.m {1.Okg-m, 7 lb-ftl
I il
]
7.
,"".t I f *oo,oto* MO,UNTBRACKET
and: orderof removal. Installin the reverse add refriger. lf you're installing new condenser, a ( a n t o i l ( S P - 1 0 :P / N 3 8 8 9 9 P 1 3 - 0 0 3 ) s e ep a g e 22-21). o ReplaceO-rings with new ones at each fitting, t a n d a p p l ya t h i n c o a t o f r e f r i g e r a no i l ( S P - 1 0 : them. beforeinstalling P/N38899-P13-003) N O T E : B e s u r e t o u s e t h e r i g h t O - r i n g sf o r to R-134a avoid leakage. mount cushions Be sureto installthe condenser into the holes. securely and test its Charge the system (see page 22-431 performance(seepage 22-261.
6x1.0mm kg-m,7 lb-ttl 10 N.m 11.0
22-41
A/C System Service

Evacuation
Onry !se service equipment that is U.L.-listed and is ce(ttd to meet the requirements SAE J2210 to remove ol e '34a trom the air conditioner system. C A U T I O N :E r p o g u r e l o a i r c o n d l t i o n a r .etrigeranl and lubricant vapot ot mlgl can irrilale eyes, nose end throat. Avold broathlng the ai1 conditioner relrlgeranl and lubrlcanl vapor or migt. ll accidental system discharge occurs,ventilatework area beloreresuming service. B - 1 3 4 a s e r v i c ee e u i D m e no r v e h i c l ea i r c o n d i t i o n e r t systemsshouldnol be pressure tested or leak lsted with compressed arr. some mixture of atr and E@ R-134ahave been shown to ba combustlble8l elevaied pressures and can rslull in flre or exploslon causing iniury or property damags. Never use compressed alr lo pre3sura trlt R.134a servlce equlpmsnt or vchlclo alr condilloner gyslama. Additionalhealth and salety inlormation may be obtained from lhe refrigerant and lubaicant manufaclurers. When an Ay'C Svstem has been opened to the atmosphere, such as during installation repair,it must or be evacuated using a R-134arefrigerant Recovery/ Recycling/Charging System.(lf the systemhas baan open for severaldays,the receiver/dryer should be replaced.) Connecta R-134arefrigerantRecovery/Recycling/ ChargingSystemto the car as shown followingthe equiomentmanutacturer's instructions. NOTE: lf low pressuredoes not reach more than 700 mm H9 (27 in-Hg)in 15 minuts, there is probably a leakin the system.Partially chargethe system and checkfor leaks{seeLeakTest). R.cov.rylR.cycling/Ghrrging Sptcm
22-42
Gharging
and is Only use service equipmenlthat is U.L.-listed of certiliedto meet the requirements SAE J2210 lo remove system. R-134atrgm lhe air conditioner C A U T I O N :E x p o 3 u r c t o e i 1 c o n d l l l o n e r rofrlgcrant and lubricanl vapor or mlll can lrltalo ye!, no3e and thloat. Avold bruathlng lhc alr condllloner ratllgoranl and lubrlcanl vapor or ml3t. It accidental system dischargeoccurs,ventilatework area blore resumingservice. Additionalhealth and salely in' and lubrilormationmay b obtainedkom the relrigrant cant manulacturers. Rctriglrlnt crpacity: 650* g 1231oz) Oo CAUTTON: not ovrrchrrgc tha tYstcm; th! comp.t!' 3or will ba drm!g!d. C o n n e c t a R - 1 3 4 8r s f r i g e r a n t R e c o v e r y / R e c y c l i n g / C h s r g i n gS y s t e mt o t h e c a r a s s h o w n f o l l o w i n g t h e instructions aquipmentmanufacturer's R.coyrry/Rlcyclin g/Charging Systm
22-43
A/C SystemService
LeakTest
that is U.L.-lisled and is Only use service equipment ol cenrlied meet the requirements SAE J2210 to remove to R'l34a lrom the air conditioner syslem. C A U T I O N :E x o o s u r e t o e i . c o n d i l i o n e r ,etrigerant and lubricant vapor or mist can irdtale eyes, nose and throgt. Avoid breathing lh air condltloner retrlgerani and lubrlcant vapqr or migl. It accidental system dischargeoccurs,ventilatework area beforeresuming setuice. R - 1 3 4 as e r v i c ee o u i o m e n o r v e h i c l e a i r c o n d i l i o n e r t syslemsshouldnot be pressuretested or leak tested with arr. compressed E@ some mixture ol air and R.134ahave been shown to be combustibleat glevated pressureg and qan resull In fire or explosion causing injury or property damags. Never use compressed air to pressure lgsl R.134a servlce equipment or vehicle ail conditionersystems. Additionalheallh and salely information may be obtained manufacturers. from the relrigerant and lubricant
l.
Rccov.rylRrcycling/Chrrging Syltlm
Connecta R-134arefrigerantRecovery/Recycling/ Charging Systemto the car as shown followingthe instructions. eouiomenlmanufacturer's NOTE:Be sure to installthe same amount ot new r e f r i g e r a n to i l b a c k i n t o t h e A / C s y s t e m b e f o r e c h a r gn g . I Open high pressurevalve to chargethe system to 14 about 100 kPa (1.0 kg/cm?. psi), then close the suppryvarve. Checkthe systemtor leaksusing a R-134a refrigerant leak detector with an accuracvof 0.5/oz.per vear or better. l f y o u f i n d l e a k st h a t r e q u i r e t h e s y s t e m t o b e opened (to repair or replacehouses.fittings, etc.). r e c o v e rt h e s y s t e m a c c o r d i n g o t h e R e c o v e r t Procedure page22-25. on
HIGHPRESSURE SIDE
5.
After checking and repairing leaks, the systemmust on be evacuated lsee SystemEvacuation page 2242t.
22-4
Electrical
Troubleshooting
T i p s a n d P r e c a u t i o n . . . . . . . . . . . . . . . . . ...... . . . . . . , 2 3 - 3 s . F i v e - s t e p r o u b l e s h o o t i n.g . . . , . . , . . . . . . . . . . . . .2 ,3 - 5 T , . . Lights, Exterior Back-upLights ........... 23-192 Brake/High Mount Blake Lights ..............23-194 . . . . . . . . . . . . . . . 2.3 - 1 8 3 . Hoadlights L i c e n s e l a t eL i g h t s. . . . . . . . . . . . . . . . . . . . . . . . . .2.3 . 1 4 8 P . .Palking ights . . . . . . . . . . .2 3 - 1 8 6 . L 23-185,188 SideMa*erLights................ T a i f f i g h t s. . . . . . . . . . . . .......23-147 T u r n S i g n s lL i g h t s . . . . . . . . . . . . . . . . . . . . . . . . . . - .2 3.-.1 8 5 .. Lights, Interiol . . . . . . . . . . . . .2 3 - 1 9 0 . Ceiling ight L ' Dash Lights BlightnessControl ...............23-201 E n r l yL i g h r ................23-173 K .. l g n i t i o n e y L i g h t . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 3.-. 17 3 TlunkLighr . . . . . . . . . . . . . . . .3 - 1 8 9 2 *Lighting System -.--..--...-. 23-174 PGM-FISystom Soction 11 ..,..,,...,..,23-213 Powel Antenna Power Distribution .......... 23-51 + P o w s rD o o r L o c k s. . . . . . . . . . . . . . . . . . . , . . , . . , . . . . .2.3 . .2 5 5 . .*Powsr Mirors -,..-...,,.,,..,23-242 Power Windows ...--..-...-.23-248 Fan Controls .,,...,., 23-'115 Radiatorand Condanser + R e a r i n d o w D e f o g g o r . . . . . . . . . . . . . . . . . . . . . . . . . .3.- 2 2 7 . 2. W ,..,..,,..,..,23-7 RefayLocations . .3. S e a tH e a t s r s C a n a d s } . . . . . . . . . . . . . . . . . . . . . . . - -2- -- 2 3 2 { *Side Markr/Turn Signal/Hazard .......... 23-196 FlasherSystem . . . . . . . . . . . . . . . . .2.3 - 1 0 1 . S p s r kP l u g s .............23-76 StartingSystem * S t e r e oS o u n dS y s t e m . , . . . . . . , . . . , . . , . . , . . , . . , . .2.3 - 2 0 6 . ., * S u n r o o f. . . . . . . . . . . . . . . . . . . . . . . .2 3 - 2 3 7 . RostrainlSystem (SRS)......... 23-287 Supplemental ( 2. V e h i c l e D e e d e n s o r V S S I. . . . . . . . . . . . . . . . . . . . . 3 - 1 3 8 S S . . . . . . . . . . . . . . . .3 - 2 6 3 2 Wiper/Washer wires, Harness. and Connectors Connector ldontitications and R . . W i r e H a r n e s s o u t i n g. . . . , . . , . . . . , . . . . . . . 2.3 - 1 3 .......... 23-332 Wi ng Diagram rRead SRSprecautions page 23-294, than installlh6 on short connecior on the airbag before wolking in these areas.
How to Use This Section

Schematic Symbols Wire Color Codes
Relayand Control Unit Locations

E n g i n e o m p a r t m o n . . . . . . . . . . . . . . . . . , ,....,,, , . , . . , 3 - 7 2 C t . . . . . . . . . . . . . . . . . .2 . - 8 .3 Dashboard ............ 23-11 Dashboard/Seat . . . . . . . . . . . .3 - 1 2 2 Floor.................
Index to Circuits and Systems

........... 3-247 2 Airbag ............... ....... Section22 Air Conditioner Anti-lock BrakeSystem {ABS) .............Ssction 19 Automatic Transmission System ......... Section 14 ..........23-66 . Battery.............. ...... Section21 Blowl Controls ...........23-102 S Charging ystsm * C i g s r e t t e i g h t o l . . . . . . . . . . . . . . . . . . . - . . . . . . . - . . . - 2.3 .-.2 2 4 L . - *Clock................ - . . . - . . - . .2 3 - 2 1 8 . . 3 .7 C o n t r o lU n i t L o c a t i o n s - . . . - . . - - . - - . . . - . . - . . . . .2- . - . ' C r u i s eC o n t r o f . . . . . . . . . . , . , ,2 3 - 2 7 2 . ...............23-180 DaytimeRunningLights (Canada) . . . . . . . . . . . .S c c t i o n1 1 . F u s lP u m p Fuses . U n d r - d a sF u s e / R l aB o x . . . . . . . . . . . . . . . . .2.3 - 4 8 h y . U n d e r - h o o F u s e / R e l aB o x . . . . . . . . . . . . , . . . .2.3 - 4 6 d y +Gauges .........23-126 C i r c u i tD i a g r a m Engine Coolant Temperature {ECT) ...23-123 Gauge............... . . . . . . . . . . . . . . .2 3 - 1 2 3 . F u e lG a u g e . . . . . , . . . . . ,2 3 - 1 2 4 . Spoedometer - . . . - . . - . . - . 2.3 - 1 2 4 . Tachometer Ground . . . . . . . . . . . . . . . . . . . . .3 - 5 9 2. Distribution . . . . . . . . . . . . . . . 2.3 - 1 3 . Locations ...... Section21 HeaterControls *Horns ............... ,.,..,,..,23-220 . r l g n i t i o nS w i t c h . . . . . . . . . . . .2 3 - 7 3 . r l g n i t i o nS y s t e m . . . . . . . . . . . .2 3 - 9 0 . . . l g n i t i o n i m i n gC o n t r o l . . . . . . . . . . . . . . . . . . . . . . . . . 2.3.- 9 3 T Indicators * A / T G e a rP o s i t i o nn d i c a t o r. . . . . , , , . . . . , . . . ,2.3 - 1 4 4 l . H i g hE e a mfn d i c a t o r. . . . . . . . . . . . . . . . . . . . . . . . . 2.3.- 1 3 2 . . * S a f e t yI n d i c a t o l . . . . . . . .2 3 - 1 5 1 2. T u r n S i g n a fn d i c a t o r . . . . . . . . . . , . , , . . . . . . . . . . . .3.- 13 2 *fntsgratedControl Unit ,..23-164 t l n t e d o c kS y s t e m . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 . .- 15 8 .3 ..
SpecialTools
Rcl.
'2,
.lr
o.
Tool Numbol
Doscription
Oty I I 1 1 I I 1 ,l
I Pago Roloronco
o o-
o.
@' @
@-'
DigitalMultimete. KS-AHM-32-003 Eelt TensionGauge oTJGG-001010A Antenna Wiench 07JAA*OO10008 Oeployment Tool oTHAZ-SGOO400 Test Harness A 07MAZ-SLOO500 Test HarnessB oTMAZ-SPOO500 Test HarnessC oTLAZ-S140300 Test Ha.nessD oTLAZ-SL40400 A 9 7 3 X _ 0 4 1 _ X X X X XVacuum Pump Gauge
23-99,293 23-1' 13,1't4 23-214 23-322 23-303 23-306 23-222, 274, 30'l 23-309 23-243
': lncludedin SRS Tool Set OTMAZ-SMSOOOA * *: lncludedin SRSTool Set OTMAZ-SLoOlOA
@ @ @
(,
@ @
23-2
Troubleshooting
Tips and Precautions
Betol Troubloshooting a Checkapplicable fuse/relay tuses in the appropriate
DOX.
Nevertry to disconnectconnectorsby pulling on their wires; pull on the connectorhalvesinstead. Always reinstallPlasticcovers.
a Check the battery for damsge, state ot chsrge, and clean and tight connections. a Check the alternatorbelt lension. CAUTION: a Do not quick-chargoa battory unlosslhe banory ground cable has bs6n disconnoctod. Otherwiseyou will damagath6 ahomator diod63. a Do not attmpt to crank the ongino with the batt6ry ground cable loosely conncted or you will seveloly damag tho widng. Handling Connectors a Make sure the connectorsare cleanand have no loose wire terminals. a Mske sure multiple cavity connectors8re pscked with grease(exceptwatertight connectorsl. a All connectorshave push-downreleasetype locks. Befoaeconnectingconnectors,make sure the terminalsare in olace and not bent.
a Check lor looseretainerand rubberseals. Some connectors have a clip on their side used to 8ttach them to a bracketon the bodv or on anothercomponent.This clip has a pull type lock.
RTAINER
Some mounted connecto.s cannot be disconnected unlessyou first releasethe lock and remove the connecto. from its bracket.
The backs of some connectors are packed with lf grease. Add greaseif necessary. the gresseis contaminated,replaceit.
ERACKET
{cont'd}
23-3
Troubleshooting
Tips and Precautions(cont'dl
a Insertthe connectorall the way and make sure it is securelylocked. a Position wires so that the open end ol the cover f a c e sd o w n . a Seat grommetsIn lheir groovesproperlv.
Fac6 open ond
A -Yl l
-M/ --P\
l r
NOT GOOO
Hsndling Wilos and Halnossos a Securewires and wire harnesses the frame with to wire ties at the designated locations. their respective a Removeclips caretully;don't damagetheir locks.
Testing and Repairs a Do not usewiresor harnesses with brokeninsulation. Replace them or repairthem by wrappingthe break with electrical tape. a After installingparts, make sure that no wires are pinchedunder them. a When using electricaltest equipment, follow the instructionsand those describedin manufacturer's this manual. a lf possible.insert the probe of the tester from the wire side (exceptwaterproofconnector).
Slippliersunderthe clip baseand throughthe hole at an the expansiontabs to releasethe angle,then squeeze cxp.
a Use a probe with a tapered tio.
SNAP.RINGPI-IER
After installing harness clips, make sure the harness doesn't inter{ere with any moving parts. Keep wire harnesses away from exhaust pipes and other hot parts, lrom sharp edges of brackets and holes. and from exposed screws and bolts.
Kit in ReIer the instructions the HondaTerminal for to terminals. identification reDlacement connector and of
23-4
Five-StepTroubleshooting
1 . Vofly Tho Complaint Turn on allthe components the problemcircuitto in verifythe customercomplaint. Notethe symptoms. Do not begindisassembly testing until you have or narowed down the oroblemarea, Analyze The Schomatic Look up the schematicfor the problemcircuit. Determine how the circuit is supposedto work by tracing the currentpaths from the power feed through the circuitcomponents ground.lf several to circuits fail at the same time, the fuse or ground is a likely cause. BSssd the symptomsand your understanding on of the circuitoperation,identifyone or more possible causesof the Droblem. 4. Fix Tho Problom make the Once the speciticproblemis identiJied. repair. Be sure to use proper tools and safe proceoures. Make Suro Tho Ci.cuit Works Turn on all components the repaired in circuit in all modesto make sure you've Jixedthe entire problem. It the problemwas a blown fuse, be sure to test all of the circuits on the fuse. Make sure no new problems turn up and the originalproblemdoes not recur,
5.
3 . lsolate Tho Problom By Tosring Th6 Circuir

Makecircuittests to checkth diagnosis you made in step 2. Keep in mind that a logical,simple procedure is the key to efficient troubleshooting. Test for the most likelycauseof failurefirst. Try to make tests at points that 8re easilvaccessible.
23-5
How to Use This Section

Schematic Symbols
AATTERY
E
r
RESISTOR
GROUND ground Component Groundterminal
FUSE
cotl, soLE otD
CIGARETTELIGHTER
A
:
I I
I.:
I I
S.-O-
t-Al +
BULB DIODE
t+J
HEATER
At
VARIABLE RESISTOR
THERMISTOR
IGNITIONSWITCH
MOTOR
fr + ilHH + + + D $ H Y II
J)TPUMP CIRCUIT BREAKER
HORN
SPEAKER. EUZZER
ANTI:NNA
TRANSISTOR(TI)
Mast
Wire Color Codes
RELAY lln no rmal po.itlon) Normally opon rlay Normally closed relay
CONDENSER
GT - I It i l
l-t^f
SWITCH {ln nrrrm6l positionl Normallyopen Normally closed switch switch
I T
TIGHT EMTTNITG DIODE ITEDI
The following abbreviationsare used to identify wire colors in the circuit schematics: W H T . . . . . . . . . . .W h i t e . Y E L . . . . . . . . . . . . .Y e l l o w . B L K . . . . . . . . . . . . .B l a c k . B L U . . . . . . . . . . . .B .l u e . . G R N . . . . . . . . . . . .G r e e n R E D . . . . . . . . . . . R. e d . . . O R N . . . . . . . . . . . .O r a n g e P N K. . . . . . . . . . . .P . n k .i B R N. . . . . . , . . . . .B , o w n .r . G R Y . . . . . . . . . . . .G r a y P U R. . . . . . . . . . . . .P u r p l e . L T B L U . . . . . . . . .L i g h tB l u e L T G R N . . . . . . . . .L i g h tG r e e n
I /f'[\ $/ I
/rn\
\Y./
I
I
00 tti
The wire insulationhas one color or one color with anothercolor stripe. The secondcolor is the stripe.
T T
REED SWITCH
9--wHr/BLK
I
t
-___----{
v lJ r Y I
CONNECTION Input I Output
CONNECTOR
.
/
/
l
+>tt
!
Ai t tt
Y
Relay and Control Unit Locations

EngineCompartment
WII{DSHIELD WIPERINTERMITTEI{T RELAYtB-rypo) I Wir. colorr: BLK,BLU^/HT, I GR I BLU/nED, /aLK,snd cR /REDI
CONDENSER NELAY FAN I Wirocolo.s:YEIA tHT, WHT/GRN, I and I BLU/RED, BLU|'EL I WHl, r 'l r Wirc color3:YEL/WHT, BLU,and BLUrYEL I
ABS MOTOR RELAY {A-typo) RAOIATORFAN RELAY lA-typo)
DIMMER RELAY (a-typol
FUSE/RELAY BOX
RELAY A/C COMPRESSOR CLUTCH NELAY
YEL/BLK, I Wiro colorr: YEL/BLK, I RED/BLU. RED and *Ii Wire coloc: BLK|'EL,BLK^/EL, NED/BLU. RED 6nd
IEST TACHOMETER COl{NECTOR
r: Wlrh OFflONAL A/C
23-7

Dashboard
CIGARETTE LIGHTER RELAY lA-typ.) Wir6 colors: YEL/RED,, WHT/BLU,BLK, I and WHT/BED I SUNROOFCLOSERELAY (B-typol
;ii,[iic I ;tir/Rl=d and BLK

I
TURN SIGNAL/ HAZARD RELAY
HOBN RELAY IA-Typo} Wir. colors: WHT/YEL,
-'
I
I
RELAY OPEN SUI{BOOF
wrNDow
{i ' 'rl
UNIT CONTROL INTEGRATED
RELAY (A-typel
r"'tE
wtNDow
DEFOGGER (A-typcl RELAY
MOTORRELAY BLOWER tA-typ6l
FUSE/RELAY BOX
PGM-FI MAII{ RELAY
FAIL.SAFE ABS FRONT nELAYlA-typol , Wir. colo.3:BRN/BLK, , YEL/GRN, I I BLK/YEL, I ond BLK I
ABS REAR FAIL.SAFE RELAY (A-typ.) , Wire colors: 8LU/BLK, , IBLK/YEL,YEL/GBN, I I and BLK I
23-A
DASH LIGHTS BRIGHTNESS CONTROL UNIT
DAYTIME RUNNING LIGHTS CONTROL UNIT (Canada)
RADIATORFAN COI{TROLMODULE
23-9

(cont'dl Dashboard
TRA SMISSIOT{ CONTROL MODULE (TCMI
23-10
Dashboard/Seat
ORIVER'SSEAT HEATERRELAY (Ctntda) SEAT HEATERMAI]II RELAY {C.n!dal , Wir. color.: WHT/BLK,' l6nd BLK I
BLK/GnN,I IYEL/BLK,
SEAT HEATERRELAY (Can.d.l PASSENGER'S
COiJTROL UNITIA/T) II{TERLOCK
23-1
Relayand ControlUnit Locations

Floor
23-12
Connector ldentificationand Wire HarnessRouting

How to ldentify Connectors: "C" for connectors, by numbershave beenassigned all connectors. to The numberis preceded the letter ldentitication "G" for ground terminalsor "T" for non-ground terminals. Location Harnsss Starter cables Batteryground cable Engineground cable Enginewire harness Engine Companment f1, T2, and + Dashboard OthoB (Floor. Dool, Trunk, and Roof)
T3 G l a n dT4 and T5 C1 0 1t h r uC 1 3 9 T'l O1 thru T'l 03 G1 0 1 C201thru C2l I G201 C301thru C326 G301 C420 thru C435 and C484 C401thru C419 C436 thru C483 G 4 0 1 ,G 4 0 2 . G 4 0 3 , and G4O4 C501 thru C514 T5O1 thru T5O9 G501,G502,G503, G504, G505 C521 thru C543 G521 G522 C551 th.u C559 G5 5 1 C6O1 thru C622 C651 thru C655 C701 thru C7O7 G701 C721 thru C731 C741 thru C748
Right enginecompartmentwire harness Left enginecompartmentwire harness Main wire harness
Right side wire harness
Lefl side wire harness Rear wire harness Dashboard wire harness Roof wire harness SRS main harness Driver'sdoor wire harness Passenger's door wire harness Rear window defoggerground wire A/C wire harness C381 thru C386 G381
c801 G801
23-1

Startor Cablos
Connector or Terminal
Numbor ot Cavitias
Location Right side ot engine compartment Right side of engine compartment
ConnoctEto fuse/relaybox Unde.-hood Starter motol Battery positive terminal
Notes
T1
r2
@
Battery
Battery GroundCables
Connector ot Torminal
T?
Numbor ot Cavities
Location Middle of engine compartment Right side of engine compartment Battery
Connocts to T16nsmissionhousing Body ground, via battery gfound cables Battery negativ terminal
Notes
EngineGround Cables
Connoctor or Torminal Number of Cavitios
Location Middle ot engine compartmnt Middl of engine compartmant Left side of engine companment
Connects to Engine mount bracket Valve cover Body glound, via engineground cables
Notos
T4 T5 G2
23-14
BATTERY POStTtVE TERMINAL BATTERY t{EGATIVE TEBMINAL
CABLES GROU]TD BATTERY
ENGINE MOUNTBBACKET
EI{GINEGROUT{D CABLES
( )
23-15
Connector ldentification and Wire Harness Routing

Errq\ne \Nne Rursess \AZZAI' Errg\rre. 2.2 t SSRQ.\
Connector or Tlminal Numbor of Cavitios Location Left side of engine compartment Middle of engine Middleof engine Middleof engine Middle of engine Middle of enginecompartment Left side of enginecompartment Middle of enginecompartment Middle of enginecompartment Middle ot engine Middle of enginecompartment Middleof engine Middle of engine Middle of engine Middle of engine Middle of engine Middle of Middle of Middle of Middle of engine engine engine engine Connects to Alternator No. 'l fuel injector No. 2 fuel injector No. 3 fuel injector No. 4 fuel injector Idle air control (lAC) valve Injectorresistor Intake air temperature(lAT) sensor Power steeringpressure(PSP)switch Enqineoil pressure switch Throttle position (TP)sensor Heatedoxygen sensor{HO2S) Vehiclespeed sensor (VSS) Countershaft speed sensor EGRvalve litt sensor Enginecoolanttemperature(ECT) switch A Back-uplight swirch (-) Back-uplight switch ( + ) lgnition coil Enginecoolanttemperature{ECT) sensor Enginecoolanttemperature(ECTI sendingunit Staner solenoid TDC/CKP/CYP sensor lgnition control module {lCM) Enginecoolant temperature(ECT) switch B Mainshaftspeed sensor Lock-upcontrol solenoidvalve Shift control solenoidvalve Junction connector Main wire harness(C428) Main wire harness{C425) Main wire harness{C426) Main wire harness{C432) Main wire harness(C432) Main wire harness(C433) Notos
c101 c 102 c103 c l04 c105 c106 c107 c 108 c110 c111 c113 c114 c115 c116 c117 c118 c119 cl20 c121 c122 c123 cl24 c125 c126 c't 27 c128 c129 c130 c131
L I S J
4 2
6
,l 4
Aft
2
I 1 4
Mrf M/T
Middleof engine
I I 2
Middle of Middle of Middle of Middle of
engine engine engine engine
c134
LtSC LIJC Lt50
10 2 14 10 10 4 14
Middle of engine Middle of engine Middle of engine Right side of enginecompartment Right side of enginecompanment Right side of enginecompartment Right side of enginecompartment Right side of enginecompartment Right side of enginecompartment Right side of enginecompartment
Arf A/T NT
NT M/T
Tl01 r't02
G1 0 1
Right side of enginecompartment Under-hood Juse/relay box Left side of enginecompartment Alternator Middle of engine Engineground,via enginewire harness
23-16
THEBMOSTAT HOUSING
c104 c108
cl
cl35 C136 26
cl13
.t
c r z rI c 1 J 7
9 r /" r o .
23-17

(H22A1Engine: I VTECI Engine Wire Harness 2.2
c101 cl02 c 103 c104 c105 c106 c107 c108 c109 c110 c 11 2 c 11 3 c114 c 1l 5 c117 c 11 8 c119 c'120 c121 c122 c123 c't24 c125 c126 c131 c132 c133 c134
Lt55
6 2
Left side ot enginecompartment Middle of engine Middle of engine Middle of engine Middleof engine Middle of enginecompartment Left side of enginecompartment Middle of enginecompartment Middle of enginecompartment
3 4 3 2
c136 c137 c138 c139

T1 0 1 T102 Tl 03
Alternator No. 1 fuel iniector No. 2 fuel injector No. 3 fuel injector No. 4 fuel injector ldle air control (lAC) valve Injectorresistor Intakeair temperature{lAT) sensor Intake air bypass (lAB) control solenoid valve Middle of engine compartment Power steering pressure (PSPI switch Middle ol engine Knock sensor (KS) Middle of enginecompartment Throttle position (TP) sensor Middleof engine Hested oxygen sensor (HO25) Middle of engine Vehiclespeed sensor(VSS) Middleof engine EGRvalve lift sensor Middle of engine Enginecoolant temperature{ECTI switch A Middleof engine Back-uplight switch ( - ) Middleof engine Back-uplight switch { + ) Middleof engine lgnitioncoil Middle of engine Enginecoolant tempersture(ECT) sensor Middle of engine Engine coolant temperature (ECT) sendingunit Middleof engine Starter solenoid TDC/CKP/CYP sensor Middleof engine Middle oJ engine lgnitioncontrol module (lCM) Middle ol engine Enginecoolanttemperature(ECT) switch B Right side ol enginecompanment Junction connector Right side of enginecompartment Main wire harness(C429) Right side of enginecompartment Main wire harness(C425) Right side ot enginecompanment Main wire harness(C426) Right side of enginecompartment Main wire harness(C432) Right side of enginecompartment Main wire harness(C4331 VTEC pressure switch Middleof engine VTEC valve Middle oJ engine Right side of enginecompartment Main wire hsrness(C484) Right side of enginecompartment Under-hood fuse/relay box Alternator Left side of enginecompartment Engineoil pressufeswitch Middle ot engine
23-1A
c113
ct31 cl32 ct 33 c1 c139 cl ct c123
c1
23-19

EngineWire Hamess (H23A1 Engine:2.3 f DOHCI
Connoctor 01 T.rminal Number ol Cavities Location Lett side of engine compartment Middleof engine lvliddle engine of Middleof engine Middleof engine Middleof enginecompanment Lett side of engine compartment Middle ot engine compartment Middleof enginecompartment Connects to otes
c101 c102 c103 c104 c105 c106 cl07 c108 c109 c110 c112 c113 c114 c115 c 11 6 c117 c118 c119 cl20 c'121 cl23 cl24 c'125 c126 c127 c128 c129 cl30 c131 c132 c133 c134
LIJI
4 2 2 2
o
2 2 4 3 3 2
1 1 4
1 I 2
2 10 2 't4 10 10 4 14
c135
Lt5t'
Alternator No- 1 fuel injector No. 2 fuel injector No. 3 tuel injector No. 4 tuel iniector ldle air control {lAC) valve Injector resistor Intakeair temperature{lAT) sensor lntake air bypass (lAB) control solenoid valve Middle of engine compartment Power steering prssure (PSPI switch Middle of engine Knock sensor(KS) Middle of engine compartment Throttle position {TP) sensor Middle of engine Heatod oxygen sensor (HO25) Middle of engine Vehicle sped sensor (VSS) Middle ol engine Countershaft sped aonaor Middle of engine EGR valve lift sensor Middle ol engine Engine coolant temperature {ECT} switch A Middle ot engine Back-up light switch ( - ) Middle of engine Back-up light switch { + ) Middl of engine lgnitioncoil Middle of engine Engine coolant temperature (ECT) sensor Middle of engine Engine coolant temperature (ECT) sending unit Middle of engine Starter solenoid Middle ot engin TDC/CKP/CYP sensor Middle of engine lgnitioncontrol module (lCM) Middle of engine Engine coolant temperature {ECTI switch B Middle of engine Mainshaft soeed sensor Middle of engine Lock-uo control solenoid valve Middleof engine Shift control solenoid valve Right side of engine compartment Junction connector Right side of sngine compartment Main wire harness(C428) Right side of enginecompartment Main wire harness1C425) Right side of engine compartment Main wire larness (C426) Right side of enginecompanment Main wire harness1C432) Right side of engine compartment Main wire harness1C432) Right side ot engine compa.tment Main wire harness{C433} Right side ot engine compartment Lft sids of engine compartment Middle oJ engine Middle of engine Undr-hood fuse/relay box Alternator Engine oil pressure switch Engineglound. via engine wire nSrness
ATT
Mrr
M/T
A/T A/T A/T
ATT M/T
T101 r102 T103

G1 0 1
23-20
THERMOSTATHOUSING
06
oa
cl15C118
El
WIRE HARI{ESS
:109cl c1o3 /
c133 cl1
cl
cl1
cl22 c123 c1 c1
c1'14 T103 12 10
23-21

Right Engine Compartment Wire Harness
Conn6ctor ol Torminal
Numborot Cavities 2
Location Middle ot enginecompartment Middle oI enginecompartment Middle oJ engine compartment Behindright front side marker light Behind lront bumoer Behindfront bumper Behindright headlight Middle ot engine compartment Behindright headlight Behindright headlight Behindright kick panel Right side of enginecompanment
Connocts to Right horn Left horn A/C pressure switch Right front side markor light Right tront turn signal light Right front fog light Right headlight (High b6am) Radiator fan motor Right headlight (Low beam) Right lront parking light Main wire harnesslC4Ol ) Body Oround, via main wire harness
l{ot6s
c204 c205 c206 c207 c208 c209 c210 c211

2 2
OPTION
22
23-22
9<P
23-23

Left Engine Compartment Wire Harness
Connoctor 01 Torminal
Numbsrof Cavitlos 2 2 2 1 2 4 I
Location BehindleJt front side marker light Behindfront bumoer Behindfront bumDer Behindleft headlight Middle of enginecompadment Behindradistor Behindleft headlight Left side ot engine compartment Lett side of engine compartment Left side of engine compartment Left side of enginecompartment Left side of engine compartment Left side of enginecompartment Left side of sngine compartment Behindfront bumpr Behindleft headlight Lett rear of engine companment Left side ot engine compartment Left side ot engine compartment Middle of enginecompartment Middle of enginecompartment Left side of ngine compartment Under middle of enginecompanment Behind left kick panel Behindlett kick Danel Behindleft kick Danel Left side ot engine companment
Connocts to Left front side markerlight Left front turn signallight Left front fog light Left headlight(High beaml A/C compressor clutch Condenserfan motor Left headlight(Low beam) Cruisecontrol actuatot A/C wire harness(C381) EGR control solenoid valve Left front wheel sensor A/C compressor clutch relay Condenserfan relay A/C diode Windshield waaher motol Left lront parkinglight Windshieldwiper motor Brake fluid level switch ( - | Braketluid level switch (+ I MAP sensor Evaporative emission (EVAP) purge control solenoid valve Windshield wiper intermittnt relay 4WS front sub steering angle sensor Main wire harness(C4621 Main wire harness(C463) Junction connector Body ground, via left enginecomoartment wire harnoss
Notas
c301 c302
LSUJ
OPTION Alc A/C

OPTIONAL
c304 c30s c306 c307 c308 c309 c310 c311 c312 c313 c314 c315 c316 c317 c318 c319 c320 c322 c323 c324 c325 c326
G301
ABS
4 4 2 1 1
Atc
A/C A/C
6 20 22 20
4WS
23-24
LEFT E GINE COMPARTMENTWIRE HARNESS
23-25

A/C Wire Harness {With optional A/Cl
Connoctor ol Torminal Numbr ol Cavitios I 4 4 4 2 Location Lelt side of engine compartment Under left Und6r left Under left Under lft Under lft side of dash side of dash side of dash side oJ dash side of dash Connocts to Left engine compartment wire harness (C3O9l A/C diode Condnser fan relsy A/C compressor clutch relay Condenser fan motor A/C compressor clutch Body ground, via A/C wire harness Notos
c381 c382 c383 c384 c385 c386

G381
Left front of engine compartment
23-26
23-27
Gonnectorldentificationand Wire HarnessRouting

Main Wire Harness(Right side of engine compartmentbranchl
Connector ol Torminal Number of Cavitios
a
Location Right side of Right side of Right side of Right side ot Right side ot Right side ot Right side of Right side of Right side of Right side of Right side of Right side ol Right side of Right side ol Right side of Right side of Right side of Right side ot enginecompartment enginecompartment engine compartment enginecompartment enginecompartment enginecompartment enginecompartment enginecompartment enginecompartment enginecompartment enginecompartment engine compartment engine compartment enginecompartment enginecompartment enginecompartment enginecompartment enginecompartment
Connects to fuse/relavbox (C945) Under-hood Under-hood fuse/relaybox (C946) fuse/relavbox (C947) Under-hood Under-hood fuse/relaybox (C948) Underhood fuse/relaybox (C9491 Enginewire harness(C133) Enginewire harness(C134) Test tachometerconnector Enginewire harness(C132) Intakeair control solenoidvalve Right front wheel sensor ABS solenoids Enginewire harness(C135) Enginewire harness{C135) Enginewire harness(C1361 ABS pressureswitch ABS motor Enginewire harness(139)
Not6s
c420 c423 c424 c425 c426 c427 c42a c429 c430 c431 c432 c433 c434 c4a4 I 14 10 2 10 10 4 14
I
DOHC ABS A/T M/T
VTEC
23-28
lcontinuos on prgo 23-3'l l
FUS/RELAY UNOER.HOOD BOX lviow lrom bolow)
MAII{ WIRE HARNESS
c427
c42A
c|+84
c429
(cont'd)
23-29

Main Wire Harness(Right side of dash and floor branch) (cont'dl
c401 c402 c403 c404 c405 c406 c407 c408 c409 c410 c411 c412 c413 c414 c415 c416 c417 c418 c419 c436 c437 c438 c439 c440 c441 c442 c443 c444 c445 c446 c447 c448
to
Under right side of dash Under right side of dash Under right side of dash Under right side of dash Under right side of dash Under right side ol dash Under right side of dash Under right side ot dash Behind glove box Behindright kick panel Behindright kick panel Behindright kick panel Behind glove box Bhindright kick panel Under right side ot dash Under right side ol da8h Under right side ol dash Under right side of dash Under right side of dash Under light side ot dash Under middleof dash Under middleoJ dash Under middleot dash Under middleof dash Under middleot dash Under middleof dash Under middleof dash Under middleoJ dash Under middleol dash Under middleot dash Behind middle ol dash Behind middle ol dash Bhind right side ol dash Under middleof dash Under middleot dash Under middleot dash
20 20 6 10 2 4 26 22 20 20 16 22 14 20 I 3 4
to
16 2 2 12 3
Right enginecompartmentwire harness (c211) Right side wire harness(CsO1) Right side wire harness (C5O2l Dashboardwire harness (C62O) Passenger'sdoor wire harness (C742) door wire harness(C741) Passenger's Blower resistor Evaporatortemperatura sensor Recirculationcontrol motor Transmission control module (TCM) Transmission control module (TCM) Junction connector Blower motot Junction connector ECM ECM ECM Daytime running lights control unit Junction connector Radiator fan control module Shift lock solenoid Cigarefte lighter Heater control panel Blower fan switch Stereo radio/cassette player Servic check connector Dsta link connector (DLC) A/T gesr position console light A/T gear position switch A/T gear position switch (Back-up light switch) Junction connector Mode control motor Body ground, via main wire harness Body ground, via main wir6 harnasa Body ground,via main wire harness Body ground, via main wirs harnss
Canada
23-30
MAIN WIREHARNESS
, Continuoa on I Ipaee 23-33 |
I Continuo! on I paso 23-29
c418
c413 c414
{cont'd)
23-31

Main Wire Harnesa(Left side of dash and floor branchl {cont'd}
Connac-tor or TcrmlnEl Numbol ot Cavities Location Under left side of dash Under lett side of dash Under left side ot dash Under lett side ot dash Under lett side oJ dash Under left side of dash Under left side of dash Under left side of dash Under left side of dash Under left side of dash Under lft side of dash Under lett side ot dash Under leli side oI dash Under left side of dssh Under lett side ot dash Conncts to Junction connectof lgnitionswitch lgnitionswitch Combination light switch Driver'sdoo. wire harness(C7221 Driver'sdoor wire harness(C721) Front main steeringangle sensor Lights-onchime lnterlock control unit Clutch interlockswitch Clutch switch Junction connector Lett side wire harness{C522} Left engine compartment wire harness(C324) Left engine compartment wire harness(C325) Dashboard wire harness(C602l Front tog light relay tuse/relaybox 1C918) Under-dash Under-dash tuse/relaybox {C922} Under-dash Juse/relay box {C920} Under-dash Juse/relay box (C915) Underdashjuse/relaybox {C914} Under-dash tuse/relaybox {C916) Under-dash luse/relaybox {C919} Integratedcontrol unit Starter cut relay Cigarette lighter relay Horn relsy Cruisecontrol unit SRS main harness{C706l Brake light switch Brake light switch ABS front fail-safe relay ABS rear fail-safe relay Seat heater main relay PGM-Flmain relay Notos
c449 c450 c451 c452 c453 c454 c455 c456 c457 c458 c459 c460 c461 c462 c463 c464 c465 c466 c467 c468 c469 c470 c471 c472 c473 c47 4 c475 c476 c477 c478 c479 c479 c480 c481
20 I 5 8 14 10 I
J
4WS Afi M/T CRUISE
20 20 20 22
,:l
r 4
14
2 J
c 16
14
1 l 4
4
4
14
c4a2 c483
2 4 4 4
Under left side of dash Under left side of dash i Under left side of dssh l Under left side of dash Under left side of dash 1 Under left side of dash | Under left side of dash lUnder left side of dash l Under left side of dash I Undsr left side ot dash Under left side ot dash Under left side of dash l Under left side of dash | Under left side of dash l Under left side of dash l Under lett side ot dash Under left side ol dash Under left side of dash Under left side ot dash Under left side of dash Under lelt side of dash
OPTION
M/T
sRs sRs cRulsE
Canada
23-32
(Continuoson page 23-31)
MAIN WIRE HARNESS
/ c453 c;54 c456 UNDER.DASH FUSE/RELAY BOX
c469
c46a c467
INTEGRATED CONTROL
23-33

Righr Side Wire Harness
Coonctor ol Tcrminal
Numborof Cavities 16 20
to
Location Jnderright side of dash Jnder right side of dash Jnder right side of dash light side of tloor iight quarter panel light quaner panel light quarter panel light quaner panel light quarter panel -elt front of trunk Left front of trunk Left front o{ tiunk lnside ol right rear wheel Inside ot right rear wheel Under middle oI trunk Under middleoI trunk Right side ot engine compartment Let-tfront of trunk Left lront oJ trunk Lett front of trunk Left front of trunk Under middle ol trunk Under middleof trunk Under middleof trunk Under middleof trunk Right side ol rear tloo. Middle tront of trunk Middle front ol trunk MiddleJ.ont of trunk Under middleof trunk
Connocts to Main wire harness(C4O2) Main wire harness(C403) wire harness(621) Dashboard ABS inspection connector ABS control unit ABS control unit ABS control unit ABS control unit Junction connector 4WS control unit 4WS control unit 4WS control unit Right rear wheel sensor Le{t rear wheel sensor 4WS rear di{ferential trans{ormer Rear main steering angle sensor Under-hood fuse/relay 4WS control unit 4WS control unit 4WS control unit 4WS control unit Rear steering motor Rear steering moto. Rear steering motor Rear steering motor Body ground, vi8 right side wire harness Body ground, via right side wire narness Body ground, via right side wire nSrness Body ground,via right side wire narness Body ground, via right side wire harness
Not6s
c501 c502 c503 c504

LCUS
c505 c506 c506 c507 c508 c509 c510 c51 1 c512

L5t5
6 14 12 20 18 20 4 18 12 2 I
ABS 4WS 4WS
c514 Tsol Ts02 T503 T504 T505 T506 T507 T508 T509 G501 G502 G503 G504 G505
4WS 4WS 4WS ABS ABS 4WS 4WS 4WS 4WS 4WS 4WS 4WS 4WS 4WS 4WS
23-34
II
T502 T503 T5()4 T505
Tsor
T5o8
REAB STEERING MOTOR I4WSI
lt,
FUSE/REI.AY BOX
RIGH?SIDE WIRE HANNESS
ABS COI{TROL U1{IT
(N
23-35

Left Side Wire Harness
Connoctor or Trrminal Number of Cavities 14 20 16
o
Location Under left side of dash Under left side of dash Behindlett kick panel Middle of center floor Middle of center floor Middle of center floo. Middle of center floor Left front ol trunk Right side of floor Left side oJ floor Left side of floor Right quarter panel Left quarter panel Lett quarter panel Left side ol rear shelf Fueltank Fuel tank Right side of rear shelf Middle ot rear shelt Left side of rear shelf Behindrear consolepanel Behind rear console panel Let't side ot floor Lett side ot floor Right quarter panel
Connects to Dashbosrd wire harness lC603) Main wire harness(C461) fuse/relaybox 1C917) Under-dash Hazard wsrning switch Parking brake switch Passengor'sseat heater switch Driver's seat heater switch Rearwire harness{C5511 Passenger'sseat heatel Driver'a seat hater Driver's seat belt switch Passenger'sdoor switch Driver's door switch Junction connectol Roo{ wirs harness{C651} Fuel gauge sending unit Ful pump Right rear spssker Trunk light Left rear apeaker Wootsr sDeakel Woofer amplifier Junction connoctor Body ground, via left side wile halnsss Body ground, via left side wire natneas
Notss
c521 c522 c523 c524 c525 c526 c527 c52A c529 c530 c531 c533 c534 c535 c536 c537 c538 c539 c540 c541 c542 c543
G521
1 6 6 18 2
'I I
Canada Canada Canada Canada
20 20 5 2
2 10 20
VTEC VTEC VTEC
23-36
c535 c52a
E 4l r l '
UNDER.OASHFUSE/RELAY BOX

RearWire Harness
Connoctor 01 Terminal Number of Cavitios Location Left front of trunk Middle of trunk Middle of trunk Middle of trunk Left side of trunk Left side of trunk Right side ot trunk Right side of trunk Right side ot trunk Middle of trunk Connects to Left side wire harness{C528} Left license light Trunk latch switch Right licenselight Left taillight Left rear side markerlight Right rear side marker light Power antenna motor Right taillight Body ground, via rea. wire narness otos
c551 c552 c554 c555 c556 c557 c558 c559

G551
18 2 8 3 8
Roof Wire Harness

Connector ol Torminal
LO5 |
Numbor ot Cavities 1 2
5
Loction Lft side oJ rear shelf Rear of roof Rear of roo{ Rear of roof Rear of roof
Connocts to Left side wire harness (C535) Rear window defogger Sunroof motor Ceilinglight High mount brake light
Not6s
c652 c653 c654
Rear Window Defogger Ground Wire

Connector ot Torminal Number of Cavhios 1 Rear of roof Rear of root Location Connocts to Rear window defogger Body ground, via rear window detogger ground wire
l{ot.!
c801
G801
23-38
BOOF WIREHAR ESS
REARWINDOW OEFOGGER GROUND
23-39

Dashboard Wire Harness
Connector ol Tsrminal Numbel of Cavitios Location Bshindleft kick oanel Under leJt side of dash Under left side of dash Under leJl side of dash Under leJt side ot dash Under leJ-t side ot dash Under left side oJ dash Under left side ot dash Under left side ot dash Behindmain gauge assembly Behindmain gauge assembly Behindmain gauge assembly Behindsub gauge assembly Behindsub gauge assembly Behindsub gauge assembly Behindmiddleot dash Under right side ot dash Under right side oJ dash Under right side ot dash Under right side of dash Under right side of dash Under left side ol dash Connects to Under-dashfuse/relay box (C9O7) Main wire harness(C464) Left side wire harness{C521) Dash lights brightness controller Cruisecontrol main switch Sunrool switch Left front tweeter Left front tweete. Junction connector Main gaug6 assembly Main gauge assembly Main gauge assembly Sub gauge assembly Sub gauge assembly Clock Dash lights brightness control unit Right tront tweete. Right tront tweeter Junction connector Main wire harness (C4O4) Right side wir harness{C5O3) Front fog light switch Notog
c601 c602 c603 c604 c605 c606 c607 c608 c609 c610 c611 c612 c613 c614 c615 c616 c618 c619 c620 c621 c622
to 14 5 6 5 1 I 20 10 5 16 10 30 5 6 'I 1 20 20 16 10
CRUISE
sRs
OPTION
23-40
DASHBOARDWIRE HARNESS
' 19
C6i4 C615 C616
2'1
C602 C6O3
r--r e
FUSE/NELAY BOX UI{DER-DASH
23-41

SRS Main Harness
Connoctor or Tarminal Number of Csvities Location Behind left kick panel Under left side of dash Under right side ot dash Middle ot floor Under right side of dash Under left side oJ dash Under left side ot dash
Middle of floor
Connocts to Under-dash tuse/r8l8ybox (C931) Lett dash sensor Right dash sensor SRS unit Passenger'sairbag assembly Main wire harness(C4781 Cable reel Body ground,via SRS main hsrness
t{otos
c701 c702 c703 c704 c705 c706 c707

G701
2 18 4
o
4WS, VTEC
23-42
-lnL t--l-E Fi-r r-:-l

-EF
lE=
[ffiEHflHflHHil
.ml
23-43

Driver's Door Wire Harness
Cooncctor 01 Torminal
Numb.r ot Caviti6s
14 8 4 6 18 2 10 6 10
Location Driver'sdoor Driver'sdoor Driver'sdoor Driver'sdoor Driver'sdoor Driver'sdoot Driver'sdoor Driver'sdoor Driver'sdoor Driver'sdoor Driver'sdoor Driver'sdoor
Connocts to Main wire hsrnsss (C454) Main wire harness(C4531 Dfiver's door soeaker Driver's Dower window motol Driver'sdoor lock actuatot Power door lock control unit Power mirror defogger switch Power mi.ror switch Driver's Dower miror actuator Driver's oower mirrot actuator Driver'sdoor lock switch Master oower window switch
otos
c721 c722 c723 c724 c725 c726 c728 c729 c729 c730
Canada USA Canada
Passenger's DoorWire Hamess

Connector or Terminal l!umb6. of Cavitios Location Passenger'sdoor Passenger's door Passenger'sdoor Passenger's door Passenger'sdoor Passenger'sdool Passenger'sdoor Passenger'sdool Passenger's door Connocts to Main wire harness (C4O6) Main wire harness (C4O5) Passenger'sdoor speakel Passenger'spowel window motor Passenger'sdoor lock actuator Passenger'spower window switch Passsnger'sdoor lock switch Passonger'spower mirror actuator Passenger'spower mirror actuator
l{ote!
c741 c7 42 c743 c744 c 74 5 c746 c7 47 c74A c 74 8
10
o
5
5
USA Canada
c745
c744
PASSENGER'S OOOB WIRE HARNESS
23-45
Fuses
Under-hoodFuse/RelayBox
tr47f,E46fC45lE44 fE43 lC42fC41ftr4oftr3s l tr4efC48f E sllEsof

c941 lTo ABS motor rohyl c942 [To ].di.tor tan r.llyl 4WS CONTROL UNIT I To right sld. wiro I
I hern63s ll5ol) I
c943 lTo dimrn.rrCryl

BATTERY
cautes [ [oretoncr 1
ALTERNATOR wtr. I I To ongino r ha.n.r{T101},1
lfo h.!d[ght
r.hyl
c945 I To mainwire I t harne$ tC42O) | c946 I To mainwlro r harn$3(C4211
c947 I To mrin wir. h.m.s. I . tc422l I
23-46
Fuse Numbor Amps

al
Wlro Colol
ABS motor relav Power distribution
Circuits and Components Ptotactd
50A
32 33 34
Jb 50
1 0 0A
50A 40A 40A
WHT
BLK/GRN
lgnitionswitch {BAT) relay Rearwindow deJogger Blower motor relav
WHT
40A
404
PGM-FImain relay WHT/RED Seat heaters(Canada),
WHT/BLU Sunrootsystem, power window system, daytime runninglights control unit

(Canadal
38 39 40
41
60A 1 5A 1 5A 1 5A
WHT WHT
4WS control unit ABS control unit (82)
WHTTYEL Turn signal/hazardrel8y, hazard warning lights WHT/YEL Horns, horn relay, brake lights, brake light signal
REO/GRN Parkinglights, dash lights control WHTA/EL Clock { + B), stereosound system, 4WS control unit, ECM, transmission module ITCM)
42 43
44
20A'
1 0A 1 5A 1 5A 1 5A 1 5A 7.5 A
WHT
Power door lock control unit
45 46
47 4A 49
WHT/GRN Condensertan motor, radiator tan control module WHT/BLU Ceilinglight, cigarettelighter rel8y,ttunk light, ignitionkey light
Jan motor Radiator
WHT/BLK ABS control unit

WHTi GRN RED/GRN ABS control unit {B1l Right headlight
50
c l
204 20A 20A-
REDryEL Left headlight, high beam indicator light
23-47
Fuses
Under-dashFuse/RelayBox
Front Vi.w {... p!96 23-50 lor bsck viowli
C901 [To turn signal/hazardroloy]
C903 [To blower molor rolayl
C9O4 [To pow.r window rol6y]
c905 open I To aunroof I r r
CgOGITo roar wlndow dologgor rolayl CgOB tTo SRS luso block (C933)l
rclay c907 ITo da.hboard I t wir6 ham6s tC6Olll

AUXILIARY FUSE HOLDER (4WSl
c931 lTo sRsm6ln I
I harno.r{C701} | c932 lTo ignitionrwltchl
c909
I To combinrtion I I light switch I
@@@q - nnrjl
I -
n tnl 23 24
U IUI
F,
| 1 a1 92 0
nr:In|:lnnnnn
Sporo fuso
UUU
l:lnnnr:rrj]nElr
UUIJUIJUIJIJ
1 2 3 4 5 6 7 8
UUIJIJUUUUT
91011121314'1516t
c933
lTo und.r{!.h box (C9O8)l turc/rclly
SRSFUSE BLOCK
C910 C91 1 C912 C913 loptionl loptionl loptionl loptlonl
23-4a
Fuso Number Amps
Wiro Colol Not used
Circuit! and Compononts Prolocted
7.5 A
5
BLU/RED
1 5A 1 0A 1 5A
BLU/RED YEL/BLU
ECM, PGM-Flmain relay, sub gaug (brakecheck circuit) Fronttog lights (option) PGM-Flmain relay Not used
WHT/BLK Seat hester svstem (Canada)

Sunroof open relay, sunroof close relay lnternal connecI|on RED/GRN Daytimerunninglights control unit {Can8d8) ODtion2 connector,blowr motor relay lnternal connect|on BLKiYEL Heater control panel, power mirror systsm, ABS control unit, tadiator fan control module, Mode/recirculation control motor Not used Rearwindow defoggerrsl8y, integratedcontrol unit, lnternal connection clutch relay, ECM A/C compressor YEL/BLK Seat heate. main relay (Canadal, YEL/RED Daytimerunninglights control unit (Csnada)
7 8
30A
1 0A 1 5A
10
l1 1 0A
12
t 5
7.5 A 1 0A 7.5 A
YEL
Gaugeand indicatorlights, clock, back-uplights
14
t 5
to
17
20A. 20A 30A

1 0A
BLK/RED Cruise control system WHT/BLK Driver's Dower window system

BLU/BLK GBN/BLK lnternal connection Passenger'spower window system wipr system Windshield Option 4 connector Stereo radio/cassette plaYer, cigarette lighter Not used Not used Not used
18
YEL/RED
l o
20 *21 '22 *23

*24
1 0A 1 5A
YEL/RED BLK/YEL
PNK
4WS control unit control module (TCM), radiatorfan control module PGM-Flmain relay, transmission SRS unit
RED SRS unit 1 0A ' 2 1 . 2 2 : A U X I L I A R Y U S EH O L D E RW i t h4 W S ) ( F *23, 24: SRS FUSEBLOCK
(cont'dl
23-49
Fuses
Under-dash Fuse/Relay Box
Brck Vhw {.!. p.gr 2348 to. tront vi.wl:
lTo m.ln wl.. h.ma$
lc470ll
c915 lTo mlin wlr! h!rno!. {C469)l
c916
lTo D.ln wlrc h.mct. (C471ll
c917 [To l.tt rid. wl.. h.rn.r. (C523ll
c918
lTo m.ln who hlrnr.r lc466ll
c920
lTo m.ln wiro ha]nor! {C468ll
c919
lTo mainwlr. hrrru.t (C472ll
c922
lTo inlin wlr. h.]no!. (c/t67)l
c921
lTo Intcgrr$d control unltl
23-50
Power Distribution
Circuit ldentification
BATTEBY
r-F-q-* I
i'
BLK SOX FUSE/REI.AY U DER-HOOO No.38 {60A) tlo.39l15A) WHT,"YELNo,40 {1541
motor Startor
wHT-
controlunit 4WS rclay Tumsional/fuiard waming lighls Hazrrd control lB2) unit ABS
&Eke sigml &akolightB, N0.49 l20Al
wm/Gnl1
ABS control {BI } unit ABS control 183) unit
0.117.54)
ABS MOTOB RELAY ALTERNATOR
Y_,.GRN/8LK ECM
-r"*
G4o'l G4o2 G404
+l$l','13l!:ltlT
BLvcRN + "*' [Tl"['13-%P"ooo'^
*'n*
wrrneo $
"*' h:o$5lJ59',0'i
*t HloollAoltfrTu""'*t
WHT/BLU +
fro p.g23 521
t' HtX'&-rol%i""tt*'
{cont'd}
23-51
PowerDistribution
Circuit ldentification (cont'dl
p4o23- 51| lFrom
Sters rdio/clssottdayor Pow6l 6nt6nn6 motor Clock Sl l+ 4WS contrclunh Tra miaiion control modul ITCM) ECM
Powatdooabck control utit
WHT/GR-+
ndidor f.n conrolmodul l.|r ,,/Cl C.ndo|tgr motorMatth Clgrott.lQht6. lgnilion light koy Keyintodock lohndd la,/Tl Intagratad conttol unil Trunk t k Cih|o fght oat! linkcortrroclor {oLCl
RADIATON FAN MODUI.! COI{TROL BIUEU( YEL Rrdiator motor f8n
raunm
ENGTNE cooLAt{T TEMPMTURE $
{Top.g623 53, 541
23-52
USA:
FUSE/NELAY BOX UNDRHOOD
. HIGH BEAM INDICA]OR LIGHT . RIGHT HEADUGHT (Hioh borml . LEFT HEADUGHT bo3ml {High
RED/GRN Right headlight{Lorvbem) Risht hadlishtlHish beeml
(20A1 No.51 bft h6dlghl {Lowb6.rhl boaml Lrft h6ad[tt[ {High High b6m indicrtor hht Foglightr6lry(oprionl
FOG UGI{T st /tTcH (Optionl
coMEINAT|oN UGHT SWTCH
>GORN
DIMMER
"-1
G401 G102 BIUiNED
_I
PASSING tot ^ G102 G404
Grc1
i\3 i oFF 2 (;--r
RED/8t(
Riohttritight F ont p.*ing lights Roa aidemerkorlights Lhons6pht6 fEhts Int6grstadcontrol unit Daehhhts DEshlights brightnosscontrol unit {Oplion O conrpclot) Ljghts lin dim modoltor clock, A,/Tg!. po*ion indicrior rd cru&aaadic8lor toft tdxght
Power Distribution
(cont'd Circuit ldentification
Canada: -HOODFUSE/REI.AY UNDEN BOX
--..+ RED/GRN , HIGH BEAM INDICATOR LIGHT . RIGHT HEADUGHT Hiohbehl . LEF.I HEADTIGHT b66m) {High
L+> 359g5115Pôuu*"
F F Lrtl hoedli0htllow borml Highbamindic3torlight Foglight rchy loFion)
Right headlighl b.rm) llow
RED/YEL----
swtTcH
l0ption)
FOG LIGHT
LD>36#S11"llf'*uo* i8ilfl8sil3il
I.O O DIMMER
onN
'"1_
'"-l_
G401 G402 G404
I I
I
REO/GRiI REDTYEI GRI.I/RED
DAYTIME RUNI{ING LIGHTS {ORI.) COMTROL UNIT
GRI'I/RED
YEURED lf;l;' Jl?illtT, < REo/cRN lH;'Jl3fliSE,, <
Rioht rdffghr Fmntprltin lightg Rrrs&re mafiorlights Lic.ns.pleto liohs kt grrtod controlunit D.!h li$ts D!,.hlights brighhGscor .ol udt (OptionO connctorl Light3 dimmodolfor {in gcsrposition cbcl A'/T indicdor cruis rM iMicrtor l.ft trtlghl
6301
BLK
23-54
No.33 FUSE {504) pqo23- 511 {From IGNITION SWTTCH .,i-
BLOC( SRS FUSE
r-----------------'l
No.24ll0A) N0.23 {15A1
Y t
l I
T
,' ^lcz
poc23 571
BLK/YEL 8LK/YEL * F lBLKIYEL BLK'YEL -
PGM Fl mainmlly Radiltor fan control modulo
Inraka comol .olsnoilv6tuo .it {DOHC} vdv6 EGR cnntol aolnoid Evroorutivc oinisioi IEVAPI lolnoillv6fuo control Putgs lightlsobo go) ch.rgino3y3t.m
|-,
F F F I I
modur ] Trsnsmblion conrlot FcMl !n3or Vhiclo spod {VSS) te! Voh.go btorllcl) lflata aitbypre! llA8lcontrcl solnoll v!tu. {DOHCI ELo uNlT N-
tlo.l3{1041
a?
YEt ......-
fioPry2s-stt
GtugE36ndlMic3tor lghtt
llntomdconnoctionl
unit co(rtrol Intagrsld SWITCH TURN SIGNAT
YEt ..+ No.l417.5A)

B["f\iREDGRNiELK*
llF
Brck- uPlight3 shift lockrohnoidlA/Tl

Crui!6 cotttol mrn switch Crubo contol unh Wndshiold wipd int.minont rcl6y wipr notot DleY Windshiold
l-
WIPE&WASHER SWTCH WINDSHIED BLKryEL lgritioncrtl
Btt,ryEL
FUSE AUXIUARY HoL.DER t4WS)
YEUREo F L
.raing lngh 36[eot 4lVSfiont main controlurtt 4WS /tWS mein tngie$nsor r6sr sloting
{cont'd)
23-55
Power Distribution
(cont'd Circuitldentification
DASH FUSE/RELAY BOX UNDER_ -/---'-r
F-_..-/
loption O connctorl Cirlrfft hhtor r6ley Sters ndio/crcaott! dryor Wootd iinD[fr6r lavan!0ak6rr) Wrth No.gl15A) connoctionl 0nterml BI.I(YL BLK/YEL
lOptbn @ connectorl lloltar conlroi p8nl Powd mkror &lurtor!
i;'
powor mlror d.io0e6r
Modacontrol motor
No.35lrcAlFUSE - I p.9.23 51 lFrom

f_-i.-
:
G401 G402 G404
' 'j- fif,HlSlBll'

moior 8bw6.
a8s fril- "f. trby il;;' i ABS contrcl unh ABS i|lpcti)n conn&lor 4WSconttol unh Rldirtorlln control tln nroduk modllo molor Rrcirdhtbn control
SluAvHr
ilo.1217.5Al
-{11)> YEURED
r\ f
DAYTIME RUNMIG UGHIS CoMTRoL UN|T (Top!0.23- 54,
ib.1l ll0Al
YEUBIX E S..t h.tt.. mlin |!hy ,VC compllasof ctxdr ralty
No.34140A, A,SE pa!623-511 lFrcm
l|l|tern.lcorlarcctionl Irtogrltod conlrol u|t|:t YEUGRN4I(GRX f,6lr wirdoyr drfo0[pr 3yritch n !r window datogoar
23-56
tGNtTtoN swrTcH lsll p.ge23551 lFrom
,a 6.[ -l ;!^,Girr -jtTMTERLoCK swrrcH cLuTcH
++
G10l G402 G404
BLX/RED -
EU(/IVI{II
strrrorsolnoid
__________r
BUoi/t{T -
strd6f solonoid
DASH FUSE/RELAY BOX UNOEF-
BLUif,ED * BtuiREDNo.36 llOA)FUSE p.g23-51) lFrcm
CM _ r6leY FGM Flmain gru!6 l&rk dck Sub
llntlmal connaclion)
loprionO conmctor) Foghht3 loptionl PGM Flm3in roky
BIUiRED YEUBLU
wm/Buf
i;'J
solth..!orlrLy
(cont'd)
23-57
Power Distribution
Circuit ldentification (cont'd)
_ UNDERDASH FUSSRETAY BOX
INTEGRATID COMTROL UNIT
Y I
'"--f,_
G4ot G402 G104
tlo.15(20A1
WffT/BtX BtU/BLK E Malter pow.. window lwhdl orivo/t @war window motor P!3!ng/! powar window motor
No.37 FUSE {404} pag623-51} {From
---> GRN/RED
GRiI/RED-
suilRooF slyncH
glnmot moior
nrtnr, -$
GRNY|-
su nooF slvrTcH
smrool r|oto,
Bt( A -:
G40l G402 G404
-p ',o,c"r
i
I
', liFlfl,#itT*f.o*'
__i
23-s8
GroundDistribution
Circuit ldentification
,l
housing Transmission
r -l G2
T.':
Valvscovor
Main.hft sp6ed snsorlA/T)
{#w"ttstu-1
l--l!l0RN/BLU
-r
I-rot-fiT/rilIl-t liorr,r,u |
r_i!lBr-u,^YEL +DIBIU/GRN
| _
i |
|
I Transmission controlmodub L
lfTCMl
Co(litolshaft spd .nsor lA/Tl
-l +j
Hostodoxygens6mor IHO2S) Knock snsor {KS)
-14
| wHT-
(TCMI Transmbsion conlrolmodul
r.* -{--.8rl*
ECM Vohicle spd s6nsor IVSS) Engino coola tomperature IECTI
posilion Cl'nk3haft {CKPIsonsor
1-i4lsLurenir l-{ElarurrcL l
1-i!JonNBLu L+lOwrniBLU f-Elont < r L-t!;lwHT
ORN WHT 8LK/RED Transmi$ion contrclmodulo ITCM) DEta connoctor link {DLcl
I I
TDC a6mor
po3rtion Cylindor $nsor ICYPI
"^-1,-.'E
BU(_
r*
WECpmssure switch{VTECI
T
I l-
riX_o,."*r,
prossurc Power stEring IPSPI switch Engin coolant tBmperature {ECTI switchA
Bt-( *
G10l
grcund E i Battory cables ground cablss tr :: Eminewirohanesg E Engino
j El Mdnnke hsmess ------S h i ew h e ld
(cont'd)
23-59
Ground Distribution
Gircuit ldentification (cont'd)
8t-K BI.K BL( B|.l( FIgt|r frcnt parldng light trghttronttumsignal light ftglt fiont skJs mffkorlight Radbtor motor fan
8U(BU(r
Right tugrghtloption) lronl Rightl lLow I h.dftgh beam) r!ft t-6rrJ
BU( +{olpjrx - elx -l | |
l-lFl su( F--lFlBU( -
,u.J
Bu( 8tx 8u( Btx Btl(
Cruka control actuator Condonlor riotor f6n trft ftlnt foghht {optiml L6ftlronrdd,.ma*6rlight bft trontrumlign.l kht
BU(BIJ( -
&*o ffrkl lvsl swhch L.ft fmnt prtjrE fght Wri$iald wipormotor Wri$bld wahd morot nlay Wind$i.H rvipor intonnittnt
BU( BU(BU(-
CondeNorfln molor(Wth optionalA./Cl
: Right6ngin6comprt||rafit wira hdtL!. : Lrft onginocompitrnant wira h!fiLd i A/C wir6 hrm63afwrthot{ronrl A/Cl
23-60
P&!rneo/! doorbck Ectuatot door Praagngar'! bck switch I I L- - - - - - - - - - - - - - - - - I I tcr dr) fhltar codrolpl|rl F pd; ff q6n lcon1;6lmodug
l-;;;;;;;il;;;-lcontolunil lghrt Daytlma running

!t* ] A8s t;t-r"f","r* haar J
AESDreiijra lwitch
BKF L
8tl( F L BLX-
Cru|..contll unit llnorlock codrolunhlA/I) lurloo poCtlon.witch DimmrtlLv
Bt(
EL! unh llightor Cigerno Hom rby

minltsring Fro||t {v/lrtt d|gl saNot
minordotog[r odva/! porv6. lcantdal minor lwilch Powot powe wlndow rwitdr Master ) powar motor window Ddvor', lock Powd door contolunh orlvor's doorlocl lwhch Odvlr'adoorbcl rcturtor
Bt( F l-
B.* +
8LK-
" Ht?'$"-rolUu,'n'*'
plryar St6ro radio/ca8atl.
G4o4
E .M6inwho hanoss
tr'
doorwirhamoss Ddver's
[ : []:
P!t!aar0a/t d@awi! htrs RlghtCd. win hrrs
(cont'd)
23-61
GroundDistribution
(cont'dl Gircuit ldentification
UNDER-OASH FUSE/REI-AY 80X
au
garg. !8!.muy j Sub gatrg6 Main allamtt Slnrooflrvhdl tug light3witch loptionl ordr liohtshhttn rs comrcl unh 'I I Mdnga{ rlsembt Cruilomdnswitch grb gmgoaslombv Clod
BLX 8rI 8Ll( Sunrcof closo rErry

Sunrcofopon l6l6y
'nrfrr*.ofttot unfl
8r( 8t.K
8U(-
#Tum
Powar window nlay Blowar notor rdrv
Combinalion ligfrt lwhdl nd windCli.ld wiper/yra$or,witdr
s|.K-D
G521 p!0.23 61t fio
#deu
BI.K 8tJ( p.g23 8l ) G404{Frcm
Bl-K ........b
Clu!$ swlth lwth cruL contol) Clurdtlm.dod(rwirdl lM/Tl

Ljght -on chim. Sart lbdar min lthy
lgrilionk y rwhch Oo'rtl.lietn.. rllrt
:]---
BU( -
lhrt r ft|l .tyitdl
ABS rbtor
G403
wir6 ham.ss tr :: oashboerdhanost tr [!ft sidr,ir
23-62
goundT504 Powor lmotorl co l4WS rclunitl
7-:i:
--^^ R6.r .ing motor ffneO st {+l Rear lt.ring motor ffarf
l-t
G505
v-:::
rTl vFl
Raar itodno rrotor fu;tion +} {oamper Radrlacrimmotor funclion- I lDempdl
ffau
8tK
) lws comrorunir
sidc El : Right wir6ham$3
(conl d)
23-63
GroundDist
Circuit
Drivor'ssoat hoatars Ddvar'3s6tt h6atd roly Ddvor's3ort hoatd 3witch Paaaong6r's hoatoa3 sost Paasangr's hostor r6lay s6!t P6ssongor's sert hortor lwitch
pump Fuol lFPl
Bt -#| x
-] s1x su
l-{M-l eu(-
f -
Hish mount blskoFght cilim lisht
--!
r.
lHlu
t* -T
lL
:Yt ] rc.N rohtt Drst6 Lln r

frunk letchrwhclr
Driv..'r r6st b6h awitch Woof.. lmplfir fwith s.wn sDoako6)
Fuol landing unit
E E E
, L"ft slde,ire t'*ness : Foof wit.. : Rear hamcss wira
23-64
Riohtr | tdltqhr Lsft r Rioht l reea $o mncr ||gnt L!-ft J Poworantonnanrotor
tt*-I"'unn I
Re.r window defogg6{
otot
wne E : Rear hmess hanss @ : sRsmain ground wir dofoggor E : R$windo\N
23-65
Battery
@ a
Baftery tluid (olectrolytl contains sulfuric acid. tt may causo aavolo burns if it gots on your skin ol In your 6yoa. Wear protoclivo clothing and a face shiold. - lf oloclrolyta g6ts on your skin or clothos. nae it off with watr immediatoly. - It electrolyta gots in your yes, flush it out by splashingwatar in your oy63 tor at least 15 minutes; call a physician immdiatoly. a A batto.y gives off hydrogan gas. ll ignit6d, tho hydlogan will oxplode and could crsck tho battory caro and aplattol acid on you. Keep sparks, tlames. snd cigatettes away flom tho battory. a Overchargingwill raiso tha tamperature ot tho oloctrolyte. Thb may forco ol6ctroly'toto splay out of tho battory vontE' Follow the chargor manufactulor's inatructions and chargo tho battory at a propol tato.
procdures. you don't have one oJ these coml{ Use eithef a JCI or BearARBSTtester. and follow the manufacturer's puterized test procedure: testers,follow this conventional To get accurateresults,the temperatureot the electrolytemust be between TOoF l21oCl and IOOoF (38oC).
lJ the case is cracked or the terminals are loose, replace the baftery.
lf the indicator shows low electrolvte, distilledwater it Dossible.
Test Load Capacity(# 1l . . . . Apply 300 amp load for 15 secondsto remove surfacecharge. Allow 15 secondsrecovetyperiod. Apply test load {see Test Load Chart). Recordvoltage at the end oJ 15 seconds.
Voltage stays above 9.6 volts; battery is OK,
23-66
Chargeon High Setting (4O amps) Chargsuntil EYEshows chargeis OK; plus an additional30 minutesto assuretull charge. NOTE:lf the battery cha,ge is very low, it may be necessary to bypass the charger's polarity protection circuitry. lf the EYEdoes not show chargeis OK within three hours, the baftery is no-good; replace it. Write down how long the battery was charged.
Test Load Capacity( # 2) Apply 30O amp load lof 15 secondsto removesurfacecharge, Allow 15 secondsrecoveryperiod. Apply test load (see Test Load Chart). Recordvoltage at the end of 15 seconds.
Voltage stays abov 9.6 volts; battery is OK.
Voltage drops below 9.6 volts; battery is no-good.
80D26L-MF
T I
I_
BATTERYCODE
TEST LOAD CHART Use the test load ot 112the cold crankingamps (CCA)printed on the labelon the top ot the baftery. lf neitheris indicated, use the informationbelow:
BATTERY CODE 80 70
55
COLDCRANKING AMPS (CCA) I 550 440 405
LOAD (amps) 270 220
200
23-67
Box Fuse/Relay Under-dash

a All SRS elect cal wiling halnesses are covered with yellow outer insulation. a Belorodisconnectingthe SRSwirs harnoss,installthe short connecto.(s) on the airbag(sl (see page 23-2941, a Roplacth ontile aftected SRS harn$s assembly if it has an opon ci.cuit or damaged wiring. NOTE: The radiomay havea codedtheJtprotection circuit. Be sureto get the customer'scode numberbeJore - Disconnecting battery. the - Removing the No. 43 (1O A) fuse. (ln the under-hood fuse/relavboxl - Removingthe radio. After service.reconnectpower to the radioand turn it on. When the word "CODE" is displayed,enter the customer's 5-digit code to restoreradio operation. 3. Removethe dashboard lower cover, knee bolster, and heaterduct,
DASHBOARD LOWER COVER
4.
Removthe door sill moldingand left kick panel
Removal: 1. Disconnectboth the negative cable and positive cable from the battery. 2. Removethe driver's foot rest.
23-68
5.
Disconnect 16-Pconnectorfrom the integrated the control unit. Remove the mounting bolts and pull the fuse/relay box away from the kick panel.
UNOER-DASH BOX FUSE/RELAY
Installatioo: 1. Reconnect the connectorsto the fuse/relaybox. NOTE: To reinstallthe SRSmain harnessconnector, push it into positionuntil it clicks, then closethe connector lid. 2. 3. 4. Installthe under-dash fuse/relaybox. Reinstall the kick panel and door sill molding. Reinstallthe knee bolster and dashboardlower cover. Connectboth the negativecableand positivecable to the battery. 6. Confirmthat all systems work properly.
o.
Disconnect fuse/.elaybox connectors the and take out the tuse/relaybox. BOX FUSE/RELAY UNDER-DASH
SRS MAIN HARNESS
NOTE: The SRSmain harness connecto.is doublelid, locked.To removeit, first lift the connector then pressthe connectortab down and pull the connector out.
23-69
Power Relays
RelayTest {A-tYPe)
.eNOTE: See page 23-198 for the tu,n signal/haz8rd lay input test and see page 23-236 for the seat heater relav test, 1. Removethe power relay from its socket. 2. Check continuitybetween relay terminals. a Seat heater main relaY a ABS front fail-s8ferelay a ABS rear fail-saferelay
a Thereshouldbe continuitvbetweenthe C and D terminals. a Thereshouldbe continuitybetweenthe A and B terto minalswhen power and groundare connected the C and D terminals.Thereshouldbe no continuitv when oower is disconnected.
a a a a a a
Starter cut relay Horn relay Cigarettelighter relay Power window relay Blower motor relay lan relay Radiator
a Condenser fan relay a A/C comoressor clutch relav
23-70
a Hsadlightrelay a R6ar window defogger r8lay a ABS motor relav
23-71
Power Relays
Relay Test (B-typel
Remove the power relay from its socket. Check continuity between relay terminals, Thereshouldbe continuitvbetweenthe A and C terto minalswhen power and groundare connected the D and E terminals. Thereshouldbe continuitybetweenthe B and C terminals when Dower is disconnected, a Windshieldwiper intermittentrelay
l1
a Dimmerrelay
a Sunroof open .elay a Sunroofclose .elav
E A
E+,6 7"-'
23-72
lgnition Switch
Test
CAUTION: a All SRS oloctrical wi ng harnassesar6 covorod wlth yellow outl insulation. a Boforedisconnectingtho SRSwira hsmess. instsll the shon connsctor(s) on the airbag(s) {soe page 23-29a1. a Roplacothe ontire affected SRS harne$ assembly it it has an open cilcuit or damagad wiring, 3, Checkfor continuitybetweenthe terminalsin each switch positionaccordingto the table.
rernrnsl WHT/ Position
BLK WHT tAcc) IBAI)
BLK/ YEL Gl)
YEL flG2t
BLU/ WHT
{sT)
-o o-o-
tl Il
-o
--o
SRS MAIN HARNESS
tE,
lower cover, left kne bol1 . Removethe dashboard ste.. and left kick panel (see page 23-68). Disconnect the 5-P connectorfrom the under-dash fuse/relavbox and disconnectthe 3-P connector from the main wire harness.
3-P CONNECTOR (Main wire harnessside)
ST IBLK/WHT}
3.P CONNECTOR
UNDER-DASH BOX FUSE/RELAY SOCXET 5.P CONNECTOB
23-73
lgnition Switch
ElectricalSwitch Replacement
CAUTION: a All SRS lectlical wiring harnossrr are covorod with yollow outor insulation. a Boforo disconnocting the SRS wir6 h.mo$, install th shon connoctor on the airbag{sl (3oo pag6 23-2941. a Replacethe entilo affactod SRS hEmossa$ombly it it has an open circuit or damagsd wiring. NOTE: The radiomay havea codedthett protection circuit. Be sure to get the customer's code number before - Disconnecting battery. the - Removing the No. 43 (1O Al fuse. fuse/relaybox) {ln the under-hood - Removing the radio. After se.vice,reconnectpower tOthe radioand turn it On. When the word "CODE" is displayed,enter the customer's 5-digit code to restoreradio operation. 3. Disconnect the 5-P connectorJromthe under-dash fuse/relav box and disconnect the 3-P connector from the main wir harness.
3.P CONNECTOR (Main wiro harness sid6l
3-P COl{ ECTOR
4.
Insert the key and turn it to "O", Removs thg cover screw and ths cover.
SRSMAIN HARNESS '1. Remove the dashboard lowsr cover and let't knee bolster. 2. Removethe steeringcolumn covers.
UPPERCOLUMN COVER
Rmove the two mounting scrsws and replaco the switch.
MOUI{TING SCREWS
23-74
Steering Lock Replacement

CAUTION: a All SRS eleclrical wiring hslnossos aro covated wlth yollow outar insulation. a Bololo disconnocting the SRS wile hamoss. install tho short connoclor(slon tho airbag(sl(saopage 23-294). a Roplacoth ontiro aftectd SRS harneasassembly lf it has an open cilcuit or damagad wiring' NOTE: The radio mav have a coded thett protection circuit. Be sureto get the customer'scode numberbefore - Disconnecting lhe battery. - Removing the No. 43 (1O Al fuse. fuse/relaybox) {ln th under-hood - Removing the radio. After service,reconnectpower to the radioand turn it on. "COOE" is displaved,enter the cusWhen the word tomer's 5-digit code to restoreradio operation, 4. Centerpunch each of the two shearbolts and drill their hads off with a 5 mm (3/ 16 in.) drill bit CAUTION: Do not damage tho switch body whon romoving the shoar bolts.
5. 6.
Remov the shear bolts trom the switch body. Installth new steering lock without the key insened. Loosely tighten the new shear bolts.
8 . Insert the ignition key and check for proper operation o{ the steeringwheel lock and that the ignition key turns freely. 9 . Tighten the shear bolts until the hex headstwist oft.
lower cover, left knse bolRemovethe dashboard ster, and lett kick panel (see page 23-68). the 5-P connectorfrom tho under-dash Disconnect from the main box and the 3-P connector fuse/relay wire harness. Remove the steering column covers {see page 23-74t.
SHEAR BOLT
lll
TWIST-OFFPORTION
23-75
StartingSystem
ComponentLocation Index
A/T GEAR POSITION
swtTcHtA/Tl
{!nd NEUTRALPOSITIONSW|TCHI Test. page 23-148 Replacoment. pago 23-149
BATTERY Test. page23-66
rM/rl i:T:i,Ii5i?* sw'rcH

Switch PositionAdjustment,sction 12
STARTER T6st, page 23-79 Solenoid Test, pag 23-83 Replacement,page 23-81 Overhaul, page 23-82 Reassembly,page 23-87
_lEr_
(M/TI STARTER CUTRELAY
Wir6 color': BLK/WHT, BLKAA'I{T,BLK/GNN, lnd 8LK/RED Test, page 23-70
f-l-D
-L-----l
--f--r
r-:-r lFl
*
--:--rl r-rr1
rfltll'l
l |
l]0mmm[[|l
|Jmm[0[D0lj
23-76
Description
Startsr Intorlock Syslom {M/T): The starter interlock system prevents the engine trom starting unless the clutch pedal is fully depressed. 15-20 mm {O.59-0.79 in) from the switch turns on at the positionwhere the clutch disengages: The clutch interlock positionoJ the clutch pedal. fully depressed position NOTE: A full stroke of the clutch pedal is 135-145 mm (5.3-5.7 in) from the fully released
SWITCH CLUTCH INTERLOCK
135- 145 mm {5.3-5.7 inl
Fully D6pro$od Posidon
23-77
StartingSystem
Circuit Diagram
UNORHOOD FUSE/RELAY 8OX
t6Nfir0N swTcH $/Hr-o
l;\
\87
I
{A/n I
crj
BLl(A,t/l{T
r--------------------------r
NEUTMIPOStTtoN swtTcH / InA/Tger \ Bwilch / \ poition
BLXNEO
T-r--'l
| )u.z
I
r I
I
k {7,5A) |RSEinELAYSOX
luNoF-oAsH
8t-u/RED
f7
. ECM ' PGM FIMAIiIREI.AY . BSAKE CHECK CIRCUIT
STATTER
23-7a
StarterTest
NOTE: The air temperaturemust be between 59 "F and 10O oF (15 oC 8nd 38 oC) betoretesting. Rccommandod Procedure: a Use a starter systsm tester a Connect and oporate ths equipment in accordance with manutacturer's instluctions. a Test and tloublshoot as dscribed. Altornat Procedura: Use the followingequipment: - Ammeter,O-4O0 A - Voltmeter, O-2O V {accurate within O.1 volt) - Tachometer, 12OOrpm 0Hook up voltmeterand ammeteras shown.
'1.
Disconnectthe 4-P connector from the ignition coil.
Check the starter engagement: Press clutch pedalall the way in (M/T).and turn the "START". The startershould the ignitionswitch to crank the engine. transmission, with manual NOTE: On carsequipped the enginewill not crank unlessthe clutch pedalis fully depressed. a lf the starter does not crank the engine,check the battery, battery positive cable. ground, nd the wire connections for looseness and corrosion. a Test again. lf the starter still does not crank the engine, bypassthe ignitionswitch circuit as follows: Unplug the BLK/wHT wire trom the solenoidterminal. Connecta iumper wire ttom the battery Dositive(+ ) terminalto the solenoidterminal.The starter should crank the engine.
NEGATIVETERMII{AL
NOTE: After this test, or any subsequent repair, resetthe ECMto clearany codes (seesection 1 1).
{cont'd)
23-79
StartingSystem
StarterTest (cont'd)
- lf the staner still does not crank the engine, remove the starter and diagnose its internal problems. - lf the starter cranksthe engine,check for an open in the BLKMHT wire and connectorsbetweenthe starter and ignitionswitch. Check the ignitionswitch. On cars with automatictransmission, check the A/T gear positionswitch (neut.alpositionswitch). and connectors. On cars with manual transmission. check the starter cut relay, clutch interlockswitch, and connecrors. NOTE; Checkthe No. 33 (50 A) fuse in the underhood Juse/rel8ybox and the starter cut relay, Check for wear or damage: The startershould crank the enginesmoothly and steadilv. lf the starter engages, but cranks the engine erratically, removethe startermotor. Checkthe starter, drive gear, and flywheel ring gear for damag. Check the drive gear overrunning clutch for binding or slippingwhen the armatureis rotated with the drive gear held. Replsce the gears if damaged. Check crankingvoltage and current draw: Voltageshould be no less than 8.5 volts. Currentshould be no more than 38O amoeres. lf voltage is too low, or current draw too high, check for; Check crsnkingrpm: Engine speedduringcrankingshouldbe above 1O0 rom. lf soeed is too low, check tor: a a a a a
o.
Loose battery or starter terminals. Excessivelyworn starter brushes. Open circuit in commutatorsegments. Dirty or damagedhelicalsplineo. drive ge8r. Defectivedrive gesr overrunning clutch.
Check the starter disengagement: Pressthe clutch pedalallthe way in {M/T},turn the ignitionswitch to "lll" and release "ll" position. to from the The starter drive gear should disengage flywheel ring gear. lJthe drivegearhangsup on the flywheelring ge8r, check for: a Solenoidplungerand switch malfunction. a Dirty drive gear assembly or damaged overrunning clutch.
a Low batterv. a Open circuit in starter armature commutator

segments.
a Starterarmaturedragging, a Shortedarmaturwinding. o Excessive drag in engine.
23-80
Clutch InterlockSwitch Test (M/Tl

Remove the dashboard lower cover and knee bolster, then disconnectthe 2-P connectortrom the switch. Check for continuitv b6tween the terminals according to the table. Terminsl
Starter Replacement
cirNOTE: The radiomay havea codedtheft protection cuit. Be sureto get the customer'scode numberbeJore - Disconnecting battery. the - Removing No.43 (10A)fuse. the (ln the under-hood fuse/relavbox) - Removing the radio. Atter service,reconnectDowerto the radioand tu.n it on, "CODE" is displsyed,enter the cusWhen the word tomer's 5-digit code to restoreradio operation. the negativecable trom the battery, 1. Disconnect
.*.n*o]---\
RELEASEO PUSHEO
G-
2.
Removethe enginewire harnessfrom the harness clip on the starter motor. Disconnect startercabletrom the B terminalon the the solenoid,8nd the BLKMHT wire trom the S terminal. NOTE: In case of an A/T model, the starter cable slso has to be removed from the bracket on the housing. transmission
3,
4.
Removethe two mountingbolts holdingthe starter, then remove the starter molor.
lJ necessary, rpl8ce th switch or adjust the switch Dosition{sse section 121.
fl
9 N.m lO.9 kg-m, 6.5 lb-ftl
23-41
StartingSystem
Starting Overhaul
CAUTION: Btoro lmoving th6 starta., disconnect tho ground cable from the battory.
BRUSH HOLDER
ARMATURE ENO COVER
OVERRUNIIII{G CLUTCH ASSEMBLY
\-s >*'Nwith PERMANENT MAGNET GEARHOUSING
@ \ l
LABYRINTH TUEE
NUT 9 N.m (0
GEARHOUSING COVER
soLEt{otD
Test, page 23-83
Wq
m"r"
)o.*o'o
23-82
Starter SolenoidTest
'|, 2. Remove the stsnr solenoid. in Checktor continuitybetweenthe terminals each solenoidplungerpositionsccordingto th table,
Terminal
COIL PULL.IN
COIL HOLD.IN
GITUUNU
Position RELEASED PUSHED
o-
HOUSI G IGROUT{D) SOLENOIO
23-83
StartingSystem
Armature lnspectionand Test
1. Inspectthe armaturesurfacefor wear or damage. Commutator Runout Standard{Now}; 0-0.02 mm {0-0.0008 in) SsrvicsLimit : 0.O5 mm (0.002 inl
Inspecl tor damage.
A dirty or burnt commutatorsuriacemay Deresurfaced with emerycloth or a lathewithin the tollowing specificstions. Commutator Diametot Standard(Newl: 28.0-28.1 mm i { 1 . 1 O 2 -1 . 1 O 6 n l SoruiceLimit ;27.5 mm (1.O8inr
COMMUTATOR
lf the commutatorrunout and diametrare within limits,checkthe commutator damage tor carfor or bon dust or brasschips betweenthe segments. 4. It the suriaceis dirty, recondition with a #SOOor it #600 sandpapr. Then, check mica deDth. ll necessary, undercut the mica with a hacksaw blad6to achieveproperdepth.
VEBNIER CALIPER
Commutator Mica Dpth ( S t a n d a r dN e w l : 0 . 4 - O . 5 m m ( 0 . 0 1 6 - 0 . 0 2 0 i n ) ServiceLimit : 0.15 mm {0.006 in}
23-a4
5 . CheckJor continuitybetweenthe segmentsof the commutator.lf an open circuitexists betweenany segments.replacethe armature.
7 . With an ohmmete.,checkthat no continuityexists between the commutatorand armaturecoil core, and betweenthe commutatorand armatureshaJt. the armature. lf continuitvexists, replace
COMMUTATOR
COILCORE
COMMUTATOR
6.
Placethe armatureon an armaturelesler. Hold a hacksawblade on the armaturecore.
ARMATURETESTER
HACKSAW BLADE
j
ARMATURE
while It the bladeis attractedto the coreor vibrates is the core is turned,the armature shorted.Replace the armature.
23-85
StartingSystem
Starter Brush HolderTest
1. Check that there is no continuity betweenthe @ and O brushholders. lf continuity exists, replace the brush holder assembly.
Starter BrushInspection
Measurebrush length. It not within the service limit, replace the armature housing and brush holde. assemblv. Brush Length Standa.d(Newl: 15.8-16.2 mm (0.62-0.64 in) Sarvice Limit : 1O.Omm {O.39 in}
HOLOER O EBUSH
HOLDER O BRUSH
@ BRUSHHOLDER
@ ERUSHHOLOER
2.
Insertthe brushinto the brushholder,and bringthe brush into contact with the commutator,then attach the a springscaleto the spring.Measure springtension at the moment the spring lifts off the brush.
SpringTension [/ itsuba ( 1. 4 K W ) Mitsuba {1.6KW) 16-18N .6-'l .8 kg, 3.5-4.O lbs) {1 1 6 - 1 8N {1 . 6 - 1 . 8k g , 3 . s - 4 . O l b s )
NOTE: To seat new brushes after installingthem in their holders, slip a strip of #5OO or #600 sandpaper, with the grit side up, over the commutator, and smoothly rotate the armature, The contact surface of the brusheswill be sandedto the same contouras the commutator.
SPRINGSCALE
23-86
Overrunning Clutch Check

1 . Check that the overrunning clutch moves along the shaft frsely. lf not, replace it. Checkthat the overrunningclutch locks in one direction and rotates smoothly in reverse. lf it does not lock in eitherdirectionor it locks in both directions, it. reDlace
Startel Reassembly
trI
Reassemblethe starter in the reverse order of disassembly. l. Pry back each brush spring with a screwdriver, then position the brush about haltway out of its the springto hold it there. holder,and release
2.
Installthe armaturein the housing.Next pry back each brush spring againand push the brushdown until it seats against the commutator, then release the springagainstthe end ot the brush.
Checkthe starterdriv gear for wear and damage. lf the gear is worn or damaged, replacethe overrunning clutch assembly; the gear is not available separately. NOTE: Check the condition ot the flywheel or totque convrter ring gear if the starter drive gear teeth are damaged.
aw
3. Installthe end cover on the brush holder. HOLDER BRUSH
23-87
Starting System
Test Performance
NOTE: Beforestarting the following checks, disconnoct the wire from terminal M,8nd make a connectionas describedbelow usingas heaw a wire 8s possible(preferablv equivalentto the wire used tor the car). Pull-in Coil Test: Connect the baftery as shown. lf the pinion protrudes, it is working properly. NOTE: Do not leavethe battery connectedfor more than 1O seconds, Retlactlng Test: Also disconnect the battery from the body. lf the pinion retracts immediately, it is working properly. NOTE: Do not l6avethe battery connectedJor more than 10 seconds.
Hold-in Coil Tsl: Disconnect the battery from the M torminal. lf the pinion does not retract, the hold-in coil is working proporly. NOTE: Do ;ot bave the battry connctodfor moro than 1O seconds.
23-88
Start.l [tlo-loadTest: 1. 2. Clamp the stsrter firmly in a vise. Connect the starter to the battery as described in the diagrambelow and confirm that the motor starts and keeps rotating. lf the electric current and motor soeed meet the specifications when the battery voltage is 8t 1 lV, the staner is working proprly. Spocitication6: Mitruba: 80 A 01 los! (aloclric currsnt), (1.4KW) 2600 rpm 01 mote (motor spoodl Mitsuba: 80 A or less (elctric curont), {1.6KW) 2600 lpm or mor. {moior spccd}
3.
23-89
lgnition System
ComponentLocation Index
IGNITIONTIMIITGCONTROLSYSTEM . Description, page 23-91 . Troubleshooting,section 11 .Inspection and Stting,page 23-93
TESTTACHOMETER
DISTRIBUTOR page 23-95 Top End Inspection, page 23-95, 97 Removal/lnstallation, page 23-96 Overhaul, Reassembly,page 23-99 lgnirioncontrol Modu16 {lcM) Troubleshooting, section 1 I ICM Input Test, Page 23-98
IGNITION COIL
Test, psge 23-1O0 SERVICECHECK COT{NECTOR {2.P)
IGNITIONWIRES Inspection and Test, page 23-99
SPARK page 23- 1O1 Inspection,
23-90
Description
lgnllion Timing Control: used in this engineprovidesoptimum control oJ ignitiontiming. A microcomputer ignition (PGM-|G) The programmed the timing in responseto engine speed and manifoldvacuum. The input signalsare transmittedby the determines TDC/CKP/CYP sensor,throttle position (TPl sensor,enginecoolanttemperature(ECT)sensor,and MAP sensor.This system, characis on which is not dependent a governoror vacuum diaphragm, capableof sefting leadangleswith complicated governorsor diaphragms. teristicswhich cannot be providedby conventional
Enginecoolanttemperature(ECT)compensation
Basic Control: The controlunit has storedwithin it the optimumbasicignitiontiming for ope.atingconditionsbasedupon enginespeed optimum ignitiontiming the system determines pressure, signalsfrom sensors, With compenssting and intakemaniJold for ambientconditionsand sends vottagepulsesto the lCM. and duration of Compensation ignitiontiming: ltem Compensation ldling RelatedSensorand Information sensor TDC/CKP/CYP MAP sensor Description lgnitiontiming is controlledto the ta.get speed accordingto the idling speed. with compensation Lag angle is adjustedaccordingto warm-up conditions to bring about a good balancebetween and exhaustgas level. operatingperformance for Compensation lead angle at low engine and lag angle at high engine coolant temperature temDerature. coolant
at Comoensation warm-up ECTsensor
ECT compensation
ECT sensor
Control at Start: lgnitiontiming is fixed at 7o BTDCJorcranking.The crankingis detectedby the TDC sensor(crankingrpm) and slarter signal.
23-91
lgnitionSystem
CircuitDiagram
- HOOD UNOER FUSEiRELAY BOX
""7
rcNtTtof{ swfTcH
ECM
IGNITION COIL
DISTTIBUTOR ASSEMELY
il:-,
-.-:1_-
TDC/CKPrcYP SENSOR
++
23-92
| *,*t1*u
. TACHOMFIER . TnANSMISSION CONTROL MODULE fICM) ' CRUISECOMTROT UNIT
GaugeAssembly
CircuitDiagram
- HooDSEÊLAY u DER Ft Box ittilfl8'I
T'ffi;ffi*"l ( + )+.-c'\-o.<\o+wtn-to
\_/
6),,
rco/-
BtK,YEt
UI{DER.DASH FUSSRELAY 80x
r-
BUVYEI
-iet'No.6lt20a) l2O FUSE
I
I I
TMNsMtsstoN
COMTRO| MoDULE {rCM)
R EOTYEI
MAIN GAUGE ASSEMSIY
YEL
l wl t l
I YEr, I
I
GRNiORN
-[r-]^' ll:' l t l
=;;;-
HIGH BEAM INDICATOR UGHT l1.4Wt
++++
GAUGE LIGHTS {3Wx5l INDICATOR POSITION DIMMING CIRCUIT
RED/BLU
D MEN FELAY
Btt(
l"
I RED
l82
I I
I
couTRot
UNIT
DASH UGHTS BRIGIITNESS
G10t G40z G404
23-126
t
I
tcn|T,oN CONTROL MOOULE
0cMl \--7
BLU 183
'---l
snmn I
MOTOR
PNK
. 4WS CONTBoLUNTT I . TnANSMTSSTON I MOOULE COMTROL {TCMI ORN . CRUISE CONTROT UNIT . ECM
-r_ J_
4WS COMTROI UNIT
Y_",_
23-127
Assembly Gauge
(cont'd) CircuitDiagram
COMBINATION LIGHT SWITCH
Y
I I
(7.5A) No.2 FUSE sigml) IST
RED/BTK
BLU/REO
cRursE
CONTROL UNIT
23-128
l
LIGHTTUBE FLUOBESCENT ; L______________---____J
t - - - - - - - - l
TEMPEMTURE FUEUNGINE COOIATIT IECT] COMTROI.CIRCUIT
D4
t-+
\---J |
8\ ENGINEo|L !. , PiESSURE :I/ SWTCH
coNrRoLUNlT
INTEGMTED
F+t
A8SCONTROL UNIT
I t
23-129
Assembly Gauge
Removal
CAUTION: a All SRS elctrical wi ng harnossesar covered with ysllow outor insulation. o Before disconnecting th6 SRS wire harn6ss, install the short connoctor(s) on th6 airbag(s) (see page 23-294t. a Roplacothe entir affected SRS harnossassembly if it has an open cilcuit or damaged wiring. . After inst8lling tho gauge a$embly, rechock tho opration ot the SRS indicator light. 2. Remove the screws and the instrumentpanelvisor.
NOTE: The radiomay havea codedtheft protectioncircuit. Be sureto get the customer'scode numberbefore - Disconnecting battery, the - R e m o v i n gh e N o . 4 3 ( 1 OA ) f u s e . t (ln the under-hood fuse/relaybox) Removingthe radio. Aiter service,reconnectDowerto the radio and turn it on. When the word "CODE" is displayed,enter the customer's 5-digit code to restoreradio operation.
Removo th screws and the black face pan6l, then disconn6ct the 6-P connector fiom ths clock reset switch.
cot{t{EcToR
BLACTFACEPANEL
1.
Removethe tweeter covers trom the dashboaad,
covERs
23-130
Main Gauge Assembly: 4. Remove the four screws from the main gauge assembly.
Sub Gaugs Assembly: 6, Remove the four screws from the sub gauge assemblv.
MAIN GAUGEASSEMBLY
Place a cloth over the dashboard to protct the main gauge assembly,then pull the assemblyout and disconnectits connectors.
7.
Placea cloth over tho dsshboardto protect the sub gauge assembly,then pull the assemblyout and disconnect its connectors.
23-131
AssemblY Gauge
BulbLocations
Main Gaugo Assmblyi
HIGH BEAM II{DICATORLIGHT II.4 W}
rl{DtcaToRLTGHT W) t1.4
RIGHTTURN SIGNAI-IT{DICATOR LIGHT (1.4 W}
sRs tNDtcatoF UGHTtl.4 Wl (1.4 4WStNDtCATOn LTGHT Wl
GAUGE ucltTs {3 w r 5l
23-132
Sub Gaugs Assombly:
LOW FUELINDICA?ORLIGIIT 13 WI CRUISELIGHT I3.2 W)
(3 ABSIT{DICATOR LIGHT WI
INDICATOR LIGHT W) 13
{Caogda)
BNAKE SYSTEM LIGHT13W} SEATBELTREMII{DER LIGHT(3 WI

CHARGIXGSYSTE'{ UGHT 13 WI
BULB BRAKE IIGHT 13Wl tf{DtcAToR
Tnu x r{lxcAToR
LIGHi (3 Wl
INDICATORLIGHT {3 WI LOW OIL PRESSURE
MALFUNCTIONINDICATOR LAMP (MIL} (3 Wl
23-133
GaugeAssembly
Disassembly
Main Gsug Assembly: SRSINDICATOR MOUNTING SCREWS (x2)
NOTE:
a Handle the terminals and Drinted circuit boards them. carefullyto avoid damaging a lf either the speedometeror the tachometr is faulty, reolacethem both as a unit.
ilil0iltltil L0l lt0tl||Tilil [0ffi[

SPEEDOMETER TI c SCREWS MOU lx3l
PRINTED CIRCUITBOARD C
HOUSTNG
G
6s -d ra
METER ODO/TRIP
page23-136
SRS INDICATORPANEL
r{e)
PAITEL FACE TACHOMETEB
Specificstion, page 23-124
PNI TED CIRCUITBOARD B
{-'2\:.
PRINTED CIRCUITAOAROA
Spcificstion, page 23-124
vtsoR
23-134
Sub Gaugs Assembly: NOTE: Handle the terminals and printed circuit boardscarefullyto avoid damagingthem.
COVER CIRCUITBOARD/REAR PRINTEO MOU TI[{G SCREWS(x 161
FUEL/ENGINE COOLANT TEMPEBATURE IECTI GAUGE Test, pge 23-139, 142
PNI EO CIRCUIf BOARO BOX
PRII{TEDCIRCUIT
FROIIT HOUSING
23-135
Meter/Odometer Speedometer/Trip
Troubleshooting
NOTE: The numbersin the table show the troubleshooting sequence. Item to be inspected 9>.
{ o -
: a
'i
a 3
.c.
!
c
c
3 E
l/,
E
'E
z E
3 f
: P v x
?i o)
(L
o:i
Symptom Odometerand trip meter work, but speedometer does

n01.
; d
1 1
Speedometer works, but odmeterand trip meter do not. Speedometer, odometer,and trip meter do not work. N O T E : V S S g r o u n di s v i a E C M ( G 1 O 1 ) . VSS Input Test (At hahess side of 3-P connGctorl No. Wire Test condition Tost: DosirEdlsult BLK Underall conditions Checkfor continuityto ground: Thereshould be continuity. Checkfor voltageto ground: Thereshouldbe battery voltage. Check for voltageto ground: There shouldbe about 5 V
2 2
Possiblecause il .esult is not obtained . An open in the wire. . P o o rg r o u n d( G 1 0 1 ) . . B l o w nN o . 2 3 { 15 A ) f u s e . Short to ground . Short to ground . An open in the wire.
BLK/YEL lgnitionswitch ON
ORN
lgnitionswitch ON
NOTE: A short to ground in the ORN wire can be causedby a short in anv comDonent connectedto it. VSS Test Speedometer does not woIk.
lnspect No. 23 (15 A) luse in undeFdash fuse/relay box before testing.
CONNECTOR
Measure voltage between the BLK/YELwire terminal and the BLK wire terminalin the harness sade the 3 P conneclor. ol (To next page)
23-136
(FrompreviousPage) Check for continuity between the BLK terminal and body ground.
Measure voltage belween the oRN and rhe BLK wire terminals.
Repair op6n between VSS and ground G101 via ECM.
ls thereabout5 V?
Ropairop6n in tho BLK/YELwiro, botwoen tho VSS and th undord6sh lus6/relay box.
Raise the lront oI the car and supportil with stands.
Repatuopon in ths ORN wi.s or shon to body grcund.
Touch a probe to the ORN wire and connect it to body ground througha voltmeter.
Slowly rotateone wheelwith the other wheel blocked.
DoesvoltagepulselromOto about 12 V?
Roplaca the vss 23-138).
(soe Page
Disconnectthe 16-P connector at the speedometer,
Touch a probe to the ORN wire and connect it to body ground through a voltmeter,
Slowly rotate one wheel with the other wheel blocked.
Doesthe meterindicate pulsingvoltage?
Repairop6n in tho ORN wir betw6n the VSS and the sp6odometer.
VehicleSpeedSensor(VSS)
Replacement
Disconnect the 3-P connector from the vehicle speedsensor (VSS). Removethe mountingbolts, then removethe VSS. NOTE: The VSS drive link is a very small part, be careful not to lose it.
Engine Low Oil Pressure

IndicatorSystem
Switch Test
1. Remove the YEL/REDwire from the engine oil pressureswitch. Checkfor continuitybetweenthe positiveterminal and the engine (groundl, a There should be continuity with the engine stopped. a There should be no continuitywhen the engine runs.
2.
3-P CONNECTOR ENGINEOIL PBESSURE SWITCH 18 N.m (1.8 kg-m, 13.0 lb-ftl 1/8 in. BSP(Eritish Standard PipeTaper)28 threads/inch. Use proper liquid sealant.
OIL FILTER
3.
Installin the reverseorder of removal. YEL/RED WIRE

POSITIVE TEBMINAL
3.
lf the switch fails to operate,check the engineoil level.lf the engineoil levelis OK, checkthe engine oil pressure and, it necessary, inspectthe oil pump (seesection 8).
23-138
FuelGauge
Test Gauge
NOTE: Reterto page 23- 129 for the circuitdiagramof the fuel gauge. 1. Check the No. 13 {1O A) fuse in the under-dash tuse/relaybox beforetesting. Open the trunk, Removethe fuel tank accesspanel. the 5-P connectorfrom the fuel gauge Disconnect sendingunit. Turn the ignition switch OFF. Connect a iumper wire between the YEL/GRN and YEL/WHT terminals. CAUTION: Do not connect power and ground to th lerminals; it will damage th6 luel gaugs. 7 . Turnthe ignitionswitch ON, and checkif the gauge "F" indicates CAUTION: Disconnct the iumpor rYireas soon as "F", or you will damags the the gaugs r6aches gau9e. a ll the fuel gaugedoes not work at all, replaceit. a lf the fuel gaugeis OK, inspectthe sendingunit
2. 3. 4.
YEL/GR
CONNECTOB
-L
I r t,---t I Fi!.-1---1 I l l t I '--'-r--YEUWHT
5.
Connect the voltmeter positive probe to the terminaland the negativeprobeto body YEL/GRN ground,then tu.n the ignitionswitch ON. There shouldbe between 5 and 8 V. a a lf the voltage is as specitied,go to step 5. lJ the voltageis not as specitied,check for: wire. An open in the YEL or YEL/GRN terminals. Looseor disconnected Faultytuel gauge.
23-139
FuelGauge
Sending Unit Test
Do not smok whils working on ths fuol @ systom. Ko6p open flame away flom th work aroa. 1. Open the lrunk. 2. 3. Removethe fuel tank accesspanelWith the ignition switch OFF. disconnectthe 5-P connectorfrom the fuel gauge sendingunit. Removethe five nuts. then take the sendingunit assemblyout of the fuel tank, a lf it does not change evenly, replacethe fuel sendingunit. a lf it changesevenly, go to step 7. 7 . Support the sending unit on a workbench in the positionshown.
b.
Check the resistancebetween the B and C terminals.lt shouldchangeevenlyas you changethe positionof the tloat.
4.
Top ot tho wortb.nch
(Bottom ol tho tuel tank)
8.
Measurethe resistancebetween the B and C terminals by moving the float to the distanceslisted Jor E (EMPTY),1/2 (HALF FULL).and F (FULLl.
Float Position Resistance lO)
E 16-32
1t2
1 1 6 - 1 8 8 2 3 9- 3 1 4
Measure the resistance between the A and B terminals. a It it is more than about 27O-33O O, reDlace the tuel sendingunit. . lf it is within about 27O-33O O, go to step 6.
E 20.5 mm ( O . 8 0i n ) 9. 73.6 mm (2.90in)
F 126mm l'4.7 inl
lf unableto obtain the above readings,replacethe fuel gauge sendingunit.
23-140
Low Fuel IndicatorSystem

Indicator Light Test
of NOTE: Referto page23-127 for the diagram the low fuel indicatorcircuit. Parkthe car on level ground. Do not smoke whil working on the E@ tusl system. Keep open flamo away lrom tho wolk area. Drain tuel only into an apploved container. Drainthe fuel tank into an approvedcontainer. Then installthe drain bolt with a new washer. A d d l e s st h a n 9 . Ot 1 2 . 4U . S .G a l ,2 . Ol m p . G a l )o f fuel and turn the ignitionswitch ON. The low luel indicatorlight shouldcome on within four minutes. 4. Removethe fuel tank accesspaneland disconnect the 5-Pconnector{rom the fuel gaugesendingunit. Connect the GRN/WHTterminal to the BLK terminal with a iumper ware. It the light comeson, the problemis the sending unlt. lf the light does not come on, the problemis an ooen in the GRN/WHT wire to the gsuge no assemblv, power to the gauge,a bad bulb, or poor ground.
til
LIGHT INDICATOR LOWFUEL (ln the subgauge assemblyl a lf the light goes on within four minutes,go on to step 5. a lf the light does not go on within four minutes, go on to step 4, 5. Add one more gallonof fuel [approx.4 f ( 1.1 U S. G a l ,O . 9 l m p . G a l ) 1 . The light should go off within four minutes.
23-141
(ECTI Engine Coolant Temperature Gauge

Gauge Test
NOTE: Reterto pag 23- 129 tor the circuitdiaglamof the enginecoolanttemperature(ECTIg8ugs. '1. Check the No. 13 (10 A) tuse in the under-dash tuse/relaybox beforetesting. Make sure the ignitionswitch is OFF,then disconnect the REDwire from the ECT sendingunit 8nd ground it with a jumper wire.
Sending Unit Test

1 . Disconnct the REDwire from the sendingunit. 2 . With the snginecold, use an ohmmeterto measure rsistancebtween the positive terminal and the engine (ground),
2.
--------.____/
REO WIRE POSITIVE TERMINAL
ECT SENDINGUNIT
REDWIRE
ECT SEI{DII{GUNIT 4.
Checkthe temoerature the coolant. of Run the engine and measu.e the change in resistancewith the engine at operatingtemperature (.adiatorfan comes on).
Turn the ignition switch ON. Check that the segmentsof the ECT gauge light up. CAUTION: Turn tho ignition switch OFF lmmdiately after the ssgmsnts light up. Failuroto do so may damag the gaug6. a lf the segmentsdo not light up, check for an open in the YEL or REDwire. lf the wire is OK, replacethe ECT gauge. a lf the segmentslight up, checkthe sendingunit.
Coolant Tempgrature (O) Resistance 5.
1 3 3 0 F( 5 6 . C ) (Engine cold) 'l42
1 8 5 0 F { 8 5 0C ) 2't20F t1000cl
49-32
lf the readingsyou get are substantially difterent from the specitications above,replace ECTsenthe ding unit.
23-142
BrakeSystem Light
BrakeSwitch Test Parking
the conRemovethe floor consoleand disconnect nectof from the switch. terminaland Checkcontinuitybetweenthe positive body ground. a There should be continuitY with the brake lever uo. a There should be no continuity with the brske lever down.
BrakeFluid Level Switch Test

Remove the reservoir cap. Check that the float the movesup and down freely;if it doesn't, replace cap assemblY. reservoir Check Jor continuity between the terminalswith the tloat uD and down, a There should be continuity with the float down a Thereshouldbe no continuitvwith the float up if cap assembly necessary. the Replace resetvoir
RESERVOIR CAP
LEVER BRAKE
a blilt-in lHas ] \ magner l DOWN POSITION contacts closed when float drops.
UP POSIIION Canads: NOTE: lf the parkingbrakeswitch is OK, but the brake system light does not work, performthe input test for the daytime running lights control unit {see page 23-180).
Switch contacts open, at properfluid level.
23-143
A/T GearPositionIndicator
Component Location Index
CAUTION: a All SRS olectdcal wi ng harnsssss are covorad with yellow outer insulation. a Betore disconnecting the SRS wile ham6ss, install the short connector(sl on the airbag{sl (see page 23-2941. a Roplacethe ntile atfocted SRS hamoss assembly it it has an open ci.cuit or damaged wiring. a Aftel installing tho gaugo assembly, recheck th operation ol the SRS indicator light.
MAIN GAUGE ASSEMBLY p6ge23-130 Removal, p6ge23-134 Disassembly, INTERLOCK SYSTEM See page 23 158 A/T GEAR POSITION INDICATOR Input Test, page23-146 Bulb Replacemenr, page 23-1
TRANSMISSIONCONTROLMODULE (TCMI See Automatic Transmission, section 14
A/T GEAR POSITIONSWITCH Test, page23-148 page 23-149 Replacement,
23-144
CircuitDiagram
BOX HOOD FUSE/RELAY UNDER-
*t-r"T
UNDER_DASH 80X FUSE/REI.AY gruo.a$omblyl llnthomaln OIMMING CIRCUIT INDICATOR AITGEAR POSITION
. ECM . TMNSMISSION CONTNOL MODUIE ITCMI
COMBIiIATION LGHTSWlTCH
TRANSMISSION COMTFOL MODULE(TCM)
I-TGRN
I I
t
10 T(
TNANSMISSION CONTNOL (TCM) MODULE INTERLOCK UNIT CONTROL
GRNAVIfi
V I
COMBINATION LIGHT SWITCH
V I
AITGEAR POStTT0N CONSOLE LIGI{T
{r.4w)
E-.'-1,i,,,,'---Jn
AITGEAR PostloN swlrcH
t t
G4o1 G402 G404
G401 G402 G(X
23-145
A/T GearPositionlndicator
IndicatorInput Test
CAUTION: a All SRS lectrical wiring harnossesa.e coveled with yllow outor insulation. a Betoro disconncting the SRS wirs harnoss, install the shon connectorls) on the airbag{s} {see page 23-294t. a Feplace tho entire atfoctod SRS hamoss assembly if it has an open circuit or damagd wiring. a After installing the gauge ssssmbly, r6check tho operation of tho SRS indicatol light. 1. Removethe main gauge assemblyfrom the dashb o a r d{ s e ep a g e2 3 - 1 3 O ) . Disconnect the 16-P and 1O-Pconnectorsfrom it. Inspectthe connectorand socket terminalsto be sure they are all makinggood contact. a lf the terminals afe bent, loose, o. corroded, repair them as necessary, and recheck the sysrem. a lf the terminalslook OK, make the loltowing input tests at the connector. - lf a test indicatesa problem,find and correct the cause,then recheckthe system. - lf all the input tests prove OK, the indicator must be faulty; replacethe gaugeassembly. NOTE: Different wires with the same color have been given a number suflix to distingujshthem are not the same). {YELj and YEL2
View from wire side SRSMAIN HARNESS
2, 3.
23-146
Test condition 1
Tost: Desiled result CheckJor continuityto ground: There shouldbe continuitY. Checktor voltageto ground: There shouldbe bsttery voltage. Check for continuity to ground; Thereshould be continuity. NOTE:Thereshouldbe no continuityin any other position,
Possiblocaus il rosult is not obtainod
BLK
YELI
Under all conditions. lgnitionswitch ON.
. Poor ground {G401,G4o2,G404). . An ooenin the wire.

. B l o w nN o . 1 ( 1 OA ) f u s e . (ln ths under-dash fuse/relayboxl . An open in the wi,8. Faulty An gear position switch. Poor ground (G4O1,G4O2,G4041. An ooen in tho wire.
GRN/WHT Shift lever in E. NOTE: Don't push the brake pedal. GRN/RED Shift lever in @. Shift lever in [. GRN GRN/BLU Shift lever in E. GRN/YEL Shift lever in @. LT GRN/ WHT 4 Shift lever in [.
light switch REDand Combination RED/BLK ON and dash lights control dial or brightness full bright. GBN/ORN lgnitionswitch ON and shift lever in any Position except @.
Check for voltagebetween RED/BLK and REDterminals: There shouldbe battery voltage. Check for voltageto ground: Thereshould be bsttery voltage fof two seconds after the ignitionswitch is tutned ON, and less than 1 V two secondslater. Check for voltageto ground: Thereshouldbe lessthan 1 V tor two secondsafter the ignition switch is turned ON, 8nd more than 5 V two seconds later. Check for voltageto ground: There shouldbe more than 1 1V .
. Faultydash lights brightness control system. . An open in the wire. . F8ultytransmission control module (TCM). . An open in the wire.
YEL'
lgnitionswitch ON and shift lever in any posation except E.
. FsultyTCM. . An open in the wire.
LT GRN
lgnitionswitch ON.
. FaultyECM or TCM. . An open in the wire.
23-147
A/T GearPosition Indicator

Switch Test A/T GearPosition
CAUTION: a All SRS ol6ctrical wiring harnessosare coverod with yallow outor insulation. a Botore disconnoctlng the SRS wiro halnass, install tho short connoctor(s) on th6 airbag(sl (s6o pagg 23-2941. a Roplacoth ontire Effoctod SRS halness assombly if it has an opon circuit or damaged wiring, a Aftr imtalling th gaug6 asEembly, rocheck tho op.ration ot tho SRS indlcator lighr. 1. Removeths console,then disconnect the 12-Pand 3-P connectorsfrom the switch. Checkfor continuitybetweenthe terminalsin each switch positionaccordingto the table. a Move the lever back and forth at each oosition without touchingthe push button, and checkfor continuitywithin the rangeof tree play. a lf there is no continuitywithin the rangeof free play, adjust tho position ot th switch as described the next page. on
2.
A/T Goar Posltlon Switch

\ T6rminal
Back-up Light Switch

I
l{eutral Positlon Switch
ffi;-------l
ll
t0
t3
15
a
lTl
-o oo--{} --{}
tr
E
--o --o --o --o --o --o o_O
tr
E
ooo-
o- *-o o- --o
23-148
A/T GearPositionSwitch
Adiustment
1 Shift to the lll positionand loosenthe switch nuts. Slidethe switch rearwardlup to 2.0 mm (0.O8in)l until there is continuitybetween No. 8 and No. 11 terminalswithin the range of free play of the shift lever. 3, Recheck for continuity between each of the termtnals. NOTE: a li adiustmentis not possible, check ior damage the shift lever detent and/or bracket, to lf there is no damage,replacethe A/T gear position switch. a The engineshouldstart when the shift leveris in position@ anywhere within the range of free play.
A/T Gear PositionSwitch Replacement

the 12-Pand Removethe console,then disconnect trom the switch. 3-P connectors Remove the two mounting nuts and remove the switch.
SWITCH SLIDERlln po3ition LLI) SHIFT LEVER
Fre play
]tl
@t
ll\''-q---------.__LOCK PIN
GEAR POSITION
swtTcH
the Position slideron the new switch to positionE as shown above. Shift the leverto to position,
5-
"Neutral". then slipthe switch in-
Attach the switch with the two mountingnuts. positions.
6 . Test the switch in the @ and $
NOTE: The engine should start when the shift leveris in position fl anywherein the rangeof free ptay.
Adjust rearward in)l lup to 2.0 mm (O.O8
Connectthe 12-P and 3-P connectors,clamp the harness.and installthe console.
23-149
A/T GearPositionIndicator
Bulb Replacement
CAUTION: a All SRS oloctrical wiring hamesses are coverod with yellow outor insulation. a Before disconncting tho SRS wir6 ham6ss, install the shon connector(s) on th 8i|bag(s) {see page 23-294t. a Replacothe ntire affectod SRS harness assembly if it has an opon ci.cuit or damaged wi.ing. a Afior installing tho gaug assombly, roch6ck tho opelation of th SRS indicator light.
1.
Remove the main gauge assembly (see page 23-130t. Disassemble the main gauge assembly(see page 23-134!. Remove the bulb from the A/T gear position indicator circuit board.
2.
3.
B U L B1 . 1 2W I I
4.
Installtheindicatorin the reverse orderof removal.
23-150
SSlisul&
Safety Indicator
ComponentLocationIndex
CAUTION: a All SRS elctrical wiling hamossos aro covared with yellow outof insulation. a Botor disconnecting th6 SRS wite harness, install the short connector(e) on tha airbag(s) (see page 23-2941. a Replacoihe ntiro aftocted SRS harnossassombly il it has an open cilcuit or damagod wiring. a After installing tho gauge assembly. rocheck ths operation of tho SRS indicator light.
SAFETYINDICATOR(ln the sub gauge sssemblyl Troubleshooting.pag 23-1 56 page23-130 Removal, fnput Test, page 23-154 page23 133 Bulb Replacement, CEILINGLIGHT Test/Replacement.page 23-1 90 HIGH MOUNT BRAKELIGHT p a g e2 3 - 1 9 5 DOOR SWITCH PASSENGER'S Test. page 23-191
BRAKESWITCH Test, page23-195
TNUNK LIGHT est, page 23-199
RIGI{T BRAKELIGHT AILURESENSOR Test, page 23-157
DRIVER'SDOOR Test, page 23- 191
LIGHT LEFTBRAKE SENSOR FAILURE 23-157 Test,page
LATCH SWITCH Test/Replscement,page 23-189
Safsiy lndicator Systsm: Bulbsare usedto indicatewhen the trunk lid or a door is not fully closed,or when a brakelight is faulty. The bulbswill remain ON Jor about two seconds after the ignition switch has been turned ON to show that the system circuit is functioning. Blako Light Bulb Fallule Indicatot: the WHT/GRNwire is constantlybeinggroundedby lf all brakelight bulbs are OK, the indicatorlight stays off because throughthe diode, in With the brakelight ott, the groundis provided the two brakelight tailuresensorsconnected series. the failuresensorrelaycoil, and the bulb filaments.With the brakelight on, alltour relays(threein the leit sensor.one in in supplyground.lJ eitherof the two bulbsis not working.the chainis brokenand the connected series, the right sensor), not being grounded.The indicatorlight comes on. WHT/GRNwire is
23-1
Safety Indicator
Circuit Diagram
-HOOD UNDER FUSE/RTAY BOX WHT/YEL
| .POWER I| 8fi|l*o' 38lY*0' POWER |

|
'Mreoncreo ,*rn*tro |
00oR tocK I
q*,*,Q*,,,n.,,,
l8fi,?f., lDooRsw'TcH
| .Y, "Y, | H
t l
-:-
| 8fii[*'' |
D00R rocK
8Rifl*'
1
:
23-15.2
*tt"r,J
+V
. ECM , TRANSMISSION CONTROL (TCMI MODULE ' CRUISE UNIT CONTROL ' ABS CONTROL UNIT
+BNlwHT
GRt{/l
LEFT !-
T A I T L I G H T, :
BRAKE LIGHI t43CPl
BLK
BLK
{
G521
23-153
Safety Indicator
InputTest Indicator
a All SRS eloclricsl widng ha]nossesare coverod with yollow outr insulation. a Bofole disconnecting the SRS wira hamss, install ths short connoctor(s) on the airbag(s) lsee page 23-294t. a Replacothe sntir affectad SRS harness assembly il it has an opon circuit or damagod wiring. a Aftor installing th6 gaug a$ombly, lochock ths operation of the SRS indicator light. 1. Removethe sub gauge assemblyfrom the dashboard (seepage 23-130).
I I
2 . Disconnect 30-P connectorfrom the sub gauge the

assembly. Inspectthe connectorand socket terminalsto be sure they are all makinggood contact. a lf the terminals are bent, loose, or corroded, repair them as necessary, and recheck the sysrem. a lf the terminalslook OK. make the following input tests at the connector. - It a test indicatesa problem,find and correct the cause,then recheckthe system. - lf allthe input tests prove OK, the printedcircuit board must be faulty; replaceit.
Viow lrom wire side
GRN/BED
SUBGAUGE ASSEMBLY
23-154
Tosi condition 1
T6str Desired rssult Checkfor continuityto ground: Thereshould be continuitv. Check for voltageto ground: There shouldbe battery voltage. Check for continuityto ground: Thereshouldbe lessthan 4 kO.
Possiblcause it result is not obtained . Poor ground {G4Ol, G4O2,G4O4l. . B l o w nN o . 1 3 ( 1 OA ) I u s e . (ln the underdashfuse/relaybox) . An open in the wire. B l o w nN o . 4 1 ( 1 5 A ) f u s e . Faultybrakeswitch. Blown brakelight bulb. Faultybrakelight failuresensor. P o o rg r o u n d( G 5 2 1 .G 5 5 1 ) . An open in the wire. Faultytrunk latch switch. P o o rg r o u n d( G 5 2 1 ) . An open in the wire.
BLK YEL
Under all conditions. lgnition switch ON.
WHT/GRNBrakepedal pushed.
GRN/BLK Trunk lid open.
Check for continuityto ground: There shouldbe continuity. NOTE:Beforetesting, remove N o . 4 6 ( 15 A ) f u s e i n t h e fuse/relay box. under-hood Connectto ground:Ceiling light shouldcome on. Check for continuityto ground: Thereshouldbe continuity. NOTE: Beforetesting. remove N o . 4 4 ( 15 A l a n d N o . 4 6 ( 15 A) fuses in the under-hood fuse/relaybox.
BLK/WHT Ceilinglight switch in

MIDDLEposition.
E l o w nN o . 4 6 ( 1 5 A l f u s e . Faultyceilinglight. An open in the wire. . Faultydoor switch. . An open in the wire.
GRN/BLU Driver'sdoor oDen.
door open. GRN/RED Passenger's
23-155
_
Safety Indicator
Troubleshooting
NOTE: The numbersin the table show the troubleshooting sequence Item to be inspected
a;
< + rr: o f
{ d
3 3 3
<t F -9
- c
o c z 3 z a c g ; G I t 9 c
Symptom
No indicatorsooerate.
Indicator lights do not come on when the ignition switch is turned to ON.
G401 G402 Y E L G404
Door indicatorlight does not come on with ooors open. Trunk indicatorlight does not come on with trunk lid open. Brakeindicatorlight does not come on with blown brake light bulb. Brakeindicatorlight remainson with good brake light bulbs. Ceilinglight does not come on with door open (with switch in MIDDLEposition).
1 1 2
1
GRN/BLK GRN/RED G521 GRN/BLK
G551
WHT/GRN or GRN BLKiWHT
23-156
i,,,
raKeLight FailureSensor I Gsr Brak Llgnr rallure Densor Test
4. Open the taillightaccesspanelto the left taillight. Remove the bulb socket housing. watch the light when the ignition switch is trTARnAMFl wire ot the turnedfrom OFFto ON with the B (GRN) 6-P connectorgroundedand the brakepedalpresseo.
LEFTFAILURESENSOR
1 . Firstmake sure the brakelights come on when the brake oedal is gressed. a lf all the brake lights come on. go to step 2. a lf one of the brake lights does not come on. check whether the bulb is blown. lf the bulb is OK. go to step 2. a lf none oi the brake lights come on, check the brake light circuit {see page 23-153). Open the trunk lid and the taillightaccesspanelto the right taillight.Removethe bulb sockethousing. Watch the TBRARE-IAMFI light in the safety inwire of the 4-P condicat( , when the B {WHT/GRN) nectoris groundedand the ignitionswitch is turned t r o m O F Ft o O N .
a It the BRAKELAMP I light comes on and stays on, there is an open in the B (GRNIwire between the le{t failure sensor and the right failure sensor. r tt ttre lEnnfELAME light does not stay on, go to step 5. a lf the IBRAKELAMP light comes on and stays wire on, check tor an open in the B (WHT/GRN) between the safety indicator and the right failuresensor. r tf the i gnnre- LAtt,tp tight does not sray on. go I to steD 3. 3, watch ttre f aRAKaLAMt light when the ignition switch is turned from OFFto ON with the D {GRN) wire of the 4-P connectorgroundedand the brake pedal pressed. o It the [6nAre LAMpllight comes on and stays on, replacethe right failuresensor. o tt ttre IERAKELAMpllight does not stay on, go to step 4.
5 . Warch rhe trRAK-E LAMFI light when the ignition

switch is turned from OFF to ON with the F (BLK) wire ot the 6-P connectorgroundedand the brake pedal pressed. r tt ttre I aR-AKaLAMP light comes on and srays I on, replacethe left tailuresensor. o tt tne IaRAKaLAMPI light does nor slay on, check for an open in the F {BLK)wire between the left failuresensorand ground,and checkJor a p o o rg r o u n da t G 5 5 1 .
23-157
Interlock System
Location Index Component
CAUTION: a All SRS sloctrical wiring hamosses ar cove?edwith yollow outer insulation. a Botolo disconnectlng ths SRS wira hamoss, install the short connector(sl on the airbag{sl, then dlsconnect the wire harnesa (soo page 23-294). a Rsplacthe sntile affected SRS hamass assembly if It has an opon clrcuit 01 damaged wiring. a Aftor inEtalling ths gaugo assombly. rechock th6 opelation ol th SRS indicator light.
A/T GEAR POSITIONII{OICATOR So page23-144
INTERLOCK CONTROL UNIT InputTest,page 23-161
KEY INTERLOCK SOLEI{OID and KEY INTERLOCK SWITCH (ln thg steering lock assembly) Test, pge 23-162
SHIFT LOCK SOLENOID Test, page 23-163 page 23'163 Replacement,
A/T
swtTcH
POStTtON
Tst, page23-148 Replcement,psg 23-149
23-158
Description
shifting: The car is equippedwith the following devicesto preventinadvertent a Shift lever with shift lock ignitionkey a Key cylinderwith interlocked Shilt Lock Systom: The shift tock system preventsthe shitt leverfrom movingto @ or p from the @ unlessyou step on the brakepedal.
NOTE: are a The shift lever cannot be shifted when the brakepedaland the accelerator steppedon at the same time. slot nearthe shift lever. by the a In caseof svstem malfunction, shift levercan be released pushinga key into the release
Key Intorlock System: When the shift leveris in any The ignitionkey cannot be removedtrom the ignitionswitch unlessthe shift leveris in L?.1. to be removeduntilthe leveris movedto for positionother than @. a solenoidis activated,makingit impossible the key the lP l.
I ne sntn tever rs In Ll:l
INTERLOCK LEVER
SOLENOID IOFFI
KEYCYLINDER
The shilt lever is in any position except l-P-l
SOLENOID (oNt
23-159
Interlock System
GircuitDiagram
NOTE: Different wires with the same color have been given a number suffix to distinguish them (GRN/WHTl and GRN/WHT' are not the same).
- HOOD UNOER FUSEiRELAY 8OX
WHT/YEI.
DASH UNOERFUSEiRELAY
GRNMIfT I
HORN CIRCUIT
8ox
SHIFT LOCK s0LE otD loN:UNLoCK)
. ERAKE UGHTS . cRutsE c0t{rRoL
{
G40l G402 G404
23-160
ControlUnit InputTest
control the Oisconnect 8-P connectorfrom the interlock untr. Inspectthe connectorand socket terminalsto be sure they are all makinggood contact. a lJ the terminalsare bent, loose, or corroded,repair and recheckthe system. them as necessary, a lt the terminalslook OK, make the following input tests at the connector. - lf a test indicatesa Droblem, find and correctthe cause,then recheckthe svstem. - lf all the input tests prove OK. substitute a known-goodcontrol unit and recheckthe system. lf the check is OK, the controlunit must be faulty; it. reDlace clickswhen the ignition NOTE: lf the shift lock solenoid is turned ON and you step on the btake pedal switch {with the shift leverin LLI),the shift lock system is electronically normal; if the shift lever cannot be shifted from LBl, test the A/T gear position switch as desctibed on page 23-148 and see section 14.
UNIT CONTROL INTERLOCK
WHT/GRN
View from wire side
Shift Lock System: No.

1
Wile
Test condilion
Test: Dosired result Check for voltage to ground: There shouldbe battery voltage. Checkfor voltageto ground: Thereshouldbe lessthan battery voltage. Checkfor continuityto ground: Thereshouldbe continuity. Checktor voltageto ground: There shouldbe battery voltage.
Possiblocause if result is not obtained Blown No. 41 (15 A) tuse. Faulty ECM. Faulty brakeswitch. Faultythrottle position (TP,sensor. An open in the wire.
WHTiGRN lgnition switch ON. Brakepedal pushed. lgnition switch ON, brake pedsl and acceleratorpushedat the s a m et i m e . GRN/WHT' Shift lever in @.
FaultyA/T gear positionswitch. G4O2,G4O4). Poorground (G4O'1. An open in the wire. Blown No. 13 {10 A) fuse. Faultyshift lock solenoid. An open in the wire.
GRN
lgnitionswitch ON.
K6y Int6 ock System: No. 1 Wire Test condition Under all conditions. Tst: Desired result Checkfor continuityto ground: There shouldbe continuity. Check for continuityto ground: There shouldbe continuity. Check for voltageto ground: There should be battery voltage. Possiblecause it lesult is not obtained . P o o rg r o u n d{ G 4 O 1 G 4 0 2 , G 4 O 4 ) , . An open in the wire. FaultyA/T gear positionswitch. Poor ground (G4O1 G4O2,G4O4). , An open in the wire. B l o w nN o . 4 6 ( 1 o A ) f u s e . Faultysteeringlock assembly(key interlocksolenoid). An open in the wire.
BLK
GRN/WHT' Shift lever in E.
WHT/RED lgnitionswitch turned to ACC (l) and the key WHT/BLU pushedall the way in.
23-161
InterlockSystem
' Kev InterlockSolenoidTest Key IntenOCK Dolenolq I esl
CAUTION: a Alt SRS elactrical wiring harnessosare covord with yollow outer insulation. Bolore disconnecting ths SRS wira ham45, inatall the shon connectorls) on tho airbag(s) lsee page 23-2941. Replacothe ntiro aftoctod SRS hamess assembly if it has an opon cilcuit or damaged wiring. 3. Checkfor continuitvbetweenthe terminalsin each switch position according to the table.
\___------1"-'"d
Po8ition lonition iwitch ACCfl) pushd Koy in. Koyrlossod.
o(J-
--o
4.
Check that the kev cannot be removed with powe. and ground connectedto the A and C terminsls. a lf the key cannot be removsd, th ksy interlock solonoidis OK. a It the key can be removed, roplace the ste8ring lock assemblv (the key intetlock solsnoid is not separstely). availabl
SRSMAINHARNESS '1. Remove the dashboard lower cover and knee bolster. Disconnectthe 8-P connectortrom the main wire narness.
2.
View trom wire side
23-162
Shift Lock SolenoidTest/Replacement

Test: the 3-P con1. Removethe console,then disconnect from the main wire nectorof the shift lock solenoid narness. NOTE: Do not connectpower to the B l-) terminal {reversepolarity}or you will damagethe diode inside the solenoid. Connect batterv oower to the A terminal and ground to the B terminal momentarily.Check the solenoidto see if it works. lf it does not work, replaceit. NOTE: a When the shift lock solenoidis ON, check that there is a cleafanceol 2.9 ! O.5 mm {0.114 t 0.020 in) between the top corner of the shift \ack\e\e\ andthe \ock p\n qroo\e \see c\earance check on this paqe). a When the shift lock solenoidis OFF, make sure that the lock pin is blocked by the shitt lock tever. a lf it is not, adjust the positionof the shift lock solenoid.
NUTS Replace. 1Ot{'m
lnstall the new shift lock solenoid in the reverse order of removaland adjust its position. a when the shift lock solenoidis ON. check that e t h e r e i s a c l e a r a n c o J 2 . 9 t O . 5 m m ( O . 1 1 4a 0.O2O in) between the top corner of the shift lock lever and the lock pin groove, and tighten nuts. the self-locking NOTE: Use brand-newselflocking nuts.
2.9 r 0.5 mm (0.'114r O.O2O Inl SHIFT LOCK LEVER
LOCK PIN GROOVE
when the shift lock solenoidis OFF,make sure that the lock pin is blocked by the shift lock tever.
Rsplacement: 1. Removethe solenoidpin. 2. Remove the self-locking nuts and shift lock solenoid.
23-163
IntegratedGontrolUnit
CircuitDiagram
Descdption An integrated control unit, located in the left kick panel, integrates the tunctions of the key - in/seat beh reminder, side marker light f lasher, wiper/washer, lights - on reminder, rear window defogger timer, entry light timer, power window ky -off timer, and engineoil pressure indicatorflashercircuits. NOTE: Different wirs with the same color have be6n given a number suffix to distinguish them (for example, GRN/RED1 GRN/RED'are not the samel. and
UNDERHOOD FUSE/RELAY BOX N0.32{1004) No.46ll5Al IGNITION SWITCH
WINOSHIELD WIPER/ WASHER SWITCH
WASHER swftcH
BLKffEL
Y
IMTEGRATED CONTNOT UNIT
IMT
COMBINATION UGHTSWTCH
II'ITERMITTENT I wrPER RELAY I
*f *Y,
' BI-UiWHT
,'
r,r,!"rt,8filI*o'
I I
POWER o00R LocK
. SAFETY INDICATOR CIRCUIT . POWER DOOR LOCK UNIT CONTROI, RED/B].U
B LK WINDSHIELD INTERMITTEMT MOTOB WIPER REI-AY WIPER
++
FROI'IT SIDE MARKER UGI{T {3CPt
Prsft v" I
iilF-*lJ ",.gFI
BI..K
@i'fl"* (
DRIVER'S BELT SEAT swtTcH

BLK
_l.L
BLK
G301
G20t
G401 G402
G522
23-164
' TRUNK UGHT , CIGARETTE LIGHTER . CEILING UGHT , KEY INTERLOCK SOTENOID
REAR REAR wtNDow wtNDow OEFOGGER DEFOGGER RELAY INDICATOR \--7
'Y
;l_
b
E I
YEUGRN
,.
I 812
G4ot G402 G{Ol
Bu(
fl
,k4
0rL
EITGINE
PRESSURE swtTcH
23-165
IntegratedControl Unit
Input Test
CAUTION: a All SRS electrical wiring halnesses are covered with yellow outer insulation. a Before disconnecting the SRS wira harness, install th shon connector(s) on the airbag{sl (see page 23-2941. a Roplacethe entire affectsd SRS harnessassembly if it has an open circuit or damaged wiring. 1. Remove the left kick panel. then disconnectthe 16-P connectortrom the integratedcontrol unit. Remove the underdash fuse/relay box, then removethe integratedcontrol unit. Inspectthe connectorand the socket terminalsto be sure they are all makinggood contact. a li the terminals are bent, loose, or corroded, repair them as necessary, and recheck the system. a lf the terminalslook OK, make the followinginput tests at the connectorand the socket. lf a test indicatesa problem,find and correct the cause,then recheckthe system. - lf allthe input tests proveOK, the controlunit must be faulty; replaceit NOTE: a Different wires with the same color have been given a number suffix to distinguishthem {Jor and not the example,GRN/RED1 GRN/RED' are same). a Do not disconnect any connectors from the fuse/relav box exceDt the one fof the under-dash integratedcontrol unit.
2.
3.
It-..-t..|.-z\
REO/BLU
23-166
GRN/WHT View trom terminal side of lhe box socket luse/relay under-dash
BLU/WHT,
GRN/BLK
connector View from wire side of the harness
Wiper Systsm: No. Terminal
Tost condition
Test: Desirod result Check for continuityto ground: Thereshouldbe continuity. Check for voltageto ground: Thereshould be battery voltage. Checkfor voltageto ground: Thereshould be battery voltage. Check tor voltageto ground: There shouldbe battery voltage, Check for voltageto ground: Thereshouldbe battery voltage.
Possiblecause if result is not obtained . Poor ground (G4Ol, G402. G4O4l . An open in the wire. B l o w nN o . 1 7 ( 3 OA ) f u s e . (ln the under dash fuse/relaybox) Faulty intermittentwiper relay. An open in the wire. B l o w nN o . 1 7 { 3 0 A ) f u s e . (ln the under-dash tuse/relay box) Faulty wiper switch. An open in the wire. B l o w nN o . 1 7 ( 3 OA ) f u s e . (ln the under-dash fuse/relaybox) Faultywiper switch. An open in the wire. Blown No. 17 (30 A) tuse. (ln the under-dash fuse/relayboxl Faultyintermittentwiper relay. Faultywindshieldwiper motor. An open in the wire.
B1 2
B2
Under all conditions,

lgnition switch ON.
810
lgnitionswitch ON and wiper switch at INT position. lgnitionswitch ON and washer switch
B'l 1
oN.
B3
lgnition switch ON.
Engine Oil PressuroIndicatol FlasherSystm: Tsst condition No, Trminal 1 B1 B9 Underall conditions. lgnition switch ON.
Tost: Desired result
Possiblecause il result is not obtaind . Poor ground (G4O1 G4O2,G4o4). , . An open in the wire. . B l o w nN o . 13 ( 10 A ) t u s e . (ln the under-dash fuse/relayboxl . An open in the wire. B l o w nN o . 4 2 ( 2 0 A ) f u s e . (ln the under-hood fuse/relayboxl light switch. Faultycombination An open in the wire. B l o w nN o . 1 3 ( 1 OA ) f u s e . (ln the under-dash fuse/relayboxl relay. Faultyturn signal/hazard An open in the wire.
Check for continuityto ground: There shouldbe continuity. Check for voltageto ground: Thereshouldbe battery voltage. Checkfor voltageto ground: Thereshould be battery voltage. Checkfor voltageto ground: It shouldchangefrom O-12 O V repeatedly.
B6
Headlightswitch ON.
87
lgnitionswitch ON and turn signalswitch to "Left". lgnitionswitch ON and turn signalswitch to "Right".
814
GRN/WHT Connectthe 85 terminal to the GRN/ WHT (orGRN/RED1) GRN/RED1 terminal.
Check front side markerlight operation:Lett (or Right)front side ma.ker light shouldcome on as the battery is connected.
Blown bulb. P o o rg r o u n dI G 3 O 1( o r G 2 O 1 ) l An open in the wire. {cont'd}
23-167
Integrated ControlUnit
Input Test (cont'd)
813
811
89
GRN/WHT
BLU/WHT'
GRN/BLK
View from terminalside of the underdash fuse/relay box socket
View from wire side oI the harness connector
Ky-in/Seat Eelt Rsminder System: No. Terminal Test condition 1
Test: Desired result Check tor continuityto groundl There shouldbe continuity. Checkfor continuityto ground: Thereshouldbe continuity. NOTE: Betoretesting, remove No. 46 (15 A) fusein the under-hood fuse/relaybox. Check for voltageto ground: It shouldbe 1 V or less. Checkfor voltageto ground: It shouldbe 1 V or less. Check for voltageto ground: Thereshould be battery voltage.
Possiblecause if result is not obtained . Poor ground (G4O1,c4O2, G4O4). . An open in the wire. . Faultydriver'sdoor switch. . An open in the wire.
B1
B8
Under all conditions. Driver'sdoor open.
BLU/WHT' lgnition
key is inserted into the ignition switch.
Faultyignitionkey switch. Poorground (G4O1,c4O2, G4O4). An open in the wire. Faultyseat belt switch. P o o rg r o u n d( G 5 2 2 ) . An open in the wire. . B l o w nN o . 1 3 ( 1 OA ) f u s e . (ln the under-dash fuse/relayboxl . An open in the wire.
RED/BLU lgnitionswitch ON and driver's seat belt unbuckled. B9

lgnition switch ON.
Power Window Key-oft Time. System: No, Terminal Test condition

1
Test: Desired tesult Check for continuityto ground: Thereshouldbe continuity. Check tor voltageto ground: The.e should be battery voltage. Check for continuityto ground: There shouldbe continuity. NOTE: Beforetesting, remove N o . 4 6 { 15 A ) t u s e i n t h e under-hood fuse/relaybox. Check for continuityto ground: There shouldbe continuity. NOTE: Beforetesting. remove No. 46 (15 A) fuse in the under-hood tuse/relaybox.
Possiblecause it .esult is not obtained . P o o rg r o u n d{ G 4 O l , c 4 O 2 , G 4 O 4 } . . An open in the wire, . B l o w nN o . 4 6 ( 1 5 A ) f u s e . {ln the underhood fuse/relaybox) . An open in the wire. ' Faultydriver'sdoor switch. . An open in the wire.
B1
B5
Under all conditions.
Underall conditions.
B8
Driver'sdoor open.
G R N / R E D ' Passenger's door open.
. Faultydoor switch. . An open in the wire.
G R N / B L K Connectthe 85 ter Check window operationl minal to the GRN/BLK Power windows shouldwork terminal. with the key OFF.
Faulty power window relay. Poor ground lG4O1, c4O2, c4O4). An open in the wire.
23-168
WHTiBLUJ ORN
8ED/BLU
GRN/WHT
View from terminal side ot the under'dash fuse/relay box socket
BLUiWHT'
GRN/8LK
connector View from wire side of the harness
Entry Light Timer System: Test condition No. Terminal

1
Test: Desired result Check for continuityto ground: There shouldbe continuity. Checkfor voltageto ground: Thereshouldbe battery voltage.
Attach to ground: lgnition key light should come on.
Possiblecaus i{ result is not obtained . P o o rg r o u n d{ G 4 O l , G 4 O 2 ,G 4 O 4 } . . An open in the wire. . B l o w nN o . 4 6 ( 15 A ) f u s e . box) lln the under hood fuse/relay . A n o p e ni n t h e w i r e .
. Blown bulb. . An open in the wire.
B1
B5
Under all conditions. Underall conditions.
WHT/BLK Under all conditions.

4
B8
Driver'sdoor open.
Check Ior continuityto ground: There shouldbe continuity. NOTE: Beloretesting, remove N o . 4 6 { ' l5 A ) I u s e i n t h e fuse/relay box. under-hood
. Faultydriver'sdoor switch. . An open in the wire.
Lights-on ReminderSystem: Test condition No. Terminal 1 2 B1 B6 U n d e ra l l c o n d i t i o n s .

Headlight switch ON.
Test: Desired result Check Ior continuityto ground: Thereshould be continuity. Check for voltageto ground: Thereshould be battery voltage. Check for voltageto ground: There shouldbe battery voltage. Check for continuityto ground: There shouldbe continuity. NOTE: Beforetesting, remove N o . 4 6 ( 1 5 A ) f u s ei n t h e box. Iuse/relay under-hood Chime Check chime operation: should activateeach time the battery is connected.
Possiblecause if result is not obtained . P o o rg r o u n d{ G 4 O 1 G 4 O 2 ,G 4 O 4 ) , . . A n o p e ni n t h e w i r e . B l o w nN o . 4 2 l 2 O A J f u s e . (ln the under-hood box) fuse/relay light switch. Faultycombination An open in the wire. . B l o w nN o . 1 3 ( 1 OA ) f u s e . (ln the underdash fuse/relay box) . A n o p e ni n t h e w i r e . . Faultydriver'sdoor switch. . A n o p e ni n t h e w i r e .
B9
l g n i t i o n w i t c hO N . s
B8
Drjver'sdoor open.
ORN
lgnition switch ON and connect the 89 terminal to the ORN termtnal,
. Faulty hime. c . An open in the wire.
(cont'd)
IntegratedControl Unit
InputTest(cont'd)
View from terminalside of the under-dashtuse/relay box socket Rear Window Defogger Timer Circuit:
View from wire side o{ the harness connector
No, 1
Terminal
Test condition Underall conditions. Defoggerswitch pushed. lgnitionswitch ON.
Test: Desired result Checkfor continuityto ground: Thereshouldbe continuity. Check for continuityto ground: There shouldbe continuityas the switch is pushed. Attach to ground: Rearwindow defoggershould work and the defoggerswitch indicatorlight shouldcome on. Check for voltageto ground: Thereshould be battery voltage.
Possiblecause if result is not obtainod . Poorground (G40'1 G402. G4O4l. . . An open in the wire. Faultydefoggerswitch. Poor ground {G4O1,c4O2, c404}. An open in the wire. Blown No. 34 (40 A) fuse. (ln the under-hood fuse/relayboxl Faultydefoggerrelay. Blown LED. An open in the wire. . B l o w nN o . 1 3 ( 1 OA ) f u s e . (ln the unde.-dash fuse/relayboxI . An open in the wire,
B1
813
812
B9
lgnitionswitch ON.
Engins Oil P.assur Indicator FlashorSvstem: No. Trminal Tst condition

I
Tsst: Dosired tosult
Possiblecause il result is not obtained . Poor ground (G4O1 G4O2,G4O4t. . . An open in the wire. . B l o w nN o . 1 3 ( 1 OA ) f u s e . (ln the under-dash fuse/relay box) . An open in the wire. . Faultychargingsystem. . An open in the wire. . Faultyengineoil pressure switch. . An open in the wire. . B l o w nb u l b . . An open in the wire.
B1 B9

lgnition switch ON.
Check lor continuityto ground: There shouldbe continuity. Checkfor voltageto ground: Thereshouldbe battery voltage. Check for voltageto ground: Thereshould be battery voltage. Check for continuityto ground: Theie should be continuity. Check indicarorlight. lf the light does not come on, attach the YEL/RED terminalto ground:The light shouldcome on as the ignitionswitch is turned ON. Check tor voltageto ground: Thereshould be battery voltage.
WHT/BLUl Enginerunning.
YEL/RED lginition switch OFF. lgnition switch ON.
Start the engine.
Insulficientoil. lmp.operlubrication. Faultyengineoil pressure switch.
23-170
System Key-inReminder
lgnition Key Switch Test
NOTE: Refer to page 23-164 tor the diagram oJ the key-in beepr circuit, and page 23-168 for the input test of the beepercircuit. the key-inbeeper When the ignitionkey is not removed, controlunit sensesgroundthroughthe integrated in the closedignitionkey switch. when you open the driver's door,the beepercircuitsensesgtoundthroughthe clos"BLU/WHT2" and ed door switch. With ground at the "88" terminals,the beepersounds. 1. Remove the dashboard lower cover and knee bolster (seepage 23-68). Disconnectthe 8-P connectorfrom the main wire harness.
Liqhts-onReminder Sy-stem
Chime Test
NOTE: Refer to page 23-165 tor the diagramof the lights-onremindercircuit, and page 23-169 for the input test of the circuit. "O" position and When the ignition key is turned to removed. with the lights on, voltage is appliedto the remindercircuit on the integratedcontrol unit. When you open the driver's door, the circuit sensesground through the closeddoor switch. "86" terminal,groundat the "88" With voltageat the "B9" terminal,the chime terminaland no voltageat the soundsto remindthe driverto turn off the lights. 1. Bemove the dashboard lower cover and knee bolster. Disconnectthe 2-P connectorfrom the main wire harness.
2.
2.
8-P CONNECTOR
2-P CONNECTOR
Check continuitybetweenterminalsA and B a Thereshouldbe continuitywith the key in the ignition switch. a There should be no continuity with the key removgd.
Test the chime by connectingbatterypower to No. to 1 terminal,grounding No. 2 terminal,and cycling the power on-off repeatedly. 4. lf the chime fails to sound every time power is cy cled, replaceit.
23-17 1
Seat Belt Reminder System

Description
NOTE: Refer to page 23-164 for the diagramof the seat belt beeper/timer circuit. With the ignitionswitch in "Run" or "Start", voltageis appliedto the beeper/timer the integratedcontrol of unit. When you unbuckle the driver's seat belt, the beeper/timer circuil sensesground.With voltageat the "89" terminaland ground at the "RED/BLU" terminal. the seat belt beeper sounds and the timer contacts closeand open.This causesthe seat belt reminder light to ilash on and off. After five secondsthe alarmstoos and the contacts .emain oDen.
SeatBeltSwitch Test
Slide the f.ont seat all the wav forward then disconnect the 2-P connector from the seat belt switch.
Chck continuitv between terminals A and B. a There should be continuity with the seat belt unbuckled. a Thereshouldbe no continuitywith the seat belt is buckled.
23-172
! l
Entry Light Timer System

lgnition Key Light Test
Remove the dashboard lower cover and knee bolster (see page 23-68). Disconnectthe 8-P connectorfrom the main wire narness.
lgnition Key Light Replacement

1, Remove the steering column covers lsee page 23-741. from the key light housing Removethe bulb/socket by turning the socket 45o counterclockwise.
2.
There should be continuity between the A and B termlnals. It there is no continuity,replacethe light.
23-173
LightingSystem
DRL INDICATORLIGHT lcanadol (ln the sub gaugassembly) page 23-133 Bulb Locations,
HIGH BEAM INDICATORLIGHT {ln the main galge assembly) page23-132 BufbLocations,
COMBINATION LIGHT SWITCH Test, page 23-178 Repfacement,page 23-182
DAYTIME RUNNINGLIGHTS CONTROLUNIT (Canadal Test, page23-180
BOX FUSE/RELAY UNDER.HOOD
tAt----TAt:-, I4A4A4I4A4!=Y -|ililil[|aL_Jat--l
FRONT LIGHT Beplacement, Page23-186
HEADLIGHTS Adjustment,page 23-184 page23-183 Replacement, TURN FRONT SIGf{AL LIGHT page23-185 Replacement, SIDE MABKERLIGHT page 23-185 Replacement,
(f, t(:) (:) to k:i -
I|
(B-type) Test, page 23-72
(A-typel Test, page 23-71
23-174
DOOR SWITCH PASSENGER'S Test, page 23-191 CEILINGLIGHT Test, page 23-190 page23-190 Replacement, TRUNK LIGHT Test, page 23-189 page 23'189 Replacement,
PLATELIGHTS LICENSE page23-188 Replacement,
SWITCH DOOB DRIVER'S Tsr,page23-'l91
REARSIOE MARKERLIGHT page 23-188 Replacment,
TAILLIGHTS Repalcement,Page 23'1 87 page 23-187 BulbReplacement,
23-175
LightingSystem
(USA) CircuitDiagram
UNDRHOOO FUSE/RELAY 8OX
BLK
BU(
COMEINATION UGIfT SWITCH BLK
rr-.'
\ /
t t
I
I
I . DASH LIGHTS BRIGHTNESS CONTROLTER . DASH LIGHTS , SIOE MARKER UGHTS . R,TAILTIGHT , TICENSE PTATE IIGHTS . INTEGRATED CONTROL UNIT . FRONT PARKING UGTTTS ' HEATER CONTROL PANET LIGHTS
l l
L.TAII.I]GHT I
G201
G40l G442 G40+
G401 G4o2 G40,1
23-176
(Canada) GircuitDiagram
No.32ll00Al No.42 {20A}
DNLINOICATOR LrGHT{3.0W1 REDffVHT {/o+ Btu
DAYTIME RUI.INING CONTROL UNIT
UGt{rs
Ln**nroT.RN/RED
GRN/RED
BRAKE FLUID |.lVEL SWTCH
23-177
LightingSystem
Combination LightSwitch Test
CAUTION: a All SRS electrical wiring halnessos ara covered with yollow outr insulation. a Bofore disconnocting tho SRS wilo harnoss, install th sho.t connector on th6 ai1b8g{se paga 23-2941, a Roplacetho entire aftected SRS harno$ assembly it it has an opon circuit or damagod widng. NOTE: The radiomay havea codedtheft Drotection circuit. Be sureto get the customer'scode numberbetore - Oisconnecting battery. the - Removing the No. 43 (1OA) fuse. (ln the under-hood tuse/relaybox) - Removingthe radio. After service,reconnectpower to the radio and turn it on. When the word "CODE" is displayed,enter the customer's5-digit code to restoreradio operation. 1. Remove the dashboard lower cover and knee bolster. Disconnect the connectors from the main wire narness. Inspectthe connectorterminalsto be surethey are all making good contact. a lf the terminals are bent, loose. or corroded, repair them as necessary, and recheck the sysrem. a lf the terminalslook OK, check for continuity betweenthem in eachswitch positionaccording to the tabl6s.
SRS MAIN HARNESS
2.
3.
2O-PCONNECTOR
5.P CONNECTOR
View from wire side
DAHSBOARDLOWERCOVEF
KNEE BOLSTER View trom wire side
23-178
Headllght/Dlmmor/Pa$ing Switch
11
23
\ Position OFF
Terminal
1l
l4
23
\J Headlight sw|Icn
a'\
LOW
a
o-o -----o o ---o
HIGH Passinq "OFF") switch siitch {Headlisht Passing "."} switch switch {Hsdlight OFF ON
ON
Tum Siqnal Swltch 23 {See pa-ge - 197 fol turn signal circuit dlagraml
\ Position RIGHT
Nut18l
Tsrminsl
o
'12
--o
ar
LEFT
---o
23-179
LightingSystem
Daytime RunningLights Control Unit Input Test lCanada)
CAUTION: a All SRS elsctrical wiring harnessesare covord with ycllow outr insulation. a Botors disconnocting the SRS wire harnoss, inatall th short connoctor on th6 airbag lsoo page 23-2941. a Rcplacetho ontire affected SRS halness assmbly it It has an open circuit or damaged wiring. 1. Pullthe front passenger's carpetaway and remove the kick Danel. Disconnectthe 14-P connectorfrom the davtime runninglights control unit. Inspectthe connectorterminalsto be surethev are all making good contact. a lf the terminSls are bent. loose, or corroded, rpair them as necessary, and recheck the svstem. a lf the terminalslook OK, make the following input tests at the connector. - lf a test indicatesa problem,find and correct the cause,then recheckthe system. - lf all the input tests proveOK, the controlunit must be faulty; replaceit. NOTE: Different wires with the same color have been given a number suffix to distinguishthem (RED/GRN1 RED/GRN, nor the same). and are
2.
3.
14.P CONNECTOR
RED/WHT
RED/GRNI GRN/WHT REO/YEL BLK
View from wire 3id
BLU I RED/ORN GRN/RED

RED/BLU 14-P CONNECTOR RADIATORFAN CONTNOLMODULE
23-180
No, 1
Wils
Test condition Under all conditions.
Test: Desired result Check for continuityto ground: There shouldbe continuitY. Check for voltageto ground: Thereshould be battery voltage.
Possiblecaus it result is not obtainod . Poor ground (G4O1 G4O2,G4O4). , . An open in the wire. Blown No. 37 (4o A) fuse. (ln the under-hood box) fuse/relay N o . 8 { 1 OA ) f u s e . Blown (ln the under-dash box) tuse/relay An open in the wire. . FaultyheadlightrelaY. . An open in the wire. . B l o w nN o . 1 2 ( 7 . 5 A ) t u s e . (ln the under-dash box) fuse/relay . An open in the wire. Faulty passingswitch. Faultydimmerrelay. Fsulty headlightrelay. Blown No. 50 (20 A) fuse. box) (ln the under-hood fuse/relay N o . 5 1 ( 2 OA ) f u s e . Blown An open in the wire. light switch. Faultycombination Faultydimmerrelay. An open in the wire. . Blown headlightbulb (high beam). . An open in the wire.
. Blown bulb. . An open in the wire.
BLK
R E D / G R N ' Under all conditions.
BLU/RED Under all conditions.
Check for voltageto ground: There should be batterY voltage. Check for voltageto ground: Thereshould be batterY votrage. Check for voltageto ground: Thereshould be battery voltage.
YEL/RED lgnitionswitch ON.
RED/GRNl Passingswitch ON.
RED/YEL
7
a
q
RED/BLU Passingswitch ON. ORN light Combination switch OFF.
Check for continuityto ground:There shouldbe continuity. Check for continuitYbetween the terminals: There shouldbe continuitY. DRL indicatorlight should come on. Brakesystem light should come on, Check lor continuityto ground: Thereshouldbe continuitY.
light RED/WHT Combination switch OFF. ' l o RED/ORN 1l
BLU
lgnition switch ON.
1 2 G R N / R E D lgnitionswitch ON.
WHT 1 3 GRNi
Parking brake lever up.
. Blown bulb. . An open in the wire. . Faultyparkingbrakeswitch. . An open in the wire.
23-141
LightingSystem
GombinationLight Switch Replacement
CAUTION: a All SRS olectrical wiring harneasesaro covered with yollow outr insulation. a Botore disconnecting th SRS wir ham6ss, install the short connector{s} on the ailbag{s} (see page 23-2941. a R6placothe ntire aftectd SRS harnessassembly il it haa an opon circuit or damagd wiring. 2. Removethe steeringcolumn covers.
COLUMNUPPER COVER
COLUMN LOWER COVER
Remove the dashboard lower cover and knee bolster.
Disconnectthe connector from the combination light switch assembly, then remove the two screws and the switch.
COMBINATION
OASHBOAROLOWERCOVEN
4.
Installin the reverseorder of removal.
23-182
Headlights
Replacement
CAUTION: a Halogen hsadllghts can becomo vory hot In urc; do not touch thom or tho attaching hardware immodiatsly alter thcy have boon tumad oft' a Do not try to replacc or claan tho headlights tYith tha lights on. 1. Removea screw, then removethe tront turn signal light (see page 23-185). Remove a scrw, th6n remove the flont side markerlight (seepage 23-185). Disconnct the connectors from the tlont turn signallights and frqnt sids ma.ker lights. Remove ths front bumper (see section 2Ol.
o.
Disconnect the 2-P connectots from the headlight bulbs. Remov the assmbly. mounting bolts and headlight
2-P CONNECTORS
2.
3.
4.
8.
After installing the hsadlights, adiust them to local requlremenls.
Disconnect the 2-P connector from the front parking light, and remove the light by removing the mounlrngscrew.
23-183
Headlights
Bulb Replacement
a Halogen hoadlights can become very hot in use; do not touch them or the attaching hardwaro immodiately aftr thoy have b6on turnd off. a Do not try to roplace or clean the headlights with ths lights on. NOTE: a Before disconnecting the left side connectors, removethe washer reservoir filler neck {one bolt). a Before disconnecting the right side connectors, removethe batteryand the enginecoolantreservoir. Disconnect the headlight. 2-P connector(s) from the
Adjustment
CAUTION: a Halogn headlights can become vry hot in us; do not touch them or the attaching hardware immediately attsr they havs bsen tuhod otf, a Do not try to replace or clean the headlights with ths lights on. 1, Adjust the headlights localrequirements turnto by ing the adjusters,
VERTICAL ADJUSTER HORIZONTAL ADJUSTER
Turn the bulb holder(s) counterclockwiseand removethe bulb{s}.
EULBHOLDERS
Do not touch the giass
auLB{65 W}
BULEt55 Wt
2.P CONNECTORS
23-184
Front Side Marker Lights

Replacement
Removethe screw and pull th front side marker light assemblyout of the front bumper.
FrontTurnSignalLights
Replacement
1, Removethe screw and pull the front turn signal light assemblyout ot the front bumper.
FRONTTURN SIGNAL LIGHT
the 2-P connectorfrom the light. Disconnect To reDlacethe bulb, turn the bulb socket 45o and removeit trom the housing. counterclockwise
the 2-P connectorfrom the light. Disconnect To reolace the bulb, turn the bulb socket 45o and removeit from the housing. counterclockwise
FRONTTURN SIGNAL LIGHT FRONTSIDE MARKERLIGHT
BULB t3 cPl
BULB t32 CPI
23-185
Front ParkingLights
Replacement
1 . Rmove the screw and sparate the parking light from the headlight assmbly. NOTE: Be carefulnot to damagethe hoadlight and the tront fender. Turn the bulb socket 45o counterclockwise and remove it from the housing, then replace the bulb.
2 . Disconnect 2-P connectorfrom the light. the
@'1
I
\
BULB15WI \ BULB SOCKET
FRONTPARKII{GLIGHT
23-186
Taillights
Replacement
1, Oon the trunk lid and removethe tear trim panel. 1
Bulb Replacement
Open the trunk lid and removethe taillightaccess panel. Removethe screws and the bulb holderpanel.
ACCESSPANEL
BULBHOLDER PANEL Oisconnectthe 8-P connector from the taillight assembly. Remove the six mounting nuts and the taillight assembly. Removethe faulty bulb by pushingit in and then turning it 45o counterclockwise. BULB{43/3 CP) O BRAKELIGHT/TAILLIGHT TURN SIGNALLIGHTBULB(45 CP} @ L O B A C K . U P I G H TB U L B( 3 2 C P )
8-P COf{NECTOR
ASSEMBLY
NOTE: a Inspect the gasket; replace it if it is distorted or stays compresseo. a After installingthem, run water over the lights to make sure they do not leak.
23-147
LicensePlateLights
Replacement
Remove the two screwsfrom the licenseplatelight assembly. Pullthe light out and disconnectthe 2-P connector f.om it.
RearSide Marker Lights

Replacement
Removethe screw from the rear side marker lioht assembly. Carefullypry the light out of the rear bumper and disconnectthe 2-P connectorfrom the light. NOTE: Be carefulnot to damagethe rear bumper.
LICENSEPLATE LIGHT
3.
Take the lens off, then replace the bulb.
3,
Remove the bulb socket by turning ir 450 counterclockwise.
23-1AA
-t
Trunk Light and Latch Switch

Trunk LightTest/Replacement
Pry ofl the trunk light lens from the housing. Pry out the light. the 2-P connectorfrom the housing. Disconnect
LatchSwitch Test/Replacement
Open the trunk lid and disconnectthe 2-P connector from the trunk latch. CheckcontinuitybetweenterminslsA and B. There should be continuity.
(3.4Wl BULA
LENS
4.
Make sure that the bulb is oK Check for continuity between A (+) and B (-) terminals. NOTE: This light has a diode in it. To get an accurate reading,eithertest it with a volt-ohmmeter tor diodes, or make sure you that comDensatas connect vour tst leads to match the polarity snown.
lJ necessary,remove the three bolts and pull the latch ou1ot the trunk lid, then disconnecttho lock rod from the latch, Disconnectthe trunk openercable from the latch.
4.
{3.4W1
rr*rffi FUSE
From
23-189
CeilingLight
Replacement
Turn th6 ciling light switch OFF. Pry ofl th lens. \ Torminal P""OFF AorA' \
!ot6
Test
Check for continuitv between the terminals in ea'ch switch positionaccordingto the table.
oG-
@
/\ \:.,.
A
--o -o
MIDDLE ON
oFrom 0.46 (l5Al FUSE A
\:/
t8w
t l
) ) '\
ON ,l
.B c b ,
OFF
I
A'B'
Remove the two acrews from the ciling light housing. Disconnect th6 3-P connsctor and rmov th housing.
23-190
DoorSwitch Test
1 . Removethe screw and pull the door switch out.
2 . Disconnect the 1-P connector and temove the

switch. Checkfor continuitybetweenthe terminalsin sach switch positionaccordingto the table.
\ Poshion
rermnal \
O TERMINAL
BASEPLATE
CLOSE OPEN
e) TERMINAL
SCREW
23-191
Back- up Lights
CircuitDiagram
- HOOD UNDER FT'S/RELAY BOX
MAIiIWIRE
A,rT GEAR POSTT|oN - uplioht
ENGINE WIRE
MAIN WIR
) )
IIFT SIDE WRHARNESS
*.*-r-l ucr{Ts I
t32oh2t t
REAR HARNESS WIRE
23-192
Back-upLights
Switch Test
Manual Transmission: 1. Turn the ignition switch ON and move the shift lever to LBJ. The back-uplights shouldcome on. a back-uplight does not go on, check for: Blown bulb in the taillightassembly. both back-uplights do not go on. check tor: Blown No. 13 (10 A) fuse in the under-dash fuse/relaybox. lf the fuse and bulbs are OK, go to step 2. It lf Disconnectthe connectorstrom the back-uplight switch, Automatic Tmnsmission: 1. Turnthe ignitionswitch on and move the shitt lever to LB-1. back-uplights shouldcome on. The a back-uplight does not go on, check for: Blown bulb in the taillightassembly. both back-uplights do not go on. check for: Blown No. 13 (1O A) fuse in the under-dash fuse/.elaybox. It the fuse and bulbs are OK, go to step 2. lf lf -
2 . Disconnectthe '12-Pconnectorfrom the A/T gear

positionswitch (back-uplight switch).
A (YELI
swtTcH
25 .m {2.5 kg-m, 1E rb-ftl
This washermust always be rplaced for the switch to lunction properly and to preventoil reaKs.
View trom wire side
Check for continuity between the A and B terminals. a There should be continuity only with the shilt lever in @. a lf there is no continuity,replacethe switch (see s e c t i o n1 3 ) . a lf there is continuity.but the back-uplights do not go on. check for: - An open in the YEL or GRN/BLK wire. - P o o rg r o u n d( G 5 5 1 ) .
Move the shiit lever back and lorth in E without touchingthe push button, and checkfor continuity between No. 9 and No. 1O terminals. Thereshouldbe continuitywithin the rangeof tree play of the shift lever. a lf there is no continuitywithin the rangeof free play, adjustthe positionof the A/T gearposition s w i t c h ( s e ep a g e2 3 - 1 4 9 ) . a l{ there is continuity,but the back-uplights do not go on, check tor: - An open in the YEL or GRN/BLK wire. P o o rg r o u n d( G 5 5 1 ) .
23-193
BrakeLightsand High Mount BrakeLight

CircuitDiagram
, ECM . TRANSMISSION COMTROT MODUI.E ITCM)
. crursE coNTnoLuNn . A8S Coilrnot UN|T
TAII"TIGHT F i
LFr !-'
I ",F*l 1 , , T 7 f ? nj
\ BRAXE ) I UGHI / ErcPI
L.
8u(
G551
23-194
BrakeSwitch Test
1 . lf one of the brakelightsdoes not go on. checkthe bulb in the taillightor the high mount brake light.
High Mount Brake Light/Bulb Replacement

1 . Removethe cover. Inspectthe bulbsand replace them if they are burned out. \,
2 . lf none of the brakelights go on, checkthe No. 41

(1 5 A) fuse in the under-hood tuse/relaybox. lf the tuse and bulbs are OK, disconnectthe 4-P connectorfrom the brakeswitch.
"JE={"
l i
4-P CONNECTOR
il+
COVER
2
ll the light is taulty, removeits two mountingbolts. the Disconnect 3-P connectorand removethe light.
4.
Check for continuity between the B and C terminals.There should be continuitvwith th brake pedal pushed. a lf there is no continuity,adjustthe pedal height (seesection 19), and recheck. a It there is still no continuity,replscethe switch. a lf there is continuity,but the brakelightsdo not go on, check for: P o o rg r o u n d( G 5 5 1 ) . - An ooen in the WHT/YELor GRN/WHTwire. - Faulty brake light failure sensors (see page 23-157t.
LrcHT HtGHttiouNT BRAKE lnstallin the reverseorder of removal, NOTE: Clean the rear window glass first. and make sure the rubber seal on the light is touching the glassall the way around.
23-195
System Flasher SideMarker/Turn Signal/Hazard

lndex Location Component
CAUTION: a All SRS olctdcal widng hamsses aro covered with ycllow outel insulation. a Bfor dlsconnecting the SRS wire hamoss, install the short connector on the 8i1b89{sl,thon diEconnoct the wke hamess (so page 23-2941o Replacotho ontiro aftocted SRS hamess assombly il it has is an open ciicuit or damagod wiring.
SRS MAIN HARNESS
UI{DER.DASH FUSE/RELAY BOX
TUNNSrcNAUHAZARD BELAY InputTest,page 23-198
SIDE MARKERLIGHT FLASHER CIRCUIT {ln the integrated control unit) fnput Test, page 23-167
TURI{ SIGIIAL II{DICATOR UGHTS (ln the gauge assomblyl Bulb Locations, page 23-132
HAZARD WARI{II{G SWTTCH Romoval, page 23-2OO Tosr, page 23-2OO
coMBll{A swtTcH
LIGHT/TURN SIGT{AL
Test, psge 23-178 Repf acoment, page 23-182
23-196
CircuitDiagram
6;\ **n" T 'u7coMBlNATror,{ .-..J^._. whr/ttl

UGHTSWITCH
-J"-l
No.13l10A)
connctionl {lntornal
v l _
l l WHTTYEI
lo lg
-l
HAZARD I WARNING I
RD/BII(
sw[cH
wtfl /YEL
I I
t A
L / l \ R
frl
TURN SIGNAL swlTcH
GRN/YEL
DASH IG}TTS BRIGITTI{ESS COMTROT UNIT TURNSIGMU RI-AY HAZARD 6 4
COMBINATION t-tcHt swtTcH
V I
I llm.md connoction connction I llntamel
MARKER FI-ASHER CIRCUIT SIDE contrclunit) llntheintagdt6d
ALUGHTS TTFI]URNSIGN
tt \?-^"V-"
t t
GRNIBIU RI{/8[U GRN/BLU
uo HTS ru*r'ono, ^,0*r -1

GRN GRN/ryEL MHT GRN,"YEL GRN/YEL
rs\
urtfim in liiTii' li5)l I ll.{
9*r*''%' , l H l s l t t
BLK BLK : G201
l I
t
( n.'9r*-[/ h,o'Y i* v :P) I S|DE I SrDr

I BT.K
l(45cP)
I
{T P)
t t
t
GRI{,frED
MABKER MA ixea I
I I I
r l
8I.( [.(
BI.K Bl-K
G55l
: G301
f , T
l G201 G40
BLK
System Flasher Signal/Hazard Side Marker/Turn

RelayInputTest Turn Signal/Hazard
CAUTION: a All SRS electrical wlring harnessosare covared with yollow outor insulation, a When disconnecting tho SRS wiro harness. inslall th short connectol on tho airbag(s). lhsn disconnoct the wiro ha.ness (soo page 23-294). a Replacthe ntiro aft6ct6d SRS hamess assmbly it it has is an open circuit or damagod wlring, Removethe driver's side kick panel.then remove relay from the under-dash the turn signal/hazard fuse/relaybox. Inspectthe socket terminalsto be sure they are all makinggood contact. a lJ the terminals are bent, loose, or corroded, repair them as necessary, and recheck the sysrem. a lf the terminalslook OK, make the following input tests at the socket. - lJ a test indicatesa problem,find and correct the cause,then recheckthe system. - lf all the input tests provB OK, the turn relay must be faulty; replaceit. signal/hazard
9ee aEo
4
1 2 3
5 6
lerminal side
23-198
No. 1
Trminal 4
Tost condition Under all conditions. Underall conditions.
Tost: Desirad rosull Checktor continuityto ground: There shouldbe continuitv. Check for voltageto gtound: There should be battery voltage. CheckJor voltageto ground: There should be battery voftage.
Possibls cause if result is nol obtainod . Poor ground {G4O1 G4O2,G4O4). , . An ooen in the wire. . B l o w nN o . 3 9 ( 1 5 A ) f u s e . (ln the under-hood fuse/relayboxi . An open in wire, . Faultyhazardwarning switch. . An ooen in the wire. B l o w nN o . 1 3 { 1 OA l f u s e . fuse/relay box) {ln the under-dash Faultyturn signalswitch. An open in the wire. . Faultyhazardwarningswitch. . An oDenin the wire. B l o w nN o . 1 3 ( 1 OA l f u s e . (ln the under-dash fuse/relay box) Faultyturn signalswitch. An ooen in th wire. Blown bulb. , P o o rg . o u n d( G 2 O 1 G 5 5 1 ) An open in the wire. Blown bulb. , P o o rg r o u n d( G 3 O 1 G 5 5 1l An open in the wire.
Hazardwaring switch
oN.
lgnitionswitch ON and turn signalswitch in Right position. 4 Hazardwarning switch ON. lgnitionswitch ON and turn signalswitch in Left position. 5
Chck for voltageto ground: There should be baftery voltage.
3 . 2
Connectthe No. 3 terminalto the No. 2 terminal. Connectthe No. 3 terminalto the No. 6 terminal.
Rightturn signallights should come on whgn the terminals are connected. Left turn signallights should come on when the terminals are connectgd.
3.6
23-199
FlasherSystem Signal/Hazard Side Marker/Turn

Hazard WarningSwitch Replacement
CAUTION: Be careful not to damage the console panls. 1. 2. Removethe front consolepanel (seesection 20). Remove the screw and turn the hazard warning switch slowly in the directionshown and removeit from the center console. the 6-P connectorfrom the switch. Disconnect
Hazard WarningSwitchTest
1 . Remove the hazardwarningswitch from the center
consolepanel.
2 . Checkfor continuitybetweenthe terminalsin each

switch positionaccordingto the table,
Te.minal
3.
il----\
ON
OFF
o-
/1
\:,/
-o o- t_r_ -o -o
CENTERCONSOLE
6.P CONNECTOR
23-200
Dash Lights Brightness Control

a All SRS olect cal wiring harnessesare coveld with yellow outor insulation. a Betor disconnecting the SRS wire harnoss, install the short connector{s) on the airbag(s) (see page 23-2941. a Roplaccthe entiro atfected SRS harnessassmbly if it has an open cilcuit or damaged wiring. a Alter installing the gaugo assombly, rechock the oDrationof tho SBS indicator light.
\ sRsMAIN HARNESS
CONTROLUNIT DASH LIGHTS BRIGXTNESS Test, page 23-2O4
DASH LIGHTS BRIGHTNESS CONTROLLER Test, page 23-203
23-201
Dash Lights Brightness Control

CircuitDiagram
BATTERv rv!98:!999l99sEsr9 No.32ll00Al No.a2 t20A)

I '\_./ r-r ' |
g3ilfl$$H3il
\_--
23-202
I
I
Test Controller
Carelully pry the switches out of the dashboatd, then disconnectthe connectorsfrom them.
betweenthe C and E terminals. Measureresistance Resistanca:8- 12 kO will va.y slightlywith temperaNOTE: Resistance
IUTE.
Measure resistance between the D and E terminals while rotatingthe adjustingdial. Resistance shouldvary from O to 1O kO as the dial is rotated. 4. Turn the controlleroft (clickingsound) and check continuity betwen the B and F terminsls.There should be no continuity. lJ the controller is faulty, remove the two screws it. and reDlace
t T i- "l(
) I cANcEL\./
\ ucrtr
t0.Bwtl
23-203
DashLightsBrightness Control
Control Unit Input Test
CAUTION: a All SRS electrical wiriog harnesssare covrd with yellow outl insulation. o Befora disconnecting tho SRS wire harness. install the short connector{s) on the airbag(s) (see page 23-294t. a Rplaceth entire aflectod SRS hahoss assombly if it has an open circuit or damagod wiring. a After installing tho gauge assembly, rocheck th6 opo.ation ot th SRS indicator light. 1 . R e m o v e t h e s u b gauge assembly {see page 23-131). 2. Disconnect the 6-P connector trom the control unit. Inspectthe connectorterminals be surethey are to all makinggood contact. a lf the terminals are bent, loose. or corroded, repair them as necessary. and recheck the svstem. a l{ the trminalslook OK. make the following inDut tests at the connector. - It a test indicatesa problem,find and correct the cause,then recheckthe system. - lf all input tests prove OK, the control unit must be faulty; replaceit
3.
RED/BLU
23-204
No.
T6st condition
Test: Dsiled rsult CheckJor continuityto ground: There shouldbe continuitv. There should be battery voltage.
Possiblocaus it r6sult is not obtainad . Poorground {G401. G402, G404). . An oosn in the wire. Blown No. 42 {2O A) fuse. (ln the under-hood tuse/relayboxl light switch. Faultycombination An ooen in the wire. . An open in the wire. . Faultycontroller. . An open in the wires.
BLK 2
RED/BLK Combinationlight switch Check for voltageto ground:
oN.
RED
light switch Attach to ground:Dash lights Combination should come on full bright. oN. between Checktor resistance the REDiGRN and RED/WHT terminals:Thereshouldbe 8- 12 kO at all times, Check for resistance between the RED/BLU and RED/WHT terminals:lt shouldvary from O- 10 k0 as the dial is rotated.
RED/GRNAdjustingdial rotating. or RED/WHT RED/BLU Adjustingdial rotating. ano RED/WHT
23-205
StereoSoundSystem
CAUTION: a All SRS oloctrical wiring hamssses ara cov6r6d with yellow outof insulation, a Blore disconnocting the SRS wire hamoss, install th short connctor{s} on tho airbag(sl (soo pago 23-2941. a Replacethe ontile aftoct6d SRS harne$ assombly it it has an opn circuit or damagod wi.ing, NOTE: The radio may have a coded theft protection circuit. Be sure to get the customer'scode numberbefore - Disconnecting battery. the - Removing the No. 43 {1O A) fuse. (ln the under-hood fuse/relaybox) - Removing the radio. After service,reconnectDowerto the radio8nd tu.n it on, When the word "CODE" is displayed,enter the customer's5-digit code to.estore radio opration.
DRIVER'S DOOR SPEAKER Rspfacament, page23-215
TWEETERS
Replacement, psge 23-216
DOORSPEAKER
Repfacement,gae 23-215
STEREO
page23-210 Removal, Termioals, page 23-21 1
PLAYER
WOOFERAMPLIFIER pae 23-212 Removal, fetminal, page 23-212
23-206
Doscliption: For the desc.iption of a factory-instslled stereo radio/cassette player, please see the owner's manual. switch. lt will extendfully wheneverthe radioswitch and the igniby The oower antennais controlld the .adio ON/OFF time. When the radioor the ignitionis shut off, the antennaretractsfully. The antenna tion switch are on at the same motor has a built-inrslay together with a limit switch for this function.
A]{TEI{NA page23-214 Repfacment,
23-207
StereoSound System
(Except CircuitDiagram SevenSpeakers System)
UNOER-HOOD FUSE/ RELAY BOX
UNDER_DASH FUSE/RETAY BOX
COMBINATION LIGHT swtTcH
j"ffi**i
I I BI-U/GRN
L--------------_J
six {Wrth sp.kaE)
o
srERo RAoro/o
CASSTTE PI.AYER
-_____-__l
l-t4 8RN/B].X
I
ANTENNA ITAD
I RED/GRN
IIIRIGHT : I I ITWEETER i
I
I
AT'ITENNA IIAD GROUND 2 A 6 YEL/{VXT POWER ANTENNA MOIOR (With antonna the r6tlect6d fullvl
l7sLu/yer +fl,en
Al5 _ GRY&Hr _l_\l
lllnEAR SPEA(ER
REOTYEI 416 BRNAVHT
RIGHT REAR SPAKER
I
G401 G402 G404
23-204
System) CircuitDiagram {WithSevenSpeakers
OASH UNDER8OX FUSEJREI,AY DRIVER'SPASSENGER'S DooR 000R SPAKEFSPEAKER
YEUWTiT AI{TNNA tlA0
YEUWIfI
AMPLIFIER WOOfER
IIAD
o @
MOTOR Ai.ITENNA rcWER ctractodfully) lha {Wrth lnr6nns
StereoSound System
Unit Removal
CAUTION; a All SRS oloctrical wiring hahsses al covrad with yallow outor inEulation, a Befors disconnecting th SRS wilo harness, install the short connsctor(s) on th airbag(s) {s6o pag 23-294t. a Replacotha entiro affected SRS harness sssembly if it has an op6n circuit or damagsd wiring. NOTE: The radiomay have a codedtheft protection circuit, Be sureto get the customer'scode numbrbefore. - Disconnecting battery, the Removing the No. 43 (1O Al fuse. (ln the under-hood fuse/relayboxl - Removingthe radio. After service.reconnectpower to the radio and turn it on. When the word "CODE" is displayed.enter the customer's 5-digit code to restoreradiooperation. 2. Remove the four mounting screws and pull the radio panel assemblyout part of the way.
RADIO PANELASSEMBLY
Disconnect the connectorsand antennalead,then removethe assembly. 4. Removethe two mounting screws. then temove the stero radio/cassette player from the panel assamblv.
Remove the 1Omountingscrews,then removethe tront console.
23-210
Player Stereo Radto/Cassette Terminals
A9 -
- - - ----> A16
Connectato A1 A2 RED/GRN Right tront speakr @ BLU/GRN Le{t lront speaker (E
A3
A5 A6 A7 A8 A9 A10 A11
RED/BLK
YEL/RED YEL/WHT BLU/YEL
Lights-on signal
WHT/YEL Constant power {Tuning memoryl

ACC Radioswilched powr Left roar speaker @ Right rear speaker O Rightfront speaker O Left lront speaker O {Not used} (Not used) (Not usedl BLK Ground(G4O1,G402, G4O4)
RED/YEL
BRN/BLK
GRY/BLK
al2
A13 A14 A15 A16
GRY/WHT Le{t rear speaker O BRN/WHT Right rear speaker O
23-21
Stereo Sound System

Woofer Amplifier Removal
1 . Removethe rga. seat (seesction 20). Removethe rear seat csnter pad (seesection 20). Removethe three screws and disconnect the 1O-p connectorfrom the amplifier,then removelr.
Woofer Amplifier Terminals
WOOFER SPEAKER
Connocts lo .81
BLU/YEL
(E Lett rearspeaker
82
84 WOOFERAMPLIFIER 10-P COI{NECIOR
GRY/WHT Left rearspoaker e

BRNAA,/HT Right rear speaker O
RED/YEL
Right rear spoaker (E
YEUWHT Radio switched Dower YEUEED ACC

87 {Not used) 8LK Ground(G522)
B8 B9
810
RED WHT
(D Wooterspeaker
Wooler spoaker O
23-212
PowerAntennaMotor Test
. l. Removethe trunk right side trim panel. the 3-P connectorfrom the motor. and Disconnect removethe connectorfrom its clamp. First, check power to the motor at the connector termrnals: a There should be battery voltage between the WHT/YEL(+) and BLK {-) terminalsallthe time a There should be battery voltage between the YEL/WHT (+) and BLK {-) terminalsonly with the ignitionand radio switched ON.
View from wire side
5.
lf the motor fails to operateproperly.replaceit.
ANTENNA MAST
3.
l_ 1* ilT t fl I I r r
Sticking Antnna: The antennasticks in eitherthe up or down position. 1. Usingthe antannanut wrench. removethe special nut, spacer,and bushing(see next pagel, Clean the antenna mast housing threads, then the spacerand bushing. reinstall
2.
PLASTICSLEEVE
ANTENNA MAST
Viewfromwireside
4.
Tesl motor operation: EXTEND: Connectbatterypower to the No. I and No. 2 terminalsand groundto the No. 3 terminal. Then disconnectpower trom the No. 2 RETRACT: terminal.
5.
Usethe antennanut wrench and torquethe special nut to 2.3 N.m (0.23 kg-m. 1 .7 lb-tt). lf the special the nut is over-torqued, antennamay stick. It sticking occurs. back the nut off until the antenna moves freelv.
23-213
Stereo Sound System

AntennaMast Replacement
NOT: The antenna mast alone can be replaced without havingto removethe power antennamotor. 1. 2. Removethe specialnut, spacer,and bushing. Carefullywithdraw the antennamast while extending it by turning the radio switch ON. Hold the new antenna so the teeth on the drive cable face in the directionshown, and insen the drive cable into the antennahousino.
(3
\,.-
g.-
SPECIALtIUT SPACER
BUSHII{G
ANTENNA MAST DRIVE CAELE
ANTENNA wRENcH / ,-/ oTJAA-OO10{)08
4.
Check for engagsment of the cable teeth to the drive gear by carefully moving the cable up and down, Turnthe radioswitch "OFF", and let the motor pull the drive cable insidethe antnnahousing.
o-
Cleanthe threadson the antennamast housing. Insert the antenna mast into the antenna housing, install the bushing and spacer, and tighten the spcialnut to 2.3 N.m (O.23kg-m. 1.7 lb-ft). NOTE: It th specialnutis overtorqued, antenthe n8 may stick, lf sticking occurs, back the nut off until thg antonna moves lrselv.
SPECIALNUT
2.3 N.m 10.23 ks-m,1.7 lb-ftl TEETH
8 . Check thst th6 sntenna mast retracts and extends

fully whn th radio switch is turned ON and OFF repeatedly.
POWENANTENNA MOTOR
23-214
PowerAntennaMotol Replacement
Remove the trunk right side trim panel. Disconnect the 3-P connector and antenna lead from the motor, thn remove the special nut and mounting nut, and take out the motor with the antennamast,
RePlacement DoorSpeaker
Remov the door panel.
2 . Rmov6the tour screws, then disconnectthe 2-P

connoctor from the speakr, and remove the soeaKer,
OTJAA-OOIOOOA
(0.23 kg-m, 1.7 lb-ft)
SPACER
ANTENT{A LEAD
colrr{EcToR
DRAIN HOSE MOUNTING NUT
MOTOR BRAC(ET
When installing the new antenna, tightsn the special nut first, thon tighten the mounting nut on the motor brackt.
23-215
StereoSoundSystem
RearSpeaker Replacement
1. Removethe three nuts from insidethe trunk, then disconnectthe connectorand removethe speaker assembly. Speeren lsseireLv / REAR LEFT
Tweeter Replacement
1. Carefully pry the tweeter cover out of the dashboard.then disconnectthe connectorsfrom the soeaker.
LEFT TWEETER COVER
Removethe two screws and removethe tweeter from the cover.
Removethe three screws from the adapter,then removethe speakercover. Remove three screws,then removethe soeaker the f.om the adaDter,
23-216
Woofer Replacement
Removethe rearseat uppertrim panel(seesection 201.
REARCONSOLEPANEL
Remove the four screws and disconnectthe 2-P connector from the speaker. then replace the sDeaKer,
WOOFERSPEAKER
2-P CONNECTOR
23-217
Clock
GircuitDiagram
FUEI EilGlNE dd CooLAi{T TEIIIPMruNE IECT1 COMTROL CIRCUTT
COi'|EI{ATON UGXT S1VITCH
V I
REO/Bt.K
8t'|(
r vaa i llFla httd! on thd lwltdt do mt tlLr to th. v*iclo loood lartsr.
G401 G402 G404
23-218
Removal/Terminals
CAUTION: a All SRS ol6ct cal widng hamosses are qovorod with yollow outef insulation. a Betor disconnecting tho SRS wire hahoss, inslall the short connector(sl on th airbag(s) (see page 23-2941. o Reolacotho entire affectod SRS harness assembly it it has an open circuit or damagod wiring. a Aft6r installing tho gauge assombly, rechock tho oporation of th6 sRs indicator light. Romoval: the right tweeter cover (seepage23-130). I . Remove 2. Remove the instrument panel visor (see page 23-130). Removethe black Jacepanel (seepage 23-130). Remove the sub gauge assembly (see page 23-131).
3. 4.
F5<- - -Fl
Yry
Terminals: Tsrminal wira F1 F2 BLK LT GRN Ground
Trminal Connectato
Connocts to Ground .,OO" SET , , H ' 'U P
light switch RED/BLK Combination
G3
G4 G5
F3
F4 F5
YEL
Displayconttol circuit lG1 (Main clock power supplyl
__
___--__-.--,,M" UP
WHT/YEL Constantpower (Time memorY) NOTE: Theseletters on the switch do not refer to the VehicleSoeedSensor.
23-219
Horns
Component LocationIndex
a All SRS olectrical wiring hahsses aro coverod with yollow outer insulation. a Beforo disconnecting the SRS wire hamss, install tha short connecto.{s} on the airbagls) {see page 23-2941. a Roplacothe ontire afloctod SRS harnossassombly il it has an open cilcuit or damagd wifng.
. HORNS fesi, page 23-221
HORN SWITCHES Tesr, page 23-222
I
t
REEL
fesr, page 23-222
23-220
CircuitDiagram
Test
I tf*";l
WHT,^YEL - WHT/YEL
BATTERY
1.
Disconnect ths 2-P connector and remove the norn. Test the horn by connecting batte.y power to one terminaland groundingthe othr. The horn should sound.
2.
+
UGTIT
HORN
2-PcOlrllrlECTOR
3,
lf it fails to sound; replaceit.
23-221
Horns
Switch Test
cAUTtOt{: a All SRS oloct cal whlng hamosaeaa.o coyorod whh yellow outer insulstion, a Bloro disconnocting the SRS wlro h!me3s. insiall iho shon connector(sl on tho alrbag(ll (rce page 23-2941. a Replacothe ntirr aftectod SRS hamoss a$embly it it has an open clrcuit or damagod widng, NOTE: The radio may havo a coded theft protection circuit. Be sure to get the customer's code number before - Disconnecting the battery. - Removing the No. 43 (1O Al tuse. (ln the under-hood fuse/r6laybox) - Removing the radio. After servica, reconnect powr to the radio and turn it on. When the word "CODE" is displayed, ent6r the customer's 5-digit cod to restore r8dio operation. 5. Installthe short connectoron the airbagconnector.
AIR BAG
CONNECTOR
/ SHORT
ACCESS PANEL
6 . Romove the dashboard lower cover.

7. Disconnectthe cable reel 6-P connectorfrom the SRS main harness, then connect Test HarnessC onlv to the cable reel side of the 6-P connector.
Disconnect the baftery negative cable, and then positive cable. Make sure the wheels are turned straight ahead. Remove the two scrows and accoss panel, th6n remove the short connector trom the acc6ss Danel, 4. Disconnsct the airbag connctor and cabl reel connector.
23-222
8 . Checkfor continuitybetweenthe No 3 terminalof

the 8-P connector of Test Harness C and body ground with the horn switch pressed.
1O. Remove the two TORXo bolts using a TORX@ T3O bit, then removethe driver'sairbagassembly.
TEST HARNESSC OTLAZ- SL/O3oo
? CONTINUITY
AIRAAG ASSEMALY
U3o a TOBXo T30 blt CONTROL CRUISE SET/RESUME
a lf there is continuity,the horn switch is OK a lf there is no continuity,go to step 9. 9. Carefullyremove the cruise control SET/RESUME switch cover by prying between the cover and shown. switch in the sequence
swlrcl{ covER 11. Checktor continuitybetweenthe horn positiveterminal and steering shaft with the horn switch pressed.
cRutsE cot{TRoL
SET/RESUME
swtTcH
HORf{ TERMII{AL POSITIVE
cRursE
CONTBOL SET,/RESUME swtTcx covER
STEERING SHAFT a lf there is continuity; - Checkthe cable reel. - check the SET/RESUME switch. the horn switch a lf the.e is no continuity,replace (seesection 17).
23-223
Gigarette Lighter
CIGARETTE LIGHTER Repf acement, page 23-226
fwrc cotolt:Veuneo,wxrlglu) .nd IBLK, WHT/RED I '2

\esr, page 23-70
CIGARETTE LIGHTER RELAY{A-tyDl
-rl -D
,__"_ * ccL___J nllfl|.|
r-:-r- l f---l -L ----------rl
ummmml
l1[0mm[[il]
23-224
CircuitDiagram
FUSE/REI.AY BOX U DER-HOOD
tct{utoN swtTcH
_ DASH UNOER FUSE/RELAY 8OX
adf**'*
wHIiBLUTwHr/BLU
6i\\
YEURED
I
I
STEREO RADIO/ PITYER CASSETTE
Bu(
G40t G402 G404
BI.K
G40r G402 G404
23-225
Lighter Gigarette
Replacement
CAUTIO : a All SRS olsctdcal widng hamesses arc covsrsd with y6llow outer insulation. a Boloro disconnecting the SRS wire hamess. install iha short connector(s) on tho airbag(s) (see page 23-2941. a Replacatho ontira affoctod SRS harness arsombly if it has an open circuh or damaged wiring. NOTE; The radio may have 8 coded theft protection circuit. Be sureto get the customer'scode numberbefore - Disconnecting battery. the - Removing the No. 43 (10 A) fuse. (ln the under-hood fuse/.elaybox) - Removing the radio. After service, reconnect power to the radio and turn it on. When the word "CODE" is displayed, enter the customer's 5-digit code to restoreradioopgration. 3. Disconnect the thermofuse housing flom the socket. CIGARETTE LIGHTER
UGHT{1.4W
4.
Remove the ring nut and sparate the cigar6tta lighter socket trom the thrmal protector. Wh6n installing the cigarette lighter, align ach lug on th face pansl, illuminstion ring, and cigarette lighter socket with the groove in the hole, then position the bulb housing on ths thermal protector hw66n ths stops in the radio panel,
SRS MAII{ HARI{ESS
6 . Mak sure that the ground wire, bulb sock6t, and

l. Removethe front console{seesection 2O}. Remove the radio panel assembly (see page 23-210t. thermofuse housing are sested against the cigartte lightsr assembly.
23-226
RearWindow Defogger
CAUTION: a All SRS electdcal wi ng hahosses ale covared with yellow outor insulation. a Beforo disconnecttng the SBS wile harne$, install the short connactor on tha airbag(3), then disconnect the wiro hamess (se page 23-294). a Replacoth6 entira aft6ctd SRS harnessassembly il k has an open circuii 01 damagod wi ng.
REARWINDOW SWITCH DEFOGGER Test, page 23-230 23-230 Replacement,
sRs MAII{ HAR]TESS
BOX UNDER-DASHFUSE/RELAY
wftDow
DEFOGGER RELAY (A-Typ6l
Test, psge 23-7'l OEFOGGER REAR Function Test, page 23-231
DEFOGGER
CIRCUIT {ln the integrated control unit} fnput Test, pago 23'170
control unit. When the defoggerswitch in th heatercontrol The rear window defoggeris controlledby the integrated controlunit and the defoggerstayson for about panelis pushed,it sendsa signalto the defoggertimer in the integrated 25 minutes,or until the ignitionis switchedoff. The indicatorlight in the switch comes on when the defoggeris ON.
RearWindow Defogger
Circuit Diagram
UTIDERIIOOD FUSE/NELAY 8OX
swncH
IGNITION
UiIDER_ DASI{ FUS]REI,AY 8OX
ll .m.lconrEtfunl COMBINANON UGHT S1ITTCH
HEANN COiITROL PAiIET
BTJqGRN
+
BU(
G801
G4o1 G402 G404
G401 G102 G10,1
DASH UGI{TS ERIGTTT ESS COMTROL UNIT
23-228
Troubleshooting
sequence. NOTE: The numbsrsin the table show tho troubleshooting
Item to be insDected
? ; 6 9 E e ! G S ,:o
ID l t o
3;
{ a
5o-
a.: a e
o+ o+
- 9
<
o
(t
T8
!li i E --c
g o o x
3
o
lo
.E
o,; 2 t c 9 . !
.FE: a
o c
o o
Symptom Defogger works, but indicator light dogs not go on. Oefogger does not work and indicator light does not go on. Defoggor doas not work, but indicatorlight goes on.
3 o
6
z a r 9 ; i
z c 3 9
1 q i c
9 o
c
o c
z c 3 9
a g i c
ot
o)
o E o-
co
5E
BLK/YEL' YEL/GRN
YEL
3 3
1
G401 BLK/GRNI, G402 YEL/WHT G404 BLK/GRN' G801
Defogger-on time too long or too short compared with the normalON time (25 minutes).
G401 G402 YEL/WHT G404
23-229
RearWindow Defogger
Switch Replacement
1. 2, Removethe front console(seesection 201. Remove the stereo radio/cassette player (s66 page 23-21Ol. Disconnect the air mix cable from the heater. \ Terminal t".*"__\ ON OFF
Switch Test
Removs th heater control Danel. Check for continuitv between th terminals according to the table.
3.
t1
14
l6
l2
-o
BEAR YVITDOW DEFOGGER SWITCH
ASSEMBLY
Remove the two mounting screws and diaconnect the connectors, then remove the hester control paner. Install in the reverse order of removal.
o.
After installing the control panel, connect the air mix cable (see section 22), and mak sure the temperature control function works correctly.
23-230
FunctionTest
CAUTION: Be careful not to scratch or damago tho defogger wires with ths toster p1ob6. 1. Check for voltage between the positive te.minal and body ground with the ignition switch and deloggerswitches ON. There should be battery voltage. a lf there is no voltage,check for: Faulty defogger relay. Faultydefoggerswitch. Faulty integrated control unit. wire. An ooen in the GRN/BLK
Wires Repair Defogger

NOTE: To make an effective repair, the broken section must be no longerthan one inch. 1. Lightly rub the srea around the break with tine steel wool, then clean it with alcohol. Carfully mask above and bslow the broken portion ot the defogge. wire with cellophanetape.
2,
a lf there is battery voltage, go to stp 2. TERMIIIAL POSMVE
TAPE
Using a small brush, apply a heavy coat of silver conductivepaint extendingabout 1/8" (3 mm) on both sidesof the break.Allow 30 minutesto dry. NOTE: Thoroughlymix the paint before use. Check for continuity between the negative terminal and body ground. It there is no continuity, check for an open in the defoggerground wire. Touch the voltmeter positive probe to the halfway point of each defogger wire and negative probo to the negativeterminal. There should be app.oximately 6 V with the ignition switch and detogger switch ON. a lf the voltage is as specified, the defogger wire is OK. a lf the voltage is not as specified, repair the defogger. - lf it is more than 6 V, ther is a break in the negativehalf of th wire. - lf it is lss than 6 V, there is a break in the Dositivehalf of the wire.
4.
wire. Check lor continuityin the repaired Apply a second coat of paint in the same way Let it drv three hours before removing the tape.
23-231
(Canadal SeatHeaters
SEATBACKHEATER Test,page23-236
SEAT HEATERRELAY Test, page 23-236
SEATHEATER MAIN RELAY lA typ6l Test,page23-70
SEATCUSHIOT{ HEATEN
Test, pago 23-236
SEAT HEATERSWITCH Test, page 23-235 Replacement.page 23-235
Description
Two heatersare providedin each front seat; one in the seat cushion and another in the seat back. In normal use, temperature automatically is controlled the thermostat[OFFabove104oF {40oCl] built into eachseatcushionheater. by Breaker1 [OFF above 'l22oF (50oC)l and breaker2 IOFFabove 158"F (70"C)1cut ott the circuitto preventabnormal temoeraturerise.
23-232
CircuitDiagram
BOX FUSEfrELAY UNDER.HOOD IGNITION SWITCH
BOX OASH FUSE/RELAY UNDER-
MAIN HEATER RELAY SEAT
R.SEAT HEATER SWTCH l 1 8LK
TI
t l l l
BLK
-t
REI.AY HEATER C R,SEAT
8 LK
I
I r i
CUSHION R.SEAT R.SEATHEA]ER
rr
lrt.----J
| I
i Ii
r r
|
r > r < r l
| O l
i1
i |
l l
I
i i
L.SEAT CUSHION
i 9l ! 8 8 , I t ' i
i
BACK L,SEAT
f o**..IJ
BLK _lr
BRI : BREAKEROFFdbove122'F lSOc)l I {4Oc)] TH1 : THERMOSTAT IOFF above1O4oF BR2: EREAKEROFFabove158oF(7Oc)l I
G521
23-233
(Ganadal SeatHeaters
Troubleshooting
NOTE: The numbersin the table show the troubleshooting sequence,
Item to be insDected
o ! 9 <
s o
r 6 < E < c v ;
F
<
^ O
3 6 or )f6 (
Z J
- 7
CI
3
(D
Symptom Seat heaters work, but indicator light does not go on. Seat heaters do not work and indicator light does not go on.
z c 3 9
6 =
t q i c
z )
--c
o ro o
@
(D
'oE
o <t
i Co o 1
o*g BLK
G401 G402 WHT/BLK, BLK/GRN G404 YEL/BLK, WHT/RED G521
Seat heaters do not wo.k, but indicator light goes on.
Left or right seat
GRN/WHT, WHT/GRN, BLU, WHT/RED, WHT/BLU

BLU, GRN
Seat cushion heater or seat back hearer does not work, but indicator light goes on.
23-234
Switch Replacement
1 . Pry the switch out ol the center consolepanel. the 6-P connectortrom the switch. Disconnect
Switch Test
1. Remove the seat heater switch Jrom the console. Check to, continuitybetweenthe terminalsaccording to the table. Torminal Position ON OFF
2. 6-P CONNECTOR
oo-
a\
\7 Z\ \7
--o --o
6t
NOTE: Left and right seat heaterswitches are the same. 6
INDICATOR t|Gt{T l0.84wl
23-235
Seat Heaters(Canada)
HeaterTest
1. Disconnect the 6-P and 4-P connectorsas shown below. NOTE: Left front seat is shown. Rightfront seat is similar.
Seat Heater RelayTest

Remove the soat, then rsmove the relav from the bottom of ths seat. Check continuity between relav terminsls. a Ther8 should be continuity between the F and A terminals, and the C and D terminals when power and ground are connected to th F 8nd E terminals. a Th6rs should be continuity between the F and D t6rminals when power is disconnected.
wire side
6-P CONNECTOR
SAT HEATER RELAY
To FLOOR HARNESS
F+P
D E F
wire side
r!+41
Soat cushion hoata.: Check for continuitybetweenthe No, 2 and No. 3 terminals(R x 103scale). Thsre shouldbe continuity. Seat back hoatel: Check for continuitybetweenthe D and No. 8 terminals(R x 103scale). There shouldbe continuitv.
NOTE: Left and right ssat heater relavs are the same.
'T t_i ,y'

t-F---------to <f
Irr
( J
-
rT
23-236
Sunroof
LocationIndex Component
a All SRS olsctricsl wiring harnossesaro coveled wlth yollow outer insulation. a Botob disconnecting tho SRS wire ha;noss, install ths short connector(s) on tho airbag(s) (soe pag6 23-294t. a Replacetho entiro affsctod SRS harnessassembly if h has an op6n circuit or damaged widng.
SUNROOFMOTOR Test, page 23-241
SUNROOF CLOSE RELAY {B typo} Test, Pag
JD
sut{RooF RELAY OPEI{
r:-l I r llfll-l
(B-typ.) Tost, page 23-72
CC
m[[[[I] |lm[
mmm|] llm[
23-237
Sunroof
CircuitDiagram
COMEINATION UGHT SWTCH
V
nED/Bu(
I I
I
I
l.
I A I RqD
OASH UGHTS ERIGHTNESS CONTROL UNIT
23-23A
Troubleshooting
sequence' NOTE: The numbersin the table show the troubleshooting Item to be insocted
sE>
;,d Q bg og o!D
@ ID
gE
6 8 9 5 b E o o = ! o < E
b= 6t' o o - l 9 2 x !. Y v F 2
6 > ( a (t;
e Y
aeg
Y 6
5 8 . .6 5 o
F.6
r.. !
I 3
g
ID 0)
Symptom Sunroof does not move, tuns. Sunroot does not move and motor does not run (sunroof can be moved with sunrootwrench). but motor With either switch.
9i b d 6 6
1
; z a z ) z ) c!P 6 =-c ; ! i ! ; -9c 9 c
E 3
- c
rL
(L
G401 BLK/YEL, G402 or GRN/YEL G404

GRN/RED or GRN/YEL GRN/REO
WHT/BLU,
With OPEN switch.
1 1
with cLosE
switch.
o G R N / R E Dr GRN/YEL
23-239
Sunroof
Switch Test/Removal
'1. Caretullypry the switches out of the dashboard, then disconnectthe connectorsfrom them. 3. Ch6ck for continuity between the terminals in each switch position sccording to the table.
rormrnal Position OFF \
o
G" @
G
A
o
-o o -o -o
OPEN
ctosE
A B
c
2. Removethe sunrool switch from the switch o8n6l. D E
) ucHT t)
t1.1wl
23-240
Motor Test
Removethe high mount brake light cover' Remove the headliner,then disconnect the 2-P connectotfrom the sunrooJmotor. Test the moto. by connectingpower and groundto the 1 and 2 terminalsaccordingto the table. The motor shouldrun smoothlY. NOTE: Motor clutch test is in section20
OPEN CLOSE
No. 1 terminalto ground No. 2 terminalto Power No. 1 terminalto Power No, 2 terminalto the ground
2.P CONNECTOR
wire sid6
2.P CONNECTOR
lf the motor does not run smoothly,replaceat
23-241
PowerMirrors
CAUTIOT{: a All SRS olectrical wi ng harnsssos a.e coverod with y6llow outol insulation. a When disconnecting th SRS wiro harness, install the short connector on th8 Eirbag(s)then disconnect tho wire hamess lso pago 23-2941. a Replacthe ontirs affected SRS hamess assembly if it has an open circuit or damaged wiring.
POWER T'IRROR SW|TCH Test, psge23-245
POWER MIRRORS Test,page23-247 Repf acement, page23-247
23-242
(USA) CircuitDiagram
UNDER.HOOO 8OX FUSSRELAY
ryIl' fffi,'' ffi,'oo;l --*-{$S,lfSl
eF["*lT
-f
UNDENOASH FUSgREtAY BOX
SWTCH POWEN MIRNOR
r l
__________Jr
l i
/tt-----_---_-------:tl\
R.rcWER MIRROR
Grc1 G,to2 G1o4
23-243
PowerMirrors
(Canada) CircuitDiagram
- r.tooD uriDER R,SE/REIAY BOX
*rrr
|.*-;iôJ;l tr00A) t50At
tt)-flo<\!twdT-l
r/ aXr \ rcnrlor
\
\l-/
I
lG2 , sl{lrcH
/EL
I lm lili,tf,"e$"
BIJ(/YEL POWER MIRRON SWTCH
OErcGGER
DOWN
23-244
SwitchTest
1. Remove the switch as described under ,,FUNCTION TEST". 2. Checkfor continuitybetweenthe terminalsin each accordingto the table. switch Dosition
Mirror SrYitch \ lermlnal \ I
10
Position
OFF
oooG-
-o -o
-{.}
UP
_o _o
LEFT T I
DOWN
o- -o oG-
UP
---I NIGHT
tEFI
oo-
-o -o -o -o -o
-{.}
RIGHT
OFF
oooooo-
r l l l LL__-___IJ
UP
=o
L l l R L l I R
DOWN
o- -o oo-o _o
-o -o
UP
LEFT
RIGHT
oeroccen ( \ swrTcH y'

Dofoggor Switch(Canada) \ lermlnal Position ON
OFF
,{l
I l
l0
"'i
I I L
RIGHT
i
I
z \ l -
lvOEFOGGER I
I rNDlCAloR | (rED)
o-
o-
-o --o
;}T l*-T-;-f E ;f,
i
J
, ? ' 1 ,. ? ' 1 ,
23-245
Power Mirrors
Function Test
Carefullypry the switch out ot the door panel. Oisconnect the connectorsfrom the switch, a lf the mirrorneithertilts down nor swings left, repair thE YEL/BLU \,virE. a lf the mirrorworks properly, checkthe mirrorswitch. Right mirlol inopemtiv: Connectthe BLK/YEL terminalot the 1O-pconnectorto the GRN/BLU terminal and the BLU/ORN BLU/BLK} {or terminalto body ground with jumper wires. The right mir.orshouldtilt down (or swing left) with the ignitionswitch ON. a It the mirror does not tilt down (or does not swing left), removethe right door panel and check for an (or open in the BLU/ORN BLU/BLK) wire betweenth right door mirror and the switch ll the wire is OK, check the right door mirror motor, a lf the mirrorneithertilts down nor swings lsft, repair the GRN/BLU wire. a lf the mirrorworks properly, checkthe mirrorswitch.
---)
Defogger test (Canadsl

NOTE: Checkthe No. 9 {15 A) Iuse in the under-dash Juse/relaybox betore testing. 1. Check for voltage between the BLK/YELterminal of the 2-P connectorand body ground with the ignition switch ON. There should be battery voltage. a It the.e is no voltage, check for an open in the BLK/YELwire between the under-d8shJuse/ felay box and the detoggerswitch. a lf there is bsttery voltage, go to step 2. Connectthe BLK/YEL terminalof the 2-p connector to the ORN terminalwith a jumper wire. Both the right and left mirro.s should g.adually warm up with the ignitionswitch ON. a It neitherwaJms up, repairthe ORN wire. a It only one fails to wa.m up, check its mirror defogger efment lsee page 23-2471. a lf both warm up, check the switch,
viw trom wire side.
lcansda)
MirrorTest
One or both inoporative: 1. Check for voltage between the BLK/YEL terminal and body ground with the ignitionswitch ON. The.e should be battery voltage. a lf there is no voltage,check for; - Blown No. 9 (15 A) tuse in the under-dash fuse/relaybox. - An open in the BLK/YEL wire. a lf there is baftery voltage, go to step 2. 2. Checkfor continuitybetweenthe BLKte,minaland body ground. There shouldbe continuity. a lf there is no continuity,check for; - An open in the BLK wire. - Poor ground (G4O1.c402, G404).
2.
Loft mirror inoDorativ: Connectthe BLK/YEL terminalot the 1O-pconnectorto the YEL/BLU (or terminat.and the BLU/ORN YEL/GRNI terminalto body ground with jumper wrres. The left mirrorshouldtilt down (or swing leftl with the ignitionswitch ON. a lf the mirror does not tilt down (or does not swing left), remove the left door panel and check tor an open in the BLU/ORN YEL/GRN) {or wire betweenthe left door mirror and the switch. lf the wire is OK. check the left door mirrormotor.
23-246
PowerMirrorMotor Test
1. C8rfullypry out the window corneJpanel with a flat tip screwdriver.
PowerMirrorReplacement
NOTE: Be{ore removing the mirror, lower the window tully. 1. Carefully pry out the window corner panel with a flat tip screwdriver. Removethe door Panel. Disconnect the 3-P or 6-P connctor from the mirlor. While holdingthe mirrorwith one hand,removethe three mountingscrews with the other.
2 . Removethe door panel.

Disconnect the 3-P or 6-P connector from the mirrot.
2. 3.
4.
3-PCONNECTOR 6-P CONI{ECTOR (Canadal tusAl
@-
4.
Test actuato. operation: Connect batterv power to the No. 3 terminaland groundto the No. 4 terminal. Connect battery powel to the No. 4 terminaland groundto the No. 3 terminal. Connect batterv power to the No, 4 terminaland groundto the No. 5 terminal. Connect battery Power to the No. 5 terminaland groundto the No. 4 terminal.
TILT UP
TILT DOWN
SWINGLEFT
SWING RIGHT
5.
Checktor continuitybetweenthe No. 1 and No. 2 terminals{RX 103scale). There shouldbe continuity.
23-247
Power Windows
PASSENGER'S WINDOW SWITCI{ Test, page 23-252 Repfacement,page 23-253 PASSENGER'S WINDOW MOTOR Tost, page23-254 Replacement,section 20
ORIVER'S WINDOW MOTOR Test,pago23-254 Replacement, section20
InputTest,page23-251 Tosr,pag 23-252 page Repfacement, 23-253
POWERWIITDOWSWITCH
E=E !
KEY.OFFTIMER CIRCUIT {ln th integratod control !nit) Inputtest, p8ge 23-168
E1El
UI{OER.DASHFUSE/RELAY BOX
Description
Power Window Key-olf Timr Oporation: The power windows can still be operated aboul 1Ominutesafter the ignitionswitch is turnedfrom the " " to the ,,1,, tor or "O" positionas long as neitherdoor has been opened.This providesa convenience parkedoccupanrs. to
23-248
CircuitDiagram
BOX FUSE/RELAY UNDER_HOOD
ernenv llffif-ffifl
@wnolu \:_/
wtNDow
PASSNGER'S WINDOWMOTOR
23-249
Power Windows
Troubleshooting
NOTE: The numbe.sin the table show the troubleshooting sequence. Item to be insoctod
! !
! ! g
E ! 9:.\
3E
.E
3
! o
c\
] ' '
ae
s 6 .. ( 9 I6 z )
Symptom Neither window works. 1 Driver'swindow does not work. Drivr's window does not work in AUTO, Passenger'swindow do6s not work. One or both windows do not work within 1O minuresaftr the ignition switch is OFF. 1
o (\
C;
3 i ;
,
E
E 3
ID
i i
ID
t
o
3 i
t
(D
.= i 3
'P 3Oo
P !
e E ! i : 9 0
ttt a
3 ! 9 c
El=
c g
o o
@
't
9 i o
Y =
g 8
- c
' o 2
3 ' (D .o
.z
o-
{ , o oc'
3 4 2
1
a
G401 G402 GRN/BLK G404 WHT/BLK

BLU
BLU/BLK
J
23-250
NOTE: The control unit is built into the master power window switch, and onlv controlsthe driver'swindow.
'1.
1O-PCONNECTOR 3-P CONNECTOR
Removethe driver'sdoor handlepaneland disconnect th 1O-P8nd 3-P connectorsfrom it. lnsoectthe connectorterminalsto be surethey are all makinggood contact. a lf the terminals are bent, loose, or corroded, reDair them as necessary, and recheck the sYstem. a It the terminalslook OK, make the tollowinginout tests at the 1O-Pconnectol - lf a test indicatesa ptoblem,{ind and correct the cause,then recheckthe system. - lf all input tests prove OK, the control unit must be faulty; replace the master power window switch.
ELKI BLK' BLU/BLK lrom wire side RED/YEL WHT/BLK BLU/YEL
No. 1
Terminal BLKl
Test condition Under all conditions.
Test: Desirsd rssult Check for continuityto ground: There shouldbe continuity. Check for voltageto ground: There shouldbe battery voltage. Checkthe driver'swindow motor: lt shouldrun.
Possiblecause if rosult is not obtained . Poor ground (G4O1 G4O2,G4O4) , ' A n o p e ni n t h e w i r e . '16 {2O A) fuse. Blown No. 1 5 or (ln the underdash fuse/relaY boxl Faultypower window relaY. An open in the wire. . Faultydriver'swindow motor. . An open in the wire.
WHT/BLK lgnitionswitch ON.
BLU/BLK RED/BLU connect the wHT/

and RED/YEL
BLK terminalto the terminal, RED/BLU terand the RED/YEL minalto the BLKI terminal,then turn the ignitionswitch ON. terminalto the BLU/ GRNterminal,and the terminalto BLU/YL the BLK terminal, then turn the ignition switch ON. connect the wHT/ BLK terminalto the terminal, RED/YEL terminal and the BLK2 terto the RED/8LU minal,then turn the ignitionswitch ON.
window BLU/YEL Connectthe BLU/BLK Checkthe passenger's

ano BLU/GRN
motor: lt shouldrun.
window motor. Faulty passenger's window switch. Faultypassenger's An open in the wire.
BLU
ano
BLK'
Connectan analogohmmeter terminals: to the BLU and BLK2 The meter needleshouldmove back and forth as the driver's window motor runs.
Faultypulser. Faultydriver'swindow motor. An open in the wire.
Power Windows
MasterPowerWindowSwitch Test
1 . Removethe driver'sdoor handlepaneland discon-
Passenger's Window Switch Test

'1. Carefully remove the passenger's door handle panel from the door, then disconnect the 5-p conneclor. Checkfor continuitybetweenthe terminalsin each switch positionaccordingto the table.
nect the 1O-Pand 3-P connectorsfrom it.
Check{or continuitvbetweenthe terminals each in switch positionaccordingto the table.
2.
DRIVEB'S SWITCH OOORHANDLE PANEL
WINDOW oooR HANDLE PANEL PASSENGER'S
MAIN SWITCH
MASTER POWER
wtNDowswtTcH
E F G H I J
Ddvo?'s Switch
\ Terminal
Position OFF
T""ryl \_____
Position
UP DOWN (AUTo) DowN
--o o- --o oo-o
UP
OFF
00wN
--o o- --o o- --o -o oo-
Passong6r'sSrvltch \ rermrnal
switch\ PositlonI Main ON

OFF
OFF ON
OFF
UP
DOWN
ON
OFF
--o o- -_o o- --o --o o-o- --o -o --o o--o o-
23-252
Switch Replacement
Maslcr powor window swilch: 1. Removethe mounting screw and pry the driver's door handlepanelout of th door panel, 2. the 10-P and 3-P connectorsfrom it' Disconnct
3.P CONNECTOR
Passangor'awindow Swhch: 1. Remove the mounting screw and pry th passenger's door handls panelout ot the door pan8l' 2. the 5-P and 3-P connectorsfrom it. Disconnect
5.P CONNECTOR
DOOR DRIVER'S PANEL HANDLE
DOOR PASSENGER'S PANEL HANDLE window switch from tha Removethe passenger's door handle panel by removingthe two mounting screws.
3.
Removethe master power window switch from the door handle panel by removingthe four mounting screws.
MASTER POWER
3.
wtNDowswlTcH
WINDOW SWITCH PASSEI{GER'S
DOOR HANDLE PANEL
23-253
Power Windows
Driver'sWindow Motor Test
Motor Tast: 1. Rmovethe door panel (seesction 20). 2. 3. Disconnect the 4-P connctor from th6 motor. Tst motor operstion by connecting battery power to the No. 3 terminaland g.oundingthe No. 4 terminal. T6st the motor in each direction bv switching the lesds. lf the motor does not run, reolaco it. Tsst motor operation by connecting power and ground to the No. 1 and No. 2 tsrminals.Test the motor in each dirctionby switchingthe leads. 4. lf the motor dos not run, rDlaceit.
Passenger's Window Motor Test

Romove the door panel (see sction 20). Disconnect the 2-P connector from the motor.
4.
View lrom wire sido
Pul3.r Tcst: Connoct the test leads of an analog ohmmtor to ths No. 1 8nd No. 2 terminals. Run the motor by connecting power and groundto th6 No. 3 8nd No. 4 terminals. The ohmmeter needl should move back and forth Es the motor runs.
wtN00w
Irl0TOR
PASSoIGERS
23-254
Power Door Locks

LocationIndex Component
CAUTION: a All SRS aloctdcal wiring harnsssare covrd with yellow outer insulation. a Bofore disconnectitrg tho SRS wire harness. install tha short connoctor on th6 airb8g(s)th6n disconnoct tho wir harnoss (s8e pags 23-2941. a Replacethe ontiro aftscted SRS hamess assembly it it has an opsn circuit or damaged witing.
DOOR LOCK SWlTCtl Test, page 23-262
SWITCH KEY CYLINOER PASSENGER'S Test, page 23-26'l DOOR LOCK ACTUATOR PASSEI{GER'S Test. page 23-261 section 20 RDlacement,
U'{IT CONTROL Test, page23-258 tcl{lTrol{ KEYSWITCH 23-171 Test,page
DRIVER'SOOOR LOCK ACTUATOR
and LOCKKNOBSWITCH Test, paee23-260 section20 Replacement,
23-255
PowerDoorLocks
CircuitDiagram
- HOOD UNOER FUSE/BEIAY 8OX
PoIYER tocKcoNlrot u n 000R
lGNlTlot'l KEY
8l PASSENGER'S lpAssENGR.s 3 5 N l,, I 000RKEY | 00oRtocK ' I SWITCH I CYUNDER PASSNGER'S I I SWITCH
swtTcH
3fi'f;.'.|
8LK
Troubleshooting
sequence. NOTE: The numbersin the table show the troubleshooting Item to be insoected
d q
! o, !n o,
i 3
* R t 5
r o
3 3 3 I 3
I
< o l
{ 6 2 ) Symptom Power door lock system doesn't work at all. Doorsdon't lock or unlock with the driver's power door lock switch. Both doors One ooor Both doors One door Both doors One ooor Both doors One door 1
1
o
o > o
o
9 c
- f
8
O Y
5 5
o-
IL
(L
o
G401 G402 W H T G404 G401 GRN/WHT G402 or GRN/RED1 G404
YEL/RED or WHT/RED
Ooorsdont't lock or uFlockwith the passnger power s door lock switch. Doorsdon't lock with th driver's door lock knob. {lgnitionkey not insertdand doors closed.l Doors donit lock or unlock with the passenger's door key cylinderswitch.
G401 BLK/WHTor G402 BLK/RED G404

YEL/REO or WHT/RED
G401 BLU/RED or G402 BLUiWHTI G404

YEL/RED or WHT/RED
2 3
I
G401 BLK/RED or G402 BLK/WHT G404

YEL/RED or WHT/RED
Doors will lock when the kev is still in the ignitionswitch and the driver's door is ooen.
G 4 0 1 BLU/WHT' G402 G R N / R E D ' G404 or GRN/BLU
23-257
Power Door Locks

ControlUnit InputTest
Removetha driver's door panel {see section 20) and disconnect the 18-P connector trom the power door lock control unit. Inspectthe connectorterminals be surethey are to all makinggood contact. a It the terminals are bent, loose, or corroded, repair them as necessary, and recheck the svstem. a lf the terminalslook OK, make the following inout test at the connectorterminals. - lf a test indicatesa problem,Jindand correct the cause.then recheckthe system. - lf all ingut tests DroveOK, the control unit must be taulty; replaceit. NOTE: Different wires with the same color have beengiven a numbersuffix to distinguish them {tor and GRN/RED,are not the examole, GRN/RED1 same).
POWER DOORLOCK
1A.P CONNECTOR
View from wi.e side
BLU/WHTI
GRlII/wXT
BLK/WHT
BLU/WHT'
23-258
Disconnect the 1
No.
1
connecto?from the control unit.

Test condition Test: Dosi?adresult Checktor continuityto ground: There shouldbe continuitv. Possibli caus6 it rosult is not obtainod . Poor ground (G401, G4O2,G4O4). . An ooen in the wire. . Fauly actuator. . An open in the wire.
Wile
BLK
WHT/RED connect the YEL/RED Check door lock operation: All doors shouldunlock. ancl terminalto the WHT YEL/RED terminal,and the WHT/REDterminalto the BLK termlnal momentarily. Connectthe wHT/ REDterminalto the WHT terminal,and terminal the YEL/RED to the BLK terminal momentarily. Check door lock ooeration: All doors shouldlock.
Reconnect the 18-P connector to the control unit.

No. wiro WHT Test condition Under all conditions. Tost: Dosirod te8ult Chsck tor voltageto ground: There should be battery vo|tage. Check for voltageto ground: Thereshouldbe 1 V or less. PosEiblocauss if result is not obtainsd . Blown No. 44 (15 Al fuse. (ln the under-hood tuse/felayboxl . An open in the wire. Faultydriver'sdoor lock switch. Poor ground (G4O1,G402, G404). An ooen in the wire. door lock switch. Faultypassenger's Poor ground (G4O1,G402, G4O4). An open in the wire. Faultydriver'sdoor lock actuator. Poorground (G4O1 G402, G4O4). , An oDenin the wire. Faultydoor switch. Poorground. An open in the wire.
GRN/WHT Driver'sdoor lock switch in LOCK.

G R N / R E D T Driver'sdoor lock
switch in UNLOCK. BLKi RED Passenger's door lock switch in LOCK. switch in UNLOCK. 6 BLU/WHTI Driver'sdoor lock knob in LOCK. BLUi RED 7 Driver'sdoor lock k n o bi n U N L O C K . Check for voltageto ground: Thereshouldbe 1 V or less. NOTE: Beforetesting, remove No. 46 (15 A) tuse in the fuse/relav under-hood box. Checkfor voltageto ground: Thereshould be 1 V or less. Checktor voltageto ground: There shouldbe I V or less as the switch is turned. CheckJor voltageto ground: There shouldbe 1 V or less. Checkfor voltageto gfound: Thereshouldbe 1 V or less.
door lock BLK/WHT Passenger's
GRN/BLU Driver'sdoor open. door G R N / R E D ' Passenger's open.
BLU/WHT' lgnitionkey is in the

ignitionswitch.
Faulty ignitionkey switch. Poor ground (G4O1 G4O2,G4O4). , An open in the wire. door cylinder. Faulty passenger's Poorground (G4O1 G402, G404). , An oDenin the wire.
BLKi RED
Passenger's door key cylinderin LOCK. cylinderin UNLOCK.
door key BLK/WHT Passenger's
To prevent damago to the motol, apply battefy voltago only momntarily.
23-259
PowerDoorLocks
Driver'sDoorLockActuator Test
t _
Remove the door panel (see soction 2O),
Check for continuity betw66n ths tsrminals in each switch positionaccordingto the table.
2 . Disconnect the 6-P connctor from ths actuator,
\------ ry'"d
Position
r0cK
UNLOCK
o-
oo
-o
DOOR LOC|(X[O8
View trom wire Sids
Test actuator operation: LOCK: With battery pow6r connected to the No. 4 terminal,groundthe No. 5 terminalmomntarily, UNLOCK:With baftry power conncted to th6 No. 5 terminal,groundth No. 4 tarminalmomentarily. CAUTION: To provont damago to thc motor, only connocl powor momontarlly.
4.
lf the actuator doea not work properly, rplaco it.
23-260
DoorLock Passenger's Tost Actuator

1. 2. Removethe door panel (seesection 201. Disconnect the 6-P connector from the actuator.
Switch Test KeyCylinder

1 . Removethe door Danel(seesection 20), the 6-P connectorJromthe actuator, Disconnect
6-P CONI{ECTOR View from wire side
6.P CONNECTOR View from wire side
T6st actuator operation: LOCK: With battery power connected to th No, 4 terminal,groundthe No. 5 terminalmomentarily, UNLOCK:With batterv power connected to ths No, 5 trminal,groundthe No. 4 terminalmomntarily. CAUTION: To provont dmag to ths motor. connsct power only momontadly, 4. It the actuator does not work properly, replsce it.
3.
Checkfor continuitybetweenthe terminalsin each switch positionaccordingto the table.
\_____jy"'l
Position LOCK UNLOCK
o-
o- ---o --o
23-261
Power Door Locks

Door Lock Switch Test
1. Removethe door handleoanel. 3.P CONNECTOR
DOOR IOCK SWTTCH
Disconnect the 3-P connectorJromthe switch. Check for continuity between the telminals in sch switch positionaccordingto the table.
Terminal A
Poshion LOCK OFF UNLOCK
o-
o-
23-262
Wiper/Washer
Index Location Component
WINDSHIELD WIPER/WASHER
swtTcH
Test, page 23-266 Repf acement, page 23-267 WINOSHIELD WIPER ARMS/BLADES Replacement,
INTERMITTENT WINOSHIELD WIPERPELAY l8-typo) Test, page 23-72
WINDSHIELDWIPER MOTOR ASSEMBLY Test, page 23-268 Repf acement. psge 23-27 O
Ut{DER.DAS}I FUSE/RELAY BOX
MOTOR Test, page 23-269
CIRCUIT WIPER/WASHER {ln the integrated control unit} fnput Test, page 23-167
23-263
WiperMasher
CircuitDiagram
UNDERHOOD FUSE/RELAY 8OX DASH UI{DER_ FUSE/RELAY BOX
INTERMITTENT WIPERCIRCUIT flntlF intoEnod \
BLK
BLK
Btx
BI.J(
G30l
G30r
G4o1 G402 m4
G30l
Grc2 G40/t
G101
23-264
Troubleshooting
sequence. NOTE: The numbersin the table show the troubleshooting
Item to be inspected
6
l!
P 9 3 E E 3
E
I
G
,
-vii
a;
r'. f
z )
Symptom Wipers do not ln all positions ln INT In LOor Hl ln MIST Bladesdo not returnto park positionwhen wipers are turned OFF, ErraticintermittentcYcle or wipers do not work in lNT. Little or no washer fluid is pumped. Wipers and washer do not work at the same ttme. 3 .2 4 1 t
E!'
5 6
X !
g E!
E E o)
o:?
E E
6 E
E E
c 9 t i 9 c 1
a)
6 :
Z Y
i5;
.2 o
o-
o o O E
GRN/BLK
G301 G401 G R No r G402 BLU/WHT G404 BLU/YEL BLU or ')

1
BLU/YEL BLU/WHT
G GRN/BLK, RN. BLU/WHTor GRN/RED
2
I
G 3 0 1 BLK/YEL
BLK/YEL
23-265
Wiper/Washer
Wiper/Washer Switch Test
1 . Remove the dashboard lower cover and knee bolster. 2. Disconnect the 5-P and 20-P connectorstrom the main wire harness. Checkfor continuitybetweenthe terminalsin each positionaccordingto the table.
20-P COI{NECTOR
DASHAOARD LOWERCOVER
KIEE EOLSTEF
U
Position
OFF
l4
15
16
11
24
INT
t0
HI '0N' Mistswitch '0N' WEsher switch
oG_
o-
ooo --o
o- ---o
23-266
Switch RePlacement Wiper/Washer

CAUTION: a Atl SRS clectrical wlring harno!343 ato covarcd whh yollow outct Inrulatlon. a Bators dbconnocting tha SRS wito hlmcss, lnstell th6 rhort connoctor(sl on tha sitbag(sl (sae pago 23-2941. a Roplaco thr cnllro Effectad SRS hamcls asr.mbly lf It has an opn circult or dsmlgod whlng' 2 the steeringcolumncovers, Remove
COVR COLUMN UPPER
1.
Remova the dashboard lower cover and l(nee bolster.
Disconnectthe 8-P connector, then remove the wip6r/washerswitch.
CONNECTOR
COVER LOWER DASHBOARD
23-267
Wiper/Washer
WindshieldWiper Motor Test
Open the hood and removethe cap nuts and the wipef arms. Be caretulnot to damagethe hood. Disconnect the 5-P connector from the wiDer motor assemblv. B lGif{/BLt(} lfl (BLU/YEL} LO(BLU}
5.
Rgconn6ct the 5-P connactor to the wior motor assembly.
6 . Connsct an analog voltmter between the As

(BLUA /HT) 8nd the E IBLK) terminals. Fun the motor by turning the wipr switch ON (LO or Hl position). Th6 voltmete. should altrnately indicate O V and mors than 4 V.
5.P CONNECIOR termanal side.
Test motor ooeration; LOW SPEED:Connect battery power to the B (GRN/BLKIterminal and ground to the LO {BLU)te.mins.. HIGH SPEED: Connect battery power to the B (GRN/BLK) terminal and ground to the Hl (BLU/YEL) termtnsl.
4.
lf the motor does not run. or Jailsto run smoothlv, reolace it.
23-268
Windshield Washer Motor Test

Rsmovs the 18ft inner fendor. Disconnect the 2-P connector from the washer motor. Tst the washsr motor by connecting battty oowel to the @ terminal and grounding the O terminsl. a lf the motor does not run, or fails to run smoothly, replsce it. a lf the motor runs smoothly, but little or no washer tluid is pumped, check for a disconnscted or blockedwasherhose,or I cloggedpump outlet.
cot{r{EcToR
2-P
23-269
Wiper/Washer
WindshieldWiper Motor Replacement
Open the hood and remove the caD nuts and the wiper arms. Be carefulnot to damagethe hood. Removethe windshieldlower molding,hood seal, and air scoop by prying the trim clips out and removingthe sctews. CAPNUT Remove the three mountingbolts and one nut from the wiper linkage,then removethe wiper motor.
NUT 22 N.m {2.2 kg-m,16 lb-ftl
MOUI{TIIIIG BOLTS 10 .m {1.O kg-m, 8 lb-ft|
3,
Disconnect the 5-P connectorfrom the wiDermotor, then remove the wiper harnessfrom the wiDer linkage.
VNPER MOTOR WIPERLII{KAGEASSEMBLY
Removethe wiper linkageassemblyby removing the three mountingbolts.
23-270
WasherMotor RePlacement
1. 2. 3. Removethe washer filler neck. Rmoveth innerfender. Disconnectthe hose and the 2-P connectortrom the washer motor' Romove the thre mounting bolts 8nd pull out the washer .esetvoil. Romove the washer motor from the washer reservolr. Removeths washel nozzlesand washer hose as necessary. During installationtake care not to pinch 8ny hoses, Instsllthe hose clips tirmly. their After installingwasher nozzlss,check/adiust aim.
4.
5.
6.
7.
8.
23-271
GruiseControl
CAUTION: a All SRS elect cal wiring harnesaosalo coverd wiih yallow outr insulation. a 8ofo.e di6connecting ths SRS wire harn6ss, install the short connector{sl on tho ai.bag{s) (see page 23-2941. a Roplacethe entiro affectod SRS harnoss assmbly if it has an open circuit or damaged wiring.
CRUISECONTROLMAIN SWITCH Test, page23,280 Replacement,page 23-280
COI{TROL UNIT fnputTesr,page23-276

CAALE REET Test, page 23-278 Repfacement.pag6 23-276, 318
SET/RESUME SWITCH Test, psge 23-278 Repf6cement. pdga 23-27 I
A/T GEAR POSINON
swtTcH
CLUTCH SWITCH Test, page 23-281 Pedal Height Adiustmnt, section
Test, page 23-149, 281 Replacoment,page 23-149
Tst, pag 23-282 Pedal Hoight Adjustmenr, section 'l I
swtTcH
23-272
CABLE ACTUATOR Adjustment, Page23-294
ACUUII,IRESERVOIR
SofenoidTest, page 23'282 Test, page 23-283 Replacement,Page 23-284 Disa$embfy, page 23'285
23-273
CruiseControl
CircuitDiagram
UNDERHOOO FUSE/RELTAY 8OX UNOEROASH FUSSRE!{Y 8OX
c0MEtNAnoir UGHT SWITCH
INDICATOR UGHT t0.84wl
IP
Il
IOSET
IP tb8h,
- rcNrnoN cot{TRot
MODUI.I {rcMl
\7
I
REEL
t
I
ErlJ
l L
P( VEHICI.T SPED
CRUISE c0l{TRot ACIUATOR
sNsoR {vsst
8u( {
l^
M,/T CLUICH : SWTTCH \ ,,/T: MGAn I ft, 12, D.l 81-K
PosrTloir swrTcH I t
{
G401 G402 G404 G40t G4!2 G(X
G301
23-274
Troubleshooting
sequonca. a The numbe.sin the table show the troubleshooting a Beforetroubleshooting. fuse/relaybox End ths No' 41 (15 A) fuse in the undr-hood - Check the No. 14 (7.5 Al fuse in the undsr-dash fuse/relaybox. - Checkthat th ho,ns sound. - Check the tachometer for propor operation.
Items to be inspscted
F
@
E; 3 ;
o 6
o o o
o
'P-
3
'P-
o o o
(!
o o o o o o
T6;
E -og I q
o
! o
!l 6
o
o
E 6 9
3 E
o o o o
o o -q .9
ut
o ,E
z
<t u, F ut a
I
6
'
o o E
3
o
o o
E'g 5
PE E ; > =
o = >
o o
Symptom Cruisecontrol cannot be set'
;:
gg !
BRNMHT, LT GRN/BLK, G401 BRN/BLK, BRN/RED, G402 ORN,LT GRN G404 BLU LT GRN/RED,
I
Cruise control can be set, but indicatorlight does not go on. Cruise speed noticeably highsl or lower than what was set. Excessive overshooting and/or when trYingto undershooting set speeo. Steady speed not held, even on a flat road with cruisecontrol set. or Car does not decelerate acwhen SET celsrateaccordinglY button is Pushed. or RESUME Set speed not cancellsd when clutch pedal is Pushed(M/T). whon Set speed not cancelled shift lever is moved to 1 (A/Tl. when Set soeed not cancelled brake pedal is pushed Set speednot cancelledwhen OFF. main switch is Dushed Set sosed not resumed when button is Pushed(with RESUME main switch ON, but set speed temporarilycancelled). 1 'I 1
1 GrtO G402 YEL,RED,RED/BLK G404

1
J
2 2
2
I 1
2 2 2 2
PNK PNK GRY, GRN/WHT LT GRN
23-275
CruiseControl
ControlUnit Input Test
CAUTION: a All SRS aloctfical widng harnessosare cov6rd with yollow outo. insulation. a Brtoro di3connoctlng the SRS wira hamoss, install tho short conn6ctor(s) on the airbag(s) (see page 23-2941. a Replacethe entiro affoctod SnS harn6ssa$ombly it it has an opon clrcuit or damagod wiring, 1. Disconnectthe 14-P connector from the control untr. Inspectthe connectorand socket terminalsto be sure they ars all makinggood contact. a lf the terminsls are bent, loose, or corrodsd. fepair them as necessary, and rechsck the system, a It the terminalslook OK, make the following input tsts at the connector, - lf a test indicates p.oblem,find and correct a th caus,then recheckthe svstem. - lf allthe inputtests proveOK, the controlunit must be faulty; replaceit.
cRUrsE coNrRoL wr / u
r4-P CON|{ECTOR
View from wire side
23-276
't
Test condition 1
Test: Dosird result Check for continuityto ground: Thereshouldbe continuity, Checkfor voltageto ground: There shouldbe battery voltage. Check tor voltageto ground: Thereshouldbe battery voltage.
Possiblocause if result is not obtain6d . Poorground {G4Ol, G4O2,G404) . An open in the wire. B l o w nN o . 1 4 { 7 . 5 A ) f u s e . (ln the under-dash box) tuse/relay Faultymain switch. An open in the wire. B l o w nN o . 4 1 ( 1 5 A ) f u s e . fuse/relay box) {ln the under-hood RESUME switch. Faulty SETi Faultycablereel. An open in the wire. clutch switch Faultyor misadjusted (M/T). A/T gear posiFaultyor misadjusted switch. tion Poor ground{G4O1,G4O2,G404). An open in the wire. . Faultyignitionsystem or ECM. . An open in the wire. Fauhyvehiclespeedsensor(VSS). P o o rg r o u n d( G 1 0 1 ) . An open in the wire.
BLK
LT GRN
Under all conditions. lgnitionswitch ON and main switch ON.
LT GRN/ BLK 4 LT GRN/ REO PNK
button pushRESUME eo. SET button pushed.
M/T: Clutch pedal pusneo. A/T: Shift lever in
E,E.o,E
Check for continuityto ground: Thereshouldbe continuity. NOTE: Thereshouldbe no continuitywhen the clutch pedal is released when the or A/T shift lever is in other positions. Check for voltageto ground: There should be baftery vortage. CheckJor voltagebetweenthe ORN @ and BLK O terminals: It should e0-'12-O-12 V b repeatedly. Check for voltageto ground: Thereshouldbe O V with the pedal pushed, and battery voltagewith the pedalreleased. Checkfor voltageto ground: There shouldbe battery voltage with the pedalpushed, and O V with the pedal released. Connectto ground:Cruiseindicator in the gaugeassemblY comes on.
BLU
Start the engine.
ORN
lgnitionswitch ON and main switch ON. Raisethe front ot the car, rotate one wheel lgnitionswitch ON, main switch ON and brake pedal pushed, then released,
GRY
. Faultybrakeswitch. . An open in the wire.
GRN/WHT Brakepedal pushed, then released.
. Faultybrakeswitch. . An open in the wire.
10
RED
lgnitionswitch ON.
Elown bulb. Blown No. 13 { 10 A} fuse. (ln the under-dash box) fuse/relay Faultydimmingcircuit in the gauge assemory. An open in the wire. . Faultyactuatorsolenoid. . An open in the wire.
1'l
BRN/RED Underall conditions.
to Check for resistance ground:Thereshouldbe 80- 1200. to Check for resistance ground:Thereshouldbe ' 1o 70- 1 0. to Check for resistance ground:Thereshouldbe 40-60 0.
'12 BRN/BLK Under all conditions.
1 3 BRN/WHT Under all conditions.
23-277
CruiseControl
Set/Resume Switch Test/Replacement
CAUTION: a All SRS lectrical wiring halnesses ar covorad wlth yellow outer inaulation. a Botoro disconnecting tho SRS wire harness, install the 6hon connector(sl on th airbag(s) (sea page 23-2941. a Replacothe ntire affected SRS harnass assembly if it has an opn circuit or damaged wiring. NOTE: The radiomay havea codedtheft protectioncircuit. Be sureto get the customer'scode numberbefore - Disconnecting battery. the Removing the No. 43 (1O A) fuse. (ln the under-hood fuse/relaybox) - Removingthe radio. After service,reconnectpower to the .adio and turn it on. When the word "CODE" is displayed. enter the customer's 5-digit code to restoreradio oDeration. 5. Installtheshort connectofon the airbagconnector.
CABLE REEL CONNECTOR
AIR BAG CONNECTOF
ACCESSPANEL SHORT CONNECTOR (RED}
o.
Remove the dashboard lower cover and knee bolster, Disconnect the cable reel 6-p connector from the SRS main harness,then connect Test HarnessC only to the cable reel side ot the 6-p connector.
Disconnectthe battery negative cable. and then positivecable. Make sure the wheels are turned straightahead. Remove the two screws and access Danel,then removethe short connectorfrom the accessDanel.
4.
Disconnectthe airbag connector from the cable reel connector.
23-278
I
L Checklor continuitybetweenthe terminalsof Test to C Harness in each switch positionaccording the table.
1 0 . Remove the two screws and cruise control

switch. SET/RESUME
SWITCH SET/BESUME \ rofinrnal
Position
ELU/NEU
SET ION) RESUME(ON}
oG-
---o
1 L TG R N / LTGRNi BLK REO
---o
a lf there is continuity.and it matchesthe table. the switch is OK. a lf there is no continuityin one or both positions, go to stsp 9.
A' A
9.
Carelullyremove the cruise control SET/RESUME switch cover by prying between the cover and switch in the sequenceshown. CRUISE CONTROL SET/RESUME
swtrcH
1 1 Checkfor continuitybetweenthe terminslsin each switch positionaccordingto the table.
CRUISE cot{TRoL SET.RESUME SWITCH COVER
Terminal Position (ONI SET RESUME ION)
AorA'
G-
---o ---o
o-
lf there is no continuityin one or both positions, reolacethe switch. a lf there is continuitYand it matchesthe table, replacethe cable reel.
23-279
GruiseControl
Main Switch Test/Replacement
1. Carefullypry the switches out of the instrument panel and disconnecttheir connecrors. 3. Checkfor continuitybetweenthe terminalsin each switch positionaccordingto the table.
termrnal Position OFF ON \
oo-
,/.\ \:.,/ /:\ \:.,/
-o o-o o-
/:\
a\
-o
INDICATOR
LIGHT
ti
5-P CONNECTOR
t0.84w) t l 7
I
\
CRUISECONTROL MA|N SWtTCt{
2.
Removethe cruise controlmain switch from the switch panel.
a lf there is no continuity,replacethe switch.
SWITCH PANEL
23-2AO
Clutch Switch Test

1. Disconnect the 3-P connector from the clutch switch. Check for continuitybetween the terminalsaccording to the table.
A/T Gear PositionSwitch Test

1. Remove the tront console, then disconnectthe 12-P connectorfrom the switch.
2.
Terminal 'c*.hP;f-l PUSHED BELEASED
o-
2,
Checktor continuitybetweenthe terminalsin each switch positionaccordingto the table.

Terminal
5 Position
tr tr
E
N
o- ------o o_- ------o --o o
tr
E
lf necessary,replacethe switch or adjust pedal height (seesection 12). 3, replace switch {seepage23-149). the lI necessary,
23-281
CruiseGontrol
r BrakeSwitch Test
1. Disconnectthe 4-P connectorfrom the switch.
ActuatorSolenoid Test
1. Disconnect the 4-P connectorfrom the actuStor,
BRAKESWITCH
View trom terminal side Measure resistance between the terminals, 2. Checkfor continuitybetweenthe te.minals according to the table. Resistance VENT SOLENOID(betwon C and Dt: 80- 120 0 VACUUM SOLEI{OID(bstwoen I 8nd Dt: 70-t100 SAFEW SOLENOID{botwoen A and Dl: 40-60 0 NOTE: Resistance will vary slightty with temperature; specified resistance is at 70oF (200c).
VEI{T VALVE
Terminal ;**;---_\ PUSHED RELEASED
G-
--o
o-
3.
lf necessary,replacethe switch of adjust pedal height (seesection 191.
VACUUMVALVE
23-2a2
ActuatorTest
1. Disconnectthe actuator cable from the actuator rod and disconnectthe 4-P connector. Connect batterv Dower to the D terminal and ground to the A, B, and C terminals. Connecta vacuum pump to the check valve. Then apply vacuum to the actuator. With voltage and vacuum still applied,try to pull the actuator rod out by hand. You should not be able to pull out. lf you can. it is defective
2.
3.
VALVE CHECK
/A@
VACUUMPUMPGAUGE a973X-041-XXXXX
I -YF / \N7
ACTUATOR
o
o_
/t:#r'.\
Disconnectground from the C terminal. The actuator rod should return. lf it does not return but the vent hose and filter are not plugged, the solenoidvalve assemblyis defective. Repeatsteps 2 through 5, and disconnectground trom the A terminal. The actuator rod should return. It it does not retu.n but the vent hose and tilter ar not plugged,the solenoidvalve assembly is defective.
View from side terminal The actuatorrod shouldpull in completely. lf the rod pulls in only part-wayor not at all, check for a leakingvacuum line or defectivesolenoid.
4.
8 . lf you replacethe solenoidvalve assembly,be sure

to use new O-ringson each solenoid.
ACTUATOR ROD
23-283
CruiseGontrol
Actuator/CableReplacement
Pull the boot back and loosen the locknut. then disconnectthe cable from the bracket.
Actuator CableAdjustment
Check that the actuator cable operatessmoothly with no bindingor sticking. Start the engine. Measurethe amount of movementof the actuator rod until the cable pulls on the acceleratorlever (enginespeedstarts to increase). Freeplay should be 11 t 1.5mm (O.43 0.06in). t
t
=
ROD ACTUATOR
Disconnect the cable end from the actuatorrod. Disconnect the 4-P connectortrom the actuator.
VACUUM HOSE
LOCKNUT
LOCKNUT FREE PLAY: a 1.5 mm 11 (0.43r 0.06 inl

4.
lf Jreeplay is not within specs,loosenthe locknut and turn the adjustingnut as required. NOTE: lf necessary. check the throttle cable free play {see section 11), then recheck the actuator rod free play.
VENTHOSE
e
4-P CONNECTOR
Retighten the locknut and recheckthe free play.
4.
Pullthe vent hose out of its grommet. Removethe two mounting bolts and the actuator with the bracket. Disconnect vacuumhosefrom the checkvalve. the lf necessary,disconnectthe cable end from the linkage over the acceleratorpedal, then turn the grommet 9Oo in the bulkhead and remove the caDle.
8.
Installin the reverseorder of removal,and adjust tree play at the actuator rod after connectingthe cable (seenext column),
23-284
I
Actuator Disassembly
FILTER COVER
b
VALVES SOLENOIO Test, pge 23-282
--)@r GROMMET
VACUUM HOSE CHECK VALVE HOSE VACUUM
6-
BBACKET ACTUATOR
ACTUATOR Test, page23-283

DRAIN HOSE
BRACKET ACTUATOR
23-285
..
SupplementalRestraintSYstem
(sRsl
Index'..."'.. '..'.'. 23-288 Location Component ' 23-2Ag Description 23-290 CircuitDiagram 23-292 WiringLocations .' 23-293 Precautions/Procedures '.23-294 .......... Troubleshooting AirbagAssembly 23-318 Replacement 23-322 Disposal CableReel 23-324 Repfacement DashSensor 23-324 Replacement SRSUnit 23-330 Replacement
Supplemental RestraintSystem (SRS)

CABLE REEL page23-324 Replacement,

SRS INDICATORLIGHT {ln the gguge assembly} Troubleshooting,page 23-298 Gsuge assembly, page 23-122 TO DRIVER'SAIREAG ASSEMBLY
TO CRUISE COI{TROL SET/RESUME SWITCH
ASSEMBLY Replacamont, page23-318

Disposal.
FRONTPASSEI{GER'S ATRBAG
UNOER.DASH FUSE/RELAY 8OX
DASH SE'{SOB Replacernent, page 23-328
ORIVER'SAIRBAG {lnctuding cowr snsorlASSEMBLY R6placement, Replacement, page 23-318 pag 23-330 Disposal,page 23-322
BIGHT DASH SEITSOR Rplacement, psge 23-328
23-288
Description
to with the seat belt.is designed helpprotectthe driver{and The SRSis a safety devicewhich, when usedin conjunction in front passenger) a frontal impact exceedinga certainset limit. the cowl sensors), cablereel,driver'sairthe SRSunit (includes The system is composedof left and right dash sensors, (Si 4WS, Si VTEC: USA, SR 4WS,SR-V:Canadamodels). passenger's airbag bag and front
SRS UNIT
AIRBAG CABI-EREEL
OPERATION: The parallel of sensotsis set As shown in the diagrambelow, the left and right dash sensorsare connectedin parallel. in In addition,a back-uppower circuitis connected connectedin seriesto each airbaginflatorcircuitand the car battery. parallelwith the car battery.The back-uppower circuit and the cowl sensorsare locatedinsidethe SRSunit. For the SRSto operate: {1) One or both cowl sensorsand one or both dash sensorsmust activate. (2) Electrical to energymust be supplied the airbaginftatorby the battery,or by the back-uppower circuitiJthe battery voltage is too low. {3) The inflator chargemust ignite and deploythe airbag. It takes about O.l secondfrom the beginningot the airbagdeploymentuntil it is completelydeflated(frontalcollision againsta fixed wall at a speed of 30 mph t50 km/hl).
I l-r t t
FRONT PASSENGER'S IA|RBAG ll AIRBAG t L . - l
Selt-diagnosissystom circuitis built into the SRSunit; when the ignitionswitch is turnedON. the SRSindicatorlight comeson A seli-diagnosis normally.It the light does not come on, or doesnot go oft goesoff after about six secondsif the system is operating and in an or atter six seconds. if it comeson while driving,it indicates abnormality the system.The systemmust be inspected as and repaired soon as possible.
23-289
Supplemental RestraintSystem (SRSI

(WithoutFrontPassenger's CircuitDiagram Airbag)
i1}358;,K%,
sRs sRsrNorcAToRcrRcurT tNotcAToR ctRcurT
lln theg.u6a8!ombv)
( ,o'ft ) 'on't'ot'*'ttt
A Y
II
J---, I Zlfoii l**'I i ir#i, l*'
wm
ti[*?
ORIVER'S ANEAG INFLATOR
F
l-1-,
o o o a a SAIrc
Btc
\_-/
BATTERY
@ @
@ @ @
o o
GNO@ tDc @
MI
@ @
SRS UI{ITI8 - PCONNECTOR
23-290
(WithFrontPassenger's Airbagl CircuitDiagram

INOICATOR CIRCUIT SRS (lnthegaug 83smbiyl
( ,lYt ),.*'t'orr*,..*
,k
|| II
BLKffEL
G401 G4.02
I I
J----, rtr
l-' I ln;'
BATTERY
WHT
I n I ll I tl
r l l
CABLE REEL SAOH DRIVER'S AIRBAG INFLATOR
I,s,; t#ff{,
FRONT PASSNGER'S AIRBAG INFLATOR
o @ a
@ @
SADC BUC
a a @ a @ o a a
GND tDc
@ @ MI @
23-291

Widng Locations
CAUTION:Maksureall SRSgroundlocations cleanand grounds socurely are are attachd. NOTE: a All SRSelectrical wiringharnesses covered are with yellowouterinsulation. a Replace entire the aftected SRSharness assembly it hasan opencircuit dsmaged il or wiring.
OASHBOAFDWIRE HARNESS ro SRS ItIDIcAToR LIGHT in GAUGE ASSEMBLY 5.P CONNECTOR SRS MAIN HARNESS to FRONTPASSENGER,S AIRAAG 3.P COITNECTOR DASHBOARD WIREHARNESS
SRS MAIN HARNESS Io UNDER DASH FUSE/RELAY BOX 2-P
SRS MAIN HARNESS SRS UNIT GROUNO MAIN WIRE HARNESS to DASHBOARDW|RE HARNESS 2O-P CONNECTOR
SRSMAINHARITESS ro RIGHT DASHsENsoR 2.P CONNECTOR
SRS MAIN HARNESSSOCKET 1A.PCONNECTOR
23-292
Precautions General
a Carefullyinspectany SRS part before you install it. Do not install any part that shows signs of being dropped or improperly handled, such as dents. cracks or detormation: Airbagassembly(driver'sand front passenger's). Dash sensors, Cablereel. SRSunit.
Airbag Handlingand Storage

lt the Do not try to disassemble airbagassembly. has no parts. Once an airbag has been operated serviceable or (deployed), cannot be repaired reused. it For temporary storage of the airbag assemblyduring service,pleaseobservethe following precautions: with the pad sura Storethe removedairbagassembly face uD.
({,
lf the airbag is improgerly stored face !!!@ d6ii, accidental deployment could propl the unit with enough folce to cause serious iniuly. . Use only a digitalmultimeter(KS-AHM-32-OO3) to check the sYstem.Using an analogcircuit tester may cause an accidentaldeploymentand possible injury. a Do not install used SRS parts Jrom another car' When makingSRS repairs,use only new parts' a Exceot when performing electrical inspections, always disconnect both the negative cable and work' positivecable at the battery beforebeginning a Replacement of the combination light and wiDer/washerswitches and cruise control switch can b done without removingthe steeringwheel: - Combination light and wiper/washer switch (seePage23-182). replacement - C.uise control switch replacement (see page 23-2741. a When rsinstallingthe SRS unit cover. be sure lt snapstogetherProperlY. Storethe removedairbagassemblyon a secureJlat surfaceaway from any high heat source (exceeding detergent and free oJ any oil, grease. 212oF/'lOOoCl or water. CAUTTON: lmproper handling or storag can intsrnally damage ths airbag assambly, making it inoperativs. lf you suspect the airbag assembly has b6n damaged, install a new unit and refer to the Dsployment/Disposal Procdules lor disposing of the damaged airbag
23-293

WiringPrecautions
a Neverattemptto modity.spliceor repairSRSwiring. NOTE: SRS wiring can be identified by special yellow outer protectivecovering.
Instslling the short connector

To avoid accidenrat deployment 8nd @ possible injury. always install ths protective short connector(s) on the driver's and passonget's airbag connector(s) belore working noar any SRS wiring. NOTE: The radio may have a s-digit coded theft protection circuit. Be sure to get the customer's code numberbefo.e disconnecting battery. the l. Disconnect the battery negative cable, then disconnectthe positivecable. Installthe short connector{s)(RED):
2.
Be sure to installthe harnesswires so that they are not pinchedo. interfering with other car parts.
Driver's Sido: a Removethe access panel from the steeringwheel, then remove the short connector (REDI from the oanet.
Make sure all SRS ground locationsare clean and groundsare securely fastenedfor optimum metal-tometal contact. Poor groundingcan cause intermittent problemsthat are difficult to diagnose.
Disconnectthe 3-P connectorbetween the driver's airbagand cablereel,then lnstalltheshort connector (RED) the airbagside of the connector. on
23-294
Front Pass6nger'sSide: a Remove the glove box, then remove the short connector (RED)from its holder.
Disconnecting the SRS Connector at the Fuse Box

CAUTION: Avoid breEking tho connctor; it's doublelock6d. 1. First lift the connectorlid with a thin screwdriver, then press the connectortab down and pull the connector out.
FRONTPASSENGCR'S AIRBAG 3.P CONNECTOR
SHOR1 CONNECTOR {RED)
SRS MAI]II HARNESS
BOX UI{DER.DASHFUSE/RELAY
Q+
BOX GLOVE Disconnect the 3-P connector between the front passenger's airbagand SRS main harness,then install the short connector (RED)on the airbag side of the connector.
SRS MAIN HARNESS
To reinstalltheconnector.push it into positionuntil it clicks.then close its lid.
23-295

Steering-related Precautions
Steering Wheel and Cable Reel Alignment
NOTE: To avoid misalignment the steeringwheel or of airbagon reassembly, make surethe wheelsare turned straightaheadbetore removingthe steeringwheel.
SteeringColumnRemoval
CAUTION: a Eefors romoving the steering column, fitst disconnoct the connctor betwoen th cable reol and the SRS main harnss. a It tho steeling column is going to bo removed withoul dismounting the stering wheel. lock ths stesring by turning tho ignition key to O-LOCKposition 01 rsmova the key from ths ignition so that the staering wh6al will not turn,
Rotatethe cable reel clockwiseuntil it stops. Then rotate it counterclockwise(approximately two turns) until: - The yellow gear tooth lines up with the alignment mark on the cover. - The arrow mark on the cablereellabelpoints straight up,
HARI{ESS
Do not replacethe originalsteeringwheel with any other design,since it will m8ke it impossible proto perly install the ai.bag (only use genuine Honda partsl. replacement After reassemblyconfirm that the wheels are still turned straight ahead and that the steering wheel spoke angle is correct. lf mino. spoke angle adjustment is necsssary, so only by adjustmentof the do tie-rods, not by removing and repositioningthe stee.ingwheel. NOTE: Modelswith 4WS Test and adiust the 4WS system (seesection 17).
23-296
I
SensorInspection
CAUTION: Take extra care whan psinting ol doing body work in the area bolow the dashboard. Avoid dirct xposule of tho sensors ol wiring to hsat guns' welding, or spraying equiPment.
InspectionAfter DePloYment
inAfter a collisionin which the airbagswere deployed, spect the following: 1. Inspect the dash sensorsfor physicaldamage. l{ the sensorsare damaged,replacethem. don't Replace, Inspectall the SRSwire harnesses. repair,any damagedharnesses. Inspectthe cable reel tor heat damage lf there is any damage,replacethe cable reel. turn the igniAJter the car is completelyrepaired, tion switch on. It the SRSindicatorlight comeson for about six secondsand then goes ofl, the SRS system is OK. lf the indicatorlight does not function properly,go to SRSTroubleshooting.
@ Disconnect both the negative and positivs battary

-o cables. a Install the short connector(s) botore working blow the dashboard ol near tho dash sensors. a After any degree of frontal body damage, inspect both dash sensors.Replacea sensorif it is dented. cracked,or deformed.
2.
3.
4.
DASI{ SENSOR
o Be sure the sensorsate installedsecurely'
DASH SENSOR
23-297
Supplemental Restraint System(SRS)

Troubleshooting
Self-diagnosisFunction
The SRSunit includesa selJ-diagnosis function.lf there is a failurein the snsors,SRSunit, inflator,or their circuits, the SRS indicator light in the gauge assembly goes ON. SRSINDICATOR LIGHT Short Connctor Installation To avoid accidontat deploymont and @ possible injury, always install the protective short con_ nectot on the drivel's ailbag connoctor and on cars oquippod wlth flont paasengor,sairbag, install protac_ tivo short connctots on thg drlver.a airbag and front paaaonger's airbag bofore working near any SRS wiring. NOTE: The radio may have a s-digit coded theJ't protection circuit. Be sure to get the customer's code numberbetore disconnecting battery. the As a system check, the SRSindicatorlight also comes on when the ignitionis iirst turned to the ll oosition.lJ the light goes otf after approximately seconds,the six system is OK. lf the SRSindicatorlight remainson (or failsto come on in the systemcheckmodel, one ot the SRScomDonents (or the wiring/connectors bgtween)is faultv. in Troubloshooting Procautions a AlwSys uso ths test hamess. Do not us tast probgs dirsctly on component connoctot tatminala ot wiros; you m8y damsgo them or th SRS unit. a Wh6n connecting any of th6 tsst hamoasos to the system. push the connectors straight-in; do not bend tho connctot torminals. a Boforo disconnacting any p8n ot tho SRS wire ha.ness, install the short connector (RED) on the driver's airbag. On csrs equippd with a front passenger's airbag, instsll shon connoctols on the driver's airbag and the front passngor,sairbag, SRS Indicator Light Troubloshooting Possibleconditions: 1. SRS indicatorlight does not come on at all _ see page 23-3OO. 2. SRSindicatorlight stays on constantly- see page 23-304. 3. SRSindicatorlight comeson in combination with a failure of another electricalsystem {brakesystem light, malfunctionindicatorlamp (MlLl etc.). Check for damage/corrosion the under-dash at fuse/relav box connector. NOTE: a Before starting the applicable troubleshooting. check the conditionof all SRS connectorsand ground points, a lf the fault is not found atter completing the applicable troubleshooting,substitute a known_ good SRS unit and check whether the indicator light goes off. 1. Oisconnect the battery negative cabl, then disconnectthe positivecable. Installthe short connector(sl: Driver'sSide: a Remove the access panel from the steering wheel, th8n.emove the short connector(RED) from the Danel.
f::=
2.
DRIVER'SAIBBAG
3.P CONNECTOR
ACCESSPANEL
a Disconnectthe connecto.between the driver's airbagand cable reel,then installthe short connctor {RED} on the airbag side of the connector. Front Passenger's Side: a Remove the glove box, then remove the short connector(REDIfrom the holder. a Disconnect the connector between the front passenger's airbagand SRSmain harness, then installthe short connector (RED)on the airbag side of the connector(seepage 23-295).
23-298
and Attachment Points Test Harnesses

A Test Harness
DRIVER'SAIRBAG ASSEMELY
A TEST HABNESS 07MAZ- SLOOSOo

2 3 't2 t
6
DRIVER'S
t 5 1
HARI{ESS C
o7LAz- s140300
FRONTPASSENGER'S AIRBAG ASSEMBLY
Test Harness B
SRS MAIN HARNESS 1g.P CONNECTOR 3.P CONNECTOR
Test HarnessD
SRS MAIN HARNESS 2.P CONNECTOR
3 2
5 5
6 6
11 12 13 12 13
15
18
1 5 t6 1 1 18
ENDI ROW B {WIREHARNESS
23-299

Troubleshooting
The SRS IndicatorDoes Not Light
CAUTION: Use only a digitatmulrimotel|KS-AHM-32_OO3) to chock tha system.
Dbconnoct tho bottory nog8tivo cablo 6nd thsn tho Dositivo cable. Install tho 3hort connocto.lsl on the airbag{3|{.e page 23-294}.
NOTE: The radio may have a s-digir coded thelt protection circuit. Be sure to get the customer,s code numberbefore disconnecting battery. the
Reconnect the battery positive cable and then the negative cable.
Do any other indicator lights (brake system light etc.) come on {in tho gauge ass6mbly)?
Inspocttho No. 13 (10 A) tuse {undeFdashfus/rclav box}
Turn the ignirionswitch OFF.
ls No. 13luse OK?
Disconnect the SRS main hamess18-Pconnector from the
Replir opon In drlhborrd wiro hsmoa! bqtwoon tho l{o. 13 tulo and glugo raa.mbly. SRS UNIT
sRs MA[{
HARI{ESS 18-P CONl{ECTOR
Tho SRS unit is taultv.
Turn the ignitionswitch OFF. {To page 23-301)
23-300
(From page 23-3OO)
Disconnect the SRS main harness 4-P connector lrom the main wire harness.
SRS MAIN HARNESS 4-P CONNECTOR
lightON? ls SRSindicator
The SRS main harnott is tauliY.
Remove the gauge assembly, then inspect the SRS indicator light b'.rlb.
Repl6cotho indicator light bulb.
Connct a voltmeler between the No. 3 terminalofthe 5 P connector and body ground.
DASHBOARDWIRE HARNESS5.P CONNECTOR
Measure the voltage between the No.3 terfiinal and body ground. {To psge 23-302}
e
BLU
Lo$ than 8.5V?
23-301
-
'

Troubleshooting(cont'dl
{Frompage 23-3OlI Sho.t in BLU wiio ot rhe da3hboardwiro hamess. Reolace tho dashboa.d wir6 harnoss.
ls therelessthan 8.5 V with the ignitionswitch ON?
Turn the ignitionswitch OFF. HARNESS5-P CONNECTOR Connect the voltmeter between the No. 1 lerminal (+) and rhe No. 5 terminal {-) oI the dashboardwire harness 5-P con, nector,
Measure the voltage between the No. 1 terminaland the No. 5 terminal.
rr--/#l t YEL
l : l r l 3 l 4 l l l
l ^ l L---(I0------r
l BLK
Battary vohlga? View lrom terminal side.
Chck tor continuity between t h e N o . 5 t e r m i n a la n d b o d y grouno. Ropoi. oD6n in rh BLK wire lNo. 5 tominall Detwoen the gauge a3sornbly and body g.ound or look to. a poor ground (c4O1, 4021. Rep.ir opon in the YL wire lNo. 1 teminall ot the de3hboardwiro hamo3s betwgen tho 9aug6 asaembly and the No. 13 luse.
Turn the ignitron switch OFF.
{To page 23-3031
23-302
{F.ompge 23-302}
Reconnecteach connctor to the gauge assembly and SRS unit then connect Test Harness A to th sRs unit.
Measure the voltag between tho No. 13 terminal and body ground for six sconds after ignition is {irst tumed on.
TEST HARI{ESS A 07MAZ- S100500 2

9
lo
1 l 12 t3 1 4 1 5 16
Moro thon
ls theremorethan 8.5 V?
SRS Indlcatot cilcuit {in tho gaugo 6!.mblyl 13taulty.
23-303
Supplemental Restraint System (SRSI

Troubleshooting {cont'd
SRS IndicatorLight Stays on Conrinuously
1. Make a photoeopy of this page (without front passenger's airbag),or the next page (with tront p a s s e n g e r 'a i r b a g ) . s Connect Test HarnessA (O7MAZ-SLOOSOOI to the SRS unit as shown. Turn the ignitionswitch ON. a Voltagesin the chart assumethe car,s,,battery voltage" is about 12 volts. Less than 12 volts will result in differentor possiblyfalse readings. a Do not disconnectthe airbag from the circuit when checkingSRS unit voltages. First,check for voltagebetweenTest Harness Term i n a lN o . 1 2 a n d g r o u n d . a lf voltage is indicated,there is a poor ground ( s e ep a g e2 3 - 3 1 7 ) . a lf no voltage is indicated,continuewith checking all the other terminals. Recordyour voltagereadings. each terminal,in tor the row of blank boxes near the top of the chart. 6. Compare each reading wilh the voltage ranges listedin the columnbelow it. lf the reading within is a range,circlethat range. a lf you circledall the Failure Mode rangesacross any row, check the car for the probableFailure Mode listedat the end of the row. (Referto the letter for that Mode on the following pages). a lf you did not circle all the ranges across any row, replacethe SRS unit with a known-good unit, and retest. - lf all your voltage readingsare now Normal, replacethe SRSunit. - lf your voltage readingsare still not normal but they don't tit within a completerow ot FailureMode ranges,check the conditionoi the terminalsin each of the SRS connectors shown in the system diagram on page
2.
3,
4.
5.
Without Front Passonger'sAirbag: NOTE: Do not disconnectthe airbagwhen checkingSRS unit voltages.
1 SADH
vcc
5 SV
8 SADC 5.6 - 7.3
10 BUC]
11.5 - 14_5
12 t3 GND rDc 0
8.5 8.4 - 13.6 10.9
P.obableFailureMode
43 -56
4 . 5 12.O - 5.5 14.3
2.8 -3.7
4 5 12.O 5.5 14.3
3.7 4.9
11 . 5 - 14.5
2 0 8.4 8.5 - 10.9
A Open in one cowl sensor. . Open in both cowl
4.5
r2.0
14.3
11 . 5 t4 5
2.O 8 . 4 - 8.5 10.9

. shon to drivf's atbag
86
4.5
12.O - 14.3
11.2 14.6
11.5 14.5 11 . 5 14.5
2.0 8 . 4 8 . 5 - r0.9 2 0 8.4 8.5 10.9

2.O 4 . 4 8 5 -10 9
Short in cowl sensor of C open in both dash sen
5.7 -1.4
8.6
4 . 5 12.O 5 5 I4.3 4 . 5 12.0 5.5 14.3
D Open in one dash sensof.
0
5.6 - 7.3 5.6 -73
11 . 5 I4.5 11.5 14.5
c Open n driver's anbag ' inllaror or .able recl H Blown SRS luse {No. 24 '' 1 0 A ) o r o p e ni n t h e w t e . Shon (o' open) in SRS In0rcalorwrre harness.
43 -5 6 4.3 5.6
0
4.5 -5 5
0 12.4 I4.3
2 . 0 8.4 8.5 - to.9

0 (8.5 8 . 4 10.9 13.6
- 14.5
23-304
With Front Passenger'sAirbag: NOTE: Do not disconnectthe airbagwhen checkingSRSunit voltages.

l 2 S A O H SAPH
vcc
5 SV
8 SADC 5.6
10 BUC]
11.5 -14.5
12 13 GND tDc 0
14
4 . 3 4.3 -5.6
4.5 12.0 - 5.5 14.3
8 . 5 8.4 - 13.6 10.9
Failurc Mode Probable
Reading
2.4 2.4 3.7 - 3.7
4 . 5 12.O 5.5 1 4 . 3
3.7 4.9
11.5 - 14.5
2.O 8 . 4
- 10.9
A openIn onecowlsenso.. . Open bothcowl in
4.5 12.0 5.5 ,14.3
11.5 - 14.5
2.0 -8.5
8.4 10.9
. Shon$ diver's or passflger's akbsginShod in cowl $nsor or C open in both dssh sen'
8.6 8.6 11.3 r1.3 5.7 -7.4 5.7
4.5
12.O - 14.3 12.O 14.3
11.2 14.6 7.4 9.7
11.5 - 14.5 .5 - 14.5 11 . 5 - 14.5
2.O 8 . 4 8.5 10.9

2.O E.4 -8.5 - 1 0 . 9
4.5
o
0 0 0 0 0
D Open in one dash sensor.
2.9 8.6 - 1 1 . 3 3.7
4.5 t2.o - 5.5 14.3 4.5 1 2 . 0 - 5.5 14.3
3.7 -4.9 3.7 -4.9

0 5.6 -'t.3 5.6
2.O 8 . 4 - 8.5- 10.9 2.O 8 . 4 -8.5 - 10.9 2.0 8.4 8 . 5 - 10.9

2.O 8.4 8.5 - r0.9
E Open in d'iver's anbog ,nllator or ceble reel. in t.onl passengers F Open Open in d.iver's and
2.9 -3.7
8.7
1r.5 14.5
11.5 14.5 |.5 14.5 11.5 14.5
8.6 8.6 -11.3
- 5 . 5 - 14.3 0
12.0
4.3 4.3
4.3 -5.6 4.3 - 5.6
ruse(No.24 SRS |r Blown '' 1 0 A l o r o o e nn l h e w i r c . i (or inin I short open) SBS ' dic.torwirchamess.
4.5 12.O 5.5 -14.3
0 8.4 t8.5 1 0 . 9 13.6
23-305
Supplemental Restraint System (SRSI

(cont'd) Troubleshooting
Mod A: Open in ono cowl sn6or. . The SRSunit is faulty. Substitute known-good a SRS unit and recheckthe voltagesaccording the chart to on page 23-304. Mode B: . Shon to dfver's or passengor's ai.bag inflatol. . Short in one dash sensor, . Op6n in both cowl s6nsor. NOTE: The radio may have a 5-digit coded theft protection circuit. Be sure to get the customer's code number beforedisconnecting battery cables. the 1. Betore disconnectingany part ot the SRS wire (RED) the harness. installthe short connector(sl on airbag(sl (see page 23-2941. Connect Test HarnessB (O7MAZ-SP0O50O) between the SRS unit and SRS msin harness 18-P conneclor. a lf there is continuity at eithel terminal, go to step 6. a lf ther is no continuity at either torminal, go 10 steD 4. 4. Reconnsct the front passenger'sairbag connector, th6n check continuity betwen the B2 terminal and body ground, and betwen the 88 terminal and body ground. 3. Reconnect the driver's airbag connector, thsn checkcontinuitybetweenthe B l terminalandbody ground, and betwesn the 87 trminal and body ground.
TESTHAR ESSB 07MAZ- SF005q'

A B
2.
TESTHARI{SS B oTMAZ- SPdr6{X'
a lf there is continuity at either terminal, go to step1O. a lf there is no continuity at either terminal, go to step 5.
23-306
- \ l
Check continuity between body ground and each terminalof both dash sensors. TEST HARNESS B 07MAZ- SP00500
7 . Check continuity between the No, 4 terminaland body ground. and between the No. 5 terminaland body ground.
a lf there is continuityat any ol the terminals,go to step12. a lf there is no continuity at any terminal, go to step13.
o.
lf there is continuity at either terminal. go to step 8. lf there is no continuity at either terminsl,the SRS main harness is faulty. Replace it and recheckthe voltagesaccordingto the chart on page 23-3O4.
Disconnectthe cable reel 6-P connectorfrom the SRS main harness,then connect Test HarnessC only to the cable reel side oI {O7LAZ-SL4O3OO) the 6-P connector.
{cont'd)
23-307
I

(s6n1'd1 Troubleshooting
8. Oisconnect the driver's airbag3-P connectorfrom the cable reel, then connect Test Harness C (07LAZ-SL4O3OO) to the driver's airbag 3-P connector. 1O. Disconnectthe front passenger's airbag3-P connector from the SRS main harness,then connect Test HarnessC {07LAZ-SL4O3O0)to the airbag side of the connector.
AIRBAG FRONTPASSENGER'S
TESTHARNESS C 07LAZ_S140300 1 1 .Check continuity between the No. 7 terminaland body ground,and betweenthe No. 8 terminaland body ground. Check continuity betwsen the No. 7 terminaland body ground, and betweenthe No. 8 terminal8nd body ground.
TEST HARNESSC oTLAZ - SL403qt
TEST HAR ESS C oTLAZ - SL4og)O
lf there is continuityat eitherterminal,the front passenger's airbag inflator is faulty. Replaceit and recheckthe voltagessccordingto ths chart on page 23-304. It there is continuity at either te.minal, the dfiver's airbag intlator is laulty. Replaceit and recheckthe voltagesaccordingto the chart on page 23-3O4. lf there is no continuity at either terminal,the cable reel is faulty, Replaceit and recheckthe voltagesaccording the chsrt on page23-304. to It there is no continuity at either terminal,the SRS main harness is faulty. Replace it and recheckthe voltagesaccordingto ths chart on page 23-304.
23-308
' t 2 .Connect Test HarnessD (O7LAZ-S14O400) between the dash sensorand SRS main hatness2-P connector.Checkcontinuitybetweenthe No.1 terminal and body ground,and betweenthe No.2 terminal and body ground.
lf resistanceis 3.8-4.2 Ko for both sensors, the SRS unit is taulty. Substitutea know-good to SRSunit and recheckthe voltagesaccording the chart on page 23-304. lf resistanceis less than 3.8 KO for either sensor, go to step 14,
't4. Connect Test HarnessD (07LAZ-SL4O4OO)between the dash sensor8nd SRS main harness2-P betweenthe No.1 connector.Checkthe resistance terminaland No. 2 terminal.
SENSOR
SRS MAIN HARf{ESS 2-P COI{IIECTOR
TESTHART{ESS D 07LAZ- SL/O4OO TEST

HARNESSD OTLAZ- SL/to4Oo
rffir
?
TEST O HARI{ESS OTLAZ SL4O/IOO
DASHSEf{SOR D TESTHARNESS OTLAiZ SL/IO4{X)
a lf there is continuityat eitherterminal,the dash sensor is faulty. Replace it and recheck the to voltagesaccording the chart on page23-304. a It there is no continuity at either terminal,the SRS main harness is faulty. Replace it and recheckthe voltagesaccordingto the chart on page 23-304. betweenthe left dash sensor 13. Checkthe resistance terminalsB12 and Bl6, and betweenthe right dash sensorterminals84 and 86.
a It rssistance is 3.8-4.2 KO, the SRS main harness is faultv. Replaceit and recheck the to voftagesaccording the chan on page23-304. a lf resistance lessthan 3.8 KO,the dashsensor is is faulty. Replace and recheckthe voltagesacit cordingto the chart on page 23-304.
B TESTHAR]IIESS 07MAZ-SPOo50{'
A I
(cont'd)
23-309
.4
Supplemental Restraint System (SRS)

Modo C: Short in cowl sgnsot. or oDn in both dash snsors. Mode D: Open in on dash sensor. NOTE: The radio may have a s-digit coded theft protection circuit. Be sure to get the customer's code numberbeforedisconnecting the bafte.y cables. 1. Beiore disconnectingany pan ot the SRS wire (RED) the harness, installthe short connector(s) on (see page 23-294l.. airbag{sl Connect Test HarnessB (07MAZ-SPoO5OO) between the SRS unit and SRS main harness 18-P connector. a lf resistance is more than 5 Kn for either set of terminals,go to step 4. a lf resistance is less than 5 KO for both sets of terminal, the SRS unit is faultv. Substitute a known-goodSRS unit and ,echeckthe voltages accordingto the chart on page 23-304. 3. Check the resistance between the left dash sensor terminals812 and 816, and betweenthe right dash sensorterminals84 and 86.
TEST HARI{ESS B oTMA;Z - SPq)sd!
2.
TESTHAR'{ESS B oTMAZ-SP00500
23-310
'!
4.
Connect Test Harness D (07LAZ-SL404OO) between the dash sensorand SRS main harness2-P connecror. Check the resistancebetween the No' 1 terminal and No. 2 terminal.
Mode E: Open in drivsr's airbag inflator or cable re6l. NOTE: The radio may have a s-digit coded thelt protection circuit. Be sure to get the customer's code the number betoredisconnecting battery cables. 1. Before disconnectingany part of the SRS wire harness,the positive cable. Installthe short con(seepage23-294). on nector(s)(RED) the airbsg(s) beConnect Test HarnessB (O7MAZ-SP005OO) tween the SRS unit and SRS main harness 18-P connector.
2.
TESTHARI{ESSD 07LAZ - 5140400
B TEST}IARNESS oTMAZ-SP00500 Reconnect the driver's airbag connector, then check the resistancebetween the B1 and the 87 terminals. B TEST HARI{ESS oTMAZ- SmO500
is lf resistance more than 5 K0. the dash sensor it is faulty. Replace and recheckthe voltagesaccordingto the chart on page 23-304. It resistanceis less than 5 KO, the SRS main the harnessis taulty. Replace SRSmain harness to and recheckthe voltagesaccording the chatt on page 23-304.
a lf resistance more than O.2 KO, go to step 4. is a lf resistance lessthan O.2 KO.the SRSunit is is faulty. Substitute a known-goodSRS unit and recheckthe voltagesaccordingto the chan on page 23-3O4.
(cont'd)
23-311
r -
'l

(66n1'd1 Troubleshooting
4. Disconnectthe cable reel 6-P connectorfrom the SRS main harness.then connect Test HarnessC (O7LAZ-SL4O300Ionly to the cable reel side of the connector.
CABLE REEL
6,
Disconnect the d.iver's airbag3-P connectortrom the cable reel harness, then connect Test Harness C {O7LAZ-SL4O30O)to the driver's airbag 3-P connector.
5.
Measure the resistance betweenthe No. 4 terminal and the No. 5 terminal.
7.
Measurethe .esistance between the No. 7 terminal and the No. I terminal.
TESTHARI{ESS C oTLAZ - S1403{tO
TEST HAB'{ESS C
oTr.Aiz st4{t3dt
lf resistance more than 0.2 KO,9o to step 6. is lf resistance less than O.2 KO, the SRS main is harness is taulty. Replaceit and recheck the voltages according to the chart on page 23-30'4,
a lf resistanceis more than O.2 KO, the drive.'s airbag intlator is faulty. Replace the airbag assembly and recheck the voltages according to the chart on page 23-304. a lf resistance is less than 0.2 KO,the cable resl is faulty. Replace it 8nd .echeck the voltages according to the chart on page 23-304.
23-312
Mode F: Open in lront passongot's airbag inflatol' NOTE: The rsdio may have a s-digit coded theft protection circuit. Bs sure to get the customer's code number before disconnecting the battery cables. 1. Belore disconnectingany part of the SRS wire (RED) the on installthe short connector(s) harness, airbag(s) (see page 23-2941' Connect Test HarnessB (o7MAz-SPoOsoo) between the SRS unit and SRS main harness 18-P connecror. ai.bagconnector, the front passenger's Reconnect then measure the resistance between the 82 terminal and 88 terminsl.
4.
airbag 3-P conDisconnectthe front passenger's nsctor from the SRS main harness,then connect Test HarnessC (O7LAZ-S14030O) to the tront passenger's airbagside of the connector.
PASSENGER'S AIRBAG
2.
3.
B TESTHABI{ESS oTMAZ- SPOO5d'

A
C TESTHARNESS 07LAZ-S140300
betweenthe No. 7 terminal the resistance Measure and the No. 8 terminal. is It resistance more than O.2 K0, go to step 4. is ll resistance lessthan O 2 KO,the SRSunit is faulty. Substitute a known-good SRS unit and recheckthe voltagesaccordingto the chart on page 23-305.
TEST HABNESS C 07LAz - S[/rO3o,0
lf resistanceis more than O.2 K0, the front the passenger's airbaginflatoris faulty. Replace airbagassemblyand recheck front passenger's the voltages accordingto the chart on page 23-305. is lf resistance lessthan O.2 KO,the cablereelis taultv. Replacethe cable reel and recheckthe to voltagesaccording the charton page23-305.
(cont'd)
23-313
Restraint System(SRSI Supplemental

Modo G: Blown SRS No. 24 fuse. or opon in the wire. NOTE: The radio may have a s-digit coded theft protection circuit. Be sure to get the customer's code the number beforedisconnecting battery cables. Check the SRS No. 24 {10 A) Juse in the underdash fuse/relaybox. lf it's OK, go on to step 2. lf it's blown, replaceit with a new 1OA tuse, then turn the ignitionswitch ON: a lf fuse doesn't blow, go on to step 2. a lf the Juseblows, troubleshoot necessarv as to find the short. 4. Reconnect the positiveand negativecablesto the battery.
5 . Measure the voltagebetweenthe B13 te.minaland body ground with the ignitionswitch ON.
TEST HARNESS B 07MAZ-SP00500

2 3
6
a a
9 9
10 11 12 10 n 12
1 5 10 I6
18 18
2 . Before disconnectingany part ot the SRS wire

(RED) the harness. installtheshort connector(s) on airbag(s) (see page 23-2941. Connect Test HarnessB (O7MAZ-SPOO5OO) between the SRS unit and SRS main harness18-P conneclor.
lf there is batteryvoltage,the SRSunit is faulty. Replace and recheckthe voltagesaccording it to the chart on page 23-304. a lf less than battery voltage, the SRS main ha.ness is faulty. Replaceit and .echeck the voltagesaccording the chart on page23-304. to
TEST HARNESSB oTMAz-SPOO500
23-314
Modo H: Short or opsn SRs indicator wiro harnosa. NOTE: The radio maY have a 5-digit coded theJl protection circuit. Be sure to get the customel's code ths numberbeJoredisconnecting battery cables. 1. Disconnsctthe SRS main harness4-P connector from the main wire harness.
BeJoredisconnectingany pan of the SRS wire (RED) the on installthe short connector(s) harness, (see page 23-2941. airbag(s) beConnect Test HarnessB (O7MAZ-SPOO5OO) tween the SRS unit and SRS main harness 18-P connecror.
4.
oTMAZ_SP00500 the battery positivecable and negative Reconnect cable.

o.
Checkfor continuitybetweenthe B1 1 terminaland body ground,
2 . Turn the ignition switch ON and wait for six
sconds.Measulethe voltage between the No' 1 terminal8nd body groundon the SRSmain harness 4-P connectorside.
B TESTHARI{ESS oTMAZ- SP(xrs(x)
SRSMAII{ HARI{ESS 4 - P CONf{ECTOR

F-"-----F-i-rl
/JLILx ' l BLU -t
l-. ,\
a lf there is continuitv,the SRS main harnessis shoned. Replacethe SRS main harness and recheckths voltagesaccordingto the chart on page 23-3O4. a lf thre is no continuity,go to step 7.
ap
t_
View from terminslside.
a lf voltageis mote than 8.5 V, go to step 8' a ll voltage is less than 8.5 V, go to step 3
23-315

7. Check for continuitybetween the B1l terminalof Test Harness (O7MAZ-SPOo5OO) the No. 1 B and terminalof the SRS main harness4-p connector.
q
Turn the ignition switch ON and wait tor six seconds. Measurethe voltage between the No. 5 terminal and body ground.
TEST HARI{ESS B 07MAZ-SPq)500

A B DASHBOARD WIRE HARNES95-P CONNECTOR
View lrom terminalside
a lf there is continuity, the SRS unit is faultv. Replace and recheckthe voltagesaccording it to the chan on page 23-304. a lf there is no continuity.there is an open in the SRS main harness. Replace the SRS main harnessand recheckthe voltagesaccordingto the chart on page 23-304. Reconnect the SRSmain harness4-P connectorto the main wire harness.Disconnectthe dashboard wire harness 5-P connector from the gauge assemblv.
a lf voltageis more than 8.5 V. the SRSindicator circuitis faulty (in the gaugeassembly). Replace the SRS indicator assembly and recheck the voltagesaccording the chart on page23-304. to a lf voltageis lessthan 8.5 V. the dashboard wire harness (or the main wire harness)is faulty. Replace and recheckthe voltagesaccording il to the chart on page 23-304.
HARNESS5.P CONNECTOB
23-316
Poor glound at SRS unit or unit mounting bolts NOTE: The radio may have a s-digit coded theit protection circuit. Be sure to get the customer's code the numberbelore disconnecting battery cables. 1. Betore disconnectingany part of the SRS wire (RED) the on harness,installthe short connector(s) (see page 23-294l,. airbag(s) Connect Test HarnessB (o7MAz-SP005oo) between the SRS unit and SRS main harness 18-P conneclor.
a lf there is continuity at either terminal, the SRS unit is Jaulty. Replace it and recheck the voltages accordingto the chart on page 23-304 a lJ there is no continuity at either terminal,the SRS unit ground, the SRS unit component grounds, or the SRS main harness is faulty. Check the grounds(checkthe SRS unit ground wire and mounting bolts) and, if necessary, rsplace the SRS main harness. Racheck the to voftagesaccording the chart on page23-304,
2.
sRsur{tT
SRS MAIN HARNESS 18-P CONNECTOR
HARNESS B
07MAZ-SP00500
Check for continuitybetweenthe 85 terminaland body ground. and the 815 terminal and body ground.
8 TESTHARNESS 07MAZ - SP005q)
23-317
Supplemental Restraint System(SRSI

Airbag Assembly Replacement
sro.e a rsmoved airbag assembtywith the E@ pad surlace up. lf tho airbag is improprly stored face down, accidental dployment could plopel th unit with nough lotce to cause satious iniury. CAUTION: a Do not install used SRS parts f.om another cat. Whn repailing as SRS, use only nw parts. o Carelully inspect ths airbag assembly before you in_ stall it. Do not install an airbag assembly that shows signs of being droppad or improperly handled, such as dents, cracks or dolotmation. a Always kep tho short connctor(sl (REDIon the air_ bag{s) whan th6 harness is disconnoctod. a Do not disasaombls ()1 tamper with the airbag assmbly. NOTE: The radio may have a s-digit coded theft protection circuit, Be sure to get the customer's code number beforedisconnecting the battery cables. l. Disconnect the battery negative cable, then disconnectthe positivecable. Installthe short connector(s)(REDIon the airbaq side of the connector(s): Oriver'sSide: a Remove the access panel from the steering wheel, then removethe shon connecto.{RED) trom the panel. a Disconnect the 3-P connector between the driver's airbag and cable feel, then insta the short connector(RED) the airbagside of the on connector. GLOVE BOX
CABLE REL3.P CONNECTOR
Front Passenger's Side: a Removethe glove box, then remove the short connector{RED)from its holder a Disconnect 3-P connectorbetweenthe front the passenger's airbagand SRSmain harness. then installthe short connector (RED)on the airbag side of the connector.
FRONT PASSENGER'S AIRBAG 3.P CONNECTOR
2.
DRIVER'S AIRBAG 3-P CONNECTOR ACCESS PANEL SHORT CONNECTOR {RED}
23-318
J.
Removethe ai.bag(s): Driver'sSide: a Remove the two TORXo bolts using a TORXo T3O bit, then remove the driver's airbag assembly,
Side: Front Passenger's a Removethe tweetet cover from the dashboard, then removethe visor and blackface panel (see p a g e2 3 - 1 3 0 ) . a Remove the glove box, then remove the four airbag mountingnuts from the lront passenger's assembly.
DRIVER'S ASSEMBLY AIRBAG DASHBOABD
GLOVE BOX TOBXO BOLT U.. . TORX@ T3O bh
a Carefully lift the front passenger's airbag assemblvout ot the dashboard.
(cont'd)
23-319
Restraint Supplemental System (SRSI

Airbag Assembly Replacement (cont,dl
CAUTIOI{: B sura to installthe SRS wi ng so thst it ie nol pinchod or intorforing with oth6r car parts. 4. Installthe new airbag(s). Driver'sSide: Placethe driver'sairbagassemblyin the steeringwheel. and secureit with new TORX@ bolts. OBIVEB'S AIRBAG Front Passenger's Side: a Placethe front passenger's airbagassemblyin the dashboard. a Loosen the two mountingnuts on the L-bracket. a P.essthe airbagassemblydownwardsand turn the adjusting nuts until they touch the lower part of the airbagassembly. a Tighten the four airbag mounting nuts, then tightenthe two mountingnuts on the L-bracket.
ADJUSTING NUT
L-BRACKET
L-BRACKET MOUNTING NUT 10 N.m 11.0kg-m, 7.2 lb-ftl Replace.
TORXO BOLT 10 N.m {1.Okg-m, 7.2 tb-ft) Reolace. U8o 6 TOBX@ T3O bit
ASSEMBLY MOUNTINGNUTS 10 N.m (1.0 kg-m, 7.2 tb-frl Replace.
23-320
5.
Rsmoveand ptoperlystore the short connsctor{s), then reconnectthe airbagconnector{s). Side: Front passenger's a Attach the short connector(REDltothe connecto, holder. the glove box, visor, and tweeter a Then reinst8ll covr on the dashboard.
Driver'sSide: a Rmov the short connector {RED)from the driver'sairbagconnector.then connectthe airbag 3-P connector to the cable reel 3-P connector. to a Attach the short connector(RED) the access the panel on the steering panel. then reinstall whel.
PASSENGER'S FRONT 3.P AIRBAG CONNECTOR
CABLEREEL3.P CONNECTOB
DRIVER'S AIRBAG 3-PCO I{ECTOR
6 . Connsct th battery positive cable, then the

negstivecable. proper conJirm assembly, the Aft6r instalting ai.ba(t system operaflon: a Turn the ignition ON {lll: The instrumentpanel SRS indicatorlight should go on for about six secondsand then go off. a Make sure both horn buttons work. cona Take a test drivs and make sure the cruase trol set/resume switch works.
tt.
SOX GLOVE
Enter the code number to restore radio operation (see page 23-206).
23-321

Ai6ag Assembly Disposal
Beforescrapping any airbag(s) {including one in a whole car to be scrappedl the airbagmust be doployed.lf the car is still within the warrantyperiod,betoreyou deploy the airbag.the Honda District Service Managermust give approvaland/or specialinstruclons. Only after an airbaghas beendeployed(asthe resultol vehiclecollision.for example),it can be scrapped. lf an airbag(s) appears intact (not deployedltrestit with extremecautaon. Followthis Drocedure: Dploying the Ai|bag(s): In-CE] NOTE: lf an SRScar is to be entirelyscrapped,its 8ir_ bag(sl should be deployedwhile still in the ca.. The airbag(slshould not b considered salvageable as part and should never be installedin anothercar. confirm that th6 airbag assombty i! @E secu.ely mountad; otherwiso sovoro porsonal injury could rsult dudng doploymont, 1. 2. Disconnectboth the negative cable and Dositiv8 cable from the batt8rv. Confirmthat the specialtoolis functioningproporly by following the check procedure on the label of the tool set box, or on page 23-317 's Front Passongef Alrbag: 4. Remove the glove box, then disconnectth6 3_p connector between the front passengr,s airbag and SRS main harness.
FBONT PASSEI{GER'S AIRBAG 3-P COt{t{EcToR
5.
Drivor's Alrbag: 3. Removethe accesspanel,then disconnct the 3_p connector between the d.iver,s airbSg and the cable reel.
Cut off the airbag connector, strip the ends of the aibag. wires, and connsct the speci6l tool alligator clips to ths bar6 wires. place the special tool approximatsly thirty fet away from the airbag. DFIVER'S AIREAG FRONT PASSEI{GER'S AIRBAG
ALUGATOR CLIPS lY.lowl
ORIVER'S AIRBAG 3.P CONNECTOB
ACCESS PANEL
23-322
o,
Connct a 12 volt battery to the tool: a lf ths g.een light on th tool goes on, tho airbag ignit8r circuit is defective and csnnot deploy th bag. Go to DamagedAirbag SpecialProcedure. a It the red light on the tool goes on, the sirbagis r8dy to be dployed.
D6ploying tho Ai6ag: Out-of-cal' NOTE: lt 8n intact airbag assembly has b6n removed from a scrapped car or has been found dotectivs or duringtransit,storage,or service,it shouldbe damaged deployedas follows: Position tho ai6a9 aslembly faco up' out!@ tlat ground at loart thlrtY feet lrom any E6EJn obstacbs or Poople.
7 . Push the tool's dployment switch. The airbag should deploy (deploymentis both highly audible and visible- a loud noisand rapidintlationof the bag, tollowod by slow deflation). . ll audible/visible deploymnt happensand the gren light on the tool goes on, continue with this procedure. . It the airbagdoesn't deploy,yet the green light goes ON, its igniter is dfective Go to DamagedAitbag SpecialProcedure.
1. Du?ing d.ployment, rho airbag !@ assembly can bcomo hot gnough to burn you. Wait thirty minutos aft6r doploymont before touching the assmbly. L Disposeof the complste airb8gassembly.No pan of it can be reused. Place it in a sturdy plsstic bag and seal it securelv. CAUTION: a Wsar a taco shiold and glovos whn handling a deploy6d Eirbag. a Wash your hands and dns6 thom wall with wat6r afior handling a doployed alrb8g.
2. 3.
Confirm that the specialtool is tunctioning properly by following the check procadureon this page or on the tool box l8bel. Remove tho short connactor from the Eirbag connector, Follow steps 5, 6, 7 and I ot th in-car dploymnt procodute.
Damagod Airbag Special Procedure' lf an airbag cannot be dcployod' ir thould !@ i6Fue tteatea aa normal scrap; it lhould stlll bo considorod a potontiallY explolivo dovico that can c.us sarious lniury. 1. It instslldin a car, tollow the rsmovsl procdure o n p a g e2 3 - 3 1 9 . In allcases,make surea short connscto.is properly installedon the airbagconngctor. Packagethe airbsg in exactly th same packaging part came in. that the new replacament "DAMAGED AIRBAG Mark the outsideof th box NoT DEPLOYED"so it does not get confused with your parts stock. Contact your Honda Oistrict Service Manager lor how and where to return it for disposal.
2.
3.
4.
5.
Doploymant Tool: Chock Plocedulo. 1. Connectthe vellow clips to both switch protoctor handles on the tool; connact th tool to a baftary' switch: greonmeanstool is OK; Pushthe operation red meanstool is Jsulty.
3 . Disconnect the bsttery and the yellow clips.
23-323

CableReelReplacement
storo a romovcd aiibag assombtywith tho @ pld rurtrco up. lf tho airbag is lmpfoporly stored taco down, eccldental dploymont could propol the unit with lnough torc6 to cause sadous iniury. CAUTION: r Carefully inspct the alrbag assembly botor6 installing h. Do not install an airbag asscmbly that shows signs ot belng droppcd or lmprop. y handled, such aa denta, cracks 01 dgtormation. a AlwayE koop th. short connoctol(s) on tho airblg(sl whn ths hames! is disconnectod. a Do not disassomble or tampr with any ailbag a8sambly. NOTE: The radio may have a s-digit cod6d theft protection circuit. Be sure to gt the customer,s code numberbetore disconnecting battery cable. the 1. Disconnect the battery nogative cable 8nd then the positivecabls. Make su,e ths wheels are facing straightahsad. Remove the dashboard lower cover, knee bolst6r, and air duct.
F
4.
Installths short connector{sl the airbag(s) (se on paga 23-2941.
CABLEREEL3.P COI{IECTOR
DNIVER'S AIRBAG 3.P
cof{t{EcToR
SHORT
cor{r{EcToR
(REDI
accEss
PAl{EL
2. 3.
Remove the driver,s airbag assembly trom tho steoring whel (two T30 TORXo bolts), then ramov the steering whel nut.
S?EERII{G IYHEEL ITUT
TORXO BOLT U.. . TOnXo T3O bh
23-324
Disconnect the connectors from the horn and cruise control set/resume switches, then remove the cable reel 3-P connectorJrom its clip.
CRUISECONTROL SET/RESUME
9. Disconnect the 6-P connector between the cable reel 8nd SRS main harness,then removethe connctor holder from th staering column.
HORN CONNECTOR
CABLEREEL
HOLDER COI{NECTOR
7. 8.
Removethe steeringwheel Jromthe column' Removethe upper and lower column covers'
1O. Removethe cable reel from the column.
COLUMN COVER UPPER
23-325

(cont'd) Cable ReelReplacement
CAUTION: a Bcforo Installingth steofng whool. th front whelg should be alignod straight ahead. a Bc aure to install the harnoss wires so that thoy ar not pinch6d or intsrfering with other car parts. a Aftor reassembly. contirm that the whoels aro still straight ah6ad and that the rteerlng wheel spoke angle is correct (road test), lf minor spoke angle adiustmont is ncesaary, do so only by adiustment ot th ti-lods. not by removing and repositioning tho stering whael. 11. 2WS: Align the cancel sleeve grooves with the cable reel projections, 13. Installthe steeringcolumnupperand lower covers, 14. Centerthe cable reel. Do this by first rotatingthe cablereelclockwiseuntil it stoDs. Then rotate it counterclockwise(approximately two turns) until: a The yellow geaf tooth lines up with the alignment mark on the cover. a The arrow mark on the cable reel label Doints straight up.
ARROW MARK
CANCELSLEEVE
CABLE REL
ALIGNMENTMABK
15. Installthe steeringwheel and aftach the csble reel connectorto the cliD.
HORI{ CONNECTOR
4WS: Be sure that the yellow make on the front main steeringanglesensorrotorfacesdownwards. It it doesn't,turn the rotortill it is in the neutrallock position(seesection 17). Carefullyinstallthe cable reel on the steeringcolumn shaft. Then attach the connectorholderto the steeringcolumn,
CRUISE CONTROL SET/RESUME SWITCH CONNECTOR
1 6 . Connect the horn connector and cruise control set/resume switch connector.
23-326
1 7 . Installthe steeringwheel nut. NOTE: Modelswith 4WS Checkthat the 4WS system is neutral(seesection 17). NUT WHEEL STEERING 50 N.m (5 kg-m,36 lb-It)
20. Removeand properlystore the short connector(s) the airbagconnector(s} {and then reconnect {RED), the glove box). reinstall 2'1. Reconnect the battery positive cable, then the negativecable, 22. Atter installing the cable re|, conJirm proper system operation: a Turn the ignition ON (ll); the instrumentpanel SRS indicatorlight should go on for about six secondsand then go otf a Make sure both horn buttons work. a Make sure the headlight and wiper switches work, a Go for a test drive and make surethe cruiseconswitch work. trol set/resume a Rotate the steering wheel counterclockwise to make sure the yellow gear tooth lines up with the slot on the cover.
TORXO BOLTS 10 N'm (1.0 kg-m. 7.2 lb-ft) BeDlace. U3o a TORXo T30 blt 18. Install the driver's airbag assembly' 19. Connect the cable reel 6-P connector to the SRS main harness, then installthe air duct, knee bolster' and dashboard lower cover.
YELLOWGEARTOOTH
23. Enter the code number to resto.e radio operation (see page 23-206).
DASHBOARDLOWERCOVER
23-327

DashSensor Replacement
CAUTION: a Oo not damsgo tho sonsor wiring. a Do not install ussd SRS parts trom anoth6. car. Whn rpairing an SRS, use only new pans. a Raplace a sansor il it is dented, c1ack6d, ol dto1med. NOTE: The radio may have a s-digit coded theft protection circuit. Be sure to get the customer's code numberbeforedisconnecting the battery cable, 1. Disconnectthe battery negative cable, thn the positivecable. Installthe shorr connector{s} the airbag{s}. on
CAALE REEL 3-P CONt{ECTOR
3,
Left Dash Sensor: Remove the footrestand left door sill molding,then pull the carpet back.
2.
4.
Right Dash Sensor: Remove the right door sillmoldingand pull backthe caroet. Removethe ECM.
SHORTCONNECTOR (RED) FRONTPASSENGER'S AIRBAG
SRS MAIN
Remove the two mounting bolts, then remove thg left or right dash sensor.
GLOVE BOX
BOLTS
23-328
CAUTION: a Bg sure to install the harness wils go thoy ar not Dinchd01 intorfering with oth6r cal parts. a Carefully inspect the new dash sonsol(sl for signs of being dropped or imploperly handl6d, such as dents, cracks or deformation. a Fol the SRS to function proporly, the dghl and lett sansors must b installd on the propor sidos.
o.
8 . Removeand properlystore the short connector(sl

(RED), {and then reconnectto aitbag connector(s) the glove boxl. reinstall 9 . Reconnectthe battery positive cable, then the negativecable.
1 0 .After installingthe dash sensor, confirm proper

system operation:Turn the ignitionON (ll); the instrumentpanelsRS indicatotlight shouldgo on for about six secondsand then go off
Installthe sensorsecurelY.
DASH SENSOR
'l 'l . Enter the code number to restoreradio operation (see page 23-206).
DASH SENSOR MOUNTINGEOLTS 8 t 1 . 2 5m m 22 N'm t2.2 kg-m. 16 lb-ft) RePlace
7.
Reinstall all other removed parts.
23-329

SRS Unit Replacement
4. a Boloro disconnecting any pan ot the SRS wire hamss. install the shon connctor(s) on th airbag(s). a Do not damage tho SRS unit terminals or connectors, a Oo not disassmble the SBS unit; it has no aorvicoable p8rts. a Stor the SRS unit in a clean, dry arsa, a Do not us any SRS unit which has ben subjcted to watel damage or shows signs of bsing droppsd 01 improperly handled, such as dents, cracks or doformation. NOTE: The radio may have a s-digit coded theft protection circuit. Be sure to get the customer's code number beforedisconnecting battery cable. the 1. Disconnectthe battery negative cable. then the oositivecable. lnstallthe short connector{s) the airbag(sllsee on page 23-2941. Rmovethe left side cover trom the SRSunit, then disconnectthe SRS main harnesslB-p connactor from the SRS unit.
SRS UNIT
SBS MAIN HARNESS 1a-P COI{NECTOR
TOBXO BOLTS Usc a TORXo T30 btr
3 . Removethe right side cover from the SRSunit.
SRS UNIT
5.
Removethe fou. SRSunit TORXo bolts, then oull the SRS unit out from the driver'sside.
_--,/
TOBXo
8()tTs
Use ! TORXo bir
23-330
t\
CAUTION: Ba sur to install tho SRSwidng so that it is not pinch6d 01 intorfefng with othor cal pada' lnstallthe new SBS unit.
Removeand properlystore the short connector{sl (and the airbagconnector(s} then reconnect {RED), the glove box). reinstall
1 0 .Reconnect the battety positive cable, then the

negativecable, 1 1 .After installing the SRS unit. confirm proper Turn the ignitionto ll; the instrusystemoperation: ment panel SRS indicator light should go on for about six secondsand then go otf
'12. Enter the code number to restore radio operation

(see page 23-206).
snsuNlr
ToRxo BOLTS 6 mm 10 N.m tl.O kg-m,7.2 lb-ft) ReDlace. U3e a TORxo T3O bit
6 TORXo SOLTS mm 1ON'm 110 kg-m'7.2 lb-ft| RePlace. Ut. a TORXo T30 blt
Connectthe SRS main harness18-P connectorto the SRS unit; push it into positionuntil it clicks. 8. Installthe SRSunit covers (right and lett).
23-331

Service Manual 92-96 - Lude

Uploaded by

Document Information

Original Description:

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Service Manual 92-96 - Lude

Uploaded by

Copyright:

Available Formats

I NT RO DUCT ION I

Fueland Emissions ZZ *Transaxle

Chassisand Paint Codes

Vehicle ldentificationNumbel and FederalMotor Vehicle Safety Standard Certification'

M2F4: l OOOOO l ExceptM2F4: 2OOOO01

Vehicle ldentificationNumbe] and CanadianMotor Vohicle Safety Standard Certification.

V.hicl ldontitication Numbo.

Tiansmission Number lManual)

'E: Inflatorwarning tag (Reterto page l-5).

K: DRIVER INFORMATION ISUNVISOB)

AIR CLEAI{ERELEMEI{T, OIL FILTEB,RECOMMENDATIOI{ ENGINEOll- and SPARK PLUG

Lift and Support Points

Lift and SuPPortPoints

@ o Always uso salty stands when wolking on or

Centerthe iacking bracket in the middle of the jack lilt Platform.

Centerthejacking bracketin the middle

4 . Sctions on this car requiringthe use of Dacro nuts

Grcon coating on tha thraad! of ao|lro bolta.

Standardsand Service Limits

width Stem installed height

t.D. height Installed

(0.ooo7-o.0021 ) 8-0.054 o.o1

''l: CHUO HATSUJOmanulactured valve sprrng. '2: NIHONHATSUJOmanulactllred valve spring

Cylinder Head/ValveTrain (H23A1 enginel - Section 6

Unit of tength:mm (in)

Widrh Stem anstalled height

Valvo spring Valve guide

(O.260-0.261 6.61-6.63 I ( 6 6 . 6 1 , 6 . 6 30 . 2 6 0 - 0 . 2) 1 13.25-1 5 1O.522-0.541 3.7 | 0 1 13 . 75 - 1 . 2 5( O . 5 4-1 . 5 6 ) 4

6.70 to.264l 6.70 {0.264)

Standardsand Service Limits

)n 6 CylinderHead/ValveTrain (H22A1 engine) Sectit

Nominal Minimum Maximum varlatron

Valve clearance Valve stem O.D. clearance Stem-to-guide Valve seat

Primary Mid Secondary PrimarY Mid Secondary lN EX lN EX lN EX IN EX IN EX

widrh height Steminstalled

5.445{0.2144) 0.08 (0.003) 0.11 (0.oo4)

2.0 10.079) 2.0 t0.079) ( 38.185 1.5033) 3 7 . 8 8 51 . 4 9 1 5 } {

t.D. height Installed

(O.OO1 0'0.0020) 0.025-0.052 (O.001 0.oo20) 0 o.025-o.052

, 2 | NIHONHATSUJOmanufactured valve spring'

valve spr'ng' CHUOHATSUJOmanufactured

Unit of length:mm linl SERVICE LIMIT

Standardsand Service Limits

Journaltaper End play

shalt Balancer beanng

-o.006) 1 o.02-0. 6 10.001 9 0.10,0.1 (0.004-0.007) -0.003) (o.oo1 o.02-0.07

o.20 (0.008) 0.21 (O.OO8) 0 . 1 2( 0 . 0 0 5 )

, 9 5 - 1 2 5( 0 . 9 5 - 1 . 2 51 3 . 5 ' 1 7 . 8 ) 169-177 {76-80) 194 (90) 8 . O 1 O . 3 1m i n . )

1 6 5 ( 1 7 4 ,1 4 5 )@ 6 , 0 0 0 1 s 9 1 1 6 8 1 4 0 )@ 6 , 0 0 0 , 1 6 3 ( 1 7 2 ,1 4 3 )@ 6 , 0 0 0 194,205(90,96) 198-208(92-98) "ON" temperature 4'13 {l-7} tfom actual Subtruct

Fuel and Emission- Section 1 1

Unil ol lengthi mm (in STANDARD(NEW)

Fuel tank Engine

Flywheel Clutch disc

o.15 (0.006) o . 2(0.008) 1 . O(0.04) 6 . O (0.2361 o . 1 5( 0 . 0 6 )

Mainshatt3rd and fourth gears

t.D. Endplay Thickness

0. 10-0.16 {0.0039-0.0063) 2 7 . 9 7 7 2 7 . 9 9 0( 1 .1 0 15 1 .10 2 0 ) 3 7 . 9 8 4 - 3 8 . O O1 1 . 4 9 5 41 . 4 9 6 1 O ) (1 2 7 . 9 8 7 2 8 . O O O .10 18 - 1 .1 0 2 4 ) 0.02 (0.0008) max.

24.94lO.982l 3 9 . 9 3{ 1 . 5 7 2 } o.05 (o.oo2)

Countershalt lsl gear Countershatt 2nd gea(

t.D. Endplay LD. Endplay Thickness

4 7. O O 9 - 4O 2 5 1 . 8 5 0 7 . 8 5 1 4 ) .7 ( 1 o.04-0. {0.002-o.004) 10 t 2 8 . 9 22 a . 9 7( 1 . '3 9 , 1 . 1 4 1 )

Standardsand Service Limits